Motor controller and vehicle with integrated powertrain
By using an integrated core structure, the heat conduction connection between the liquid-cooled bridge tube and the power tube, and the snap-fit positioning of the connecting bracket, the problem of integrating and arranging the power module and capacitor module in the motor controller is solved, achieving efficient heat dissipation and low-cost motor controller design.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHUHAI ENPOWER ELECTRIC
- Filing Date
- 2025-05-06
- Publication Date
- 2026-06-19
AI Technical Summary
In existing motor controllers, the integrated arrangement of power modules and capacitors affects assembly efficiency and cost control, and the heat dissipation effect is poor.
The integrated core structure is adopted, and the power tubes are connected by heat conduction through liquid-cooled bridge tubes. Combined with connecting brackets and snap-fit structures, the power module and capacitor module are integrated. By cooperating with positioning columns and slots, some bolt fastening is eliminated, which improves the integration of the equipment and reduces costs.
It achieves efficient heat dissipation and improved equipment integration, while reducing manufacturing costs and increasing assembly efficiency.
Smart Images
Figure CN224385928U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of new energy equipment, and in particular to an integrated motor controller and a vehicle. 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, one for receiving positive power and the other for receiving negative power, and one current output terminal for outputting a current signal to one phase of the motor. Furthermore, controllable switching devices such as power transistors and capacitors need to be installed between the two DC power terminals and the current output terminal. The power transistors can be thyristors or IGBTs, used to control the DC power. During operation, the power transistors generate waste heat, so heat dissipation is generally required.
[0004] In addition, 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. Therefore, the integrated arrangement of power transistors and capacitors directly affects the assembly efficiency and cost control of the motor controller. Utility Model Content
[0005] The primary objective of this invention is to provide a motor controller for an integrated mechanism.
[0006] The second objective of this invention is to provide a vehicle equipped with the aforementioned motor controller.
[0007] To achieve the primary objective of this utility model, it provides an integrated motor controller, comprising a housing and a core mechanism housed within the housing. The core mechanism includes a capacitor module, a power module, two connecting brackets, and a circuit board. The capacitor module and power module are arranged along the length direction. The capacitor module includes a capacitor housing and multiple capacitors, which are housed within the capacitor housing. The capacitor housing is filled with potting compound. Capacitor sidewalls are provided on both sides of the capacitor housing in the width direction, and positioning posts are provided on the capacitor sidewalls. The power module includes a liquid-cooled bridge tube and multiple power transistors. The liquid-cooled bridge tube extends along the width direction and has liquid-cooled flow channels extending along the width direction. Thermally conductive sidewalls are provided on both sides of the liquid-cooled bridge tube in the length direction. The multiple power transistors are encapsulated... The liquid-cooled bridge tube is connected to the heat-conducting side for heat conduction. First locking blocks are provided on the liquid-cooled sidewalls at both ends in the width direction, and at least two second locking blocks are provided on the liquid-cooled top wall in the height direction. The two second locking blocks are located on opposite sides in the width direction. Two connecting brackets are located on opposite sides in the width direction. Each connecting bracket includes a connecting sidewall and a connecting top wall that are connected to each other. The connecting top wall is located at the top of the connecting sidewall in the height direction. The connecting sidewall is provided with a positioning hole and a first locking groove, and the connecting top wall is provided with a second locking groove. The positioning post is connected to the positioning hole, and the first locking groove engages with the first locking block, and the second locking groove engages with the second locking block. The circuit board is located at the top of the capacitor module and power module in the height direction, and the power transistors and capacitors are connected to the circuit board.
[0008] As can be seen from the above scheme, the power transistor and the liquid-cooled bridge tube are connected by heat conduction, and the waste heat on the power transistor can be efficiently conducted to the liquid-cooled bridge tube for heat dissipation. The capacitor module is arranged on one side of the power module along its length and is integrated and connected by connecting brackets. Specifically, the power transistor module and the capacitor module are integrated and installed into the housing through connecting brackets located on both sides of the width direction, the connection between the positioning post and the positioning hole, and the engagement of the slot and the locking block. This improves the integration of the equipment. The process advantage of the locking or positioning structure is that it eliminates most of the bolt fastening, effectively reducing costs and improving production efficiency.
[0009] A further proposed solution is that the first card slot is located below the second card slot, and the first card slot has an opening below it. The first card slot moves from top to bottom and engages with the first card block, while the second card slot moves from top to bottom and has an interference fit with the second card block.
[0010] A further solution is to provide two second locking blocks on the side of the liquid-cooled bridge tube in each width direction, with the two second locking blocks arranged along the length direction, and two second locking slots provided on the connecting top wall, with the two second locking slots arranged along the length direction, and one second locking slot engaging with one second locking block.
[0011] As can be seen from the above, the first slot moves from top to bottom and engages with the first block, which in turn facilitates the engagement and positioning of the second slot and the second block. Furthermore, the arrangement of the two second blocks makes the relative position of the liquid-cooled bridge tube and the capacitor housing more stable.
[0012] A further proposed solution is to have a connection hole on the top wall, a support plate on the side wall below the top wall, a support column between the top wall and the support plate, and the connection hole passing through the support column and the support plate; a fixing column is provided on the bottom wall of the outer shell, the support plate is located above the fixing column, and screws pass through the connection hole to connect with the fixing column.
[0013] As can be seen above, connecting the screw to the fixing post through the connecting hole not only effectively fixes the position of the connecting bracket, but also effectively installs and fixes the capacitor module and power module.
[0014] A further improvement is to provide a positioning piece on the connecting sidewall below the support piece, with the positioning piece located below and adjacent to the bottom wall of the capacitor housing.
[0015] A further proposed solution is to provide two support plates and two support columns on the connecting sidewall. The two support plates are located on both sides of the positioning plate along the length direction, and the two support plates are located on both sides of the capacitor sidewall along the length direction.
[0016] As can be seen from the above, the arrangement of the positioning plates facilitates the assembly and fixation of the support columns. Furthermore, by utilizing the support plates located on both sides of the capacitor sidewall, and the positioning plates and support columns located in the side gap of the capacitor module, the structure becomes more compact, which is conducive to the small-scale integrated layout of the equipment.
[0017] A further embodiment includes a capacitor module comprising a first connecting bar and a second connecting bar. The first connecting bar is arranged in an arch shape and includes a base plate, a first side plate, a second side plate, a first connecting piece, and a second connecting piece. The base plate extends along the length direction, and the first and second side plates are located on opposite sides of the length direction. The base plate connects the first and second side plates. Multiple first connecting pieces extend along the length direction and are disposed at the ends of the first side plates, and second connecting pieces extend along the length direction and are disposed at the ends of the second side plates. The first and second connecting pieces extend in opposite directions. The second connecting bar extends along the length direction. The device has a third connecting piece and a fourth connecting piece at each end, which extend in opposite directions along the length. The second connecting bar and the base plate are located on opposite sides of the height direction. The base plate, the first side plate, the second side plate, and the second connecting bar form a capacitor slot. Multiple capacitors are installed in the capacitor slot. The first electrode of the capacitor is electrically connected to the base plate, and the second electrode of the capacitor is electrically connected to the second connecting bar. The multiple capacitors, the first connecting bar, and the second connecting bar are installed inside the capacitor housing. The first connecting piece, the second connecting piece, the third connecting piece, and the fourth connecting piece are located outside the capacitor housing. The pins of the second connecting piece and the fourth connecting piece are soldered to the circuit board.
[0018] A further proposed solution is to have a connection electrode on one end of the power transistor near the circuit board, a second connection piece connecting to the connection electrode of the power transistor on one side of the heat-conducting side, and a fourth connection piece connecting to the connection electrode of the power transistor on the other side of the heat-conducting side.
[0019] As can be seen from the above, by integrating the two connecting bars and the capacitor inside the capacitor housing, and with the connecting pieces concentrated and led out to both sides, it is convenient to connect to the power transistors on both sides and to facilitate the centralized soldering connection of the circuit board.
[0020] 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
[0021] Figure 1 This is a structural diagram of an embodiment of the motor controller of this utility model.
[0022] Figure 2 This is a structural diagram of the motor controller embodiment of this utility model after the cover is opened.
[0023] Figure 3 This is a structural diagram of the mechanism in an embodiment of the motor controller of this utility model.
[0024] Figure 4 This is an exploded view of the mechanism in an embodiment of the motor controller of this utility model.
[0025] Figure 5This is an exploded view of the mechanism in an embodiment of the motor controller of this utility model from another perspective.
[0026] Figure 6 This is a structural diagram of the power module in an embodiment of the motor controller of this utility model.
[0027] Figure 7 This is a structural diagram of the power module in an embodiment of the motor controller of this utility model from another perspective.
[0028] Figure 8 This is an exploded view of the power module in an embodiment of the motor controller of this utility model.
[0029] Figure 9 This is an exploded view of the power module in an embodiment of the motor controller of this utility model from another perspective.
[0030] Figure 10 This is an exploded view of the capacitor module in an embodiment of the motor controller of this utility model.
[0031] Figure 11 This is a further exploded view of the capacitor module in the embodiment of the motor controller of this utility model.
[0032] Figure 12 This is a cross-sectional view of the motor controller embodiment of this utility model at the support column.
[0033] Figure 13 This is a partial cross-sectional view of the power module in an embodiment of the motor controller of this utility model.
[0034] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation
[0035] Motor controller example:
[0036] Reference Figures 1 to 13 The motor controller includes a housing 1 and a core 20. 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 then the coolant flows through the liquid cooling channel 311 in the liquid cooling bridge tube 31.
[0037] The mechanism 20 includes a power module 3, a capacitor module 2, a circuit board 203, an input copper busbar 204, and a connecting bracket 4. The connection end of the input copper busbar 204 is located at the DC input port 113. The input copper busbar 204 is connected to the source or drain of the capacitor module 2 and multiple power transistors 34 through the bridging of the connecting copper busbar. The connecting bracket 4 is connected between 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 312 is arranged downwards and is used to connect to the liquid cooling tank 116.
[0038] The power module 3 includes a liquid-cooled bridge tube 31, multiple power transistors 34, a potting housing 32, and a thermal circuit board 35. The liquid-cooled bridge tube 31 has a liquid-cooled flow channel 311 arranged along the width direction Y. The liquid-cooled bridge tube 31 has liquid-cooled interfaces 312 at both ends of the liquid-cooled flow channel 311 along the width direction Y. The liquid-cooled bridge tube 31 has heat-conducting side surfaces 313 on both sides of the length direction X. The liquid-cooled bridge tube 31 has a first end face 314 and a second end face at both ends of the height direction Z. The two liquid-cooled interfaces 312 are located on the first end face 314. The liquid-cooled bridge tube 31 has a first locking block 317 at both ends of the width direction Y. The liquid-cooled top wall of the liquid-cooled bridge tube in the height direction Z has four second locking blocks 316, of which two second locking blocks 316 form a group and are arranged on both sides of the width direction Y. The two second locking blocks 316 on the same side are arranged along the length direction X.
[0039] The packages of multiple power transistors 34 are thermally connected to the outer wall of the liquid-cooled bridge tube 31. Specifically, the multiple power transistors 34 are arranged in two rows along the width direction Y to form two power transistor groups. The two power transistor groups are located on both sides of the liquid-cooled bridge tube 31 along the length direction X. The packages of multiple power transistors 34 are thermally connected to the heat-conducting side 313. The packages of power transistors 34 are welded to the outer wall of the liquid-cooled bridge tube 31.
[0040] The power transistor 34 has a first connection electrode 341 at its first end in the height direction Z, and two second connection electrodes 342 and a third connection electrode 343 at its second end in the height direction. The third connection electrode 343 is the gate of the power transistor and is arranged in a pin configuration for soldering to the circuit board 23. The two second connection electrodes 342 are located on both sides of the third connection electrode 343. In one group of power transistors, the first connection electrode 341 is the source and the second connection electrode 342 is the drain, while in the other group of power transistors, the first connection electrode 341 is the drain and the second connection electrode 342 is the source.
[0041] The potting housing 32 surrounds the liquid-cooled bridge tube 31 and the multiple power tubes 34. Specifically, the potting housing 32 includes an inner baffle 323, an outer baffle 33, and a bottom baffle 321. The inner baffle 323, the outer baffle 33, and the bottom baffle 321 all extend along the width direction Y. The bottom baffle 321 is located on the outer side of the first end face 314 based on the height direction Z. The bottom baffle 321 is connected between the inner baffle 323 and the outer baffle 33. The inner baffle 323 and the outer baffle 33 are located on both sides of the length direction X, respectively. The inner baffle 323 and the outer baffle 33 are respectively connected to the outer side of the heat-conducting side 313.
[0042] The liquid cooling interface 312 is located on the first end face 312 of the liquid cooling bridge tube 31 in the height direction Z. The pins of the liquid cooling interface 312 and the third connection electrode 343 of the power tube 34 are arranged in opposite directions in the height direction Z. The bottom baffle 321 is located between the two liquid cooling interfaces 312. The third connection electrode 343 and the second connection electrode 342 of the power tube 34 are located outside the potting cavity.
[0043] The bottom baffle 321 has bottom retaining portions 322 on both edges in the length direction X. The bottom baffle 321 is raised in the middle. The flat plate portion 363 is located in the raised portion of the bottom baffle 321. The inner baffle 323 has a side retaining portion 325 on its edge in the height direction Z. The outer baffle 33 has a side retaining portion 331 on its edge in the height direction Z. The bottom retaining portions 322 can be detachably engaged with the side retaining portions 331 and 325. The heat-conducting side 313 facing the outer baffle 33 has first positioning holes 3151 at both ends in the width direction Y. The outer baffle 33 has first positioning posts 332 at both ends in the width direction Y. The first positioning posts 332 are connected by studs and are connected to the first positioning holes 3151. On the heat-conducting side 313 facing the inner baffle 323, a second positioning hole 3152 is provided at both ends of the width direction Y. A second positioning post 324 is provided at both ends of the inner baffle 323 in the width direction Y. The second positioning post 324 is connected to the second positioning hole 3152.
[0044] The outer baffle 33 has three phase output posts 333 along the length direction X. The phase output posts 333 are connected to the power tubes 34 of the corresponding phase bridge arms. Each phase output post 333 has a connecting piece 366 connected to the outside of the outer baffle 33. The power module 3 also includes three phase connection pieces, which are located inside the potting housing 32 and wrapped with potting compound. The phase connection pieces extend from the bottom baffle 321 to the outer baffle 33. Each phase connection piece includes a width connection piece 361 and a height connection piece 362. The width connection piece 361 extends along the length direction X, and the height connection piece 362 extends along the height direction Z. The flat plate portion 363 of the width connection piece 361 is connected to the first connection electrode 341 of the power tube 34 located on both sides of the length direction X. A thermally conductive putty 318 is provided between the width connection piece 361 and the liquid-cooled bridge tube 31. The first connection electrode 341 has a bent connection portion at the thermally conductive putty 318. The bent connection portion is L-shaped and is welded to the width connection piece 361.
[0045] The height connecting piece 362 is located on the outer side of the power transistor 34 along the length direction X. The height connecting piece 362 has a welding part 365 at its first end in the height direction Z. The welding part 365 is arranged in a planar manner. The width connecting piece 361 has multiple welding branches 364 at its end near the height connecting piece 362. There are gaps between the multiple welding branches 364. The welding branches 364 are deflected toward the height connecting piece 362. The multiple welding branches 364 are welded to the welding part 365 respectively. The outer baffle 33 has a positioning step 337 at the welding part 365. The welding branches 364 and the welding part 365 are located in the positioning step 337. The height connecting piece 362 is connected to the phase output post 333 at its second end in the height direction Z. This enables the phase connecting piece to be connected to the first connection electrode 341 of the power transistor 34 located on both sides of the length direction X, and the phase connecting piece to be connected to the phase output post 333.
[0046] The outer baffle 33 has a C-shaped groove 335 and a longitudinal groove 336 on the outer periphery of the phase output post 333. The longitudinal groove 336 extends along the height direction Z and is located at the notch of the C-shaped groove 335. A magnetic core 371 is provided in the C-shaped groove 335. A current sensor 372 is provided in the longitudinal groove 336. The pins of the current sensor 372 extend along the height direction Z toward the circuit board 23. The pins of the current sensor 372 are soldered to the circuit board 23.
[0047] Multiple thermistors are provided on the thermistor circuit board 35. The thermistor circuit board 35 is located inside the potting housing 32 and on the side of the power transistor 34. The thermistors are used to detect the temperature of the power transistor 34. The thermistor circuit board 35 has a signal port 351 outside the potting housing 32. The signal port 351 is connected to the circuit board 23.
[0048] The inner baffle 323, the outer baffle 33 and the bottom baffle 321 form a potting cavity. The potting cavity of the potting shell 32 is filled with potting glue. The potting glue wraps around the outer periphery of the packages of multiple power transistors 34, the thermal circuit board 35, the three phase connection pieces, the first end face 314 and the two thermally conductive side faces 313. The liquid cooling interface 312 and the pins of multiple power transistors 34 are all located outside the potting shell 32.
[0049] 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 holes are arranged along the width direction Y, staggered along the width direction Y, and misaligned 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. Two positioning posts 2141 are provided on the capacitor sidewall 214, extending along the width direction Y.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] Two input copper busbars 204 are connected to the first connecting piece 234 and the third connecting piece 241 respectively. The second connecting piece 235 and the extension connecting piece 25 on the other side are connected to the positive input terminal and the negative input terminal of the power tube in the power module 3 respectively. Pins 236 and 251 are soldered to the circuit board 203 respectively.
[0054] Two connecting brackets 4 are located on both sides of the width direction Y. The connecting bracket 4 includes a connecting side wall 41 and a connecting top wall 42 that are connected to each other. The connecting top wall 42 is located at the top of the connecting side wall 41 based on the height direction Z. The connecting side wall 41 is provided with two positioning holes 411 and a first slot 47. The connecting top wall 42 is provided with two second slots 423. The first slot 47 is located below the second slots 423 and has an opening below it. The first slot 47 moves from top to bottom and engages with the first locking block 317. The second slot 423 moves from top to bottom and is press-fitted with the second locking block 316. When the interference fit is achieved, it can be assembled by a crimping clamp and then connected with the positioning pin 2141 and the positioning hole 411 to realize the fixed connection between the connecting bracket 4 and the liquid-cooled bridge tube 31.
[0055] The top wall 42 is provided with a connecting hole 421. Below the top wall 42, the connecting side wall 41 has two support plates 44 and two support pillars 45. Support pillars 45 are positioned between the top wall 42 and the support plates 44. The connecting hole 421 passes through the support pillars 45 and the support plates 44. Below the support plates 44, the connecting side wall 41 has a positioning plate 46, located below and adjacent to the bottom wall 213 of the capacitor housing 21. The two support plates 44 are located on both sides of the positioning plate 46 along the length direction X, and the two support plates 44 are also located on both sides of the capacitor side wall 214 along the length direction X. The two support pillars 45 are also located on both sides of the capacitor side wall 214 along the length direction X. The bottom wall of the outer casing 1 has two fixing pillars 117, one fixing pillar 117 opposite to one support plate 44. The support plate 44 is located above the fixing pillar 117, and screws pass through the connecting hole 421 to connect with the fixing pillar 117.
[0056] Circuit board 203 is located at the top of capacitor module 2 and power module 3 in the height direction Z. Power transistors and capacitors are connected to circuit board 203, that is, they are soldered to circuit board 203 through pins 236 and 251 respectively. Alternatively, they can be soldered to circuit board through the pins of the fourth connecting piece. In addition, the second connecting piece 235 and the extension connecting piece 25 extend to the power transistor 34. The second connecting piece 235 is connected to the connecting electrode 342 of one side of the power transistor 34, and the extension connecting piece 25 connected to the fourth connecting piece is connected to the connecting electrode 342 of the other side of the power transistor 34. The second end face of the liquid-cooled bridge tube 31 is also provided with thermally conductive putty 319. The thermally conductive putty 319 is adjacent to the second connecting piece 235 and the extension connecting piece 25, thereby forming heat conduction and achieving electrical insulation.
[0057] Example of a means of transportation:
[0058] 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.
[0059] As can be seen from the above, through the heat conduction connection between the power transistor and the liquid-cooled bridge tube, the waste heat on the power transistor can be efficiently conducted to the liquid-cooled bridge tube for heat dissipation. The capacitor module is arranged on one side of the power module along its length and is integrated and connected through connecting brackets. Specifically, through connecting brackets located on both sides in the width direction, and through the connection of positioning posts and positioning holes, as well as the engagement of slots and blocks, the power transistor module and capacitor module are integrated and then installed into the housing, thereby improving the integration of the equipment. Furthermore, the technological advantages of the engagement or positioning structure, by eliminating most of the bolt fastening, effectively reduce costs and improve production efficiency.
Claims
1. A motor controller with an integrated mechanism, comprising a housing and a mechanism disposed within the housing, characterized in that: The mechanism includes a capacitor module, a power module, two connecting brackets and a circuit board. The capacitor module and the power module are arranged along the length direction. The capacitor module includes a capacitor housing and multiple capacitors. The multiple capacitors are disposed in the capacitor housing. The capacitor housing is filled with potting compound. The capacitor housing has capacitor sidewalls on both sides in the width direction. The capacitor sidewalls are provided with positioning posts. The power module includes a liquid-cooled bridge tube and multiple power transistors. The liquid-cooled bridge tube extends along the width direction and is provided with a liquid-cooled flow channel extending along the width direction. The liquid-cooled bridge tube is provided with heat-conducting sides on both sides in the length direction. The packages of the multiple power transistors are thermally connected to the heat-conducting sides. The liquid-cooled bridge tube is provided with first retaining blocks on the liquid-cooled sidewalls at both ends in the width direction. The liquid-cooled bridge tube is provided with at least two second retaining blocks on the liquid-cooled top wall in the height direction. The two second retaining blocks are respectively located on both sides in the width direction. The two connecting brackets are respectively located on both sides of the width direction. Each connecting bracket includes a connecting side wall and a connecting top wall that are connected to each other. The connecting top wall is located at the top of the connecting side wall based on the height direction. The connecting side wall is provided with a positioning hole and a first slot. The connecting top wall is provided with a second slot. The positioning post is connected to the positioning hole. The first slot engages with the first locking block. The second slot engages with the second locking block. The circuit board is located at the top of the capacitor module and the power module based on the height direction, and the power transistor and the capacitor are connected to the circuit board.
2. The motor controller according to claim 1, characterized in that: The first card slot is located below the second card slot. The first card slot has an opening below it. The first card slot moves from top to bottom and engages with the first card block. The second card slot moves from top to bottom and is press-fitted with the second card block.
3. The motor controller according to claim 2, characterized in that: The liquid-cooled bridge tube is provided with two second locking blocks on the side of each width direction, and the two second locking blocks are arranged along the length direction. The connecting top wall is provided with two second locking slots, and the two second locking slots are arranged along the length direction. One second locking slot engages with one second locking block.
4. The motor controller according to claim 1, characterized in that: The connecting top wall is provided with a connecting hole, the connecting side wall is provided with a support plate below the connecting top wall, a support column is provided between the connecting top wall and the support plate, and the connecting hole passes through the support column and the support plate; The bottom wall of the outer casing is provided with a fixing post, the support plate is located above the fixing post, and the screw passes through the connecting hole and is connected to the fixing post.
5. The motor controller according to claim 4, characterized in that: The connecting sidewall is provided with a positioning piece below the support piece. The positioning piece is located below the bottom wall of the capacitor housing and is adjacent to the bottom wall of the capacitor housing.
6. The motor controller according to claim 5, characterized in that: The connecting sidewall is provided with two support plates and two support columns. The two support plates are located on both sides of the positioning plate along the length direction, and the two support plates are located on both sides of the capacitor sidewall along the length direction.
7. The motor controller according to any one of claims 1 to 6, characterized in that: The capacitor module includes a first connecting bar and a second connecting bar. The first connecting bar is arranged in an arch shape and is provided with a base plate, a first side plate, a second side plate, a first connecting piece, and a second connecting piece. The base plate extends along the length direction. The first side plate and the second side plate are located on opposite sides of the length direction. The base plate is connected between the first side plate and the second side plate. A plurality of first connecting pieces extend along the length direction and are disposed at the ends of the first side plate. The second connecting pieces extend along the length direction and are disposed at the ends of the second side plate. The first connecting pieces and the second connecting pieces extend in opposite directions. The second connecting bar extends along the length direction, and a third connecting piece and a fourth connecting piece are respectively provided at both ends of the second connecting bar in the length direction. The third connecting piece and the fourth connecting piece extend in opposite directions along the length direction. The second connecting bar and the base plate are respectively located on both sides of the height direction. The base plate, the first side plate, the second side plate and the second connecting bar form a capacitor groove. Multiple capacitors are disposed in the capacitor slot, the first electrode of the capacitor is electrically connected to the base plate, the second electrode of the capacitor is electrically connected to the second connecting bar, the multiple capacitors, the first connecting bar and the second connecting bar are disposed in the capacitor housing, and the first connecting piece, the second connecting piece, the third connecting piece and the fourth connecting piece are located outside the capacitor housing; The pins of the second connecting piece and the pins of the fourth connecting piece are soldered to the circuit board, respectively.
8. The motor controller according to claim 7, characterized in that: The power transistor has a connection electrode at one end near the circuit board. The second connection piece is connected to the connection electrode of the power transistor on one side of the heat-conducting side, and the fourth connection piece is connected to the connection electrode of the power transistor on the other side of the heat-conducting side.
9. A means of transport, characterized in that, Including the motor controller as described in any one of claims 1 to 8.