Inverter brick structure, motor controller, motor assembly and vehicle

Abstract

The utility model discloses an inversion brick structure, a motor controller, a motor assembly and a vehicle, the inversion brick structure comprises an installation shell, the installation shell is provided with an installation cavity, two ends of the installation shell in a first direction are respectively a first end and a second end; the capacitor is arranged in the mounting cavity; the driving board, the power module and the control board are arranged at the first end, and the control board is arranged at the second end. According to the inversion brick structure provided by the utility model, on one hand, the driving board, the power module and the control board are arranged on the mounting shell for mounting the capacitor, so that the integration degree of the inversion brick structure can be improved, the inversion brick structure is easier to arrange in the motor controller, and the production difficulty and the design difficulty of the motor controller are reduced; the interval between the driving board and the control board is large, a shielding board arranged between the driving board and the control board can be omitted, and therefore the production cost of the motor controller is reduced.

Description

TECHNICAL FIELD

[0001] The utility model relates to motor controller technical field especially is involved in a kind of inverter brick structure, motor controller, motor assembly and vehicle. BACKGROUND

[0002] Motor controller is important component in motor system, to realize the work of motor, many components will be set in the inside of motor controller, in relevant technology, the integration of motor controller internal component is poor, so that the production difficulty and design difficulty of motor controller are higher. SUMMARY

[0003] The utility model aims at at least one of the technical problems existing in prior art is solved.For this purpose, the utility model provides an inverter brick structure, the inverter brick structure can make the structure more compact inside motor controller.

[0004] The utility model further provides a motor controller with the above-mentioned inverter brick structure.

[0005] The utility model further provides a motor assembly with the above-mentioned motor controller.

[0006] The utility model further provides a vehicle with the above-mentioned motor assembly.

[0007] According to the inverter brick structure of the utility model first aspect, including: installation shell, the installation shell is formed with installation cavity, the installation shell in the first direction two ends are first end and second end respectively;Capacitor, the capacitor is located in the installation cavity;Drive board, power module and control board, the drive board and the power module are located in the first end, and the control board is located in the second end.

[0008] According to the inverter brick structure of the utility model first aspect, on the one hand, by drive board, power module and control board are arranged on the installation capacitor installation shell, the integration degree of inverter brick structure can be improved, makes inverter brick structure more easily arranged in motor controller, thereby reduce the production difficulty and design difficulty of motor controller, on the other hand, the interval between drive board and control board is larger, can dispense with the shield plate between drive board and control board, thereby reduce the production cost of motor controller.

[0009] According to some embodiments of the utility model, the inverter brick structure further includes: hall sensor, the hall sensor board is connected on the drive board.

[0010] According to some embodiments of the utility model, first end form with magnetic ring installation department, magnetic ring installation department be located power module in second direction one side, second direction perpendicular to first direction, the inverter brick structure still include: three -phase magnetic ring, three -phase magnetic ring set in magnetic ring installation department.

[0011] According to some embodiments of the utility model, magnetic ring installation department includes magnetic ring installation groove, magnetic ring installation groove form in magnetic ring installation department in second direction one side away from power module, three -phase magnetic ring set in magnetic ring installation groove.

[0012] According to some embodiments of the utility model, magnetic ring installation groove is annular, in the radial inner side of magnetic ring installation groove, the magnetic ring installation department forms on the hole in second direction through magnetic ring installation department, the inverter brick structure still include: three -phase copper bar, three -phase copper bar wear set in the hole, and three -phase copper bar towards power module one end is fixed on installation shell, three -phase copper bar with power module electric connection.

[0013] According to some embodiments of the utility model, drive board and power module in first direction laminated arrangement, and drive board is located power module one side away from installation shell.

[0014] According to some embodiments of the utility model, installation shell forms cooling flow channel in, at least part of cooling flow channel set in installation cavity one side towards first end.

[0015] According to some embodiments of the utility model, cooling flow channel includes: first flow section, second flow section and third flow section are connected in turn, first flow section and third flow section extend along first direction, first flow section and third flow section are located installation cavity two sides in third direction respectively, third direction is perpendicular to first direction, second flow section extends along third direction and is located installation cavity one side towards first end.

[0016] According to some embodiments of the utility model, first flow section and second flow section all through second end in first direction, the first flow section in the through -hole of second end is first interface, the through -hole of second flow section in second end is second interface, one of first interface and second interface is the entrance of cooling flow channel, and the other is the outlet of cooling flow channel.

[0017] According to some embodiments of the utility model, second end is equipped with first lug and second lug, first interface is formed on first lug, and second interface is formed on second lug.

[0018] According to some embodiments of the present application, the part of the end face of the first end is recessed towards the second end to form the open second flow section, the power module covers the opening of the second flow section, and the power module is sealingly connected with the periphery of the opening of the second flow section.

[0019] According to some embodiments of the present application, a first sealing groove is further formed on the end face of the first end, the first sealing groove is arranged around the opening of the second flow section, a first sealing ring is arranged in the first sealing groove, the power module covers the first sealing groove, and the first sealing ring is abutted between the power module and the inner wall of the first sealing groove.

[0020] According to some embodiments of the present application, the capacitor comprises a capacitor core, a positive copper bar and a negative copper bar, the positive copper bar has a positive connection part, the negative copper bar has a negative connection part, the positive connection part and the negative connection part are respectively arranged at two ends of the capacitor core in the first direction, and the positive connection part and the negative connection part are electrically connected with the capacitor core.

[0021] According to some embodiments of the present application, one end of the mounting shell in the second direction forms a mounting opening communicating with the mounting cavity, the second direction is perpendicular to the first direction, a filling member is filled between the capacitor and the inner wall of the mounting cavity, the positive copper bar further has a positive terminal electrically connected with the positive connection part, the negative copper bar further has a negative terminal electrically connected with the negative connection part, and the positive terminal and the negative terminal both extend out of the mounting opening.

[0022] According to some embodiments of the present application, the positive terminal comprises a first positive terminal and a second positive terminal, the negative terminal comprises a first negative terminal and a second negative terminal, the first positive terminal and the first negative terminal are arranged on one side of the mounting shell forming the mounting opening and are arranged in the third direction, the first direction, the second direction and the third direction are perpendicular to each other, the second positive terminal and the second negative terminal are arranged on one side of the mounting shell in the third direction, and the second positive terminal and the second negative terminal are arranged in the second direction.

[0023] According to some embodiments of the present application, a plurality of inverter brick mounting parts are further arranged on the mounting shell, the inverter brick mounting parts are used for mounting the inverter brick structure in the motor controller, the inverter brick mounting part comprises a first mounting part, the first mounting part is arranged at one end of the mounting shell towards the second positive terminal, and in the second direction, the first mounting part is arranged between the second positive terminal and the second negative terminal.

[0024] According to some embodiments of the present application, the mounting shell is an injection molded part.

[0025] According to some embodiments of the present application, the inverter brick structure further comprises: a first mounting member and a second mounting member, the first mounting member and the second mounting member are both insert molded in the mounting shell, the first mounting member is used for mounting the power module, and the second mounting member is used for mounting the three-phase copper bar.

[0026] According to the motor controller of the second aspect of the present application, the inverter brick structure according to the first aspect of the present application is arranged, so that the production difficulty, design difficulty and production cost of the motor controller can be reduced, the component integration of the inverter brick structure is high, the size of the motor controller can be reduced, and the arrangement of the motor controller is facilitated.

[0027] According to the motor controller of the second aspect of the present application, the inverter brick structure according to the first aspect of the present application is arranged, so that the production difficulty, design difficulty and production cost of the motor controller can be reduced, the component integration of the inverter brick structure is high, the size of the motor controller can be reduced, and the arrangement of the motor controller is facilitated.

[0028] According to the motor assembly of the third aspect of the present application, the motor controller according to the second aspect of the present application is arranged, so that the production difficulty and production cost can be reduced.

[0029] According to the motor assembly of the third aspect of the present application, the motor controller according to the second aspect of the present application is arranged, so that the production difficulty and production cost can be reduced.

[0030] According to the vehicle of the fourth aspect of the present application, the motor assembly according to the third aspect of the present application is arranged, so that the production difficulty and production cost can be reduced.

[0031] According to the vehicle of the fourth aspect of the present application, the motor assembly according to the third aspect of the present application is arranged, so that the production difficulty and production cost can be reduced.

[0032] Additional aspects and advantages of the present application will be partially given in the following description, partially will become obvious from the following description, or will be understood by the practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 is a schematic view of the inverter brick structure according to the embodiments of the present application;

[0034] Figure 2 is Figure 1 a schematic view of the inverter brick structure shown in FIG.

[0035] Figure 3 is Figure 2 a sectional view in the A-A direction shown in FIG.

[0036] Figure 4 is Figure 1A schematic diagram of the inverter brick structure shown from another angle;

[0037] Figure 5 yes Figure 4 The sectional view shown in the BB direction;

[0038] Figure 6 yes Figure 1 An exploded view of the mounting housing and capacitors shown;

[0039] Figure 7 yes Figure 1 A schematic diagram of the mounting housing shown;

[0040] Figure 8 yes Figure 1 The diagram shows another angle of the mounting housing.

[0041] Figure label:

[0042] 100. Inverter brick structure;

[0043] 10. Mounting shell; 11. Mounting cavity; 12. First end; 121. First sealing groove; 122. First sealing ring; 13. Second end; 14. Magnetic ring mounting part; 141. Magnetic ring mounting groove; 142. Clearance hole; 15. Cooling channel; 151. First flow section; 152. Second flow section; 153. Third flow section; 16. First protrusion; 161. Second sealing groove; 162. Second sealing ring; 17. Second protrusion; 171. Third sealing groove; 172. Third sealing ring; 18. Mounting port; 19. Inverter brick mounting part; 191. First mounting part; 192. First mounting hole;

[0044] 20. Capacitor; 21. Capacitor core; 22. Positive copper busbar; 221. Positive connection part; 222. Positive terminal; 2221. First positive terminal; 2222. Second positive terminal; 223. First positive connection section; 224. Second positive connection section; 23. Negative copper busbar; 231. Negative connection part; 232. Negative terminal; 2321. First negative terminal; 2322. Second negative terminal; 233. First negative connection section; 234. Second negative connection section; 24. First insulating paper; 25. Second insulating paper;

[0045] 30. Driver board;

[0046] 40. Power module; 41. Second mounting hole;

[0047] 50. Control panel;

[0048] 60. Hall effect sensor;

[0049] 70. Three-phase magnetic ring; 71. Three-phase copper busbar;

[0050] 80. First mounting component; 81. Second mounting component;

[0051] 90. Flexible flat cable. Detailed Implementation

[0052] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0053] The following is for reference. Figures 1-8 The inverter brick structure 100 according to a first aspect embodiment of the present invention is described.

[0054] like Figures 1-5 As shown, the inverter brick structure 100 according to the first aspect embodiment of the present invention includes: a mounting shell 10, a capacitor 20, a drive board 30, a power module 40, and a control board 50.

[0055] Specifically, the mounting housing 10 has a mounting cavity 11, and the mounting housing 10 is in a first direction (e.g., Figure 1 The two ends (in the up-down direction shown) are the first end 12 and the second end 13, respectively. The capacitor 20 is located in the mounting cavity 11, the drive board 30 and the power module 40 are located at the first end 12, and the control board 50 is located at the second end 13.

[0056] The functions and electrical connections of capacitor 20, driver board 30, power module 40 and control board 50 are well known in the art and will not be described in detail here. Driver board 30 and control board 50 are connected by a flexible flat cable 90.

[0057] It is understandable that the number of components used to implement the functions of the motor controller is fixed within the motor controller. In this embodiment, by integrating the drive board 30, power module 40, and control board 50 onto the mounting housing 10 that houses the capacitor 20, the inverter brick structure 100 achieves a high degree of integration and a small size. This reduces the number of modules within the motor controller during design, simplifies the internal structure, and makes the smaller inverter brick structure 100 easier to arrange within the motor controller, thus reducing the design complexity. During production, the capacitor 20, drive board 30, power module 40, and control board 50 can be installed together into the motor controller, requiring fewer steps and reducing the manufacturing complexity.

[0058] By placing the drive board 30 and the control board 50 at opposite ends of the mounting housing 10 in the first direction, the distance between the drive board 30 and the control board 50 is relatively large, resulting in less electromagnetic interference from the drive board 30 to the control board 50. Furthermore, the mounting housing 10 and the capacitor 20 act as a barrier between the drive board 30 and the control board 50, further reducing electromagnetic interference between them. Consequently, the shielding plate between the drive board 30 and the control board 50 can be eliminated, simplifying the inverter brick structure 100 and reducing its production cost.

[0059] According to the first aspect of the present invention, the inverter brick structure 100 has the following advantages: First, by arranging the drive board 30, power module 40 and control board 50 on the mounting shell 10 for mounting capacitor 20, the integration level of the inverter brick structure 100 can be improved, making it easier to arrange the inverter brick structure 100 within the motor controller, thereby reducing the production and design difficulty of the motor controller. Second, the large spacing between the drive board 30 and the control board 50 eliminates the need to set a shielding plate between the drive board 30 and the control board 50, thereby reducing the production cost of the motor controller.

[0060] In some embodiments of this utility model, such as Figure 1 As shown, the inverter brick structure 100 also includes a Hall sensor 60, which is connected to the drive board 30.

[0061] Therefore, the separate mounting structure for the Hall sensor 60 can be eliminated, thereby further improving the integration level of the inverter brick structure 100. Preferably, the Hall sensor 60 is board-mounted onto the driver board 30 via pin connectors.

[0062] In some embodiments of this utility model, such as Figure 1 , Figure 4 , Figure 6 and Figure 7 As shown, a magnetic ring mounting portion 14 is formed at the first end 12, and the magnetic ring mounting portion 14 is located in the power module 40 in the second direction (e.g., Figure 1 On one side of the front-back direction shown in the diagram, the second direction is perpendicular to the first direction. The inverter brick structure 100 also includes a three-phase magnetic ring 70, which is disposed on the magnetic ring mounting part 14.

[0063] During motor control operation, the three-phase magnetic ring 70 can suppress the interference of high-frequency electromagnetic signals on the components on the inverter brick structure 100. The mounting structure of the three-phase magnetic ring 70 is integrated on the mounting shell 10. On the one hand, it can further improve the integration degree of the inverter brick structure 100. On the other hand, it can reduce the assembly steps during the production process, thereby reducing the number of tolerance accumulations and improving the positional accuracy of the three-phase magnetic ring 70 after assembly.

[0064] In some embodiments of this utility model, such as Figure 1 As shown, the magnetic ring mounting part 14 includes a magnetic ring mounting groove 141, which is formed on the side of the magnetic ring mounting part 14 away from the power module 40 in the second direction, and the three-phase magnetic ring 70 is disposed in the magnetic ring mounting groove 141.

[0065] During the assembly process, the magnetic ring mounting groove 141 can position and guide the three-phase magnetic ring 70, enabling the three-phase magnetic ring 70 to be quickly assembled into place, thereby reducing assembly difficulty and improving assembly efficiency. After assembly, the magnetic ring mounting groove 141 has a large contact area with the three-phase magnetic ring 70, which has a good limiting effect on the three-phase magnetic ring 70, and can improve the stability of the three-phase magnetic ring 70 on the mounting shell 10 and the reliability of the connection.

[0066] In some embodiments of this utility model, such as Figure 1 As shown, the magnetic ring mounting groove 141 is annular. On the radial inner side of the magnetic ring mounting groove 141, the magnetic ring mounting part 14 has a clearance hole 142 that penetrates the magnetic ring mounting part 14 in a second direction. The inverter brick structure 100 also includes a three-phase copper busbar 71, which passes through the clearance hole 142. The end of the three-phase copper busbar 71 facing the power module 40 is fixed to the mounting shell 10, and the three-phase copper busbar 71 is electrically connected to the power module 40.

[0067] The three-phase copper busbar 71 is used to connect to the external load. By setting the three-phase copper busbar 71 in the clearance hole 142 on the radial inner side of the magnetic ring mounting groove 141, the space occupied by the three-phase copper busbar 71 and the magnetic ring mounting part 14 can overlap, thereby further reducing the size of the inverter brick structure 100 and reducing the difficulty of arranging the inverter brick structure 100 in the motor controller.

[0068] In some embodiments of this utility model, such as Figures 1-3 As shown, the drive board 30 and the power module 40 are stacked in the first direction, and the drive board 30 is located on the side of the power module 40 away from the mounting housing 10.

[0069] This can further reduce electromagnetic interference between the drive board 30 and the control board 50, thereby improving the reliability of the inverter brick structure 100 during operation.

[0070] In some embodiments of this utility model, such as Figure 1 , Figure 3 , Figure 5 and Figure 7 As shown, a cooling channel 15 is formed inside the mounting housing 10, and at least a portion of the cooling channel 15 is located on the side of the mounting cavity 11 facing the first end 12.

[0071] In other words, some of the cooling channels 15 can be located on the side of the mounting cavity 11 facing the first end 12, or all of the cooling channels 15 can be located on the side of the mounting cavity 11 facing the first end 12.

[0072] At least a portion of the cooling channel 15 is located between the capacitor 20 and the power module 40. It is understood that during the operation of the inverter brick structure 100, the power module 40 and the capacitor 20 will generate a lot of heat, which will be transferred to the mounting shell 10. During the flow of the cooling medium in the cooling channel 15, it will exchange heat with the mounting shell 10. By locating at least a portion of the cooling channel 15 between the capacitor 20 and the power module 40, the cooling medium can better exchange heat with the capacitor 20 and the power module 40, thereby achieving cooling of the power module 40 and the capacitor 20 and improving the reliability of the inverter brick structure 100 during operation.

[0073] By integrating the cooling channel 15 into the mounting housing 10, the integration level of the inverter brick structure 100 can be further improved, and the contact area between the cooling medium and the mounting housing 10 is larger, which can improve the cooling effect on the inverter brick structure 100.

[0074] In some embodiments of this utility model, such as Figure 3 and Figure 7 As shown, the cooling channel 15 includes a first flow section 151, a second flow section 152, and a third flow section 153 connected in sequence. The first flow section 151 and the third flow section 153 extend along a first direction and are respectively located in the mounting cavity 11 in a third direction (e.g., in the third direction). Figure 1 On both sides of the left and right direction shown in the figure, the third direction is perpendicular to the first direction, and the second flow section 152 extends along the third direction and is located on the side of the mounting cavity 11 facing the first end 12.

[0075] During the operation of the inverter brick structure 100, the cooling medium flows sequentially through the first flow section 151, the second flow section 152, and the third flow section 153. During the flow in the first flow section 151 and the second flow section 152, the cooling medium can exchange heat effectively with the capacitor 20. During the flow in the second flow section 152, the cooling medium can exchange heat effectively with the power module 40 and the capacitor 20. Thus, the cooling effect of the cooling medium on the capacitor 20 and the power module 40 can be guaranteed, so that the cooling efficiency of the capacitor 20 and the power module 40 can meet the working requirements.

[0076] In some embodiments of this utility model, such as Figure 3 and Figure 8As shown, the first flow section 151 and the second flow section 152 both penetrate the second end 13 in the first direction. The penetration port of the first flow section 151 at the second end 13 is the first interface, and the penetration port of the second flow section 152 at the second end 13 is the second interface. One of the first interface and the second interface is the inlet of the cooling channel 15, and the other is the outlet of the cooling channel 15.

[0077] The first interface and the second interface are used to connect to the external cooling water circuit. Taking the first interface as the inlet of the cooling channel 15 and the second interface as the outlet of the cooling channel 15 as an example, the flow process of the cooling medium in the cooling channel 15 is described.

[0078] During the operation of the inverter brick module, the cooling medium from the external water circuit enters the first flow section 151 through the first interface and then flows out through the second flow section 152 and the third flow section 153. During the flow of the cooling medium, it exchanges heat with the inner wall of the cooling channel 15, thereby cooling the inverter brick structure 100. The cooling medium in the first flow section 151 and the third flow section 153 can effectively absorb the heat on the capacitor 20, and the cooling medium in the third flow section 153 can effectively absorb the heat on the power module 40 and the capacitor 20.

[0079] During the product design process, parameters such as the cross-sectional shape, cross-sectional size, or relative angle of the first flow section 151, the second flow section 152, and the third flow section 153 can be adjusted to meet more product design needs.

[0080] In some embodiments of this utility model, such as Figure 3 and Figure 8 As shown, the second end 13 is provided with a first protrusion 16 and a second protrusion 17, with a first interface formed on the first protrusion 16 and a second interface formed on the second protrusion 17.

[0081] Therefore, it is easier to connect the first and second interfaces to the external water channel, and it is easier to form the external water channel, the connection structure between the first and second interfaces, and the sealing structure on the first protrusion 16 and the second protrusion 17, thereby further reducing the production difficulty of the inverter brick structure 100. It is understood that the external water channel, the connection structure between the first and second interfaces, and the sealing structure will occupy some space. By setting the first protrusion 16 and the second protrusion 17, the external water channel, the connection structure between the first and second interfaces, and the sealing structure can be made not to occupy the space in the mounting cavity 11, thereby allowing the capacitor 20 to have a larger arrangement space, and thus a larger capacitor 20 can be arranged.

[0082] Preferably, a second sealing groove 161 is formed on the first protrusion 16, and a second sealing ring 162 is provided in the second sealing groove 161. The first interface is sealed to the external water channel through the second sealing ring 162. A third sealing groove 171 is formed on the second protrusion 17, and a third sealing ring 172 is provided in the third sealing groove 171. The second interface is sealed to the external water channel through the third sealing ring 172.

[0083] The first and second interfaces are elliptical, which increases the contact area between the second sealing ring 162 and the third sealing ring 172 and the external water channel, thereby improving the sealing reliability at the first and second interfaces.

[0084] In some embodiments of this utility model, such as Figure 6 and Figure 7 As shown, a portion of the end face of the first end 12 is recessed toward the second end 13 to form an open second flow section 152. The power module 40 covers the opening of the second flow section 152, and the power module 40 is sealed to the periphery of the opening of the second flow section 152.

[0085] Therefore, when the cooling medium flows in the second flow section 152, it can directly contact the power module 40 and exchange heat, thereby improving the cooling efficiency of the power module 40 and simplifying the structure of the mounting shell 10, thus further reducing the production difficulty of the inverter brick structure 100.

[0086] In some embodiments of this utility model, such as Figure 1 , Figure 6 and Figure 7 As shown, a first sealing groove 121 is also formed on the end face of the first end 12. The first sealing groove 121 is arranged around the opening of the second flow section 152. A first sealing ring 122 is provided in the first sealing groove 121. The power module 40 covers the first sealing groove 121, and the first sealing ring 122 abuts between the power module 40 and the inner wall of the first sealing groove 121.

[0087] By setting the first sealing ring 122, a sealed connection can be achieved between the power module 40 and the periphery of the open opening of the second flow section 152. The first sealing ring 122 does not require any other processing during assembly, and the assembly steps are relatively simple, which can further reduce the production difficulty of the inverter brick module.

[0088] In some embodiments of this utility model, such as Figure 1 and Figure 6As shown, capacitor 20 includes: capacitor core 21, positive copper busbar 22 and negative copper busbar 23. Positive copper busbar 22 has a positive connection portion 221 and negative copper busbar 23 has a negative connection portion 231. Positive connection portion 221 and negative connection portion 231 are respectively disposed at both ends of capacitor core 21 in a first direction. Positive connection portion 221 and negative connection portion 231 are both electrically connected to capacitor core 21.

[0089] During the operation of capacitor 20, positive copper busbar 22 and negative copper busbar 23 conduct electricity at both ends of capacitor core 21 in the first direction. In this way, the distance between positive copper busbar 22 and negative copper busbar 23 is large, and the stray inductance generated by positive copper busbar 22 and negative copper busbar 23 is small, which can further improve the reliability of inverter brick structure 100 during operation.

[0090] Preferably, both the positive electrode connection portion 221 and the negative electrode connection portion 231 are plate-shaped, and the positive electrode connection portion 221 and the negative electrode connection portion 231 are respectively attached to both ends of the capacitor core 21 in the first direction.

[0091] In some embodiments of this utility model, the capacitor 20 further includes an aluminum plate disposed between the positive electrode connection portion 221 and the negative electrode connection portion 231. By providing the aluminum plate, the aluminum plate can act as a barrier between the drive board 30 and the control board 50, thereby further reducing electromagnetic interference between the drive board 30 and the control board 50.

[0092] In some embodiments of this utility model, such as Figure 1 , Figure 6 , Figure 7 and Figure 8 As shown, the mounting shell 10 has a mounting opening 18 at one end in the second direction that communicates with the mounting cavity 11. The second direction is perpendicular to the first direction. The space between the capacitor 20 and the inner wall of the mounting cavity 11 is filled with potting compound. The positive copper busbar 22 also has a positive terminal 222, which is electrically connected to the positive terminal connection part 221. The negative copper busbar 23 also has a negative terminal 232, which is electrically connected to the negative terminal connection part 231. Both the positive terminal 222 and the negative terminal 232 extend out of the mounting opening 18.

[0093] Among them, the positive terminal 222 and the negative terminal 232 are used for the capacitor 20 to be connected to the circuit in the motor controller. During the assembly process, the capacitor 20 is first installed into the mounting cavity 11 through the mounting port 18, and the positive terminal 222 and the negative terminal 232 are extended out of the mounting cavity 11 through the mounting port 18. Then, potting compound is poured into the mounting cavity 11. After the potting compound solidifies, it will form a potting component. In this way, the potting component can fix the capacitor 20, and the potting component can better transfer the heat on the capacitor 20 to the mounting shell 10, and then exchange heat with the cooling medium.

[0094] By providing the mounting port 18, space can be provided for the capacitor 20 to be assembled into the mounting cavity 11, and the arrangement of the positive terminal 222 and the negative terminal 232 can be facilitated.

[0095] In some embodiments of this utility model, such as Figure 6 As shown, the positive terminal 222 includes a first positive terminal 2221 and a second positive terminal 2222, and the negative terminal 232 includes a first negative terminal 2321 and a second negative terminal 2322. The first positive terminal 2221 and the first negative terminal 2321 are disposed on the side of the mounting housing 10 where the mounting opening 18 is formed and are spaced apart in the third direction. The first direction, the second direction and the third direction are perpendicular to each other. The second positive terminal 2222 and the second negative terminal 2322 are disposed on the side of the mounting housing 10 in the third direction, and the second positive terminal 2222 and the second negative terminal 2322 are spaced apart in the second direction.

[0096] During assembly, the first positive terminal 2221, the second positive terminal 2222, the second positive terminal 2222, and the second negative terminal 2322 are connected to different circuits in the motor controller. There can be one of each of the first positive terminal 2221, the second positive terminal 2222, the second positive terminal 2222, and the second negative terminal 2322, or there can be multiple of each. During product design, the number of the first positive terminal 2221, the second positive terminal 2222, the second positive terminal 2222, and the second negative terminal 2322 can be adjusted according to the product design requirements.

[0097] Preferably, there are multiple first positive terminals 2221 and first negative terminals 2321, and the first positive terminals 2221 and first negative terminals 2321 are arranged alternately in the third direction. For example, there are two, three or four first positive terminals 2221 and two, three or four first negative terminals 2321.

[0098] In some embodiments of this utility model, such as Figure 6As shown, the positive electrode copper busbar 22 also includes a first positive electrode connecting section 223. One end of the first positive electrode connecting section 223 is connected to the positive electrode connecting part 221, and the other end extends in a first direction toward the negative electrode copper busbar 23 and out of the mounting shell 10. The first positive terminal 2221 is connected to the other end of the first positive electrode connecting section 223. The negative electrode copper busbar 23 also includes a first negative electrode connecting section 233. One end of the first negative electrode connecting section 233 is connected to the negative electrode connecting part 231, and the other end extends in a first direction away from the positive electrode copper busbar 22 and out of the mounting shell 10. The first negative terminal 2321 is connected to the other end of the first negative electrode connecting section 233. The first positive electrode connecting section 223 and the first negative electrode connecting section 233 are stacked and insulated from each other by a first insulating paper 24. Thus, the arrangement of the first positive terminal 2221 and the first negative terminal 2321 can be realized.

[0099] The positive electrode copper busbar 22 also includes a second positive electrode connection section 224, which has a first slot, which is a U-shaped slot. The negative electrode copper busbar 23 also includes a second negative electrode connection section 234, which has a second slot, which is a U-shaped slot. The second positive electrode connection section 224 is electrically connected to the positive electrode connection part 221 and is engaged with the mounting housing 10 on the third-direction side edge through the first slot. The second negative terminal connection section 234 is electrically connected to the negative terminal connection part 231 and is engaged with the second positive terminal connection section 224 through the second slot. The second positive terminal connection section 224 and the second negative terminal connection section 234 are insulated from each other by the second insulating paper 25. The second positive terminal 2222 is located on the side of the second positive terminal connection section 224 away from the mounting cavity 11, and the second negative terminal 2322 is located on the side of the second negative terminal connection section 234 away from the mounting cavity 11. Thus, the arrangement of the second positive terminal 2222 and the second negative terminal 2322 can be realized.

[0100] In some embodiments of this utility model, such as Figure 5 and Figure 6 As shown, the mounting housing 10 is also provided with a plurality of inverter brick mounting parts 19. For example, there can be two, three or four inverter brick mounting parts 19. The inverter brick mounting parts 19 are used to install the inverter brick structure 100 in the motor controller. The inverter brick mounting parts 19 include: a first mounting part 191, which is located at one end of the mounting housing 10 facing the second positive terminal 2222. In the second direction, the first mounting part 191 is located between the second positive terminal 2222 and the second negative terminal 2322.

[0101] Therefore, the first mounting part 191 can block the second positive terminal 2222 and the second negative terminal 2322, thereby reducing the probability of a short circuit between the second positive terminal 2222 and the second negative terminal 2322 and improving the reliability of the inverter brick structure 100 during operation.

[0102] Preferably, the inverter brick mounting part 19 includes a first mounting hole 192, and the mounting shell 10 is mounted on the controller by bolts. The first mounting part 191 extends out of the mounting shell 10 by a larger dimension than the other inverter brick mounting parts 19 extend out of the mounting shell 10. This makes it easier for the first mounting hole 192 to avoid the second positive terminal 2222 and the second negative terminal 2322, thereby reducing the interference of the second positive terminal 2222 and the second negative terminal 2322 on the bolt connection operation.

[0103] In some embodiments of this utility model, the mounting shell 10 is an injection-molded part. Injection-molded parts have higher production efficiency, which can improve the production efficiency of the inverter brick structure 100, and the structural strength of injection-molded parts is higher, making it easier to ensure that the strength of the mounting shell 10 meets the usage requirements.

[0104] In some embodiments of this utility model, such as Figure 1 As shown, the inverter brick structure 100 also includes: a first mounting component 80 and a second mounting component 81. Both the first mounting component 80 and the second mounting component 81 are embedded in the mounting shell 10 by injection molding. The first mounting component 80 is used to install the power module 40, and the second mounting component 81 is used to install the three-phase copper busbar 71.

[0105] In this way, the first mounting part 80 and the second mounting part 81 can be integrated on the mounting shell 10. During the assembly process, the number of assembly steps can be reduced, thereby reducing the number of tolerance accumulation steps. Furthermore, the connection strength of the insert injection molding is relatively high, making it easier to ensure that the connection strength between the first mounting part 80 and the second mounting part 81 and the mounting shell 10 meets the design requirements.

[0106] Preferably, both the first mounting part 80 and the second mounting part 81 are nuts. The power module 40 is provided with a second mounting hole 41. The fastening bolt passes through the second mounting hole 41 and is connected to the first mounting part 80, thereby realizing the installation of the power module 40 on the mounting shell 10. The three-phase copper busbar 71 is provided with a third mounting hole. The fastening bolt passes through the third mounting hole and is connected to the mounting hole, thereby realizing the installation of the three-phase copper busbar on the mounting shell 10.

[0107] The motor controller according to a second aspect of the present invention includes: the inverter brick structure 100 described above according to the first aspect of the present invention.

[0108] According to the second aspect of the present invention, by setting the inverter brick structure 100 according to the first aspect of the present invention, the production difficulty, design difficulty and production cost of the motor controller can be reduced. Moreover, the inverter brick structure 100 has a high degree of component integration, which can reduce the size of the motor controller and facilitate the layout of the motor controller.

[0109] The motor assembly according to a third aspect of the present invention includes: the motor controller described above according to a second aspect of the present invention.

[0110] According to the motor assembly of the third aspect of the present invention, by setting the motor controller according to the second aspect of the present invention, the production difficulty and production cost can be reduced.

[0111] The vehicle according to a fourth aspect of the present invention includes: the motor assembly described above according to a third aspect of the present invention.

[0112] The vehicle according to the fourth aspect embodiment of the present invention, by providing the motor assembly according to the third aspect embodiment of the present invention, can reduce production difficulty and production cost.

[0113] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0114] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0115] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0116] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0117] Although embodiments of the present invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An inverter brick structure (100), characterized in that, include: Mounting shell (10) having a mounting cavity (11) at its two ends in a first direction, which are a first end (12) and a second end (13). A capacitor (20) is disposed in the mounting cavity (11); The device includes a drive board (30), a power module (40), and a control board (50), wherein the drive board (30) and the power module (40) are located at the first end (12), and the control board (50) is located at the second end (13).

2. The inverter brick structure (100) according to claim 1, characterized in that, Also includes: Hall sensor (60), the Hall sensor (60) board is connected to the drive board (30).

3. The inverter brick structure (100) according to claim 1, characterized in that, The first end (12) is provided with a magnetic ring mounting part (14), which is located on one side of the power module (40) in a second direction, the second direction being perpendicular to the first direction. The inverter brick structure (100) further includes a three-phase magnetic ring (70), which is disposed on the magnetic ring mounting part (14).

4. The inverter brick structure (100) according to claim 3, characterized in that, The magnetic ring mounting part (14) includes a magnetic ring mounting groove (141), which is formed on the side of the magnetic ring mounting part (14) away from the power module (40) in the second direction, and the three-phase magnetic ring (70) is disposed in the magnetic ring mounting groove (141).

5. The inverter brick structure (100) according to claim 4, characterized in that, The magnetic ring mounting groove (141) is annular. On the radial inner side of the magnetic ring mounting groove (141), a clearance hole (142) is formed on the magnetic ring mounting part (14) that penetrates the magnetic ring mounting part (14) in the second direction. The inverter brick structure (100) further includes a three-phase copper busbar (71), which passes through the clearance hole (142) and has one end facing the power module (40) fixed to the mounting shell (10). The three-phase copper busbar (71) is electrically connected to the power module (40).

6. The inverter brick structure (100) according to claim 1, characterized in that, The drive board (30) and the power module (40) are stacked in the first direction, and the drive board (30) is located on the side of the power module (40) away from the mounting housing (10).

7. The inverter brick structure (100) according to claim 6, characterized in that, A cooling channel (15) is formed inside the mounting housing (10), and at least a portion of the cooling channel (15) is located on the side of the mounting cavity (11) facing the first end (12).

8. The inverter brick structure (100) according to claim 7, characterized in that, The cooling channel (15) includes a first flow section (151), a second flow section (152), and a third flow section (153) connected in sequence. The first flow section (151) and the third flow section (153) extend along the first direction. The first flow section (151) and the third flow section (153) are located on both sides of the mounting cavity (11) in a third direction, which is perpendicular to the first direction. The second flow section (152) extends along the third direction and is located on the side of the mounting cavity (11) facing the first end (12).

9. The inverter brick structure (100) according to claim 8, characterized in that, The first flow segment (151) and the second flow segment (152) both penetrate the second end (13) in the first direction. The penetration port of the first flow segment (151) at the second end (13) is the first interface, and the penetration port of the second flow segment (152) at the second end (13) is the second interface. One of the first interface and the second interface is the inlet of the cooling channel (15), and the other is the outlet of the cooling channel (15).

10. The inverter brick structure (100) according to claim 9, characterized in that, The second end (13) is provided with a first protrusion (16) and a second protrusion (17), the first interface is formed on the first protrusion (16), and the second interface is formed on the second protrusion (17).

11. The inverter brick structure (100) according to claim 8, characterized in that, A portion of the end face of the first end (12) is recessed toward the second end (13) to form an open second flow section (152), the power module (40) is sealed at the opening of the second flow section (152), and the power module (40) is sealed to the periphery of the opening of the second flow section (152).

12. The inverter brick structure (100) according to claim 11, characterized in that, A first sealing groove (121) is also formed on the end face of the first end (12). The first sealing groove (121) is arranged around the opening of the second flow section (152). A first sealing ring (122) is provided in the first sealing groove (121). The power module (40) covers the first sealing groove (121), and the first sealing ring (122) abuts between the power module (40) and the inner wall of the first sealing groove (121).

13. The inverter brick structure (100) according to claim 1, characterized in that, The capacitor (20) includes: a capacitor core (21), a positive copper busbar (22) and a negative copper busbar (23). The positive copper busbar (22) has a positive connection portion (221), and the negative copper busbar (23) has a negative connection portion (231). The positive connection portion (221) and the negative connection portion (231) are respectively disposed at both ends of the capacitor core (21) in the first direction. The positive connection portion (221) and the negative connection portion (231) are both electrically connected to the capacitor core (21).

14. The inverter brick structure (100) according to claim 13, characterized in that, The mounting shell (10) has a mounting opening (18) at one end in a second direction that communicates with the mounting cavity (11). The second direction is perpendicular to the first direction. The space between the capacitor (20) and the inner wall of the mounting cavity (11) is filled with a potting compound. The positive copper busbar (22) also has a positive terminal (222), which is electrically connected to the positive terminal connection (221). The negative copper busbar (23) also has a negative terminal (232), which is electrically connected to the negative terminal connection (231). Both the positive terminal (222) and the negative terminal (232) extend out of the mounting port (18).

15. The inverter brick structure (100) according to claim 14, characterized in that, The positive terminal (222) includes a first positive terminal (2221) and a second positive terminal (2222), and the negative terminal (232) includes a first negative terminal (2321) and a second negative terminal (2322). The first positive terminal (2221) and the first negative terminal (2321) are disposed on the side of the mounting housing (10) where the mounting opening (18) is formed and are spaced apart in a third direction. The first direction, the second direction, and the third direction are perpendicular to each other. The second positive terminal (2222) and the second negative terminal (2322) are disposed on the mounting housing (10) on the third direction side, and the second positive terminal (2222) and the second negative terminal (2322) are arranged at intervals in the second direction.

16. The inverter brick structure (100) according to claim 15, characterized in that, The mounting housing (10) is also provided with a plurality of inverter brick mounting parts (19), which are used to install the inverter brick structure (100) in the motor controller. The inverter brick mounting part (19) includes: a first mounting part (191), which is located at one end of the mounting housing (10) facing the second positive terminal (2222). In the second direction, the first mounting part (191) is located between the second positive terminal (2222) and the second negative terminal (2322).

17. The inverter brick structure (100) according to any one of claims 1-16, characterized in that, The mounting shell (10) is an injection molded part.

18. The inverter brick structure (100) according to claim 17, characterized in that, The inverter brick structure (100) further includes: a first mounting component (80) and a second mounting component (81), both the first mounting component (80) and the second mounting component (81) being embedded in the mounting shell (10). The first mounting component (80) is used to install the power module (40), and the second mounting component (81) is used to install the three-phase copper busbar (71).

19. A motor controller, characterized in that, include: The inverter brick structure (100) according to any one of claims 1-18.

20. A motor assembly, characterized in that, include: The motor controller according to claim 19.

21. A vehicle, characterized in that, include: The motor assembly as claimed in claim 20.

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