Capacitor-integrated new energy commercial vehicle electric drive bus support capacitor device

Abstract

The utility model discloses a new energy commercial vehicle electrically-driven bus supporting capacitor device of an integrated capacitor, which comprises a bus capacitor shell, and a Y capacitor module, a direct current switching copper bar, a driving module switching copper bar and a wire harness fixing seat are integrated on the bus capacitor shell. The new energy commercial vehicle electric drive bus support capacitor device integrated with the capacitor is located between the direct current module and the drive module, and the whole capacitor device plays a role in realizing alternating current and direct current separation in the controller; the direct current terminal inputs electric energy through the direct current switching copper bar in front of the bus capacitor shell; and the driving module switching copper bar behind the bus capacitor shell transmits the electric energy to the driving plate, and the driving plate is connected with the three-phase terminal, so that the effective separation of the alternating current module and the direct current module is realized.

Description

Technical Field

[0001] This application belongs to the technical field of electric vehicle motor controllers, and particularly relates to a capacitor support device for the electric drive bus of a new energy commercial vehicle with integrated capacitors. Background Technology

[0002] With the continuous advancement of new energy commercial vehicle technology, electric drive systems are developing towards integration, high performance, and high efficiency. Traditional electric drive controller layouts involve placing AC and DC modules side-by-side on one side, with X and Y capacitors arranged independently. This layout presents several problems, including longer copper busbars inside the controller, increasing material costs, and requiring additional space within the controller to accommodate these capacitors and copper busbars, thus limiting the flexibility of controller design.

[0003] Furthermore, traditional layout schemes also pose risks of electromagnetic interference and thermal coupling. Electromagnetic interference between AC and DC modules may affect the stability and performance of the electric drive system, while thermal coupling may cause the internal temperature of the controller to rise, affecting the reliability and lifespan of the system.

[0004] Therefore, in the context of the integrated development of electric drive systems for new energy commercial vehicles, how to design a new type of electric drive bus support capacitor device that can optimize the internal layout of the controller, reduce electromagnetic interference and thermal coupling, and reduce the length and cost of copper busbars has become an urgent problem to be solved.

[0005] To address the aforementioned issues, this invention proposes an integrated capacitor support capacitor device for the electric drive busbar of new energy commercial vehicles. The aim is to achieve effective separation of AC and DC modules within the controller by integrating a Y-capacitor module and a DC-DC converter copper busbar, thereby reducing electromagnetic interference and thermal coupling. Simultaneously, it optimizes the internal layout of the controller, lowers costs, and improves system stability and performance. Summary of the Invention

[0006] The purpose of this application is to provide an integrated capacitor support capacitor device for the electric drive bus of a new energy commercial vehicle. Through integrated design, the AC and DC modules inside the controller are effectively separated, reducing electromagnetic interference and thermal coupling. At the same time, the internal layout of the controller is optimized, the cost is reduced, and the stability and performance of the system are improved.

[0007] To achieve the above objectives, the solution proposed in this application is:

[0008] A new energy commercial vehicle electric drive bus support capacitor device with integrated capacitors includes: a bus capacitor housing, on which are integrated:

[0009] The device comprises a Y-capacitor module, a DC-DC converter copper busbar, a drive module converter copper busbar, and a wire harness mounting base. The front side of the bus capacitor housing has a fixed protrusion plate perpendicular to the front side of the bus capacitor housing and three first partition plates. The length direction of the fixed protrusion plate is consistent with the length direction of the front side of the bus capacitor housing. Two first partition plates are respectively located on both sides of the fixed protrusion plate, and another first partition plate is located in the middle of the top of the fixed protrusion plate. Two sets of upper mounting holes are symmetrically opened on the top of the fixed protrusion plate, and one set of lower mounting holes is opened on the bottom of the fixed protrusion plate. The upper part of the fixed protrusion plate is divided into two independent first spaces by the first partition plates, and the two sets of upper mounting holes are located in the two first spaces respectively. The lower part of the fixed protrusion plate forms an independent second space through the first partition plates. The DC-DC converter copper busbar is fixedly installed in each set of upper mounting holes, and the Y-capacitor module is fixedly installed in the lower mounting hole. The Y-capacitor module is installed at the bottom of the fixed protrusion plate, and the DC-DC converter copper busbar is installed at the top of the fixed protrusion plate. The Y-capacitor module is electrically connected to the DC-DC converter copper busbar via wires.

[0010] The drive module adapter copper busbar is arranged parallel to one side of the rear side of the bus capacitor housing, and each output terminal of the drive module adapter copper busbar is provided with a drive module connection hole.

[0011] The top of the bus capacitor housing is provided with multiple wire harness fixing seats.

[0012] Preferably, the Y-capacitor module includes a Y-capacitor circuit board and a Y-capacitor. The Y-capacitor circuit board is vertically stacked and soldered onto the top of the Y-capacitor, electrically connected to the Y-capacitor. The top of the Y-capacitor circuit board is provided with Y-capacitor positioning pins, Y-capacitor mounting holes, and lower mounting positioning pin holes. The Y-capacitor mounting holes are arranged in three columns along the length of the Y-capacitor circuit board, with each column including two Y-capacitor mounting holes arranged side by side along the width direction. Two Y-capacitor positioning pins and one lower mounting positioning pin hole are provided between the Y-capacitor positioning pins and the Y-capacitor mounting holes located in the middle of the Y-capacitor circuit board and away from the busbar capacitor housing. The Y-capacitor includes a positive Y-capacitor and a negative Y-capacitor.

[0013] Preferably, the bottom of the fixed protrusion plate is further provided with two lower mounting positioning pins. The positions of the two lower mounting positioning pins on the fixed protrusion plate correspond to and are adapted to the positions of the lower mounting positioning pins on the Y capacitor circuit board. The lower mounting positioning pins are used to position and fix the Y capacitor circuit board. The lower mounting holes include a first lower mounting hole and a Y capacitor positioning pin mounting hole. The first lower mounting holes are arranged in three columns along the length direction of the fixed protrusion plate. Each column includes two first lower mounting holes arranged side by side along the width direction. There are two Y capacitor positioning pin mounting holes and one lower mounting positioning pin between the first lower mounting holes in adjacent columns. The two Y capacitor positioning pin mounting holes are arranged side by side along the width direction of the fixed protrusion plate. There is a lower mounting positioning pin between the Y capacitor positioning pin mounting hole and the first lower mounting hole located in the middle of the fixed protrusion plate and away from the side of the bus capacitor housing. The lower mounting positioning pins and the lower mounting positioning pin holes on the Y capacitor circuit board are interference fit. The first lower mounting hole and the Y capacitor mounting hole are coaxial. The Y capacitor positioning pin mounting holes and the Y capacitor positioning pins are interference fit.

[0014] Preferably, there are two DC-DC converter copper busbars, one positive and one negative. The positive and negative copper busbars are separated by a first partition plate located in the middle of the top of the fixed protrusion plate. The top of the fixed protrusion plate is set as the positive copper busbar, and the bottom of the fixed protrusion plate is set as the positive Y capacitor. The top of the fixed protrusion plate is set as the negative copper busbar, and the bottom of the fixed protrusion plate is set as the negative Y capacitor. Each DC-DC converter copper busbar has a copper busbar mounting hole, a Y capacitor round nut hole, and a wire harness mounting hole. The copper busbar mounting hole is located on the side of the DC-DC converter copper busbar near the middle first partition plate, and the Y capacitor round nut hole and the wire harness mounting hole are located on the side away from the middle first partition plate. The Y capacitor round nut hole is located on the side near the bus capacitor housing, and the wire harness mounting hole is located on the side away from the bus capacitor housing. The Y capacitor round nut hole is coaxial with the Y capacitor mounting hole on the Y capacitor circuit board near its end and near the bus capacitor housing.

[0015] Preferably, the upper mounting hole includes a first upper mounting hole and a second upper mounting hole. The first upper mounting hole is coaxial with the copper busbar mounting hole, and the second upper mounting hole is coaxial with the hole for placing the Y capacitor round nut. The first upper mounting hole is used to fix the DC adapter copper busbar.

[0016] Preferably, it further includes a DC transfer copper bar round bolt, a DC transfer copper bar round nut, a Y-capacitor mounting short bolt, and a Y-capacitor mounting short bolt nut, a Y-capacitor mounting long bolt, and a Y-capacitor mounting long bolt nut. The DC transfer copper bar round nut is disposed in the first upper mounting hole, and both the Y-capacitor mounting short bolt nut and the Y-capacitor mounting long bolt nut are disposed in the first lower mounting hole. The DC transfer copper bar round bolt passes through the copper bar mounting hole and is finally threadedly connected to the DC transfer copper bar round nut in the first upper mounting hole. Except for the first lower mounting hole that is coaxial with the Y-capacitor mounting hole on the side of the Y-capacitor circuit board close to its end and close to the bus capacitor housing, the Y-capacitor mounting short bolt passes through the Y-capacitor mounting hole and is threadedly connected to the Y-capacitor mounting short bolt nut in the remaining first lower mounting holes. The Y-capacitor mounting long bolt passes through the Y-capacitor mounting hole and is finally threadedly connected to the Y-capacitor mounting long bolt nut in the first lower mounting hole that is coaxial with the Y-capacitor mounting hole on the side close to the bus capacitor housing. The Y-capacitor mounting long bolt that exceeds the depth of the first lower mounting hole also sequentially passes through the second upper mounting hole and the hole for placing the Y-capacitor round nut. The Y-capacitor module is connected to the lower mounting holes of the fixed convex plate through the Y-capacitor mounting holes, and the DC transfer copper bar is connected to the upper mounting holes of the fixed convex plate through the copper bar mounting holes. The Y-capacitor mounting short bolt and the Y-capacitor mounting long bolt are used to fix the Y-capacitor module.

[0017] Preferably, the driving module connection holes are arranged in parallel at intervals along the length direction of the bus capacitor housing. The second upper mounting hole is connected and coaxial with the first lower mounting hole that is coaxial with the Y-capacitor mounting hole on the side of the Y-capacitor circuit board close to its end and close to the bus capacitor housing, and the first lower mounting hole coaxial with the Y-capacitor mounting hole does not penetrate the entire fixed convex plate. The Y-capacitor positioning pin mounting hole, the first upper mounting hole, and the second upper mounting hole do not penetrate the entire fixed convex plate. The driving module connection holes are used to connect the driving module.

[0018] Preferably, it further includes a bus capacitor mounting copper sleeve. Fixed mounting holes are provided at both sides of the bus capacitor housing, at both ends of the front side of the bus capacitor housing, and at both ends outside the first partition plates provided on both sides of the fixed convex plate. The fixed mounting holes are embedded with bus capacitor mounting copper sleeves, and the bus capacitor mounting copper sleeves are used to enhance the fixing strength.

[0019] Preferably, the adjacent fixed mounting holes on both sides of the bus capacitor housing are separated by an inclined second partition plate. The second partition plate is fixedly provided outside the bus capacitor housing. On both sides close to the endpoints of the fixed mounting holes provided at both ends of the front side of the bus capacitor housing, there are also provided inclined third partition plates, and the third partition plates are fixedly provided outside the bus capacitor housing. A plurality of the wire harness fixing seats are integrally formed with the bus capacitor housing, and the connection shape between the plurality of wire harness fixing seats at the top of the bus capacitor housing is in the shape of "廿". The adjacent wire harness fixing seats are connected by transverse reinforcing ribs. The bus capacitor housing is a rectangular frame structure. The second partition plate and the third partition plate are used to enhance the structural strength and isolation.

[0020] Preferably, it also includes a wire harness bracket, which is mounted on top of the wire harness mounting base by screws, and is used to secure the wire harness.

[0021] The integrated capacitor support capacitor device for the electric drive bus of a new energy commercial vehicle provided in this application has the following advantages compared with the prior art:

[0022] (1) The present invention relates to a new energy commercial vehicle electric drive bus support capacitor device with integrated capacitors located between the DC module and the drive module. The capacitor device as a whole plays the role of AC-DC separation in the controller: the DC terminal inputs electrical energy through the DC transfer copper bus in front of the bus capacitor housing, and the drive module transfer copper bus behind the bus capacitor housing transmits the electrical energy to the drive board, and the drive board is then connected to the three-phase terminal, thereby realizing the effective separation of the AC module and the DC module; the design of this application effectively separates the DC module and the drive module and increases the distance between them, which significantly reduces the electromagnetic interference and thermal coupling effect between the modules, reduces safety hazards, and reduces the need for shielding structure between controller modules, further reducing the design difficulty.

[0023] (2) This utility model integrates the Y-capacitor module directly onto the bus capacitor housing and utilizes the compact design of the DC-DC converter copper busbar to significantly reduce the length of the internal copper busbar of the controller, thereby lowering material and production costs. Simultaneously, it optimizes the internal layout of the controller, improving space utilization; making maintenance and upgrades of the Y-capacitor module and DC-DC converter copper busbar more convenient. When a module malfunctions or requires an upgrade, it can be replaced or upgraded individually without disassembling and replacing the entire controller, reducing maintenance costs and downtime.

[0024] (3) This utility model modularizes, standardizes, and scales up the design of the integrated Y capacitor module and DC-DC converter copper busbar, reducing the design and development cycle and production cycle of the electric drive controller product. While maintaining product versatility, this design provides diverse configuration options, further reducing the cost and maintenance difficulty of the controller.

[0025] (4) This utility model effectively improves the anti-interference capability of the system, reduces the failure and downtime caused by electromagnetic interference and thermal coupling, optimizes the layout and heat dissipation to improve the heat dissipation performance and load capacity of the system, and ensures the stable operation of the system under high load and harsh environment. Attached Figure Description

[0026] Figure 1 This invention presents a schematic diagram of the overall structure of a new energy commercial vehicle electric drive bus support capacitor device with integrated capacitors.

[0027] Figure 2 This invention presents a schematic front view of a capacitor-integrated support capacitor device for the electric drive busbar of a new energy commercial vehicle.

[0028] Figure 3 This invention presents a top view schematic diagram of a new energy commercial vehicle electric drive bus support capacitor device with integrated capacitors.

[0029] Figure 4 This invention presents a schematic diagram of the copper busbar structure of a new energy commercial vehicle electric drive busbar support capacitor device with integrated capacitors.

[0030] Figure 5 This invention presents a schematic diagram of the Y-capacitor module structure of an integrated capacitor-supporting capacitor device for electric drive busbars of new energy commercial vehicles.

[0031] Figure 6 This invention provides a schematic diagram of the top of a fixed protrusion plate on the bus capacitor housing of a new energy commercial vehicle electric drive bus support capacitor device with integrated capacitors.

[0032] Figure 7 The diagram shows the bottom of the fixed protrusion plate on the bus capacitor housing of a new energy commercial vehicle electric drive bus support capacitor device with integrated capacitor according to the present invention.

[0033] Explanation of reference numerals in the attached drawings: 101, Bus capacitor housing; 102, Y capacitor module; 103, DC-DC converter copper busbar; 104, Drive module converter copper busbar; 105, Wire harness mounting bracket; 106, Bus capacitor mounting copper sleeve; 107, Wire harness frame;

[0034] 1011. Fixed protrusion plate; 1012. First partition plate; 1013. First space; 1014. Second space; 1015. Second partition plate; 1016. Third partition plate; 1017. Fixed mounting hole;

[0035] 1021, Y capacitor circuit board; 1022, Y capacitor; 10211, Y capacitor positioning pin; 10212, Y capacitor mounting hole; 10213, lower mounting positioning pin hole;

[0036] 1031, Copper busbar mounting hole; 1032, Hole for Y capacitor mounting nut; 1033, Wire harness mounting hole;

[0037] 1041, drive module connection hole; 1051, transverse reinforcing rib;

[0038] 10111, Upper mounting hole; 10112, Lower mounting hole; 10113, Lower mounting positioning pin;

[0039] 101121, First mounting hole; 101122, Y capacitor positioning pin mounting hole;

[0040] 101111, First upper mounting hole; 101112, Second upper mounting hole. Detailed Implementation

[0041] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of this application. Furthermore, it should be noted that, for ease of description, only the parts relevant to this application are shown in the accompanying drawings, not the entire structure. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this application.

[0042] The terms “comprising” and “having”, and any variations thereof, used in this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such process, method, product, or apparatus.

[0043] In this application, the reference to "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described in this application can be combined with other embodiments.

[0044] Example 1

[0045] like Figure 1-3 As shown, a new energy commercial vehicle electric drive bus support capacitor device with integrated capacitors includes: a bus capacitor housing 101, on which the following are integrated:

[0046] The system includes a Y-capacitor module 102, a DC-DC converter copper busbar 103, a drive module converter copper busbar 104, and a wire harness mounting base 105. The front side of the bus capacitor housing 101 is provided with a fixing protrusion 1011 perpendicular to the front side of the bus capacitor housing 101 and three first partition plates 1012. The length direction of the fixing protrusion 1011 is consistent with the length direction of the front side of the bus capacitor housing 101. Two first partition plates 1012 are respectively arranged on both sides of the fixing protrusion 1011, and the other first partition plate 1012 is located at the middle of the top of the fixing protrusion 1011. Two sets of upper mounting holes 10111 are symmetrically opened on the top of the fixing protrusion 1011, and a set of lower mounting holes 10111 is opened on the bottom of the fixing protrusion 1011. Mounting holes 10112, the upper part of the fixing protrusion 1011 is divided into two independent first spaces 1013 by the first partition plate 1012, the two sets of upper mounting holes 10111 are respectively located in the two first spaces 1013, the lower part of the fixing protrusion 1011 is formed by the first partition plate 1012 to form an independent second space 1014, the DC converter copper busbar 103 is fixedly installed in each set of upper mounting holes 10111, the Y capacitor module 102 is fixedly installed in the lower mounting hole 10112, the Y capacitor module 102 is installed at the bottom of the fixing protrusion 1011, the DC converter copper busbar 103 is installed at the top of the fixing protrusion 1011; the Y capacitor module 102 is electrically connected to the DC converter copper busbar 103 through wires;

[0047] The drive module adapter copper busbar 104 is arranged parallel to the rear side of the bus capacitor housing 101, and each output terminal of the drive module adapter copper busbar 104 is provided with a drive module connection hole 1041.

[0048] The top of the bus capacitor housing 101 is provided with multiple wire harness fixing seats 105.

[0049] The driver module connection hole is used to connect the driver module and provide input to the driver module.

[0050] The DC converter copper busbar is embedded in the busbar support capacitor device and is used to connect the DC copper busbar of the controller. The two DC converter copper busbars are positive and negative respectively. The first partition plate, located in the middle of the top of the fixed protrusion plate, is used to separate the positive and negative terminals.

[0051] This utility model discloses an integrated capacitor support capacitor device for the electric drive busbar of a new energy commercial vehicle, located between the DC module and the drive module. The capacitor device as a whole plays a role in achieving AC / DC separation within the controller: the DC terminal inputs electrical energy through the DC transfer copper busbar in front of the busbar capacitor housing, and the drive module transfer copper busbar behind the busbar capacitor housing transfers the electrical energy to the drive board, which is then connected to the three-phase terminals, thereby achieving effective separation between the AC module and the DC module. This application design effectively separates the DC module and the drive module and increases the distance between them, significantly reducing electromagnetic interference and thermal coupling effects between the modules, reducing safety hazards, and reducing the need for shielding structures between controller modules, further reducing design difficulty.

[0052] In existing controller designs, the AC and DC modules are placed close together, which causes them to affect each other's heat generation. The design in this application effectively separates the DC module and the drive module and increases the distance between them, which significantly reduces electromagnetic interference and thermal coupling effects between modules, reduces safety hazards, and reduces the need for shielding structures between controller modules, further reducing design difficulty.

[0053] The DC module and the drive module are placed parallel to each other, with an additional three-phase terminal below the drive module. This ensures more even heat distribution and reduces electromagnetic interference and thermal coupling between modules. A first partition plate positioned in the middle of the top of the fixed protrusion separates the positive and negative terminals, further reducing electromagnetic interference between modules.

[0054] Example 2

[0055] like Figure 5 As shown, preferably, the Y-capacitor module 102 includes a Y-capacitor circuit board 1021 and a Y-capacitor 1022. The Y-capacitor circuit board 1021 is vertically stacked and soldered onto the top of the Y-capacitor 1022 and electrically connected to the Y-capacitor 1022. The top of the Y-capacitor circuit board 1021 is provided with a Y-capacitor positioning pin 10211, a Y-capacitor mounting hole 10212, and a lower mounting positioning pin hole 10213. The Y-capacitor mounting holes 10212 are arranged in three columns along the length of the Y-capacitor circuit board 1021, and each column includes two Y-capacitors arranged side by side along the width direction. Mounting holes 10212, each of the adjacent columns of Y capacitor mounting holes 10212 is provided with two Y capacitor positioning pins 10211 and one lower mounting positioning pin hole 10213. The two Y capacitor positioning pins 10211 are arranged side by side along the width direction of the Y capacitor circuit board 1021. Each Y capacitor positioning pin 10211 and the Y capacitor mounting hole 10212 located in the middle of the Y capacitor circuit board 1021 and away from the bus capacitor housing 101 is provided with a lower mounting positioning pin hole 10213. The Y capacitor 1022 includes a positive Y capacitor and a negative Y capacitor.

[0056] like Figure 7 As shown, preferably, the bottom of the fixing protrusion 1011 is further provided with two lower mounting positioning pins 10113. The positions of the two lower mounting positioning pins 10113 on the fixing protrusion 1011 correspond to and are adapted to the positions of the lower mounting positioning pins 10113 on the Y capacitor circuit board 1021. The lower mounting positioning pins 10113 are used to position and fix the Y capacitor circuit board 1021. The lower mounting hole 10112 includes a first lower mounting hole 101121 and a Y capacitor positioning pin mounting hole 101122. The first lower mounting holes 101121 are arranged in three columns along the length direction of the fixing protrusion 1011. Each column includes two first lower mounting holes 101121 arranged side by side along the width direction. There is a space between the first lower mounting holes 101121 in adjacent columns. Two Y-capacitor positioning pin mounting holes 101122 and one lower mounting positioning pin 10113 are provided. The two Y-capacitor positioning pin mounting holes 101122 are arranged side by side along the width direction of the fixed protrusion plate 1011. A lower mounting positioning pin 10113 is provided between the Y-capacitor positioning pin mounting holes 101122 and the first lower mounting hole 101121 located in the middle of the fixed protrusion plate 1011 and away from the busbar capacitor housing 101. The lower mounting positioning pin 10113 is interference-fitted with the lower mounting positioning pin hole 10213 on the Y-capacitor circuit board 1021. The first lower mounting hole 101121 is coaxial with the Y-capacitor mounting hole 10212. The Y-capacitor positioning pin mounting holes 101122 and the Y-capacitor positioning pin 10211 are interference-fitted.

[0057] like Figure 5 As shown, preferably, there are two DC-DC converter copper busbars 103, one positive and one negative. The positive and negative busbars are separated by a first partition plate 1012 located in the middle of the top of the fixed protrusion plate 1011. The top of the fixed protrusion plate 1011 is configured as the positive copper busbar, with the bottom of the fixed protrusion plate 1011 corresponding to the positive Y-capacitor. The top of the fixed protrusion plate 1011 is configured as the negative copper busbar, with the bottom of the fixed protrusion plate 1011 corresponding to the negative Y-capacitor. Each DC-DC converter copper busbar 103 has a copper busbar mounting hole 1031, a Y-capacitor round nut hole 1032, and... The wire harness mounting hole 1033 and the copper busbar mounting hole 1031 are located on the side of the DC adapter copper busbar 103 near the middle first partition plate 1012. The Y capacitor round nut hole 1032 and the wire harness mounting hole 1033 are located on the side away from the middle first partition plate 1012. The Y capacitor round nut hole 1032 is located on the side near the bus capacitor housing 101, and the wire harness mounting hole 1033 is located on the side away from the bus capacitor housing 101. The Y capacitor round nut hole 1032 is coaxial with the Y capacitor mounting hole 10212 on the Y capacitor circuit board 1021 near its end and near the bus capacitor housing 101.

[0058] like Figure 6 As shown, the upper mounting hole 10111 includes a first upper mounting hole 101111 and a second upper mounting hole 101112. The first upper mounting hole 101111 is coaxial with the copper busbar mounting hole 1031, and the second upper mounting hole 101112 is coaxial with the Y capacitor round nut hole 1032. The first upper mounting hole 101111 is used to fix the DC adapter copper busbar 103.

[0059] This invention integrates the Y-capacitor module directly onto the bus capacitor housing and utilizes a compact design with the DC-DC converter busbar, significantly reducing the length of the internal copper busbar in the controller and lowering material and production costs. Simultaneously, it optimizes the internal layout of the controller, improving space utilization and making maintenance and upgrades of the Y-capacitor module and DC-DC converter busbar more convenient. When a module malfunctions or requires an upgrade, it can be replaced or upgraded individually without disassembling and replacing the entire controller, reducing maintenance costs and downtime.

[0060] This invention modularizes, standardizes, and scales up the design of the integrated Y-capacitor module and DC-DC converter busbar, reducing the design, development, and production cycles of electric drive controller products. This design maintains product versatility while providing diverse configuration options, further reducing controller cost and maintenance complexity.

[0061] Preferably, the mounting also includes a DC adapter copper busbar round bolt, a DC adapter copper busbar round nut, a Y capacitor mounting short bolt and a Y capacitor mounting short bolt nut, a Y capacitor mounting long bolt and a Y capacitor mounting long bolt nut. The DC adapter copper busbar round nut is disposed in the first upper mounting hole 101111, and the Y capacitor mounting short bolt nut and the Y capacitor mounting long bolt nut are both disposed in the first lower mounting hole 101121. The DC adapter copper busbar round bolt passes through the copper busbar mounting hole 1031 and is finally threaded onto the DC adapter copper busbar round nut in the first upper mounting hole 101111. Except for the first lower mounting hole 101121 coaxial with the Y capacitor mounting hole 10212 on the side of the Y capacitor circuit board 1021 near its end and near the bus capacitor housing 101, the Y capacitor mounting short bolt passes through the Y capacitor mounting hole 10212 and is threaded onto the remaining first... The Y-capacitor mounting short bolt nut is installed in the lower mounting hole 101121. The Y-capacitor mounting long bolt passes through the Y-capacitor mounting hole 10212 and is finally threaded onto the Y-capacitor mounting long bolt nut in the first lower mounting hole 101121, which is coaxial with the Y-capacitor mounting hole 10212, near the side of the bus capacitor housing 101. The Y-capacitor mounting long bolt, which exceeds the depth of the first lower mounting hole 101121, also passes through the second upper mounting hole 101112 and the Y-capacitor round nut hole 1032 in sequence. The Y-capacitor module 102 is connected to the lower mounting hole 10112 of the fixing protrusion plate 1011 through the Y-capacitor mounting hole 10212. The DC adapter copper busbar 103 is connected to the upper mounting hole 10111 of the fixing protrusion plate 1011 through the copper busbar mounting hole 1031. The capacitor mounting short bolt and the Y-capacitor mounting long bolt are used to fix the Y-capacitor module.

[0062] The round nut hole for the Y capacitor is used to avoid the mounting bolts of the Y capacitor; the wire harness mounting hole is used to install the high voltage acquisition line. After installation, the high voltage acquisition line needs to be routed inside the controller. The wiring method is to fix the wire harness inside the controller to the wire harness frame with cable ties.

[0063] Preferably, the drive module connection holes 1041 are arranged parallel to each other along the length of the bus capacitor housing 101; the second upper mounting hole 101112 is coaxial with the first lower mounting hole 101121, which is coaxial with the Y capacitor mounting hole 10212 on the Y capacitor circuit board 1021 near its end and near the bus capacitor housing 101, and the first lower mounting hole 101121, which is coaxial with the Y capacitor mounting hole 10212, does not penetrate the entire fixed protrusion plate 1011; the Y capacitor positioning pin mounting hole 101122, the first upper mounting hole 101111, and the second upper mounting hole 101112 do not penetrate the entire fixed protrusion plate 1011; the drive module connection hole 1041 is used to connect the drive module.

[0064] Preferably, it further includes a bus capacitor mounting copper sleeve 106. Both sides of the bus capacitor housing 101, and both ends of the front side of the bus capacitor housing 101, and both ends outside the first partition plate 1012 provided on both sides of the fixed convex plate 1011 are provided with fixed mounting holes 1017. The bus capacitor mounting copper sleeve 106 is embedded in the fixed mounting holes 1017, and the bus capacitor mounting copper sleeve 106 is used to enhance the fixing strength.

[0065] The whole bus capacitor housing 101 is fixed through the fixed mounting holes 1017 and the bus capacitor mounting copper sleeve 106.

[0066] The bus capacitor mounting copper sleeve 106 embedded in the fixed mounting holes 1017 of the bus capacitor 101 provides support when the capacitor is installed inside the controller.

[0067] Preferably, the adjacent fixed mounting holes 1017 on both sides of the bus capacitor housing 101 are separated by an inclined second partition plate 1015; the second partition plate 1015 is fixedly arranged outside the bus capacitor housing 101, and inclined third partition plates 1016 are further provided on both sides near the endpoints of the fixed mounting holes 1017 at both ends of the front side of the bus capacitor housing 101, and the third partition plates 1016 are fixedly arranged outside the bus capacitor housing 101; a plurality of the wire harness fixing seats 105 are integrally formed with the bus capacitor housing 101, and the connection shape between the plurality of wire harness fixing seats 105 on the top of the bus capacitor housing 101 is in the shape of "廿", and the adjacent wire harness fixing seats 105 are connected by a transverse reinforcing rib 1051; the bus capacitor housing 101 is a rectangular frame structure; the second partition plate 1015 and the third partition plate 1016 are used to enhance the structural strength and isolation.

[0068] The design of the first partition plate, the second partition plate and the third partition plate enhances the rigidity of the end face structure, provides a stable support for the bus capacitor housing, and plays a significant role in structural strengthening.

[0069] The connection between the wire harness fixing seats 105 with ribs provides structural strengthening for the wire harness fixing seats and is arranged on the bus capacitor housing 101.

[0070] Preferably, it further includes a wire harness rack 107. The wire harness rack 107 is installed on the top of the wire harness fixing seat 105 by screws, and the wire harness rack 107 is used to fix the wire harness.

[0071] The wire harness inside the controller can be fixed on the wire harness rack 401 by a tie strap to prevent the loosening of the interface caused by the vibration of the wire harness.

[0072] This invention integrates the Y-capacitor module directly onto the bus capacitor housing and utilizes a compact design with the DC-DC converter busbar, significantly reducing the length of the internal copper busbar in the controller and lowering material and production costs. Simultaneously, it optimizes the internal layout of the controller, improving space utilization and making maintenance and upgrades of the Y-capacitor module and DC-DC converter busbar more convenient. When a module malfunctions or requires an upgrade, it can be replaced or upgraded individually without disassembling and replacing the entire controller, reducing maintenance costs and downtime.

[0073] This device is applicable to the electric drive system of pure electric commercial vehicles. An integrated capacitor bus support capacitor device for new energy commercial vehicles is located between the DC module and the drive module. The capacitor device as a whole plays the role of AC and DC separation in the controller: the DC terminal inputs electrical energy through the DC transfer copper bus in front of the bus capacitor housing, and the drive module transfer copper bus behind the bus capacitor housing transfers the electrical energy to the drive board. The drive board is then connected to the three-phase terminal, thereby achieving effective separation between the AC module and the DC module.

[0074] The foregoing has described specific embodiments of this specification. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps recited in the claims may be performed in a different order than that shown in the embodiments and may still achieve the desired result. Furthermore, the processes depicted in the specification do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are possible or may be advantageous.

[0075] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of this disclosure (including the claims) is limited to these examples; within the framework of this disclosure, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of one or more embodiments of this specification as described above, which are not provided in detail for the sake of brevity.

[0076] Furthermore, to simplify the description and discussion, while specific details have been set forth to describe exemplary embodiments of this disclosure, it will be apparent to those skilled in the art that one or more embodiments of this specification may be practiced without these specific details or with variations thereof. Therefore, these descriptions should be considered illustrative rather than restrictive.

Claims

1. An integrated capacitor new energy commercial vehicle electric drive bus support capacitor device, characterized in that, It includes: bus capacitor shell (101), bus capacitor shell (101) integrated with: Y capacitor module (102), DC adapter copper bar (103), drive module adapter copper bar (104) and wire harness fixing seat (105); The front side of the bus capacitor shell (101) is provided with a fixed protruding plate (1011) perpendicular to the front side of the bus capacitor shell (101) and three first partition plates (1012), the length direction of the fixed protruding plate (1011) is consistent with the length direction of the front side of the bus capacitor shell (101), two first partition plates (1012) are respectively arranged on both sides of the fixed protruding plate (1011), and the other first partition plate (1012) is arranged at the middle position of the top of the fixed protruding plate (1011), the top of the fixed protruding plate (1011) is symmetrically provided with two groups of upper mounting holes (10111), the bottom of the fixed protruding plate (1011) is provided with a group of lower mounting holes (10112), the upper portion of the fixed protruding plate (1011) is divided into two independent first spaces (1013) by the first partition plate (1012), the two groups of upper mounting holes (10111) are respectively located in the two first spaces (1013), the lower portion of the fixed protruding plate (1011) forms an independent second space (1014) through the first partition plate (1012), the DC adapter copper bar (103) is fixedly installed in each group of upper mounting holes (10111), the Y capacitor module (102) is fixedly installed in the lower mounting hole (10112), the Y capacitor module (102) is installed at the bottom of the fixed protruding plate (1011), and the DC adapter copper bar (103) is installed at the top of the fixed protruding plate (1011); The Y capacitor module (102) is electrically connected with the DC adapter copper bar (103) through wires; The drive module adapter copper bar (104) is arranged on one side of the rear side of the bus capacitor shell (101), and each output terminal of the drive module adapter copper bar (104) is provided with a drive module connecting hole (1041); The top of the bus capacitor shell (101) is provided with a plurality of wire harness fixing seats (105).

2. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 1, characterized in that, The Y capacitor module (102) comprises a Y capacitor circuit board (1021) and a Y capacitor (1022), the Y capacitor circuit board (1021) is arranged on the top of the Y capacitor (1022) in a vertical stack manner and is electrically connected with the Y capacitor (1022), the top of the Y capacitor circuit board (1021) is provided with a Y capacitor positioning pin (10211), a Y capacitor mounting hole (10212) and a lower mounting positioning pin hole (10213); the Y capacitor mounting hole (10212) is arranged in three columns along the length direction of the Y capacitor circuit board (1021), each column comprises two Y capacitor mounting holes (10212) arranged side by side along the width direction, two Y capacitor positioning pins (10211) and one lower mounting positioning pin hole (10213) are arranged between the Y capacitor mounting holes (10212) of adjacent columns, the two Y capacitor positioning pins (10211) are arranged side by side along the width direction of the Y capacitor circuit board (1021), and one lower mounting positioning pin hole (10213) is arranged between the Y capacitor positioning pin (10211) and the Y capacitor mounting hole (10212) arranged at the middle position of the Y capacitor circuit board (1021) and away from one side of the bus capacitor shell (101); the Y capacitor (1022) comprises a positive Y capacitor and a negative Y capacitor.

3. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 1, characterized in that, The bottom of the fixed protruding plate (1011) is further provided with two lower mounting positioning pins (10113), the positions of the two lower mounting positioning pins (10113) correspond to and are adapted to the positions of the lower mounting positioning pin holes (10113) on the Y capacitor circuit board (1021), and the lower mounting positioning pins (10113) are used for positioning and fixing the Y capacitor circuit board (1021); the lower mounting hole (10112) comprises a first lower mounting hole (101121) and a Y capacitor positioning pin mounting hole (101122), the first lower mounting hole (101121) is arranged in three columns along the length direction of the fixed protruding plate (1011), each column comprises two first lower mounting holes (101121) arranged side by side along the width direction, two Y capacitor positioning pin mounting holes (101122) and one lower mounting positioning pin (10113) are arranged between the first lower mounting holes (101121) of adjacent columns, the two Y capacitor positioning pin mounting holes (101122) are arranged side by side along the width direction of the fixed protruding plate (1011), and one lower mounting positioning pin (10113) is arranged between the Y capacitor positioning pin mounting hole (101122) and the first lower mounting hole (101121) arranged at the middle position of the fixed protruding plate (1011) and away from one side of the bus capacitor shell (101); the lower mounting positioning pin (10113) is in interference fit with the lower mounting positioning pin hole (10213) on the Y capacitor circuit board (1021), the first lower mounting hole (101121) is coaxial with the Y capacitor mounting hole (10212), and the Y capacitor positioning pin mounting hole (101122) is in interference fit with the Y capacitor positioning pin (10211).

4. The new energy commercial vehicle electric drive bus supporting capacitor device integrated with a capacitor according to claim 3, characterized in that, The two DC switching copper bars (103) are a positive copper bar and a negative copper bar, and the positive copper bar and the negative copper bar are isolated by a first partition plate (1012) arranged in the middle of the top of the fixed protruding plate (1011). The top of the fixed protruding plate (1011) is arranged to correspond to the bottom of the fixed protruding plate (1011) as a positive Y capacitor, and the top of the fixed protruding plate (1011) is arranged to correspond to the bottom of the fixed protruding plate (1011) as a negative Y capacitor. A copper bar mounting hole (1031), a Y capacitor round nut hole (1032), and a wire harness mounting hole (1033) are arranged on each of the DC switching copper bars (103). The copper bar mounting hole (1031) is arranged on one side of the DC switching copper bar (103) close to the middle first partition plate (1012), the Y capacitor round nut hole (1032) and the wire harness mounting hole (1033) are arranged on the side away from the middle first partition plate (1012), the Y capacitor round nut hole (1032) is arranged on the side close to the bus capacitor shell (101), and the wire harness mounting hole (1033) is arranged on the side away from the bus capacitor shell (101); the Y capacitor round nut hole (1032) is coaxial with the Y capacitor mounting hole (10212) on the Y capacitor circuit board (1021) close to the end and close to the bus capacitor shell (101) side.

5. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 4, characterized in that, The upper mounting hole (10111) includes a first upper mounting hole (101111) and a second upper mounting hole (101112), the first upper mounting hole (101111) is coaxial with the copper bar mounting hole (1031), and the second upper mounting hole (101112) is coaxial with the Y capacitor round nut hole (1032); the first upper mounting hole (101111) is used to fix the DC switching copper bar (103).

6. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 5, characterized in that, The DC adapter copper round bolt, the DC adapter copper round nut, the Y capacitor installation short bolt and the Y capacitor installation short bolt nut, the Y capacitor installation long bolt and the Y capacitor installation long bolt nut, the DC adapter copper round nut is arranged in the first upper installation hole (101111), the Y capacitor installation short bolt nut and the Y capacitor installation long bolt nut are arranged in the first lower installation hole (101121); the DC adapter copper round bolt passes through the copper bar installation hole (1031) and is finally screwed on the DC adapter copper round nut in the first upper installation hole (101111), except that the first lower installation hole (101121) coaxial with the Y capacitor installation hole (10212) on the side close to the bus capacitor shell (101) and close to the end of the Y capacitor circuit board (1021), the Y capacitor installation short bolt passes through the Y capacitor installation hole (10212) and is screwed on the Y capacitor installation short bolt nut in the remaining first lower installation hole (101121), the Y capacitor installation long bolt passes through the Y capacitor installation hole (10212) and is finally screwed on the Y capacitor installation long bolt nut in the first lower installation hole (101121) on the side close to the bus capacitor shell (101) and coaxial with the Y capacitor installation hole (10212), the Y capacitor installation long bolt exceeding the hole depth of the first lower installation hole (101121) also passes through the second upper installation hole (101112) and the Y capacitor round nut hole (1032) in sequence; the Y capacitor module (102) is connected with the lower installation hole (10112) of the fixed protruding plate (1011) through the Y capacitor installation hole (10212), and the DC adapter copper bar (103) is connected with the upper installation hole (10111) of the fixed protruding plate (1011) through the copper bar installation hole (1031); the capacitor installation short bolt and the Y capacitor installation long bolt are used for fixing the Y capacitor module.

7. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 1, characterized in that, The driving module connection hole (1041) is arranged in parallel along the length direction of the bus capacitor shell (101); the second upper installation hole (101112) is communicated with and coaxial with the first lower installation hole (101121) coaxial with the Y capacitor installation hole (10212) on the side close to the bus capacitor shell (101) and close to the end of the Y capacitor circuit board (1021), and the first lower installation hole (101121) coaxial with the Y capacitor installation hole (10212) does not pass through the entire fixed protruding plate (1011); the Y capacitor positioning pin installation hole (101122), the first upper installation hole (101111) and the second upper installation hole (101112) do not pass through the entire fixed protruding plate (1011); the driving module connection hole (1041) is used for connecting the driving module.

8. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 7, characterized in that, It also includes the bus capacitor installation copper sleeve (106), both sides of the bus capacitor shell (101), both ends of the front side of the bus capacitor shell (101), both ends of the first partition plate (1012) outside the fixed protruding plate (1011) are provided with fixed mounting holes (1017), the fixed mounting holes (1017) are embedded with bus capacitor installation copper sleeve (106), and the bus capacitor installation copper sleeve (106) is used for enhancing the fixing strength.

9. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 1, characterized in that, The adjacent fixed mounting holes (1017) on both sides of the bus capacitor shell (101) are separated by the inclined second partition plate (1015); the second partition plate (1015) is fixedly arranged outside the bus capacitor shell (101), and the two sides close to the end point of the fixed mounting hole (1017) arranged at both ends of the front side of the bus capacitor shell (101) are also provided with the inclined third partition plate (1016), and the third partition plate (1016) is fixedly arranged outside the bus capacitor shell (101); a plurality of the wire harness fixing seats (105) are integrally formed with the bus capacitor shell (101), the connection shape between the plurality of wire harness fixing seats (105) at the top of the bus capacitor shell (101) is "twenty" shape, and the adjacent wire harness fixing seats (105) are connected through the transverse reinforcing ribs (1051); the bus capacitor shell (101) is a rectangular frame structure; the second partition plate (1015) and the third partition plate (1016) are used for enhancing the structural strength and isolation.

10. The integrated capacitor new energy commercial vehicle electric drive bus support capacitor device according to claim 9, characterized in that, It also includes the wire harness frame (107), which is installed on the top of the wire harness fixing seat (105) through screws, and the wire harness frame (107) is used for fixing the wire harness.

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