Controller of heavy truck electric automobile

Abstract

The utility model discloses a controller of a heavy truck electric automobile. The controller comprises a control shell, the control shell is provided with a first containing cavity with an opening in the top, and a wire holder is installed at one end in the first containing cavity. A thin-film capacitor is mounted on one side in the first accommodating cavity, and an input positive terminal and an input negative terminal are mounted on the thin-film capacitor; six upper-layer output terminal assemblies are mounted at intervals in the length direction of the upper part of one side of the thin-film capacitor, and three lower-layer output terminal assemblies are mounted at intervals in the length direction of the lower part of one side of the thin-film capacitor. According to the utility model, the three-dimensional laminated layout of the thin-film capacitors and the IGBT modules is adopted, the U-phase and W-phase modules are arranged on the upper layer, the V-phase modules are arranged on the lower layer, and the water-cooling plate is adopted in the middle, so that the double-sided IGBT can be cooled, the bus connection length can be shortened, the system loss can be reduced, and the system efficiency can be improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of automobile controller, especially relates to a controller of heavy truck electric automobile. BACKGROUND

[0002] The existing heavy truck electric automobile motor controller requires high power, three IGBTs are connected in parallel for each phase, there are 9 IGBTs in horizontal layout for UVW three phases, the traditional parallel layout mode occupies space, causes the volume of the controller to be too large, the cost to increase, the vibration risk to increase, and the long bus connection leads to the increase of high-frequency switching loss, which affects the system efficiency. UTILITY MODEL CONTENTS

[0003] The utility model discloses a kind of controllers of heavy truck electric automobile, which adopts film capacitor and IGBT module three-dimensional layering type layout, upper layer layout U phase and W phase module, lower layer layout V phase module, middle water-cooled plate is used, double-sided IGBT is given heat dissipation, and bus connection length can be shortened, reduce system loss, improve system efficiency.

[0004] To achieve the above object, the following technical scheme is adopted:

[0005] The application discloses a controller of a heavy truck electric vehicle, which comprises a control shell, wherein the control shell is provided with a first cavity with an opening at the top, and a terminal block is arranged at one end in the first cavity; a film capacitor is arranged at one side in the first cavity, and an input positive terminal and an input negative terminal are arranged on the film capacitor; six upper-layer output terminal assemblies are arranged on the upper side of one side of the film capacitor in the length direction at intervals, and three lower-layer output terminal assemblies are arranged on the lower side of one side of the film capacitor in the length direction at intervals; a water-cooling plate is further arranged at one side of the film capacitor in the first cavity, and a first mounting groove penetrating into the first cavity is further arranged at the bottom of the control shell below the water-cooling plate; the bottom of the water-cooling plate is partially exposed in the first mounting groove; two sides of the first mounting groove are further provided with displacement holes, the lower part of the film capacitor is arranged in one of the displacement holes, and the three lower-layer output terminal assemblies of the film capacitor are arranged into the first mounting groove; three V-phase IGBT modules in parallel with each other are further arranged at the bottom of the water-cooling plate in the first mounting groove, and one end of each V-phase IGBT module is connected with a lower-layer output terminal assembly; three U-phase IGBT modules in parallel with each other and three W-phase IGBT modules in parallel with each other are further arranged at the top of the water-cooling plate, one end of the three U-phase IGBT modules and one end of the three W-phase IGBT modules are connected with an upper-layer output terminal assembly; a driving board is further arranged on the U-phase IGBT modules and the W-phase IGBT modules; a control board connected with the driving board is further arranged above the driving board; a positive input busbar and a negative input busbar are arranged on the terminal block, the positive input busbar is connected with the input positive terminal, and the negative input busbar is connected with the input negative terminal; a V-phase output busbar, a U-phase output busbar and a W-phase output busbar are further arranged on the terminal block; the V-phase output busbar is connected with the other end of the three V-phase IGBT modules, the U-phase output busbar is connected with the other end of the three U-phase IGBT modules, and the W-phase output busbar is connected with the other end of the three W-phase IGBT modules; an interface assembly is further arranged at one end of the control shell close to the terminal block; and a sealing top cover for sealing the first cavity is further connected to the top of the control shell.

[0006] Further, the upper-layer output terminal assembly comprises an upper-layer output positive terminal and an upper-layer output negative terminal, and the lower-layer output terminal assembly comprises a lower-layer output positive terminal and a lower-layer output negative terminal.

[0007] Further, the interface assembly comprises a positive input interface, a negative input interface, a V-phase output interface, a U-phase output interface and a W-phase output interface.

[0008] Further, a mounting support is further connected above the driving board in the first cavity, and the control board is arranged on the mounting support.

[0009] Further, the sealing top cover is provided with an access hole corresponding to the terminal seat, and a removable access cover plate is installed at the access hole.

[0010] Further, a bottom cover is detachably installed at the opening of the first mounting groove.

[0011] Further, a fixing support is installed at one end of the control shell, and a fixing hole is formed in the fixing support.

[0012] By adopting the above scheme, the utility model has the beneficial effects that:

[0013] The utility model discloses a three-dimensional laminated layout of film capacitor and IGBT module, upper layer layout U phase and W phase module, lower layer layout V phase module, adopt water -cooling plate in the middle, give double -sided IGBT heat dissipation, and can shorten bus connection length, reduce system loss, improve system efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 It is the structural schematic diagram of the utility model;

[0015] Figure 2 It is Figure 1 It is the structural schematic diagram of the sealing top cover;

[0016] Figure 3 It is Figure 2 It is the structural schematic diagram of the control shell and terminal seat;

[0017] Figure 4 It is Figure 3 It is the structural schematic diagram of V phase output bus, U phase output bus and W phase output bus;

[0018] Figure 5 It is Figure 4 It is the structural schematic diagram of another view;

[0019] Figure 6 It is the explosion drawing of the utility model;

[0020] Among them, the drawing mark explanation is:

[0021] 1, control shell; 2, wiring seat; 3, film capacitor; 4, V-phase IGBT module; 5, U-phase IGBT module; 6, W-phase IGBT module; 7, drive board; 8, control board; 11, sealing top cover; 12, positive input interface; 13, negative input interface; 14, V-phase output interface; 15, U-phase output interface; 16, W-phase output interface; 17, water cooling plate; 18, fixed support; 31, input positive terminal; 32, input negative terminal; 33, upper layer output positive terminal; 34, upper layer output negative terminal; 35, lower layer output positive terminal; 36, lower layer output negative terminal; 21, positive input busbar; 22, negative input busbar; 23, V-phase output busbar; 24, U-phase output busbar; 25, W-phase output busbar; 101, bottom cover; 102, mounting bracket; 103, maintenance cover plate; 104, first clamping groove. DETAILED DESCRIPTION

[0022] The utility model will be described in detail below in combination with the drawings and specific embodiments.

[0023] Reference Figures 1 to 6The utility model provides a kind of controller of heavy truck electric car, in an embodiment, including control casing 1;The control casing 1 is equipped with the first cavity with the opening of top, and one end in the first cavity is equipped with terminal block 2;One side in the first cavity is equipped with film capacitor 3, and input positive terminal 31 and input negative terminal 32 are installed on film capacitor 3;Six upper layer output terminal assemblies are installed on the length direction of one side upper portion of film capacitor 3 with interval, and three lower layer output terminal assemblies are installed on the length direction of one side lower portion of film capacitor 3 with interval;Water-cooling plate 17 is also installed in the first cavity close to one side of film capacitor 3, and the bottom of control casing 1 is below water-cooling plate 17 and is also equipped with the first installation slot that is through to the first cavity;The bottom part of water-cooling plate 17 is exposed in the first installation slot;Two sides in the first installation slot are also equipped with let hole, and the lower portion of film capacitor 3 is in one let hole, and the three lower layer output terminal assemblies of film capacitor 3 are arranged by being inserted into the first installation slot;Three V-phase IGBT modules 4 that are parallel to each other are also installed in the first installation slot at the bottom of water-cooling plate 17, and one end of each V-phase IGBT module 4 corresponds with a lower layer output terminal assembly connection;Three U-phase IGBT modules 5 that are parallel to each other and three W-phase IGBT modules 6 that are parallel to each other are also installed on the top of water-cooling plate 17, and one end of three U-phase IGBT modules 5 and one end of three W-phase IGBT modules 6 correspond with an upper layer output terminal assembly connection;Driving board 7 is also installed on U-phase IGBT module 5 and W-phase IGBT module 6;The control board 8 connected with driving board 7 is also arranged above driving board 7;Positive input busbar 21 and negative input busbar 22 (positive input busbar 21 and negative input busbar 22 adopt two-layer laminated structure, can save the volume inside controller, so that overall structure is more compact) are installed on terminal block 2, and positive input busbar 21 is connected with input positive terminal 31, and negative input busbar 22 is connected with input negative terminal 32;V-phase output busbar 23, U-phase output busbar 24 and W-phase output busbar 25 are also installed on terminal block 2;V-phase output busbar 23 is connected with the other end of three V-phase IGBT modules 4, U-phase output busbar 24 is connected with the other end of three U-phase IGBT modules 5, and W-phase output busbar 25 is connected with the other end of three W-phase IGBT modules 6 (V-phase output busbar 23, U-phase output busbar 24 and W-phase output busbar 25 adopt three-layer laminated structure, further save the volume inside controller);Interface assembly is also installed on one end of control casing 1 close to terminal block 2;Sealing top cover 11 for sealing the first cavity is also connected on the top of control casing 1.

[0024] Continue to refer to Figures 1 to 6As shown, in the embodiment, the upper layer output terminal assembly includes an upper layer output positive terminal 33 and an upper layer output negative terminal 34; the lower layer output terminal assembly includes a lower layer output positive terminal 35 and a lower layer output negative terminal 36; the interface assembly includes a positive input interface 12, a negative input interface 13, a V-phase output interface 14, a U-phase output interface 15, and a W-phase output interface 16, and a water inlet and a water outlet in communication with the water cooling plate 17; in the embodiment, by dividing the U-phase, W-phase and V-phase of the IGBT module into a two-layer structure, the U-phase and W-phase modules are arranged in the upper layer, and the V-phase modules are arranged in the lower layer, thereby realizing efficient use of space, greatly reducing the volume of the controller, and making it more suitable for installation in the limited internal space of a heavy truck electric vehicle; meanwhile, due to the reduction in the volume of the controller, the size of the shell is also reduced, thereby reducing the amount of material used and lowering the cost, and the middle is the water cooling plate, which can cool the IGBT modules on both sides, thereby reducing the planar area occupied, and meanwhile, the lower layer output terminal of the capacitor directly passes through the clearance hole and is bolted with the lower layer V-phase IGBT DC input terminal, thereby shortening the current path, reducing the parasitic inductance, and improving the system efficiency.

[0025] The first cavity is further connected with a mounting bracket 102 above the driving plate 7; and the control plate 8 is mounted on the mounting bracket 102.

[0026] In an embodiment, a maintenance opening is further formed in the sealing top cover 11 corresponding to the terminal seat 2, and a maintenance cover plate 103 is detachably mounted at the maintenance opening. The maintenance opening can facilitate maintenance of the controller, and the top edge of the control shell 1 is further provided with a first clamping groove 104 in a ring structure, and a sealing ring is embedded in the first clamping groove 104. The sealing ring can improve the waterproof performance of the controller, and the opening of the first mounting groove is further provided with a bottom cover 101 which is detachably mounted; and one end of the control shell 1 is further provided with a fixed support 18, and the fixed support 18 is further provided with a fixing hole in which a screw is locked to lock and fix the controller in the vehicle interior, which is convenient for installation and dismounting.

[0027] The above is only a preferred embodiment of the utility model, and is not used to limit the utility model, and any modification, equivalent replacement and improvement within the spirit and principle of the utility model should be included in the protection scope of the utility model.

Claims

1. A controller of a heavy duty electric vehicle, characterized by, The utility model provides a control casing, the control casing is equipped with first cavity with opening in the top, and the one end of first cavity is equipped with terminal block, one side of first cavity is equipped with film capacitor, and the input positive terminal and input negative terminal are equipped on film capacitor, six upper layer output terminal assemblies are equipped on the upper length direction of one side of film capacitor, three lower layer output terminal assemblies are equipped on the lower length direction of one side of film capacitor, water cooling plate is equipped on the side of film capacitor in first cavity, and the bottom of control casing is equipped with first installation groove that passes through to first cavity, the bottom of water cooling plate is partly exposed in first installation groove, two sides of first installation groove are equipped with let -alone hole, the lower part of film capacitor is in one let -alone hole, and three lower layer output terminal assemblies of film capacitor are arranged in first installation groove, the bottom of water cooling plate is equipped with three V phase IGBT modules that are parallelly connected in first installation groove, and one end of V phase IGBT module is connected with lower layer output terminal assembly, the top of water cooling plate is equipped with three U phase IGBT modules that are parallelly connected and three W phase IGBT modules that are parallelly connected, and one end of three U phase IGBT modules and one end of three W phase IGBT modules are connected with upper layer output terminal assembly, drive board is equipped on U phase IGBT module and W phase IGBT module, the upper of drive board is equipped with control board that is connected with drive board, the terminal block is equipped with positive input busbar and negative input busbar, and positive input busbar is connected with input positive terminal, and negative input busbar is connected with input negative terminal, V phase output busbar, U phase output busbar and W phase output busbar are equipped on terminal block, another end of three V phase IGBT modules is connected with V phase output busbar, another end of three U phase IGBT modules is connected with U phase output busbar, and another end of three W phase IGBT modules is connected with W phase output busbar, the one end of control casing is equipped with interface assembly, and the top of control casing is connected with sealing top cover that is used for sealing first cavity.

2. The controller of a heavy duty electric vehicle according to claim 1, wherein, The upper layer output terminal assembly includes an upper layer output positive terminal and an upper layer output negative terminal.

3. The controller of claim 2, wherein, The interface assembly includes a positive input interface, a negative input interface, a V phase output interface, a U phase output interface, and a W phase output interface.

4. The controller of claim 1, wherein, The control board is mounted on the mounting bracket.

5. The controller of a heavy duty electric vehicle according to claim 1, wherein, The sealing top cover is provided with an access hole corresponding to the terminal block, and a removable access cover plate is mounted on the access hole.

6. The controller of a heavy duty electric vehicle according to claim 1, wherein, The first installation groove is provided with a removable bottom cover.

7. The controller of a heavy duty electric vehicle according to claim 1, wherein, The control casing is provided with a fixing support, and the fixing support is provided with a fixing hole. The control casing is provided with a fixing support, and the fixing support is provided with a fixing hole.

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