Motor controller, electric control system and vehicle

Abstract

The utility model relates to a motor controller, an electric control system and a vehicle, the motor controller comprises an inversion module and a three-phase intelligent fuse, and the inversion module is used for converting direct current into alternating current; and the three-phase intelligent fuse is connected between the inversion module and the motor, so that overcurrent protection and short-circuit protection of the three-phase end of the motor controller are realized.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and more particularly to a motor controller, an electronic control system, and a vehicle. Background Technology

[0002] Traditional motor controllers may fail to respond promptly if short circuits occur between the three phases due to reasons such as damaged insulation, potentially causing serious damage to the motor controller and the motor.

[0003] Based on the characteristics of relevant technologies, the technical problems of short circuits and faults existing in the three-phase terminals of motor controllers are deduced. Summary of the Invention

[0004] This application provides a motor controller, an electronic control system, and a vehicle, in which a three-phase smart fuse is placed between the inverter module and the motor, thereby at least partially solving the aforementioned technical problems.

[0005] To achieve the above objectives, according to a first aspect of this application, a motor controller is provided for controlling the operation of a motor, comprising:

[0006] Inverter module, used to convert direct current to alternating current;

[0007] The three-phase smart fuse has one end connected to one end of the inverter module and the other end connected to the motor.

[0008] Optionally, the inverter module includes a first Hall sensor, and the three-phase smart fuse is connected between the motor and the first Hall sensor.

[0009] Optionally, it also includes a bus intelligent fuse, one end of which is connected to the other end of the inverter module.

[0010] Optionally, it also includes a DC module connected to the other end of the bus smart fuse.

[0011] Optionally, the DC module includes a DC bus interface, which is connected to the other end of the bus smart fuse.

[0012] Optionally, the inverter module includes a second Hall sensor, and one end of the bus smart fuse is connected to the second Hall sensor.

[0013] Optionally, it also includes a dual magnetic ring filter assembly, which is disposed within the DC module.

[0014] Optionally, it also includes a DC module and at least one power distribution interface, the DC module being electrically connected to the at least one power distribution interface.

[0015] Optionally, the power distribution interface includes at least one of an AC power distribution interface, a thermistor power distribution interface, and a minimum mean square power distribution interface.

[0016] Optionally, the power distribution interface is directly connected to the DC module via a power distribution cable harness.

[0017] Optionally, the DC module includes at least one power distribution fuse, and at least one of the power distribution fuses is electrically connected to the power distribution interface.

[0018] Optionally, the DC module further includes a DC bus copper bus, on which a connection portion is formed for electrical connection with the power distribution interface.

[0019] Optionally, the DC bus copper bus includes a DC bus interface connected to the front drive electronic control bus, and the connection part is disposed close to the DC bus interface relative to the dual magnetic ring filter assembly.

[0020] Optionally, the DC bus copper bus includes a positive terminal trace and a negative terminal trace, and the connection portion includes a first connection portion and a second connection portion, wherein the first connection portion is formed on the positive terminal trace and the second connection portion is formed on the negative terminal trace.

[0021] Optionally, the DC module further includes a power distribution copper busbar, which is electrically connected to the connection part.

[0022] Optionally, the power distribution copper busbar includes a positive terminal and a negative terminal of the power distribution copper busbar respectively connected to both ends of a power distribution interface. The positive terminal line is connected to the positive terminal of the power distribution copper busbar through the first connecting part, and the negative terminal line is connected to the negative terminal of the power distribution copper busbar through the second connecting part.

[0023] According to a second aspect of this application, an electronic control system is provided, including a motor controller as described in any of the above embodiments.

[0024] According to a third aspect of this application, a vehicle is also provided, including a motor controller as described in any of the above embodiments, or including an electronic control system as described in the above embodiments.

[0025] In the motor controller of this application embodiment, a three-phase intelligent fuse is set inside the motor controller, thereby realizing overcurrent protection and short circuit protection of the three-phase terminals of the motor controller. At the same time, it also improves the maintenance efficiency of the motor controller and alleviates the technical problems of short circuits and faults between the three-phase terminals of the existing motor controller.

[0026] Other features and advantages of this application will be described in detail in the following detailed description section. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings, wherein the same reference numerals in the following description denote the same parts.

[0029] Figure 1 This is a structural block diagram of the motor controller provided in an exemplary embodiment of this disclosure;

[0030] Figure 2 This is an exploded view of the motor controller provided in an exemplary embodiment of this disclosure;

[0031] Figure 3 This is a schematic diagram of the power distribution principle of the motor controller provided in an exemplary embodiment of this disclosure;

[0032] Figure 4 This is a schematic diagram of the first structure of the motor controller provided in the exemplary embodiments of this disclosure;

[0033] Figure 5 This is a schematic diagram of a second structure in the motor controller provided in an exemplary embodiment of this disclosure;

[0034] Figure 6 This is a schematic diagram of a third structure of a motor controller provided in an exemplary embodiment of this disclosure.

[0035] Explanation of reference numerals in the attached figures:

[0036] 1. Motor controller; 2. Inverter module; 3. Three-phase intelligent fuse; 4. Motor; 5. DC module; 6. Control module; 7. First Hall sensor; 8. Bus intelligent fuse; 9. DC bus copper busbar; 91. DC bus interface; 92. Output interface; 93. Connection part; 901. First connection part; 902. Second connection part; 94. Positive terminal wiring; 95. Negative terminal wiring; 10. Second Hall sensor; 11. Dual magnetic ring filter assembly; 12. Power distribution interface; 13. Front drive electric control busbar; 14. Power distribution copper busbar; 141. Positive terminal of copper busbar; 142. Negative terminal of copper busbar; 15. Power distribution fuse; 16. Printed circuit board; 17. Three-phase copper busbar; 18. Support capacitor; 19. Silicon carbide module; 20. First cover plate; 21. Second cover plate; 22. Drive board; 23. Control board; 24. Low-voltage connector; 25. Vehicle low-voltage wiring harness; 26. Cooling water channel; 27. Other systems; 28. Water pump; 29. ​​Radiator; 121. AC power distribution interface; 122. Thermistor power distribution interface; 123. Minimum mean square power distribution interface. Detailed Implementation

[0037] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the protection scope of this application.

[0038] According to the first aspect of this application, please refer to Figure 1 and Figure 2 The motor controller 1 provided in this disclosure includes an inverter module 2 and a three-phase smart fuse 3. The inverter module 2 is used to convert DC power into AC power; the three-phase smart fuse 3 is connected between the inverter module 2 and the motor 4.

[0039] Among them, motor controller 1 is used to control the operation of motor 4, which can be a generator or a drive motor.

[0040] It is understandable that the three-phase intelligent fuse 3 refers to an intelligent protection device for three-phase power systems. The three-phase intelligent fuse 3 can not only realize overcurrent protection and short circuit protection of the three-phase terminals of the motor controller 1, but also realize fault isolation to prevent a fault in one phase of the motor 4 or the motor controller 1 from affecting the other normal phases and the normal operation of the entire system. Fault isolation also makes it easier for maintenance personnel to quickly locate the fault point, thereby improving the maintenance efficiency of the motor controller 1.

[0041] In this embodiment, the three-phase intelligent fuse 3 is installed inside the motor controller 1, thereby realizing overcurrent protection and short circuit protection of the three-phase terminals of the motor controller 1, and at the same time, improving the maintenance efficiency of the motor controller 1.

[0042] In one embodiment, please refer to Figure 1 and Figure 2 The front drive electric control bus 13 is connected to the DC bus interface 91 of the DC module 5 of the motor controller 1.

[0043] The battery pack is connected to the other end of the front drive electronic control bus 13.

[0044] Understandably, the current is supplied from the battery pack, passes through the front drive electronic control bus 13 and the motor controller 1, and reaches the motor 4.

[0045] In one embodiment, please refer to Figure 1 and Figure 2 It also includes a control module 6, which is used to control the inverter module 2.

[0046] The control module 6 includes a control board 23, a driver board 22, and a low-voltage connector 24.

[0047] The control module 6 may have at least one of the following functions: signal analysis, detection, transmission, and control.

[0048] The low-voltage connector 24 is used for electrical connection with the low-voltage wiring harness 25 of the vehicle, and the two ends of the control board 23 are connected to the drive board 22 and the low-voltage connector, respectively.

[0049] It is understandable that the control board 23 is connected to the motor 4 via feedback. By detecting whether the motor 4 is malfunctioning, when the motor 4 is malfunctioning, the abnormal signal is transmitted to the control board 23 through the feedback connection between the motor 4 and the control board 23. The control board 23 then adjusts the motor controller 1, thereby enabling the motor 4 to resume normal operation.

[0050] In one embodiment, please refer to Figure 1 and Figure 2 The inverter module 2 includes a first Hall sensor 7, and a three-phase smart fuse 3 is connected between the motor 4 and the first Hall sensor 7.

[0051] Understandably, when an abnormal situation occurs during the operation of motor 4, resulting in excessive current, the three-phase intelligent fuse 3 will come into play, cutting off the current path of the corresponding phase to prevent excessive current from damaging the power devices inside the motor controller 1 and the motor 4 itself.

[0052] It should be noted that if a short circuit occurs in the three-phase circuit of motor 4 due to reasons such as damaged insulation, the three-phase intelligent fuse 3 can promptly stop the short circuit current from continuing to flow, thus avoiding dangerous situations such as fires.

[0053] It is worth noting that the three-phase intelligent fuse 3 is connected to two of the three phases, and the two fuses work independently without affecting each other. If the power device of a certain phase fails, causing abnormal current in that phase, the corresponding three-phase intelligent fuse 3 will blow, so that the other two phases can still maintain some functions of the system to a certain extent. This not only improves the safety performance of the motor controller 1, but also saves its maintenance costs.

[0054] In one embodiment, please refer to Figure 1 and Figure 2 It also includes a bus intelligent fuse 8, one end of which is connected to the other end of the inverter module 2.

[0055] Among them, the busbar intelligent insurance 8 is an integrated active and passive insurance system.

[0056] It is understandable that the integrated active and passive insurance refers to the following: when the bus intelligent insurance 8 detects an impending abnormal situation such as a bus short circuit, it takes proactive measures to adjust and prevent the fault from occurring. When the proactive measures fail to prevent the fault from occurring, the passive insurance mechanism is quickly activated to cut off the circuit and prevent further damage to the motor controller 1 and the occurrence of safety accidents.

[0057] In this embodiment, the bus intelligent fuse 8 can further reduce the failure rate and provide stronger protection for the safe operation of the motor controller 1.

[0058] In one embodiment, a DC module 5 is also included, which is connected to the other end of the bus smart fuse 8.

[0059] Understandably, DC module 5 is used to output a stable DC signal to inverter module 2.

[0060] In one embodiment, please refer to Figure 1 and Figure 2 The DC module 5 includes a DC bus interface 91, which is connected to the other end of the bus smart fuse 8.

[0061] Understandably, the DC module 5 is connected to the other end of the bus smart fuse 8 via the DC bus interface 91, which improves the stability of signal transmission.

[0062] In one embodiment, the inverter module 2 includes a second Hall sensor 10, and one end of the bus smart fuse 8 is connected to the second Hall sensor 10.

[0063] Understandably, the second Hall sensor 10 is connected to one end of the bus intelligent fuse 8, which converts the DC signal into an AC signal and outputs it to the motor 4 more stably through the second Hall sensor 10.

[0064] In one embodiment, please refer to Figure 1 and Figure 2 It also includes a dual magnetic ring filter component 11.

[0065] Understandably, the dual magnetic ring filter assembly 11 can shield the motor controller 1 from noise interference from external electrical equipment, thereby improving the electromagnetic compatibility performance of the motor controller 1.

[0066] In one embodiment, please refer to Figure 1 and Figure 2 It also includes a DC module 5, and a dual magnetic ring filter component 11 is disposed within the DC module 5.

[0067] Understandably, the dual magnetic ring filter assembly 11 achieves power distribution before filtering in its structure. Power distribution before filtering can better shield the noise interference of external electrical equipment to the motor controller 1, and at the same time reduce the noise interference of the motor controller 1 to the external power distribution electrical equipment.

[0068] In one embodiment, please refer to Figure 1 and Figure 2 It also includes a bus intelligent fuse 8, a DC module 5 including a DC bus interface 91, and a dual magnetic ring filter assembly 11 connected between the DC bus interface 91 and the bus intelligent fuse 8.

[0069] Understandably, the dual magnetic ring filter assembly 11 is connected between the DC bus interface 91 and the bus intelligent fuse 8, thereby further improving the electromagnetic compatibility performance of the motor controller 1.

[0070] In one embodiment, please refer to Figure 1 and Figure 2 It also includes a DC module 5, which is used to electrically connect to the power distribution interface 12.

[0071] In one embodiment, the power distribution interface 12 includes at least one of an AC power distribution interface 121, a thermistor power distribution interface 122, and a minimum mean square power distribution interface 123.

[0072] The power distribution interface 12 can be of at least one of the following types: alternating current (AC), thermistor (PTC), and least mean square (LMS).

[0073] Understandably, by including at least one of the following types of power distribution interface 12: alternating current (AC), positive temperature coefficient (PTC), and least mean square (LMS), the number of power distribution interface types 12 is increased, thereby improving the diversity of power distribution.

[0074] In one embodiment, please refer to Figure 1 and Figure 2 The power distribution interface 12 is directly connected to the DC module 5 via a power distribution cable harness.

[0075] Understandably, in the prior art, the power distribution interface 12 needs to be electrically connected to the battery pack. However, directly connecting the power distribution interface 12 to the battery pack via the power distribution harness would require a longer power distribution harness, resulting in an excessively long power distribution harness. In this embodiment, the power distribution interface 12 is directly connected to the motor controller 1 via the power distribution harness. Since the motor controller 1 is electrically connected to the battery pack, the length of the power distribution harness can be reduced while the power distribution interface 12 is electrically connected to the battery pack, thereby saving space in the vehicle's wiring harness and reducing the power distribution burden.

[0076] In one embodiment, please refer to Figure 1 and Figure 2 The DC module 5 includes at least one power distribution fuse 15, which is electrically connected to the power distribution interface 12.

[0077] Understandably, please refer to Figure 1 and Figure 2 The DC module 5 may include only one power distribution fuse 15, which is electrically connected to any power distribution interface 12 to improve the safety performance of the motor controller 1.

[0078] In this embodiment, while electrically connecting a power distribution fuse 15 to a specific power distribution interface 12 for safety protection, the number of power distribution fuses 15 can be reduced, thereby lowering costs.

[0079] In one embodiment, please refer to Figure 1 and Figure 2 The number of power distribution interfaces 12 is multiple, and the DC module 5 also includes multiple power distribution fuses 15, which are electrically connected to the multiple power distribution interfaces 12 one by one.

[0080] Among them, the power distribution fuse 15 includes at least one of AC (Alternating Current) power distribution fuse 15, PTC (Positive Temperature Coefficient) power distribution fuse 15, and LMS (Least Mean Square) power distribution fuse 15.

[0081] It is understandable that corresponding types of power distribution fuses 15 are provided for different types of power distribution interfaces 12, so that the power distribution fuses 15 are more sensitive when the power distribution system is abnormal, thereby further improving the safety performance of the motor controller 1.

[0082] In one embodiment, please refer to Figure 3 , Figure 4 , Figure 5 , Figure 6 It also includes a dual magnetic ring filter assembly 11, and the DC module 5 also includes a DC bus copper bus 9. The DC bus copper bus 9 includes a DC bus interface 91 connected to the front drive electronic control bus 13. A connection part 93 is formed on the DC bus copper bus 9. The connection part 93 is used to electrically connect with the power distribution interface 12. The connection part 93 is set close to the DC bus interface 91 relative to the dual magnetic ring filter assembly 11.

[0083] The DC bus copper bus 9 also includes an output interface 92 connected to the second Hall sensor 10.

[0084] Understandably, since the connection part 93 is closer to the DC bus interface 91 than the dual magnetic ring filter assembly 11, the current is connected from the DC bus interface 91, which causes the power distribution interface 12, which is electrically connected to the connection part 93, to receive current before the filter assembly; thus, the motor controller 1 achieves the function of power distribution before filtering in its structure, which improves the electromagnetic compatibility performance of the entire motor controller.

[0085] In one embodiment, please refer to Figure 3 , Figure 4 , Figure 5 , Figure 6 The DC bus copper bus 9 includes a positive terminal trace 94 and a negative terminal trace 95. The connection part 93 includes a first connection part 901 and a second connection part 902. The first connection part 901 is formed on the positive terminal trace 94, and the second connection part 902 is formed on the negative terminal trace 95.

[0086] The connecting part 93 can be a double-ended stud, with the two parts of the double-ended stud connected to the positive terminal line 94 and the negative terminal line 95 respectively. The design of the double-ended stud can effectively save internal space of the motor controller 1.

[0087] In one embodiment, please refer to Figure 3 , Figure 4 , Figure 5 , Figure 6 The DC module 5 also includes a power distribution copper busbar 14, which includes a positive terminal 141 and a negative terminal 142 connected to the two ends of a power distribution interface 12. The positive terminal line 94 is connected to the positive terminal 141 of the power distribution copper busbar through a first connection part 901, and the negative terminal line 95 is connected to the negative terminal 142 of the power distribution copper busbar through a second connection part 902.

[0088] Among them, the positive terminal 141 of the power distribution copper busbar includes multiple positive terminals, and the negative terminal 142 of the power distribution copper busbar includes multiple negative terminals. The number of positive terminals can be equal to the number of negative terminals.

[0089] Among them, the power distribution fuse 15 is connected between a positive terminal and a negative terminal.

[0090] In one embodiment, please refer to Figure 4 , Figure 5 , Figure 6 The current signal first passes through the first Hall sensor 7, and then passes through the three-phase smart fuse 3 and the three-phase copper busbar 17 in sequence, and then outputs the current signal to the motor.

[0091] In one embodiment, the motor controller 1 further includes a cooling channel 26 for heat dissipation of the motor controller 1.

[0092] The cooling water channel is thermally connected to other systems 27, water pump 28, and radiator 29.

[0093] In one embodiment, a support capacitor 18 and a silicon carbide module 19 are also included, the silicon carbide module 19 being used to implement the switching control function.

[0094] The supporting capacitor 18 and the silicon carbide module 19 are connected in series between the first Hall sensor 7 and the second Hall sensor 10.

[0095] In one embodiment, please refer to Figure 2 It also includes a first cover plate 20 and a second cover plate 21.

[0096] The first cover plate 20 is located on the side of the second cover plate 21 away from the three-phase copper busbar 17.

[0097] The second cover plate 21 is disposed on the side of the printed circuit board 16 near the first cover plate 20.

[0098] It is understandable that the first cover plate 20 and the second cover plate 21 serve to protect the various components inside the motor controller 1.

[0099] According to a second aspect of this disclosure, an electronic control system is provided, which includes a motor controller 1 of any of the above embodiments; the electronic control system has all the beneficial effects of the motor controller 1 described above, which will not be repeated here.

[0100] According to a third aspect of this disclosure, a vehicle is provided that includes an electronic control system or motor controller 1 of any of the above embodiments, and the vehicle has all the beneficial effects of the electronic control system or motor controller 1 of any of the embodiments, which will not be repeated here.

[0101] The vehicle may be a gasoline vehicle, a plug-in hybrid vehicle, or a new energy vehicle, etc., and this disclosure does not make any specific restrictions.

[0102] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0103] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0104] The embodiments, implementation methods, and related technical features of this application can be combined and substituted for each other without conflict.

[0105] The above are merely preferred embodiments of this application and are not intended to limit this application in any way. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of this application without departing from the scope of the technical solution of this application shall still fall within the scope of the technical solution of this application.

Claims

1. A motor controller (1) for controlling the operation of a motor (4), characterized in that, include: Inverter module (2) is used to convert DC power to AC power; Three-phase smart fuse (3), one end of which is connected to one end of the inverter module (2), and the other end of which is used to connect to the motor (4).

2. The motor controller (1) according to claim 1, characterized in that, The inverter module (2) includes a first Hall sensor (7), and the three-phase smart fuse (3) is connected between the motor (4) and the first Hall sensor (7).

3. The motor controller (1) according to claim 1, characterized in that, It also includes a bus intelligent fuse (8), one end of which is connected to the other end of the inverter module (2).

4. The motor controller (1) according to claim 3, characterized in that, It also includes a DC module (5), which is connected to the other end of the bus smart fuse (8).

5. The motor controller (1) according to claim 4, characterized in that, The DC module (5) includes a DC bus interface (91), which is connected to the other end of the bus smart fuse (8).

6. The motor controller (1) according to claim 5, characterized in that, The inverter module (2) includes a second Hall sensor (10), and one end of the bus smart fuse (8) is connected to the second Hall sensor (10).

7. The motor controller (1) according to claim 4, characterized in that, It also includes a dual magnetic ring filter assembly (11), which is disposed within the DC module (5).

8. The motor controller (1) according to claim 1, characterized in that, It also includes a DC module (5) and at least one power distribution interface (12), the DC module (5) being electrically connected to at least one power distribution interface (12).

9. The motor controller (1) according to claim 8, characterized in that, The power distribution interface (12) includes at least one of the following: AC power distribution interface (121), thermistor power distribution interface (122), and minimum mean square power distribution interface (123).

10. The motor controller (1) according to claim 9, characterized in that, The power distribution interface (12) is directly connected to the DC module (5) via a power distribution cable harness.

11. The motor controller (1) according to claim 8, characterized in that, The DC module (5) includes at least one power distribution fuse (15), and at least one of the power distribution fuses (15) is electrically connected to the power distribution interface (12).

12. The motor controller (1) according to claim 8, characterized in that, The DC module (5) also includes a DC bus copper bus (9), on which a connection part (93) is formed, which is used to electrically connect with the power distribution interface (12).

13. The motor controller (1) according to claim 12, characterized in that, It also includes a dual magnetic ring filter assembly (11), which is disposed in the DC module (5); the DC bus copper bus (9) includes a DC bus interface (91) connected to the front drive electrical control bus (13), and the connection part (93) is disposed close to the DC bus interface (91) relative to the dual magnetic ring filter assembly (11).

14. The motor controller (1) according to claim 13, characterized in that, The DC bus copper bus (9) includes a positive terminal trace (94) and a negative terminal trace (95). The connection part (93) includes a first connection part (901) and a second connection part (902). The first connection part (901) is formed on the positive terminal trace (94), and the second connection part (902) is formed on the negative terminal trace (95).

15. The motor controller (1) according to claim 14, characterized in that, The DC module (5) also includes a power distribution copper busbar (14), which is electrically connected to the connection part (93).

16. The motor controller (1) according to claim 15, characterized in that, The power distribution copper busbar (14) includes a positive terminal (141) and a negative terminal (142) of the power distribution copper busbar respectively connected to both ends of a power distribution interface (12). The positive terminal line (94) is connected to the positive terminal (141) of the power distribution copper busbar through the first connecting part (901), and the negative terminal line (95) is connected to the negative terminal (142) of the power distribution copper busbar through the second connecting part (902).

17. An electronic control system, characterized in that, Includes the motor controller (1) as described in any one of claims 1 to 16.

18. A vehicle, characterized in that, It includes the motor controller (1) as described in any one of claims 1 to 16, or the electronic control system as described in claim 17.

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