A power module, motor controller, electrically controlled assembly, and vehicle

Abstract

This application provides a power module, a motor controller, an electronic control assembly, and a vehicle. The power module includes: a first power module comprising: at least two first bridge arms arranged along a second direction on the same first substrate; all terminals of at least one first terminal pair in at least one of the first bridge arms arranged along a first direction; the second direction being perpendicular to the first direction. This reduces the area occupied by the signal terminal block layout, improves the space utilization of the control circuit PCB adapted to the power module, and compresses the PCB area.

Description

Technical Field

[0001] This application relates to the field of motor controller technology, and more particularly to a power module, a motor controller, an electronic control assembly, and a vehicle. Background Technology

[0002] The power module is one of the key semiconductor modules in a vehicle control system. At a minimum, the power module can be used for electrical energy conversion. For example, in hybrid vehicles, the power module can convert direct current (DC) to alternating current (AC) to power the drive motor, or it can convert the AC output from the generator motor to DC to charge the vehicle battery. Typically, a printed circuit board is located above the power module, containing control circuitry that controls the switching of the power semiconductors in the power bridge circuit via signal terminals.

[0003] In existing power modules, the signal terminals connected to the power bridge circuit are typically located around the perimeter of the power bridge circuit. For design convenience, existing signal terminals are numerous and varied, widely distributed, and spaced far apart. However, in power module design, to ensure electrical safety, sufficient spacing must be maintained between signal terminals, and the layout of the signal terminals must allow enough space for components in the control circuitry. This reduces the space utilization of the printed circuit board (PCB), increasing the PCB area and consequently the size of the power module.

[0004] Therefore, it is urgent to optimize the design of power modules and promote their miniaturization. Utility Model Content

[0005] In view of the above problems, this application provides a power module, a vehicle, a motor controller, an electronic control assembly, and a vehicle, to reduce the layout area occupied by signal terminals in the power module. The specific solution is as follows:

[0006] In a first aspect, this application provides a power module, including a first power module, the first power module comprising:

[0007] At least two first bridge arms arranged in the second direction on the same first liner;

[0008] All terminals of at least one first terminal pair in at least one first bridge arm are arranged along a first direction; the second direction is perpendicular to the first direction.

[0009] Optionally, the first power module is a power generation module.

[0010] Optionally, the second direction is parallel to the surface of the first liner, just like the first direction.

[0011] Optionally, all terminals of at least one terminal pair in each of the first bridge arms are arranged along the first direction.

[0012] Optionally, each of the first bridge arms includes a first terminal group and a second terminal group;

[0013] The first terminal group is electrically connected to the upper bridge circuit of the first bridge arm and includes one of the terminal pairs;

[0014] The second terminal group is electrically connected to the lower bridge circuit of the first bridge arm and includes one of the terminal pairs.

[0015] Optionally, the terminal pair of the first terminal group includes a first emitter terminal and a first gate terminal;

[0016] And / or,

[0017] The terminal pair of the second terminal group includes a second emitter terminal and a second gate terminal.

[0018] Optionally, the terminal pair of the first terminal group further includes a first collector terminal; and / or,

[0019] The terminal pair of the second terminal group further includes a second collector terminal.

[0020] Optionally, the first power module includes a first collector terminal;

[0021] The upper bridge circuits of the at least two first bridge arms arranged along the second direction share the first collector terminal.

[0022] Optionally, the first power module further includes a first temperature measuring terminal group, which includes two first temperature measuring terminals arranged along the first direction, and the first temperature measuring terminals are used to measure the temperature of the first liner.

[0023] Secondly, this application also provides a motor controller, including the power module provided in any of the above embodiments.

[0024] Thirdly, this application also provides an electronic control assembly, including a motor controller as provided in any of the above embodiments.

[0025] Fourthly, this application also provides a vehicle including the electronic control assembly provided in any of the above embodiments.

[0026] The power module provided in this application includes a first power module, which includes at least two first bridge arms arranged along a first direction and disposed on the same first substrate; all terminals of at least one terminal pair in at least one first bridge arm are arranged along a second direction. Compared with the signal terminals arranged along the edge in the prior art, the layout is more compact, reducing the area of ​​the signal terminals projected onto the printed circuit board, thereby increasing the free area on the printed circuit board and improving the space utilization of the printed circuit board. Attached Figure Description

[0027] Figure 1 A schematic diagram of the topology of a range-extended vehicle is shown.

[0028] Figure 2 A schematic diagram of the topology of the drive module and the power generation module in the prior art is shown;

[0029] Figure 3 A layout diagram of signal terminals in the prior art is shown;

[0030] Figure 4 An optional layout diagram of the signal terminals provided in an embodiment of this application is shown;

[0031] Figure 5 A schematic diagram of the clearance space formed by the signal terminals provided in an embodiment of this application is shown.

[0032] The reference numerals in the figure indicate:

[0033] 1-Power generation module; 2-Drive module; 3-PCB projection range; 31-First clearance space; 32-Second clearance space; 33-Third clearance space; 34-Fourth clearance space; 35-Fifth clearance space. Detailed Implementation

[0034] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings, which illustrate preferred embodiments of the application. However, this application may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this application will be thorough and complete.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0036] New energy vehicles include electric drive systems, which use electricity to propel the vehicle. Taking range-extended electric vehicles as an example, their topology is as follows: Figure 1 As shown. The core component is the range extender, whose main function is to activate when the battery charge drops to a certain level, causing the engine to drive the generator to produce electricity. Part of the generated electricity can be used to power the drive motor, and the other part can be used to charge the battery.

[0037] Range-extended electric vehicles (REEVs) offer numerous advantages, including: During daily urban commutes, they can operate on pure electric power with zero emissions, reducing exhaust pollution and meeting environmental protection requirements. Furthermore, electric drive is more energy-efficient than gasoline drive, lowering energy consumption and operating costs.

[0038] Range-extended electric vehicles are equipped with an engine as a range extender. When the battery is low, the engine can start to generate electricity to provide continuous power to the vehicle, avoiding the range anxiety problem caused by the limited driving range of pure electric vehicles and making long-distance travel more convenient.

[0039] In addition, range-extended electric vehicles also have the following advantages in terms of driving experience:

[0040] Pure electric drive: The range-extended topology is essentially a pure electric drive system. The vehicle's power is entirely provided by the electric motor; the engine does not directly drive the vehicle but instead acts as a generator, starting when the battery is low to convert fuel into electricity to power the electric motor or charge the battery. This pure electric drive method ensures a single and pure power source for the vehicle, consistent with the drive system of pure electric vehicles, fundamentally guaranteeing a comfortable driving experience.

[0041] Rapid power response: The characteristics of an electric motor allow it to output maximum torque instantly. In range-extended electric vehicles, when the driver presses the accelerator pedal, the electric motor responds immediately, quickly delivering powerful acceleration for rapid start-up and acceleration. This instantaneous power response is far superior to traditional gasoline vehicles, giving the driver a more direct and rapid push-back feeling. Whether it's frequent start-stop maneuvers in urban traffic or overtaking maneuvers on highways, it can easily handle the situation, providing a smooth driving experience.

[0042] No power interruption: Since range-extended electric vehicles are always driven by an electric motor, there is no power interruption issue like that experienced during gear shifts in traditional gasoline vehicles. Power output remains continuous and smooth at both low and high speeds. Even when the battery is low and the engine starts generating electricity, the system uses precise control strategies to ensure that the electric motor's power output is unaffected, preventing any jerking or power interruption. This provides the driver with a consistently stable driving experience, enhancing driving comfort and safety.

[0043] However, in existing technologies, the electric drive assembly of range-extended electric vehicles includes components such as a generator, drive motor, generator controller, and drive motor controller. The generator controller and drive motor controller are independent components, each with its own power supply (e.g., using diodes, IGBTs, SiC semiconductors for AC-DC conversion), current sensors, temperature sensors, and motor rotor position sensors. This results in high weight, size, and cost, necessitating optimization.

[0044] Figure 2 This diagram illustrates the topology of the drive module and power generation module in an existing range-extended electric vehicle. (See also...) Figure 2 The drive module converts the direct current (DC) from the high-voltage battery into alternating current (AC) to power the vehicle's drive motor, providing torque to rotate the wheels. The generator module converts the AC output from the generator back to DC to charge the high-voltage battery or power the drive motor. Figure 2 The power generation module shown as an example is a three-phase full-bridge circuit; the drive module consists of three independent half-bridges. See also... Figure 2 The power generation module / drive module provided in this application (taking a 3-phase full-bridge as an example) includes three bridge arms (or a group of bridge arms). Each bridge arm includes an upper bridge arm and a lower bridge arm. The upper bridge arm and the lower bridge arm each include an active switching chip and a passive freewheeling chip connected in reverse parallel with it. In this application, the rectifier bridge and the power generation bridge are collectively referred to as the power bridge.

[0045] A schematic diagram of the drive module and power generation module of an existing range-extended electric vehicle. (For example...) Figure 3 As shown, both the existing drive module and the power generation module use a half-bridge module as the smallest unit. Figure 3 A schematic diagram of the layout of signal terminals in the prior art is shown. For example... Figure 3 As shown, in the prior art, both the drive module and the power generation module employ three independent half-bridge circuits, with signal terminals arranged along the substrate edge of each half-bridge circuit. See also... Figure 3Gate signal terminal G1, emitter signal terminal E1, and collector signal terminal C1 are used to transmit the U-phase upper bridge drive signal of the drive module; gate signal terminal G2, emitter signal terminal E2, and collector signal terminal C2 are used to transmit the U-phase lower bridge drive signal of the drive module; gate signal terminal G3, emitter signal terminal E3, and collector signal terminal C3 are used to transmit the V-phase lower bridge drive signal of the drive module; gate signal terminal G4, emitter signal terminal E4, and collector signal terminal C4 are used to transmit the V-phase lower bridge drive signal of the drive module. Gate signal terminal G5, emitter signal terminal E5, and collector signal terminal C5 are used to transmit the W-phase lower bridge drive signal of the drive module; gate signal terminal G6, emitter signal terminal E6, and collector signal terminal C6 are used to transmit the W-phase lower bridge drive signal of the drive module; temperature measurement signal terminals T1 and T2 are used to transmit the signal of the U-phase temperature measuring resistor; temperature measurement signal terminals T3 and T4 are used to transmit the signal of the V-phase temperature measuring resistor; and temperature measurement signal terminals T5 and T6 are used to transmit the signal of the W-phase temperature measuring resistor. Each half-bridge unit requires at least 8 signal terminals, and the drive module or power generation module requires at least 24 signal terminals. To ensure electrical safety with the power bridge circuit and related control circuit components in the power module, sufficient spacing between signal terminals is required, along with adequate clearance for the installation of control circuit components. For example, the spacing and clearance between signal terminals must meet the requirements of safety specifications (e.g., GB / T 16935.1-2008). This leads to an increase in the area of ​​the printed circuit boards (hereinafter referred to as PCBs) required to house the control circuitry associated with the power bridge circuit.

[0046] In view of this, this application provides a power module, including a first power module. For example... Figure 4 As shown, the first power module includes: at least two first bridge arms arranged along a second direction on the same first liner; and all terminals of at least one first terminal pair in at least one of the first bridge arms arranged along the first direction. The first direction and the second direction are parallel to the surface of the first liner. The first direction and the second direction are perpendicular. Exemplarily, the first power module is a power generation module. Exemplarily, as... Figure 4 As shown, the power generation module includes three first bridge arms corresponding to the U, V, and W phases respectively, arranged along a second direction. Each first bridge arm includes at least one first terminal pair, such as E8 and G8, or G7 and E7. All terminals of at least one first terminal pair are arranged along the first direction. Figure 4As shown, the terminals of at least one pair of E8, G8, and E7, G7 are arranged along a first direction. For example, E8 and G8 are arranged vertically, and E7 and G7 are arranged horizontally; or, E8 and G8 are arranged vertically, and E7 and G7 are arranged vertically; or, E8 and G8 are arranged horizontally, and E7 and G7 are arranged vertically.

[0047] It should be noted that the vertical arrangement described in this application is not limited to a strictly vertical arrangement. For example, for two vertically arranged terminals, the angle between the line connecting the centers of the terminals and the second direction is within the range of 90°±15°. Similarly, the horizontal arrangement described in this application is not limited to a strictly horizontal arrangement. For example, for two horizontally arranged terminals, the angle between the line connecting the centers of the terminals and the first direction is within the range of 90°±15°.

[0048] According to the embodiments of this application, such as Figure 4 As shown, each first bridge arm includes a first terminal group and a second terminal group; the first terminal group is electrically connected to the upper bridge circuit of the first bridge arm and includes a terminal pair; the second terminal group is electrically connected to the lower bridge circuit of the first bridge arm and includes a terminal pair. For example, the first terminal group includes a terminal pair comprising two terminals, E8 and G8. As another example, the second terminal group includes a terminal pair comprising two terminals, E7 and G7.

[0049] According to some optional implementations, the terminal pairs corresponding to the upper bridge arm in the first bridge arm are arranged along a first direction. For example, Figure 4 E8 and G8 are arranged along the first direction.

[0050] According to some optional implementations, the terminal pairs corresponding to the lower bridge circuit in the first bridge arm are arranged along a first direction. For example, Figure 4 E7 and G7 are arranged along the first direction.

[0051] According to some optional implementations, the terminal pairs corresponding to the upper and lower bridge circuits in the first bridge arm are arranged along a first direction. For example... Figure 4 E8 and G8 are arranged along the first direction, and E7 and G7 are arranged along the first direction.

[0052] According to an optional embodiment of this application, the terminal pair of the first terminal group includes a first emitter terminal and a first gate terminal. In this document, the emitter terminal is denoted by E, and the gate terminal by G. For example, the first emitter terminal includes E8, E10, and E12; the first gate terminal includes G8, G10, and G12.

[0053] According to an optional embodiment of this application, the terminal pair of the second terminal group includes a second emitter terminal and a second gate terminal. In this document, the emitter terminal is denoted by E, and the gate terminal by G. For example, the second emitter terminal includes E7, E9, and E11; the second gate terminal includes G7, G9, and G11.

[0054] According to some optional embodiments, the first terminal group further includes a first collector terminal. Optionally, the second terminal group further includes a second collector terminal. The collector terminal is denoted by C herein. Exemplarily, at least one first bridge arm's first terminal group includes a first terminal pair and a first collector terminal. The first terminal pair and the first collector terminal are arranged along a first direction. Exemplarily, a first emitter terminal, a first gate terminal, and a first collector terminal are arranged along the first direction, their vertical order determined according to design requirements. Also exemplaryly, the first gate terminal and the first emitter terminal are arranged along a second direction, with the first collector terminal positioned above or below the line connecting them. Optionally, at least one first bridge arm's second terminal group includes a second terminal pair and a second collector terminal. The second terminal pair and the second collector terminal are arranged along the first direction. For example, the second emitter terminal, the second gate terminal, and the second collector terminal are arranged along the first direction, their vertical order determined according to design requirements. Also, for example, the second gate terminal and the second emitter terminal are arranged along the second direction, with the second collector terminal positioned above or below the line connecting them.

[0055] See Figure 2 In the upper bridge circuit, all the collectors of the insulated-gate bipolar transistor (IGBT) chips have the same potential. Similarly, in the lower bridge circuit, all the emitters of the IGBT chips also have the same potential. The collectors of the IGBT chips in the lower bridge circuit and the emitters of the IGBT chips in the upper bridge circuit also have the same potential.

[0056] According to an optional embodiment of this application, the first power module further includes a first collector terminal (such as...). Figure 4 (As shown in C7); at least two upper bridge circuits of the first bridge arms arranged along the second direction share the first collector terminal.

[0057] According to some alternative implementations, the first power module further includes a second collector terminal, and the lower bridge circuits of at least two first bridge arms arranged along a second direction share a common emitter terminal.

[0058] According to some optional embodiments, the first power module further includes a first temperature sensing terminal group. The first temperature sensing terminal group includes two first temperature sensing terminals arranged along a first direction, which are used to measure the temperature of the first liner. For example, the first temperature sensing terminal group includes T7 and T8, which are connected to a first temperature sensor.

[0059] According to some optional implementations, in the first power module, at least two first bridge arms share a first collector terminal. The first collector terminal and the first temperature sensing terminal are located on the same side of the first liner. For example, as shown... Figure 4 As shown, the first collector terminal C7 and the first temperature measuring terminal group (T7 and T8) are located on the left side of the first liner.

[0060] According to some optional embodiments, in the first power module, at least two first bridge arms share a second emitter terminal. Optionally, the second emitter terminal and the first temperature sensing terminal group are located on the same side of the first substrate. Optionally, the second emitter terminal and the second gate terminals of at least two bridge arms are arranged along a second direction. For example, the lower bridge circuit of the first bridge arm shares the second emitter terminal E7; wherein E7, G7, G9, and G11 are arranged along the second direction. As another example, the lower bridge circuit of the first bridge arm shares the second emitter terminal E7; E7 and the first temperature sensing terminal group are located on the same side of the first substrate.

[0061] It should be noted that in this article, the first bridge arm is also referred to as the first bridge circuit, and the upper / lower bridge circuit is referred to as the upper / lower bridge arm.

[0062] According to embodiments of this application, any terminal pair in the first power module includes an emitter terminal and a gate terminal. Optionally, the two terminals in any terminal pair can be arranged horizontally or vertically. In the first power module provided by this application, each bridge arm includes at least one terminal pair, the terminal pairs between different bridge arms are arranged along a second direction, and the terminals in the same terminal pair are arranged along a first direction, making the terminal arrangement more compact. Furthermore, this application further reduces the number of terminals in the first power module by having the upper bridge circuits of different bridge arms share collector terminals, the lower bridge circuits of different bridge arms share emitter terminals, and terminals with equal potentials in the upper and lower bridge circuits share terminals. This makes the terminal layout more compact and is more conducive to improving the space utilization of the PCB.

[0063] According to embodiments of this application, the power module provided in this application further includes a second power module. Exemplarily, the second power module is a drive module.

[0064] According to an embodiment of this application, the second power module includes at least two second bridge arms arranged along a second direction. Each second bridge arm includes an upper bridge circuit and a lower bridge circuit, both of which include power semiconductors. The upper bridge circuit and the lower bridge circuit are arranged along a first direction.

[0065] The second power module may also include a second substrate, with the second bridge arm disposed on the second substrate. Each second substrate may have a half-bridge circuit, forming an inverter bridge or rectifier bridge, with the second bridge arm being the half-bridge circuit, and each half-bridge circuit corresponding to a current flowing through it.

[0066] In the embodiments of this application, such as Figure 4 As shown, the second direction is parallel to the liner structure of the power module and is arranged along the arrangement direction of the second bridge arm; the first direction is parallel to the liner structure of the second power module. That is, the second direction is parallel to the surface of the first liner, just like the first direction. The second direction is perpendicular to the first direction.

[0067] Each second bridge arm also includes a third terminal group and a fourth terminal group, used to transmit signals from the corresponding upper bridge circuit and lower bridge circuit, respectively. The third terminal group is used to transmit the emitter signal, gate signal, and collector signal of the power semiconductor in the upper bridge circuit; the fourth terminal group is used to transmit the emitter signal and gate signal of the power semiconductor in the lower bridge circuit.

[0068] According to embodiments of this application, the third terminal group includes a third emitter terminal, a third gate terminal, and a third collector terminal arranged along a first direction. In an optional embodiment, the third terminal group includes a third emitter terminal electrically connected to the emitter of a power semiconductor in the upper bridge circuit, a third gate terminal electrically connected to the gate of a power semiconductor in the upper bridge circuit, and a third collector terminal electrically connected to the collector of a power semiconductor in the upper bridge circuit, wherein the third emitter terminal, the third gate terminal, and the third collector terminal are arranged along the first direction. The fourth terminal group includes a fourth emitter terminal electrically connected to the emitter of a power semiconductor in the lower bridge circuit and a fourth gate terminal electrically connected to the gate of a power semiconductor in the lower bridge circuit, wherein the fourth emitter terminal and the fourth gate terminal are arranged along the first direction.

[0069] Since the collector of the power semiconductor in the lower bridge circuit of the second bridge arm in this embodiment is shared with the emitter of the power semiconductor in the upper bridge, the second terminal group may not have a collector terminal. Therefore, the collector signal transmission of the power semiconductor in the lower bridge circuit is omitted in the second terminal group, and the second terminal group may also include a collector terminal.

[0070] The third and fourth terminal groups are arranged along the first direction on the second power module. Compared with the prior art, where the upper bridge circuit signal terminals and the lower bridge circuit signal terminals are arranged relatively dispersedly along the first direction on the edge of the substrate structure, the arrangement of the signal terminals is changed, making the layout of the signal terminals more concentrated, compact and non-dispersed, and reserving sufficient space for the layout of the circuit board.

[0071] Compared to traditional technologies that use multiple types of signal terminals, the embodiments of this application reduce the number of terminals in the first / second power modules by simplifying terminal types and using shared terminals. This reduces the area occupied by the vias on the corresponding PCB board while meeting the installation specification clearance requirements, thereby helping to reduce the size of the adapter PCB board.

[0072] In an optional embodiment, the third and fourth terminal groups are arranged along the first direction and positioned in the middle portion of the second substrate in the second direction. Compared to the conventional arrangement of terminals around the perimeter of the half-bridge circuit, this layout places the terminals in the middle portion of the second bridge arm, allowing for chip mounting space on both sides, resulting in a more compact terminal arrangement. Furthermore, by reducing the number of terminals, the terminal arrangement in the second power module can be made more compact, thereby reducing the corresponding PCB board size. Simultaneously, the more compact terminal arrangement also helps ensure sufficient distance between the vias on the PCB board and the PCB itself, facilitating the placement of components and the mounting of the PCB board.

[0073] The second power module may also include a second temperature sensor and a second temperature measurement terminal group. The second temperature measurement terminal group is electrically connected to the second temperature sensor. The second temperature sensor measures the temperature of the second liner of the corresponding phase's second bridge arm and outputs the signal through the second temperature measurement terminal group. Specifically, the second temperature measurement terminal group includes two second temperature measurement terminals (e.g., T1 and T2, T3 and T4, T5 and T6), which are connected to both ends of the second temperature sensor. The third terminal group, the second temperature measurement terminal group, and the fourth terminal group are arranged along the first direction on the second bridge arm.

[0074] In an optional embodiment, a second temperature sensor and a second temperature measurement terminal group are provided on the second liner corresponding to one phase of the multi-phase second bridge arm. By measuring temperature using only one second temperature sensor, the number of terminals can be reduced. For example, the second liner of the second power module is provided with the second temperature measurement terminal group. The power module is equipped with a cooling device, and the coolant in the cooling device can flow from the second power module to the first power module. The temperature of the second liner closest to the first power module is the highest temperature of the second power module. Considering cost reduction, only detecting the highest temperature of the second power module can also ensure the normal operation of the solution.

[0075] In an optional embodiment, each of the second arms of the second power module is provided with a second temperature sensor and a second set of sensors.

[0076] In an optional embodiment, the second temperature sensing terminal group is disposed in the first direction between the third and fourth terminal groups of the second bridge arm, which also facilitates leaving space on both sides of the second bridge arm. The second temperature sensing terminal group includes at least two second temperature sensing terminals, which are arranged along the second direction. The two third terminals are arranged horizontally along the second direction, which can save height space in the first direction.

[0077] In this embodiment, the third terminal group and the fourth terminal group are arranged along the first direction. It is not required that the two terminal groups be aligned along a straight line parallel to the first direction. They can also be staggered by a certain distance, as long as the third terminal group and the fourth terminal group are arranged along the first direction as a whole.

[0078] For example, the second bridge arm includes an IGBT (Insulated-Gate Bipolar Transistor) and an FRD (Fast Recovery Diode).

[0079] Exemplarily, the third terminal group and the fourth terminal group are located in the middle portion of the first bridge arm along the first direction, and the third terminal group and the fourth terminal group are aligned along the second direction, with... Figure 4 The arrangement corresponds to the layout in the text.

[0080] For example, the upper bridge circuit and the lower bridge circuit are offset in the second direction. At this time, the third terminal group is arranged in the middle part of the upper bridge arm circuit and the fourth terminal group is arranged in the middle part of the lower bridge circuit. Although the third terminal group and the fourth terminal group are distributed along the first direction, they are offset in the first direction.

[0081] For example, the third terminal group and the fourth terminal group are not located in the middle part of the second bridge arm, but are located on different sides of the second bridge arm along the second direction. Specifically, the third terminal group is located on the right side of the upper bridge circuit and the fourth terminal group is located on the left side of the lower bridge circuit.

[0082] For example, the third terminal group and the fourth terminal group are also respectively located on different sides of the second bridge arm along the second direction, specifically the third terminal group is located on the left side of the upper bridge circuit and the fourth terminal group is located on the right side of the lower bridge circuit.

[0083] As can be seen, the positions of the third and fourth terminal groups can be arranged according to actual needs, and the third and fourth terminal groups can be arranged along the second direction.

[0084] According to the embodiments of this application, the arrangement direction of the second temperature measuring terminal group can be either the first direction or the second direction.

[0085] Next, combined Figure 4 and Figure 5The power module provided in this application is described by way of example.

[0086] For example, this application provides a power module with a more compact signal terminal layout. For instance... Figure 5 As shown, the power module includes a power generation module 1 and a drive module 2. In this application, the power generation bridge circuit of the power generation module is referred to as the first bridge circuit (first bridge arm); the drive bridge circuit in the drive module is referred to as the second bridge circuit (second bridge arm). The first bridge circuit includes an upper bridge circuit (upper bridge arm) and a lower bridge circuit (lower bridge arm); the second bridge circuit includes an upper bridge circuit (upper bridge arm) and a lower bridge circuit (lower bridge arm). The first bridge circuit and its corresponding signal terminals are disposed on one side surface of the first substrate. The second bridge circuit and its corresponding signal terminals are disposed on one side surface of the second substrate.

[0087] like Figure 4 As shown, along the first direction, the signal terminal group in the power generation module includes a first signal terminal group and a second signal terminal group. The first signal terminal group is used for electrical connection with the upper bridge circuit of the first bridge arm, and the second signal terminal group is used for electrical connection with the lower bridge circuit of the first bridge arm. See also Figure 4 The first signal terminal group and the second signal terminal group are arranged along a first direction, the first direction being... Figure 4 The vertical direction (i.e., the direction from the first bridge arm to the second bridge arm).

[0088] According to an embodiment of this application, the first signal terminal group is arranged in a matrix, with signal terminals in the same column arranged along a first direction. Thus, as... Figure 4 As shown, the signal terminal layout is more compact. Correspondingly, the space between the signal terminals and the PCB edge can be used to arrange components, improving the PCB space utilization and effectively reducing the PCB area. Figure 4 As shown, optionally, the first signal terminal group is in the form of a 2×N matrix, where the columns of the matrix correspond to the phases of the first bridge circuit. For example, Figure 4 If the first bridge circuit is a three-phase rectifier bridge circuit, then the corresponding first signal terminal group includes 3 columns. For example... Figure 4 As shown, each column in the first signal terminal group includes two signal terminals. Furthermore, the two signal terminals in each column are electrically connected to the gate and emitter of the target phase in the first bridge arm, respectively.

[0089] It should be noted that the gate and emitter of the target phase in the drive bridge circuit and the generator bridge circuit refer to the gate and emitter of the power semiconductor used for active switching in the target phase circuit. These power semiconductors include metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated-gate bipolar transistors (IGBTs), silicon carbide field-effect transistors (SiCMOSFETs), gallium nitride field-effect transistors (GaN FETs), and bipolar junction transistors (BJTs).

[0090] For example, such as Figure 4 As shown, each column in the first signal terminal group, from top to bottom, consists of an emitter signal terminal and a gate signal terminal. Exemplarily, emitter signal terminal E8 and gate signal terminal G8 are respectively electrically connected to the U-phase emitter and U-phase gate of the upper arm of the first bridge circuit; emitter signal terminal E10 and gate signal terminal G10 are respectively electrically connected to the V-phase emitter and V-phase gate of the upper arm of the first bridge circuit; emitter signal terminal E12 and gate signal terminal G12 are respectively electrically connected to the W-phase emitter and W-phase gate of the upper arm of the first bridge circuit. Exemplarily, the positions of the emitter signal terminals and gate signal terminals can be interchanged along the first direction.

[0091] like Figure 4 As shown, the first signal terminal group further includes a collector signal terminal for electrical connection to the collectors of the power semiconductors of all phases in the upper arm of the first bridge circuit. When the first bridge circuit is a full-bridge circuit, the collectors of all phases in the upper arm are electrically connected, allowing the collectors of all phases to share the same collector signal terminal. Therefore, optionally, as... Figure 4 As shown, the first signal terminal group includes a collector signal terminal C7. (As indicated...) Figure 4 As shown, the collector signal terminal C7 is disposed in a region near the first edge of the first substrate. The first edge is any side of the first substrate in a second direction, which is perpendicular to the first direction. Figure 4 As shown, the second direction is the second direction, and the first side corresponds to the left or right edge of the first substrate. Optionally, as... Figure 4As shown, the collector signal terminal C7 is disposed in the area where two adjacent sides intersect on the first substrate, thereby effectively utilizing the space of the substrate. Correspondingly, this allows the first signal terminal group to form sufficient clearance space on the control PCB corresponding to the first bridge circuit. Optionally, the distance between the collector signal terminal C7 and any other signal terminal is greater than the distance between the emitter signal terminal and the gate signal terminal, in order to reduce its coupling interference to other signal terminals.

[0092] According to an embodiment of this application, the first bridge circuit further includes a first temperature-sensing resistor. Exemplarily, the first signal terminal group further includes two temperature-sensing signal terminals. The two first temperature-sensing terminals are used for electrical connection to the two ends of the first temperature-sensing resistor in the first bridge circuit. Figure 4 As shown, two first temperature sensing signal terminals are disposed in the region of the first substrate near the first side. Exemplarily, the collector signal terminal C7, temperature sensing signal terminal T7, and temperature sensing signal terminal T8 are arranged sequentially along a first direction. According to an embodiment of this application, optionally, the number of first temperature sensing signal terminals does not increase with the number of phases of the first bridge circuit. Optionally, the temperature sensing resistor is a thermistor, such as an NTC thermistor (Negative Temperature Coefficient).

[0093] According to an embodiment of this application, the second signal terminal group is arranged in an array, with the signal terminals in the same column arranged along a first direction. For example... Figure 4 As shown, optionally, the second signal terminal group is a 2×N matrix, where the columns of the matrix correspond to the phases of the first bridge circuit. For example, Figure 4 If the first bridge circuit is a three-phase rectifier bridge circuit, then the corresponding second signal terminal group includes 3 columns. For example... Figure 4 As shown, each column in the second signal terminal group includes two signal terminals. Furthermore, the two signal terminals in each column are electrically connected to the gate and emitter of the target phase in the second bridge arm, respectively.

[0094] For example, such as Figure 4 As shown, each column in the second signal terminal group, from top to bottom, consists of a gate signal terminal and an emitter signal terminal. Exemplarily, gate signal terminal G7 and emitter signal terminal E7 are respectively used for electrical connection to the U-phase emitter and U-phase gate of the lower arm of the first bridge circuit; gate signal terminal G9 and emitter signal terminal E9 are respectively used for electrical connection to the V-phase emitter and V-phase gate of the lower arm of the first bridge circuit; gate signal terminal G11 and emitter signal terminal E11 are respectively used for electrical connection to the W-phase emitter and W-phase gate of the lower arm of the first bridge circuit. It is easy to understand that the positions of the emitter signal terminal and the gate signal terminal can be interchanged along the first direction.

[0095] According to an embodiment of this application, when the first bridge circuit is a full-bridge rectifier, the emitters of all phases in the lower bridge arm are electrically connected, allowing the emitters of all phases to share the same emitter signal terminal. Therefore, optionally, the second signal terminal group includes N gate signal terminals arranged along a second direction and one emitter signal terminal. The position of the emitter signal terminal shared by the lower bridge arm can be flexibly configured. For example, the emitter signal terminal shared by the lower bridge arm can be located in a region close to the first side. For example, the emitter signal terminal shared by the lower bridge arm and the collector signal terminal shared by the upper bridge arm are arranged along the first direction. This further reduces the space occupied by the second signal terminal group.

[0096] According to an embodiment of this application, optionally, the first signal terminal group and the second signal terminal group corresponding to the same target in the first bridge circuit are not aligned. For example... Figure 4 As shown, the gate signal terminal G8 and emitter signal terminal E8 of the upper bridge of phase U are not collinear with the gate signal terminal G7 and emitter signal terminal E7 of the lower bridge of phase U. This further reduces coupling interference between the upper and lower bridge signal terminals.

[0097] Figure 5 A schematic diagram of the clearance space formed by the signal terminal group provided in an embodiment of this application is shown. Figure 5 As shown, dashed box 3 illustrates the projected area of ​​the control circuit PCB adapted to the power generation module and drive module within the power module. Dashed box 3 is for illustrative purposes only and does not represent actual dimensions or proportions. Exemplarily, the portion of the control circuit PCB corresponding to the power generation module is the first PCB, and the portion corresponding to the power generation module is the second PCB. Here, the first PCB and the second PCB can be a logical division or a physical separation. According to embodiments of this application, such as... Figure 4 and Figure 5 As shown, the drive module and the power generation module are integrated into the same space. That is, the first bridge circuit and the second bridge circuit are integrated into the same space. This allows them to share the same heat sink.

[0098] According to an embodiment of this application, a plurality of through holes are formed on the first PCB, corresponding to the layout of the first signal terminal group and the second signal terminal group. These through holes are used to pass through the signal terminals. Optionally, the plurality of through holes on the first PCB and the edge of the first PCB along a first direction form a first region, which is used to house components of the control circuit. Figure 5 As shown, the first region includes a first avoidance space 31 and a second avoidance space 32. Figure 5As shown, a first clearance space 31 is formed between the first signal terminal group and the edge of the PCB; a second clearance space 32 is formed between the second signal terminal group and the edge of the PCB. Optionally, the first clearance space 31 and the second clearance space 32 are collectively referred to as the first region. The dimension of the first clearance space 31 or the second clearance space 32 along the first direction is greater than or equal to 15 mm; the dimension of the first clearance space 31 or the second clearance space 32 along the second direction is less than or equal to 48 mm. To reduce the area of ​​the first PCB while meeting safety regulations, the dimension of the first region along the first direction is not less than 15 mm. To ensure a safe distance between components on the first PCB and the second PCB while meeting safety regulations, the dimension of the second region along the second direction does not exceed 48 mm.

[0099] According to an embodiment of this application, the second bridge circuit (drive bridge circuit) of the power module includes a second number of sub-circuits, each sub-circuit being a half-bridge circuit, and the second number corresponding to the second bridge circuit. Each sub-circuit includes an upper circuit and a lower bridge circuit. Figure 4 As shown, a second number of sub-circuits are respectively disposed on one side surface of a second number of independent second substrates. Optionally, Figure 4 In the first center axis, the vertical center axis of the second substrate is the first center axis, and the horizontal center axis of the second substrate is the second center axis.

[0100] According to embodiments of this application, the power module further includes a third signal terminal group and a fourth signal terminal group. The third signal terminal group is used to transmit electrical signals of the upper arm of the second bridge circuit, and the fourth signal terminal group is used to transmit electrical signals of the lower arm of the second bridge circuit. The third and fourth signal terminal groups are located on opposite sides of the second central axis of the second substrate. In some optional embodiments, the third signal terminal group includes emitter signal terminals, gate signal terminals, and collector signal terminals arranged along a first direction; the emitter signal terminals, gate signal terminals, and collector signal terminals are respectively used to connect the emitter, gate, and collector of the power semiconductor in the third bridge arm. Optionally, the emitter signal terminals, gate signal terminals, and collector signal terminals in the third signal terminal group are located in a region close to the first central axis of the second substrate. The fourth signal terminal group includes gate signal terminals and emitter signal terminals arranged along the first direction. Optionally, the emitter signal terminals and gate signal terminals in the fourth signal terminal group are located in a region close to the first central axis of the second substrate. Exemplarily, the positions of the gate signal terminals, emitter signal terminals, and collector signal terminals in the third signal terminal group can be interchanged. For example, the positions of the gate signal terminal and the emitter signal terminal in the fourth signal terminal group can be interchanged. Optionally, as... Figure 4 and Figure 5As shown, in this application, the third signal terminal group and the fourth signal terminal group are arranged along the first central axis. It should be noted that the third and fourth signal terminal groups are not limited to being strictly arranged along the first central axis; they also include cases where they are located in the vicinity of the first central axis. Furthermore, the third and fourth signal terminal groups may be aligned or not. Signal terminals within the same signal terminal group may or may not be arranged in a straight line.

[0101] Optionally, such as Figure 4 As shown, emitter signal terminal E2, gate signal terminal G2, and collector signal terminal C2 are used to electrically connect to the emitter, gate, and collector of the upper arm of phase U of the second bridge circuit, respectively; emitter signal terminal E1 and gate signal terminal E2 are used to electrically connect to the emitter and gate of the lower arm of phase U of the second bridge circuit, respectively; emitter signal terminal E4, gate signal terminal G4, and collector signal terminal C4 are used to electrically connect to the emitter, gate, and collector of the upper arm of phase V of the second bridge circuit, respectively; emitter signal terminal E3 and gate signal terminal E3 are used to electrically connect to the emitter and gate of the lower arm of phase V of the second bridge circuit, respectively; emitter signal terminal E6, gate signal terminal G6, and collector signal terminal C6 are used to electrically connect to the emitter, gate, and collector of the upper arm of phase W of the second bridge circuit, respectively; emitter signal terminal E5 and gate signal terminal E5 are used to electrically connect to the emitter and gate of the lower arm of phase W of the second bridge circuit, respectively.

[0102] According to an optional implementation, in the corresponding upper or lower bridge arm of the driving module, the gate signal terminal and the emitter signal terminal are low-voltage terminals (e.g., E2 and G2, E1 and G1). Therefore, they can be arranged collinearly in the first direction or not collinearly. Optionally, a third terminal group. Optionally, the third terminal group and the fourth terminal group in the same sub-circuit of the driving module have a preset deviation along the second direction, thereby further reducing coupling interference between the upper and lower bridge arms.

[0103] According to embodiments of this application, the collector signal terminals (e.g., C2, C4, C6) in the driving module are high-voltage terminals. Therefore, increasing the spacing between the collector signal terminals and other signal terminals, and increasing the spacing between the collector signal terminals themselves, helps to reduce coupling interference between signal terminals. Optionally, in the same bridge arm, the spacing between the collector signal terminal and the gate signal terminal or the emitter signal terminal is greater than the spacing between the gate signal terminal and the emitter signal terminal in the same bridge arm. Optionally, in each sub-circuit of the driving module, the collector signal terminal and the low-voltage terminal are not collinear in the first direction. For example, Figure 4 In this configuration, the collector signal terminal C2 is not collinear with the emitter signal terminal E2 and the gate signal terminal G2 in a first direction. For example, the emitter signal terminals in adjacent phases are far apart from each other. Figure 4 In the middle, the emitter signal terminal C2 and the emitter signal terminal C4 are far apart from each other.

[0104] According to an embodiment of this application, each sub-circuit in the second bridge circuit further includes a temperature-sensing resistor. Optionally, the second temperature-sensing signal terminal group further includes two second temperature-sensing signal terminals, which are used for electrical connection with the temperature-sensing resistor in the second bridge circuit. Optionally, the second temperature-sensing signal terminals are disposed in the region between the upper and lower bridge arms of the sub-circuit. Exemplarily, the two second temperature-sensing signal terminals are disposed along the second direction in the region near the second central axis, and the two second temperature-sensing signal terminals are respectively disposed on both sides of the first central axis. Figure 4 As shown, temperature signal terminals T1 and T2 are used to measure the temperature of phase U of the drive module; temperature signal terminals T3 and T4 are used to measure the temperature of phase V of the drive module; and temperature signal terminals T5 and T6 are used to measure the temperature of phase W of the drive module. According to some optional embodiments, at least one sub-circuit in the drive module includes a temperature-sensing resistor. Correspondingly, at least one sub-circuit in the drive module includes two second temperature-sensing signal terminals. Exemplarily, the second temperature-sensing signal terminals of this application are arranged near the middle region of the second substrate. Correspondingly, the temperature-sensing resistor is also located closer to the middle region of the second substrate. This allows for monitoring of temperature changes in the space occupied by adjacent sub-circuits, thus enabling a further reduction in the number of temperature-sensing signal terminals by reducing the number of temperature-sensing resistors, thereby optimizing the terminal layout.

[0105] According to an embodiment of this application, a plurality of through holes are formed on the second PCB, corresponding to the layout of the third signal terminal group and the fourth signal terminal group, and the plurality of through holes are used for passing through the signal terminals. Optionally, along the first direction, the plurality of through holes on the second PCB and the edge of the second PCB form a second region, and the second region is used to house components of the control circuit. Exemplarily, the second region includes a third clearance space 33. Figure 5 As shown, the third clearance space 33 has a dimension greater than or equal to 15 mm along the first direction; the second region has a dimension less than or equal to 110 mm along the second direction. To reduce the area of ​​the second PCB while meeting safety regulations, the dimension of the second region along the first direction is not less than 15 mm. To ensure a safe distance between the components on the second PCB and the first PCB while meeting safety regulations, the dimension of the second region along the second direction does not exceed 110 mm.

[0106] According to an embodiment of this application, along the second direction, a fourth clearance space 34 and a fifth clearance space 35 are formed between the signal terminals of sub-circuits of different phases of the second bridge circuit. The areas projected onto the second PCB by the fourth clearance space 34 and the fifth clearance space 35 are used to house devices of the control circuit. For a given area of ​​the second PCB, the dimensions of the fourth clearance space 34 and the fifth clearance space 35 are linked in the second direction, and both must meet the clearance requirements in safety specifications (e.g., GB / T 16935.1-2008).

[0107] According to an embodiment of this application, the distance between the nearest signal terminal between any two adjacent second bushings is less than or equal to 30 mm. For example, as shown... Figure 5 As shown, the dimensions of the fourth clearance space 34 and the fifth clearance space 35 in the second direction are less than or equal to 30 mm.

[0108] According to an embodiment of this application, along the first direction, the distance between the two farthest signal terminals on any one of the second substrates is greater than or equal to 46 mm. For example, as shown... Figure 5 As shown, the dimensions of the fourth clearance space 34 and the fifth clearance space 35 in the first direction are greater than or equal to 30 mm.

[0109] Secondly, this application also provides a motor controller, including the power module provided in any of the above embodiments.

[0110] Thirdly, this application also provides an electronic control assembly, including a motor controller as provided in any of the above embodiments.

[0111] Fourthly, this application also provides a vehicle including the electronic control assembly provided in any of the above embodiments.

[0112] Compared to existing technologies where signal terminals are arranged along the substrate edge, the power module provided in this application uses a matrix arrangement of the first and second signal terminal groups, making the emitter and gate signal terminals more concentrated and reducing the space occupied by the signal terminal groups. Furthermore, when the corresponding power generation bridge circuit is a full-bridge circuit, all phases of the upper bridge arm share the collector signal terminal, and the lower bridge arm shares the emitter signal terminal. This reduces the number of collector signal terminals in the upper bridge arm and emitter signal terminals in the lower bridge arm of the power generation module to one, making their layout more flexible. The full-bridge circuit in the power generation module provided in this application allows the power generation module to be integrated onto the same first substrate, further reducing the number of temperature-sensing resistors, thereby reducing the number of temperature-sensing signal terminals and the required layout space for them. This ensures sufficient clearance at both ends of the PCB board to accommodate control circuit components, reducing the overlap area with power semiconductors in the power generation module while meeting safety regulations for electrical clearances. According to the embodiments of this application, in the driving module provided by this application, the gate signal terminal, emitter signal terminal, and collector signal terminal are arranged along the vertical central axis of the second substrate, and the temperature sensing signal terminal is arranged along the horizontal central axis. This ensures sufficient clearance space (fourth clearance space and fifth clearance space) between the signal terminals in adjacent two-phase sub-circuits. Simultaneously, since the signal terminals are arranged along the central axis, excessive redundant space on both sides of the second substrate is avoided, shortening the distance between adjacent two sub-circuits and reducing the corresponding area of ​​the second PCB. Furthermore, the power module provided by this application adopts a combined driving module and power generation module design. The signal terminal layout provided by the embodiments of this application can further compress the volume of the combined power module, reducing the PCB area by more than 40%.

[0113] The above description is merely a specific implementation of the embodiments of this application, but the protection scope of the embodiments of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the embodiments of this application should be included within the protection scope of the embodiments of this application. Therefore, the protection scope of the embodiments of this application should be determined by the protection scope of the claims.

Claims

1. A power module, characterized by Includes a first power module, the first power module comprising: At least two first bridge arms arranged in the second direction on the same first liner; All terminals of at least one first terminal pair in at least one first bridge arm are arranged along a first direction; The second direction is perpendicular to the first direction.

2. The power module of claim 1, wherein, The first power module is a power generation module.

3. The power module of claim 2, wherein, The second direction is parallel to the surface of the first liner, just like the first direction.

4. The power module according to any one of claims 1-3, characterized in that, In each of the first bridge arms, all terminals of at least one terminal pair are arranged along the first direction.

5. The power module of claim 4, wherein, Each of the first bridge arms includes a first terminal group and a second terminal group; The first terminal group is electrically connected to the upper bridge circuit of the first bridge arm and includes one of the terminal pairs; The second terminal group is electrically connected to the lower bridge circuit of the first bridge arm and includes one of the terminal pairs.

6. The power module of claim 5, wherein, The terminal pair of the first terminal group includes a first emitter terminal and a first gate terminal; And / or, The terminal pair of the second terminal group includes a second emitter terminal and a second gate terminal.

7. The power module according to claim 6, characterized in that, The first terminal group further includes a first collector terminal; and / or, The second terminal group also includes a second collector terminal.

8. The power module of claim 6, wherein, The first power module includes a first collector terminal; The upper bridge circuits of the at least two first bridge arms arranged along the second direction share the first collector terminal.

9. The power module of any one of claims 1-3, wherein, The first power module further includes a first temperature measuring terminal group, which includes two first temperature measuring terminals arranged along the first direction. The first temperature measuring terminals are used to measure the temperature of the first liner.

10. An electric machine controller characterized by Includes the power module according to any one of claims 1-9.

11. An electrically controlled assembly, characterized by Includes the motor controller according to claim 10.

12. A vehicle characterized by comprising: Including the electronic control assembly according to claim 11.

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