Motor controller integration system

Abstract

This application relates to the field of electric vehicle technology, and in particular to a motor controller integrated system. The motor controller integrated system includes: an electronic control housing, the interior of which is hollow; a first partition disposed within the electronic control housing, dividing the internal space of the electronic control housing into a first chamber and a second chamber; a power supply module disposed in the first chamber; a power distribution module disposed in the first chamber; and a motor controller module including multiple electronic components, some of which are disposed in the first chamber and others in the second chamber. The motor controller integrated system provided by this application, through structural optimization, places a portion of each unit in the MCU module in the compact second chamber and another portion in the more spacious first chamber, resulting in a compact structure, high integration, significantly reduced lateral dimensions, and effective control of longitudinal thickness, thus making the overall size of this motor controller integrated system smaller.

Description

Technical Field

[0001] This application relates to the field of electric vehicle technology, and in particular to a motor controller integrated system. Background Technology

[0002] Currently, existing multi-in-one motor controller integration systems generally include a motor controller (MCU, Multipoint Control Unit), an on-board charger (OBC), and a power module (OCDC) integrating high and low voltage DC / DC conversion, a high-voltage power distribution unit (PDU), and even a vehicle control unit (VCU), a battery management unit (BDU), etc. Most motor controller integration systems on the market currently adopt a flat layout, with each module laid flat within the control housing, and the entire motor controller integration system located above the motor and reducer. However, this traditional arrangement, along with the integrated multi-in-one electric drive system, often results in relatively large dimensions in all directions, requiring significant installation space. Utility Model Content

[0003] The purpose of this application is to provide a motor controller integration system, which to a certain extent solves the technical problems of existing motor controller integration systems, which mostly adopt a flat setting, have low integration, and are large in size after integration with motors and reducers.

[0004] This application provides a motor controller integrated system, including: an electronic control housing, wherein the interior of the electronic control housing is hollow;

[0005] A first partition is disposed inside the electrical control housing, and the first partition divides the internal space of the electrical control housing into a first chamber and a second chamber;

[0006] A power module, wherein the power module is disposed in the first chamber;

[0007] A power distribution module is disposed in the first chamber;

[0008] A motor controller module, comprising multiple electronic devices, wherein a portion of the electronic devices are disposed in the first chamber and another portion of the electronic devices are disposed in the second chamber.

[0009] In the above technical solution, the motor controller integrated system further includes a second partition, which is disposed in the first chamber and divides the first chamber into a third chamber and a fourth chamber.

[0010] The power distribution module is located in the third chamber;

[0011] The power module is located in the fourth chamber.

[0012] In any of the above technical solutions, the motor controller module further includes:

[0013] A power module unit, wherein the power module unit is disposed in the second chamber;

[0014] A thin-film capacitor, wherein the thin-film capacitor is disposed in the second chamber;

[0015] A DC filter unit is disposed in the third chamber.

[0016] In any of the above technical solutions, the motor controller module further includes a three-phase output unit, which includes an upper three-phase component and a lower three-phase component;

[0017] The upper three-phase assembly is disposed in the fourth chamber; the lower three-phase assembly is disposed in the second chamber.

[0018] In any of the above technical solutions, the DC filter unit further includes multi-stage filtering, wherein the multi-stage filtering includes at least one capacitor filter and at least one magnetic ring filter.

[0019] In any of the above technical solutions, the upper three-phase component further includes a filter magnetic ring, which is disposed on the upper three-phase component.

[0020] In any of the above technical solutions, the first partition is further provided with a flow channel, and the plate surface of the first partition corresponding to the flow channel forms a heat dissipation surface, and the power module unit is disposed on the heat dissipation surface.

[0021] In any of the above technical solutions, the first partition is further provided with a heat dissipation component at least at the position corresponding to the thin film capacitor.

[0022] In any of the above technical solutions, the motor controller integrated system further includes:

[0023] A first cover plate, which seals the first chamber;

[0024] The second cover plate seals the second chamber.

[0025] In any of the above technical solutions, the electronic control housing is further disposed above the half-shaft of the electric vehicle;

[0026] The first chamber is located above the second chamber; the third chamber and the fourth chamber are distributed to the left and right.

[0027] Compared with the prior art, the beneficial effects of this application are as follows:

[0028] The motor controller integrated system provided in this application includes: an electrical control housing, the interior of which is hollow; a first partition, disposed within the electrical control housing, which divides the internal space of the electrical control housing into a first chamber and a second chamber; a power supply module, disposed in the first chamber; a power distribution module, disposed in the first chamber; and a motor controller module, comprising multiple electronic components, some of which are disposed in the first chamber and others in the second chamber.

[0029] The motor controller integrated system provided in this application optimizes the structure by placing a portion of each unit in the MCU module in a compact second chamber and another portion in a more spacious first chamber. This results in a compact structure with high integration. The rational layout of each component significantly reduces the lateral dimension compared to the traditional flat layout, while effectively controlling the longitudinal thickness. This makes the overall size of the motor controller integrated system smaller, allowing it to be installed above the vehicle's half-shaft, making full use of the space above the half-shaft. By controlling the volume of the motor controller integrated system, the overall size of the system after integration with the motor and reducer can be controlled. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0031] Figure 1 An exploded view of the structure of the motor controller integrated system provided in the embodiments of this application;

[0032] Figure 2 A cross-sectional view of the structure of the motor controller integrated system provided in the embodiments of this application;

[0033] Figure 3 An isometric view of the electrical control housing of the motor controller integrated system provided in this application embodiment;

[0034] Figure 4 Another isometric view of the electrical control housing of the motor controller integrated system provided in the embodiments of this application;

[0035] Figure 5 Axonometric view of the DC filter unit of the motor controller integrated system provided in this application embodiment;

[0036] Figure 6 An isometric view of the three-phase output unit of the motor controller integrated system provided in this application embodiment.

[0037] Figure label:

[0038] 1-Electrical control housing, 11-First partition, 12-Second partition, 101-First chamber, 102-Second chamber, 103-Third chamber, 104-Fourth chamber, 1001-Flow channel, 21-Power module unit, 22-DC filter unit, 23-Three-phase output unit, 231-Lower three-phase assembly, 2321-Filter magnetic ring, 232-Upper three-phase assembly, 24-Film capacitor, 3-Power supply module, 4-Power distribution module, 5-First cover plate, 6-Second cover plate. Detailed Implementation

[0039] The technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this application, but not all embodiments.

[0040] The components of the embodiments of this application described and shown in the accompanying drawings can be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of this application provided in the drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application.

[0041] Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0042] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

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

[0044] The following reference Figures 1 to 6 This application describes an embodiment of a motor controller integrated system.

[0045] See Figures 1 to 6 As shown, an embodiment of this application provides a motor controller integrated system. This motor controller integrated system includes an electrical control housing 1, a first partition 11, a power supply module 3, a power distribution module 4, and a motor controller module. The electrical control housing 1 is hollow inside. The first partition 11 is disposed inside the electrical control housing 1, and the edge of the first partition 11 is connected to the inner wall of the electrical control housing 1. The first partition 11 is coaxially disposed with the electrical control housing 1, such that the first partition 11 divides the internal space of the electrical control housing 1 into two parts, namely a first chamber 101 and a second chamber 102. The power supply module 3 and the power distribution module 4 are disposed in the first chamber 101. The motor controller module includes multiple electronic devices, some of which are disposed in the first chamber 101 and others in the second chamber 102. As can be seen, the motor controller integrated system provided in this application optimizes the structure of the electric control housing 1 by dividing its internal space and placing each module in a different cavity, making the layout of each module compact. Compared with the existing flat layout structure, it reduces the axial and radial space occupied by the motor, thereby reducing the size of the multi-in-one electric drive assembly in all directions. After integration with the motor, reducer, etc., it does not result in an excessively large overall volume.

[0046] Specifically, both ends of the electronic control housing 1 have openings. Preferably, one end of the electronic control housing 1 has an upward opening, and the other end has a downward opening. A first partition 11 is disposed inside the electronic control housing 1. The edge of the first partition 11 is connected to the inner wall of the electronic control housing 1. The first partition 11 is coaxially arranged with the electronic control housing 1. The first partition 11 divides the internal space of the electronic control housing 1 into two chambers, namely the first chamber 101 and the second chamber 102. The first chamber 101 is located above the first partition 11, and the second chamber 102 is located below the first partition 11.

[0047] Furthermore, the integrated motor controller system also includes a second partition 12, which is disposed in the first chamber 101. The second partition 12 is erected on the upper surface of the first partition 11, and the bottom edge of the second partition 12 is connected to the upper surface of the first partition 11. The second partition 12 divides the first chamber 101 into two chambers, namely the third chamber 103 and the fourth chamber 104.

[0048] Preferably, the electronic control housing 1, the first partition 11, and the second partition 12 are integrally formed, forming an integrated structure. By setting the first partition 11 and the second partition 12, the internal space of the electronic control housing 1 is rationally divided. On the one hand, this improves the space utilization rate of the electronic control housing 1, allows for the rational distribution of various components, fully utilizes the internal space of the electronic control housing 1, improves the integration of the motor controller integrated system, and significantly reduces the overall volume of the motor controller integrated system. This allows the motor controller integrated system to be installed above the half-shaft of the electric vehicle without interfering with the half-shaft, making full use of the space above the half-shaft.

[0049] Furthermore, the power module 3 (OCDC) includes an integrated on-board charger (OBC) and a high-low voltage DC-DC converter (DCDC). The spatial shape defined by the fourth chamber 104 is roughly adapted to the shape of the power module 3, and the power module 3 is disposed within the fourth chamber 104. Multiple connecting posts are provided within the fourth chamber 104, and the power module 3 is provided with connecting holes. Screws or other fasteners are used to pass through the connecting holes and connect to some of the connecting posts to fix the power module 3 within the fourth chamber 104.

[0050] Furthermore, the power distribution module 4 is specifically a high-voltage power distribution PDU (Power Distribution Unit) module, which is an important component of the motor control assembly. The power distribution module 4 is located in the third chamber 103. A connecting column is also provided in the third chamber 103. The power distribution module 4 is connected to the connecting column by fasteners to fix the power distribution module 4 in the third chamber 103.

[0051] Furthermore, the motor controller (MCU) module includes: a power module unit 21, a thin film capacitor 24, and a DC filter unit 22, wherein the power module unit 21 is disposed in the second chamber 102, the DC filter unit 22 is disposed in the third chamber 103, and the thin film capacitor 24 is disposed in the third chamber 103.

[0052] Preferably, the power supply module 3, DC filter unit 22, and power distribution module 4 are arranged in parallel, which helps to reduce the vertical height of the integrated motor controller system.

[0053] Furthermore, in this embodiment, the DC filter unit 22 adopts multi-stage filtering. Preferably, the DC filter unit 22 includes eight stages of filtering, including two stages of X capacitor filtering, three stages of Y capacitor filtering, and three stages of magnetic ring filtering. At the same time, the DC high voltage input and OBC output share the entire filter unit circuit, which not only effectively ensures EMC (Electromagnetic Compatibility) performance, but also effectively reduces the structural space of EMC filter design, ensuring EMC performance within a limited space.

[0054] Furthermore, the motor controller module also includes a three-phase output unit 23, which specifically includes an upper three-phase component 232 and a lower three-phase component 231. The upper three-phase component 232 is located in the fourth chamber 104, and the lower three-phase component 231 is located in the second chamber 102.

[0055] Preferably, in the second chamber 102, the power module unit 21, the thin film capacitor 24 and the lower three-phase assembly 231 are arranged in parallel to reduce the vertical height occupied by the three components.

[0056] Preferably, in the fourth chamber 104, the upper three-phase assembly 232 is located below the power supply module 3.

[0057] Furthermore, the integrated motor controller system also includes a filter magnetic ring 2321. The upper three-phase component 232 includes a filling shell, the interior of which is hollow to form a cavity. The filter magnetic ring 2321 is filled into the filling shell. By setting the filter magnetic ring 2321, the electromagnetic interference of the current loop between the motor controller and the motor can be effectively reduced, and the electromagnetic compatibility of the integrated motor controller system can be further improved.

[0058] Furthermore, the first partition 11 has a flow channel 1001 inside, and the flow channel 1001 is filled with a cooling medium, which can be a common coolant. The surface of the first partition 11 facing the flow channel 1001 forms a heat dissipation surface, which at least covers a portion of the surface of the first partition 11. The power module unit 21 is disposed on the heat dissipation surface, and the bottom of the power module unit 21 is in contact with the heat dissipation surface, which enables heat dissipation of the power module unit 21.

[0059] Furthermore, a heat sink is provided between the first partition 11 and the film capacitor 24. The heat sink is specifically a heat dissipation medium applied to the first partition 11. The heat dissipation medium can be thermally conductive sealant, thermally conductive pad, thermally conductive silicone grease, etc.

[0060] Furthermore, the integrated motor controller system also includes a first cover plate 5 and a second cover plate 6. The first cover plate 5 covers the upper opening of the electrical control housing 1. The first cover plate 5 simultaneously seals the third chamber 103 and the fourth chamber 104, so as to encapsulate the power module 3 and the upper three-phase component 232 in the fourth chamber 104, and encapsulate the DC filter unit 22 and the power distribution module 4 in the third chamber 103.

[0061] The second cover plate 6 is placed over the lower opening of the electrical control housing 1 to encapsulate the power module unit 21 and the lower three-phase assembly 231 in the second chamber 102.

[0062] In summary, the motor controller integrated system provided in this application, through structural optimization, places a portion of each unit in the MCU module in the compact second chamber 102 and another portion in the more spacious first chamber 101. This results in a compact structure and high integration. The rational layout of each component significantly reduces the lateral dimension compared to the traditional flat layout, while effectively controlling the longitudinal thickness. This makes the overall size of the motor controller integrated system smaller, allowing it to be installed above the vehicle's half-shaft, fully utilizing the space above the half-shaft. By controlling the volume of the motor controller integrated system, the overall size after integration with the motor and reducer can be controlled.

[0063] In addition, the DC filter unit 22 of this motor controller integrated system adopts multi-stage filtering, which effectively improves the electromagnetic compatibility of the system assembly.

[0064] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A motor controller integrated system, characterized in that, include: An electronic control housing, wherein the interior of the electronic control housing is hollow; A first partition is disposed inside the electrical control housing, and the first partition divides the internal space of the electrical control housing into a first chamber and a second chamber; A power module, wherein the power module is disposed in the first chamber; A power distribution module is disposed in the first chamber; A motor controller module, comprising multiple electronic devices, wherein a portion of the electronic devices are disposed in the first chamber and another portion of the electronic devices are disposed in the second chamber.

2. The motor controller integrated system according to claim 1, characterized in that, The motor controller integrated system also includes a second partition, which is disposed in the first chamber and divides the first chamber into a third chamber and a fourth chamber. The power distribution module is located in the third chamber; The power module is located in the fourth chamber.

3. The motor controller integrated system according to claim 2, characterized in that, The motor controller module includes: A power module unit, wherein the power module unit is disposed in the second chamber; A thin-film capacitor, wherein the thin-film capacitor is disposed in the second chamber; A DC filter unit is disposed in the third chamber.

4. The motor controller integrated system according to claim 2, characterized in that, The motor controller module also includes a three-phase output unit, which includes an upper three-phase component and a lower three-phase component; The upper three-phase assembly is disposed in the fourth chamber; the lower three-phase assembly is disposed in the second chamber.

5. The motor controller integrated system according to claim 3, characterized in that, The DC filter unit includes multi-stage filtering, which includes at least one capacitor filter and at least one magnetic ring filter.

6. The motor controller integrated system according to claim 4, characterized in that, The upper three-phase component includes a filter magnetic ring, which is disposed on the upper three-phase component.

7. The motor controller integrated system according to claim 3, characterized in that, The first partition is provided with a flow channel, and the plate surface of the first partition corresponding to the flow channel forms a heat dissipation surface, and the power module unit is disposed on the heat dissipation surface.

8. The motor controller integrated system according to claim 3, characterized in that, The first partition is provided with a heat sink at least at the position corresponding to the thin film capacitor.

9. The motor controller integrated system according to claim 2, characterized in that, The motor controller integrated system also includes: A first cover plate, which seals the first chamber; The second cover plate seals the second chamber.

10. The motor controller integrated system according to any one of claims 2 to 9, characterized in that, The electronic control housing is located above the half-shaft of the electric vehicle; The first chamber is located above the second chamber; the third chamber and the fourth chamber are distributed to the left and right.

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