Vehicle-mounted controller filtering structure
By designing a magnetic core around the copper busbar of the vehicle controller, the EMC noise problem of the AC input port of the vehicle controller was solved, effectively suppressing high-frequency and low-frequency noise, improving EMC performance, and reducing cost and space requirements.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- UNITED AUTOMOTIVE ELECTRONICS SYST
- Filing Date
- 2025-05-30
- Publication Date
- 2026-05-19
AI Technical Summary
The vehicle controller has EMC noise issues at the AC input port, making it impossible to filter it directly on the PCB board.
A vehicle-mounted controller filtering structure is designed to suppress high-frequency noise by surrounding the magnetic core with a copper busbar. The first and second copper busbars are overlapped, and the magnetic core is surrounded in the overlap area to control the high-frequency electric field generated by the switching devices. The magnetic core is arranged outside the housing to reduce space requirements.
It effectively suppresses high-frequency and low-frequency noise, improves EMC performance, reduces costs, reduces the number of components used, enables product miniaturization, and ensures installation stability.
Smart Images
Figure CN224264951U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of filtering technology, and in particular to a filtering structure for an on-board controller. Background Technology
[0002] With the increasing growth of the new energy vehicle market, on-board controllers are being used more and more, such as on-board chargers and motor controllers. The function of an on-board charger is to convert AC power into high-voltage DC power to charge the power battery of a new energy vehicle, ensuring its normal operation. The AC input terminal in most cases transmits the AC power from the grid to the on-board charger via a copper busbar. Due to bus voltage fluctuations and the rapid switching of MOSFETs inside the on-board charger, abnormal electromagnetic compatibility (EMC) noise is coupled at the AC input port. However, due to space constraints on the PCB board, direct filtering on the PCB is not possible. Similarly, motor controllers also face similar issues.
[0003] Therefore, there is an urgent need for an on-board controller with good built-in filtering capabilities to reduce noise and improve EMC performance. Utility Model Content
[0004] The purpose of this utility model is to provide a vehicle controller filter structure. This vehicle controller filter structure suppresses high-frequency noise by combining magnetic cores around the first and second copper busbars, thereby improving the overall EMC performance of the vehicle controller filter structure.
[0005] This application discloses an on-board controller filtering structure, which includes:
[0006] A copper busbar is used to form a conductive path between the voltage input port and the power circuit.
[0007] The magnetic core is enclosed within a shielded cavity.
[0008] The magnetic core surrounds the transition copper busbar to suppress electromagnetic interference signals generated by the transition copper busbar.
[0009] Furthermore, the transition copper busbar includes a first copper busbar and a second copper busbar, with at least a portion of the first copper busbar overlapping a portion of the second copper busbar to form an overlapping area, and the magnetic core surrounding the overlapping area.
[0010] Furthermore, the vehicle controller filtering structure also includes a switching device for controlling the conductive path, and the electric field formed by the voltage pulse generated by the switching device during the switching action is defined as a high-frequency electric field;
[0011] In the overlapping region, the overlapping direction of the first copper busbar and the second copper busbar is a preset direction, which is the same as the radiation direction of the high-frequency electric field.
[0012] Furthermore, the vehicle controller filtering structure also includes a housing with a accommodating chamber, in which the first copper busbar and the second copper busbar are both arranged, and the magnetic core is sleeved on the outside of the housing, so that the housing, the first copper busbar and the second copper busbar all pass through the shielding chamber.
[0013] Furthermore, both the first copper busbar and the second copper busbar are injection molded into the accommodating cavity.
[0014] Furthermore, the magnetic core includes a first pair of mating magnetic cores and a second pair of mating magnetic cores connected to each other, the first pair of mating magnetic cores and the second pair of mating magnetic cores cooperating with each other to enclose and form the shielding cavity.
[0015] Furthermore, the magnetic core is a "U / I" magnetic core or a "U / U" magnetic core.
[0016] Furthermore, the first pair of mating magnetic cores is glued to the second pair of mating magnetic cores.
[0017] Furthermore, the first pair of mating magnetic cores and / or the second pair of mating magnetic cores are bonded to the outer surface of the housing.
[0018] Furthermore, the mating surface of the first mating magnetic core is provided with a slot, and the second mating magnetic core is snapped into the mating surface of the first mating magnetic core.
[0019] Furthermore, the magnetic core is made of ferrite or nanocrystals.
[0020] The vehicle controller filtering structure provided by this utility model has at least the following beneficial effects, including but not limited to:
[0021] 1) The vehicle controller filter structure suppresses high-frequency noise through the structural design of the magnetic core around the adapter copper busbar, thereby improving the overall EMC performance of the vehicle controller filter structure;
[0022] 2) The vehicle controller filter structure effectively reduces low-frequency noise by overlapping the first copper busbar and the second copper busbar. At the same time, the magnetic core encloses the overlapping area, which can effectively suppress high-frequency noise. The mutual cooperation of high and low frequency noise suppression further improves the overall EMC performance of the vehicle controller filter structure.
[0023] 3) In the filtering structure of the vehicle controller, the overlapping direction of the first copper busbar and the second copper busbar is the same as the radiation direction of the high-frequency electric field, which can prevent the electric field from passing through and forming a loop, thereby further reducing low-frequency noise. That is, if the high-frequency electric field passes through the original arrangement direction of the copper busbar, if there is a gap in the middle of the copper busbar, the electric field will form a loop between the copper busbars after passing through, generating an induced electromotive force, forming a voltage difference, and thus causing interference. The arrangement of this application can avoid the generation of such interference.
[0024] 4) The magnetic core in the filter structure of the vehicle controller is arranged outside the housing, which can further reduce the space requirement in the housing. It can cooperate with the housing to save PCB space and reduce the use of components such as magnetic core capacitors in the vehicle controller, thereby reducing costs and miniaturizing the product. In addition, the magnetic core adopts an enclosed design and uses fixing glue or slot structure to ensure stable installation, avoiding the magnetic core from falling off or loosening during operation. Attached Figure Description
[0025] This specification will be further described by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting; in these embodiments, the same reference numerals denote the same structures, wherein:
[0026] Figure 1 This is a schematic diagram of a vehicle controller filtering structure provided in an embodiment of this application;
[0027] Figure 2 One of the schematic diagrams showing the arrangement of the first copper busbar and the second copper busbar provided in the embodiments of this application;
[0028] Figure 3 A second schematic diagram illustrating the arrangement of the first and second copper busbars provided in an embodiment of this application;
[0029] Figure 4 This is an exploded view of the vehicle controller filtering structure provided in the embodiments of this application;
[0030] Figure 5 This is a front view of the vehicle controller filtering structure provided in an embodiment of this application;
[0031] Figure 6 This is a schematic diagram of another vehicle controller filtering structure provided in an embodiment of this application;
[0032] Figure 7 This is a schematic diagram of another vehicle controller filtering structure provided in an embodiment of this application.
[0033] Icons: 100 - Vehicle controller filter structure; 10 - First copper busbar; 11 - Second copper busbar; 121 - Matching magnetic core; 122 - Shielding chamber; 13 - Housing; 131 - Receiving chamber; 14 - Bushing. Detailed Implementation
[0034] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.
[0035] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the illustrations only show the components related to the present invention and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.
[0036] Please refer to Figures 1-7 This application discloses an on-board controller filtering structure 100, including a connecting copper busbar and a magnetic core. The connecting copper busbar forms a conductive path between the voltage input port and the power circuit; the magnetic core itself encloses a shielded cavity; wherein the magnetic core surrounds the connecting copper busbar to suppress electromagnetic interference signals generated by the connecting copper busbar.
[0037] It is worth noting that high-current switching, sudden load changes, and rise / fall in bus capacitor voltage can all cause bus voltage fluctuations. The on-board controller filter structure 100, through its design of incorporating a magnetic core around the connecting copper busbar, suppresses high-frequency noise, thereby improving the overall EMC performance of the on-board controller filter structure 100.
[0038] Optionally, the connecting copper busbar may include a first copper busbar and a second copper busbar, with the magnetic core surrounding the first copper busbar 10 and the second copper busbar 11, so that both the first copper busbar 10 and the second copper busbar 11 pass through the shielding chamber 122.
[0039] It should be noted that the first copper busbar 10 and the second copper busbar 11 can be the L copper busbar (live wire copper busbar) and the N copper busbar (neutral wire copper busbar) respectively. Under normal operating conditions, current can flow from the L copper busbar into the load (e.g., the on-board charger) and then return to the power source through the N copper busbar to form a closed circuit.
[0040] In specific application scenarios, the inventors discovered through research that the design of the magnetic core enclosure can reduce noise in the high-frequency band (30MHz) by at least 10dB.
[0041] In this embodiment, at least a portion of the first copper busbar 10 overlaps with a portion of the second copper busbar 11 to form an overlapping region, and the magnetic core surrounds the overlapping region.
[0042] Please refer to this again. Figure 2 and Figure 3 These are schematic diagrams showing two different arrangements of the first copper busbar 10 and the second copper busbar 11. In a preferred embodiment, as shown... Figure 3 As shown, the vehicle controller filter structure 100 also includes a switching device (not shown in the figure, which may be a MOSFET) for controlling the conductive path. The electric field formed by the voltage pulse generated by the switching device during the switching operation is defined as a high-frequency electric field. In the overlapping region, the overlapping direction of the first copper busbar 10 and the second copper busbar 11 is a preset direction (i.e., the direction that extends out of the screen). The preset direction is the same as the radiation direction of the high-frequency electric field. The high-frequency electric field includes at least the electric field formed by the voltage pulse generated during the switching operation of the switching device.
[0043] It should be noted that in electric vehicle charging equipment and on-board controllers, on-board chargers, motor controllers, and DC-DC converters typically employ high-frequency switching technology. Switching devices (such as MOSFETs and IGBTs) generate high-frequency voltage pulses during high-speed switching. These high-frequency pulses create a high-frequency electric field on the conductors and can propagate through space as electromagnetic waves. In this case, if the high-frequency electric field originates from the original arrangement direction of the copper busbar (… Figure 2 When the electric field passes through the copper busbars (as shown in the arrangement direction), if there are gaps in the middle of the copper busbars, a loop will be formed between the copper busbars after the electric field passes through, generating an induced electromotive force, creating a voltage difference, and thus causing interference. The preferred embodiment (…) Figure 3 The arrangement of the components can avoid the generation of this interference, thereby further reducing low-frequency noise.
[0044] In specific application scenarios, the inventors discovered through research that Figure 3 The arrangement shown can reduce low-frequency (130kHz) noise by 6-8dB.
[0045] Please refer to this again. Figure 1 , Figure 4 and Figure 5 The vehicle controller filter structure 100 also includes a housing 13 with a accommodating chamber 131. The first copper busbar 10 and the second copper busbar 11 are both arranged in the accommodating chamber 131, and the magnetic core is sleeved on the outside of the housing 13, so that the housing 13, the first copper busbar 10 and the second copper busbar 11 are all inserted into the shielding chamber 122.
[0046] It should be noted that the shell 13 can be a plastic shell 13 in order to reduce production costs while ensuring structural strength.
[0047] It is worth noting that the magnetic core in the vehicle controller filter structure 100 is arranged outside the housing 13, which can further reduce the space requirement within the accommodating chamber 131 and avoid high-temperature demagnetization of the magnetic core (which is not arranged inside the housing). The vehicle controller filter structure 100 can cooperate with the magnetic core and the housing 13 to save PCB space and reduce the use of components such as magnetic core capacitors in the vehicle controller, thereby reducing costs and miniaturizing the product.
[0048] In this embodiment, both the first copper busbar 10 and the second copper busbar 11 are injection molded into the accommodating chamber 131.
[0049] It is worth noting that injection molding ensures a firm bond between the first copper busbar 10 and the second copper busbar 11 and the housing 13, preventing the copper busbars from loosening or shifting due to vibration or external force during use. Furthermore, the injection molding process avoids the complex operations associated with traditional mechanical fixing or welding, thus improving production efficiency.
[0050] Please refer to this again. Figure 4 The magnetic core includes a first pair of mating magnetic cores and a second pair of mating magnetic cores that are connected to each other. The first pair of mating magnetic cores and the second pair of mating magnetic cores cooperate with each other to form a shielded cavity.
[0051] It is worth noting that the design of two mating magnetic cores 121 makes the installation and replacement of magnetic cores more convenient, and has the advantage of low maintenance cost.
[0052] In this embodiment, the magnetic core is a "U / I" magnetic core or a "U / U" magnetic core.
[0053] In this embodiment, the first pair of mating magnetic cores can be bonded to the second pair of mating magnetic cores using a first fixing adhesive. Simultaneously, the first pair of mating magnetic cores and / or the second pair of mating magnetic cores can be bonded to the outer surface of the housing using a second fixing adhesive. It is understood that the first and second fixing adhesives can be the same adhesive or different adhesives; this embodiment does not constitute a limitation on their specific types.
[0054] It is worth noting that, such as Figure 4 , Figure 4The vehicle controller filter structure 100 shown consists of two mating magnetic cores 121, both of which are "U"-shaped magnetic cores. The assembly process can be as follows: 1) First, using an injection molding machine, inject the L / N copper busbar and bushing 14 (the bushing can be made of stainless steel and fixed to the water-cooled plate housing 13 with bolts to achieve product fixation) into the housing 13; 2) Apply fixing adhesive to the front of the housing 13 to fix each magnetic core to the housing 13. Apply magnetic core adhesive to the mating surfaces of the magnetic cores; 3) Apply plastic shell fixing adhesive to the back of the housing 13, and press the two magnetic cores together under pressure. After high-temperature curing in an oven for a certain period, remove the cores and apply fixing adhesive to the grooves in the housing 13; 4) Test the product's insulation, withstand voltage, inductance, and impedance performance.
[0055] It is also worth noting that, such as Figure 6 , Figure 6 The on-board controller filter structure 100 shown consists of one mating magnetic core 121 that is a "U"-shaped magnetic core and another mating magnetic core 121 that is an "I"-shaped magnetic core. This embodiment can improve reliability under vibration and reduce the amount of magnetic core material and lower the cost of the magnetic core. The assembly process can be as follows: 1) Apply plastic shell fixing adhesive to the back of the I-shaped magnetic core and stick it to the housing 13; 2) Apply magnetic core fixing adhesive to the mounting surface of the U-shaped magnetic core, press it onto the I-shaped magnetic core under certain pressure, and then place it in an oven for high-temperature curing for a certain period of time before taking it out; 3) Apply fixing adhesive to the outer surface of the U-shaped magnetic core.
[0056] It is also worth noting that, such as Figure 7 , Figure 7 The first and second mating magnetic cores of the vehicle controller filter structure 100 can be fixedly connected to the housing by clips, or the first and second mating magnetic cores are still fixed by adhesive bonding. This embodiment can reduce the amount of glue used in the housing and increase the plastic clips and slots, making the fixing method more reliable.
[0057] In this embodiment, the magnetic core is made of ferrite or nanocrystals. It is understood that both ferrite and nanocrystal materials have high magnetic permeability, which can effectively absorb and attenuate high-frequency electromagnetic waves and significantly reduce high-frequency noise.
[0058] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.
[0059] Throughout this description, numerous specific details, such as examples of components and / or methods, are provided to provide a complete understanding of embodiments of this application. However, those skilled in the art will recognize that embodiments of this invention may be practiced without one or more of these specific details or by other devices, systems, components, methods, parts, materials, components, etc. In other instances, well-known structures, materials, or operations have not been specifically shown or described in detail to avoid obscuring aspects of embodiments of this application.
[0060] Throughout this specification, references to "an embodiment," "an embodiment," or "a specific embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention, but not necessarily in all embodiments. Therefore, the various representations of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout the specification do not necessarily refer to the same embodiment. Furthermore, a particular feature, structure, or characteristic of any specific embodiment of the present invention can be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments described herein may be based on the teachings herein and will be considered part of the spirit and scope of the present invention.
[0061] It should also be understood that one or more of the elements shown in the figures may be implemented in a more separate or more integrated manner, or may even be removed because they are inoperable in certain circumstances or provided because they may be useful for a particular application.
[0062] Furthermore, unless otherwise expressly stated, any arrows in the accompanying drawings should be considered illustrative only and not limiting. Additionally, unless otherwise stated, the term "or" as used herein is generally intended to mean "and / or". Where a term is anticipated to provide a separation or combination capability that is unclear, a combination of components or steps will also be considered as indicated.
[0063] As used herein and throughout the claims below, unless otherwise specified, “a” and “the” include the plural references. Similarly, as used herein and throughout the claims below, unless otherwise specified, “in” means “in” and “on”.
[0064] The above description of the embodiments shown in this utility model (including the content in the abstract of the specification) is not intended to be an exhaustive enumeration or to limit the utility model to the precise forms disclosed herein. Although specific embodiments and examples of the utility model have been described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the utility model, as will be recognized and understood by those skilled in the art. As indicated, these modifications can be made to the utility model in accordance with the above description of the embodiments of this application, and such modifications will be within the spirit and scope of the utility model.
[0065] This document has generally described the systems and methods in detail to aid in understanding the present invention. Furthermore, various specific details have been set forth to provide a general understanding of the embodiments of this application. However, those skilled in the art will recognize that embodiments of the present invention can be practiced without one or more specific details, or using other devices, systems, accessories, methods, components, materials, parts, etc. In other instances, well-known structures, materials, and / or operations have not been specifically shown or described in detail to avoid obscuring various aspects of the embodiments of this application.
Claims
1. A filtering structure for an on-board controller, characterized in that, include: A copper busbar is used to form a conductive path between the voltage input port and the power circuit. The magnetic core is enclosed within a shielded cavity. The magnetic core surrounds the transition copper busbar to suppress electromagnetic interference signals generated by the transition copper busbar.
2. The vehicle controller filtering structure according to claim 1, characterized in that, The transition copper busbar includes a first copper busbar and a second copper busbar, with at least a portion of the first copper busbar overlapping a portion of the second copper busbar to form an overlapping area, and the magnetic core enclosing the overlapping area.
3. The vehicle controller filtering structure according to claim 2, characterized in that, The vehicle controller filtering structure also includes a switching device for controlling the conductive path, and the electric field formed by the voltage pulse generated by the switching device during the switching action is defined as a high-frequency electric field. In the overlapping region, the overlapping direction of the first copper busbar and the second copper busbar is a preset direction, which is the same as the radiation direction of the high-frequency electric field.
4. The vehicle controller filtering structure according to claim 2, characterized in that, The vehicle controller filtering structure also includes a housing with a accommodating chamber, in which the first copper busbar and the second copper busbar are both arranged, and the magnetic core is sleeved on the outside of the housing, so that the housing, the first copper busbar and the second copper busbar all pass through the shielding chamber.
5. The vehicle controller filtering structure according to claim 4, characterized in that, Both the first copper busbar and the second copper busbar are injection molded into the accommodating cavity.
6. The vehicle controller filtering structure according to claim 4, characterized in that, The magnetic core includes a first pair of mating magnetic cores and a second pair of mating magnetic cores that are connected to each other. The first pair of mating magnetic cores and the second pair of mating magnetic cores cooperate with each other to enclose and form the shielding cavity.
7. The vehicle controller filtering structure according to claim 6, characterized in that, The magnetic core is either a "U / I" core or a "U / U" core.
8. The vehicle controller filtering structure according to claim 6, characterized in that, The first pair of mating magnetic cores is glued to the second pair of mating magnetic cores.
9. The vehicle controller filtering structure according to claim 8, characterized in that, The first pair of mating magnetic cores and / or the second pair of mating magnetic cores are bonded to the outer surface of the housing.
10. The vehicle controller filtering structure according to claim 6, characterized in that, The mating surface of the first mating magnetic core has a slot, and the second mating magnetic core is snapped into the mating surface of the first mating magnetic core.
11. The vehicle controller filtering structure according to claim 1, characterized in that, The magnetic core is made of ferrite or nanocrystals.