Motor control device, electric drive system, and vehicle
The design of the axially extended controller housing and partition ribs solves the problems of space compactness and electromagnetic isolation of the motor controller, achieving high electromagnetic compatibility and a simplified assembly process, and improving the overall performance of the motor controller.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SCHAEFFLER TECHNOLOGIES AG & CO KG
- Filing Date
- 2025-04-01
- Publication Date
- 2026-06-09
AI Technical Summary
Existing motor controllers suffer from problems such as insufficient space compactness, complex internal layout, poor electromagnetic isolation performance, and low assembly efficiency in integrated design.
The controller housing features an axially extended design, with functional components arranged in sections at multiple mounting points. Electromagnetic isolation is achieved using partition ribs, and the modular design combined with coolant piping simplifies the assembly process.
It improves space utilization and integration, reduces electromagnetic interference, enhances electromagnetic compatibility and ease of assembly, and ensures reliable system operation.
Smart Images
Figure CN224343112U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of vehicles. More specifically, this utility model relates to a motor control device for vehicles. Background Technology
[0002] With the rapid development of new energy vehicles, the integrated design of motor controllers is receiving increasing attention. In existing technologies, the integration of the motor and motor controller typically employs an axial arrangement to save space and make the entire system more compact. However, while optimizing the controller's height, existing solutions often result in a slight increase in the controller's length and width, affecting overall compactness. Furthermore, existing technologies also have certain shortcomings in terms of electromagnetic isolation performance and ease of assembly.
[0003] For example, in some existing technical solutions, the core components of the motor controller are arranged in a relatively dispersed manner, resulting in a complex internal layout and low assembly efficiency; at the same time, electromagnetic interference problems have not been effectively solved, affecting the stability of the system. Therefore, how to optimize the internal layout, improve electromagnetic isolation performance, and simplify the assembly process while reducing the height of the motor controller has become a problem that urgently needs to be solved by those skilled in the art.
[0004] Therefore, a compact motor control device is needed. Utility Model Content
[0005] One objective of this invention is to provide a compact motor control device. Another objective is to provide a motor control device that is easy to assemble. A further objective is to provide a motor control device capable of improving electromagnetic isolation performance.
[0006] One aspect of this utility model provides a motor control device, comprising: a motor end cover; a controller housing having an axially extending inner cavity and connected to the motor end cover to form a receiving space, wherein the controller housing defines a first mounting portion, a second mounting portion, a third mounting portion, and a fourth mounting portion distributed in a plane perpendicular to the axial direction; a filter mounted to the first mounting portion of the controller housing; a low-voltage connector mounted to the second mounting portion of the controller housing; an AC busbar mounted to the third mounting portion of the controller housing; and a sub-assembly mounted to the fourth mounting portion of the controller housing.
[0007] According to an embodiment of the present invention, the sub-assembly includes: a capacitor bank, a power management module, and a printed circuit board assembly arranged in an axially overlapping manner, wherein the printed circuit board assembly is positioned closest to the motor end cover.
[0008] According to an embodiment of the present invention, the controller housing further includes a first coolant pipe and a second coolant pipe, and the sub-assembly further includes a third coolant pipe. When the sub-assembly is installed on the fourth mounting part of the controller housing, the inlet end of the third coolant pipe is in fluid communication with the first coolant pipe, and the outlet end of the third coolant pipe is in fluid communication with the second coolant pipe.
[0009] According to an embodiment of the present invention, the controller housing further includes a partition rib disposed between the first mounting portion and the second mounting portion and extending axially, for electromagnetic isolation of the filter and the low-voltage connector.
[0010] According to an embodiment of the present invention, the motor control device further includes an AC module and three AC conductive posts, which are installed on the motor end cover, wherein the AC module, AC conductive posts and AC busbars are arranged to overlap axially.
[0011] According to an embodiment of the present invention, the motor control device further includes an input terminal, which is mounted to the controller housing and connected to a filter, such that the input terminal is partially located within and partially located outside the receiving space.
[0012] According to an embodiment of the present invention, the controller housing further includes a first window configured to allow access to the connection points of the input terminals and the filter from the outside of the controller housing, and the motor control device further includes a first window cover connected to the controller housing from the outside of the controller housing and covering the first window.
[0013] According to an embodiment of the present invention, the controller housing further includes a second window configured to allow access from the outside of the controller housing to the connection points of the AC busbar and the AC conductive post, and the motor control device further includes a second window cover connected to the controller housing from the outside of the controller housing and covering the second window.
[0014] One aspect of this utility model provides an electric drive system, including a motor control device according to an embodiment of this utility model.
[0015] One aspect of this utility model provides a vehicle including a motor control device according to an embodiment of this utility model.
[0016] In the motor control device and electric drive system including the motor control device according to embodiments of the present invention, the inner cavity of the controller housing of the motor control device extends axially, and the functional components of the motor control device are arranged in partitions through multiple mounting parts, avoiding axial overlap and improving space utilization and integration. By setting partition ribs, electromagnetic isolation between the filter and the low-voltage connector is effectively achieved, reducing near-field coupling and electromagnetic interference, and improving electromagnetic compatibility. The sub-assembly adopts a modular design, integrating the capacitor bank, power management module, and printed circuit board assembly into one unit, simplifying the assembly process and improving maintenance convenience. Through the coolant pipes inside the controller housing and the coolant pipes inside the sub-assembly, heat from key heat-generating components can be efficiently removed, ensuring reliable system operation. Furthermore, the windows and window covers on the controller housing facilitate the connection and maintenance of functional components, while providing good sealing and protection. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of an electric drive system including a motor controller according to an embodiment of the present invention.
[0018] Figure 2 This is an exploded view of a motor controller according to an embodiment of the present invention.
[0019] Figure 3 This is an axial schematic diagram of a motor controller according to an embodiment of the present invention.
[0020] Figure 4 This is an axial view of the other side of the motor controller according to an embodiment of the present invention.
[0021] Figure 5 This is an axial schematic diagram of the controller housing of a motor controller according to an embodiment of the present invention.
[0022] Figure 6 This is an axial view of the other side of the controller housing of the motor controller according to an embodiment of the present invention. Detailed Implementation
[0023] Hereinafter, embodiments of the present invention are described with reference to the accompanying drawings. The following detailed description and drawings are provided to exemplarily illustrate the principles of the present invention. The present invention is not limited to the described preferred embodiments, and the scope of the present invention is defined by the claims. The present invention will now be described in detail with reference to exemplary embodiments, some of which are illustrated in the accompanying drawings. The following description is made with reference to the accompanying drawings, and unless otherwise indicated, the same reference numerals in different drawings represent the same or similar elements. The solutions described in the following exemplary embodiments do not represent all solutions of the present invention. Rather, these solutions are merely examples of systems and methods of various aspects of the present invention covered by the appended claims.
[0024] This invention provides a motor control device. The motor control device according to embodiments of this invention can be installed in vehicles, particularly electric or hybrid vehicles. More specifically, the electric drive system of a vehicle may include the motor control device. Exemplary embodiments of this invention are now described with reference to the accompanying drawings. It should be understood that only certain embodiments of this invention are shown in the drawings, and the scope of this invention should be determined according to the claims.
[0025] Figure 1 This is a schematic diagram of an electric drive system including a motor controller according to an embodiment of the present invention. Figure 2 This is an exploded view of a motor controller according to an embodiment of the present invention. Figure 3 This is an axial schematic diagram of a motor controller according to an embodiment of the present invention. Figure 4 This is an axial view of the other side of the motor controller according to an embodiment of the present invention. Figure 5 This is an axial schematic diagram of the controller housing of a motor controller according to an embodiment of the present invention. Figure 6 This is an axial view of the other side of the controller housing of the motor controller according to an embodiment of the present invention.
[0026] According to embodiments of the present invention, such as Figure 1 As shown, the electric drive system includes a motor control unit 100, a motor 200, and a transmission 300. The motor 200 and the transmission 300 are arranged coaxially. The motor control unit 100 is used to control the operation of the motor 200. In an exemplary embodiment, the transmission 300 and the motor control unit 100 are respectively disposed on opposite axial sides of the motor 200.
[0027] According to embodiments of the present invention, such as Figures 1 to 5The motor control device 100 includes a motor end cover 110 and a controller housing 120. The controller housing 120 has an axially extending inner cavity. The controller housing 120 is axially connected to the motor end cover 110, thereby forming a receiving space between the motor end cover 110 and the controller housing 120. It should be understood that the motor end cover 110 is a shared component of the motor 200 and the motor control device 100, forming, on the one hand, a receiving cavity for the motor 200 to house the stator and rotor of the motor 200, and on the other hand, a receiving space for the motor control device 100 to house the functional components of the motor control device 100. In an exemplary embodiment, the controller housing 120 is bolted to the motor end cover 110. In some embodiments, the motor end cover 110 and the controller housing 120 may be made of aluminum alloy or the like.
[0028] According to embodiments of the present invention, such as Figure 2 and Figure 5 As shown, the controller housing 120 includes a first mounting portion 121, a second mounting portion 122, a third mounting portion 123, and a fourth mounting portion 124 located within its inner cavity. The first mounting portion 121, the second mounting portion 122, the third mounting portion 123, and the fourth mounting portion 124 are distributed in a plane perpendicular to the axial direction, so that the mounting portions do not overlap axially. This rational layout of the mounting portions achieves the partitioned arrangement of various functional components, which is beneficial for improving integration and optimizing space utilization. Each mounting portion may be provided with corresponding mounting holes and positioning structures.
[0029] According to an embodiment of the present invention, the motor control device 100 further includes a filter 130, which is mounted to a first mounting portion 121 of the controller housing 120. The filter 130 is used to suppress electromagnetic interference, smooth voltage, and protect the battery on the high-voltage side. In an exemplary embodiment, the filter 130 is connected to the first mounting portion 121 by bolts.
[0030] According to an embodiment of the present invention, the motor control device 100 further includes an input terminal 131 for mounting to the controller housing 120 and connecting to the filter 130. In an exemplary embodiment, the input terminal 131 is bolted to the controller housing 120. Figure 3 As shown, input terminal 131 is partially located within and partially located outside the housing of motor control device 100. The portion of input terminal 131 located outside the housing of motor control device 100 can be connected to the vehicle's power battery. The portion of input terminal 131 located within the housing of motor control device 100 is connected to filter 130.
[0031] According to an embodiment of the present invention, the motor control device 100 further includes a low-voltage connector 140, which is mounted to a second mounting portion 122 of the controller housing 120. The low-voltage connector 140 is used to transmit control signals, sensor data, etc. In an exemplary embodiment, the low-voltage connector 140 is connected to the second mounting portion 122 by bolts.
[0032] In an exemplary embodiment, the controller housing 120 further includes a partition rib 125 disposed between the first mounting portion 121 and the second mounting portion 122 and extending axially. The partition rib 125 provides electromagnetic isolation between the filter 130 mounted to the first mounting portion 121 and the low-voltage connector 140 mounted to the second mounting portion 122. Due to its axial height, the partition rib 125 effectively avoids or reduces near-field coupling and electromagnetic interference between the filter 130 and the low-voltage connector 140. In some embodiments, the axial height of the partition rib 125 is greater than the axial thickness of the filter 130 and / or the axial thickness of the low-voltage connector 140.
[0033] According to an embodiment of the present invention, the motor control device 100 further includes an AC busbar 151, which is mounted to a third mounting portion 123 of the controller housing 120. In an exemplary embodiment, the AC busbar 151 is connected to the third mounting portion 123 by bolts.
[0034] According to an embodiment of this utility model, the motor control device 100 further includes an AC module 152 and three AC conductive posts 153. The AC busbar 151, AC module 152, and AC conductive posts 153 are arranged axially overlapping to form an AC output module, used to output three-phase AC power to the motor 200 to control the operation of the motor 200. The AC conductive posts 153 are respectively inserted into the through holes of the AC module 152 and connected to the three output terminals of the AC busbar 151.
[0035] In an exemplary embodiment, such as Figure 4 As shown, AC module 152 and AC conductive post 153 are mounted to motor end cover 110. More specifically, AC conductive post 153 is inserted into AC module 152, and AC module 152 is connected to motor end cover 110. In an exemplary embodiment, AC module 152 is bolted to motor end cover 110. Thus, when motor end cover 110 is connected to controller housing 120, AC conductive post 153 inserted into AC module 152 can be connected to AC busbar 151.
[0036] According to an embodiment of the present invention, the motor control device 100 further includes a sub-assembly 160, which is mounted to a fourth mounting portion 124 of the controller housing 120. In an exemplary embodiment, the sub-assembly 160 is bolted to the fourth mounting portion 124.
[0037] Subassembly 160 employs a modular design. In an exemplary embodiment, subassembly 160 includes a capacitor bank 161, a power management module 162, and a printed circuit board assembly 163 arranged sequentially and overlappingly along the axial direction. In subassembly 160, the printed circuit board assembly 163 is positioned closest to the motor end cover 110. The capacitor bank 161 is electrically connected to the output of the filter 130, for example, as a DC-LINK capacitor. The power management module 162 is disposed between the capacitor bank 161 and the printed circuit board assembly 163 for voltage conversion and power supply. The printed circuit board assembly 163 is used to execute motor control algorithms and signal processing and is electrically connected to a low-voltage connector 140. By employing a modular design, subassembly 160 can be integrally mounted into the fourth mounting portion 124 of the controller housing 120 without requiring individual component installation.
[0038] According to an embodiment of the present invention, the controller housing 120 further includes a first coolant pipe 126 and a second coolant pipe 127. In some embodiments, the first coolant pipe 126 and the second coolant pipe 127 are formed in the housing wall of the controller housing 120. The sub-assembly 160 further includes a third coolant pipe (not shown). The third coolant pipe is disposed inside the sub-assembly 160 to be close to key heat-generating components, such as the capacitor bank 161. When the sub-assembly 160 is installed to the fourth mounting portion 124 of the controller housing 120, the inlet end of the third coolant pipe of the sub-assembly 160 is in fluid communication with the first coolant pipe 126, and the outlet end of the third coolant pipe is in fluid communication with the second coolant pipe 127. In this way, coolant can flow sequentially through the first coolant pipe 126, the third coolant pipe, and the second coolant pipe 127, effectively carrying away the heat generated by the sub-assembly 160.
[0039] In some embodiments, the motor control device 100 further includes an inlet 171 and an outlet 172. The inlet 171 is connected to a first coolant conduit 126 of the controller housing 120 for supplying coolant to the motor control device 100. The outlet 172 is connected to a second coolant conduit 127 of the controller housing 120 for discharging coolant from the motor control device 100.
[0040] According to an embodiment of the present invention, the controller housing 120 further includes a first window 181 for accessing the connection between the input terminal 131 and the filter 130 from the outside of the controller housing 120. In an exemplary embodiment, the first window 181 is disposed at the first mounting portion 121 of the controller housing 120. The first window 181 facilitates the connection and maintenance of the input terminal 131 and the filter 130. In some embodiments, the first window 181 includes a plurality of operating holes.
[0041] According to an embodiment of the present invention, the motor control device 100 further includes a first window cover 191, which is connected to the controller housing 120 from the outside of the controller housing 120 and covers the first window 181. The first window cover 191 serves both a protective and sealing function and facilitates maintenance operations. In an exemplary embodiment, the first window cover 191 is connected to the controller housing 120 by bolts.
[0042] According to an embodiment of the present invention, the controller housing 120 further includes a second window 182 for accessing the connection between the AC busbar 151 and the AC conductive post 153 from the outside of the controller housing 120. In an exemplary embodiment, the second window 182 is disposed at the second mounting portion 122 of the controller housing 120. The first window 181 facilitates the connection of the AC busbar 151 to the controller housing 120 by bolts from the outside of the controller housing 120, and also facilitates the connection of the AC busbar 151 to the AC conductive post 153. In some embodiments, the second window 182 includes a plurality of operating holes.
[0043] According to an embodiment of the present invention, the motor control device 100 further includes a second window cover 192, which is connected to the controller housing 120 from the outside of the controller housing 120 and covers the second window 182. The second window cover 192 serves both a protective and sealing function and facilitates maintenance operations. In an exemplary embodiment, the second window cover 192 is bolted to the controller housing 120.
[0044] In the motor control device and electric drive system including the motor control device according to embodiments of the present invention, the inner cavity of the controller housing of the motor control device extends axially, and the functional components of the motor control device are arranged in partitions through multiple mounting parts, avoiding axial overlap and improving space utilization and integration. By setting partition ribs, electromagnetic isolation between the filter and the low-voltage connector is effectively achieved, reducing near-field coupling and electromagnetic interference, and improving electromagnetic compatibility. The sub-assembly adopts a modular design, integrating the capacitor bank, power management module, and printed circuit board assembly into one unit, simplifying the assembly process and improving maintenance convenience. Through the coolant pipes inside the controller housing and the coolant pipes inside the sub-assembly, heat from key heat-generating components can be efficiently removed, ensuring reliable system operation. Furthermore, the windows and window covers on the controller housing facilitate the connection and maintenance of functional components, while providing good sealing and protection.
[0045] Although the present invention has been described with reference to exemplary embodiments, it should be understood that the present invention is not limited to the construction and methods of the above embodiments. Rather, the present invention is intended to cover various modifications and equivalent configurations. Furthermore, although various elements and method steps of the disclosed invention have been shown in various exemplary combinations and constructions, other combinations including more or fewer elements or methods also fall within the scope of the present invention.
[0046] List of reference signs
[0047] 100 motor control device;
[0048] 110 motor end cover;
[0049] 120 controller housing;
[0050] 121 First Installation Department;
[0051] 122 Second Installation Section;
[0052] 123 Third Installation Department;
[0053] 124 Fourth Installation Department;
[0054] 125 dividing ribs;
[0055] 126 First coolant pipe;
[0056] 127 Second coolant pipe;
[0057] 130 filter;
[0058] 131 input terminals;
[0059] 140 low-voltage connector;
[0060] 151 AC busbars;
[0061] 152 Communication Modules;
[0062] 153 AC conductive pillars;
[0063] 160-point assembly;
[0064] 161 capacitor bank;
[0065] 162 power management module;
[0066] 163 Printed Circuit Board Assembly;
[0067] 171 water inlet nozzle;
[0068] 172 water outlet;
[0069] 181 First Window;
[0070] 182 Second Window;
[0071] 191 First window cover;
[0072] 192 Second window cover;
[0073] 200 motor;
[0074] 300 transmission.
Claims
1. A motor control device (100), characterized in that, The motor control device (100) includes: Motor end cover (110); A controller housing (120) having an axially extending inner cavity and connected to the motor end cover (110) to form a receiving space, wherein the controller housing (120) defines a first mounting portion (121), a second mounting portion (122), a third mounting portion (123) and a fourth mounting portion (124) distributed in a plane perpendicular to the axial direction. A filter (130) is mounted to the first mounting portion (121) of the controller housing (120). A low-voltage connector (140) is mounted to the second mounting portion (122) of the controller housing (120). An AC busbar (151) is mounted to the third mounting portion (123) of the controller housing (120); and Sub-assembly (160) is mounted to the fourth mounting portion (124) of the controller housing (120).
2. The motor control device (100) according to claim 1, characterized in that, The subassembly (160) includes: a capacitor bank (161), a power management module (162), and a printed circuit board assembly (163) arranged in an axially overlapping manner, wherein the printed circuit board assembly (163) is positioned closest to the motor end cover (110).
3. The motor control device (100) according to claim 2, characterized in that, The controller housing (120) further includes a first coolant pipe (126) and a second coolant pipe (127), and the sub-assembly (160) further includes a third coolant pipe. When the sub-assembly (160) is installed on the fourth mounting part (124) of the controller housing (120), the inlet end of the third coolant pipe is in fluid communication with the first coolant pipe (126), and the outlet end of the third coolant pipe is in fluid communication with the second coolant pipe (127).
4. The motor control device (100) according to claim 3, characterized in that, The controller housing (120) also includes a partition rib (125) disposed between the first mounting portion (121) and the second mounting portion (122) and extending axially for electromagnetic isolation of the filter (130) and the low-voltage connector (140).
5. The motor control device (100) according to claim 4, characterized in that, The motor control device (100) further includes an AC module (152) and three AC conductive posts (153), which are mounted to the motor end cover (110). The AC module (152), the AC conductive post (153), and the AC busbar (151) are arranged in an axially overlapping manner.
6. The motor control device (100) according to claim 5, characterized in that, The motor control device (100) further includes: An input terminal (131) is mounted to the controller housing (120) and connected to the filter (130) such that the input terminal (131) is partially located within and partially located outside the receiving space.
7. The motor control device (100) according to claim 6, characterized in that, The controller housing (120) also includes a first window (181) configured to allow access from the outside of the controller housing (120) to the connection between the input terminal (131) and the filter (130), and The motor control device (100) also includes a first window cover (191) which is connected to the outside of the controller housing (120) and covers the first window (181).
8. The motor control device (100) according to claim 7, characterized in that, The controller housing (120) also includes a second window (182) configured to allow access from the outside of the controller housing (120) to the connection between the AC busbar (151) and the AC conductive post (153), and The motor control device (100) also includes a second window cover (192) which is connected to the controller housing (120) from the outside of the controller housing (120) and covers the second window (182).
9. An electric drive system, characterized in that, The electric drive system includes a motor control device (100) according to any one of claims 1 to 8.
10. A vehicle, characterized in that, The vehicle includes a motor control device (100) according to any one of claims 1 to 8.