Motor controller, power assembly and vehicle

Abstract

The utility model provides a motor controller, power assembly and vehicle, wherein the motor controller includes electric cabinet, IGBT module and insulating colloid, electric cabinet includes box body and potting shell, the box body is equipped with the accommodation cavity, the potting shell is arranged in the accommodation cavity, the potting shell is equipped with the potting cavity, the IGBT module is arranged in the potting cavity, the insulating colloid is arranged in the potting cavity, the IGBT module is arranged in the potting cavity, and the insulating colloid is arranged in the potting cavity. And at least part of the IGBT module is covered. The technical scheme of the utility model aims to reduce the damage of electric arc to other components in the electric cabinet and prolong the service life of the motor controller.

Description

TECHNICAL FIELD

[0001] The utility model relates to vehicle technical field, specifically related to motor controller, power assembly and vehicle. BACKGROUND

[0002] The vehicle includes a power assembly that provides driving force for the vehicle, and the power assembly includes a motor and a motor controller that controls operation of the motor. In related technology, the motor controller includes a DC module, an IGBT module, and an AC module connected in sequence. It can be understood that the IGBT module plays an important role in converting DC current into AC current, and the motor is used to receive the AC current.

[0003] However, the researchers found that when the vehicle is running, a large current will pass through the IGBT module, which causes the IGBT module to produce an arc, thereby damaging other components in the electric control box, and thus reducing the service life of the motor controller. SUMMARY

[0004] The embodiments of the utility model provide a kind of motor controller, power assembly and vehicle, can reduce electric arc damage to other components in the electric control box, improve the service life of the motor controller.

[0005] In a first aspect, the embodiments of the utility model provide a kind of motor controller, and the motor controller includes:

[0006] The electric control box includes a box body and a glue-filled shell, the box body is provided with a receiving cavity, the glue-filled shell is arranged in the receiving cavity, and the glue-filled shell is provided with a glue-filled cavity;

[0007] The IGBT module is arranged in the glue-filled cavity; and

[0008] The insulating glue is arranged in the glue-filled cavity and covers at least part of the IGBT module.

[0009] In an embodiment, the IGBT module includes an IGBT module and a driving board, the driving board is used to control the IGBT module, and the insulating glue covers the IGBT module and the driving board.

[0010] In an embodiment, in the first direction, one end of the glue-filled shell is connected to the box body, and the other end is provided with a glue-filled port communicated with the receiving cavity, and in the first direction, the minimum distance between the side of the IGBT module close to the glue-filled port and the glue-filled port is less than or equal to 6mm.

[0011] In one embodiment, the motor controller further includes a three-phase busbar disposed in the receiving cavity. The three-phase busbar includes a first mounting base and a plurality of first busbars disposed in the first mounting base. At least one of the first busbars extends into the potting cavity and is connected to the IGBT module. The insulating adhesive covers the portion of the first busbar extending into the potting cavity.

[0012] In one embodiment, the potting shell has a clearance hole, and at least one of the first conductive bars passes through the clearance hole to extend into the potting cavity.

[0013] In one embodiment, the motor controller further includes a sensor disposed within the potting cavity, the sensor being used to seal the gap between a first conductive bar and the clearance hole.

[0014] In one embodiment, the potting shell includes a shell body and a first baffle plate separately disposed from the shell body. The first baffle plate is provided with the clearance hole for the first conductive busbar to pass through. The first baffle plate is used to be assembled onto the shell body.

[0015] In one embodiment, the first baffle plate is inserted into the shell body.

[0016] In one embodiment, the shell body includes two second baffles disposed opposite to each other. The second baffles are disposed in the housing and have a first end near the three-phase busbar. The first end is bent to have a limiting segment extending toward the other side. The shell body also includes a limiting rib extending in the same direction as the limiting segment. The limiting rib is disposed in the housing. In the extending direction of the first busbar, the limiting rib and the limiting segment are spaced apart to form a slot for the first baffle to be inserted.

[0017] In one embodiment, the first baffle plate is also connected to the second baffle plate via the insulating adhesive.

[0018] In one embodiment, the motor controller further includes a bus capacitor module, which includes a first positive conductor and a first negative conductor. The IGBT module includes a second positive conductor and a second negative conductor. The first positive conductor extends into the potting cavity to connect with the second positive conductor, and the first negative conductor extends into the potting cavity to connect with the second negative conductor. The insulating adhesive covers the portion of the first positive conductor extending into the potting cavity and also covers the portion of the first negative conductor extending into the potting cavity. The insulating adhesive also covers the second positive conductor and the second negative conductor.

[0019] In one embodiment, the potting shell has a clearance opening through which the first positive electrode conductive busbar and the first negative electrode conductive busbar extend into the potting cavity.

[0020] In one embodiment, the bus capacitor module includes a second mounting base, and the first positive electrode conductive bus and the first negative electrode conductive bus are respectively disposed on the second mounting base. The second mounting base is used to block the clearance opening to prevent the insulating colloid from flowing out of the clearance opening.

[0021] In one embodiment, the motor controller further includes a relay assembly, which includes a third mounting base, a relay, a circuit board, a detection contact, and a third conductive bus. The relay is disposed on the third mounting base and connected to the third conductive bus. The third conductive bus is connected to the bus capacitor module. The circuit board is disposed on the third mounting base. The detection contact is connected to the relay and the circuit board and is used to detect whether the third conductive bus and the relay are connected.

[0022] In one embodiment, the relay is configured as a caseless relay.

[0023] Secondly, embodiments of the present invention provide a powertrain, the powertrain including a motor and a motor controller as described above, the motor controller being connected to the motor.

[0024] In one embodiment, the powertrain further includes a reduction gear assembly at the output end of the motor, the reduction gear assembly and the motor being disposed side by side on one side of the housing, and the housing portion extending into the space between the reduction gear assembly and the motor.

[0025] Thirdly, embodiments of the present invention provide a vehicle that includes the aforementioned powertrain.

[0026] The beneficial effects of the embodiments of this utility model are as follows:

[0027] In embodiments of this invention, an insulating colloid is used to cover the IGBT module to suppress arcing, thereby reducing damage to other components in the electrical control box caused by the arc and improving the service life of the motor controller. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a perspective view of the powertrain provided in an embodiment of the present utility model;

[0030] Figure 2 yes Figure 1 Exploded view of part of the structure of the motor controller;

[0031] Figure 3 yes Figure 2 A partial structural diagram of the motor controller;

[0032] Figure 4 yes Figure 3 Enlarged view of point A in the middle;

[0033] Figure 5 yes Figure 2 Schematic diagram of the structure of a three-phase busbar;

[0034] Figure 6 yes Figure 5 Another structural schematic diagram of a three-phase busbar;

[0035] Figure 7 yes Figure 2 Schematic diagram of the middle bus capacitor module;

[0036] Figure 8 yes Figure 2 A schematic diagram of the structure of the intermediate filter component;

[0037] Figure 9 yes Figure 8 A partial structural diagram of the intermediate filter component;

[0038] Figure 10 yes Figure 2 Schematic diagram of the structure of the relay assembly;

[0039] Figure 11 yes Figure 10 Another structural diagram of the relay assembly;

[0040] Figure 12 yes Figure 1 Exploded view of part of the structure of the motor controller;

[0041] Figure 13 yes Figure 12 Enlarged view of point B in the middle;

[0042] Figure 14 yes Figure 13 A schematic diagram of the structure of the middle bus capacitor module, the overlapping conductor bus, and the IGBT module;

[0043] Figure 15 yes Figure 14 A schematic diagram of the structure of the overlapping conductive busbar and protective layer.

[0044] 100. Powertrain; 200. Motor; 300. Reduction Gear; 400. Motor Controller; 410. Electrical Control Box; 421. First End Plate; 422. Second End Plate; 423. Side Panel; 424. Receiving Cavity; 430. Glue Filling Shell; 431. Shell Body; 432. Second Baffle Plate; 433. Limiting Section; 434. Limiting Rib; 435. First Baffle Plate; 436. Glue Filling Cavity; 437. Glue Filling Port; 439. Clearance Port; 440. Clearance Hole; 45 1. Shielding cavity; 510. IGBT module; 511. IGBT module; 514. Driver board; 520. Three-phase busbar; 521. First mounting base; 522. First busbar; 523. U-phase busbar; 524. V-phase busbar; 525. W-phase busbar; 526. Adapter busbar; 528. Protection device; 529. N-phase busbar; 530. Busbar capacitor module; 531. Second mounting base; 532. First positive busbar; 533. ... 534. First N-line conductive busbar; 537. First Y-capacitor; 538. DC magnetizing ring; 550. Filter assembly; 551. Second conductive busbar; 552. Third positive conductive busbar; 553. Third negative conductive busbar; 554. Second N-line conductive busbar; 555. Grounding conductive busbar; 556. Nano-amorphous magnetic ring; 557. Ferrite magnetic ring; 558. Filter board; 559. Second Y-capacitor; 560. Relay assembly; 561. Third mounting base; 562. Relay; 563. Circuit board; 564. Detection contact; 565. Third conductor bus; 566. Fourth negative conductor bus; 567. Third neutral conductor bus; 568. U-shaped magnet; 569. Magnetic arm; 570. Sensing chip; 700. Heat dissipation path; 810. Negative fuse; 820. Positive fuse; 830. Power distribution fuse; 840. Overlapping conductor bus; 841. Laser positioning hole; 850. Protective layer; 860. X capacitor; 900. Sensor. Detailed Implementation

[0045] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present utility model. In addition, it should be understood that the specific embodiments described herein are only for illustration and explanation of the present utility model and are not intended to limit the present utility model. In the present utility model, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the upper and lower positions of the device in actual use or operation, specifically the drawing directions in the accompanying drawings; while "inner" and "outer" refer to the outline of the device.

[0046] The vehicle includes a powertrain that provides driving force to the vehicle, and the powertrain includes an electric motor and a motor controller for controlling the operation of the electric motor. In related technologies, the motor controller includes a DC module, an IGBT module, and an AC module connected in sequence. It is understood that the IGBT module plays a crucial role in converting DC current into AC current, and the motor is used to receive this AC current.

[0047] However, researchers discovered that when the vehicle is running, a large current flows through the IGBT module, causing arcing in the IGBT module, which damages other components in the electrical control box and reduces the lifespan of the motor controller.

[0048] Therefore, this utility model provides a motor controller, which aims to reduce the damage caused by electric arc to other components in the electrical control box and improve the service life of the motor controller.

[0049] Reference Figures 1 to 15 In one embodiment of this utility model, the motor 200 includes an electrical control box 410, an IGBT module, and insulating colloid. The electrical control box 410 includes a housing and a potting shell 430. The housing has a receiving cavity 424, and the potting shell 430 is disposed within the receiving cavity 424. The potting shell 430 has a potting cavity 436 within it. The IGBT module is disposed within the potting cavity 436, and the insulating colloid is disposed within the potting cavity 436, covering at least a portion of the IGBT module. This suppresses arcing from the IGBT module, thereby reducing damage to other components within the electrical control box 410 caused by arcing and improving the service life of the motor controller 400.

[0050] In one embodiment, the IGBT module includes an IGBT module and a driver board 514. The driver board 514 is used to control the IGBT module, and an insulating colloid covers both the IGBT module and the driver board 514. Thus, the insulating colloid not only contacts the IGBT module but also the driver board 514, which helps to further reduce damage to other components within the electrical control box 410 caused by electric arcing and improves the service life of the motor controller 400.

[0051] There are various relative positional relationships between the IGBT module and the driver board 514. For example, in the first direction, one end of the potting housing 430 is connected to the enclosure, and the other end has a potting port 437 communicating with the receiving cavity 424. The IGBT module and the driver board 514 are stacked sequentially in the direction near the potting port 437. In some other embodiments, the driver board 514 and the IGBT module are stacked sequentially in the direction near the potting port 437.

[0052] In one embodiment, the thickness direction of the IGBT module aligns with the orientation of the potting port 437. A potting gap, ranging from 2mm to 12mm, is provided between the outer periphery of the IGBT module and the potting shell 430. This allows for a reduction in the height of the potting shell 430, resulting in a thinner control box 410. Furthermore, a smaller potting gap makes it more difficult for insulating adhesive to enter, while a larger gap results in a larger potting shell 430, hindering miniaturization of the control box 410. Therefore, a potting gap between 2mm and 12mm allows for easier entry of insulating adhesive while maintaining a smaller potting shell 430, thus promoting miniaturization of the control box 410. In some other embodiments, the length direction of the IGBT module aligns with the height direction of the potting shell 430.

[0053] In one embodiment, in the first direction, one end of the potting shell 430 is connected to the housing, and the other end is provided with a potting port 437 communicating with the receiving cavity 424. In the first direction, the minimum distance between the side of the IGBT module near the potting port 437 and the potting port 437 is less than or equal to 6 mm. This avoids the potting shell 430 from being too large in the first direction, which is beneficial for miniaturizing the control box 410. Further, in one embodiment, in the first direction, one end of the potting shell 430 is connected to the housing, and the other end is provided with a potting port 437 communicating with the receiving cavity 424. The IGBT module and the drive board 514 are arranged sequentially in the direction near the potting port 437. In the first direction, the minimum distance between the side of the drive board 514 near the potting port 437 and the potting port 437 is less than or equal to 6 mm.

[0054] In one embodiment, the motor controller 400 further includes a three-phase busbar 520 disposed in a receiving cavity 424. The three-phase busbar 520 includes a first mounting base 521 and a plurality of first conductive bars 522 disposed in the first mounting base 521. The first conductive bars 522 are connected to IGBT modules. Researchers have found that arcing can occur at the connection points between the first conductive bars 522 and the IGBT modules. To address this, at least one first conductive bar 522 extends into a potting cavity 436 to connect to the IGBT module, and an insulating adhesive covers the portion of the first conductive bar 522 extending into the potting cavity 436. In this way, the insulating adhesive can effectively reduce the damage to other components within the motor controller 400 caused by arcing. Further, in one embodiment, the first conductive bar 522 is connected to an IGBT module.

[0055] In one embodiment, the potting shell 430 has a clearance hole 440, through which at least one first conductive bus 522 passes to extend into the potting cavity 436. This simplifies the structure of the first conductive bus 522 and reduces the need for the first conductive bus 522 to enter the potting cavity 436 by bending.

[0056] In one embodiment, the motor controller 400 further includes a sensor 900 disposed within the potting cavity 436, which blocks the clearance hole 440. It is understood that the sensor 900 is not only used to detect the current in the first conductive busbar 522, but also reused as a component to prevent insulating adhesive from flowing out of the clearance hole 440. This facilitates a simplification of the structure of the motor controller 400. Exemplarily, the sensor 900 may be, but is not limited to, a sensor 900 for detecting the current flowing through the first conductive busbar 522. The sensor 900 may be configured as a Hall sensor 900. The type of sensor 900 can also be other, as long as it can detect the current in the first conductive busbar 522.

[0057] In one embodiment, the potting housing 430 includes a housing body 431 and a first baffle plate 435 separately disposed from the housing body 431. The first baffle plate 435 is provided with a clearance hole 440 for the first conductive bus 522 to pass through. The first baffle plate 435 is used to assemble onto the housing body 431. Thus, the user can first pass the first conductive bus 522 through the clearance hole 440, and then install the three-phase conductive bus 520 onto the housing body 431 along with the first baffle plate 435.

[0058] There are many ways to install the first baffle plate 435 onto the housing body 431. In one embodiment, the first baffle plate 435 is inserted into the housing body 431. The insertion process is simple and convenient, which is beneficial for the automated production of the motor controller 400. In some other embodiments, the first baffle plate 435 is screwed onto the housing body 431.

[0059] In one embodiment, the housing body 431 includes two opposing second baffle plates 432 disposed in the housing. Each second baffle plate 432 has a first end near the three-phase busbar 520, which is bent to have a limiting segment 433 extending towards the other. The housing body 431 also includes a limiting rib 434 extending in the same direction as the limiting segment 433, disposed in the housing. In the extending direction of the first busbar 522, the limiting rib 434 and the limiting segment 433 are spaced apart to create a slot for insertion of the first baffle plate 435. It is understood that the slot opening faces the same direction as the glue-filling port 437. This allows for a compact structure of the motor controller. It also ensures that the minimum distance between the side of the three-phase busbar 520 away from the glue-filling housing 430 and the housing in the extending direction of the first busbar 522 is less than the length of the first busbar 522 extending into the glue-filling cavity 436. During the process of installing the three-phase busbar 520 into the enclosure, the first busbar 522 can be inserted through the corresponding clearance hole 440 first, and then the three-phase busbar 520 and the first baffle plate 435 can be moved together so that the three-phase busbar 520 is installed in the enclosure and the first baffle plate 435 is inserted into the shell body 431.

[0060] For example, the housing includes a first end plate 421, a second end plate 422, and a side panel 423 that together enclose the receiving cavity 424. In a first direction, the first end plate 421 and the second end plate 422 are respectively disposed at both ends of the side panel 423. A second baffle plate 432 is disposed on the first end plate 421, and a limiting rib 434 is disposed on the first end plate. In the extending direction of the first conductive busbar 522, the minimum distance between the side of the three-phase conductive busbar 520 away from the glue-filling shell 430 and the side panel 423 is less than the length of the first conductive busbar 522 extending into the glue-filling cavity 436.

[0061] In one embodiment, the first baffle plate 435 is also connected to the second baffle plate 432 by insulating adhesive. Thus, the insulating adhesive not only prevents arcing damage to other components, but also connects the first baffle plate 435 and the second baffle plate 432.

[0062] In one embodiment, the three-phase busbar 520 further includes a trigger member disposed on the first mounting base 521 and an actuator connected to the trigger member. The trigger member can trigger the actuator to move toward the first busbar 522 and disconnect the circuit containing at least two of the first busbars 522. This reduces the risk of damage to the components of the motor controller 400. The triggering condition of the trigger member may be, but is not limited to, triggering when the motor controller 400 receives a back electromotive force exceeding a threshold transmitted from the motor 200.

[0063] The trigger can have various structural forms. For example, the trigger can be configured as an explosive mechanism. When the motor controller 400 receives a back electromotive force exceeding a threshold from the motor 200, the explosive mechanism detonates to drive the actuator towards the first conductive busbar 522. The actuator, under inertia, breaks at least two of the first conductive busbars 522, thereby severing the circuit containing at least two of the first conductive busbars 522. In some other embodiments, the explosive device can also have other structural forms, as long as it enables the trigger to trigger the actuator when the motor controller 400 receives a back electromotive force exceeding a threshold from the motor 200, causing the actuator to move towards the first conductive busbar 522 and sever the circuit containing at least two of the first conductive busbars 522. Further details are omitted here. For ease of explanation in conjunction with the accompanying drawings, the trigger and actuator are defined here as a whole as the protective device 528.

[0064] In one embodiment, the plurality of first conductive busbars 522 include a U-phase conductive busbar, a V-phase conductive busbar, and a W-phase conductive busbar. The V-phase conductive busbar is positioned between the U-phase and W-phase conductive busbars along its width. An actuator is used to move toward and destroy the U-phase and W-phase conductive busbars. Because the U-phase and W-phase conductive busbars are located further outwards than the V-phase conductive busbars, the actuator can more easily destroy them. In some other embodiments, the actuator is used to move toward and destroy the U-phase and V-phase conductive busbars.

[0065] In one embodiment, the three-phase busbar 520 further includes a transition busbar 526 disposed on the first mounting base 521, with the U-phase busbar connected to the transition busbar 526 and the W-phase busbar connected to the transition busbar 526. In another embodiment, the three-phase busbar 520 further includes an N-phase busbar.

[0066] In one embodiment, the motor controller 400 further includes a bus capacitor module 530, which includes a first positive conductor bus 532 and a first negative conductor bus 533. The IGBT module includes a second positive conductor bus 512 and a second negative conductor bus 513. The first positive conductor bus 532 and the second positive conductor bus 512 are connected, and the first negative conductor bus 533 and the second negative conductor bus 513 are connected. Researchers have found that arcing occurs at the portion of the first positive conductor bus 532 connected to the second positive conductor bus 512, and arcing also occurs at the portion of the first negative conductor bus 533 connected to the second negative conductor bus 513. Therefore, the first positive conductive bus 532 extends into the potting cavity 436 to connect with the second positive conductive bus 512, and the first negative conductive bus 533 extends into the potting cavity 436 to connect with the second negative conductive bus 513. Insulating adhesive covers the portion of the first positive conductive bus 532 extending into the potting cavity 436, as well as the portion of the first negative conductive bus 533 extending into the potting cavity 436. The insulating adhesive also covers the second positive conductive bus 512 and the second negative conductive bus 513. Thus, the portion of the first positive conductive bus 532 extending into the potting cavity 436, through the insulating adhesive, can effectively reduce the damage to other components within the motor controller 400 caused by arcing. Similarly, the portion of the first negative conductive bus 533 extending into the potting cavity 436, through the insulating adhesive, can effectively reduce the damage to other components within the motor controller 400 caused by arcing. The second positive conductive bus 512 and the second negative conductive bus 513, through the insulating adhesive, can also effectively reduce the damage to other components within the motor controller 400 caused by arcing.

[0067] In one embodiment, the potting shell 430 has a clearance opening 439 through which the first positive electrode conductive busbar 532 and the first negative electrode conductive busbar 533 extend into the potting cavity 436. This simplifies the structural form of the first positive electrode conductive busbar 532 and the first negative electrode conductive busbar 533, and reduces the need for the first positive electrode conductive busbar 532 and the first negative electrode conductive busbar 533 to enter the potting cavity 436 by bending.

[0068] In one embodiment, the bus capacitor module 530 includes a second mounting base 531. A first positive conductive bus 532 and a first negative conductive bus 533 are respectively disposed on the second mounting base 531. The second mounting base 531 blocks the clearance opening 439 to prevent insulating adhesive from flowing out of the clearance opening 439. It can be understood that the second mounting base 531 is not only used for mounting the first positive conductive bus 532 and the first negative conductive bus 533, but also reused as a component to prevent insulating adhesive from flowing out of the clearance opening 439. This helps to simplify the structure of the motor controller 400.

[0069] In one embodiment, the motor controller 400 further includes a connecting conductive bus 840, through which the first negative conductive bus 533 is connected to the second negative conductive bus 513. The connection between the first negative conductive bus 533 and the second negative conductive bus 513 via the connecting conductive bus 840 allows for more flexible positioning of the two busbars. Furthermore, it prevents the distance between the bus capacitor module 530 and the IGBT module from becoming too small, thus improving the safety factor of the motor controller 400.

[0070] There are many ways to connect the overlapping conductive busbar 840 to the first negative conductive busbar 533 and the second negative conductive busbar 513. In one embodiment, the overlapping conductive busbar 840 is laser-welded to the first negative conductive busbar 533 and the second negative conductive busbar 513. In some other embodiments, the first negative conductive busbar 533 and the second negative conductive busbar 513 are connected by bolts.

[0071] To facilitate laser positioning in laser welding equipment, in one embodiment, the overlapping conductive busbar 840 is provided with laser positioning holes 841 for positioning the laser beam. Thus, the laser welding equipment can define the initial position of the laser beam through the laser positioning holes 841. In one embodiment, two laser positioning holes 841 are provided.

[0072] In one embodiment, the overlapping conductive bus 840 is further provided with a protective layer 850, which is made of a high-temperature resistant material and / or an insulating material. The high-temperature material makes the overlapping conductive bus 840 less likely to melt under laser irradiation, and the insulating material can prevent other components of the motor controller 400 from accidentally touching the protective layer 850 and causing a short circuit, which helps to improve the safety of the motor controller 400.

[0073] In one embodiment, the bus capacitor module 530 further includes a negative fuse 810, a positive fuse 820, and a distribution fuse 830 disposed on the second mounting base 531. Thus, the negative fuse 810, positive fuse 820, and distribution fuse 830 share a single second mounting base 531, which helps reduce the number of structural components in the bus capacitor module 530 and improves the automation level of the motor controller 400 manufacturing process. In one embodiment, two distribution fuses 830 are provided.

[0074] In one embodiment, the bus capacitor module 530 further includes components such as a first Y capacitor, a DC magnetizing ring 538, and a first N-line conductive bus. The electrical connection relationship of the first Y capacitor, the DC magnetizing ring 538, the first N-line conductive bus, the first positive conductive bus 532, and the first negative conductive bus 533 can be, but is not limited to, referring to related technologies, and will not be described in detail here.

[0075] It is worth mentioning that the electrical connection relationships of the components in the bus capacitor module 530 can be, but are not limited to, referring to relevant technologies, and will not be elaborated on here.

[0076] In one embodiment, the motor controller 400 further includes a bus connector and a filter assembly 550. The filter assembly 550 connects the bus connector and the bus capacitor module 530. The bus connector is also used to connect a battery pack. The filter assembly 550 includes a second conductive bus 551, a nano-amorphous magnetic ring 556, and a ferrite magnetic ring 557. The second conductive bus 551 connects the bus connector and the bus capacitor module 530. The nano-amorphous magnetic ring 556 and the ferrite magnetic ring 557 are sleeved on the second conductive bus 551. The nano-amorphous magnetic ring 556 has a good filtering effect in the low-frequency range, but its filtering effect decreases very quickly as the frequency increases. The ferrite magnetic ring 557 is less affected by frequency, which is beneficial for meeting EMC requirements. In some other embodiments, other types of magnetic rings can be used to replace the nano-amorphous magnetic ring 556 and the ferrite magnetic ring 557 according to actual needs, and no limitation is made here.

[0077] In one embodiment, the filter assembly 550 further includes an X capacitor and a second Y capacitor, a filter plate 558, a grounding busbar 555, and a second N-line busbar. The second busbar 551 includes a third positive busbar 552 and a third negative busbar 553. The electrical connections of the X capacitor, the second Y capacitor, the second N-line busbar, the grounding busbar 555, the filter plate 558, and the second busbar 551 can be, but are not limited to, referring to related technologies, and will not be elaborated further here. The second Y capacitor is used to suppress common-mode interference, and the X capacitor is used to suppress differential-mode interference, which is beneficial for meeting EMC requirements.

[0078] In one embodiment, the motor controller 400 further includes a relay assembly 560, which includes a third mounting base 561, a relay 562, a circuit board 563, a detection contact 564, and a third conductive bus 565. The relay 562 is mounted on the third mounting base 561 and connected to the third conductive bus 565. The third conductive bus 565 is connected to the bus capacitor module 530. The circuit board 563 is mounted on the third mounting base 561. The detection contact 564 connects the relay 562 and the circuit board 563, and is used to detect whether the third conductive bus 565 of the relay 562 is conductive with the relay 562. The detection contact 564 eliminates the need for a detection wiring harness connecting the relay 562 and the circuit board 563, facilitating automation in the manufacturing of the motor controller 400. In some other embodiments, an auxiliary contact may also be located on the third conductive bus 565 and connected to the circuit board 563.

[0079] In one embodiment, the relay 562 is configured as a caseless relay 562. It can be understood that a caseless relay 562 is a relay 562 that does not have its own casing, which makes the relay assembly 560 smaller in size, thus contributing to the miniaturization of the motor controller 400.

[0080] In one embodiment, the relay assembly 560 further includes a U-shaped magnet passing through a circuit board 563. The circuit board 563 is provided with a sensing chip 570, which is disposed between the two magnetic arms 569 of the U-shaped magnet. The sensing chip 570 is used to detect the magnitude of the current passing through the third conductive bus 565. Thus, the magnitude of the current passing through the third conductive bus 565 can be detected by the sensing chip 570.

[0081] In one embodiment, the third conductive bus 565 includes a fourth negative conductive bus 566 and a third N-line conductive bus. Multiple relays 562 are provided, and each relay 562 is correspondingly connected to a fourth negative conductive bus 566 and a third N-line conductive bus.

[0082] In one embodiment, the motor controller 400 further includes a power supply circuit for outputting the supply voltage. The housing is provided with a heat dissipation path 700 through which coolant flows, passing over the IGBT module, the power supply circuit, and the bus capacitor module 530. This heat dissipation path 700 allows coolant to flow through it. Thus, the temperatures of the IGBT module, the power supply circuit, and the bus capacitor module 530 will not become excessively high, resulting in higher operating efficiency for the motor controller 400.

[0083] In one embodiment, the heat dissipation flow path 700 is elongated, with one end serving as an inlet for coolant flow and the other end as an outlet for coolant flow. This simplifies the structure of the heat dissipation flow path 700, allowing for a shorter length and a more compact structure of the motor controller 400, thus reducing its manufacturing cost.

[0084] There are many types of coolant; for example, water is used as the coolant.

[0085] In one embodiment, the electrical control box 410 further includes a flow path cover plate disposed in the receiving cavity 424 and connected to the box wall of the box body. This flow path cover plate and the box wall together restrict the heat dissipation flow path 700. In some other embodiments, the heat dissipation flow path 700 is formed inside the box wall of the box body.

[0086] In one embodiment, the flow path cover and the housing wall are connected by welding. This makes the connection between the flow path cover and the housing wall more stable, which helps to improve the sealing performance of the heat dissipation flow path 700 and reduce the risk of coolant leakage. Furthermore, it simplifies the molding process of the heat dissipation flow path 700 and facilitates the design of its routing. In some other embodiments, the flow path cover is bonded to the housing wall.

[0087] In one embodiment, the electrical control box 410 further includes a shielding shell with a receiving cavity 424, the shielding shell having a shielding cavity 451, and the power supply circuit being located in the shielding cavity 451 to improve EMC performance.

[0088] Secondly, embodiments of this utility model provide a powertrain 100, which includes a motor 200 and the aforementioned motor controller 400. The motor controller 400 adopts all the technical solutions of all the above embodiments, and therefore has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here. The motor controller 400 is connected to the motor 200.

[0089] In one embodiment, the powertrain 100 further includes a reduction gear 300 connected to the output end of the motor 200. The reduction gear 300 and the motor 200 are arranged side by side on one side of the housing, and part of the housing extends into the space between the reduction gear 300 and the motor 200. This increases the volume of the housing and improves the space utilization of the powertrain 100.

[0090] Secondly, embodiments of this utility model provide a vehicle including the aforementioned powertrain 100. The powertrain 100 employs all the technical solutions of all the above embodiments, and therefore possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.

[0091] The embodiments of this utility model have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this utility model. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A motor controller, characterized in that, include: An electrical control box includes a box body and a glue-filling shell. The box body has a receiving cavity, and the glue-filling shell is disposed in the receiving cavity. The glue-filling shell has a glue-filling cavity inside. The IGBT module is located inside the potting cavity; as well as An insulating colloid is disposed within the potting cavity and covers at least a portion of the IGBT module.

2. The motor controller according to claim 1, characterized in that, The IGBT module includes an IGBT module and a driver board. The driver board is used to control the IGBT module, and the insulating colloid covers the IGBT module and the driver board.

3. The motor controller according to claim 1, characterized in that, In the first direction, one end of the potting shell is connected to the housing, and the other end is provided with a potting port communicating with the receiving cavity. In the first direction, the minimum distance between the side of the IGBT module near the potting port and the potting port is less than or equal to 6mm.

4. The motor controller according to claim 1, characterized in that, The motor controller further includes a three-phase busbar disposed in the receiving cavity. The three-phase busbar includes a first mounting base and a plurality of first busbars disposed in the first mounting base. At least one of the first busbars extends into the potting cavity and is connected to the IGBT module. The insulating adhesive covers the portion of the first busbar extending into the potting cavity.

5. The motor controller according to claim 4, characterized in that, The potting shell has a clearance hole, and at least one of the first conductive bars passes through the clearance hole to extend into the potting cavity.

6. The motor controller according to claim 5, characterized in that, The motor controller also includes a sensor, which is located inside the potting cavity and blocks the clearance hole.

7. The motor controller according to claim 5, characterized in that, The glue-filled shell includes a shell body and a first glue-blocking plate separately disposed from the shell body. The first glue-blocking plate is provided with a clearance hole for the first conductive busbar to pass through. The first glue-blocking plate is used to be assembled onto the shell body.

8. The motor controller according to claim 7, characterized in that, The first baffle plate is inserted into the shell body.

9. The motor controller according to claim 8, characterized in that, The shell body includes two opposing second baffles, which are disposed in the housing. Each second baffle has a first end near the three-phase busbar. The first end is bent to have a limiting segment extending toward the other side. The shell body also includes a limiting rib extending in the same direction as the limiting segment. The limiting rib is disposed in the housing. In the extending direction of the first busbar, the limiting rib and the limiting segment are spaced apart to form a slot for the first baffle to be inserted.

10. The motor controller according to claim 9, characterized in that, The first baffle plate is also connected to the second baffle plate via the insulating adhesive.

11. The motor controller according to claim 1, characterized in that, The motor controller further includes a bus capacitor module, which includes a first positive conductor and a first negative conductor. The IGBT module includes a second positive conductor and a second negative conductor. The first positive conductor extends into the potting cavity to connect with the second positive conductor, and the first negative conductor extends into the potting cavity to connect with the second negative conductor. The insulating adhesive covers the portion of the first positive conductor extending into the potting cavity and also covers the portion of the first negative conductor extending into the potting cavity. The insulating adhesive also covers the second positive conductor and the second negative conductor.

12. The motor controller according to claim 11, characterized in that, The potting shell has a clearance opening, through which the first positive electrode and the first negative electrode extend into the potting cavity.

13. The motor controller according to claim 12, characterized in that, The bus capacitor module includes a second mounting base, and the first positive electrode conductive bus and the first negative electrode conductive bus are respectively disposed on the second mounting base. The second mounting base blocks the clearance opening to prevent the insulating colloid from flowing out of the clearance opening.

14. The motor controller according to claim 11, characterized in that, The motor controller also includes a relay assembly, which includes a third mounting base, a relay, a circuit board, detection contacts, and a third busbar. The relay is mounted on the third mounting base, the relay is connected to the third conductive bus, the third conductive bus is connected to the bus capacitor module, the circuit board is mounted on the third mounting base, the detection contact is connected to the relay and the circuit board, and the detection contact is used to detect whether the third conductive bus and the relay are connected.

15. The motor controller according to claim 14, characterized in that, The relay is configured as a caseless relay.

16. A powertrain, characterized in that, It includes a motor and a motor controller as described in any one of claims 1 to 15, wherein the motor controller is connected to the motor.

17. The powertrain according to claim 16, characterized in that, The powertrain also includes a reduction gear assembly at the output end of the motor. The reduction gear assembly and the motor are arranged side by side on one side of the housing, and part of the housing extends into the space between the reduction gear assembly and the motor.

18. A vehicle, characterized in that, Includes the powertrain as described in claim 16 or 17.

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