A multi-stage filtering integrated module of a composite structure, an electric drive system and a vehicle

Abstract

The utility model discloses a kind of multi-stage filtering integrated module of composite structure, electric drive system and vehicle, belong to new energy electric car electric drive technical field, multi-stage filtering integrated module of composite structure includes upper cover fastener, lower fastener, capacitor filter module, magnetic filter module, bus copper bar, external copper bar, connecting copper column;The magnetic ring is sleeved in the outer circumferential surface of copper bar along copper bar extension direction;Capacitor filter module includes PCB board and the capacitor welded on PCB board, capacitor filter module is crimped with bus copper bar by connecting copper column, another grounding hole is additionally provided on PCB board, ensure that the Y capacitor of connecting bus copper bar and ground can have good electrical contact with metal shell;The multi-stage filtering integrated module of composite structure can guarantee its effective suppression new energy electric car's common mode and differential mode noise in electric drive, while guarantee the simplicity of assembly and the stability of fastening, filtering integrated module meets national standard, with the characteristics of better electrical and structural stability.

Description

Technical Field

[0001] This utility model relates to the field of electric drive technology for new energy electric vehicles, specifically a multi-stage filter integrated module with a composite structure, an electric drive system, and a vehicle. Background Technology

[0002] With the rapid development of new energy vehicles (NEVs), on-board power electronic systems are evolving towards higher voltage (800V and above) and higher power density (>20kW / L). Core components such as electric drive systems, on-board chargers (OBCs), and DC-DC converters generate broadband (10kHz-1GHz) electromagnetic interference (EMI) during operation. Furthermore, the broadband current noise generated by these electric drive systems (such as high-frequency switching noise and common-mode / differential-mode interference) can be conducted or radiated to external devices through cables, seriously threatening system stability and electromagnetic compatibility (EMC) performance. Therefore, electric drive filters, as core components for suppressing current noise, directly affect the reliability and safety of the equipment.

[0003] Currently, traditional electric drive filters generally adopt an integrated potting structure, integrating components such as magnetic rings and capacitors into a single housing and fixing it in place with potting compound. While this structure improves mechanical strength and heat dissipation, it also has significant drawbacks. Once the internal magnetic rings, capacitors, or other components are damaged, the entire filter must be replaced, resulting in high maintenance costs and wasted resources. Furthermore, the integrated potting structure leads to a dense component layout, lacking modular design and making it difficult to flexibly adjust filter parameters or perform partial upgrades for different operating conditions.

[0004] Existing filters often employ CLC topology or a single magnetic core material. However, for practical filtering capabilities, a single-stage inductor can only provide limited insertion loss, especially in wideband noise scenarios (such as the simultaneous presence of low-frequency motor harmonics and high-frequency switching noise), where its overall attenuation characteristics are insufficient to meet high EMC requirements. Furthermore, the permeability and frequency characteristics of a single magnetic core material (such as ferrite or nanocrystals) are fixed, resulting in a narrow filtering frequency band coverage. Utility Model Content

[0005] To address the problems existing in the prior art, this utility model provides a multi-stage filter integrated module with a composite structure, an electric drive system, and a vehicle, which can effectively suppress common-mode and differential-mode noise, reduce electromagnetic interference, and improve electromagnetic compatibility.

[0006] This utility model is achieved through the following technical solution:

[0007] A multi-stage filter integrated module with a composite structure includes a housing, and a magnetic filter module and a capacitor filter module disposed on both sides of the housing;

[0008] The magnetic filter module includes a top cover, multiple magnetic rings, and copper busbars. The top cover has multiple fixing cavities. Multiple magnetic rings are sleeved on the copper busbars and installed in the fixing cavities respectively. The copper busbars are located at the bottom of the top cover, and the top cover is located at the top of the housing. The ends of the copper busbars are connected to the housing through inserts. The fixing cavities are filled with potting compound.

[0009] The capacitor filter module includes multiple parallel capacitor filter units. Each capacitor filter unit includes a PCB board and capacitors soldered to the PCB board. The capacitors include X capacitors and symmetrical Y capacitors. The PCB board is located at the bottom of the housing and is connected to the copper busbar through connecting copper pillars. Encapsulating glue is applied between the PCB board and the capacitors.

[0010] Preferably, the copper busbar includes a positive busbar and a negative busbar, which are equally spaced. Each end of the positive busbar and the negative busbar has a fixing hole connected to an insert, and multiple magnetic rings are fitted onto the positive and negative busbars.

[0011] Preferably, the magnetic ring is composed of a ferrite magnetic ring or a nanocrystalline magnetic ring, and includes at least one ferrite magnetic ring.

[0012] Preferably, a positioning structure is provided between the housing and the top cover.

[0013] Preferably, the copper busbar is provided with multiple crimping holes, and multiple connecting copper pillars are embedded in the housing. The upper end of the connecting copper pillar is connected to the copper busbar, and the lower end is connected to the connecting hole of the PCB board.

[0014] Preferably, the two ends of the X capacitor are connected to the positive busbar and the negative busbar, respectively;

[0015] One end of the Y capacitor is connected to the positive or negative busbar copper bus, and the other end is connected to the grounding hole on the PCB board.

[0016] Preferably, the capacitor filter module is a three-stage capacitor filter module, comprising three parallel capacitor filter units, which are arranged sequentially along the extension direction of the copper busbar.

[0017] Preferably, the housing is provided with multiple external copper busbars, which are used to connect fuses and external ports.

[0018] An electric drive system includes a multi-stage filter integrated module with the composite structure.

[0019] A vehicle including the aforementioned electric drive system.

[0020] Compared with the prior art, the present invention has the following beneficial technical effects:

[0021] This application presents a multi-stage filter integrated module with a composite structure, employing a combination of ferrite magnetic rings and nanocrystalline magnetic rings to ensure that the overall attenuation characteristics meet high EMC level requirements in broadband noise environments. Furthermore, the coordinated layout of two-stage magnetic rings and three-stage capacitors forms a multi-order filter network, significantly improving overall insertion loss. In addition, the housing structure is optimized into two parts: a top cover and a main body. The top cover is only potted and fixed to the magnetic core, ensuring that even if problems occur during subsequent production and assembly, only this part needs to be replaced, effectively reducing module maintenance costs. It also ensures ease of capacitor installation and stability of the busbar copper busbar fixation during module assembly, and guarantees good heat dissipation for the magnetic core and capacitors during normal operation. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the multi-stage filter integrated module with a composite structure in this utility model.

[0024] Figure 2 This is an exploded view of the multi-stage filter integrated module structure of the composite structure in this utility model.

[0025] Figure 3 This is a schematic diagram of the assembly of copper busbars and magnetic rings in the multi-stage filter integrated module with composite structure in this utility model.

[0026] Figure 4 This is a schematic diagram of the capacitor filter module in the multi-stage filter integrated module with composite structure in this utility model.

[0027] Figure 5 This is a schematic diagram of the installation of the filter module in the multi-stage filter integrated module with composite structure in this utility model.

[0028] Figure 6 This is a circuit topology diagram of the multi-stage filter integrated module with composite structure in this utility model.

[0029] In the diagram: 1-Magnetic filter module; 2-Capacitor filter module; 3-Bus busbar; 4-External copper busbar; 5-Connecting copper post; 6-Top cover; 7-Outer shell; 8-First magnetic ring; 9-Second magnetic ring; 10-Axial through hole; 11-X capacitor; 12-Y capacitor; 13-PCB board; 14-Grounding hole; 15-Positive busbar; 16-Negative busbar; 17-Fastening insert; 18-Grounding insert; 19-Positioning hole; 20-Copper busbar fixing groove; 21-Fixing cavity; 22-Crimping hole. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0031] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0032] like Figure 1 , 2 As shown, a multi-stage filter integrated module with a composite structure includes a housing 7, and a magnetic filter module 1 and a capacitor filter module 2 disposed on both sides of the housing.

[0033] The magnetic filter module 1 includes a top cover, a multi-stage magnetic filter assembly, and a copper busbar 3. The multi-stage magnetic filter assembly includes multiple magnetic rings, which are sleeved on the copper busbar. The top cover has multiple fixing cavities 21, and the multiple magnetic rings are respectively installed in the fixing cavities 21. The copper busbar is located at the bottom of the top cover, and the top cover is located at the top of the housing. The end of the copper busbar is connected to the housing through an insert. The space between the top cover and the multi-stage magnetic filter assembly is filled with potting compound.

[0034] The capacitor filter module 2 includes multiple parallel capacitor filter units. Each capacitor filter unit includes a PCB board 13 and a capacitor connected thereto. The PCB board is located at the bottom of the housing and is connected to the copper busbar 3 through an insert. A filling potting compound is provided between the PCB board 13 and the capacitor.

[0035] In some embodiments, in order to ensure the filtering performance of the multi-stage filter integrated module, the multi-stage capacitor filter component is a three-stage capacitor filter module, and the multi-stage magnetic filter component is a two-stage magnetic filter module.

[0036] The copper busbar 3 includes a positive busbar copper busbar 15 and a negative busbar copper busbar 16. The positive busbar copper busbar 15 and the negative busbar copper busbar 16 are arranged at equal intervals. The two ends of the positive busbar copper busbar 15 and the negative busbar copper busbar 16 are respectively provided with fixing holes for connecting inserts.

[0037] like Figure 3 As shown, the magnetic filter module includes a first magnetic ring and a second magnetic ring. The first magnetic ring and the second magnetic ring are nanocrystalline magnetic rings 8 and / or ferrite magnetic rings 9. Since the cutoff frequency of nanocrystalline is relatively low, if the filter integrated module is used at a high frequency, at least one magnetic ring is a ferrite magnetic ring to ensure that the filter integrated module has a wide operating frequency. The two magnetic rings are sleeved on the positive bus copper bus 15 and the negative bus copper bus 16.

[0038] The top cover has two fixing cavities 21, and the top of the housing has a copper busbar fixing groove 20. Two magnetic rings are respectively set in the fixing cavities 21. The two ends of the copper busbar are set in the copper busbar fixing groove 20. The fixing cavities 21 are filled with potting compound, which encapsulates the copper busbar and magnetic rings.

[0039] The housing 7 is provided with multiple inserts, which are fastening inserts 17. Four fastening inserts 17 are embedded in the top of the housing and correspond to the positions of the fixing holes at the ends of the copper busbars. The encapsulated top cover is installed on the top of the housing. The fastening inserts are coaxial with the fixing holes of the copper busbars, and the fasteners pass through the fixing holes and are connected to the fastening inserts 17.

[0040] In some embodiments, to ensure that the filter integrated module has good filtering performance, the capacitor filter module is set as a three-stage capacitor module, which includes three parallel capacitor filter units. The three capacitor filter units are arranged sequentially along the extension direction of the copper busbar. The capacitor filter unit includes a PCB board 13 and capacitors soldered on the PCB board 13.

[0041] The positive busbar copper bus 15 and the negative busbar copper bus 16 are provided with multiple crimping holes 22 for connecting each capacitor filter unit. Multiple connecting copper pillars 5 are embedded in the housing. The upper end of the connecting copper pillar 5 is connected to the copper busbar, and the lower end is connected to the PCB board. The PCB board is provided with connecting holes and grounding holes 14.

[0042] Optionally, the capacitor includes an X capacitor and / or a pair of symmetrical Y capacitors.

[0043] See Figures 4-6 In practical applications, the noise that the filter integrated module needs to filter out can be divided into two types: common-mode noise and differential-mode noise. For capacitor filter module 2, the capacitors are divided into X capacitor 11 and Y capacitor 12.

[0044] For differential mode noise, an X capacitor is used for filtering. The two ends of the X capacitor are connected to the positive bus copper bus 15 and the negative bus copper bus 16 respectively to filter out differential mode noise between the positive and negative bus copper bus. Specifically, the X capacitor is connected to the PCB board, and the PCB board is electrically connected to the positive and negative bus copper bus through two connecting copper pillars 5 respectively.

[0045] For common-mode noise, magnetic filter module 1 and Y capacitor 12 are used for filtering. The two ends of the Y capacitor are connected to any one of the copper busbars 3 and the electrical ground, respectively. That is, the two ends of the Y capacitor are connected to the positive busbar 15 or the negative busbar 16 through the PCB board, and to the grounding hole, which is grounded. Therefore, in the design of the filter integrated module, it is necessary to ensure that each stage of capacitor filter unit includes at least one X capacitor or a pair of symmetrical Y capacitors.

[0046] To ensure the filtering capability of the integrated filter module for common-mode noise removal, the magnetic filter module 1 and the Y capacitor 12 need to work together. However, the Y capacitor needs to be connected between any bus copper bus and the electrical ground. For electric drive systems, the metal casing of the electric drive is generally used as the electrical ground. Therefore, a grounding hole 14 is provided on the PCB board to ensure that each Y capacitor can be directly connected to the metal casing through an independent grounding hole, and the inter-stage or intra-stage coupling of the capacitor filter module will not be completed through the grounding hole.

[0047] In another embodiment, the housing 7 is provided with a plurality of external copper busbars 4, which are used to connect fuses and external ports.

[0048] Optionally, the number of external copper busbars is three, and the housing is provided with three positioning slots. The three external copper busbars are respectively set in the three positioning slots. One end of two external copper busbars is crimped with the positive busbar copper busbar 15 and the negative busbar copper busbar 16. The other end of the two external copper busbars is used to connect to the external port, and the other external copper busbar is used to connect to the fuse.

[0049] Actual testing revealed that electric drives are categorized into 400V and 800V platforms based on their rated voltage. Therefore, for the filter integrated module, a potential difference exists between its positive and negative busbars, and under these conditions, the busbars will carry a current exceeding 150A. Thus, to ensure the filter integrated module's conductivity when connected to the electric drive while keeping the busbar heating within a controllable range, the current carrying capacity of the positive and negative busbar cross-sections needs to be controlled, ensuring that the theoretical maximum current carrying capacity does not exceed 8A / mm². 2However, it is worth noting that at the connection between the copper busbar and the PCB board, because connecting copper pillars 5 are needed to ensure the connection, holes are drilled in both the copper busbar 3 and the PCB board 13 to ensure stable installation. Therefore, the current carrying capacity here needs to be calculated by adding the cross-sectional areas of the copper busbar and the connecting copper pillars 5, and using this cross-sectional area to calculate its theoretical maximum current carrying capacity. The connection between the external copper busbar 4 and the busbar copper busbar 3 is the same as the connection between the connecting copper pillars 5 and the busbar copper busbar 3.

[0050] like Figure 2 As shown, to ensure the stability of the module during production and actual use, and to fully secure the magnetic core filter module 1 and busbar copper busbar 3, which play a major role in the filter integrated module, the module's outer shell is divided into two parts: an upper cover 6 and a housing 7. The upper cover 6 contains a fastening insert 17 and a grounding insert 18. The fastening insert 17 is embedded in the upper cover 6 by its outer texture and directly contacts the copper busbar. Screws from the PCB board 13 side pass through the connecting copper post 5 and engage with the fastening insert 17 to secure the capacitor filter module 2 and the upper cover 6. The grounding insert is electrically connected to the grounding hole 14 of the PCB board 13 by pressing it against the fastening insert 17, protecting the upper cover 6 and the PCB board 13 from excessive torque and damage when pressed against the grounding post at the installation location.

[0051] The aforementioned housing 7 is provided with a fastening insert 17, a positioning hole 19, a fixing groove, and an external copper busbar 4. The fastening insert 17 is used to fasten the busbar copper busbar 3 and the external copper busbar 4; the positioning hole 19 is used to determine the installation position of the upper cover housing 6; the fixing groove is used to install the magnetic filter module 1, the capacitor filter module 2, the connecting copper pillar 5, and the external fuse; the external copper busbar 4 is used to connect the busbar copper busbar 3, the external fuse, and the external port.

[0052] In the above structure, the upper cover 6 and the outer shell 7 are used to fix the magnetic ring and the copper busbar, and potting compound is filled between the magnetic ring and the upper cover and the outer shell; the potting compound can be made of: silicone potting compound, epoxy resin potting compound, polyurethane potting compound, modified silane potting compound, or thermally conductive potting compound.

[0053] The screws and the fastening inserts 17 in the top cover 6 complete the fixation of the PCB board 13, but the capacitor is only soldered to the PCB board 13 and there is no other fixation method. Therefore, potting compound is filled between the PCB board 13 and the capacitor.

[0054] The potting compound is made of materials such as epoxy resin, silicone, polyurethane, acrylic structural adhesive, and modified silane.

[0055] Example 1

[0056] An electric drive system includes a multi-stage filter integrated module with the composite structure.

[0057] The multi-stage filter module with integrated composite structure in the electric drive system effectively suppresses common-mode and differential-mode noise, making it particularly suitable for high-voltage (800V and above) and high-power-density (>20kW / L) applications. The magnetic filter module employs a two-stage structure of nanocrystalline magnetic rings and ferrite magnetic rings, covering a wide frequency band (10kHz-1GHz) for noise suppression. The capacitor filter module further optimizes the filtering effect through a three-stage parallel X and Y capacitor design. Furthermore, the modular design of the module facilitates maintenance, reducing system maintenance costs, while the use of potting compound ensures structural stability and heat dissipation performance, enabling it to maintain high efficiency even under harsh operating conditions.

[0058] Example 2

[0059] A vehicle comprising the electric drive system described in Example 1.

[0060] Applying the aforementioned electric drive system to vehicles significantly improves the overall vehicle's electromagnetic compatibility and reliability. This vehicle, through an integrated multi-stage filtering module with a composite structure, effectively reduces electromagnetic interference (EMI) generated by the electric drive system, preventing interference with sensitive onboard equipment such as the BMS, sensors, and communication modules. Furthermore, the miniaturized and lightweight design of the module optimizes the vehicle's spatial layout and energy efficiency, meeting the requirements of new energy vehicles for high integration and low energy consumption. Actual testing shows that this filtering module meets international and national standards, ensuring stable vehicle operation in complex electromagnetic environments. Simultaneously, its maintainability design significantly reduces the total lifecycle cost, providing technical support for the widespread adoption of new energy vehicles.

[0061] This application discloses a multi-stage filter integrated module with a composite structure, which features high integration, simple structure, miniaturization, and lightweight. By using multiple stages of filters, it can effectively suppress common-mode noise and differential-mode noise of new energy electric drives, meeting the requirements of international and national standards, and ensuring that other functions of new energy electric vehicles are not affected.

[0062] The above content is only for illustrating the technical concept of this utility model and should not be construed as limiting the scope of protection of this utility model. Any modifications made to the technical solution based on the technical concept proposed in this utility model shall fall within the scope of protection of the claims of this utility model.

Claims

1. A multi-stage filter integrated module with a composite structure, characterized in that, It includes a housing, and magnetic filter modules and capacitor filter modules disposed on both sides of the housing; The magnetic filter module includes a top cover, multiple magnetic rings, and copper busbars. The top cover has multiple fixing cavities. Multiple magnetic rings are sleeved on the copper busbars and installed in the fixing cavities respectively. The copper busbars are located at the bottom of the top cover, and the top cover is located at the top of the housing. The ends of the copper busbars are connected to the housing through inserts. The fixing cavities are filled with potting compound. The capacitor filter module includes multiple parallel capacitor filter units. Each capacitor filter unit includes a PCB board and capacitors soldered to the PCB board. The capacitors include X capacitors and symmetrical Y capacitors. The PCB board is located at the bottom of the housing and is connected to the copper busbar through connecting copper pillars. The space between the PCB board and the capacitors is filled with potting compound.

2. The multi-stage filter integrated module with a composite structure according to claim 1, characterized in that, The copper busbar includes a positive busbar and a negative busbar, which are equally spaced. Each end of the positive busbar and the negative busbar has a fixing hole, which is connected to an insert. Multiple magnetic rings are fitted on the positive and negative busbars.

3. The multi-stage filter integrated module with a composite structure according to claim 1, characterized in that, The magnetic ring is composed of a ferrite magnetic ring or a nanocrystalline magnetic ring, and includes at least one ferrite magnetic ring.

4. The multi-stage filter integrated module with a composite structure according to claim 1, characterized in that, A positioning structure is provided between the shell and the top cover.

5. The multi-stage filter integrated module with a composite structure according to claim 1, characterized in that, The copper busbar is provided with multiple crimping holes, and multiple connecting copper pillars are embedded in the housing. The upper end of the connecting copper pillar is connected to the copper busbar, and the lower end is connected to the connecting hole of the PCB board.

6. The multi-stage filter integrated module with a composite structure according to claim 2, characterized in that, The two ends of the X capacitor are connected to the positive busbar and the negative busbar, respectively. One end of the Y capacitor is connected to the positive or negative busbar copper bus, and the other end is connected to the grounding hole on the PCB board.

7. The multi-stage filter integrated module with a composite structure according to claim 1, characterized in that, The capacitor filter module is a three-stage capacitor filter module, which includes three parallel capacitor filter units, arranged sequentially along the extension direction of the copper busbar.

8. The multi-stage filter integrated module with a composite structure according to claim 1, characterized in that, The housing is provided with multiple external copper busbars, which are used to connect fuses and external ports.

9. An electric drive system, characterized in that, The multi-stage filter integrated module includes the composite structure described in any one of claims 1-8.

10. A vehicle, characterized in that, Includes the electric drive system as described in claim 9.

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