Transfer capacitor module, integrated capacitor assembly and motor controller

Abstract

The utility model provides a transfer capacitor module, an integrated capacitor assembly and a motor controller, and relates to the technical field of electronic power, and the transfer capacitor module comprises a housing which is internally provided with a first area and a second area; the capacitor core is encapsulated in the first area; the nanocrystalline magnetic core is encapsulated in the second area; the copper bar is connected with the capacitor core and the nanocrystalline magnetic core and extends out of the two sides of the shell; and the current sensor is connected to the copper bar between the capacitor core and the nanocrystalline magnetic core.

Description

TECHNICAL FIELD

[0001] The utility model relates to electronic power technical field especially, relate to a kind of switching capacitor module, integrated capacitor assembly and motor controller. BACKGROUND

[0002] With the high-speed development of new energy vehicles, there is a higher demand for the miniaturization of core components, motor controllers. In order to meet the layout requirements of the vehicle and the requirements of crash test, the control envelope and boundary are strictly limited. As a core device inside the control, the bus capacitor is difficult to be placed in the right place in some cases.

[0003] In terms of miniaturization, with the reduction in size, the capacitance, voltage resistance and other key performance indicators of the capacitor are easily affected. In the integration process, different functional modules are integrated together, which may cause electromagnetic interference, heat dissipation difficulties and other problems. For example, when multiple capacitor elements are closely integrated, electromagnetic coupling between them may cause signal distortion. If the heat generated by the integrated module cannot be effectively dissipated, it will affect the life and performance of the capacitor. Therefore, there is a lack of a capacitor module that meets the miniaturization and integration application scenarios. SUMMARY

[0004] In order to overcome the above technical defects, the purpose of the utility model is to provide a switching capacitor module, integrated capacitor assembly and motor controller, which solves the problem that the existing capacitor module cannot meet the miniaturization and integration application scenarios.

[0005] The utility model discloses a kind of switching capacitor modules, comprising:

[0006] Shell, which has first area and second area in it;

[0007] Capacitor core, potting is in the first area;

[0008] Nanocrystalline magnetic core, potting is in the second area;

[0009] Copper bar, connecting the capacitor core and nanocrystalline magnetic core, and extending out both sides of the shell;

[0010] Current sensor, connected on the copper bar between the capacitor core and nanocrystalline magnetic core.

[0011] Preferably, it further includes support connected on the shell;

[0012] The support includes a support portion for placing the current sensor and an extension portion located on both sides of the support portion;

[0013] The copper bar is folded and placed on the extension portion and connected to both sides of the current sensor.

[0014] Preferably, bolts are arranged on the support to pass through the copper bar and the extension to detachably connect the copper bar on the support.

[0015] Preferably, a first heat dissipation water channel acting on the first region is arranged in the shell.

[0016] The utility model also provides a kind of integrated capacitor assembly, including the above-mentioned switching capacitor module, still including:

[0017] Basic capacitor module is connected to one side of the switching capacitor module;

[0018] Filtering assembly is connected to the side of the second region away from the basic capacitor module.

[0019] Preferably, the second heat dissipation water channel is integrated on the basic capacitor module, and the second heat dissipation water channel is communicated with the first heat dissipation water channel.

[0020] Preferably, power assembly is connected to the basic capacitor module.

[0021] Preferably, the basic capacitor module and the switching capacitor module are arranged side by side in width direction.

[0022] Preferably, the basic capacitor module and the switching capacitor module share a shell on the connected side.

[0023] The utility model also provides a kind of motor controller, applies the above-mentioned switching capacitor module and / or the above-mentioned integrated capacitor assembly.

[0024] After the above technical scheme is adopted, compared with prior art, the following beneficial effects are obtained:

[0025] The present application obtains switching capacitor module with filtering function, current monitoring and heat dissipation function by integrating heat dissipation water channel, current sensor, nanocrystalline magnetic core and capacitor core.

[0026] The switching capacitor module is independently applicable, and can be integrated with other capacitor modules to expand capacitor to form integrated capacitor assembly, effectively reduce module occupied space, solve the problem that existing capacitor module cannot meet miniaturization and integration application scene.

[0027] The switching capacitor module integrates nanocrystalline magnetic core inside and connects filtering assembly outside, greatly reduces the influence of common mode inductance, improves anti-interference performance, improves reliability and safety. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 A structure schematic view of the switching capacitor module, integrated capacitor assembly and motor controller embodiment one of the utility model;

[0029] Figure 2 A structure schematic view of the current sensor in the switching capacitor module, integrated capacitor assembly and motor controller embodiment one of the utility model;

[0030] Figure 3 A structure schematic view of the support in the switching capacitor module, integrated capacitor assembly and motor controller embodiment one of the utility model;

[0031] Figure 4 A circuit schematic view of the current sensor position in the switching capacitor module, integrated capacitor assembly and motor controller embodiment one of the utility model;

[0032] Figure 5 A structure schematic view of the integrated capacitor assembly of the switching capacitor module, integrated capacitor assembly and motor controller embodiment two of the utility model.

[0033] Reference signs:

[0034] 1-switching capacitor module; 11-housing; 12-capacitor core; 13-nanocrystalline magnetic core; 14-copper bar; 2-current sensor; 3-support; 31-supporting part; 32-extension; 33-bolt; 4-basic capacitor module; 5-power assembly; 6-filter assembly. DETAILED DESCRIPTION

[0035] The advantages of the utility model will be further described below in combination with the drawings and specific embodiments.

[0036] The exemplary embodiments will be described in detail herein below with reference to the drawings. When the following description refers to the drawings, same numbers in different drawings represent the same or similar elements unless otherwise indicated. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present disclosure. Instead, they are merely examples of apparatuses and methods consistent with some aspects of the present disclosure as detailed in the appended claims.

[0037] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used in this disclosure and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0038] It should be understood that, although the terms first, second, third, etc. can be employed in this disclosure to describe various information, the information is not to be limited to these terms. These terms are only used to distinguish one category of information from another. Depending on the context, the word "if" as used herein can be interpreted to mean "when" or "upon" or "in response to determining".

[0039] In the description of the present application, it should be understood that the orientation or positional relationship indicated by the terms "longitudinal", "transverse", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation of the present application.

[0040] In the description of the present application, unless otherwise specified and limited, it should be noted that the terms "mounting", "connecting", "connection" should be understood in a broad sense, for example, it can be mechanical connection or electrical connection, or the communication between two elements, or direct connection, or indirect connection through an intermediate medium, and those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0041] In the subsequent description, the suffix such as "module", "component" or "unit" used to represent elements is only for the convenience of the description of the present application, and has no specific meaning. Therefore, "module" and "component" can be used interchangeably.

[0042] Embodiment one: the embodiment discloses a switching capacitor module 1, which can be used as an independent module for miniaturization and integration application scenarios, or also as an extended capacitor, connected with the capacitor module (basic capacitor module 4 described below) in the original application scenario, to overcome the problem that the existing part of the scene capacitor is large, and the capacitor capacity is not enough after reducing the size of the capacitor.

[0043] Specifically, referring to Figures 1-4 , the switching capacitor module 1 comprises:

[0044] The shell 11 has a first area and a second area inside; the first area and the second area are arranged side by side along the length direction of the shell 11, and the two areas can be set to different shapes for distinction, or can be without distinction, and after the capacitor core 12 and the nanocrystalline magnetic core 13 are placed therein, they are fixed by pouring and sealing;

[0045] The capacitor core 12 is poured and sealed in the first area to form a capacitor area;

[0046] The nanocrystalline magnetic core 13 is filled in the second area to form a filtering area. It can be understood that other magnetic cores that can achieve the integration effect can also be used.

[0047] The copper bar 14, including positive and negative copper bars 14, connects the capacitor core 12 and the nanocrystalline magnetic core 13 and extends out of both sides of the shell 11. Specifically, one end is connected to the capacitor core 12 (located at one end of the capacitor core 12) and the other end is connected to the nanocrystalline magnetic ring (located at one end of the nanocrystalline magnetic ring).

[0048] In this embodiment, the inside of the shell 11 is divided into two areas to integrate the nanocrystalline magnetic core 13 in the capacitor module, that is, to integrate the EMC function on the capacitor module. The integration in the inside of the shell 11 reduces the number of components and welding points, reduces the assembly complexity, and improves the production efficiency. The integration of the nanocrystalline magnetic core 13 can effectively reduce the power ripple and electromagnetic interference, and also reduce the parasitic inductance and parasitic resistance.

[0049] The adapter capacitor module 1 of this embodiment also includes a current sensor 2 connected to the copper bar 14 (located in the shell 11) between the capacitor core 12 and the nanocrystalline magnetic core 13, that is, the current monitoring is integrated with the capacitor. The current sensor 2 is directly coupled to the current path of the capacitor core 12 (through the copper bar 14 inside it), and the signal transmission delay can be shortened to the nanosecond level. Compared with the microsecond level delay of the external sensor, the monitoring effect and efficiency are better, and the application scenarios are more extensive.

[0050] Based on the above, the integrated current sensor 2 also adopts a magnetic shielding design (the above-mentioned nanocrystalline magnetic core 13), which can suppress the interference of the electromagnetic field around the capacitor on the current measurement, and improve the accuracy of the monitoring result. Further, the overall volume of the adapter capacitor module 1 is effectively reduced, which is different from the existing arrangement of connecting independent current sensors 2 through wires, reducing the connection and reducing the damage in the application process; In addition, the current sensor 2 is integrated in the inside of the shell 11, which can also reuse the power supply / circuit of the capacitor, etc., reducing repeated design and optimizing space utilization.

[0051] In this embodiment, the current sensor 2 is arranged on the copper bar 14 at the current input side of the capacitor core 12, accurately monitors the current input, and makes the monitoring result more accurate. Specifically, as an example, it can be regarded that there is a gap between the capacitor core 12 and the nanocrystalline magnetic ring, which is connected through the arrangement of the current sensor 2 (see Figure 3 and Figure 4 , Figure 4 The corresponding circuit diagram of the current sensor 2 is shown, in which the left side is the capacitor core 12 and the right side is the nanocrystalline magnetic ring.

[0052] In the embodiment, in order to improve the stability of the integrated current sensor 2, a support 3 for supporting the current sensor 2 is further included; the support 3 includes a supporting portion 31 for placing the current sensor 2 and an extension portion 32 located on both sides of the supporting portion 31; the copper bar 14 is folded to be located on both sides of the extension portion 32 and connected to the current sensor 2; and the support 3 is connected to the shell 11.

[0053] Based on the above, as an example, the current sensor 2 is located in the middle, and the copper bar 14 is folded to both sides of the current sensor 2; as an option, the supporting portion 31 and the extension portion 32 can be made of metal materials, so that after the current sensor 2 and the copper bar 14 are connected, the support 3 can be used to realize partial current transmission (electrical connection).

[0054] The support 3 is fixed in the adapter capacitor module 1 in cooperation with the support, and it can be understood that a detachable mode including but not limited to clamping and bolt 33 connection can be used for convenient assembly. The support 3 is arranged between the first region and the second region, and as an option, other support structures can be further arranged for integrating other sensors or adjusting the position of the current sensor 2 to meet different application requirements.

[0055] In the embodiment, the bolt 33 is arranged on the support 3 to pass through the copper bar 14 and the extension portion 32 to detachably fix the copper bar 14 on the support 3, and the copper bar 14 is fixed in the adapter capacitor module 1 by the bolt 33, thereby reducing the safety risk caused by displacement between the copper bar 14 and the support 3 during use.

[0056] In the embodiment, the capacitor core 12 and the nanocrystalline magnetic ring are filled after being arranged in the shell 11, a filling baffle can be arranged on the shell 11 for convenient operation, filling is beneficial to the integrity of the adapter capacitor module 1, and is also convenient for batch operation and improves production efficiency.

[0057] In a preferred embodiment, the shell 11 is arranged with a first heat dissipation water channel (in the shell 11, not shown in the figure) acting on the first region, that is, the effect of an integrated water cooling plate, and is arranged around the first region, that is, the capacitor region (for capacitor heat dissipation, and to a certain extent, part of the heat of the nanocrystalline magnetic ring can also be removed), thereby realizing the integration of the heat dissipation function, without the need for additional arrangement of a heat dissipation component, reducing the mounting and fixing points, improving the integration and miniaturization, and at the same time, the heat dissipation water channel is integrated in the shell 11, reducing the transfer thermal resistance between the capacitor core 12 and the shell 11, and providing a better heat dissipation effect.

[0058] In addition, the shell 11 in the embodiment can be applied to a metal shell 11, thereby improving the heat dissipation effect of the integrated heat dissipation waterway, and the distribution and structure of the heat dissipation waterway can be selected according to the application scene. Through the integration of the above-mentioned (first) heat dissipation waterway, current sensor 2, nanocrystalline magnetic core 13 and capacitor core 12, the switching capacitor module 1 with filtering function and current monitoring is obtained, and multiple modules / devices are integrated, thereby effectively reducing the occupied space of the module.

[0059] The switching capacitor module 1 of the embodiment can be independently applied, combined or connected with other modules, and applied in batches, so as to meet the needs of different integrated and / or miniaturized scenes.

[0060] Embodiment two: the embodiment also provides an integrated capacitor assembly, which can be an integrated application example of the above-mentioned switching capacitor module 1. Figures 1-4 , and also includes: Figure 5

[0061] The basic capacitor module 4 is connected to one side of the switching capacitor module 1.

[0062] The filtering assembly 6 is connected to the side of the second area away from the basic capacitor module 4.

[0063] In the embodiment, the basic capacitor module 4 can be a capacitor module that has been applied or must be applied in the application scene, such as a DC-link capacitor (DC bus capacitor). A smaller basic capacitor module 4 can be selected due to the need to meet the miniaturized scene, and at this time, in order to meet the power application, the above-mentioned switching capacitor module 1 can be integrated to realize the expansion of the basic capacitor module 4. Since the switching capacitor module 1 can be arranged relatively independently, it can be arranged at any position in the scene (such as stacked or parallel arrangement, which can realize connection), thereby meeting the needs of different scenes.

[0064] The basic capacitor module 4 is connected to the end of the copper bar 14 (located at one end of the capacitor core 12) of the first area of the shell 11 of the switching capacitor module 1, to realize the expansion of the capacitor; the filtering assembly 6 can be a filter or a filtering circuit designed for the application scene, which is connected to the end of the copper bar 14 (located at one end of the nanocrystalline magnetic ring) of the second area of the shell 11 of the switching capacitor module 1, to perform further filtering, further reduce parasitic parameters, reduce the influence of common-mode inductance, improve EMC performance, enhance reliability and anti-interference ability.

[0065] ​In the embodiment, the basic capacitor module 4 is connected with a power component 5, which specifically includes but is not limited to a power semiconductor device, and further can be integrated with an electronic device such as a sensor, etc., to realize multifunctional integration, and can be provided with a plurality of interfaces, etc., for application in different devices / systems in different scenarios.

[0066] In a preferred embodiment, the integrated capacitor assembly can also be integrated with a heat dissipation function, and the basic capacitor module 4 is integrated with a second heat dissipation channel, wherein the second heat dissipation channel is in communication with the first heat dissipation channel, and the integrated capacitor assembly as a whole forms a (large) heat dissipation channel (such as Figure 5 only the water pipe connected to the heat dissipation channel is shown in the upper side), and the integrated capacitor assembly as a whole is subjected to heat dissipation, so that a separate heat dissipation component is not required, and a plurality of water inlets and outlets are not required, thereby reducing the safety hazards caused by heat generation of each component during use and improving the use safety.

[0067] In a preferred embodiment, as described above, considering the application in a miniaturized scenario, the integrated capacitor assembly preferably reduces the space occupation, and therefore the basic capacitor module 4 and the switching capacitor module 1 are arranged side by side in the width direction, i.e., along the shorter side, if Figure 5 the transverse direction is the length direction, the basic capacitor module 4 and the switching capacitor module 1 are connected in the longitudinal direction, which reduces the requirement for the transverse space, makes the integrated capacitor assembly have a higher integration degree and a more concentrated space occupation, and can be arranged close to the basic capacitor module 4 and the switching capacitor module 1, so that the integrated capacitor assembly is arranged in an approximately regular cuboid shape, thereby facilitating assembly, transportation or application.

[0068] Based on the above, as an optional arrangement, the basic capacitor module 4 and the switching capacitor module 1 share a shell 11 on the side connected thereto, i.e., the space occupation can be further optimized, and the shell 11 can also realize reuse of the heat dissipation channel described above, so as to improve the heat dissipation efficiency and reduce the connection points between the modules.

[0069] In the embodiment, the integrated capacitor assembly integrates the switching capacitor module 1 described above, utilizes the switching capacitor module 1 to realize expansion of the basic capacitor module 4, and further integrates a filtering function, a current monitoring function (through the current sensor 2 on the switching capacitor module 1), a heat dissipation function, etc., so as to realize a capacitor assembly with high integration and suitable for a miniaturized scenario, reduce the application of a connecting piece, reduce the space occupation, reduce the cost, improve the efficiency and application effect.

[0070] The embodiment also provides a motor controller applying the above-mentioned relay capacitor module 1 of the first embodiment and / or the above-mentioned integrated capacitor assembly. The motor controller is a core device for controlling the operation state of a motor and is widely applied in many fields such as new energy vehicles, hybrid vehicles and the like. It can be understood that the motor controller also comprises modules / assemblies / components / devices and the like connected with the above-mentioned relay capacitor module 1 and / or integrated capacitor assembly to realize application, and connects a power system, a control system and the like according to different application scenarios.

[0071] It should be noted that the embodiments of the utility model have better implementation, and do not limit the utility model in any form, and any skilled person in the art can change or modify the equivalent effective embodiments by using the above-mentioned disclosed technical content, as long as the content of the utility model technical scheme is not deviated, and any modification or equivalent change and modification of the above-mentioned embodiments according to the technical essence of the utility model still belongs to the range of the utility model technical scheme.

Claims

1. A capacitor adapter module, characterized in that... ,include: The shell has a first region and a second region inside; The capacitor core is encapsulated in the first region; Nanocrystalline magnetic core, encapsulated in the second region; A copper busbar connects the capacitor core and the nanocrystalline magnetic core, and extends out from both sides of the housing; A current sensor is connected to a copper busbar between the capacitor core and the nanocrystalline magnetic core.

2. The adapter capacitor module according to claim 1, characterized in that... : It also includes a bracket connected to the housing; The bracket includes a support portion for placing the current sensor and extension portions located on both sides of the support portion; The copper busbar is folded over and placed on the extension and connected to both sides of the current sensor.

3. The adapter capacitor module according to claim 2, characterized in that... : Bolts are provided on the bracket to detachably connect the copper busbar to the bracket by passing through the copper busbar and the extension.

4. The adapter capacitor module according to claim 1, characterized in that... : The housing is provided with a first heat dissipation channel that acts on the first region.

5. An integrated capacitor assembly, characterized in that... : Includes the adapter capacitor module as described in claim 4 above; Also includes: The basic capacitor module is connected to one side of the adapter capacitor module; A filter component is connected to the side of the second region away from the basic capacitor module.

6. The integrated capacitor assembly according to claim 5, characterized in that... : The basic capacitor module integrates a second heat dissipation channel, wherein the second heat dissipation channel is connected to the first heat dissipation channel.

7. The integrated capacitor assembly according to claim 5, characterized in that... : A power component is connected to the basic capacitor module.

8. The integrated capacitor assembly according to claim 5, characterized in that... : The basic capacitor module and the transition capacitor module are arranged side by side along the width direction.

9. The integrated capacitor assembly according to claim 5, characterized in that... : The basic capacitor module and the adapter capacitor module share a common housing on the same side.

10. A motor controller, characterized in that... The adapter capacitor module described in any one of claims 1-4 and / or the integrated capacitor assembly described in any one of claims 5-9 are applied.

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