A power module, motor controller, electric drive assembly, and vehicle

Abstract

The application provides a power module, a motor controller, an electric drive assembly and a vehicle. The power module specifically comprises a power module main body, at least two phase connection terminals arranged on the power module main body, and at least two magnetic cores arranged on the at least two phase connection terminals; the projections of the at least two phase connection terminals on a first plane are arranged along a first direction; the at least two magnetic cores on the at least two phase connection terminals are arranged in a staggered manner along a second direction; the second direction intersects the first direction, and the first plane is parallel to the first direction and the second direction. The position of each magnetic core is set, so that the width and thickness of each magnetic core can be increased, the magnetic saturation of the magnetic core is effectively avoided, the measurement accuracy and the low crosstalk and attenuation phase shift are ensured, and in addition, the spacing of each measured conductor can be reduced, which is helpful for promoting the miniaturization and integration of related components.

Description

Technical Field

[0001] This application relates to the field of new energy vehicles, and in particular to a power module, a motor controller, an electric drive assembly, and a vehicle. Background Technology

[0002] In the electronic control system of new energy vehicles, current sensors are mainly used to monitor the current in real time, thereby providing support for precise current control to ensure the efficient and safe operation of the electronic control system.

[0003] Current sensors in the prior art, such as Hall effect current sensors, are equipped with magnetic cores made of high permeability materials. Taking a power module in an electronic control system as an example, one of the aforementioned magnetic cores is set at each phase connection terminal of the power module to concentrate the magnetic field generated by the current of that phase and to block crosstalk between the magnetic fields of adjacent phase currents.

[0004] In conventional power modules, the magnetic cores are usually arranged in a straight line, and the cores need to maintain a certain size to avoid magnetic saturation when detecting large currents. However, as the integration of power modules increases, the spacing between the copper busbars on the power module becomes smaller. This makes the horizontal space of the copper busbars very limited, but the magnetic cores still need to maintain a certain size. This means that multiple magnetic cores cannot be placed side by side on a power module. Utility Model Content

[0005] In order to solve or improve the defects existing in the prior art, the first aspect of this application provides a power module, which specifically includes a power module body, a plurality of phase connection terminals disposed on the outside of the power module body, and a plurality of current sensors correspondingly disposed on the plurality of phase connection terminals.

[0006] The projections of multiple connected ends onto the first plane are arranged along a first direction;

[0007] The power module body includes a substrate and multiple chips; among the multiple current sensors, at least one set of adjacent current sensors are staggered along a second direction, the second direction being perpendicular to the first direction, and the first plane being parallel to the first and second directions.

[0008] Optionally, the current sensor includes a magnetic core; among the plurality of current sensors, the magnetic cores of at least one group of adjacent current sensors at least partially overlap in projection along the second direction.

[0009] Optionally, the current sensor includes a magnetic core; among the multiple current sensors, the sum of the thicknesses of the magnetic cores of at least one group of adjacent current sensors on opposite sides along the first direction is greater than the distance between the projections of the corresponding two connected ends on the first plane.

[0010] Optionally, it includes three phase connection terminals, and multiple current sensors including a first current sensor, a second current sensor and a third current sensor arranged sequentially along a first direction on the projection of the first plane; along a second direction, the second current sensor is disposed between the power module body and the first current sensor, and the second current sensor is disposed between the power module body and the third current sensor.

[0011] Alternatively, along the second direction, the second current sensor is disposed on the side of the first current sensor away from the power module body, and the second current sensor is disposed on the side of the third current sensor away from the power module body.

[0012] Optionally, along the second direction, the first current sensor and the third current sensor are arranged side by side.

[0013] Optionally, multiple current sensors are arranged sequentially along a first direction, and their distance from the power module body along a second direction increases or decreases.

[0014] Optionally, the current sensor includes a magnetic core and a sensing chip; the magnetic core at least partially surrounds the corresponding phase connection end and has an air gap; the sensing chip is disposed within the air gap.

[0015] Optionally, the magnetic core may include a U-shaped magnetic core or multiple C-shaped magnetic cores.

[0016] Optionally, the sensing chip is specifically a Hall effect sensor chip.

[0017] Optionally, multiple chips are mounted on the same substrate to form multiple phase arms in a multiphase bridge topology circuit; the multiple phase connection terminals are electrically connected to the multiple phase arms in a one-to-one correspondence.

[0018] Optionally, the power module can be configured as a generator module.

[0019] A second aspect of this application provides a power module, including a power module body, at least two phase connection terminals disposed on the power module body, and at least two magnetic cores disposed on the at least two phase connection terminals;

[0020] At least two connected ends are arranged along a first direction when their projections onto the first plane are aligned.

[0021] At least two magnetic cores on at least two connected ends are offset from each other along a second direction;

[0022] The second direction intersects the first direction, and the first plane is parallel to both the first and second directions.

[0023] Optionally, the second direction is perpendicular to the first direction.

[0024] Optionally, each phase connection end is provided with a corresponding magnetic core;

[0025] The projections of two adjacent connected magnetic cores onto a first plane at least partially overlap in a first direction.

[0026] Optionally, the magnetic core has a gap of at least 1 mm with the adjacent phase connection end.

[0027] Optionally, at least two adjacent magnetic cores each extend in a direction perpendicular to the first plane, and the sum of the thicknesses of the two adjacent portions along the first direction is greater than the distance between the projections of the corresponding two connected ends on the first plane along the first direction.

[0028] Optionally, it includes three phase connection terminals, each corresponding to a magnetic core; the magnetic core includes a first magnetic core, a second magnetic core, and a third magnetic core arranged sequentially along a first direction on the projection of the first plane;

[0029] Along the second direction, the second magnetic core is disposed between the power module body and the first magnetic core, and the second magnetic core is disposed between the power module body and the third magnetic core; or, along the second direction, the first magnetic core is disposed between the power module body and the second magnetic core, and the third magnetic core is disposed between the power module body and the second magnetic core.

[0030] Optionally, the first and third magnetic cores are arranged side by side along the second direction.

[0031] Optionally, at least two magnetic cores are arranged sequentially along the first direction, and their distance from the power module body along the second direction increases or decreases.

[0032] Optionally, the power module body includes multiple chips constituting multi-phase bridge arms; the chips in at least two bridge arms are disposed on the same substrate, and at least two phase connection terminals are electrically connected to at least two phase bridge arms in a one-to-one correspondence.

[0033] Optionally, the power module body is configured as a power generation module for connection with a generator motor.

[0034] Optionally, the spacing between adjacent connecting ends is 14mm to 7mm.

[0035] A third aspect of this application provides a motor controller, which specifically includes the power module described in the foregoing technical solution or any of its alternative solutions.

[0036] The fourth aspect of this application provides an electric drive assembly, which specifically includes the motor controller described in the foregoing technical solutions or any of their alternative solutions.

[0037] The fifth aspect of this application provides a vehicle that specifically includes the electric drive assembly described in the foregoing technical solution or any of its alternatives.

[0038] Through the optimization of the positions of the magnetic cores of the current sensors on the power module, the width and thickness of each magnetic core can be increased, effectively avoiding magnetic core magnetic saturation and the problem of inaccurate current detection caused by magnetic saturation.

[0039] On the other hand, on the premise of ensuring the width and thickness of each magnetic core, the spacing between the connected ends of adjacent power modules can be reduced. Combining the scheme of integrating multiple bridge arms in the power module on the same substrate can effectively reduce the overall size of the power module, which helps to promote the miniaturization and integration of the power module and related components. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 Shows a schematic structural diagram of the power module provided by an embodiment of the present application;

[0041] Figure 2 Shows a schematic structural diagram of the current sensor part in the power module provided by an embodiment of the present application (upright "pin" shape);

[0042] Figure 3 Shows a schematic structural diagram of the current sensor part in the power module provided by an embodiment of the present application (inverted "pin" shape);

[0043] Figure 4 Shows a schematic structural diagram of the current sensor part in the power module provided by an embodiment of the present application ("step" shape);

[0044] Figure 5 Shows a schematic structural diagram of the current sensor part in the power module provided by an embodiment of the present application (a variant of the upright "pin" shape);

[0045] Figure 6 Shows a schematic structural diagram of the current sensor part in the power module provided by an embodiment of the present application (a variant of the inverted "pin" shape);

[0046] Figure 7 Is a front view schematic diagram of the sensor magnetic core involved in an embodiment of the present application;

[0047] Figure 8 Is a top view schematic diagram of the sensor magnetic core involved in an embodiment of the present application;

[0048] Figure 9 Is a schematic diagram of the topology principle of the range-extended electric vehicle applied by the power module provided by an embodiment of the present application.

[0049] Labels in the figure:

[0050] 100: Current sensor, 200: Power module main body;

[0051] 101: First current sensor; 102: Second current sensor; 103: Third current sensor;

[0052] 201: Connection end;

[0053] 110: Magnetic core; 120: Sensor chip;

[0054] 111: First magnetic core, 112: Second magnetic core, 113: Third magnetic core;

[0055] 1101: Air gap, 1102: Core center, 1103: Chamfer. Detailed Implementation

[0056] This application will now be described more fully below with reference to the accompanying drawings. However, this application can be implemented in many different ways and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided herein to make this application more detailed and complete. The same reference numerals denote the same objects throughout the drawings.

[0057] In the specification of this application, when a device / module / structure is referred to as being "connected to" other devices / modules / structures, such as "connected to" other devices / modules / structures, the device / module / structure may be directly connected to or directly coupled to other devices / modules / structures, or there may be an intervening third device / module / structure; in addition, in the embodiments of this application, "connection" may be an electrical connection, a structural connection, or a connection between layers.

[0058] This application defines "first direction" and "second direction" as reference directions. The above definitions are for the purpose of more accurately disclosing the technical solutions of this application and do not constitute a limitation on this application. It should be understood that in the embodiments of this application, descriptions such as "along the first direction" or "along the second direction" include both the setting and arrangement along the positive direction and the setting and arrangement along the negative direction.

[0059] In this application's embodiments, the "first plane" is a reference plane that is parallel to both the aforementioned "first direction" and "second direction." This plane is the one attached in the embodiments. Figures 1 to 6 The drawing plane, Figures 1 to 6 The shapes shown are all projections of the structures involved onto the aforementioned "first plane".

[0060] For power modules in new energy vehicles, such as power generation (rectifier) ​​modules or drive (inverter) modules, each phase connection terminal needs to be independently equipped with a current sensing device to measure the current of each phase and support the electronic control system to accurately control the current of each phase.

[0061] In the high-current and high-current-variable-amplitude operating conditions common in new energy vehicles, the aforementioned current sensing device may experience magnetic core saturation, which in turn leads to inaccurate current measurement and indirectly affects the precise control of the current.

[0062] To alleviate the aforementioned magnetic saturation problem, increasing the cross-sectional area of ​​the magnetic core is advantageous. In practical applications, such as... Figure 7 As shown, the magnetic core thickness h can be increased, or the magnetic core chamfer 1103 can be increased (when the chamfer radius increases, the magnetic core 110 expands further and thus increases the cross-sectional area), both of which can optimize the magnetic saturation problem. However, it is obvious that in the aforementioned optimization process, the magnetic core width w (the size occupied by the magnetic core along the first direction when it is installed at the connection end) will increase, and the space between adjacent connection ends is limited, making it impossible to install a magnetic core 110 with a larger width w.

[0063] On the other hand, in order to make reasonable use of the limited space in new energy vehicles, various components in new energy vehicles are developing towards high integration and miniaturization. However, the aforementioned large magnetic core width w undoubtedly hinders the high integration and miniaturization of components.

[0064] To address the aforementioned issues in the prior art, such as the lack of space for adjacent current sensor cores when the distance between adjacent connection terminals is close, and the limitation on miniaturization and integration of components due to the required sufficient thickness or chamfer of the current sensor core, this application first provides an embodiment of a current sensing device, such as... Figure 1 As shown, the current sensing device includes multiple current sensors 100 for measuring the current inside multiple conductors (e.g., the aforementioned connection terminals).

[0065] In a typical embodiment, multiple current sensors 100 are used to measure multiple phase currents in a multiphase circuit (such as a three-phase circuit commonly used in new energy vehicles).

[0066] like Figure 1 As shown, in this embodiment, the current sensing device measures multiple conductors, specifically along... Figure 1 The multiple connection terminals are arranged sequentially in the first direction (lateral direction). Therefore, each current sensor 100 is also arranged sequentially along the first direction and is respectively mounted on each connection terminal to be measured.

[0067] In an alternative embodiment, the aforementioned plurality of conductors may not be coplanar; for example, some conductors may have an orientation towards... Figure 1 The observation direction is either in the direction of observation or tilted away from the aforementioned observation direction; or, a portion of the conductor is parallel to other conductors but has an offset toward or away from the aforementioned observation direction.

[0068] In an embodiment, the orthographic projections of the plurality of conductors onto the first plane are as follows: Figure 1 As shown, they are arranged along a first direction, wherein the first plane is parallel to the aforementioned first direction and also parallel to... Figure 1 The second direction (longitudinal) is shown. Typically, the aforementioned connection end can be a connecting copper busbar, such as a flat, rectangular copper (electrical) connection structure.

[0069] In this embodiment, multiple connection terminals may originate from the same electrical module / component, or they may originate from multiple different electrical modules / components.

[0070] like Figure 1 As shown, in a typical embodiment, the conductors (connection ends) measured by the current sensing device are all parallel to each other and extend in a second direction (longitudinal direction), which is perpendicular to the aforementioned first direction.

[0071] In one embodiment, at least one group of adjacent current sensors are staggered relative to each other along a second direction. Specifically, such as... Figure 1 As shown, two adjacent current sensors along the first direction, such as the two current sensors on the left and in the middle of the figure, are positioned such that the left current sensor is positioned relatively lower (i.e. offset in the negative direction of the second direction), while the middle current sensor is positioned relatively higher (i.e. offset in the positive direction of the second direction). The offset between the two sensors is such that the lower end of the middle current sensor is located above the upper end of the left current sensor.

[0072] Explanatory, the use of "a group of adjacent" devices in the embodiments refers to two adjacent devices of the same kind, such as current sensors, interconnecting terminals, etc., and there are no other devices of the same kind between them.

[0073] Therefore, the two adjacent current sensors are staggered in the second direction, so that the conductors (connecting ends) carrying the two current sensors can be placed closer together, or, with the spacing between the conductors (connecting ends) fixed, the current sensors can have a larger width and a larger thickness.

[0074] The current sensor in the embodiments typically includes a magnetic core fitted around the outer periphery of a conductor. The thickness and width of the magnetic core 110 determine the overall thickness and width of the current sensor. In the embodiments of this application, as... Figure 7 As shown, the thickness of the magnetic core 110 is mainly the thickness h of the two sides (left and right sides in the figure) along the first direction, and the width is mainly the width w along the first direction.

[0075] In a typical embodiment, the current sensor 100 is a non-contact current sensor with a magnetic core 110, wherein the magnetic core is made of a high permeability material, such as ferrite, silicon steel sheet or permalloy, for focusing the magnetic field generated by the current in the conductor being measured, and based on the aforementioned magnetic field, obtaining the current parameter to be measured by a sensing element such as a sensing chip 120.

[0076] like Figure 7 As shown, the magnetic core 110 has an air gap 1101, as... Figure 2 As shown, the aforementioned sensor chip 120 is disposed within the air gap 1101.

[0077] The magnetic core 110 is shaped to at least partially surround the conductor being measured, for example, as shown in the image. Figure 7 The diagram shows a U-shaped magnetic core (U CORE), through which the conductor being tested passes. The conductor passes through the hollowed-out center region 1102 of the magnetic core.

[0078] In an optional embodiment, the magnetic core may also include multiple C-shaped magnetic cores (not shown in the figures), for example, consisting of two symmetrical semi-annular C-shaped magnetic cores. When the two magnetic cores are closed, they form a rectangular or circular magnetic circuit, with an air gap in the middle for mounting the sensor chip.

[0079] In this embodiment, the sensing chip is specifically a Hall effect sensing chip.

[0080] In an embodiment, such as Figure 1 As shown, the magnetic cores of at least one group of adjacent current sensors 100 do not overlap in projection along the first direction; in other words, the distance between the two projections is 0 or has a gap g as shown in the figure. Specifically, the projection along the first direction can be a projection on a plane perpendicular to the first direction.

[0081] In the foregoing embodiments, due to the staggered arrangement of adjacent magnetic cores, the thickness h of the two sides of the magnetic core, or the overall width w (width along the first direction), can be larger, such as... Figure 1 As shown, the edges of the left and right sides of the magnetic core can be staggered in the first direction, that is, they have... Figure 1 The overlap distance s is shown in the figure. In contrast, in the prior art, since the magnetic cores of each current sensor 100 are all flush (along the second direction), the magnetic core thickness can only reach a maximum of d / 2 when the distance between the conductors to be measured is d. However, in the embodiments of this application, the magnetic core width h can be greater than d / 2. In other words, in the embodiments, the sum of the thickness h of the magnetic cores 110 of at least one group of adjacent current sensors on opposite sides along the first direction can be greater than the distance d between the corresponding two conductors.

[0082] like Figure 1As shown, for at least one set of cores 110 of adjacent current sensors, the projections along the second direction at least partially overlap, that is, there is an overlapping region with a width of s in the figure. Specifically, the adjacent cores 110 take the second direction (the longitudinal direction in the figure) as the projection direction, and the orthographic projections on a plane perpendicular to the second direction (as the projection plane) at least partially overlap.

[0083] Typically, the embodiments in the present application are applicable to application scenarios including three conductors (connection ends), such as three-phase connection ends, for respectively measuring the currents of three phases. Specifically, as Figure 2 or Figure 3 shown, the current sensors include a first current sensor 101, a second current sensor 102, and a third current sensor 103 whose projections on the first plane are arranged in sequence along the first direction in the figure.

[0084] As Figure 2 or Figure 3 shown, along the second direction: the first current sensor 101 and the third current sensor 103 are arranged side by side, that is, their heights in the second direction in the figure are the same.

[0085] In a typical embodiment, as Figure 2 shown, the second current sensor 102 is adjacent to the distal ends of the first current sensor 101 and the third current sensor 103 along the second direction, that is, the second current sensor 102 is arranged above the first current sensor 101 and the third current sensor 103, and the first current sensor 101 and the third current sensor 103 are arranged side by side below the second current sensor 102; the first current sensor 101, the second current sensor 102, and the third current sensor 103 form a layout in the shape of a "pin" or a "mountain".

[0086] In another embodiment, as Figure 3 shown, the second current sensor 102 is adjacent to the proximal ends of the first current sensor 101 and the third current sensor 103 along the second direction, that is, the second current sensor 102 is arranged below the first current sensor 101 and the third current sensor 103, and the first current sensor 101 and the third current sensor 103 are arranged side by side above the second current sensor 102, and the first current sensor 101, the second current sensor 102, and the third current sensor 103 form an inverted "pin" - shaped layout.

[0087] In another embodiment, as Figure 5 or Figure 6 shown, in the second direction, the first current sensor 101 and the third current sensor 103 may be uneven, that is, as shown in the figure, there is a height difference between the two. Combining the foregoing embodiments, it can form as Figure 5 or Figure 6 As shown, it is an approximately regular / upside-down "pin" shape, but the layout form at both ends is asymmetric.

[0088] In an optional embodiment, multiple current sensors 100 are arranged in sequence along a first direction, and the distance between the device (such as the power module body 200) connected to the conductor along a second direction increases or decreases. For example, as Figure 4 shown, the first current sensor 101, the second current sensor 102, and the third current sensor 103 can be arranged along an inclined (compared with the first direction or the second direction) straight line. For example, the second current sensor 102 is arranged at the far end of the first current sensor 101 along the second direction, and the third current sensor 103 is arranged at the far end of the second current sensor 102 along the second direction; or, the second current sensor 102 is arranged at the proximal end of the first current sensor 101 along the second direction, and further, the third current sensor 103 is arranged at the proximal end of the second current sensor 102 along the second direction.

[0089] In an optional embodiment, the magnetic cores 110 of the first current sensor 101, the second current sensor 102, and the third current sensor 103 and the air gaps 1101 all face the same direction. For example Figure 1 as shown, the air gaps 1101 all face the observation direction in the figure. Similarly, the sensing chips in the three current sensors are all arranged on the same side of each conductor (connection end), and this setting helps to improve the consistency of current measurement of each conductor.

[0090] In an optional embodiment, the air gaps 1101 of adjacent current sensor magnetic cores are arranged to face in opposite directions. For example, the air gaps 1101 of the magnetic cores of the first current sensor 101 and the third current sensor 103 face Figure 1 the observation direction in Figure 1 while the air gap 1101 of the magnetic core of the second current sensor 102 faces away from

[0091] the observation direction in Figures 1 to 3 i.e., it is blocked behind the conductor (connection end) in the middle.

[0092] In an optional embodiment, for at least one group of adjacent current sensors, the gap g between them along the second direction is 1 mm or more, such as 1 mm, 1.2 mm, 1.3 mm, etc.

[0093] In an optional embodiment, the distance between the magnetic core of the current sensor and other adjacent conductors is controlled to be 1 mm or more, such as 1 mm, 1.2 mm, 1.3 mm, etc.

[0094] This application also provides an embodiment of a power module, specifically as follows: Figure 1 As shown, the device includes a power module body 200, a plurality of interconnecting terminals 201 disposed on the outside of the power module body 200 and arranged along a first direction on a first plane, and a plurality of current sensors 100 disposed on the plurality of interconnecting terminals 201 in a corresponding manner; wherein at least one group of adjacent current sensors are staggered along a second direction, the second direction being perpendicular to the first direction.

[0095] In an optional embodiment, the aforementioned plurality of interconnecting ends 201 may not be coplanar; for example, some interconnecting ends 201 may have an orientation... Figure 1 The observation direction is either in the direction of observation or tilted away from the aforementioned observation direction; or, some of the phase connection ends 201 are parallel to other phase connection ends, but have an offset toward or away from the aforementioned observation direction.

[0096] In a typical embodiment, the power module body 200 includes a substrate and multiple chips, as well as necessary heat dissipation and support structures.

[0097] In a typical embodiment, the power module is a three-phase power module, which is provided with a rectifier circuit structure or an inverter circuit structure, and includes three phase connection terminals (e.g., phase copper busbars). Three current sensors 100 are respectively disposed on the three phase connection terminals to detect the three-phase current of the power module.

[0098] It should be understood that the power module body 200 in the embodiment is provided with electronic components and necessary electrical connection structures, such as conductor strips, conductor patterns or flying wires, required to form a three-phase rectifier circuit or a three-phase inverter circuit.

[0099] In the embodiment, the current sensor 100 provided on each phase connection terminal 201 of the aforementioned power module includes a magnetic core 110 and a sensing chip 120. The magnetic core 110 at least partially surrounds the corresponding connection terminal 201 and has an air gap 1101; the sensing chip 120 is disposed within the air gap 1101.

[0100] In the embodiment, the magnetic core 110 disposed on any phase connection terminal 201 of the aforementioned power module is shaped such that it at least partially surrounds the phase connection terminal 201 under test, for example, as shown in the figure. Figure 7 The diagram shows a U-shaped magnetic core (U CORE), with the measured phase connection end 201 passing through the hollowed-out center 1102 region of the core. Optionally, the magnetic core may also include multiple C-shaped magnetic cores (not shown in the figure), such as two symmetrical semi-annular C-shaped magnetic cores. When the two magnetic cores are closed, they form a rectangular or circular magnetic circuit, with an air gap in the middle for mounting the sensor chip 120.

[0101] In a preferred embodiment, the sensing chip 120 is specifically a Hall sensing chip.

[0102] In a typical embodiment, at one end of the power module body 200, three connection terminals 201 are arranged in sequence along a first direction, and each connection terminal 201 extends along a second direction. Among them, the magnetic cores 110 of at least one group of adjacent current sensors at least partially overlap in the projection along the second direction. As Figure 1 shown, in an optional embodiment, for at least one group of adjacent current sensors, the gap g between the two along the second direction is 1 mm or more, such as 1 mm, 1.2 mm, 1.3 mm, etc.

[0103] In an optional embodiment, the distance between the magnetic core of the current sensor and the other adjacent connection terminal 201 is controlled to be 1 mm or more, such as 1 mm, 1.2 mm, 1.3 mm, etc.

[0104] Since the adjacent magnetic cores 110 are arranged in a staggered manner, in the embodiment, the sum of the thicknesses of the opposite sides of the magnetic cores 110 of at least one group of adjacent current sensors along the first direction can be greater than the distance between the projections of the corresponding two connection terminals 201 on the first plane.

[0105] In the embodiment, as Figure 2 or Figure 3 shown, the plurality of current sensors 100 include a first current sensor 101, a second current sensor 102, and a third current sensor 103 whose projections on the first plane are arranged in sequence along the first direction. Correspondingly, the power module includes three connection terminals 201 to be measured, which respectively correspond to the U, V, and W phases of the three-phase circuit.

[0106] Along the second direction:

[0107] The first current sensor 101 and the third current sensor 103 are arranged side by side.

[0108] As Figure 3 shown, the second current sensor 102 is arranged between the power module body 200 and the first current sensor 101 and the third current sensor 103, that is, the three current sensors are arranged in an inverted "pin" shape.

[0109] Alternatively, the second current sensor 102 can be arranged on the side of the first current sensor 101 and the third current sensor 103 away from the power module body 200. In other words, the three current sensors are arranged in a "pin" shape.

[0110] In another embodiment, as Figure 5 or Figure 6As shown, in the second direction, the first current sensor 101 and the third current sensor 103 may not be aligned, that is, as shown in the figure, there is a height difference between the two. Combining with the foregoing embodiments, it can form as Figure 5 or Figure 6 shown, an approximate positive / inverted "pin" shape, but the layout form with asymmetric ends.

[0111] In an alternative embodiment, multiple current sensors 100 are arranged in sequence along the first direction, and the distance from the power module body 200 along the second direction increases or decreases. For example, as Figure 4 shown, the first current sensor 101, the second current sensor 102, and the third current sensor 103 may be arranged in an inclined (compared with the first direction or the second direction) straight line. For example, the second current sensor 102 is arranged at the distal end of the first current sensor 101 along the second direction, and the third current sensor 103 is arranged at the distal end of the second current sensor 102 along the second direction; or, the second current sensor 102 is arranged at the proximal end of the first current sensor 101 along the second direction, and further, the third current sensor 103 is arranged at the proximal end of the second current sensor 102 along the second direction.

[0112] It should be understood that in the foregoing embodiments of the current sensing device, the features possessed by each current sensor 100 can all be applied to the power module provided by the embodiments. Limited by space, they are not listed repeatedly in this application.

[0113] In the prior art, power modules, such as power generation modules or drive modules based on Insulated Gate Bipolar Transistors (IGBTs), all adopt half-bridge packaging. Specifically, three mutually independent substrates are provided, and a half-bridge (Half-Bridge, including 1 bridge arm and 2 switching devices) module is arranged on each substrate, and a three-phase full-bridge (Three-Phase Full-Bridge, including 3 bridge arms and 6 switching devices) module is formed by the half-bridge modules distributed on the three substrates (or a bridge circuit module with more phases is formed by more half-bridge modules). In addition, the three substrates need to be welded to the copper substrate separately.

[0114] Among them, a connection end 201 is correspondingly arranged on one side of each half-bridge module, and the current sensor installed on the connection end 201, especially the magnetic core with a certain width in the current sensor, makes it impossible to arrange the adjacent connection ends 201 close to each other, which hinders the integration of the corresponding half-bridge modules to a certain extent.

[0115] In the aforementioned embodiments, by staggering the magnetic cores 110 on adjacent phase connection terminals 201, each adjacent phase connection terminal 201 can be arranged close to each other, making it possible to integrate multiple half-bridge modules that were originally disposed on different substrates. Therefore, in the preferred embodiment, multiple half-bridge modules in the power module are integrated and disposed on the same substrate.

[0116] Specifically, the power module body 200 includes a substrate and multiple chips; the multiple chips are disposed on the same substrate to form the bridge arms of multiple phases in a multiphase bridge topology circuit; the multiple phase connection terminals 201 are electrically connected to the bridge arms of the multiple phases in a one-to-one correspondence.

[0117] The aforementioned chips specifically include power switch chips (such as IGBTs or silicon carbide field-effect transistors SiCMOSFETs) and diode chips (such as Fast Recovery Diodes, FRDs).

[0118] The aforementioned multiphase bridge topology circuit specifically includes a symmetrical circuit structure composed of power switches and diodes, used to realize the conversion of electrical energy from DC to AC or from AC to DC.

[0119] Typically, the aforementioned multiphase bridge topology circuit can be specifically a three-phase full-bridge circuit, which includes six switching devices to generate three-phase alternating current (inverter mode) or convert three-phase alternating current into direct current (rectifier mode).

[0120] In one embodiment, the bridge arms of any two phases in the three-phase full-bridge circuit of the power module are integrated on the same substrate, and the remaining bridge arm is formed separately on another substrate, thus forming a half-bridge module and a full-bridge (containing 2 bridge arms and 4 switching devices) module, which together constitute a three-phase full-bridge module. In this embodiment, the magnetic cores disposed on the two phase connection terminals 201 corresponding to the two phase bridge arms integrated on the same substrate are offset from each other along a second direction.

[0121] In a typical embodiment, a substrate in the power module body 200, on which multiple power switch chips and diode chips are disposed, are used to form a three-phase full-bridge circuit. For example, on the same substrate, six insulated-gate bipolar transistor chips and six corresponding fast recovery diode chips are disposed simultaneously to form three phase bridge arms. In this embodiment, the three-phase full-bridge circuit includes three phase connection terminals 201, and a first current sensor 101, a second current sensor 102, and a third current sensor 103 respectively disposed on the three phase connection terminals 201, with the magnetic cores 110 of adjacent current sensors staggered along a second direction.

[0122] In a typical embodiment, the aforementioned power module is configured as a power generation module, or it may also be configured as a drive module, depending on the specific device connected to the connection terminal 201 during application and the actual function performed by the power module. For example, when the connection terminal 201 is connected to a generator and the power module functions as a rectifier, the power module constitutes a power generation module; similarly, when the connection terminal 201 is connected to a motor and the power module functions as an inverter, the power module constitutes a drive module.

[0123] This application provides a power module, such as... Figure 1 or Figure 2 As shown, the system includes a power module body 200, at least two connection terminals 201 disposed on the power module body 200, and at least two magnetic cores 110 disposed on the at least two connection terminals 201. The projections of the at least two connection terminals 201 on the first plane are arranged along a first direction.

[0124] At least two magnetic cores on at least two connected ends 201 are offset from each other along a second direction;

[0125] The second direction intersects the first direction, and the first plane is parallel to both the first and second directions.

[0126] In the foregoing embodiment, more specifically, the direction perpendicular to the first plane is used as the projection direction. Along this projection direction, the orthographic projections of at least two connected ends 201 on the first plane are arranged along the first direction, i.e., along... Figure 1 The horizontal arrangement within.

[0127] In the aforementioned embodiment, the magnetic core is misaligned in the second direction (vertical direction in the figure), which saves the spacing between the connected ends 201 in the first direction (horizontal direction in the figure), allowing the copper busbars to be placed closer together and improving the integration.

[0128] In an optional embodiment, the second direction is perpendicular to the first direction.

[0129] In an optional embodiment, each phase connection end 201 is respectively provided with a magnetic core 110;

[0130] The magnetic cores 110 of two adjacent connected ends 201 at least partially overlap in the projection on the first plane in the first direction.

[0131] In the aforementioned embodiments, the spacing in the first direction (horizontal direction in the figure) between the connected terminals 201 is further reduced, resulting in better integration.

[0132] In a preferred embodiment, the magnetic core 110 has a gap of at least 1 mm with the adjacent connection terminal 201 to ensure electrical isolation between the magnetic core 110 and the connection terminal 201.

[0133] In a preferred embodiment, at least two adjacent magnetic cores 110 each extend in a direction perpendicular to the first plane, and the sum of the thicknesses of the two adjacent portions along the first direction is greater than the distance between the projections of the corresponding two connected ends 201 on the first plane along the first direction.

[0134] Combination Figures 1 to 6 ,as well as Figure 7 In one embodiment, for example, for two adjacent magnetic cores 110, the sum of the thickness h on the right side of the left magnetic core and the thickness h on the left side of the right magnetic core is less than the distance between the connecting ends of the two magnetic cores.

[0135] In the aforementioned embodiments, the thickness of the magnetic core can break through the limitation of the gap distance between the connecting ends, the cross-sectional area of ​​the magnetic core can be made larger, and the problem of magnetic saturation is less likely to occur. On the other hand, the power module has better integration.

[0136] In a typical embodiment, it includes three phase connection terminals 201, and each phase connection terminal 201 is respectively provided with a magnetic core 110; the magnetic core 110 includes a first magnetic core 111, a second magnetic core 112 and a third magnetic core 113 whose projections on the first plane are arranged sequentially along the first direction;

[0137] Along the second direction, the second magnetic core 112 is disposed between the power module body 200 and the first magnetic core 111, and the second magnetic core 112 is disposed between the power module body 200 and the third magnetic core 113;

[0138] or,

[0139] Along the second direction, the first magnetic core 111 is disposed between the power module body 200 and the second magnetic core 112, and the third magnetic core 113 is disposed between the power module body 200 and the second magnetic core 112.

[0140] In an alternative embodiment, the first magnetic core 111 and the third magnetic core 113 are arranged side by side along the second direction.

[0141] In an optional embodiment, at least two magnetic cores 110 are arranged sequentially along a first direction, and their distance from the power module body 200 along a second direction increases or decreases.

[0142] In a typical embodiment, the power module body 200 includes multiple chips constituting multiphase bridge arms; the chips in at least two bridge arms are disposed on the same substrate, and at least two phase connection terminals 201 are electrically connected to at least two phase bridge arms in a one-to-one correspondence.

[0143] In a typical embodiment, the power module body 200 is configured as a power generation module for connection with a generator motor.

[0144] In an optional embodiment, due to the integration of the phase bridge arms on the same backing plate, the spacing between adjacent phase connection ends 201 is 14mm to 7mm. Preferably, the spacing between adjacent phase connection ends 201 is 8mm to 7mm. More preferably, the minimum spacing between adjacent phase connection ends 201 can be 7mm, for example, values ​​of 7.5mm to 7mm, 7.4mm to 7mm, 7.3mm to 7mm, 7.2mm to 7mm, 7.1mm to 7mm, or the nominal spacing between adjacent phase connection ends 201 is 7mm.

[0145] The solutions in this application are applicable to power modules with a small spacing between the interconnecting ends 201 after integration, especially power modules with a spacing of 14mm to 7mm between the interconnecting ends 201, and power modules with a minimum spacing of about 7mm between the interconnecting ends 201. This application also provides a motor controller, which includes the power module described in the foregoing embodiments and any of their preferred, optional, or typical embodiments.

[0146] This application also provides an electric drive assembly, which includes a motor controller as described in the foregoing embodiments and any of their preferred, optional or typical embodiments.

[0147] This application also provides a vehicle that includes the drive assembly described in the foregoing embodiments and any of their preferred, optional or typical embodiments.

[0148] The power module, motor controller, and (electric) drive assembly involved in the foregoing embodiments are particularly suitable for range-extended new energy vehicles, and the vehicle involved in the foregoing embodiments is also preferably a range-extended new energy vehicle. To provide a more comprehensive disclosure of this application, the following is an illustrative description of range-extended new energy vehicles.

[0149] Range-extended electric vehicles have the following topology: Figure 9 As shown.

[0150] The core component of a range-extended electric vehicle is the range extender. Its main function is to activate the range extender when the battery charge drops to a certain level, causing the engine to drive a generator to produce electricity. Part of the generated electricity can be used to power the drive motor, and the other part can be used to charge the battery.

[0151] Range-extended electric vehicles (REEVs) have many advantages. For example, in daily urban commuting, REEVs can be driven purely on electricity, achieving zero emissions, reducing exhaust pollution, and meeting environmental protection requirements. They are also more energy-efficient than fuel-powered vehicles, reducing energy consumption and operating costs. REEVs are equipped with an engine as a range extender. When the battery is low, the engine can start to generate electricity, providing continuous power to the vehicle. This avoids the range anxiety problem caused by the limited range of pure electric vehicles, making long-distance travel more convenient.

[0152] Furthermore, range-extended electric vehicles (REEVs) offer numerous advantages in terms of driving experience. Essentially, a REEV is a pure electric drive system where the vehicle's power comes entirely from the electric motor. The engine does not directly drive the vehicle but instead acts as a generator, starting when the battery is low to convert fuel into electricity to power the electric motor or charge the battery. This pure electric drive method ensures a single and pure power source, consistent with the driving mechanism of pure electric vehicles, fundamentally guaranteeing a comfortable driving experience.

[0153] On the other hand, the characteristics of electric motors determine that they can output maximum torque instantly. In range-extended electric vehicles, when the driver presses the accelerator pedal, the electric motor can respond quickly and output powerful force to achieve rapid start and acceleration. This instantaneous power response is far superior to that of traditional fuel vehicles, allowing the driver to feel a more direct and rapid push-back feeling. Whether it is in the frequent start-stop of urban roads or overtaking operations on highways, it can easily cope with the situation and bring a smooth driving experience.

[0154] On the other hand, during the driving process of a range-extended vehicle, since it is always driven by an electric motor, there is no power interruption problem when shifting gears as in traditional fuel vehicles. Whether driving at low speed or high speed, the power output remains continuous and stable. Even when the battery is low, during the process of the engine starting to generate electricity, the system can ensure that the power output of the electric motor is not affected through a precise control strategy, without any jerking or power interruption. This provides the driver with a consistently stable driving experience, improving driving comfort and safety.

[0155] Currently, the electric drive assembly of range-extended electric vehicles includes components such as a generator, a drive motor, a generator controller, and a drive motor controller. Among them, the generator controller and the drive motor controller are two independent components, each with its own power module, current sensor, temperature sensor, and motor rotor position sensor, etc. Their weight, size, and cost are relatively high, and they urgently need to be optimized, which is one of the original intentions of this application.

[0156] In summary, the embodiments of this application, by setting the position of the current sensor magnetic core, can increase the width and thickness of each magnetic core, effectively avoiding magnetic core saturation and the resulting current detection inaccuracy, ensuring measurement accuracy and low crosstalk and attenuation phase shift.

[0157] On the other hand, while ensuring the width and thickness of each sensor core, the spacing between adjacent connection ends (especially the connection ends between power modules) can be reduced. Combined with the scheme of integrating multiple bridge arms in the power module onto the same substrate, the overall size of the power module can be effectively reduced, which helps to promote the miniaturization and integration of power modules and related components.

Claims

1. A power module, characterized in that, It includes a power module body (200), at least two phase connection ends (201) disposed on the power module body (200), and at least two magnetic cores (110) disposed on the at least two phase connection ends (201). The projections of the at least two connected ends (201) on the first plane are arranged along the first direction; At least two magnetic cores on at least two connected ends (201) are offset from each other along a second direction; The second direction intersects the first direction, and the first plane is parallel to both the first and second directions.

2. The power module according to claim 1, characterized in that, The second direction is perpendicular to the first direction.

3. The power module according to claim 1 or 2, characterized in that, Each of the phase connection terminals (201) is respectively provided with a magnetic core (110); The magnetic cores (110) of two adjacent connected ends (201) at least partially overlap in a first direction when projected onto a first plane.

4. The power module according to claim 3, characterized in that, The magnetic core (110) has a gap of at least 1 mm with the adjacent phase connection end (201).

5. The power module according to any one of claims 1 to 4, characterized in that, At least two adjacent magnetic cores (110) each extend in a direction perpendicular to the first plane, and the sum of the thicknesses of the two adjacent portions along the first direction is greater than the distance between the projections of the corresponding two connected ends (201) on the first plane along the first direction.

6. The power module according to any one of claims 1 to 5, characterized in that, It includes three phase connection terminals (201), each of the phase connection terminals (201) is respectively provided with a magnetic core (110); the magnetic core (110) includes a first magnetic core (111), a second magnetic core (112) and a third magnetic core (113) whose projections on the first plane are arranged sequentially along the first direction. Along the second direction, the second magnetic core (112) is disposed between the power module body (200) and the first magnetic core (111), and the second magnetic core (112) is disposed between the power module body (200) and the third magnetic core (113); or, Along the second direction, the first magnetic core (111) is disposed between the power module body (200) and the second magnetic core (112), and the third magnetic core (113) is disposed between the power module body (200) and the second magnetic core (112).

7. The power module according to claim 6, characterized in that, Along the second direction, the first magnetic core (111) and the third magnetic core (113) are arranged side by side.

8. The power module according to any one of claims 1 to 7, characterized in that, The at least two magnetic cores (110) are arranged sequentially along a first direction, and the distance between them and the power module body (200) along a second direction increases or decreases.

9. The power module according to any one of claims 1 to 8, characterized in that, The power module body (200) includes multiple chips constituting multiphase bridge arms; the chips in at least two of the multiphase bridge arms are disposed on the same substrate, and the at least two phase connection terminals (201) are electrically connected to the at least two phase bridge arms in a one-to-one correspondence.

10. The power module according to any one of claims 1 to 9, characterized in that, The power module body (200) is configured as a power generation module for connection with a generator motor.

11. The power module according to any one of claims 1 to 10, characterized in that, The spacing between adjacent connecting ends (201) is 14 mm to 7 mm.

12. A motor controller, characterized in that, Includes the power module as described in any one of claims 1 to 11.

13. An electric drive assembly, characterized in that, Including the motor controller as described in claim 12.

14. A vehicle, characterized in that, Includes the electric drive assembly as described in claim 13.

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