Motor controller and vehicle with transfer busbar to adjust outgoing lines

Abstract

This utility model provides a motor controller and vehicle that utilizes an adapter busbar to adjust the outgoing lines. The controller includes a housing, a mechanism, an adapter busbar, and a terminal block. The adapter busbar includes a mounting bracket and two busbars. The mounting bracket has end face grooves, and a partition wall is provided between the two end face grooves. A positioning peripheral wall is provided on the outer periphery of the partition wall in each end face groove. A welding notch is provided above the positioning peripheral wall, and an exit notch is provided below the positioning peripheral wall. Through the mounting bracket arrangement of the adapter busbar, when the connecting plate is installed in the end face groove, the two busbars are spaced apart by the partition wall and welded to the connecting piece connected to the capacitor through the welding notch. The extension plate can extend to the terminal block position. By utilizing the fixed and extended design of the busbar, the input wiring through the circuit board is no longer required. Therefore, it is beneficial for convenient adjustment of the outgoing line position, optimization of the wiring layout, and miniaturization of the equipment.

Description

Technical Field

[0001] This utility model relates to the field of new energy equipment, and in particular to a motor controller and a vehicle that utilizes a transfer busbar to adjust the outgoing lines. Background Technology

[0002] New energy vehicles are characterized by being environmentally friendly and less polluting because they do not burn gasoline or diesel fuel. With the vigorous promotion and application of new energy power generation such as hydropower, wind power, solar power and nuclear power, many new energy vehicles are gradually being promoted and applied, such as new energy electric cars, new energy electric buses, new energy electric trucks, new energy electric cleaning vehicles, new energy electric rail transit vehicles, new energy electric air vehicles and new energy electric shipping vehicles.

[0003] The aforementioned vehicles generally have electrical equipment such as motor controllers, on-board chargers, on-board power supplies, inverters, or transformers. Taking the motor controller as an example, the power unit within the motor controller receives DC power from the battery and inverts it into AC power for output to the motor. Therefore, each power module corresponds to one phase of a three-phase motor, used to output one phase of the U, V, and W power supply to the motor. Each power module has two terminals for receiving DC power, used to receive positive and negative power respectively, and one current output terminal to output a current signal to one phase of the motor. When the motor controller receives DC power from the battery, it generally needs to pass through a filter circuit. The filter circuit has multiple capacitors. In existing technical solutions, these capacitors are generally soldered onto a circuit board, and the input DC copper busbar is also soldered onto the circuit board. The circuit connection is achieved through the copper-clad traces on the circuit board. This input wiring scheme is therefore inflexible in terms of output or wiring methods and is not conducive to the arrangement of terminal blocks. Utility Model Content

[0004] The primary objective of this invention is to provide a motor controller that utilizes an adapter busbar to facilitate the adjustment of the outgoing line position.

[0005] The second objective of this invention is to provide a vehicle having the aforementioned motor controller.

[0006] To achieve the primary objective of this invention, a motor controller utilizing an adapter busbar for adjusting the outgoing wiring is provided. The controller includes a housing, a core mechanism, an adapter busbar, and a terminal block. The core mechanism, adapter busbar, and terminal block are housed within the housing. The core mechanism includes a capacitor module, and the capacitor module, adapter busbar, and terminal block are arranged along the length direction. The adapter busbar includes a mounting bracket and two busbars. The mounting bracket extends along the width direction and has end face grooves on both sides along the length direction. These end face grooves extend along the width direction, and a partition wall is provided between the two end face grooves. Each end face groove has a positioning peripheral wall on the outer periphery of the partition wall. Each side of the positioning peripheral wall has a welding notch at the top and a lead-out notch at the bottom. The busbar has a connecting plate and an extension plate. The extension plate is connected to the lower edge of the connecting plate. The connecting plate is fixed in the end face groove and has a clearance fit with the positioning peripheral wall. The extension plate extends from the lead-out notch to the terminal block. The capacitor module includes a capacitor housing, multiple capacitors, and two connecting bars. The multiple capacitors are set inside the capacitor housing. The two connecting bars are connected to the positive and negative terminals of the capacitors. Each connecting bar has a connecting piece outside the capacitor housing. One connecting piece is located at a welding notch and is welded to the upper edge of a connecting plate.

[0007] As can be seen from the above scheme, by arranging the mounting bracket of the busbar, when the connecting plate is installed in the end face groove, the two busbars are arranged at intervals through the partition wall, and are welded to the connecting piece connected to the capacitor through the welding notch. The extension plate can be extended to the terminal block position. Then, by utilizing the fixed and extended design of the busbar, it is no longer necessary to go through the input wiring of the circuit board. Therefore, it is beneficial to adjust the outgoing line position, optimize the line layout, and also facilitate the integration and miniaturization of the equipment.

[0008] A further improvement is that the mounting bracket has mounting parts at both ends in the width direction, and the mounting parts are fixedly connected to the outer shell.

[0009] A further proposed solution is to install two support columns inside the casing, with one support column opposite to a mounting part, and the support column and the mounting part being fixedly connected.

[0010] As can be seen from the above, the arrangement of the mounting section and support column ensures that the adapter busbar is stably installed inside the housing.

[0011] A further proposed solution is to place the extension plate at one end of the connecting plate along its width direction.

[0012] A further proposed solution is to extend the extension plate parallel to the horizontal direction and perpendicular to the connecting plate.

[0013] As can be seen from the above, the extension plate extends from one end in the width direction and is then offset to facilitate the arrangement of the terminal block. Furthermore, the horizontal extension of the extension plate facilitates wiring and connection operations.

[0014] A further proposed solution is to have multiple welding notches on the upper part of each side positioning perimeter wall, with the welding notches arranged along the width direction.

[0015] A further proposed solution is to have multiple welding notches on the two side positioning perimeter walls staggered along the width direction.

[0016] A further proposed solution is to arrange two adjacent welding notches at different heights.

[0017] As can be seen from the above, the staggered and misaligned arrangement of the welding notches facilitates the corresponding welding of the connecting pieces of the two connecting rows and improves the isolation between the two connecting pieces.

[0018] To achieve the second objective of this utility model, this utility model provides a means of transportation, including a motor controller as described above. Attached Figure Description

[0019] Figure 1 This is a structural diagram of an embodiment of the motor controller of this utility model.

[0020] Figure 2 This is a structural diagram of the motor controller embodiment of this utility model after the cover is opened.

[0021] Figure 3 This is a structural diagram of the circuit device in an embodiment of the motor controller of this utility model.

[0022] Figure 4 This is an exploded view of the capacitor module in an embodiment of the motor controller of this utility model.

[0023] Figure 5 This is a further exploded view of the capacitor module in the embodiment of the motor controller of this utility model.

[0024] Figure 6 This is a structural diagram of the circuit device in the embodiment of the motor controller of this utility model from another perspective.

[0025] Figure 7 This is an exploded view of the transition busbar in an embodiment of the motor controller of this utility model.

[0026] Figure 8 This is a structural diagram of the transition busbar in an embodiment of the motor controller of this utility model.

[0027] Figure 9 This is a cross-sectional view of an embodiment of the motor controller of this utility model.

[0028] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0029] Motor controller example:

[0030] Reference Figures 1 to 9 The motor controller includes a housing 1, a core 20, a busbar 4, and a terminal block 117. The housing includes a base 11 and a cover 12. The base 11 forms a device receiving cavity 111. The core 20 is disposed inside the receiving cavity 111. The cover 12 covers the outside of the receiving cavity 111 and is connected to the base 11. The base 11 has a DC input port 113, a signal interface 114, and a three-phase output port 112 on both sides in the length direction X. The base 11 has a liquid cooling interface 115 on the side wall in the width direction Y. The base 11 has a liquid cooling tank 116 at the bottom. The liquid cooling interface 115 is connected to the liquid cooling tank 116, and the coolant flows through the liquid cooling channel in the liquid cooling bridge tube of the power module 3.

[0031] The mechanism 20 includes a power module 3, a capacitor module 2, a circuit board 203, and a connecting bracket 204. The connecting bracket 204 connects the power module 3 and the capacitor module 2. The circuit board 203 is arranged above the power module 3 and the capacitor module 2. The liquid cooling interface of the power module 3 is arranged downwards and is used to connect to the liquid cooling tank 116. The power module 3, the capacitor module 2, the adapter busbar 4, and the terminal block 117 are arranged along the length direction.

[0032] Capacitor module 2 includes a capacitor housing 21, a first connecting bar 23, a second connecting bar 24, multiple capacitors 221, and two Y-capacitors 222. The capacitor housing 21 has a top wall 212, a bottom surface 213, two capacitor side walls 214, and a wiring side wall 215. The top wall 212 and the bottom surface 213 are located on opposite sides in the height direction Z, and the two capacitor side walls 214 are located on opposite sides in the width direction Y. The capacitor side walls 214 connect between the top wall 212 and the bottom wall 213. The wiring side wall 215... Located on one side along the length direction X and connected to the top wall 212, bottom wall 213, and two capacitor sidewalls 214, the wiring sidewall 215 is provided with multiple first wiring holes 216 and multiple second wiring holes 217. These first wiring holes 216 and second wiring holes 217 are arranged along the width direction Y, staggered along the width direction Y, and staggered along the height direction Z. The top wall 212, bottom wall 213, two capacitor sidewalls 214, and wiring sidewall 215 form a potting cavity 211. The potting cavity 211 has a potting opening on the other side of the wiring sidewall 215 along the length direction X.

[0033] The first connecting bar 23 is arranged in an arch shape and is used as a positive terminal connecting bar. The first connecting bar 23 is provided with a base plate 231, a first side plate 232, a second side plate 233, a plurality of first connecting pieces 234 and second connecting pieces 235. The base plate 231 extends along the length direction X. The first side plate 232 and the second side plate 233 are located on both sides of the length direction X, respectively. The base plate 231 is connected between the first side plate 232 and the second side plate 233. A plurality of first connecting pieces 234 extend along the length direction X and are provided on the end of the first side plate 232. The second connecting pieces 235 extend along the length direction X and are provided on the end of the second side plate 233. The first connecting pieces 234 and the second connecting pieces 235 extend in opposite directions. The second connecting piece 235 is provided with a plurality of connecting fingers and pins 236 at the connecting fingers.

[0034] The second connecting bar 24 extends along the length direction X and serves as the negative terminal connecting bar. A third connecting piece 241 and a fourth connecting piece 242 are respectively provided at both ends of the second connecting bar 24 along the length direction X. The third connecting piece 241 and the fourth connecting piece 242 extend in opposite directions along the length direction X. The capacitor assembly includes an extension connecting piece 25, which extends along the length direction X and is connected to the fourth connecting piece 242. A second insulating paper 262 is provided between the second connecting piece 235 and the extension connecting piece 25. The extension connecting piece 25 is provided with multiple connecting fingers, and pins 251 are provided at the connecting fingers. The second connecting bar 24 and the base plate 231 are located on opposite sides of the height direction Z. The base plate 231, the first side plate 232, the second side plate 233, and the second connecting bar 24 form a capacitor slot.

[0035] Multiple capacitors 221 and Y capacitors 222 form a capacitor core, which is disposed within a capacitor slot. The first electrode of capacitor 221 is electrically connected to the base plate 231, and the second electrode of capacitor 221 is electrically connected to the second connecting bar 24. The positive and negative terminals of Y capacitor 222 are also electrically connected to the base plate 231 and the second connecting bar 24, respectively. Multiple capacitors 221, the first connecting bar 23, and the second connecting bar 24 are disposed within a potting cavity 211. The base plate 231 is close to the bottom wall 213, and the second connecting bar 24 is close to the top wall 212. Multiple first wiring holes 216 and multiple second wiring holes 217 are all close to the top wall 212. A first connecting piece 234 passes through the first wiring hole 216, and a third connecting piece 234 passes through the second wiring hole 217. Connecting piece 241 passes through second wiring hole 217. Y capacitor 222 is provided with grounding piece 2221, which extends along the length direction X. Wiring side wall 215 is provided with third wiring hole 218, and grounding piece 2221 passes through third wiring hole 218. Grounding piece 2221 and third wiring hole 218 are close to bottom wall 213. Second connecting piece 235 and fourth connecting piece 242 are located outside potting opening. First insulating paper 261 is provided between second connecting piece 235 and fourth connecting piece 242. Potting cavity 211 is filled with potting glue, which wraps around multiple capacitors 221, Y capacitor 222, first connecting bar 23 and second connecting bar 24.

[0036] The adapter busbar 4 includes a mounting bracket 41 and two busbars 42. The mounting bracket 41 extends along the width direction Y. The mounting bracket 41 has end face grooves 411 on both sides in the length direction X. The end face grooves 411 extend along the width direction Y. A partition wall 412 is provided between the two end face grooves 411. A positioning peripheral wall 413 is provided on the outer periphery of the partition wall 412 of each end face groove 411. Multiple welding notches 414 are provided above each positioning peripheral wall 413, arranged along the width direction Y. The welding notches 414 on the two positioning peripheral walls 413 are staggered along the width direction Y, with adjacent welding notches 414 arranged at different heights. A lead-out notch 415 is provided below each positioning peripheral wall 413, located near one end in the width direction Y.

[0037] The busbar 42 is provided with a connecting plate 421 and an extension plate 422. The extension plate 422 is connected to the lower edge of the connecting plate 421. The extension plate 422 is located at one end of the connecting plate 421 based on the width direction Y. The extension plate 422 extends parallel to the horizontal direction and is perpendicular to the connecting plate 421.

[0038] A connecting plate 421 is fixed in an end face groove 411 and has a clearance fit with the positioning peripheral wall 413. An extension plate 422 extends from the lead-out notch 415 to the terminal block 117. The DC input port 113 is connected to the terminal block 117, and the DC input terminal passes through the DC input port 113 and can be connected to the extension plate 422. The first connecting piece 234 and the third connecting piece 241 are located at the welding notches 414 on both sides, and are welded to the upper edges of the connecting plates 421 on both sides. The second connecting piece 235 and the extension connecting piece 25 on the other side are connected to the positive and negative input terminals of the power transistor in the power module 3, respectively. The pins 236 and 251 are welded to the circuit board 203.

[0039] Mounting bracket 41 has mounting portions 416 at both ends in the width direction Y. Mounting portions 416 have mounting holes 417 along the height direction. There are two support columns 117 inside the housing 1. One support column 117 is opposite to one mounting portion 416. The support column 117 is fixedly connected to the mounting portion 416 by screws passing through the mounting holes 417, thereby achieving a fixed connection between the support column 117 and the mounting portion 416.

[0040] Example of a means of transportation:

[0041] The vehicles include motor controllers as described above, and the vehicles can be new energy electric cars, new energy electric buses, new energy electric freight trucks, new energy electric cleaning vehicles, new energy electric rail transit vehicles, new energy electric air vehicles, new energy electric shipping vehicles, etc.

[0042] As can be seen from the above, by arranging the mounting brackets of the busbars, when the connecting plate is installed in the end face groove, the two busbars are arranged at intervals through the partition wall and welded to the connecting piece connected to the capacitor through the welding notch. The extension plate can extend to the terminal block position. Then, by utilizing the fixed and extended design of the busbars, it is no longer necessary to go through the input wiring of the circuit board. Therefore, it is beneficial to adjust the outgoing line position, optimize the line layout, and also to reduce the integration and miniaturization of the equipment.

Claims

1. A motor controller that adjusts the output wires using a transition busbar, comprising a housing, a core, a transition busbar, and a terminal block, wherein the core, the transition busbar, and the terminal block are disposed within the housing, and the core includes a capacitor module, wherein the capacitor module, the transition busbar, and the terminal block are arranged along the length direction; Its features are: The adapter busbar includes a mounting bracket and two busbars. The mounting bracket extends along the width direction and has end face grooves on both sides of the mounting bracket in the length direction. The end face grooves extend along the width direction and a partition wall is provided between the two end face grooves. Each end face groove has a positioning peripheral wall on the outer periphery of the partition wall. Each positioning peripheral wall has a welding notch above it and an exit notch below it. The busbar is provided with a connecting plate and an extension plate. The extension plate is connected to the lower edge of the connecting plate. The connecting plate is fixed in the end face groove and has a clearance fit with the positioning peripheral wall. The extension plate extends from the lead-out notch to the terminal block. The capacitor module includes a capacitor housing, multiple capacitors, and two connection bars. The multiple capacitors are disposed inside the capacitor housing, and the two connection bars are connected to the positive and negative terminals of the capacitors. Each connection bar is provided with a connecting piece outside the capacitor housing, and one connecting piece is located at a welding notch and welded to the upper edge of a connecting plate.

2. The motor controller according to claim 1, characterized in that: The mounting bracket has mounting portions at both ends in the width direction, and the mounting portions are fixedly connected to the outer shell.

3. The motor controller according to claim 2, characterized in that: The housing contains two support columns, one of which is opposite to the mounting part, and the support column is fixedly connected to the mounting part.

4. The motor controller according to claim 1, characterized in that: The extension plate is located at one end of the connecting plate in the width direction.

5. The motor controller according to claim 4, characterized in that: The extension plate extends parallel to the horizontal direction and is perpendicular to the connecting plate.

6. The motor controller according to any one of claims 1 to 5, characterized in that: Multiple welding notches are provided above the positioning peripheral wall on each side, and the multiple welding notches are arranged along the width direction.

7. The motor controller according to claim 6, characterized in that: The multiple welding notches on the positioning peripheral walls on both sides are staggered along the width direction.

8. The motor controller according to claim 7, characterized in that: The two adjacent welding notches are arranged at different heights.

9. A means of transport, characterized in that, Including the motor controller as described in any one of claims 1 to 8.

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