Motor controller and vehicle

Abstract

The application relates to the technical field of vehicles, in particular to a motor controller and a vehicle. The motor controller comprises a shell assembly, a capacitor module, a filter module, an output module and a power module. The shell assembly has a first accommodating area and a second accommodating area, the capacitor module is arranged in the first accommodating area, the filter module is arranged in the first accommodating area and is arranged along the length direction of the shell assembly itself in the first accommodating area, the filter module comprises a first insulating piece, a first input connection row integrated in the first insulating piece, a filter assembly and a first output connection row. At least part of the output module is arranged in the second accommodating area and is arranged along the height direction of the shell assembly itself in the first accommodating cavity. The power module is arranged in the second accommodating area and is arranged along the length direction of the output module, and the output module is connected with the capacitor module through the power module. The motor controller provided by the application can improve the compactness and space utilization of the motor controller.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and more particularly to a motor controller and a vehicle. Background Technology

[0002] With the rapid development of new energy technologies and the continuous advancement of environmental protection technologies globally, the performance and reliability of motor controllers in new energy heavy-duty trucks, as the core carriers of green logistics, have become a key focus of the industry. As a core component of the vehicle's power system, the motor controller directly affects the vehicle's energy efficiency, stability, and range.

[0003] In related technologies, motor controllers adopt a multi-module distributed layout, which has problems such as low integration and low space utilization. Utility Model Content

[0004] This application provides a motor controller and a vehicle, the motor controller being able to improve its internal compactness and increase space utilization.

[0005] To achieve the above objectives, the technical solution of this application is as follows:

[0006] In a first aspect, this application provides a motor controller, comprising: a housing assembly including a housing body and an isolator, the housing body having a first receiving cavity, the isolator being located within the first receiving cavity and connected to the housing body to divide the first receiving cavity into a first receiving area and a second receiving area arranged along the height direction of the housing assembly itself, the first receiving area and the second receiving area being partially connected; a capacitor module disposed in the first receiving area, the capacitor module including a capacitor body and a first connection terminal and a second connection terminal disposed on the capacitor body, the capacitor body including a plurality of continuously connected outer sidewalls, the first connection terminal and the second connection terminal being respectively located on two adjacent outer sidewalls, and at least a portion of the second connection terminal being located in the second receiving area; a filter module disposed in the first receiving area and arranged along the length direction of the housing assembly itself with respect to the capacitor module, the filter module including a first insulating member and a first input connection bar integrated in the first insulating member, a filter component and a first output connection bar, the first output connection bar being connected to the first connection terminal; an output module, at least partially disposed in the second receiving area and arranged along the height direction of the capacitor module; and a power module disposed in the second receiving area and arranged along the length direction of the output module, the output module being connected to the second connection terminal through the power module.

[0007] In one possible implementation, the motor controller provided in this application includes a first input connection bar comprising a first input sub-bar and a second input sub-bar, the first input sub-bar and the second input sub-bar being insulated from each other by a first insulating member; the filtering component includes a filtering chip, the first input sub-bar and the second input sub-bar being located on the same side of the filtering chip.

[0008] In one possible implementation, the motor controller provided in this application includes a first output connection bar comprising a first output sub-bar and a second output sub-bar, the first output sub-bar and the second output sub-bar being insulated from each other by a first insulating member, the first output sub-bar being connected to a first input sub-bar, and the second output sub-bar being connected to a second input sub-bar; and / or, the first insulating member comprises a first insulating wall, the first input sub-bar and the second input sub-bar being located on opposite sides of the first insulating wall and being in contact with the first insulating wall, the wall thickness of the first insulating wall being greater than or equal to 1 mm and less than or equal to 2.5 mm.

[0009] In one possible implementation, the motor controller provided in this application has, along the width direction of the housing assembly itself, a first insulating member having a first slot, a second slot, and a second receiving cavity connecting the first slot and the second slot; a first output connection bar is embedded in the second receiving cavity, and a portion of the first output connection bar protrudes out of the second receiving cavity via the first slot and is connected to the capacitor module; a first input connection bar is embedded in the second receiving cavity and is connected to the first output connection bar, and a portion of the first input connection bar protrudes out of the second receiving cavity via the second slot; wherein, the first slot and the second slot are respectively located on opposite sides of the first insulating member along the length direction.

[0010] In one possible implementation, the motor controller provided in this application further includes a first magnetic ring and a second magnetic ring in the filtering component; the first insulating member further includes a first receiving portion and a second receiving portion, the first receiving portion being disposed around the input end of the first input connection bar, and the first magnetic ring being received in the first receiving portion; the second receiving portion is located between the first slot and the second slot, and the second magnetic ring is received in the second receiving portion.

[0011] In one possible implementation, the motor controller provided in this application includes an output module comprising a second insulating member and a second input connection bar, a Hall element, and a three-phase output connection bar integrated into the second insulating member; the second insulating member includes a plurality of sequentially connected insulating parts, each insulating part having a through slot, the plurality of through slots being isolated from each other; the three-phase output connection bar includes a plurality of output connection parts, each output connection part being inserted into one of the through slots; the input end of the three-phase output connection bar is connected to the second input connection bar, and the output end of the three-phase output connection bar is used to output AC power; a plurality of Hall elements are provided, each Hall element being sleeved on one of the insulating parts.

[0012] In one possible implementation, the motor controller provided in this application includes an insulating part comprising a second insulating wall, the second insulating wall forming a through groove, two adjacent through grooves being isolated from each other by the second insulating wall, the wall thickness of the second insulating wall being greater than or equal to 1 mm and less than or equal to 2.5 mm; and / or, the distance between two adjacent output connection parts being greater than or equal to 1 mm and less than or equal to 2.5 mm.

[0013] In one possible implementation, the motor controller provided in this application further includes a first cover plate, a housing, and a second cover plate. Along the height direction, the housing has a first opening and a second opening, and the first cover plate and the second cover plate are respectively covered on the first opening and the second opening to form a first receiving cavity together with the housing; and / or, the first cover plate and the second cover plate are respectively detachably connected to the housing.

[0014] In one possible implementation, the motor controller provided in this application has a housing with opposing input ports and output ports along its length, and the input end of the first input connection bar is used to connect to an external power supply via the input port; at least a portion of the three-phase output connection bar is located outside the housing via the output port.

[0015] In one possible implementation, the motor controller provided in this application further includes a circuit board module. The circuit board module is located in the first receiving cavity and arranged with the power module along the height direction. The circuit board module includes an integrated circuit board, a shielding plate, and signal terminals. The shielding plate and signal terminals are respectively disposed on opposite sides of the integrated circuit board in the height direction. The integrated circuit board is connected to the output module and the power module.

[0016] In one possible implementation, the motor controller provided in this application further includes a connecting bar, one end of which is welded to a power module, and the other end of which is welded to a second connecting end, so as to connect a capacitor module to the power module; and / or, at least two of the plurality of outer sidewalls are fitted and connected to the inner wall of the housing assembly.

[0017] Secondly, this application provides a vehicle including the aforementioned motor controller.

[0018] The motor controller and vehicle provided in this application include a housing assembly, a capacitor module, a filter module, an output module, and a power module. The housing assembly includes a housing body and an isolator. The housing body has a first receiving cavity. The isolator is located within the first receiving cavity and connected to the housing body, dividing the first receiving cavity into a first receiving area and a second receiving area arranged along the height direction of the housing assembly itself. The first and second receiving areas are partially connected. The capacitor module is located within the first receiving area and includes a capacitor body and a first connection terminal and a second connection terminal disposed on the capacitor body. The capacitor body includes multiple continuously connected outer sidewalls. The first and second connection terminals are respectively located on two adjacent outer sidewalls, thereby improving the compactness between the modules. The filter module is located within the first receiving cavity and arranged with the capacitor module along the length direction of the housing assembly itself. At least a portion of the output module is located within the second receiving area and arranged with the capacitor module along the height direction of the housing assembly itself. The power module is located within the second receiving area and arranged with the output module along the length direction. The filtering module includes a first insulating component and a first input connection bar, a filtering component, and a first output connection bar integrated into the first insulating component. The first input connection bar, the filtering component, and the first output connection bar are injection molded into a single piece through the first insulating component, which can improve the compactness of the arrangement of the first input connection bar, the filtering component, and the first output connection bar, reduce the overall size of the filtering module, and make the fit with adjacent components such as the capacitor module and the power module within the housing assembly more compact. Thus, the compact layout among the capacitor module, the filtering module, the output module, and the power module improves the integration and space utilization of the motor controller. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of the motor controller provided in the embodiments of this application;

[0021] Figure 2 for Figure 1 Exploded view;

[0022] Figure 3 for Figure 2 A schematic diagram of the intermediate filtering module;

[0023] Figure 4 for Figure 3 A schematic diagram of a local structure in the image;

[0024] Figure 5 for Figure 2 A schematic diagram of the output module;

[0025] Figure 6 for Figure 1 Another perspective illustration;

[0026] Figure 7 for Figure 1 Another perspective illustration;

[0027] Figure 8 for Figure 2 Schematic diagram of the medium capacitor module Figure 1 ;

[0028] Figure 9 for Figure 2 Schematic diagram of the medium capacitor module Figure 2 .

[0029] Explanation of reference numerals in the attached figures:

[0030] 100 - Housing assembly; 110 - First receiving cavity; 110a - First receiving area; 110b - Second receiving area; 120 - First cover plate; 130 - Housing; 131 - Input port; 140 - Second cover plate;

[0031] 200 - Capacitor module; 210 - Capacitor body; 211 - Outer wall; 220 - First connection terminal; 230 - Second connection terminal;

[0032] 300 - Filter module; 310 - First insulating component; 311 - First insulating wall; 312 - First slot; 313 - Second slot; 314 - First receiving portion; 315 - Second receiving portion; 320 - First input connection bar; 321 - First input sub-bar; 322 - Second input sub-bar; 330 - Filter assembly; 331 - Filter chip; 340 - First output connection bar; 341 - First output sub-bar; 342 - Second output sub-bar;

[0033] 400 - Output module; 410 - Second insulator; 411 - Insulation part; 420 - Second input connection bar; 430 - Hall element; 440 - Three-phase output connection bar; 441 - Output connection part;

[0034] 500-Power Module;

[0035] 600 - Circuit board module; 610 - Integrated circuit board; 620 - Shielding board; 630 - Signal terminal;

[0036] 700-Connecting bar;

[0037] 800-Insulating Paper;

[0038] X - Length direction; Y - Width direction; Z - Height direction.

[0039] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the preferred embodiments of this application will be described in more detail below with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of this application, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0041] It should be noted that in the description of the embodiments of this application, the terms "upper", "lower", "inner", "outer" and other terms indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of description, and do not indicate or imply that the device or component must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the embodiments of this application.

[0042] Furthermore, it should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0043] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "fixation," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0044] In related technologies, the modules in motor controllers are arranged in a relatively dispersed manner, resulting in low integration and low space utilization.

[0045] In view of this, the motor controller and vehicle provided in this application include a housing assembly, a capacitor module, a filter module, an output module, and a power module. The housing assembly includes a housing body and an isolator. The housing body has a first receiving cavity. The isolator is located within the first receiving cavity and connected to the housing body, dividing the first receiving cavity into a first receiving area and a second receiving area arranged along the height direction of the housing assembly itself. The first and second receiving areas are partially connected. The capacitor module is located within the first receiving area. The capacitor module includes a capacitor body and a first connection terminal and a second connection terminal disposed on the capacitor body. The capacitor body includes multiple continuously connected outer sidewalls. The first and second connection terminals are respectively located on two adjacent outer sidewalls, thereby improving the compactness between the modules. The filter module is located within the first receiving area and arranged with the capacitor module along the length direction of the housing assembly itself. At least a portion of the output module is located within the second receiving area and arranged with the capacitor module along the height direction of the housing assembly itself. The power module is located within the second receiving area and arranged with the output module along the length direction of the output module. The filtering module includes a first insulating component and a first input connection bar, a filtering component, and a first output connection bar integrated into the first insulating component. The first input connection bar, the filtering component, and the first output connection bar are injection molded into a single piece through the first insulating component, which can improve the compactness of the arrangement of the first input connection bar, the filtering component, and the first output connection bar, reduce the overall size of the filtering module, and make the fit with adjacent components such as the capacitor module and the power module within the housing assembly more compact. Thus, the compact layout among the capacitor module, the filtering module, the output module, and the power module improves the integration and space utilization of the motor controller.

[0046] The present application will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0047] See Figure 1 and Figure 2This application provides a motor controller, including a housing assembly 100, a capacitor module 200, a filter module 300, an output module 400, and a power module 500. The housing assembly 100 includes a housing body and an isolator. The housing body has a first receiving cavity 110. The isolator is located within the first receiving cavity 110 and connected to the housing body, dividing the first receiving cavity 110 into a first receiving region 110a and a second receiving region 110b arranged along the height direction Z of the housing assembly. The first receiving region 110a and the second receiving region 110b are partially connected. The capacitor module 200 is disposed in the first receiving cavity 110 and includes a capacitor body 210 and a first connection terminal 220 and a second connection terminal 230 disposed on the capacitor body 210. A filter module 300 is disposed in the first receiving area 110a and arranged with the capacitor module 200 along the length direction X of the housing assembly 100. The filter module 300 includes a first insulating member 310 and a first input connection bar 320, a filter component 330, and a first output connection bar 340 integrated in the first insulating member 310. The first output connection bar 340 is connected to the first connection terminal 220. At least a portion of the output module 400 is disposed in the second receiving area 110b and arranged with the capacitor module 200 along the height direction Z of the housing assembly 100. A power module 500 is disposed in the second receiving area 110b and arranged with the output module 400 along the length direction X. The output module 400 is connected to the second connection terminal 230 through the power module 500.

[0048] Understandably, the housing assembly 100 has a first receiving cavity 110, which provides installation space for the capacitor module 200, filter module 300, output module 400, and power module 500, effectively protecting the internal modules from interference and damage from the external environment. Optionally, the housing assembly 100 may adopt an IP68 protection standard to effectively prevent dust and water damage, thereby ensuring the stability and reliability of the motor controller during operation and extending the service life of the motor controller.

[0049] In a specific implementation, the first receiving cavity 110 can be divided into a first receiving region 110a and a second receiving region 110b arranged sequentially along the height direction Z. The first receiving region 110a can be understood as being closer to the ground than the second receiving region 110b. See [link to relevant documentation] Figure 2The capacitor module 200 can be disposed in the first receiving cavity 110 and located in the first receiving area 110a. The capacitor module 200 may include a capacitor body 210 and a first connecting end 220 and a second connecting end 230 disposed on the capacitor body 210. The capacitor body 210 includes a plurality of interconnected outer sidewalls 211. The first connecting end 220 and the second connecting end 230 are respectively located on two adjacent outer sidewalls 211, and at least a portion of the second connecting end 230 is located in the second receiving area 110b. Optionally, the second connecting end 230 may be located on one outer sidewall 211 in the height direction Z, and the first connecting end 220 may be located on one outer sidewall 211 in the length direction X. The capacitor body 210 is used to store and release electrical energy. During vehicle operation, the capacitor body 210 can store excess electrical energy when there is an oversupply of electrical energy, and release the stored electrical energy in a timely manner when the demand for electrical energy increases, thereby stabilizing the voltage and smoothing the current, ensuring the stable operation of the motor controller. See also Figure 7 The first connection terminal 220 and the second connection terminal 230 are important interfaces for the electrical connection between the capacitor body 210 and other modules. One of the first connection terminal 220 and the second connection terminal 230 can be an input terminal, and the other can be an output terminal. Optionally, the first connection terminal 220 can be an input terminal, and the second connection terminal 230 can be an output terminal. See also... Figure 9 Insulating paper can be placed between the input and output terminals to isolate them from each other. Furthermore, the first connection terminal 220 can be located on the side of the capacitor body 210 facing the filter module, thereby facilitating the connection between the first connection terminal 220 and the filter module and shortening the transmission path of the electrical signal. The second connection terminal 230 can be located on the side of the capacitor body 210 facing the second receiving area 110b, thereby facilitating the output of the electrical signal from the second connection terminal 230 to the power module 500, improving the compactness between modules, and increasing the space utilization of the first receiving cavity 110 and the vehicle chassis.

[0050] The isolation component may include an isolation plate. Along its length direction X, the orthographic projection of the isolation plate onto the bottom wall of the housing body can be set to be less than the length of the bottom wall of the housing body, thereby enabling communication between the first receiving area 110a and the second receiving area 110b, facilitating the connection between the capacitor module 200 and the power module 500. Alternatively, clearance holes may be provided on the isolation plate to enable communication between the first receiving area 110a and the second receiving area 110b. It is understood that by providing the isolation component, it is convenient to pot the first receiving area 110a with adhesive during the assembly of the motor controller, thereby achieving a stable connection between the capacitor module 200 and the housing assembly 100.

[0051] See Figure 3The filter module 300 can be disposed in the first receiving cavity 110 and located in the first receiving area 110a, arranged along the length X of the housing assembly 100 with the capacitor module 200. The filter module 300 may include a first insulating member 310 and a first input connection bar 320, a filter component 330, and a first output connection bar 340 integrated in the first insulating member 310. The function of the first insulating member 310 is to ensure electrical insulation between the various components inside the filter module 300, preventing safety hazards such as short circuits. The first input connection bar 320 is used to receive externally input electrical energy signals, and the filter component 330 filters the input electrical energy signals to remove noise and interference signals, making the output electrical energy signal purer and more stable. The first output connection bar 340 is connected to the first connection terminal 220 of the capacitor module 200, transmitting the filtered electrical energy signal to the capacitor module 200, providing a stable power source for the charging and discharging of the capacitor module 200.

[0052] It should be noted that the first insulating component 310 is made of insulating material, and optionally, it can be injection molded as a single piece with the first input connection bar 320, the filter assembly 330, and the first output connection bar 340. This avoids the safety distances and connection structures required for independent installation of each component in traditional distributed designs. The insulating properties of the first insulating component 310 reduce safety distances and improve the compactness of the arrangement of the first input connection bar 320, the filter assembly 330, and the first output connection bar 340. This satisfies electrical insulation requirements while eliminating redundant space, reducing the overall size of the filter module 300 and allowing for a more compact fit with adjacent components such as the capacitor module 200 and the power module 500 within the housing assembly 100, thereby improving space utilization.

[0053] Optionally, the first output connection bus 340 and the first input connection bus 320 may include copper busbars.

[0054] The output module 400 is at least partially disposed in the first receiving cavity 110, and is arranged along the height direction Z of the housing assembly 100 within the first receiving cavity 110, together with the capacitor module 200. Specifically, the output module 400 may be located in the second receiving area 110b. This arrangement makes full use of the space in the first receiving cavity 110, improving space utilization. The output module 400 serves to output the processed electrical energy signal to the vehicle drive system in the motor controller.

[0055] The power module 500 is disposed in the first receiving cavity 110 and located in the second receiving area 110b, arranged along the length direction X with the output module 400. The output module 400 is connected to the second connection terminal 230 of the capacitor module 200 through the power module 500. The power module 500 plays the role of power amplification and conversion in the motor controller. The power module 500 can amplify and convert the electrical energy provided by the capacitor module 200 to meet the high-power electrical energy requirements of the vehicle drive system. Optionally, the power module 500 may include silicon carbide.

[0056] In practice, the externally input electrical energy is first filtered by the filter component 330 of the filter module 300 to remove high-frequency interference, forming a stable input power supply. Then, the electrical energy flows into the capacitor module 200 through the first output connector 340. The capacitor body 210 stores and buffers the electrical energy, suppressing voltage fluctuations. The electrical energy stabilized by the capacitor module 200 is transmitted to the power module 500 through the second connector 230. The power module 500 converts the low-voltage DC power into high-voltage or high-frequency AC power suitable for the vehicle drive system, and the amplitude, frequency, and phase of the power are adjusted by the output module 400 before finally being output to the drive system.

[0057] The compact layout of the capacitor module 200, filter module 300, output module 400, and power module 500 improves the integration and internal space utilization of the motor controller in this application, thereby reducing the size of the motor controller itself and improving the space utilization of the vehicle chassis. Furthermore, this integrated design facilitates the installation and maintenance of the motor controller, enhancing convenience and reliability during vehicle production and use.

[0058] See Figure 3 and Figure 4 In some embodiments, the first input connection row 320 includes a first input sub-row 321 and a second input sub-row 322, which are insulated from each other by a first insulating member 310; the filter assembly 330 includes a filter chip 331, and the first input sub-row 321 and the second input sub-row 322 are located on the same side of the filter chip 331.

[0059] It is understood that the first input connection bar 320 may include a first input sub-bar 321 and a second input sub-bar 322 arranged in parallel, which are electrically isolated by being embedded in the first insulating member 310. For example, the first insulating member 310 has parallel grooves at corresponding positions, and the first input sub-bar 321 and the second input sub-bar 322 are respectively embedded in different grooves. The insulating material between the grooves forms a safe electrical gap to ensure that the first input sub-bar 321 and the second input sub-bar 322 do not interfere with each other. Optionally, the first input sub-bar 321 may be a positive copper bar, and the second input sub-bar 322 may be a negative copper bar.

[0060] It should be noted that the first insulating member 310 allows the first input sub-bar 321 and the second input sub-bar 322 to be located on the same side of the filter chip 331, so that the pins of the filter chip 331 can be oriented towards the first input sub-bar 321 and the second input sub-bar 322. The first input sub-bar 321 and the second input sub-bar 322 can be soldered to their corresponding pins via extension terminals. This arrangement shortens the electrical connection path. By placing the first input sub-bar 321 and the second input sub-bar 322 on the same side of the filter chip 331, the problem of connection lines detouring around both sides of the filter chip 331 in related technologies can be avoided, making the peripheral layout of the filter chip 331 more compact, effectively shortening the power signal transmission distance, and reducing the impact of parasitic inductance and capacitance of the lines on the filtering effect.

[0061] Compared to the traditional distributed first input connection bar 320, which requires additional insulation spacing and wiring space, this solution effectively reduces the installation space required for the first input connection bar 320 and the filter chip 331 through integrated design. It also reduces line impedance and power signal loss, improving the energy transmission efficiency of the filter module 300. Combined with the overall compact layout, this further enhances the reliability and space utilization of the motor controller.

[0062] See Figure 3 and Figure 4 In some embodiments, the first output connection bar 340 includes a first output sub-bar 341 and a second output sub-bar 342. The first output sub-bar 341 and the second output sub-bar 342 are insulated from each other by a first insulating member 310. The first output sub-bar 341 is connected to the first input sub-bar 321, and the second output sub-bar 342 is connected to the second input sub-bar 322. In other embodiments, the first insulating member 310 includes a first insulating wall 311. The first input sub-bar 321 and the second input sub-bar 322 are located on opposite sides of the first insulating wall 311 and are in contact with the first insulating wall 311. The wall thickness of the first insulating wall 311 is greater than or equal to 1 mm and less than or equal to 2.5 mm.

[0063] It is understood that the first output connection bar 340 may include a first output sub-bar 341 and a second output sub-bar 342, which are electrically isolated by being embedded in the first insulating member 310. Optionally, the first insulating member 310 has parallel grooves at corresponding positions, and the first output sub-bar 341 and the second output sub-bar 342 are respectively embedded in different grooves. The insulating material between the grooves forms a safe electrical gap to ensure that the first output sub-bar 341 and the second output sub-bar 342 do not interfere with each other. The first output sub-bar 341 may be a positive copper bar, and the second output sub-bar 342 may be a negative copper bar. The first output sub-bar 341 is connected to the first input sub-bar 321, and the second output sub-bar 342 is connected to the second input sub-bar 322. Externally input electrical energy first enters the first input connection bar 320, and then is delivered to the capacitor module 200 through the first output connection bar 340.

[0064] In specific implementation, the first input sub-bar 321 and the second input sub-bar 322 are located on opposite sides of the first insulating wall 311, and the wall thickness of the first insulating wall 311 can be set to be greater than or equal to 1 mm and less than or equal to 2.5 mm. This setting ensures sufficient insulation performance, effectively isolating the first output sub-bar 341 and the second output sub-bar 342, while avoiding excessive space occupation due to an overly thick first insulating wall 311, thus contributing to the compactness of the motor controller. Furthermore, by setting the first insulating component 310, the reliability of the filter module 300 under vibration and high-temperature environments can also be ensured.

[0065] See Figure 3 and Figure 4 In some embodiments, along the width direction Y of the housing assembly 100 itself, the first insulating member 310 has opposing first slots 312 and second slots 313, and a second receiving cavity connecting the first slots 312 and second slots 313. A first output connection bar 340 is embedded in the second receiving cavity, and a portion of the first output connection bar 340 protrudes out of the second receiving cavity via the first slot 312 and is connected to the capacitor module 200. A first input connection bar 320 is embedded in the second receiving cavity and is connected to the first output connection bar 340, and a portion of the first input connection bar 320 protrudes out of the second receiving cavity via the second slot 313. The first slots 312 and second slots 313 are located on opposite sides of the first insulating member 310 along its length direction X.

[0066] The first slot 312 and the second slot 313 are located on opposite sides of the length X of the first insulating member 310 (for example, the first slot 312 is near the capacitor module 200, and the second slot 313 is near the external power interface). The second receiving cavity extends through the interior of the first insulating member 310, providing space for the first input connection bar 320 and the first output connection bar 340. One end of the first input connection bar 320 is used to connect to an external power source, and the other end is electrically connected to the first output connection bar 340 within the second receiving cavity. The other end of the first output connection bar 340 extends through the first slot 312 and connects to the first connection terminal 220 of the capacitor module 200.

[0067] The first slot 312 and the second slot 313 are located on both sides of the first insulating member 310, which facilitates the connection of the first input connection bar 320 to the external power supply and the connection of the first output connection bar 340 to the capacitor module 200, thereby further optimizing space utilization and improving the overall integration of the motor controller. In addition, the first input connection bar 320 and the first output connection bar 340 are fixed to the first insulating member 310 by an integral injection molding process, which simplifies the assembly process and improves structural stability.

[0068] See Figure 3 In some embodiments, the filter assembly 330 further includes a first magnetic ring and a second magnetic ring. The first insulating member 310 further includes a first receiving portion 314 and a second receiving portion 315. The first receiving portion 314 is disposed around the input end of the first input connection bar 320, and the first magnetic ring is received in the first receiving portion 314. The second receiving portion 315 is located between the first slot 312 and the second slot 313, and the second magnetic ring is received in the second receiving portion 315.

[0069] In a specific implementation, the filter assembly 330 may include a first magnetic ring and a second magnetic ring. To fix the first and second magnetic rings, the first insulating member 310 may include a first receiving portion 314 and a second receiving portion 315. The first receiving portion 314 is disposed around the input end of the first input connection bar 320 to accommodate the first magnetic ring. The first magnetic ring can filter the input current. The second receiving portion 315 is disposed between the first slot 312 and the second slot 313, and the second magnetic ring is accommodated within the second receiving portion 315. The second magnetic ring further filters the current to make the current output to the capacitor module 200 more stable. By setting the first and second magnetic rings, the filtering effect can be enhanced.

[0070] See Figure 5In some embodiments, the output module 400 includes a second insulator 410 and a second input connection bar 420, a Hall element 430, and a three-phase output connection bar 440 integrated within the second insulator 410. The second insulator 410 includes a plurality of sequentially connected insulating portions 411, each with a through slot. The through slots are isolated from each other. The three-phase output connection bar 440 includes a plurality of output connection portions 441, each inserted into one of the through slots. The input terminal of the three-phase output connection bar 440 is connected to the second input connection bar 420, and the output terminal of the three-phase output connection bar 440 is used to output alternating current. In some optional embodiments, a plurality of Hall elements 430 are provided, each Hall element 430 being fitted onto one of the insulating portions 411.

[0071] In a specific implementation, the second insulating member 410 may include three sequentially connected insulating portions 411, each insulating portion 411 having a through slot. Adjacent through slots are isolated by insulating material, forming independent electrical channels. The three-phase output connection bus 440 may be a copper busbar, which may include three output connection portions 441, each output connection portion 441 being inserted into a different through slot, and forming an integral structural component with the second insulating member 410 through injection molding. Thus, the second insulating member 410 can reduce the risk of phase-to-phase short circuits in the output connection portions 441 and reduce the number of external connection wires.

[0072] The second input connector 420 can be a copper busbar, which can be connected to the power module 500 by laser welding to improve current transmission efficiency and reduce resistance loss. After conversion, the electrical energy is transmitted to the three-phase output connector 440. The output end of the three-phase output connector 440 is designed with an interface structure adapted to the drive motor, which can convert DC power into three-phase AC power with controllable frequency and phase to provide power input for the vehicle drive motor.

[0073] Understandably, three Hall elements 430 can be configured, and the Hall elements 430 are used for overcurrent protection and current monitoring. Each Hall element 430 is respectively sleeved on the outside of the corresponding third insulating part 411. This configuration can reduce the probability of the Hall element 430 being interfered with by the current of the second input connection bar 420, thereby accurately monitoring the current.

[0074] It should be noted that each output connection part 441 is inserted into a different through slot and forms an integral structure with the second insulating part 410 through injection molding process. The insulation characteristics of the second insulating part 410 can reduce the safety distance, thereby improving the compactness of the layout and reducing the size of the output module 400 to improve space utilization.

[0075] In some embodiments, the insulating portion 411 includes a second insulating wall that surrounds a through groove. Adjacent through grooves are isolated from each other by the second insulating wall. The wall thickness of the second insulating wall is greater than or equal to 1 mm and less than or equal to 2.5 mm. In some alternative embodiments, the distance between two adjacent output connections 441 is configured to be greater than or equal to 1 mm and less than or equal to 2.5 mm.

[0076] It is understandable that setting the thickness of the second insulating wall in the range of 1mm to 2.5mm, including the two extreme values ​​of 1mm and 2.5mm, can meet the insulation requirements of the output connection part 441, and can also avoid the waste of space caused by excessive wall thickness, so that the adjacent through slots are arranged compactly.

[0077] By providing a second insulating wall, the distance between two adjacent output connection portions 441 is configured within the range of 1mm to 2.5mm. On one hand, isolating adjacent output connection portions 441 with the second insulating wall meets minimum electrical clearance requirements, preventing interphase arcing or leakage current. On the other hand, compared to traditional discrete designs, this application can reduce the overall width of the three-phase output connection bar 440, improving the compactness of the output module 400 and increasing space utilization. Furthermore, by providing the second insulating element 410, the reliability of the three-phase output connection bar 440 under vibration and high-temperature environments can be ensured.

[0078] See Figure 2 In some embodiments, the shell body further includes a first cover plate 120, a shell 130, and a second cover plate 140. Along the height direction Z, the shell 130 has a first opening and a second opening, and the first cover plate 120 and the second cover plate 140 are respectively disposed over the first opening and the second opening, so as to jointly enclose a first receiving cavity 110 with the shell 130. Optionally, the first cover plate 120 and the second cover plate 140 are detachably connected to the shell 130.

[0079] Understandably, the housing assembly 100 adopts a split, detachable structure to balance sealing and ease of maintenance. The housing 130 is hollow, with a first opening and a second opening respectively at both ends along the height direction Z.

[0080] The first cover plate 120 and the second cover plate 140 respectively cover the first opening and the second opening, and are fixed to the housing 130 by bolt connection, snap-fit ​​engagement or other detachable methods. For example, the edge of the housing 130 is provided with a flange and has mounting holes, and the first cover plate 120 and the second cover plate 140 are provided with threaded holes at corresponding positions. Screws are passed through the mounting holes to achieve fastening, so as to ensure the dustproof and waterproof performance of the first receiving cavity 110.

[0081] This design creates a closed and easily detachable three-dimensional space within the first accommodating cavity 110, providing a safe installation environment for internal components such as the capacitor module 200 and filter module 300. The detachable connection facilitates module installation during production assembly and subsequent maintenance and repair, improving maintenance efficiency.

[0082] See Figure 2 In some embodiments, the housing 130 has opposing input ports 131 and output ports along its length X, and the input terminal of the first input connection bar 320 is used to connect to an external power supply via the input port 131. At least a portion of the three-phase output connection bar 440 is located outside the housing 130 via the output ports.

[0083] It should be noted that this configuration creates a through-path signal transmission path on housing 130. The input terminal of the first input connector 320 is electrically connected to an external power supply via input port 131 to ensure stable input of high-voltage current. At least a portion of the three-phase output connector 440 is located outside housing 130 via output ports for connection to the vehicle's drive system.

[0084] Therefore, by placing the input port 131 and the output port on opposite sides of the housing 130, the cross-interference of the internal connecting lines of the housing 130 can be reduced, the physical distance between the current input and output can be shortened, and the internal structure of the housing 130 can be made more compact.

[0085] See Figure 2 In some embodiments, a circuit board module 600 is also included. The circuit board module 600 is located within the first receiving cavity 110 and arranged along the height direction Z with the power module 500. The circuit board module 600 includes an integrated circuit board 610, a shielding plate 620, and signal terminals 630. The shielding plate 620 and the signal terminals 630 are respectively disposed on opposite sides of the integrated circuit board 610 in the height direction Z. The integrated circuit board 610 is connected to the output module 400 and the power module 500. It should be noted that the integrated circuit board 610 is configured to integrate control and drive functions.

[0086] The shielding plate 620 and signal terminals 630 are respectively disposed on opposite sides of the integrated circuit board 610 in the Z-direction of the height direction. The shielding plate 620 effectively blocks external electromagnetic interference, ensuring the stable operation of the integrated circuit board 610. Specifically, the shielding plate 620 can be made of metal and disposed on the front side of the integrated circuit board 610 to form an electromagnetic shielding cavity, effectively isolating external high-frequency noise from interfering with the control signals. The signal terminals 630 are used to realize signal interaction with external devices.

[0087] The integrated circuit board 610 is connected to the output module 400 and the power module 500. On one hand, the integrated circuit board 610 is used to control and regulate the AC power output by the output module 400 to adapt to the needs of the vehicle drive system. On the other hand, the integrated circuit board 610 can drive the power module 500 to ensure its efficient and stable operation, thereby improving the performance and reliability of the motor controller.

[0088] Understandably, by using integrated circuit board 610, compared to the separate arrangement of control circuit board and drive circuit board in related technologies, this application can reduce connecting lines, improve the compactness of circuit board module 600, thereby reducing the size of circuit board module 600 and improving space utilization. In specific implementation, in order to avoid the circuits performing drive functions and the circuits performing control functions from interfering with each other, a partitioned design can be adopted on the same substrate to design circuits with different functions on different partitions.

[0089] Furthermore, by stacking the circuit board module 600 and the power module 500 vertically along the height direction Z, the space utilization of the first receiving cavity 110 is further optimized, enabling the control function and power conversion function to achieve efficient collaboration within a compact space.

[0090] See Figure 6 In some embodiments, one end of the connecting bar 700 is welded to the power module 500, and the other end of the connecting bar 700 is welded to the second connecting end 230, so that the capacitor module 200 is connected to the power module 500.

[0091] See Figure 8 and Figure 9 In other embodiments, the capacitor body 210 of the capacitor module 200 includes a plurality of outer sidewalls 211, at least two of which are fitted and connected to the inner wall of the housing assembly 100.

[0092] It should be noted that the connecting busbar 700 can be a copper busbar. The connecting busbar 700 can be connected to the power module 500 and the second connecting terminal 230 via laser welding. Furthermore, during the assembly of the motor controller, all connections between copper busbars can be made using laser welding. Laser welding offers high precision, ensuring low impedance and high reliability at the connection points between copper busbars. It should also be noted that the capacitor core of the capacitor body 210 can be placed inside the housing 130, and then the capacitor core and housing 130 can be potted together. This allows multiple outer walls 211 of the capacitor body 210 to connect to the housing 130, thereby enhancing the stability of the capacitor body 210 and preventing it from shaking. Through the multi-faceted connection between the capacitor body 210 and the housing 130, the heat generated during operation of the capacitor body 210 can be quickly dissipated, improving heat dissipation.

[0093] Based on the above embodiments, this application provides a vehicle that includes the motor controller provided in any of the above embodiments.

[0094] The motor controller has been described in detail in the above embodiments and will not be repeated here.

[0095] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A motor controller, characterized in that, include: A housing assembly includes a housing body and a spacer. The housing body has a first receiving cavity. The spacer is located in the first receiving cavity and connected to the housing body to divide the first receiving cavity into a first receiving area and a second receiving area arranged along the height direction of the housing assembly itself. The first receiving area and the second receiving area are partially connected. A capacitor module is disposed in the first receiving area. The capacitor module includes a capacitor body and a first connection end and a second connection end disposed in the capacitor body. The capacitor body includes a plurality of connected outer sidewalls. The first connection end and the second connection end are respectively located on two adjacent outer sidewalls, and at least a portion of the second connection end is located in the second receiving area. A filtering module is disposed in the first accommodating area and arranged with the capacitor module along the length of the housing assembly itself. The filtering module includes a first insulating member and a first input connection bar, a filtering component, and a first output connection bar integrated into the first insulating member. The first output connection bar is connected to the first connection end. The output module is at least partially disposed in the second accommodating area and arranged with the capacitor module along the height direction; A power module is disposed in the second accommodating area and arranged along the length direction with the output module. The output module is connected to the second connection terminal through the power module.

2. The motor controller according to claim 1, characterized in that, The first input connection bar includes a first input sub-bar and a second input sub-bar, and the first input sub-bar and the second input sub-bar are insulated from each other by the first insulating member; The filtering component includes a filtering chip, and the first input sub-row and the second input sub-row are located on the same side of the filtering chip.

3. The motor controller according to claim 2, characterized in that, The first output connection bar includes a first output sub-bar and a second output sub-bar. The first output sub-bar and the second output sub-bar are insulated from each other by the first insulating member. The first output sub-bar is connected to the first input sub-bar, and the second output sub-bar is connected to the second input sub-bar. And / or, the first insulating element includes a first insulating wall, the first input sub-bar and the second input sub-bar are respectively located on opposite sides of the first insulating wall and are in contact with the first insulating wall, and the wall thickness of the first insulating wall is greater than or equal to 1 mm and less than or equal to 2.5 mm.

4. The motor controller according to claim 1, characterized in that, Along the width direction of the housing assembly itself, the first insulating member has a first slot, a second slot, and a second receiving cavity that connects the first slot and the second slot. The first output connection bar is embedded in the second receiving cavity, and a portion of the first output connection bar protrudes out of the second receiving cavity through the first slot and is connected to the capacitor module. The first input connection bar is embedded in the second receiving cavity and connected to the first output connection bar, and a portion of the first input connection bar protrudes out of the second receiving cavity through the second slot; The first slot and the second slot are located on opposite sides of the first insulating member along the length direction.

5. The motor controller according to claim 4, characterized in that, The filtering component further includes a first magnetic ring and a second magnetic ring; The first insulating member further includes a first receiving portion and a second receiving portion, the first receiving portion being disposed around the input end of the first input connection bar, and the first magnetic ring being received in the first receiving portion; The second receiving portion is located between the first slot and the second slot, and the second magnetic ring is received in the second receiving portion.

6. The motor controller according to claim 1, characterized in that, The output module includes a second insulating element, a second input connection bar integrated into the second insulating element, a Hall element, and a three-phase output connection bar; The second insulating component includes a plurality of insulating parts connected in sequence, each insulating part having a through slot, the plurality of through slots being isolated from each other, and the three-phase output connection bar including a plurality of output connection parts, each output connection part being inserted into one of the through slots; The input terminal of the three-phase output connector is connected to the second input connector, and the output terminal of the three-phase output connector is used to output AC power. The Hall element is configured as a plurality of components, and each Hall element is sleeved on one of the insulating portions.

7. The motor controller according to claim 6, characterized in that, The insulating part includes a second insulating wall, which surrounds and forms the through groove. Two adjacent through grooves are isolated from each other by the second insulating wall. The wall thickness of the second insulating wall is greater than or equal to 1 mm and less than or equal to 2.5 mm. And / or, the distance between two adjacent output connections is greater than or equal to 1 mm and less than or equal to 2.5 mm.

8. The motor controller according to claim 6, characterized in that, The shell body also includes a first cover plate, a shell and a second cover plate. Along the height direction, the shell has a first opening and a second opening. The first cover plate and the second cover plate are respectively covered on the first opening and the second opening, so as to form the first receiving cavity together with the shell. And / or, the first cover plate and the second cover plate are detachably connected to the housing, respectively.

9. The motor controller according to claim 8, characterized in that, The housing has opposite input ports and output ports along the length direction, and the input end of the first input connection bar is used to connect to an external power supply via the input port; At least a portion of the three-phase output connectors are located outside the housing via the output ports.

10. The motor controller according to any one of claims 1 to 9, characterized in that, It also includes a circuit board module, which is located in the second accommodating area and arranged with the power module along the height direction. The circuit board module includes an integrated circuit board, a shielding plate, and signal terminals. The shielding plate and the signal terminals are respectively disposed on opposite sides of the integrated circuit board in the height direction. The integrated circuit board is connected to the output module and the power module.

11. The motor controller according to any one of claims 1 to 9, characterized in that, It also includes a connecting strip, one end of which is welded to the power module, and the other end of which is welded to the second connecting end, so that the capacitor module is connected to the power module; And / or, at least two of the plurality of outer sidewalls are fitted and connected to the inner wall of the housing assembly.

12. A vehicle, characterized in that, Including the motor controller as described in any one of claims 1 to 11.

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