Inverter brick for new energy automobile motor controller
By integrating current sensors, IGBT modules, and other components into a modular inverter brick structure, the problems of insufficient positional accuracy and fixing strength of the current sensors are solved, achieving higher installation accuracy and vibration resistance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANG SU JIN MAI DIAN KONG KE JI YOU XIAN GONG SI
- Filing Date
- 2025-03-13
- Publication Date
- 2026-05-26
Smart Images
Figure CN224289660U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of inverter unit technology, specifically an inverter brick for a new energy vehicle motor controller. Background Technology
[0002] The current sensor is a very important component in the motor controller of new energy vehicles. Its function is to receive the AC signal output by the controller, detect the current in real time, and transmit the detected current to the drive motor of the vehicle through the control loop.
[0003] Currently, current sensors are mostly soldered onto the PCB inside the controller and then assembled with the three-phase terminals. There is no fixed connection between the current sensor and the three-phase terminals, resulting in low positional accuracy and weak sensor mounting strength. Therefore, we propose an inverter brick for new energy vehicle motor controllers. Utility Model Content
[0004] The purpose of this invention is to provide an inverter brick for a new energy vehicle motor controller to solve the problems mentioned in the background art.
[0005] To achieve the above objectives, this utility model provides the following technical solution:
[0006] An inverter brick for a new energy vehicle motor controller includes: a main frame, a current sensor, an IGBT module, a discharge resistor, a Y capacitor, a DC support capacitor, and a PCBA module.
[0007] The main frame includes a switch mounting section on the left and a capacitor mounting section on the right.
[0008] The switch mounting part is provided with a U-phase current input terminal, a V-phase current input terminal and a W-phase current input terminal on one side, and the current sensor is also installed on one side of the switch mounting part. The IGBT module is installed in the switch mounting part, and the U-phase current input terminal, V-phase current input terminal and W-phase current input terminal are respectively connected to the IGBT module through the current sensor.
[0009] The DC support capacitor is installed inside the capacitor mounting part, and a discharge resistor is installed on one side of the capacitor mounting part and a Y capacitor is installed on the other side.
[0010] The switch mounting part and the capacitor mounting part are connected on one side with a T+ output terminal and a T- output terminal. The two output terminals of the IGBT module are connected in parallel with the DC support capacitor, the discharge resistor and the Y capacitor, and the current signal is output through the T+ output terminal and the T- output terminal.
[0011] The PCBA module is enclosed on the main frame, and the PCBA module is used to collect the current signal of the current sensor, and obtain the PWM signal through gate-level drive to control the IGBT module to generate the current used to drive the motor.
[0012] Preferably, three sets of grooves are provided on one side of the switch mounting part, and the current sensor is encapsulated in the grooves by potting glue.
[0013] Preferably, the DC support capacitor is encapsulated within the capacitor mounting portion by potting.
[0014] Preferably, the U-phase current input terminal, V-phase current input terminal, and W-phase current input terminal are copper pins. One end of the copper pin extends to the outside of the switch mounting part to connect to the three-phase power input, and the other end extends into the switch mounting part to connect to the power input terminal of the IGBT module.
[0015] Compared with the prior art, the beneficial effects of this utility model are as follows: The inverter brick for the new energy vehicle motor controller integrates the current sensor, capacitor, PCBA module and IGBT module used in the inverter unit of the new energy vehicle motor controller into one body through the main frame, so that the overall structure is a modular brick structure. The main frame is divided into left and right switch mounting parts and capacitor mounting parts, so that the IGBT module and capacitor module have their own suitable mounting space, the installation position accuracy is higher, and the overall vibration resistance and reliability of the inverter unit are improved. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0017] Figure 2 This is a schematic diagram showing the overall structure of this utility model broken down.
[0018] Figure 3 This is a circuit connection schematic diagram of this utility model.
[0019] In the picture:
[0020] 1. Main frame; 11. Switch mounting part; 111. U-phase current input terminal; 112. V-phase current input terminal; 113. W-phase current input terminal; 114. Groove; 12. Capacitor mounting part; 121. T+ output terminal; 122. T- output terminal;
[0021] 2. Current sensor;
[0022] 3. IGBT module;
[0023] 4. Discharge resistor;
[0024] 5. Y capacitor;
[0025] 6. DC support capacitor;
[0026] 7. PCBA module. Detailed Implementation
[0027] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0028] In the description of this patent, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this patent according to the specific circumstances.
[0029] An inverter brick for a new energy vehicle motor controller, such as Figure 1 and Figure 2As shown, it includes: a main frame 1, a current sensor 2, an IGBT module 3, a discharge resistor 4, a Y capacitor 5, a DC support capacitor 6, and a PCBA module 7. The main frame 1 includes a switch mounting section 11 on the left and a capacitor mounting section 12 on the right. A U-phase current input terminal 111, a V-phase current input terminal 112, and a W-phase current input terminal 113 are provided on one side of the switch mounting section 11. A current sensor 2 is also installed on one side of the switch mounting section 11. The IGBT module 3 is installed inside the switch mounting section 11. The U-phase current input terminal 111, the V-phase current input terminal 112, and the W-phase current input terminal 113 are respectively connected to the IGBT module 3 through the current sensor 2. A DC support capacitor 6 is installed inside the capacitor mounting part 12, and a discharge resistor 4 is installed on one side of the capacitor mounting part 12 and a Y capacitor 5 is installed on the other side. A T+ output terminal 121 and a T- output terminal 122 are provided on one side of the connection end between the switch mounting part 11 and the capacitor mounting part 12. The two output terminals of the IGBT module 3 are connected in parallel with the DC support capacitor 6, the discharge resistor 4 and the Y capacitor 5, and the current signal is output through the T+ output terminal 121 and the T- output terminal 122. The PCBA module 7 is covered on the main frame 1, and the PCBA module 7 is used to collect the current signal of the current sensor 2, and obtain the PWM signal through the gate-level drive to control the IGBT module 3 to generate the current used to drive the motor. Therefore, the inverter brick for the new energy vehicle motor controller of this utility model integrates the current sensor, capacitor, PCBA module and IGBT module used in the inverter unit of the new energy vehicle motor controller into one body through the main frame 1, so that the overall structure is a modular brick structure. The main frame 1 is divided into a left and right structure of switch mounting part 11 and capacitor mounting part 12, so that the IGBT module and capacitor module have their own suitable mounting space, the installation position accuracy is higher, and the overall vibration resistance and reliability of the inverter unit are improved.
[0030] Specifically, three sets of grooves 114 are provided on one side of the switch mounting part 11, and the current sensor 2 is encapsulated in the grooves 114 by potting glue, and the DC support capacitor 6 is encapsulated in the capacitor mounting part 12 by potting glue. Figure 2 As shown, potting encapsulation can improve the installation accuracy of the current sensor 2 and the DC support capacitor 6, and the adhesive can form a soft buffer layer after curing, preventing damage to the current sensor 2 and the DC support capacitor 6.
[0031] Specifically, the U-phase current input terminal 111, V-phase current input terminal 112, and W-phase current input terminal 113 are made of copper pins. One end of the copper pin extends to the outside of the switch mounting part 11 to connect to the three-phase power input, and the other end extends into the switch mounting part 11 to connect to the power input terminal of the IGBT module 3. In this embodiment, three sets of grooves 114 opened on one side of the switch mounting part 11 connect to the position where the current input terminal is installed, so that after the current sensor 2 is connected to the current input terminal, an electrical connection is formed by potting and encapsulation. The side of the copper pin extending into the switch mounting part 11 has a certain elasticity. When the IGBT module 3 is fixed in the switch mounting part 11, the power input terminal is just pressed on the copper pin to form an electrical connection.
[0032] In this embodiment, as Figure 3 As shown, the external new energy vehicle motor controller detects the current signal through current sensor 2 and transmits it to the PCBA module. The PCBA module, based on the signal input from the vehicle, controls the gate-level drive. The gate-level drive generates a PWM signal to control the IGBT module 3, which in turn generates the current used by the new energy vehicle drive motor. The DC support capacitor 6 smooths the bus voltage, ensuring its stability during IGBT module 3 operation. The discharge resistor 4 quickly discharges electrical energy from the system, ensuring system safety. The Y capacitor 5 minimizes high-frequency noise on the bus and reduces electromagnetic interference. This constitutes the circuit connection principle of the entire new energy vehicle motor controller using an inverter brick.
[0033] In this embodiment, the inverter brick for the new energy vehicle motor controller integrates the current sensor 2, Y capacitor 5, DC support capacitor 6, PCBA module 7, and IGBT module 3 used in the inverter unit of the new energy vehicle motor controller into one unit through the main frame 1, so that the overall structure is a modular brick-shaped structure. The main frame 1 is divided into a left and right structure of switch mounting part 11 and capacitor mounting part 12, so that the IGBT module and capacitor module have their own suitable installation space, the installation position accuracy is higher, and the overall vibration resistance and reliability of the inverter unit are improved.
[0034] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.
Claims
1. An inverter brick for a new energy vehicle motor controller, characterized in that, include: Main frame (1), current sensor (2), IGBT module (3), discharge resistor (4), Y capacitor (5), DC support capacitor (6), PCBA module (7). The main frame (1) includes a switch mounting part (11) on the left half and a capacitor mounting part (12) on the right half. The switch mounting part (11) is provided with a U-phase current input terminal (111), a V-phase current input terminal (112) and a W-phase current input terminal (113) on one side, and the current sensor (2) is also installed on one side of the switch mounting part (11). The IGBT module (3) is installed in the switch mounting part (11), and the U-phase current input terminal (111), V-phase current input terminal (112) and W-phase current input terminal (113) are respectively connected to the IGBT module (3) through the current sensor (2). The DC support capacitor (6) is installed in the capacitor mounting part (12), and a discharge resistor (4) is installed on one side of the capacitor mounting part (12), and a Y capacitor (5) is installed on the other side. The switch mounting part (11) and the capacitor mounting part (12) are provided with a T+ output terminal (121) and a T- output terminal (122) on one side. The two output terminals of the IGBT module (3) are connected in parallel to the DC support capacitor (6), the discharge resistor (4) and the Y capacitor (5) and then output current signals through the T+ output terminal (121) and the T- output terminal (122). The PCBA module (7) is covered on the main frame (1), and the PCBA module (7) is used to collect the current signal of the current sensor (2), and obtain the PWM signal through gate-level drive to control the IGBT module (3) to generate the current used to drive the motor.
2. The inverter brick for a new energy vehicle motor controller according to claim 1, characterized in that, Three sets of grooves (114) are provided on one side of the switch mounting part (11), and the current sensor (2) is encapsulated in the grooves (114) by potting glue.
3. The inverter brick for a new energy vehicle motor controller according to claim 1, characterized in that, The DC support capacitor (6) is encapsulated in the capacitor mounting part (12) by potting.
4. The inverter brick for a new energy vehicle motor controller according to claim 1, characterized in that, The U-phase current input terminal (111), V-phase current input terminal (112) and W-phase current input terminal (113) are copper pins. One end of the copper pin extends to the outside of the switch mounting part (11) to connect to the three-phase power input, and the other end extends into the switch mounting part (11) to connect to the power input terminal of the IGBT module (3).