All-in-one controller for electric automobile

Abstract

The utility model belongs to the technical field of electric automobiles, and discloses an all-in-one controller for an electric automobile, which comprises a high-voltage power distribution module, a motor controller module, a power supply module and a box body assembly, and is characterized in that the high-voltage power distribution module is electrically connected with the motor controller module and the power supply module respectively; the box body assembly comprises a first box body and a second box body which are installed in the first direction. The first box body is provided with a first accommodating space and a second accommodating space along a second direction, the first accommodating space is provided with a first opening, the second accommodating space is provided with a second opening opposite to the opening direction of the first opening, the second box body is provided with a third opening, and the first opening faces the third opening and is communicated with the third opening; the high-voltage power distribution module can penetrate through the third opening to be arranged in the second box body, the motor controller module can penetrate through the first opening and the third opening to be arranged in the first containing space and the second box body, the power module can penetrate through the second opening to be arranged in the second containing space, modular design is achieved, and the assembling efficiency is high.

Description

Technical Field

[0001] This utility model relates to the field of electric vehicle technology, and in particular to an all-in-one controller for electric vehicles. Background Technology

[0002] The all-in-one controller integrates vehicle power management, motor control, and high-voltage power distribution functions, making it a core component of electric vehicles. All-in-one controllers are characterized by their small footprint and miniaturization, thus improving the integration and reliability of electric vehicles. However, the internal components of an all-in-one controller are scattered, and the assembly process is serial, resulting in long assembly times, low efficiency, and significant maintenance difficulties. Utility Model Content

[0003] The purpose of this utility model is to provide an all-in-one controller for electric vehicles. Through modular design, each module is assembled in parallel, and then multiple modules are assembled into the assembly. The assembly time is short and the efficiency is high. Only the corresponding module that needs to be repaired is replaced or repaired, and the difficulty of subsequent maintenance is low.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] An all-in-one controller for electric vehicles includes a high-voltage power distribution module, a motor controller module, a power supply module, and a housing assembly, wherein the high-voltage power distribution module is electrically connected to the motor controller module and the power supply module, respectively.

[0006] The enclosure assembly includes a first enclosure and a second enclosure installed along a first direction; the first enclosure is provided with a first accommodating space and a second accommodating space along a second direction, the first accommodating space has a first opening, the second accommodating space has a second opening with an opening direction opposite to that of the first opening, the second enclosure has a third opening, and the first opening faces the third opening and communicates with the third opening.

[0007] The high-voltage power distribution module can pass through the third opening to be disposed in the second housing, the motor controller module can pass through the first opening and the third opening to be disposed in the first accommodating space and the second housing, and the power supply module can pass through the second opening to be disposed in the second accommodating space.

[0008] In some possible implementations, the motor controller module includes a filter, a shielding plate, a drive motor control board, and a power module arranged sequentially along the first direction. The filter is electrically connected to the high-voltage power distribution module, and the filter is isolated from the drive motor control board and the power module by the shielding plate.

[0009] In some possible implementations, the motor controller module further includes an AC terminal block disposed on one side of the filter along the third direction; the second enclosure is provided with a first partition, and both the filter and the AC terminal block are disposed in the second enclosure and on both sides of the first partition along the third direction.

[0010] In some possible implementations, the AC terminal block and the filter are located on the same side of the shielding plate, and the output copper busbar of the power module passes through the shielding plate to be electrically connected to the AC terminal block.

[0011] In some possible implementations, the second enclosure is provided with a second partition, and the AC terminal block and the high-voltage power distribution module are located on both sides of the second partition along the second direction.

[0012] In some possible implementations, the motor controller module further includes a bus capacitor, the filter, the bus capacitor, and the power module are electrically connected in sequence, and the drive motor control board is connected to the power module; the input copper busbar of the bus capacitor passes through the shielding plate to connect to the filter.

[0013] In some possible implementations, the motor controller module further includes a heat sink, and the bus capacitor, the heat sink, the power module, the drive motor control board and the shielding plate are stacked along the first direction and connected by fasteners; the heat sink is connected to the first housing and the filter is connected to the second housing.

[0014] In some possible implementations, the high-voltage power distribution module includes a circuit board assembly electrically connected to the power supply module, and a third partition is provided between the first housing and the second housing, wherein the circuit board assembly and the power supply module are electrically connected and disposed on both sides of the third partition along the first direction.

[0015] In some possible implementations, the high-voltage power distribution module further includes a terminal block assembly; the terminal block assembly is electrically connected to the motor controller module; the circuit board assembly is disposed on the side of the terminal block assembly near the first housing, the circuit board assembly is connected to the side of the terminal block assembly near the first housing by fasteners, and the terminal block assembly is connected to the second housing by fasteners.

[0016] In some possible implementations, the housing assembly further includes a first cover plate disposed at the second opening; and / or, the housing assembly further includes a second cover plate, wherein the second housing has a fourth opening on a side opposite to the first housing, and the second cover plate is disposed at the fourth opening.

[0017] The beneficial effects of this utility model are:

[0018] This utility model provides a multi-functional controller for electric vehicles. It employs a modular design, incorporating a high-voltage power distribution module, a motor controller module, a power supply module, and a housing assembly. Each module is assembled in parallel before being assembled into a complete assembly, resulting in short assembly time and high efficiency. During later maintenance, only the module requiring repair is removed from the assembly for replacement or repair, simplifying maintenance. Removed modules are returned to the factory for repair separately, without affecting the end customer's use of the vehicle, greatly improving flexibility and convenience. The housing assembly is divided into a first housing and a second housing. The first housing is further divided into a first accommodating space and a second accommodating space. The second housing and the first accommodating space are connected by a first opening and a third opening. Part of the second housing and the first accommodating space are used to house the motor controller module, the second accommodating space is used to house the power supply module, and the remaining space of the first housing is used to house the high-voltage power distribution module. This rational division of the housing assembly's internal space maximizes its utilization, resulting in a more compact internal structure for the multi-functional controller. The design of the first, second, and third openings facilitates assembly and further improves assembly efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the all-in-one controller provided in a specific embodiment of this utility model;

[0020] Figure 2 This is an exploded view of the all-in-one controller provided in a specific embodiment of this utility model;

[0021] Figure 3 This is a schematic diagram of a high-voltage power distribution module installed in the second enclosure according to a specific embodiment of this utility model;

[0022] Figure 4 This is a schematic diagram of a motor controller module provided in a specific embodiment of this utility model;

[0023] Figure 5 This is a schematic diagram of a power module provided in a specific embodiment of this utility model.

[0024] In the picture:

[0025] 100. High-voltage power distribution module; 110. Terminal block assembly; 111. Terminal block; 112. Second conductive copper busbar; 113. Relay; 114. Fuse; 120. Circuit board assembly; 121. High-voltage power distribution circuit board; 122. Connector; 123. Second terminal mounting port;

[0026] 200. Motor controller module; 210. Filter; 211. First conductive copper busbar; 212. Mounting foot; 220. Shielding plate; 221. First clearance hole; 222. Second clearance opening; 230. Drive motor control board; 240. Power module; 250. AC terminal block; 260. Bus capacitor; 261. Input copper busbar; 270. Heat sink;

[0027] 300. Power supply module; 310. First terminal mounting port;

[0028] 400, Box assembly; 410, First box; 411, First opening; 412, Second opening; 420, Second box; 421, Third opening; 422, Fourth opening; 430, First cover plate; 440, Second cover plate;

[0029] 500, partition assembly; 510, first partition; 520, second partition; 530, third partition; 800, wiring harness. Detailed Implementation

[0030] To make the technical problems solved by this utility model, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of this utility model will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0031] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" 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 or an electrical 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 based on the specific circumstances.

[0032] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0033] like Figures 1-5 As shown, this embodiment provides an all-in-one controller for electric vehicles, including a high-voltage power distribution module 100, a motor controller module 200, a power supply module 300, and a housing assembly 400. The first direction is X-axis, the second direction is Y-axis, and the third direction is Z-axis. The first, second, and third directions are arranged at angles to each other. In this embodiment, the first, second, and third directions are perpendicular to each other.

[0034] The high-voltage power distribution module 100 includes a terminal block assembly 110 and a circuit board assembly 120. Specifically, the terminal block assembly 110 includes a terminal block 111, a second conductive copper busbar 112, a relay 113, and at least one fuse 114. The circuit board assembly 120 includes a high-voltage power distribution circuit board 121 and at least one connector 122 for realizing high-voltage power distribution functions.

[0035] The power module 300 includes an on-board charger (OBC) and a DC / DC converter for implementing power management functions for electric vehicles. The power module 300 has at least four first terminal mounting ports 310, and the high-voltage power distribution circuit board 121 of the circuit board assembly 120 has at least four second terminal mounting ports 123. The first terminal mounting ports 310 and the second terminal mounting ports 123 correspond one-to-one and are connected via a wiring harness 800. The two ends of the wiring harness 800 are connected to the first terminal mounting ports 310 and the second terminal mounting ports 123 via screws, thereby achieving electrical connection between the power module 300 and the high-voltage power distribution module 100 and enabling power flow transfer between them.

[0036] The motor controller module 200 includes a filter 210, a drive motor control board 230, a power module 240, an AC terminal block 250, and a bus capacitor 260, used to realize motor control functions. The filter 210, bus capacitor 260, power module 240, and AC terminal block 250 are electrically connected in sequence. The drive motor control board 230 is connected to the power module 240. Specifically, the input copper busbar 261 of the filter 210 and the bus capacitor 260 are fixedly connected by screws or other fasteners to achieve electrical connection. The output copper busbar of the power module 240 is connected to the AC terminal block 250 by screws or other fasteners to achieve electrical connection. The filter 210 has a first conductive copper busbar 211. The second conductive copper busbar 112 of the terminal block assembly 110 is connected to the first conductive copper busbar 211 by screws or other fasteners, thereby realizing the electrical connection between the high-voltage power distribution module 100 and the motor controller module 200, and realizing the power flow transfer between the high-voltage power distribution module 100 and the motor controller module 200.

[0037] The enclosure assembly 400 includes a first cover plate 430, a first enclosure 410, a second enclosure 420, and a second cover plate 440 arranged sequentially along a first direction. The first enclosure 410 includes a first receiving space and a second receiving space arranged along a second direction. The first receiving space has a first opening 411, and the second receiving space has a second opening 412. The opening directions of the first opening 411 and the second opening 412 are opposite. The second enclosure 420 has a third opening 421 and a fourth opening 422 at both ends along the first direction. The first opening 411 and the third opening 421 face each other and are connected. The first receiving space and the second receiving space are separated by a partition plate along the second direction. The first cover plate 430 is located at the second opening 412, and the second cover plate 440 is located at the fourth opening 422.

[0038] The high-voltage power distribution module 100 can pass through the third opening 421 to be installed in the second housing 420, the motor controller module 200 can pass through the first opening 411 and the third opening 421 to be installed in the first accommodating space and the second housing 420, and the power supply module 300 can pass through the second opening 412 to be installed in the second accommodating space.

[0039] The modular design, comprising the high-voltage power distribution module 100, motor controller module 200, power supply module 300, and enclosure assembly 400, allows for parallel assembly of each module before final assembly into the final assembly. This results in short assembly time and high efficiency. During later maintenance, only the modules requiring repair are removed from the assembly for replacement or repair, simplifying the maintenance process. Removed modules are returned to the factory for repair separately, without affecting the end customer's use of the vehicle, significantly improving flexibility and convenience. By dividing the housing assembly 400 into a first housing 410 and a second housing 420, and the first housing 410 further divided into a first accommodating space and a second accommodating space, the second housing 420 and the first accommodating space are connected through a first opening 411 and a third opening 421. Part of the space in the second housing 420 and the first accommodating space in the first housing 410 are used to accommodate the motor controller module 200, the second accommodating space in the first housing 410 is used to accommodate the power supply module 300, and the remaining space in the first housing 410 is used to accommodate the high-voltage power distribution module 100. This rational division of the internal space of the housing assembly 400 fully utilizes the internal space, resulting in a more compact internal structure for the multi-functional controller. The placement of the first opening 411, the second opening 412, and the third opening 421 facilitates assembly and further improves assembly efficiency.

[0040] The motor controller module 200 also includes a shielding plate 220. Specifically, the filter 210, shielding plate 220, drive motor control board 230, power module 240, and bus capacitor 260 are arranged sequentially along a first direction. The filter 210 is isolated from the drive motor control board 230 and power module 240 by the shielding plate 220. Since the drive motor control board 230 and power module 240 are both powered by AC, while the filter 210 is powered by DC, the shielding plate 220 isolates the motor controller module 200 and filter 210 from the drive motor control board 230 and power module 240 in the first direction, preventing electromagnetic interference between them and solving the electromagnetic compatibility problem.

[0041] Optionally, the motor controller module 200 also includes a heat sink 270, which is located between the bus capacitor 260 and the power module 240 for heat dissipation of the motor controller module 200.

[0042] The motor controller module 200 also includes an AC terminal block 250, which and the filter 210 are located on the same side of the shielding plate 220. The power module 240 is electrically connected to the AC terminal block 250.

[0043] Optionally, the output copper busbar of the power module 240 passes through the shielding plate 220 to connect to the AC terminal block 250, and the input copper busbar 261 of the bus capacitor 260 passes through the shielding plate 220 to connect to the filter 210. The shielding plate 220 has a first clearance hole 221 and a second clearance opening 222. The output copper busbar passes through the first clearance opening, and the input copper busbar 261 passes through the second clearance opening 222.

[0044] The filter 210 and the AC terminal block 250 are arranged along the third direction. The second housing 420 is provided with a first partition 510. The filter 210 and the AC terminal block 250 are both located in the second housing 420 and on both sides of the first partition 510 along the third direction. The filter 210 is supplied with DC power and the AC terminal block 250 is supplied with AC power. Therefore, by setting the first partition 510, the filter 210 and the AC terminal block 250 are isolated from each other, preventing mutual electromagnetic interference and solving the problem of mutual electromagnetic compatibility.

[0045] The second enclosure 420 contains a second partition 520, with the AC terminal block 250 and the high-voltage power distribution module 100 located on both sides of the second partition 520 along a second direction. Specifically, the terminal block assembly 110 of the high-voltage power distribution module 100 is connected to the filter 210, both of which are energized with direct current. Therefore, the second partition 520 can isolate the terminal block assembly 110 and the AC terminal block 250, preventing electromagnetic interference.

[0046] The terminal block assembly 110 and the circuit board assembly 120 are stacked along a first direction. The circuit board assembly 120 is located on the side of the terminal block assembly 110 closest to the first housing 410. The circuit board assembly 120 is electrically connected to the power module 300. A third partition 530 is provided between the first housing 410 and the second housing 420. The circuit board assembly 120 and the power module 300 are electrically connected and located on both sides of the third partition 530 along the first direction. The DC portion of the circuit board assembly 120 and the AC portion of the power module 300 are isolated by the third partition 530 to prevent mutual electromagnetic interference and solve the problem of electromagnetic compatibility.

[0047] Optionally, the assembly steps for the all-in-one controller for electric vehicles include:

[0048] Step 1: Circuit board assembly 120 is connected to one side of terminal block assembly 110 via fasteners. Shielding plate 220, drive motor control board 230, power module 240, heat sink 270, and bus capacitor 260 are stacked sequentially and fixed together using screws or other fasteners. AC terminal block 250 is connected to power module 240. The on-board charger (OBC) and DC / DC converter are assembled inside power module 300.

[0049] Step 2: The terminal block assembly 110 is connected to the second housing 420 by fasteners, so that the high-voltage power distribution module 100 can be installed inside the second housing 420. Specifically, the terminal block 111, the second conductive copper busbar 112, the relay 113 and at least one fuse 114 are respectively installed inside the second housing 420. Then, the circuit board assembly 120 is installed on the second housing 420 or the terminal block assembly 110.

[0050] The filter 210 is installed inside the second housing 420. The filter 210 has mounting feet 212, which are connected to the second housing 420 by screws or other fasteners. The filter 210 is electrically connected to the terminal block assembly 110 of the high-voltage power distribution module 100. The power supply module 300 is fixedly connected to the second accommodating space by screws or other fasteners.

[0051] The shielding plate 220, drive motor control board 230, power module 240, heat sink 270, bus capacitor 260, and AC terminal block 250 are placed as a whole in the second accommodating space. The heat sink 270 is connected to the first accommodating space by screws and other fasteners, while the AC terminal block 250 is located outside the first accommodating space. Since the motor controller module 200 has many components stacked along the first direction, the filter 210 and the heat sink 270 are respectively fixed to the second housing 420 and the first accommodating space to ensure installation stability.

[0052] Step 3: The first enclosure 410 and the second enclosure 420 are connected by screws and other fasteners, so that the AC terminal block 250 is located inside the second enclosure 420. The power module 300 and the high-voltage distribution module 100 are connected by a wiring harness 800, and then the first cover plate 430 is connected to the second opening 412 of the first enclosure 410 by screws.

[0053] Step 4: Connect the input copper busbar 261 of the filter 210 and the bus capacitor 260 electrically from the fourth opening 422, and finally install the second cover plate 440 at the fourth opening 422.

[0054] Alternatively, the electrical connection between the filter 210 and the terminal block assembly 110 of the high-voltage power distribution module 100 can also be made in the fourth step from the fourth opening 422, and can be assembled as needed.

[0055] Optionally, the first partition 510, the second partition 520, and the third partition 530 form a partition assembly 500. Before the first step, the partition assembly 500 can be configured as separate first partition 510, second partition 520, and third partition 530, or a structure in which parts of the first partition 510, second partition 520, and third partition 530 are integrated. The partition assembly 500 is pre-installed on the first housing 410 and the second housing 420. The first partition 510, second partition 520, and third partition 530 pre-divide the housing assembly 400, and the corresponding modules can be installed in the corresponding positions.

[0056] Optionally, in the second step, after installing the corresponding modules in the first housing 410 and the second housing 420, the corresponding partitions are then installed in the corresponding positions. Then, the first housing 410 and the second housing 420 are snapped together for assembly.

[0057] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. An all-in-one controller for electric vehicles, characterized in that, It includes a high-voltage power distribution module (100), a motor controller module (200), a power supply module (300), and a housing assembly (400), wherein the high-voltage power distribution module (100) is electrically connected to the motor controller module (200) and the power supply module (300), respectively; The housing assembly (400) includes a first housing (410) and a second housing (420) installed along a first direction; the first housing (410) is provided with a first accommodating space and a second accommodating space along a second direction, the first accommodating space having a first opening (411), the second accommodating space having a second opening (412) opposite to the opening direction of the first opening (411), and the second housing (420) having a third opening (421), the first opening (411) facing the third opening (421) and communicating with the third opening (421); The high-voltage power distribution module (100) can pass through the third opening (421) to be disposed in the second housing (420), the motor controller module (200) can pass through the first opening (411) and the third opening (421) to be disposed in the first accommodating space and the second housing (420), and the power supply module (300) can pass through the second opening (412) to be disposed in the second accommodating space.

2. The all-in-one controller for electric vehicles according to claim 1, characterized in that, The motor controller module (200) includes a filter (210), a shielding plate (220), a drive motor control board (230), and a power module (240) arranged sequentially along the first direction. The filter (210) is electrically connected to the high-voltage power distribution module (100), and the filter (210) is isolated from the drive motor control board (230) and the power module (240) through the shielding plate (220).

3. The all-in-one controller for electric vehicles according to claim 2, characterized in that, The motor controller module (200) further includes an AC terminal block (250) disposed on one side of the filter (210) along the third direction; the second housing (420) is provided with a first partition (510), the filter (210) and the AC terminal block (250) are both disposed in the second housing (420) and on both sides of the first partition (510) along the third direction.

4. The all-in-one controller for electric vehicles according to claim 3, characterized in that, The AC terminal block (250) and the filter (210) are located on the same side of the shielding plate (220), and the output copper busbar of the power module (240) passes through the shielding plate (220) to be electrically connected to the AC terminal block (250).

5. The all-in-one controller for electric vehicles according to claim 3, characterized in that, The second enclosure (420) is provided with a second partition (520), and the AC terminal block (250) and the high voltage power distribution module (100) are located on both sides of the second partition (520) along the second direction.

6. The all-in-one controller for electric vehicles according to claim 2, characterized in that, The motor controller module (200) also includes a bus capacitor (260). The filter (210), the bus capacitor (260), and the power module (240) are electrically connected in sequence. The drive motor control board (230) is connected to the power module (240). The input copper busbar (261) of the bus capacitor (260) passes through the shielding plate (220) to connect with the filter (210).

7. The all-in-one controller for electric vehicles according to claim 6, characterized in that, The motor controller module (200) further includes a heat sink (270). The bus capacitor (260), the heat sink (270), the power module (240), the drive motor control board (230), and the shielding plate (220) are stacked along the first direction and connected by fasteners. The heat sink (270) is connected to the first housing (410), and the filter (210) is connected to the second housing (420).

8. The all-in-one controller for electric vehicles according to claim 1, characterized in that, The high-voltage power distribution module (100) includes a circuit board assembly (120), a third partition (530) is provided between the first housing (410) and the second housing (420), the circuit board assembly (120) is electrically connected to the power supply module (300), and is located on both sides of the third partition (530) along the first direction.

9. The all-in-one controller for electric vehicles according to claim 8, characterized in that, The high-voltage power distribution module (100) further includes a terminal block assembly (110); the terminal block assembly (110) and the motor controller module (200) are electrically connected; the circuit board assembly (120) is disposed on the side of the terminal block assembly (110) near the first housing (410), the circuit board assembly (120) is connected to the side of the terminal block assembly (110) near the first housing (410) by fasteners, and the terminal block assembly (110) is connected to the second housing (420) by fasteners.

10. The all-in-one controller for electric vehicles according to any one of claims 1-9, characterized in that, The housing assembly (400) further includes a first cover plate (430) disposed at the second opening (412); and / or, the housing assembly (400) further includes a second cover plate (440), the second housing (420) having a fourth opening (422) on the side opposite to the first housing (410), the second cover plate (440) being disposed at the fourth opening (422).

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