New energy automobile motor controller bus capacitor

Abstract

The utility model discloses a new energy automobile motor controller bus capacitor, which is characterized in that a thin film capacitor assembly is arranged in a shell, a first positioning structure is arranged on the part, exposed outside the shell, of a leading-out terminal, and a second positioning structure matched with the first positioning structure is arranged on the shell and corresponds to the position of each first positioning structure; through the cooperation of the first positioning structure and the second positioning structure, the position of the leading-out terminal relative to the shell is determined, the position stability of the leading-out terminal during filling can be ensured without the help of a packaging tool, the tool installation step is omitted, the production efficiency is improved, and the manufacturing cost of the capacitor is reduced.

Description

Technical Field

[0001] This utility model relates to the field of capacitors for new energy vehicles, specifically to a bus capacitor for a new energy vehicle motor controller. Background Technology

[0002] The new energy vehicle market is fiercely competitive, and automakers are shifting the pressure to reduce costs to the upstream supply chain. Bus capacitors are key components in electric drive systems, accounting for 10% to 20% of the overall cost of the electric drive controller. The main costs of capacitors are divided into material costs (70%), manufacturing costs (25%), and other costs (5%). Under intense market competition, capacitor manufacturers have optimized material costs to the limit. To improve product competitiveness, increase company profitability, and ensure sustainable and healthy development, reducing capacitor manufacturing costs is an urgent issue that needs to be addressed.

[0003] During capacitor production, potting and encapsulation are required. Current technology requires the use of special encapsulation tooling for this operation. The tooling can position the AC terminals of the capacitor exposed outside the casing, and the tooling cost accounts for 70% of the manufacturing cost. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides a bus capacitor for a new energy vehicle motor controller that eliminates the need for specialized tooling for packaging and production, thereby improving production efficiency and reducing capacitor manufacturing costs.

[0005] To achieve the above objectives, this utility model is implemented through the following technical solution:

[0006] A bus capacitor for a new energy vehicle motor controller includes an open housing with a thin-film capacitor assembly installed within it. The thin-film capacitor assembly includes a capacitor core and a laminated busbar, which is electrically connected to the two poles of the capacitor core. The laminated busbar has multiple lead-out terminals. Its distinguishing feature is:

[0007] A first positioning structure is provided on the part of the lead-out terminal exposed outside the housing. A matching second positioning mechanism is provided on the housing corresponding to the position of the first positioning structure on each lead-out terminal. The position of the lead-out terminal relative to the housing is determined by the cooperation of the first positioning structure and the second positioning structure.

[0008] Furthermore, a filter assembly is also installed in the housing, which includes a magnetic ring, a DC input copper busbar, and a filter capacitor. The DC input copper busbar passes through the ring hole of the magnetic ring and is connected to the laminated busbar. Both the DC input copper busbar and the laminated busbar are connected to the filter capacitor. The grounding pin of the filter capacitor is connected to a grounding plate. The DC input copper busbar and the grounding plate are provided with a first positioning structure on the exposed parts of the housing. A matching second positioning mechanism is provided on the housing corresponding to the position of the first positioning structure on each DC input copper busbar. A matching second positioning mechanism is provided on the housing corresponding to the position of the first positioning structure on each grounding plate. Through the cooperation of the matching first positioning structure and the second positioning structure, the position of the DC input copper busbar and the grounding plate relative to the housing is determined.

[0009] Furthermore, the first positioning structure is a positioning through hole and / or a positioning notch and / or a positioning pin, and the second positioning structure is a positioning pin or a positioning groove.

[0010] Furthermore, a first positioning notch is formed by recessing one side of the lead-out terminal, and a first positioning pin is provided on the outer shell corresponding to each first positioning notch position. The first positioning notch and the first positioning pin cooperate to position the lead-out terminal.

[0011] Furthermore, a second positioning notch is provided on the side of the DC input copper busbar away from the film capacitor assembly, and a second positioning pin is provided on the housing corresponding to the position of the second positioning notch. The second positioning pin and the second positioning notch cooperate to achieve the positioning of the DC input copper busbar.

[0012] Furthermore, the end of the grounding piece furthest from the filter capacitor is bent to form a positioning pin, and a positioning groove is provided on the outer casing corresponding to the positioning pin position. The positioning pin is inserted into the positioning groove to achieve the positioning of the grounding piece.

[0013] Furthermore, the grounding plate is provided with a positioning through hole, and a third positioning pin is provided on the outer shell at the position corresponding to the positioning through hole, and the positioning pin is inserted into the positioning through hole.

[0014] This utility model has the following beneficial effects:

[0015] By providing a first positioning structure on the exposed portion of the lead-out terminal outside the housing, and a matching second positioning structure on the housing corresponding to each of the first positioning structures, the first and second positioning structures cooperate to position the lead-out terminal, thus ensuring the positional stability of the lead-out terminal during filling without the need for tooling. This invention reduces the manufacturing cost of film capacitors for electric vehicles, producing capacitors that do not require specialized tooling for packaging, improving production efficiency, and lowering capacitor manufacturing costs.

[0016] For capacitors equipped with filtering components, a first positioning structure is also provided on the DC input copper busbar and the grounding plate. A matching second positioning structure is provided on the outer casing at the position of the first positioning structure on the DC input copper busbar and the grounding plate. Through the cooperation of the first positioning structure and the second positioning structure, the lead terminals, DC input copper busbar and grounding plate of the entire capacitor are fixed. This is equivalent to fixing the position of the thin film capacitor assembly and the filtering assembly inside the outer casing. Then, potting and encapsulation are performed. This ensures that the thin film capacitor assembly and the filtering assembly are installed in place on the outer casing without the need for encapsulation fixtures. Attached Figure Description

[0017] Figure 1 This is a top view structural schematic diagram of the capacitor according to an embodiment of the present invention;

[0018] Figure 2 This is an assembly diagram of the thin-film capacitor assembly and the filter assembly;

[0019] Figure 3 yes Figure 1 An exploded view of the capacitor;

[0020] Figure 4 yes Figure 3 Another perspective view. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0023] like Figures 1 to 4As shown, this embodiment discloses a bus capacitor for a new energy vehicle motor controller, including a housing 1 with an opening. A thin-film capacitor assembly 2 and a filter assembly 3 are installed in the housing 1 (in other embodiments, the capacitor may not have a filter assembly). Adhesive is filled into the housing 1 to fix the thin-film capacitor assembly 2 and the filter assembly 3. The thin-film capacitor assembly 2 includes a capacitor core 21 and a multilayer busbar 22. The multilayer busbar 22 is electrically connected to the two poles of the capacitor core 21. The filter assembly 3 is connected to the multilayer busbar 22. The filter assembly 3 includes a magnetic ring 31, a DC input copper busbar 32, and a filter capacitor 33. The DC input copper busbar 32 passes through the annular hole of the magnetic ring 31 and is connected to the multilayer busbar 22. Both the DC input copper busbar 32 and the multilayer busbar 22 are connected to the filter capacitor 33. The thin-film capacitor assembly 2 and the filter assembly 3 are existing structures for making capacitors. This embodiment will not elaborate on the structure of the thin-film capacitor assembly 2 and the filter assembly 3; refer to existing technology.

[0024] The lead-out terminal 23, DC input copper busbar 32 and grounding plate 34 are all provided with a first positioning structure on the exposed parts of the outer casing 1. The outer casing 1 is provided with a matching second positioning structure for each first positioning structure. Through the cooperation of the first positioning structure and the second positioning structure, the position of the lead-out terminal 23, DC input copper busbar 32 and grounding plate 34 relative to the outer casing 1 is determined.

[0025] In specific structures, such as Figure 4 The stacked busbar 22 has multiple lead-out terminals 23. The housing 1 has an opening (through which the thin-film capacitor assembly 2 and filter assembly 3 are inserted, and then glue is applied to the opening) on ​​one side, and a row of first threaded holes 11 for fixing the lead-out terminals 23 is provided. The first positioning structure on the lead-out terminals 23 is a first positioning notch 231. Specifically, each lead-out terminal 23 has a recessed first positioning notch 231 on one side, and a first positioning pin 12 (second positioning structure) is provided next to each first threaded hole 11 corresponding to the first positioning notch 231. The positioning of the lead-out terminals 23 is achieved through the one-to-one cooperation between the first positioning pin 12 and the first positioning notch 231.

[0026] like Figure 3 The side of the DC input copper busbar 32 away from the film capacitor assembly 2 is provided with a second positioning notch 321 (first positioning structure). The second positioning pin 13 (second positioning structure) is provided next to the second wiring thread hole 17 on the housing 1 for fixing the DC input copper busbar 32, corresponding to the position of the second positioning notch 321. The positioning of the DC input copper busbar 32 is achieved by the cooperation of the second positioning pin 13 and the second positioning notch 321.

[0027] like Figure 3The grounding pin of the filter capacitor 33 is connected to a grounding piece 34. The end of the grounding piece 34 away from the filter capacitor 33 is bent to form a positioning pin 341 (first positioning structure). Next to the third wiring threaded hole 14 on the outer shell 1 for fixing the grounding piece 34, a positioning groove 15 (second positioning structure) is provided at the position of the positioning pin 341. The direction in which the positioning pin 341 is inserted into the positioning groove 15 is consistent with the direction in which the thin film capacitor assembly 2 and the filter assembly 3 are installed into the outer shell 1. In this way, when the thin film capacitor assembly 2 and the filter assembly 3 are installed into the outer shell 1, the positioning pin 341 can be inserted into the positioning groove 15, thereby realizing the positioning of the grounding piece 34.

[0028] Preferred, such as Figure 3 The grounding piece 34 is also provided with a positioning through hole 342 (one or more positioning through holes 342 can be provided. In this embodiment, the part of the grounding piece 34 exposed outside the outer shell 1 is relatively long, so two positioning through holes 342 are provided). A third positioning pin 16 (second positioning structure) is provided on the outer shell 1 at the position corresponding to the positioning through hole 342 (first positioning structure). During assembly, the positioning pin is inserted into the positioning through hole 342 to further fix the position of the grounding piece 34.

[0029] The first positioning structure and the second positioning structure work together to position the lead-out terminal 23, the DC input copper busbar 32 and the grounding piece 34. Furthermore, the lead-out terminal 23, the DC input copper busbar 32 and the grounding piece 34 are fixed, which is equivalent to fixing the positions of the thin film capacitor assembly 2 and the filter assembly 3 inside the housing 1. Then, potting and encapsulation are performed. This ensures that the thin film capacitor assembly 2 and the filter assembly 3 are installed in place on the housing 1 without the need for encapsulation fixtures.

[0030] The above-described embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. These modifications or substitutions do not cause the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model. Therefore, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

Claims

1. A bus capacitor for a new energy vehicle motor controller, comprising an open housing, a thin-film capacitor assembly installed within the housing, the thin-film capacitor assembly comprising a capacitor core and a laminated busbar, the laminated busbar being electrically connected to the two poles of the capacitor core, and the laminated busbar having multiple lead-out terminals, characterized in that: A first positioning structure is provided on the part of the lead-out terminal exposed outside the housing. A matching second positioning mechanism is provided on the housing corresponding to the position of the first positioning structure on each lead-out terminal. The position of the lead-out terminal relative to the housing is determined by the cooperation of the first positioning structure and the second positioning structure.

2. The bus capacitor for the new energy vehicle motor controller according to claim 1, characterized in that: The housing also houses a filter assembly, which includes a magnetic ring, a DC input copper busbar, and a filter capacitor. The DC input copper busbar passes through the ring hole of the magnetic ring and connects to the laminated busbar. Both the DC input copper busbar and the laminated busbar are connected to the filter capacitor. The grounding pin of the filter capacitor is connected to a grounding plate. The exposed parts of the DC input copper busbar and the grounding plate on the outside of the housing have a first positioning structure. The housing has a matching second positioning mechanism corresponding to the first positioning structure position on each DC input copper busbar and a matching second positioning mechanism corresponding to the first positioning structure position on each grounding plate. Through the cooperation of the matching first and second positioning structures, the position of the DC input copper busbar and the grounding plate relative to the housing is determined.

3. The new energy vehicle motor controller bus capacitor according to claim 1 or 2, characterized in that: The first positioning structure is a positioning through hole and / or positioning notch and / or positioning pin, and the second positioning structure is a positioning pin or positioning groove.

4. The bus capacitor for a new energy vehicle motor controller according to claim 1 or 2, characterized in that: A first positioning notch is formed by an indentation on one side of the lead-out terminal. A first positioning pin is provided on the outer shell corresponding to each first positioning notch position. The first positioning notch and the first positioning pin cooperate to position the lead-out terminal.

5. The new energy vehicle motor controller bus capacitor according to claim 2, characterized in that: A second positioning notch is provided on the side of the DC input copper busbar away from the film capacitor assembly. A second positioning pin is provided on the housing corresponding to the position of the second positioning notch. The second positioning pin and the second positioning notch cooperate to position the DC input copper busbar.

6. The bus capacitor for a new energy vehicle motor controller according to claim 2, characterized in that: The end of the grounding piece away from the filter capacitor is bent to form a positioning pin. The outer casing has a positioning groove corresponding to the positioning pin position. The positioning pin is inserted into the positioning groove to achieve the positioning of the grounding piece.

7. The new energy vehicle motor controller bus capacitor according to claim 6, characterized in that: The grounding plate is provided with a positioning through hole, and a third positioning pin is provided on the outer shell at the position corresponding to the positioning through hole. The positioning pin is inserted into the positioning through hole.

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