Motor controller, motor and vehicle

Abstract

The application provides a motor controller, a motor and a vehicle, and belongs to the technical field of automobiles, and comprises a cooling plate, a power module and a capacitor module, the power module and the capacitor module are respectively attached to the two sides of the cooling plate to form a laminated structure; the plate surface of the cooling plate is perpendicular to the main shaft of the motor, so that the laminated structure is perpendicular to the main shaft of the motor. The motor controller provided by the application is arranged with the plate surface of the cooling plate being perpendicular to the main shaft of the motor, the power module, the cooling plate and the capacitor of the controller form a laminated structure and are perpendicular to the main shaft of the motor, so that the controller can be installed by using the narrow limited space around the motor, the development demand of high integration and miniaturization is realized, and the demand of the limited space arrangement in the vehicle is met; meanwhile, the two high-power devices are respectively attached and installed on the two sides of the cooling plate, the power module and the capacitor can be effectively reduced in heat while meeting the integration and miniaturization, and the heat dissipation effect of the small-sized high-integrated controller is improved.

Description

Technical Field

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

[0002] Vehicle electric drive systems are evolving towards higher power density and greater compactness. Therefore, the motor controller in the electric drive system not only needs to be highly efficient, but also needs to be highly integrated and miniaturized to meet the limited space requirements of the vehicle. However, high power density electric drive systems generate more heat under high current and high switching frequency conditions, which can easily lead to overheating of the controller, affecting its performance or even causing permanent damage. Therefore, while miniaturizing and highly integrating, there is also the problem of poor heat dissipation. Utility Model Content

[0003] The purpose of this application is to provide a motor controller, motor, and vehicle that aims to solve the heat dissipation problem caused by limited space layout and high integration miniaturization.

[0004] Firstly, to achieve the above objectives, the technical solution adopted in this application is: to provide a motor controller integrated on a motor, comprising: a cooling plate, a power module and a capacitor module, wherein the power module and the capacitor module are respectively attached to both sides of the cooling plate to form a stacked structure; the surface of the cooling plate is perpendicular to the main shaft of the motor, so that the stacked structure is perpendicular to the main shaft of the motor.

[0005] The motor controller provided in this application has a cooling plate arranged perpendicular to the motor's main shaft. The controller's power module, cooling plate, and capacitor form a stacked structure perpendicular to the motor's main shaft. This allows the controller to be installed in the limited space around the motor, meeting the development requirements of high integration and miniaturization, and satisfying the space constraints of the vehicle interior. At the same time, the power module and capacitor, as two high-power devices that generate a lot of heat during motor operation, are respectively attached to both sides of the cooling plate. This not only meets the requirements of integration and miniaturization but also effectively reduces the heat generated by the power module and capacitor, thereby improving the heat dissipation effect of this miniaturized and highly integrated controller and enhancing its performance.

[0006] In conjunction with the first aspect, one possible implementation also includes an integrated board, which is stacked on the side of the power module away from the cooling plate, and the surface of the integrated board is perpendicular to the main shaft of the motor.

[0007] In the above technical solution, compared with the method of some motor controllers that combine the control board and the drive board into one, the integrated board in this application integrates the control board, the drive board and the TCU board. By integrating these three boards with different functions into one integrated board, compared with the prior art of making these three boards separately and installing them separately, the space occupied is reduced, which is conducive to the miniaturization and integration of the controller and is convenient for installation in a small space.

[0008] In conjunction with the first aspect, in one possible implementation, the cooling plate has a mounting groove on its surface facing the power module, and the internal cooling channel within the cooling plate has an open opening in the mounting groove to expose the cooling medium; the power module is embedded in the mounting groove and can directly contact the cooling medium of the internal cooling channel.

[0009] In the above technical solution, the mounting slot for the power module is directly set on the cooling plate. On the one hand, it can reflect the concept of integration. On the other hand, when the cooling medium flows through the mounting slot, it can directly contact the power module, realizing direct heat exchange between the heat of the power module and the cooling medium flowing in the cooling plate. This eliminates the intermediate links and thus improves the heat exchange effect.

[0010] In conjunction with the first aspect, in one possible implementation, a first sealing ring is provided between the power module and the opening of the internal cooling channel. This first sealing ring prevents leakage of the cooling medium between the power module and the internal cooling channel, thus improving the reliability of the seal.

[0011] In conjunction with the first aspect, in one possible implementation, the system further includes a controller housing and a cover plate that covers the controller housing, the controller housing being integrated into the outer casing of the motor; the cooling plate being mounted on the controller housing and forming a receiving cavity for accommodating the capacitor module between the cooling plate and the bottom surface of the controller housing; the bottom surface of the controller housing being perpendicular to the main shaft of the motor.

[0012] In the above technical solution, the cavity formed by the cooling plate and the bottom surface of the controller housing provides a stable mounting space for the capacitor module, which is beneficial for heat dissipation and ensures stable performance. Meanwhile, the controller housing is integrated into the motor housing, reducing the overall installation space and making the structure more compact. Furthermore, the bottom surface of the controller housing is perpendicular to the motor spindle, adapting to the aforementioned stacked structure, demonstrating a miniaturization and integration different from existing technologies.

[0013] In conjunction with the first aspect, in one possible implementation, two first external cooling channels are arranged in parallel inside the controller housing; an internal cooling channel in the cooling plate is connected in series between the two first external cooling channels; and the capacitor module is sandwiched between the internal cooling channel and the two first external cooling channels.

[0014] In the above technical solution, the capacitor module is sandwiched between the inner cooling channel and the outer cooling channel, which can make full use of the efficient heat dissipation capacity brought by the double-layer cooling structure. The heat generated by the capacitor module during operation can be quickly dissipated through the inner cooling channel and the outer cooling channel, effectively reducing the operating temperature of the capacitor module. This ensures the stable performance of the capacitor module, reduces the risk of performance degradation or even damage due to overheating, and improves the overall heat dissipation performance of the controller, thereby enhancing the reliability and stability of the controller.

[0015] In conjunction with the first aspect, in one possible implementation, the controller housing is further provided with a second external cooling channel, the two ends of which are respectively connected to the first external cooling channel, and the internal cooling channel in the cooling plate is connected in parallel with the second external cooling channel to form a double-layer cooling structure.

[0016] In the above technical solution, the cooling medium can enter the inner cooling channel and the outer cooling channel to exchange heat generated by the power module and capacitor module in the controller, thereby improving the heat exchange speed and heat exchange effect.

[0017] In conjunction with the first aspect, one possible implementation further includes a filter module, an excitation fuse, a DC current sensor, and a three-phase output module; the filter module and the excitation fuse are mounted on the cooling plate and are on the same side as the capacitor module; the DC current sensor is mounted on the excitation fuse; the three-phase output module is connected to the power module and is located near the motor.

[0018] In the above technical solution, the filter module, excitation fuse and DC current sensor in the controller are installed in the housing cavity. Therefore, most of the components in the controller are arranged between the inner cooling channel and the outer cooling channel, which can improve the overall heat dissipation efficiency and heat dissipation effect of the controller. Concentrating these components in this housing cavity also has the function of integration, which is conducive to the overall miniaturization.

[0019] Secondly, embodiments of this application also provide a motor equipped with the aforementioned motor controller.

[0020] The motor provided in this application, due to the use of such a highly integrated, miniaturized controller with good heat dissipation, can not only adapt to installation in narrow and long spaces, but also reduce motor failure problems caused by controller overheating and improve the performance of the motor.

[0021] Thirdly, embodiments of this application also provide a vehicle equipped with the aforementioned motor controller.

[0022] Because the aforementioned vehicles are equipped with such a highly integrated, miniaturized controller with good heat dissipation, it not only facilitates overall miniaturization and weight reduction, but also reduces vehicle malfunctions caused by controller overheating, thereby improving the overall performance of the vehicle. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 A three-dimensional structural diagram of the motor provided in an embodiment of this application;

[0025] Figure 2 This is a schematic diagram of the main structure of the motor provided in an embodiment of this application;

[0026] Figure 3 For along Figure 2 Cross-sectional view of the AA line (showing the high-voltage circuit from the controller to the motor);

[0027] Figure 4 for Figure 2 The diagram shows the rear view of the motor.

[0028] Figure 5 For along Figure 4 Cross-sectional view of the middle BB line (showing the stacked structure of the controller)

[0029] Figure 6 A three-dimensional structural diagram of the controller provided in an embodiment of this application (showing the power module side);

[0030] Figure 7 A schematic diagram of the main structure of the controller provided in the embodiment of this application (showing the high voltage circuit path on the power module side, with arrows indicating the path of the high voltage circuit within the controller).

[0031] Figure 8 An exploded view of the controller provided in an embodiment of this application (showing the capacitor module);

[0032] Figure 9 An exploded view of the controller provided in an embodiment of this application (showing the power module);

[0033] Figure 10 A three-dimensional structural diagram of the controller housing provided in an embodiment of this application (showing that the external cooling channel and the internal cooling channel are connected in series).

[0034] Figure 11 This is a schematic diagram of the front view structure of the controller housing provided in an embodiment of this application;

[0035] Figure 12 For along Figure 11 Cross-sectional view of the CC line (showing the cavity between the controller housing and the cooling plate).

[0036] Figure 13 A schematic diagram of the controller stack-up structure provided in the embodiment of this application (forming a power brick, with the inner cooling channel connected in series with the first outer cooling channel).

[0037] Figure 14 A schematic diagram of the high-voltage circuit from the controller to the motor provided in the embodiments of this application;

[0038] Figure 15 This is a schematic diagram of the structure in which the inner cooling channel and the second outer cooling channel are connected in parallel, as provided in an embodiment of this application.

[0039] In the diagram: 1. Controller housing; 2. Reinforcing rib; 3. High-voltage connector; 4. Three-phase cover plate; 5. Outer shell; 6. Controller cover plate; 7. Outlet pipe connector; 8. Inlet pipe connector; 9. Power module; 10. Cooling plate; 11. Capacitor module; 12. Three-phase output module; 13. Integrated board; 14. Connecting copper busbar; 15. Second sealing ring; 16. Filter module; 17. Excitation fuse; 18. External water inlet; 19. External water outlet; 20. Straight-through port; 21. Support column; 22. Mounting groove; 23. Opening; 24. Receiving cavity; 25. Three-phase AC busbar; 26. Internal cooling channel; 27. Sealing plug; 28. First sealing ring; 29. ​​Sealing sleeve; 30. DC current sensor; 31. First external cooling channel; 32. Second external cooling channel. Detailed Implementation

[0040] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0041] It should be noted that when an element is referred to as being "set on" another element, it can be directly on or indirectly on that other element. It should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are used only for the convenience of describing this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0042] 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. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a few" means two or more, unless otherwise explicitly specified.

[0043] It should be noted that the directions or positional relationships indicated by "front", "rear", "inner", "outer", "up", and "down" in this embodiment are based on the vehicle's own orientation. The front of the vehicle represents "front", the rear of the vehicle represents "rear", the top of the vehicle represents "up", the bottom of the vehicle represents "down", the "inner" side refers to the side facing the driver's cab, and the "outer" side refers to the side facing the driver's cab.

[0044] In addition, the front-rear direction of the vehicle body as defined in the embodiments of this application refers to the front-rear direction of the vehicle's forward direction during driving; the left-right direction of the vehicle body as defined refers to the left-right direction of the vehicle's forward direction during driving; and the up-down direction of the vehicle body as defined refers to the up-down direction of the vehicle's forward direction during driving.

[0045] Please refer to the following: Figures 1 to 15 The motor controller provided in this application will now be described. The motor controller, integrated on the motor, includes: a cooling plate 10, a power module 9, and a capacitor module 11. The power module 9 and the capacitor module 11 are respectively attached to both sides of the cooling plate 10, forming a stacked structure (see...). Figure 13 and Figure 15 The surface of the cooling plate 10 is perpendicular to the main shaft of the motor, so that the resulting stacked structure is perpendicular to the main shaft of the motor. Figure 5 In the figure, 'a' represents the axis of the motor spindle, which is perpendicular to the cooling plate 10, the integrated plate 13, and the stacked structure formed by the power bricks.

[0046] The motor controller provided in this application differs from existing motor controllers where the board surface is spatially parallel to the motor's main shaft. The cooling plate 10 is arranged perpendicular to the motor's main shaft. The power module 9, cooling plate 10, and capacitor module 11 of the controller form a stacked structure perpendicular to the motor's main shaft. This allows the controller to be installed in the limited space around the motor, meeting the demands for high integration and miniaturization, and satisfying the requirements of limited space within the vehicle. Simultaneously, the power module 9 and capacitor module 11, as two high-power devices that generate significant heat during motor operation, are respectively mounted on both sides of the cooling plate 10. This effectively reduces the heat generated by the power module 9 and capacitor module 11 while achieving integration and miniaturization, thereby improving the heat dissipation effect of this miniaturized, highly integrated controller and enhancing its performance.

[0047] Specifically, in existing technologies, controllers are generally integrated into a cuboid. Although the large surface area formed by the controller may spatially intersect with the motor's main shaft, the overall controller and the motor's main shaft are parallel. However, the controller provided in this application is spatially perpendicular to the motor's main shaft, and in the stacked structure of the controller, the motor's main shaft is perpendicular to the stacking direction. This allows the controller to be placed in a small space above the motor, while the power module 9 and capacitor module 11 are located on opposite sides of the cooling plate 10, which also facilitates rapid heat dissipation of the two high-power devices, thereby ensuring the controller's operating performance.

[0048] Power module 9 is a SiC module, which is the core power switching device of the motor controller, used to convert the DC power from the battery into AC power to drive the motor (inverter function). Compared with traditional silicon-based IGBTs, SiC modules have advantages such as higher switching frequency, lower conduction loss, and higher temperature resistance, which can improve system efficiency and power density. SiC (silicon carbide) is a high-power electrical device in the controller and generates a lot of heat.

[0049] Capacitor module 11 is a DC-link capacitor, a passive device mainly used in inverter circuits for smoothing filtering, absorbing high-amplitude pulsating current, and preventing voltage overshoot and transient overvoltage from affecting power devices. DC-Link capacitors are typically high-power components in controllers, primarily used for smoothing filtering and absorbing high-frequency transient currents; their power rating depends on the specific application.

[0050] Therefore, the cooling plate 10 in this application is mainly used to dissipate heat from the capacitor module 11 and the power module 9. By directly cooling the capacitor module 11 and the power module 9 through the cooling plate 10, the heat dissipation effect is improved, the damage to the controller caused by high temperature overheating is reduced, and the service life of the controller is extended.

[0051] See Figure 3As shown, the motor controller provided in this application also includes an integrated board 13, which is stacked on the side of the power module 9 away from the cooling plate 10. The surface of the integrated board 13 is perpendicular to the main shaft of the motor. That is, the integrated board 13 is parallel to the cooling plate 10. In this way, the controller forms a four-layer stacked structure with a small thickness in the stacking direction, which can be arranged in a small and limited space.

[0052] The integrated board 13 is located on the outside of the power module 9. In order to avoid the electrical connection between the integrated board 13 and the power module 9 being loose and to ensure signal stability, the integrated board 13 is positioned and installed. Specifically, multiple support pillars 21 perpendicular to the surface of the cooling plate 10 are set on the cooling plate 10. The integrated board 13 is supported and fixed on the support pillars 21 to ensure stable support.

[0053] Compared to some motor controllers that combine the control board and the drive board into one, the integrated board 13 in this application integrates the control board, the drive board and the TCU board. By integrating these three boards with different functions onto one integrated board 13, compared to the prior art of manufacturing and installing these three boards separately, the space occupied is reduced, which is conducive to the miniaturization and integration of the controller and to installation in a small space.

[0054] Explanatory:

[0055] The core function of the control board is to be responsible for the execution of motor control algorithms, system status monitoring, and communication management.

[0056] The core function of the Gate Driver Board is to amplify the weak PWM signal from the control board and drive the SiC / IGBT module safely and reliably.

[0057] The core function of the TCU (Transmission Control Unit) board is to manage the transmission shift logic and coordinate the electric motor and mechanical transmission system.

[0058] In some embodiments, see Figure 9 As shown, a mounting groove 22 is provided on the surface of the cooling plate 10 facing the power module 9. The internal cooling channel 26 in the cooling plate 10 has an open opening 23 for exposing the cooling medium in the mounting groove 22. The power module 9 is embedded in the mounting groove 22 and can directly contact the cooling medium of the internal cooling channel 26.

[0059] In the above technical solution, the mounting slot 22 for installing the power module 9 is directly set on the cooling plate 10. This not only embodies the concept of integration, but also allows the cooling medium flowing through the mounting slot 22 to directly contact the power module 9, achieving direct heat exchange between the heat of the power module 9 and the cooling medium flowing within the cooling plate 10. This eliminates intermediate steps and thus improves the heat exchange effect. Furthermore, the design of the mounting slot 22 also provides excellent positioning for the power module 9, making installation easier.

[0060] In some embodiments, see Figure 9 and Figure 13 As shown, a first sealing ring 28 is provided between the power module 9 and the opening 23 of the inner cooling channel 26. The first sealing ring 28 can prevent the cooling medium from leaking between the power module 9 and the inner cooling channel 26, thereby improving the reliability of the seal.

[0061] See Figures 1 to 12 The motor controller provided in this application also includes a controller housing 1 and a controller cover 6 covering the controller housing 1. The controller housing 1 is integrated on the outer shell 5 of the motor. The cooling plate 10 is installed on the controller housing 1 and forms a receiving cavity 24 for accommodating the capacitor module 11 between the cooling plate 10 and the bottom surface of the controller housing 1. The bottom surface of the controller housing 1 is perpendicular to the main shaft of the motor.

[0062] In the above technical solution, the cavity 24 formed by the cooling plate 10 and the bottom surface of the controller housing 1 provides a stable installation space for the capacitor module 11, which is beneficial for the heat dissipation of the capacitor module 11 and ensures its stable performance. At the same time, the controller housing 1 is integrated into the motor housing 5, reducing the overall installation space and making the structure more compact. The bottom surface of the controller housing 1 is perpendicular to the motor spindle, which is suitable for the aforementioned stacked structure, reflecting a miniaturization and integration that is different from the prior art.

[0063] The controller housing 1 is integrated into the motor housing 5, and there are several integration methods: the first is that the two are formed separately and then fixed together with bolts; the second is that the two are formed as a single piece. Figures 1 to 12 (As shown); the third type is where the two can be welded together.

[0064] A reinforcing rib 2 is also provided on the outer side of the controller housing 1 to enhance the strength of the controller housing 1 and provide reliable support for the internal cooling plate 10, power module 9, capacitor module 11 and other components; the reinforcing rib 2 is arranged in a grid pattern.

[0065] In this application, the controller cover 6 is fastened to the controller housing 1 by bolts and sealed with sealant, and the controller cover 6 covers the outside of the integrated plate 13.

[0066] In this application, the cooling plate 10 is fastened to the controller housing 1 with bolts; alternatively, the cooling plate 10 can be integrally formed with the controller housing 1. In this case, the bottom surface of the controller housing 1 also needs to be separately formed, defined as the bottom cover. This is because power devices need to be installed on both sides of the cooling plate 10. Therefore, both the controller cover 6 and the bottom cover need to be removable to facilitate the installation of the corresponding power devices on both sides of the cooling plate 10. The power devices here include the power module 9, capacitor module 11, filter module 16, excitation fuse 17, and DC current sensor 30 mentioned herein.

[0067] In some embodiments, see Figure 10 and Figure 13 As shown, two first external cooling channels 31 are arranged in parallel inside the controller housing 1; an internal cooling channel 26 in the cooling plate 10 is connected in series between the two first external cooling channels 31; and a capacitor module 11 is clamped between the internal cooling channel 26 and the external cooling channel 31. One of the first external cooling channels 31 is connected to the external water inlet 18 on the controller housing 1, and the other is connected to the external water outlet 19 at the top of the controller housing.

[0068] In the above technical solutions, see Figure 10 and Figure 13 As shown, the capacitor module 11 is sandwiched between the inner cooling channel 26 and the two first outer cooling channels 31, which can make full use of the efficient heat dissipation capacity brought by the double-layer cooling structure. The heat generated by the capacitor module 11 during operation can be quickly dissipated through the inner cooling channel 26 and the first outer cooling channels 31, effectively reducing the operating temperature of the capacitor module 11. This ensures the stable performance of the capacitor module 11, reduces the risk of performance degradation or even damage due to overheating, and improves the overall heat dissipation performance of the controller, thereby enhancing the reliability and stability of the controller.

[0069] See Figure 13 As shown by the middle arrow, the cooling medium enters a first external cooling channel 31 from the external inlet 18, passes through the internal cooling channel 26 and then enters another first external cooling channel 31, finally flowing out from the external outlet 19. At the same time, it exchanges heat with the power module 9 and capacitor module 11 in the controller, improving the heat exchange speed and heat exchange effect.

[0070] See Figure 8 and Figure 10 As shown, Figure 8 The position e in the middle and Figure 10 Connect at point b in the middle. Figure 8 f in Figure 10 By connecting at point c, the internal cooling channel 26 can be connected in series with the two first external cooling channels 31.

[0071] SeeFigure 15 The controller housing 1 also has a second external cooling channel 32 inside. Both ends of the second external cooling channel 32 are connected to the first external cooling channel 31. The internal cooling channel 26 inside the cooling plate 10 is connected in parallel with the second external cooling channel 32, forming a double-layer cooling structure. The cooling medium entering through the external inlet 18 enters one of the first external cooling channels 31, partly entering the second external cooling channel 32 and partly entering the internal cooling channel 26, finally converging into the first external cooling channel 31 connected to the external outlet 19, and flowing out from the external outlet 19. (See [reference]). Figure 15 As indicated by the middle arrow.

[0072] In the above technical solution, the inner cooling channel 26 and the second outer cooling channel 32 are connected in parallel. The cooling medium can enter the inner cooling channel 26 and the second outer cooling channel 32 at the same time, and exchange the heat generated by the power module 9 and the capacitor module 11 in the controller. The cooling medium can absorb more heat, improve the heat exchange speed and heat exchange effect.

[0073] In the above technical solution, an inlet pipe connector 8 and an outlet pipe connector 7 are respectively installed on the outer water inlet 18 and the outer water outlet 19 of the controller housing 1 to facilitate connection to the external cooling pipeline and supply the internal cooling channel 26 in the cooling plate 10 and the first external cooling channel 31 and the second external cooling channel 32 in the controller housing 1. Sealing rings are installed at each pipe connector to prevent leakage of the cooling medium.

[0074] Due to manufacturing process requirements, a straight-through opening 20 is provided on the inner cooling channel 26 of the cooling plate 10 (see...). Figure 8 , Figure 13 and Figure 15 After the straight-through port 20 is sealed with a sealing plug 27, only the inner inlet and inner outlet of the inner cooling channel 26 need to be maintained. A sealing sleeve 29 is provided at the connection between the inner inlet and inner outlet of the inner cooling channel 26 and the first outer cooling channel 31 inside the controller housing 1 to seal the interface and prevent leakage of the cooling medium.

[0075] See Figures 1 to 9 , Figure 14 As shown, the motor controller provided in this application also includes a filter module 16, an excitation fuse 17, a DC current sensor 30, and a three-phase output module 12. The filter module 16 and the excitation fuse 17 are mounted on the cooling plate 10 and are on the same side as the capacitor module 11. The DC current sensor 30 is mounted on the excitation fuse 17. The three-phase output module 12 is connected to the power module 9 and is located close to the side of the motor. The three-phase output module 12 is integrated into the power module 9.

[0076] In the above technical solution, the filter module 16, the excitation fuse 17 and the DC current sensor 30 in the controller are installed in the housing cavity 24. Therefore, most of the components in the controller are arranged between the inner cooling channel 26 and the first outer cooling channel 31 and the second outer cooling channel 32, which can improve the overall heat dissipation efficiency and heat dissipation effect of the controller. Concentrating these components in this housing cavity 24 also has the function of integration, which is conducive to the overall miniaturization.

[0077] In this application, a high-voltage connector 3 is provided on the outside of the controller housing 1. The high-voltage connector 3 is installed on the side close to the excitation fuse 17. The three-phase output copper busbar of the controller is connected to the three-phase input copper busbar of the motor after passing through the connecting copper busbar 14.

[0078] See Figure 7 As shown, the high-voltage circuit of the controller provided in this application is as follows: the high-voltage current passes through the high-voltage connector 3, the excitation fuse 17, the DC current sensor 30, the filter module 16, the capacitor module 11, the power module 9 and the three-phase output module 12 in sequence, and then outputs three-phase AC power from the controller's three-phase AC bus 25. After passing through the connecting copper bus 14, it is input to the motor's three-phase input copper bus to provide three-phase AC power to the motor windings.

[0079] A window is provided on the controller housing 1 at the position corresponding to the copper busbar 14, and a three-phase cover plate 4 is provided on the window (see...). Figures 1 to 3 , Figure 8 As shown), and is sealed with a second sealing ring 15, so that the connecting copper busbar 14 and the three-phase AC busbar 25 can be fixedly connected by bolts through the window on the controller housing 1.

[0080] In this application, the high-voltage connector 3, the excitation fuse 17, the DC current sensor 30, the filter module 16, the capacitor module 11, the power module 9, the three-phase output module 12, and the cooling plate 10 also constitute a highly integrated power brick (see...). Figure 13 ), installed inside the controller housing 1, which makes it easier to achieve miniaturization of the controller.

[0081] Based on the same inventive concept, this application also provides a motor equipped with the aforementioned motor controller.

[0082] In this application, the controller housing 1 of the motor controller and the outer shell 5 of the motor are integrally formed. This integrally formed structure can ensure the strength of the connection between the motor controller and the motor, avoid the problem of weak connection caused by welding defects, and also avoid the risk of bolt breakage due to uneven bolt tightness after long-term use.

[0083] The motor provided in this application, due to the use of such a highly integrated, miniaturized controller with good heat dissipation, can not only adapt to installation in narrow and long spaces, but also reduce motor failure problems caused by controller overheating and improve the performance of the motor.

[0084] Based on the same inventive concept, this application also provides a vehicle equipped with the aforementioned motor controller.

[0085] Because the aforementioned vehicles are equipped with such a highly integrated, miniaturized controller with good heat dissipation, it not only facilitates overall miniaturization and weight reduction, but also reduces vehicle malfunctions caused by controller overheating, thereby improving the overall performance of the vehicle.

[0086] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A motor controller, integrated on a motor, characterized in that, include: The cooling plate (10), power module (9) and capacitor module (11) are respectively attached to the two sides of the cooling plate (10) to form a stacked structure; the surface of the cooling plate (10) is perpendicular to the main shaft of the motor so that the stacked structure is perpendicular to the main shaft of the motor.

2. The motor controller as described in claim 1, characterized in that, It also includes an integrated board (13), which is stacked on the side of the power module (9) away from the cooling plate (10), and the surface of the integrated board (13) is perpendicular to the main shaft of the motor.

3. The motor controller as described in claim 1, characterized in that, The cooling plate (10) has a mounting groove (22) on its surface facing the power module (9). The internal cooling channel (26) in the cooling plate (10) has an open opening (23) for exposing the cooling medium in the mounting groove (22). The power module (9) is embedded in the mounting groove (22) and can directly contact the cooling medium of the internal cooling channel (26).

4. The motor controller as described in claim 3, characterized in that, A first sealing ring (28) is provided between the power module (9) and the opening (23) of the internal cooling channel (26).

5. The motor controller as described in claim 1, characterized in that, It also includes a controller housing (1) and a cover plate (6) covering the controller housing (1), the controller housing (1) being integrated on the outer shell (5) of the motor; the cooling plate (10) is mounted on the controller housing (1) and forms a receiving cavity (24) for accommodating the capacitor module (11) between the cooling plate (1) and the bottom surface of the controller housing (1); the bottom surface of the controller housing (1) is perpendicular to the main shaft of the motor.

6. The motor controller as described in claim 5, characterized in that, The controller housing (1) has two first external cooling channels (31) arranged in parallel inside; the internal cooling channel (26) in the cooling plate (10) is connected in series between the two first external cooling channels (31); the capacitor module (11) is sandwiched between the internal cooling channel (26) and the two first external cooling channels (31).

7. The motor controller as described in claim 6, characterized in that, The controller housing (1) is also provided with a second external cooling channel (32), the two ends of which are connected to the first external cooling channel (31). The internal cooling channel (26) in the cooling plate (10) is connected in parallel with the second external cooling channel (32) to form a double-layer cooling structure.

8. The motor controller as described in claim 5, characterized in that, It also includes a filter module (16), an excitation fuse (17), a DC current sensor (30), and a three-phase output module (12); the filter module (16) and the excitation fuse (17) are mounted on the cooling plate (10) and are on the same side as the capacitor module (11); the DC current sensor (30) is mounted on the excitation fuse (17); the three-phase output module (12) is connected to the power module (9) and is located close to the motor.

9. An electric motor, characterized in that, It is equipped with a motor controller as described in any one of claims 1-8.

10. A vehicle, characterized in that, It is equipped with a motor controller as described in any one of claims 1-8.

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