Integrated motor controller

Abstract

The utility model discloses an integrated motor controller, and relates to the technical field of motors, and the motor controller comprises a heat dissipation pedestal, a power module, a heat dissipation pedestal cover plate, a capacitor group, and a control panel. The front surface of the heat dissipation base is provided with a front water channel, and the back surface is provided with a back water channel; the power module is arranged on the back of the heat dissipation base and covers the back water channel; the heat dissipation base cover plate is arranged on the front face of the heat dissipation base and covers the front face water channel, a first containing cavity and a second containing cavity are formed in the heat dissipation base cover plate, and the first containing cavity is located between the heat dissipation base and the second containing cavity; the capacitor bank is placed in the first accommodating cavity; the control panel is fixedly installed at the open end of the second containing cavity. The power module and the capacitor bank are respectively arranged on the front surface and the back surface of the heat dissipation base, so that the occupied space can be reduced, the flow resistance can be greatly reduced, and the electromagnetic compatibility can be improved.

Description

Integrated motor controller Technical Field

[0001] This application relates to the field of motor technology, and in particular to an integrated motor controller. Background Technology

[0002] The motor controller is one of the core components of an electric vehicle and a decisive factor in its power performance. It obtains the vehicle's requirements from the vehicle controller and electrical energy from the battery pack. After modulation by its own inverter, it obtains the current and voltage needed to control the motor and supplies them to the motor, ensuring that the motor's speed and torque meet the vehicle's requirements.

[0003] With the rapid development of electric vehicles, all-in-one drive motor systems are widely used due to their integration, high efficiency, and compact structure. The motor controller, as the core of the all-in-one drive motor system, integrates power devices, water-cooled plates for heat dissipation, capacitor assemblies, control boards, and drive boards into a compact unit, significantly improving the system's power density and reliability. However, with the widespread application of all-in-one drive motor systems, the motor controller occupies a significant amount of space, resulting in insufficient remaining space for other modules within the same volume. This limits further integration and miniaturization of the system.

[0004] In addition, the integration of multiple functional modules in the all-in-one drive motor system makes the electromagnetic interference problem more complex. The high-frequency switching action in the motor controller will generate electromagnetic interference, affecting the normal operation of other functional modules.

[0005] The capacitor components and power devices in the motor controller generate a lot of heat when operating at high power. As the power density of the motor controller increases, the heat dissipation problem becomes increasingly prominent.

[0006] To meet the demands for integration, miniaturization, electromagnetic interference, and heat dissipation in motor controllers, the industry urgently needs to develop a new type of integrated motor controller. Summary of the Invention

[0007] This application provides an integrated motor controller that addresses technical issues such as the large space occupied by the motor controller, battery interference caused by high-frequency switching affecting the normal operation of other functional modules, and the increasingly prominent heat dissipation problem due to increased power density.

[0008] This application provides an integrated motor controller, including:

[0009] A heat dissipation base, wherein the front of the heat dissipation base is provided with a front water channel and the back of the heat dissipation base is provided with a back water channel communicating with the front water channel;

[0010] A power module is disposed on the back of the heat sink base and is used to cover the back water channel;

[0011] A heat sink cover is disposed on the front side of the heat sink base and is used to cover the front water channel. The heat sink cover is provided with a first accommodating cavity and a second accommodating cavity, wherein the first accommodating cavity is located between the heat sink base and the second accommodating cavity.

[0012] The capacitor bank is placed inside the first accommodating cavity;

[0013] The control panel is fixedly installed at the open end of the second accommodating cavity.

[0014] Preferably, the front waterway includes an upper front waterway and a lower front waterway; the upper front waterway has an upper through groove connecting the upper front waterway and the back waterway, and the lower front waterway has a lower through groove connecting the lower front waterway and the back waterway.

[0015] One end of the upper front water channel is connected to a water inlet; one end of the lower front water channel is connected to a water outlet.

[0016] Preferably, the upper front water channel includes a first upper front water channel, a second upper front water channel, and a third upper front water channel; the lower front water channel includes a first lower front water channel, a second lower front water channel, and a third lower front water channel; the rear water channel includes a first rear water channel, a second rear water channel, and a third rear water channel.

[0017] The first upper front water channel has a first upper through groove connecting the first upper front water channel and the first back water channel; the second upper front water channel has a second upper through groove connecting the second upper front water channel and the second back water channel; the third upper front water channel has a third upper through groove connecting the third upper front water channel and the third back water channel.

[0018] The first lower front water channel has a first lower through groove connecting the first lower front water channel and the first back water channel; the second lower front water channel has a second lower through groove connecting the second lower front water channel and the second back water channel; the third lower front water channel has a third lower through groove connecting the third lower front water channel and the third back water channel.

[0019] The first lower front waterway is connected to the second lower front waterway, and the second upper front waterway is connected to the third upper front waterway.

[0020] One end of the first front water channel is connected to the water inlet; one end of the third lower front water channel is connected to the water outlet.

[0021] Preferably, the power module includes a first power switch module, a second power switch module, and a third power switch module;

[0022] The first power switch module is used to cover the first back water channel; the second power switch module is used to cover the second back water channel; and the third power switch module is used to cover the third back water channel.

[0023] Preferably, the integrated motor controller further includes a first sealing ring, a second sealing ring, and a third sealing ring;

[0024] The first sealing ring is disposed in a first sealing groove provided on the side wall of the first back water channel; the second sealing ring is disposed in a second sealing groove provided on the side wall of the second back water channel; and the third sealing ring is disposed in a third sealing groove provided on the side wall of the third back water channel.

[0025] Preferably, the integrated motor controller further includes a first mounting block, a second mounting block, a third mounting block, and a fourth mounting block;

[0026] The first power switch module covers the first back water channel via the first mounting block and the second mounting block; the second power switch module covers the second back water channel via the second mounting block and the third mounting block; the third power switch module covers the third back water channel via the third mounting block and the fourth mounting block.

[0027] Preferably, the integrated motor controller further includes a drive board;

[0028] The back of the heat sink is provided with four first mounting posts, which are located at the four corners of the heat sink respectively.

[0029] The drive board is mounted on the four mounting posts by fasteners.

[0030] Preferably, the integrated motor controller further includes a shielded ribbon cable; the shielded ribbon cable is used to connect the control board and the drive board.

[0031] Preferably, the first accommodating cavity includes a first side plate, a second side plate disposed opposite to the first side plate, a third side plate disposed opposite to the first side plate, and a fourth side plate and a fifth side plate disposed opposite to each other; the fourth side plate connects the first side plate and the second side plate, and the fifth side plate connects the first side plate and the third side plate; wherein the second side plate and the third side plate are spaced apart by a preset distance, and the fourth side plate and the fifth side plate have the same width.

[0032] Preferably, the integrated motor controller further includes a baffle;

[0033] The second side plate is provided with a first sliding groove, and the third side plate is provided with a second sliding groove opposite to the first sliding groove;

[0034] The baffle is inserted into the first slide groove and the second slide groove.

[0035] Preferably, the second accommodating cavity includes a sixth side plate opposite to the third side plate, and a seventh side plate and an eighth side plate disposed opposite to each other;

[0036] The sixth side plate and the eighth side plate are of equal height, and the third side plate and the seventh side plate are of equal height, wherein the height of the third side plate is greater than the height of the sixth side plate;

[0037] The second accommodating cavity is provided with four second mounting posts, which are respectively located at the connection between the third side plate and the seventh side plate, the connection between the seventh side plate and the sixth side plate, the connection between the sixth side plate and the eighth side plate, and the connection between the eighth side plate and the third side plate;

[0038] The control board is fixedly mounted on the four second mounting posts.

[0039] Preferably, the integrated motor controller further includes a shielding cover; the shielding cover is disposed above the control board and mounted on the four second mounting posts by fasteners.

[0040] Preferably, the integrated motor controller further includes a third accommodating cavity for housing a capacitor filter assembly.

[0041] Preferably, the integrated motor controller further includes a positive DC bus and a negative DC bus;

[0042] The positive DC bus and the negative DC bus are disposed above the capacitor bank and electrically connected to the capacitor bank. One side of the positive DC bus and one side of the negative DC bus are electrically connected to the positive and negative terminals of the power module, respectively. The other side of the positive DC bus and the other side of the negative DC bus are electrically connected to the positive and negative terminals of the capacitor filter assembly, respectively.

[0043] Preferably, the integrated motor controller further includes insulating paper; the insulating paper is disposed between the capacitor bank and the side plate of the first accommodating cavity.

[0044] The beneficial effects of the embodiments of this application include at least the following:

[0045] 1) The integrated motor controller of this application includes a heat sink base, a power module, a heat sink cover, a capacitor bank, and a control board. The heat sink base has a front water channel on the front and a back water channel on the back. The power module is located on the back of the heat sink base and covers the back water channel. The heat sink cover is located on the front of the heat sink base and covers the front water channel. The heat sink cover has a first accommodating cavity and a second accommodating cavity, wherein the first accommodating cavity is located between the heat sink base and the second accommodating cavity. The capacitor bank is placed in the first accommodating cavity. The control board is fixedly installed at the open end of the second accommodating cavity. The power module and the capacitor bank are respectively located on the back and front of the heat sink base, allowing the power module and the capacitor bank to share water channels, significantly reducing flow resistance and improving heat dissipation performance to ensure efficient operation and long-term stability of the system. The capacitor bank is horizontally placed in the first accommodating cavity of the heat sink cover, and the power module is vertically located on the back of the heat sink base. This three-dimensional layout compresses space and reduces space occupation.

[0046] 2) The height of the third side plate of the first accommodating cavity and the height of the seventh side plate of the second accommodating cavity are greater than the height of the sixth side plate, so that the capacitor bank and the control board are separated by the third side plate, achieving a good isolation interference capability.

[0047] 3) The shielding cover is placed above the control board to further optimize electromagnetic compatibility.

[0048] 4) The drive board and control board are connected by a shielded cable, which provides better electromagnetic compatibility performance. Attached Figure Description

[0049] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0050] Figure 1 is a three-dimensional structural diagram of an integrated motor controller according to an embodiment of this application;

[0051] Figure 2 is a front view of the integrated motor controller according to an embodiment of this application;

[0052] Figure 3 is another perspective structural schematic diagram of the integrated motor controller according to an embodiment of this application;

[0053] Figure 4 is a three-dimensional structural diagram of the integrated motor controller without the drive board according to an embodiment of this application;

[0054] Figure 5 is a three-dimensional structural diagram of the heat sink according to an embodiment of this application;

[0055] Figure 6 is a schematic diagram of the back structure of the heat sink according to an embodiment of this application;

[0056] Figure 7 is a front structural diagram of the heat sink according to an embodiment of this application;

[0057] Figure 8 is a three-dimensional structural diagram of a heat sink cover plate with capacitor bank, control board and magnetic ring, etc., according to an embodiment of this application.

[0058] Figure 9 is a three-dimensional structural diagram of the heat sink cover plate according to an embodiment of this application. Detailed Implementation

[0059] The technical solutions of this application will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0060] The various embodiments or implementation methods described in this specification are presented in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other.

[0061] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "a" or "the" can also be understood to convey either singular or plural usage.

[0062] It should be readily understood that the terms “on,” “above,” and “on top of” in this disclosure should be interpreted in the broadest possible sense, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on top of something” but also “on top of something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0063] Furthermore, for ease of explanation, spatially relative terms such as "below," "below," "under," "above," and "above" may be used to describe the relationship of one element or feature relative to other elements or features as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation other than those shown in the figures. The device may have other orientations (rotated 90 degrees or in other orientations), and the spatially relative descriptive terms used herein may be interpreted accordingly.

[0064] In one embodiment of this utility model, an integrated motor controller is provided. Specifically, please refer to Figure 1, which shows a three-dimensional structural diagram of the integrated motor controller according to this application embodiment; Figure 2, which shows a front structural diagram of the integrated motor controller according to this application embodiment; Figure 4, which shows a three-dimensional structural diagram of the integrated motor controller according to this application embodiment without the drive board; Figure 5, which shows a three-dimensional structural diagram of the heat sink base according to this application embodiment; Figure 6, which shows a rear structural diagram of the heat sink base according to this application embodiment; Figure 7, which shows a front structural diagram of the heat sink base according to this application embodiment; Figure 8, which shows a three-dimensional structural diagram of the heat sink cover plate according to this application embodiment, which includes a capacitor bank, a control board, and a magnetic ring; and Figure 9, which shows a three-dimensional structural diagram of the heat sink cover plate according to this application embodiment. The integrated motor controller according to one embodiment of this utility model includes a heat sink base 10, a power module 6, a heat sink cover plate 20, a capacitor bank 30, and a control board 4. The heat dissipation base 10 has front water channels 1031, 1032, 1033, 1051, 1052, and 1053 on its front side, and back water channels 1071, 1072, and 1073 on its back side, which communicate with the front water channels. The heat dissipation base 10 enables double-sided heat dissipation, significantly reducing flow resistance. The heat dissipation base 10 can be made of a metal material, such as aluminum, which facilitates processing and shaping.

[0065] The power module 6 is disposed on the back of the heat sink 10 and is used to cover the back water channels 1071, 1072, and 1073. Specifically, the power module 6 is disposed above the back water channels 1071, 1072, and 1073 and is mechanically sealed to the back water channels 1071, 1072, and 1073, thereby forming a sealed back cooling cavity in the space formed by the back water channels 1071, 1072, and 1073 and the surface of the power module 6 facing the heat sink 10, for dissipating heat from the power module.

[0066] A heat sink cover 20 is disposed on the front side of the heat sink base 10 and is used to cover the front water channels 1031, 1032, 1033, 1051, 1052, and 1053. Specifically, by mechanical processes, such as friction stir welding or screw fixing, one side plate of the heat sink cover 20 is fixed to the front side of the heat sink base 10 and covers the front water channels 1031, 1032, 1033, 1051, 1052, and 1053, thereby forming a sealed front cooling cavity in the space formed by the front water channels 1031, 1032, 1033, 1051, 1052, and 1053 and the surface of one side plate of the heat sink cover 20.

[0067] The heat sink cover 20 is provided with a first accommodating cavity 201 and a second accommodating cavity 202, wherein the first accommodating cavity 201 is located between the heat sink base 10 and the second accommodating cavity 202. By providing multiple accommodating cavities on the heat sink cover 20 to house corresponding functional modules, it helps to improve integration and reduce space occupation.

[0068] The capacitor bank 30 is placed within the first accommodating cavity 201. The capacitor bank may include multiple capacitor cells. After the multiple capacitor cells are placed within the first accommodating cavity 201, potting compound is poured into the first accommodating cavity to encapsulate the multiple capacitor cells, providing excellent vibration resistance and insulation. The capacitor may be a film capacitor.

[0069] The control board 4 is fixedly installed at the open end of the second accommodating cavity 202. The control board 4 is fixedly installed to the open end of the second accommodating cavity 202 by screws or other fasteners, wherein the side of the control board with the components welded to it faces the bottom surface of the second accommodating cavity 202, so that the components can be located inside the second accommodating cavity 202, which is beneficial to improving space utilization.

[0070] In this embodiment, the heat sink base 10 is placed vertically, while the heat sink cover 20 is placed horizontally, improving integration, compressing space, and reducing space occupation. Furthermore, the power module and the capacitor bank are located on the back and front of the heat sink base, respectively, allowing them to share a water channel, significantly reducing flow resistance. Additionally, the heat sink cover 20 can be made of a metal material, such as aluminum, which provides excellent isolation and shielding between the capacitor bank and the control board, improving electromagnetic interference resistance and significantly enhancing electromagnetic compatibility performance.

[0071] Furthermore, the front water channel includes an upper front water channel and a lower front water channel; the upper front water channel has an upper through groove connecting the upper front water channel and the rear water channel, and the lower front water channel has a lower through groove connecting the lower front water channel and the rear water channel. One end of the upper front water channel is connected to a water inlet 101; one end of the lower front water channel is connected to a water outlet 102. The coolant provided by the external cooling device flows into the upper front water channel through the water inlet 101, flows into the rear water channel through the upper through groove, then flows into the lower front water channel through the lower through groove, flows into the water outlet through the lower front water channel, and finally flows back to the external cooling device from the water outlet. The coolant absorbs heat from the capacitor bank at the upper and lower front water channels and absorbs heat from the power module at the rear water channel, thereby achieving heat dissipation for the capacitor bank and the power module.

[0072] In this embodiment, the number of upper front water channels can be one, the number of lower front water channels can be one, and the number of rear water channels can also be one. The upper front water channel is an elongated groove on the front of the heat dissipation base 10 and close to the top of the heat dissipation base 10, and the lower front water channel is an elongated groove on the front of the heat dissipation base 10 and close to the bottom of the heat dissipation base 10. The length of the elongated groove can be equal to or slightly less than the length of the first accommodating cavity 201, which mainly depends on the length occupied by the capacitor bank in the first accommodating cavity 201; the rear water channel is a groove on the back of the heat dissipation base 10, and the size of the groove depends on the area occupied by the heat-generating device in the power module, which is not limited here.

[0073] In this embodiment, the number of upper front channels, lower front channels, and rear channels corresponds one-to-one with the number of power switch modules in the power module. As shown in Figures 4, 5, 6, and 7, the power module 6 includes a first power switch module 61, a second power switch module 62, and a third power switch module 63. The upper front channels include a first upper front channel 1031, a second upper front channel 1032, and a third upper front channel 1033; the lower front channels include a first lower front channel 1051, a second lower front channel 1052, and a third lower front channel 1053; and the rear channels include a first rear channel 1071, a second rear channel 1072, and a third rear channel 1073.

[0074] The first upper front water channel 1031 has a first upper through groove 1041 connecting the first upper front water channel 1031 and the first back water channel 1071; the second upper front water channel 1032 has a second upper through groove 1042 connecting the second upper front water channel 1032 and the second back water channel 1072; and the third upper front water channel 1033 has a third upper through groove 1043 connecting the third upper front water channel 1033 and the third back water channel 1073.

[0075] The first lower front water channel 1051 has a first lower through groove 1061 connecting the first lower front water channel 1051 and the first back water channel 1071; the second lower front water channel 1052 has a second lower through groove 1062 connecting the second lower front water channel 1052 and the second back water channel 1072; and the third lower front water channel 1053 has a third lower through groove 1063 connecting the third lower front water channel 1053 and the third back water channel 1073.

[0076] The first lower front water channel 1051 and the second lower front water channel 1052 are connected, and the second upper front water channel 1032 and the third upper front water channel 1033 are connected. One end of the first upper front water channel 1031 is connected to the water inlet 101, and one end of the third lower front water channel 1053 is connected to the water outlet 102.

[0077] One end of the upper front waterway is connected to a water inlet 101; one end of the lower front waterway is connected to a water outlet 102.

[0078] The heat sink cover 20 mechanically seals the first upper front water channel 1031, the second upper front water channel 1032, the third upper front water channel 1033, the first lower front water channel 1051, the second lower front water channel 1052, and the third lower front water channel 1053, so that the heat sink cover 20 and the first upper front water channel 1031, the second upper front water channel 1032, the third upper front water channel 1033, the first lower front water channel 1051, the second lower front water channel 1052, and the third lower front water channel 1053 form a front cooling cavity.

[0079] The first power switch module 61 is used to cover the first back water channel 1071; the second power switch module 62 covers the second back water channel 1072; the third power switch module 63 covers the third back water channel 1073, so that a first back cooling cavity is formed between the first back water channel 1071 and the first power switch module 61, a second back cooling cavity is formed between the second back water channel 1072 and the second power switch module 62, and a third back cooling cavity is formed between the third back water channel 1073 and the third power switch module 63.

[0080] Furthermore, the integrated motor controller also includes a first sealing ring 111, a second sealing ring 112, and a third sealing ring 113. The first sealing ring 111 is disposed within a first sealing groove 1091 provided on the side wall of the first back water channel 1071; the second sealing ring 112 is disposed within a second sealing groove 1092 provided on the side wall of the second back water channel 1072; and the third sealing ring 113 is disposed within a third sealing groove 1093 provided on the side wall of the third back water channel 1073. The presence of the first sealing ring 111, the second sealing ring 112, and the third sealing ring 113 effectively prevents coolant leakage.

[0081] Furthermore, the integrated motor controller also includes a first mounting block 1081, a second mounting block 1082, a third mounting block 1083, and a fourth mounting block 1084. The first power switch module 61 is mounted on the back of the heat dissipation base 10 via the first mounting block 1081 and the second mounting block 1082, and covers the first back water channel 1071; the second power switch module 62 is mounted on the back of the heat dissipation base 10 via the second mounting block 1082 and the third mounting block 1083, and covers the second back water channel 1072; the third power switch module 63 is mounted on the back of the heat dissipation base 10 via the third mounting block 1083 and the fourth mounting block 1084, and covers the third back water channel 1073.

[0082] In this embodiment, the coolant provided by the external cooling device flows into the first upper front water channel 1031 through the water inlet 101. The coolant flows into the first back water channel 1071 through the first upper through groove 1041, then into the first lower front water channel 1051 through the first lower through groove 1061, then into the second lower front water channel 1052 through the first lower front water channel 1051, then into the second back water channel 1072 through the second lower through groove 1062, and finally into the second upper through groove 1052. The water flows into the second upper front water channel 1032 through the channel 1042, then into the third upper front water channel 1033 through the second upper front water channel 1032, then into the third back water channel 1073 through the third upper through channel 1043, and finally into the third lower front water channel 1053 through the third lower through channel 1063. The water then flows into the outlet port 102 through the third lower front water channel 1053, and then back to the external cooling device through the outlet port 102, thereby achieving heat dissipation for the capacitor bank and the power module.

[0083] Please refer to Figure 3 for another perspective structural diagram of the integrated motor controller according to an embodiment of this application. The integrated motor controller further includes a drive board 8; the back of the heat sink 10 is provided with four first mounting posts 103, which are respectively located at the four corners of the heat sink 10. The drive board 8 is mounted on the four mounting posts using fasteners, such as screws. Furthermore, the drive board 8 is electrically connected to the pins of the first power switch module 61, the second power switch module 62, and the third power switch module 63 through a selective soldering process.

[0084] As shown in Figure 1, the integrated motor controller further includes a shielded cable 7, such as a shielded FFC harness; the shielded cable 7 is used to connect the control board 4 and the drive board 8. Using a shielded FFC harness to achieve signal transmission between the control board 4 and the drive board 8 provides good electromagnetic compatibility performance.

[0085] As shown in Figures 1, 8, and 9, the first accommodating cavity 201 includes a first side plate 2011, a second side plate 2012 opposite to the first side plate 2011, a third side plate 2013 opposite to the first side plate 2011, and a fourth side plate 2014 and a fifth side plate 2015 opposite to each other. The fourth side plate 2014 connects the first side plate 2011 and the second side plate 2012, and the fifth side plate 2015 connects the first side plate 2011 and the third side plate 2013. The second side plate 2012 and the third side plate 2013 are spaced apart by a predetermined distance, and the second side plate 2012 is provided with a first sliding groove 2016, and the third side plate is provided with a second sliding groove 2017 opposite to the first sliding groove 2016. The width W of the fourth side plate 2014 and the fifth side plate 2015 is equal, that is, the second side plate 2012 and the third side plate 2013 are located in the same plane.

[0086] Furthermore, the second side plate 2012, the third side plate 2013, and the fourth side plate 2014 have the same height, and are all less than the height of the first side plate 2011. The first side plate is fixed to the front of the heat dissipation base 10 by mechanical processes, such as friction stir welding, and covers the front water channels to form a front cooling cavity.

[0087] Furthermore, the integrated motor controller also includes a positive DC bus 31 and a negative DC bus 32. Insulating paper 34 is provided between the positive DC bus 31 and the negative DC bus 32 for insulation and isolation, ensuring safety. The positive DC bus 31 and the negative DC bus 32 are stepped. The first platform of the positive DC bus 31 and the negative DC bus 32 is placed inside the first accommodating cavity 201 and located above the capacitor bank 30, electrically connected to the positive and negative terminals of the capacitor bank, respectively. The second platform of the positive DC bus 31 and the negative DC bus 32 is placed above the top of the heat dissipation base 10. After the positive DC bus 31 and the negative DC bus 32 are installed with the capacitor bank 30, potting compound is poured into the first accommodating cavity 201 to pot the capacitor bank, improving vibration resistance and insulation performance.

[0088] One side of the positive DC bus 31 and one side of the negative DC bus 32 are electrically connected to the positive and negative terminals of the power module 6, respectively. Specifically, one side of the positive DC bus 31 is electrically connected to the positive terminal 612 of the first power switch module 61, the positive terminal 622 of the second power switch module 62, and the positive terminal 632 of the third power switch module 63, respectively. The one side of the negative DC bus 32 is electrically connected to the negative terminals 611 and 613 of the first power switch module 61, the negative terminals 621 and 623 of the second power switch module 62, and the positive and negative terminals 631 and 633 of the third power switch module 63, respectively.

[0089] The connection between the first platform and the second platform is parallel to the first side plate 2011. Insulating paper is also provided between the negative DC bus 32 and the heat sink base 10 for insulation isolation.

[0090] Furthermore, the integrated motor controller also includes insulating paper 33; the insulating paper 33 is disposed between the capacitor group 30 and the side plate of the first accommodating cavity 201 to achieve high voltage isolation.

[0091] Furthermore, the integrated motor controller also includes a baffle 21, which is inserted into the first slide groove 2016 and the second slide groove 2017. The baffle 21 has positive busbar lead slots and negative busbar lead slots for leading out the other side of the positive DC busbar 31 and the other side of the negative DC busbar 32, respectively. The height of the baffle 21 can be less than the height of the second side plate 2012. The baffle 21 effectively provides electrical isolation for the functional modules on both sides of the baffle.

[0092] As shown in Figures 1, 8 and 9, the second accommodating cavity 202 includes a sixth side plate 2021 opposite to the third side plate 2013, and a seventh side plate 2022 and an eighth side plate 2023 disposed opposite to each other.

[0093] The sixth side plate 2021 and the eighth side plate 2023 have the same height h2, and the third side plate 2013 and the seventh side plate 2022 have the same height h1, wherein the height h1 of the third side plate 2013 is greater than the height h2 of the sixth side plate 2021. The third side plate 2013 and the seventh side plate 2022 act as a barrier, effectively providing electrical isolation between the capacitor bank 30 and the control board 4, thus helping to reduce electromagnetic interference.

[0094] The second accommodating cavity 202 is provided with four second mounting posts 209, which are respectively located at the connection between the third side plate 2013 and the seventh side plate 2022, the connection between the seventh side plate 2022 and the sixth side plate 2021, the connection between the sixth side plate 2021 and the eighth side plate 2023, and the connection between the eighth side plate 2023 and the third side plate 2013.

[0095] Furthermore, the integrated motor controller also includes a shielding cover 5; the shielding cover 5 is disposed above the control board 4 and mounted on the four second mounting posts 209 by fasteners. Specifically, the control board 4 is first placed on the four second mounting posts 209, and then the shielding cover 5 is placed above the control board 4. The shielding cover 5 and the control board 4 are locked onto the four second mounting posts 209 by passing screws through the corresponding through holes on the shielding cover 5 and the control board 4.

[0096] Furthermore, the integrated motor controller also includes a positive lead terminal 1 and a negative lead terminal 2, with the other side of the positive DC bus 31 and the other side of the negative DC bus 32 respectively connected to one end of the positive lead terminal 1 and one end of the negative lead terminal 2.

[0097] Furthermore, the integrated motor controller also includes a boss 204, on which the other end of the positive lead 1 and the other end of the negative lead 2 are disposed.

[0098] Furthermore, the integrated motor controller also includes a magnetic ring 3, which is disposed on one side of the boss 204, wherein the side of the boss 204 is located on the same side as the water inlet interface.

[0099] Furthermore, the integrated motor controller also includes a third accommodating cavity 203, which is used to house a capacitor filter assembly. The third accommodating cavity 203 is located between the boss 204 and the seventh side plate 2022.

[0100] The other side of the positive DC bus 31 and the other side of the negative DC bus 32 are electrically connected to the positive and negative terminals of the capacitor filter assembly, respectively. The baffle 21 effectively provides electrical isolation for the capacitor bank and capacitor filter assembly, thus improving electromagnetic compatibility performance.

[0101] In this embodiment, the heat sink base 10 is placed vertically, while the heat sink cover 20 is placed horizontally, improving integration, compressing space, and reducing space occupation. Furthermore, the power module and the capacitor bank are located on the back and front of the heat sink base, respectively, allowing them to share a water channel, significantly reducing flow resistance. Additionally, the heat sink cover 20 and the heat sink base 10 can be made of metal, such as aluminum, providing excellent isolation and shielding, improving electromagnetic interference resistance, and significantly enhancing electromagnetic compatibility performance. Moreover, the height of the third side plate of the first accommodating cavity and the seventh side plate (the side closest to the positive and negative DC busbars) is greater than the height of the sixth and eighth side plates, effectively providing electrical isolation. Furthermore, adding a shielding cover above the control board further enhances electrical isolation, thereby improving electromagnetic compatibility performance. The control board and drive board are connected by shielded cables, further optimizing electromagnetic compatibility performance.

[0102] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the 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 or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. An integrated motor controller, characterized in that, include: A heat dissipation base, the front of which has a front water channel and the back of which has a back water channel communicating with the front water channel; a power module, disposed on the back of the heat dissipation base and used to cover the back water channel; a heat dissipation base cover, disposed on the front of the heat dissipation base and used to cover the front water channel, the heat dissipation base cover having a first accommodating cavity and a second accommodating cavity, wherein the first accommodating cavity is located between the heat dissipation base and the second accommodating cavity; a capacitor bank, placed in the first accommodating cavity; and a control board, fixedly installed at the open end of the second accommodating cavity.

2. The integrated motor controller according to claim 1, characterized in that, The front waterway includes an upper front waterway and a lower front waterway; the upper front waterway has an upper through groove connecting the upper front waterway and the rear waterway, and the lower front waterway has a lower through groove connecting the lower front waterway and the rear waterway; one end of the upper front waterway is connected to a water inlet; and one end of the lower front waterway is connected to a water outlet.

3. The integrated motor controller according to claim 2, characterized in that, The upper front waterway includes a first upper front waterway, a second upper front waterway, and a third upper front waterway; the lower front waterway includes the first lower front waterway, the second lower front waterway, and the third lower front waterway; the rear waterway includes a first rear waterway, a second rear waterway, and a third rear waterway; the first upper front waterway has a first upper through-slot connecting the first upper front waterway and the first rear waterway; the second upper front waterway has a second upper through-slot connecting the second upper front waterway and the second rear waterway; the third upper front waterway has a third upper through-slot connecting the third upper front waterway and the third rear waterway. The system comprises the following: a first lower front water channel having a first lower through-channel connecting the first lower front water channel and the first rear water channel; a second lower front water channel having a second lower through-channel connecting the second lower front water channel and the second rear water channel; and a third lower front water channel having a third lower through-channel connecting the third lower front water channel and the third rear water channel. The first lower front water channel is connected to the second lower front water channel, and the second upper front water channel is connected to the third upper front water channel. One end of the first upper front water channel is connected to the water inlet. One end of the third lower front water channel is connected to the water outlet.

4. The integrated motor controller according to claim 3, characterized in that, The power module includes a first power switch module, a second power switch module, and a third power switch module; the first power switch module is used to cover the first back water channel; the second power switch module covers the second back water channel; and the third power switch module covers the third back water channel.

5. The integrated motor controller according to claim 4, characterized in that, The integrated motor controller further includes a first sealing ring, a second sealing ring, and a third sealing ring; the first sealing ring is disposed in a first sealing groove provided on the side wall of the first back water channel; the second sealing ring is disposed in a second sealing groove provided on the side wall of the second back water channel; and the third sealing ring is disposed in a third sealing groove provided on the side wall of the third back water channel.

6. The integrated motor controller according to claim 4, characterized in that, The integrated motor controller further includes a first mounting block, a second mounting block, a third mounting block, and a fourth mounting block; the first power switch module covers the first back water channel through the first mounting block and the second mounting block; the second power switch module covers the second back water channel through the second mounting block and the third mounting block; the third power switch module covers the third back water channel through the third mounting block and the fourth mounting block.

7. The integrated motor controller according to claim 1, characterized in that, The integrated motor controller also includes a drive board; the back of the heat sink is provided with four first mounting posts, which are located at the four corners of the heat sink respectively; the drive board is mounted on the four mounting posts by fasteners.

8. The integrated motor controller according to claim 7, characterized in that, The integrated motor controller further includes a shielded cable; the shielded cable is used to connect the control board and the drive board.

9. The integrated motor controller according to claim 1, characterized in that, The first accommodating cavity includes a first side plate, a second side plate disposed opposite to the first side plate, a third side plate disposed opposite to the first side plate, and a fourth side plate and a fifth side plate disposed opposite to each other; the fourth side plate connects the first side plate and the second side plate, and the fifth side plate connects the first side plate and the third side plate; wherein the second side plate and the third side plate are spaced apart by a preset distance, and the fourth side plate and the fifth side plate have the same width.

10. The integrated motor controller according to claim 9, characterized in that, The integrated motor controller also includes a baffle; the second side plate is provided with a first sliding groove, and the third side plate is provided with a second sliding groove opposite to the first sliding groove; the baffle is inserted into the first sliding groove and the second sliding groove.

11. The integrated motor controller according to claim 9, characterized in that, The second accommodating cavity includes a sixth side plate opposite to the third side plate, and a seventh side plate and an eighth side plate opposite to each other; the sixth side plate and the eighth side plate are of equal height, and the third side plate and the seventh side plate are of equal height, wherein the height of the third side plate is greater than the height of the sixth side plate; the second accommodating cavity is provided with four second mounting posts, which are respectively located at the connection between the third side plate and the seventh side plate, the connection between the seventh side plate and the sixth side plate, the connection between the sixth side plate and the eighth side plate, and the connection between the eighth side plate and the third side plate; the control plate is fixedly mounted on the four second mounting posts.

12. The integrated motor controller according to claim 11, characterized in that, The integrated motor controller also includes a shield; the shield is disposed above the control board and mounted on the four second mounting posts by fasteners.

13. The integrated motor controller according to claim 1, characterized in that, The integrated motor controller also includes a third accommodating cavity for housing a capacitor filter assembly.

14. The integrated motor controller according to claim 13, characterized in that, The integrated motor controller further includes a positive DC bus and a negative DC bus; the positive DC bus and the negative DC bus are disposed above the capacitor bank and electrically connected to the capacitor bank; one side of the positive DC bus and one side of the negative DC bus are electrically connected to the positive terminal and the negative terminal of the power module, respectively; the other side of the positive DC bus and the other side of the negative DC bus are electrically connected to the positive terminal and the negative terminal of the capacitor filter assembly, respectively.

15. The integrated motor controller according to claim 1, characterized in that, The integrated motor controller also includes insulating paper; the insulating paper is disposed between the capacitor bank and the side plate of the first accommodating cavity.

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