Motor controller and vehicle

Abstract

This disclosure relates to a motor controller and a vehicle. The motor controller includes a mounting housing and two safety capacitors disposed within the mounting housing. Each safety capacitor includes a capacitor body and at least two connection terminals connected to the capacitor body and protruding from a first side of the capacitor body in a first direction. The second sides of the two capacitor bodies are positioned opposite each other and spaced apart in the first direction. The two safety capacitors are symmetrically arranged about an axis extending along a second direction, wherein the first and second directions are perpendicular to each other. The symmetrical arrangement of the two safety capacitors about the axis along the second direction allows for a balanced distribution of capacitors within the mounting housing, improving space utilization. Furthermore, the symmetrical arrangement forms a balanced discharge circuit, effectively improving the cancellation rate of common-mode interference current and enhancing safety and reliability.

Description

Technical Field

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

[0002] With the widespread use of home appliances and industrial equipment, electromagnetic interference problems in circuits have become more prominent, and the demand for electrical safety has increased. Early safety capacitors were mostly paper or oil-immersed capacitors, which were large in size and had poor capacitance stability. Their main function was to filter and suppress power line noise, but their safety performance was limited.

[0003] In related technologies, safety capacitors often use metallized thin films to replace the transmission medium, which effectively improves the withstand voltage and self-healing performance. However, in terms of arrangement, they cannot effectively reduce the cancellation rate of mode interference current, resulting in poor safety and reliability. Utility Model Content

[0004] To overcome the problems existing in the related technologies, this disclosure provides a motor controller and a vehicle.

[0005] According to a first aspect of the present disclosure, a motor controller is provided, the motor controller including a mounting housing and two safety capacitors disposed in the mounting housing; The safety capacitor includes a capacitor body and at least two connection terminals, wherein the connection terminals are connected to the capacitor body and protrude from a first side of the capacitor body in a first direction; The second sides of the two capacitor bodies are positioned opposite each other and spaced apart in the first direction; and the two safety capacitors are arranged symmetrically about an axis extending along the second direction. Wherein, the first direction and the second direction are perpendicular to each other.

[0006] The two safety capacitors are symmetrically arranged about the axis along the second direction, ensuring even distribution of the capacitors within the mounting housing and improving space utilization. Secondly, this symmetrical arrangement forms a balanced discharge circuit, effectively improving the cancellation rate of common-mode interference current and enhancing safety and reliability. Furthermore, the two capacitor bodies are positioned opposite each other and spaced apart in the first direction, utilizing airflow for heat dissipation. This avoids heat conduction caused by the two capacitor bodies being in close contact, which could lead to localized overheating and extend their service life.

[0007] In some embodiments, the connection terminals are configured as two, namely an electrical terminal and a grounding terminal, which are opposite to and spaced apart in a second direction; The electrical terminals are electrically connected to the input power line of the motor controller, and the grounding terminal is connected to the mounting housing.

[0008] The electrical terminals connect to the high-voltage power line, while the grounding terminal connects to the mounting housing, avoiding the risk of contact between the electrical terminals and the grounding terminal. Even if the electrical terminals experience poor contact due to aging or vibration, the high-voltage current cannot form a short circuit through the grounding terminal, reducing the probability of arcing or fire. Furthermore, the connection between the grounding terminal and the mounting housing allows the housing to act as a "shielding layer," providing electromagnetic shielding for the high-voltage power line. High-frequency noise generated by the high-voltage power line can be guided into the mounting housing through the grounding terminal, reducing the risk of radiation into the external space.

[0009] In some embodiments, the mounting housing is formed with a flow channel extending along the first direction, and the electrical terminal and the grounding terminal are respectively located on both sides of the flow channel along the second direction.

[0010] The flow channel tube, as a key component for the transmission of cooling media, requires a certain amount of space within the mounting housing. By distributing the electrical terminals and grounding terminals on both sides of the flow channel tube in the second direction, the space on both sides of the flow channel tube is effectively utilized, improving the compactness of the structural design. Furthermore, with the electrical and grounding terminals located on opposite sides of the flow channel tube, maintenance personnel can access the terminals from either side to complete wiring, testing, or replacement operations without moving or disassembling the flow channel tube.

[0011] In some embodiments, the flow channel is provided with two mounting portions, which are located on the same side of the flow channel along the second direction and spaced apart in the first direction; wherein, the mounting portions are correspondingly provided with the grounding terminal, and the grounding terminal is connected to the corresponding mounting portion.

[0012] By providing two mounting portions on the same side of the flow channel tube along the second direction, the installation and arrangement of the two grounding terminals of the two safety capacitors are facilitated. These mounting portions can be constructed in any suitable manner, and this disclosure does not limit their application. As an extension of the flow channel tube, the mounting portion is integrally formed or fixedly connected to the flow channel tube, providing stable mechanical support for the grounding terminals. The grounding terminals are fixed to the mounting portion, preventing loosening or detachment due to vibration or impact, thus ensuring the long-term reliability of the grounding path.

[0013] In some embodiments, the motor controller includes a fastener, the mounting portion having a threaded hole, the grounding terminal having a first mounting hole, and the fastener passing through the first mounting hole to be threadedly connected to the threaded hole.

[0014] The grounding terminal can be secured simply by aligning its first mounting hole with the threaded hole on the mounting section and then inserting and tightening the fastener. No additional welding or bonding steps are required, thus improving assembly convenience. Furthermore, when it is necessary to replace the grounding terminal or test its grounding performance, disassembly can be achieved simply by rotating the fastener in the opposite direction, without needing to disassemble the flow channel or mounting section, reducing maintenance difficulty and time costs.

[0015] In some embodiments, the grounding terminal has a first mounting hole and a first soldering area; the electrical terminal has a second mounting hole and a second soldering area. The first mounting hole and the second mounting hole are arranged symmetrically about an axis extending along the first direction, and the first welding area and the second welding area are arranged symmetrically about an axis extending along the first direction.

[0016] The grounding terminal has a first mounting hole and a first welding area, while the electrical terminal has a second mounting hole and a second welding area. This means that the grounding terminal and the electrical terminal can be connected in both welding and screw-in scenarios, expanding the application scenarios for their connection.

[0017] In some embodiments, the motor controller includes fasteners and a connecting busbar; The fastener passes through the first mounting hole to connect with the mounting housing, the connecting busbar is electrically connected to the input power line of the motor controller, and the second welding area is welded to the connecting busbar.

[0018] Specifically, the first welding area of ​​the grounding terminal is not used for welding, and the second mounting hole of the electrical terminal is not used for screwing. The reason for this arrangement is that although the two safety capacitors are arranged in different positions, they need to be able to share the same space. After one safety capacitor is rotated horizontally by 180 degrees, it can also be used as the other safety capacitor and meet the installation requirements of the terminal.

[0019] In some embodiments, the cross-sectional area of ​​the grounding terminal is between 4 square millimeters and 6 square millimeters.

[0020] By limiting the cross-sectional area of ​​the grounding terminal in this way, the current carrying capacity of the grounding terminal can be effectively increased, thereby improving safety and reliability and extending its service life.

[0021] In some embodiments, the mounting housing is formed with an isolation plate located between the two safety capacitors, the isolation plate extending along the second direction and along a third direction; wherein the first direction, the second direction, and the third direction are mutually perpendicular.

[0022] The isolation plate serves several key advantages. Firstly, it physically separates the two safety capacitors, preventing direct heat accumulation and thus avoiding localized overheating. Secondly, the isolation plate acts as a physical support for the two capacitors, separating and fixing them in predetermined positions to prevent collisions or friction during vibrations.

[0023] According to a second aspect of the present disclosure, a vehicle is also provided, the vehicle including the motor controller described above.

[0024] The technical solutions provided by the embodiments of this disclosure can include the following beneficial effects: The two safety capacitors are symmetrically arranged about an axis along a second direction, resulting in a balanced distribution of capacitors within the mounting housing and improving space utilization. Secondly, the symmetrical arrangement forms a balanced discharge circuit, effectively improving the cancellation rate of common-mode interference current and enhancing safety and reliability. Furthermore, the two capacitor bodies are positioned opposite each other and spaced apart in the first direction, utilizing airflow for heat dissipation, avoiding heat conduction caused by the two capacitor bodies being in close contact, thus preventing localized overheating and extending service life.

[0025] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0026] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure.

[0027] Figure 1 This is a schematic diagram of a portion of the structure of a motor controller according to one embodiment of the present disclosure.

[0028] Figure 2 yes Figure 1 A magnified view of a section at point E in the middle.

[0029] Figure 3 This is a schematic diagram of a portion of the structure of a motor controller according to one embodiment of the present disclosure.

[0030] Figure 4 yes Figure 3 A magnified view of a section at point F.

[0031] Figure 5This is a schematic diagram of the structure of the safety capacitor of a motor controller according to one embodiment of the present disclosure.

[0032] Explanation of reference numerals in the attached figures 1. Housing; 11. Flow channel; 111. Mounting part; 12. Isolation plate; 2. Safety capacitor; 21. Capacitor body; 22. Connecting terminal; 221. Electrical terminal; 2210. Second mounting hole; 2211. Second welding area; 222. Grounding terminal; 2220. First mounting hole; 2221. First welding area; 3. Fasteners; 4. Connecting busbars; A. First direction; B. Second direction; C. Third direction. Detailed Implementation

[0033] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0034] In this disclosure, unless otherwise stated, the directional terms "first direction," "second direction," and "third direction" are mutually perpendicular; see reference for details. Figure 1 As shown. The terms used, such as "first" and "second," are only used to distinguish one element from another and do not indicate any order or importance.

[0035] In the description of this disclosure, it should also be noted that, unless otherwise expressly specified and limited, the terms "setup" and "connection" 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 direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0036] Reference Figures 1 to 5 As shown, this disclosure provides a motor controller, which includes a mounting housing 1 and two safety capacitors 2 disposed on the mounting housing 1. Each safety capacitor 2 includes a capacitor body 21 and at least two connection terminals 22. The connection terminals 22 are connected to the capacitor body 21 and protrude from a first side of the capacitor body 21 in a first direction A. The second sides of the two capacitor bodies 21 are positioned opposite each other and spaced apart in the first direction A; and the two safety capacitors 2 are symmetrically arranged about an axis extending along a second direction B; wherein the first direction A and the second direction B are perpendicular to each other.

[0037] In the above technical solution, firstly, the two safety capacitors 2 are arranged symmetrically about the axis along the second direction B, so that the capacitors are evenly distributed within the mounting housing 1, improving space utilization. Secondly, the symmetrical arrangement can form a balanced discharge circuit, thereby effectively improving the cancellation rate of common-mode interference current and enhancing safety and reliability. Furthermore, the two capacitor bodies 21 are positioned opposite each other and spaced apart in the first direction A, utilizing airflow for heat dissipation, avoiding heat conduction caused by the two capacitor bodies 21 being in close contact, which could lead to localized overheating and extend service life.

[0038] Optionally, the safety capacitor 2 mentioned above can be constructed as a Y capacitor. The main function of the Y capacitor is to suppress common-mode noise (common-mode interference). Common-mode interference refers to the high-frequency voltage difference between the live wire (L) and the ground wire (PE), and between the neutral wire (N) and the ground wire (PE) in a circuit. It is usually caused by power grid fluctuations, high-frequency signal coupling inside the equipment, or electromagnetic radiation in space. This type of interference can pollute the power grid through line conduction or space radiation, affecting the normal operation of the equipment itself or other equipment.

[0039] The working principle of a Y capacitor is as follows: when a capacitor is connected across the "live / neutral wire and ground wire" (such as L-PE or N-PE), it forms a low-impedance "high-frequency bypass". When common-mode interference signals occur, high-frequency noise will be "shunted" to the ground wire by the Y capacitor, preventing it from propagating in the internal wiring of the equipment or the external power grid.

[0040] In one implementation, reference Figure 3 and Figure 4 As shown, the connection terminal 22 is configured as two terminals, namely electrical terminal 221 and grounding terminal 222. The electrical terminal 221 and grounding terminal 222 are arranged opposite to each other and spaced apart in the second direction B. The electrical terminal 221 is electrically connected to the input high voltage power line of the motor controller, and the grounding terminal 222 is connected to the mounting housing 1.

[0041] In this embodiment, electrical terminal 221 is connected to the high-voltage power line, and grounding terminal 222 is connected to the mounting housing 1, avoiding the risk of contact between electrical terminal 221 and grounding terminal 222. Even if electrical terminal 221 experiences poor contact due to aging or vibration, high-voltage current cannot form a short-circuit loop through grounding terminal 222, reducing the probability of arc discharge or fire. Furthermore, the connection between grounding terminal 222 and mounting housing 1 allows mounting housing 1 to act as a "shielding layer," providing electromagnetic shielding for the high-voltage power line. High-frequency noise generated by the high-voltage power line can be guided into mounting housing 1 through grounding terminal 222, reducing the risk of radiation into the external space.

[0042] In another embodiment, refer to Figure 4As shown, the mounting housing 1 has a flow channel 11 extending along the first direction A, and electrical terminals 221 and grounding terminals 222 are located on both sides of the flow channel 11 along the second direction B.

[0043] In this embodiment, the arrangement of the flow channel 11, as a key component for the transmission of media such as cooling medium, requires a certain amount of space in the mounting housing 1. By distributing the electrical terminals 221 and the grounding terminals 222 on both sides of the flow channel 11 in the second direction B, the arrangement space on both sides of the flow channel 11 is effectively utilized, improving the compactness of the structural design. In addition, with the electrical terminals 221 and the grounding terminals 222 located on both sides of the flow channel 11, maintenance personnel can approach the terminals from both sides respectively, and complete wiring, testing, or replacement operations without moving or disassembling the flow channel 11.

[0044] Optionally, refer to Figure 3 and Figure 4 As shown, the flow channel tube 11 is provided with two mounting parts 111. The two mounting parts 111 are provided on the same side of the flow channel tube 11 along the second direction B and are spaced apart in the first direction A. The mounting parts 111 are provided corresponding to the grounding terminal 222, and the grounding terminal 222 is connected to the corresponding mounting part 111.

[0045] In this embodiment, by providing two mounting portions 111 on the same side of the flow channel 11 along the second direction B, it is convenient to install and arrange the two grounding terminals 222 of the two safety capacitors 2. The mounting portion 111 can be constructed in any suitable mounting structure, and this disclosure does not limit it. As an extension of the flow channel 11, the mounting portion 111 is integrally formed or fixedly connected to the flow channel 11, providing stable mechanical support for the grounding terminals 222. The grounding terminals 22 are fixed to the mounting portion 111, preventing loosening or detachment due to vibration or impact, and ensuring the long-term reliability of the grounding path.

[0046] In other embodiments, refer to Figure 2 , Figure 4 as well as Figure 5 As shown, the motor controller includes a fastener 3, a mounting portion 111 with a threaded hole, and a grounding terminal 222 with a first mounting hole 2220. The fastener 3 passes through the first mounting hole 2220 to be threadedly connected to the threaded hole.

[0047] In this embodiment, during installation, the grounding terminal 2222's first mounting hole 2220 is aligned with the threaded hole on the mounting part 111, and the fastener 3 is inserted and tightened to complete the fixing. No additional welding or bonding steps are required, improving the convenience of assembly. Secondly, when it is necessary to replace the grounding terminal 222 or test the grounding performance, it can be disassembled simply by rotating the fastener 3 in the reverse direction, without needing to disassemble the flow channel pipe 11 or the mounting part 111, reducing the difficulty and time cost of maintenance.

[0048] For example, the fastener 3 described above can be constructed as a fastening screw or a fastening bolt, and this disclosure does not limit the specific structure of the fastener 3. As for the mounting part 111 described above, it can be constructed as a mounting stud, the interior of which has a threaded hole that mates with the thread of the fastener 3, but this disclosure does not limit the specific structure of the fastener 3 and the mounting part 111.

[0049] Optionally, refer to Figure 4 and Figure 5 As shown, the grounding terminal 222 has a first mounting hole 2220 and a first welding area 2221; the electrical terminal 221 has a second mounting hole 2210 and a second welding area 2211; wherein the first mounting hole 2220 and the second mounting hole 2210 are symmetrically arranged about an axis extending along the first direction A, and the first welding area 2221 and the second welding area 2211 are symmetrically arranged about an axis extending along the first direction A.

[0050] In this embodiment, the grounding terminal 222 is provided with a first mounting hole 2220 and a first welding area 2221, and the electrical terminal 221 is provided with a second mounting hole 2210 and a second welding area 2211. That is, the grounding terminal 222 and the electrical terminal 221 can be connected in both welding and screwing scenarios, thus expanding the application scenarios of the connection between the grounding terminal 222 and the electrical terminal 221.

[0051] For example, when one of the safety capacitors 2 is rotated horizontally by 180°, the original grounding terminal 222 of the installed capacitor 2 can also be used as the electrical terminal 221, and the original electrical terminal 221 can also be used as the grounding terminal 222; that is, although the two safety capacitors 2 are installed in different positions, they can be used interchangeably.

[0052] Optionally, refer to Figure 4 and Figure 5 As shown, the motor controller includes a fastener 3 and a connecting busbar 4; the fastener 3 passes through a first mounting hole 2220 to connect with the mounting housing 1, the connecting busbar 4 is electrically connected to the input high-voltage power line of the motor controller, and the second welding area 2211 is welded to the connecting busbar 4.

[0053] In this embodiment, the grounding terminals 222 of the two safety capacitors 2 are connected to the mounting housing 1 via the first mounting holes 2220 and fasteners 3, and the electrical terminals 221 are welded to the connecting busbar 4 via the second welding area 2211, thereby realizing the installation connection of the grounding terminals 222 and the electrical terminals 221.

[0054] For the grounding terminal 222, the first welding area 2221 on it is not used for welding. For the electrical terminal 221, the second mounting hole 2210 on it is not used for screwing. The reason for this arrangement is that although the two safety capacitors 2 are arranged in different positions, they need to be able to share. After one of the safety capacitors 2 is rotated horizontally by 180°, it can also be used as the other safety capacitor 2 and meet the installation requirements of the terminal.

[0055] For example, when one of the safety capacitors 2 is rotated horizontally by 180°, its original grounding terminal 222 is aligned with the connecting busbar 4. The redundant first welding area 2221 of the grounding terminal 222 can also be welded to the connecting busbar 4, effectively becoming a new electrical terminal 221. Furthermore, the original electrical terminal 221 of the safety capacitor 2 is aligned with the mounting part 111, and the redundant second mounting hole 2210 can also be screwed into the mounting part 111.

[0056] Optionally, the grounding terminal 222 and electrical terminal 221 mentioned above can be integrally formed with the capacitor body 21 by injection molding. The specific materials of the grounding terminal 222 and electrical terminal 221 can be silver-plated terminals, but this disclosure does not limit the specific molding method.

[0057] Optionally, the cross-sectional area of ​​the grounding terminal 222 is between 4 square millimeters and 6 square millimeters. For example, the cross-sectional area of ​​the grounding terminal 222 can be 4 square millimeters, or 5 square millimeters, or 6 square millimeters. By limiting the cross-sectional area of ​​the grounding terminal 222 in this way, the current-carrying area of ​​the grounding terminal 222 can be effectively increased. Compared with the circular pin structure in related technologies, the parasitic inductance of 5nH can be reduced, the current carrying capacity of the grounding terminal 222 can be improved, safety and reliability can be enhanced, and service life can be extended.

[0058] Additionally, refer to Figure 1 and Figure 2As shown, the mounting housing 1 has an isolation plate 12, which is located between two safety capacitors 2. The isolation plate 12 extends along the second direction B and along the third direction C; wherein the first direction A, the second direction B and the third direction C are perpendicular to each other.

[0059] In this embodiment, firstly, by setting the isolation plate 12, the two safety capacitors 2 can be physically separated, preventing the heat from the two safety capacitors 2 from directly accumulating and avoiding local overheating. Secondly, the isolation plate 12 can serve as a physical support for the two safety capacitors 2, separating and fixing them in a predetermined position to prevent the two safety capacitors 2 from colliding or rubbing against each other during vibration.

[0060] This disclosure also provides a vehicle that includes the aforementioned motor controller.

[0061] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of this disclosure. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this disclosure are indicated by the following claims.

[0062] It should be understood that this disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims.

Claims

1. A motor controller, characterized in that, The motor controller includes a mounting housing and two safety capacitors disposed in the mounting housing; The safety capacitor includes a capacitor body and at least two connection terminals, wherein the connection terminals are connected to the capacitor body and protrude from a first side of the capacitor body in a first direction; The second sides of the two capacitor bodies are positioned opposite each other and spaced apart in the first direction; and the two safety capacitors are arranged symmetrically about an axis extending along the second direction. Wherein, the first direction and the second direction are perpendicular to each other.

2. The motor controller according to claim 1, characterized in that, The connection terminal is configured as two, namely an electrical terminal and a grounding terminal, and the electrical terminal and the grounding terminal are arranged opposite to each other and spaced apart in the second direction; The electrical terminals are electrically connected to the input power line of the motor controller, and the grounding terminal is connected to the mounting housing.

3. The motor controller according to claim 2, characterized in that, The mounting housing has a flow channel extending along the first direction, and the electrical terminal and the grounding terminal are respectively located on both sides of the flow channel along the second direction.

4. The motor controller according to claim 3, characterized in that, The flow channel is provided with two mounting parts, which are located on the same side of the flow channel along the second direction and spaced apart in the first direction; wherein, the mounting parts are correspondingly provided with the grounding terminal, and the grounding terminal is connected to the corresponding mounting part.

5. The motor controller according to claim 4, characterized in that, The motor controller includes a fastener, the mounting portion has a threaded hole, the grounding terminal has a first mounting hole, and the fastener passes through the first mounting hole to be threadedly connected to the threaded hole.

6. The motor controller according to claim 2, characterized in that, The grounding terminal has a first mounting hole and a first welding area; the electrical terminal has a second mounting hole and a second welding area. The first mounting hole and the second mounting hole are arranged symmetrically about an axis extending along the first direction, and the first welding area and the second welding area are arranged symmetrically about an axis extending along the first direction.

7. The motor controller according to claim 6, characterized in that, The motor controller includes fasteners and connecting busbars; The fastener passes through the first mounting hole to connect with the mounting housing, the connecting busbar is electrically connected to the input power line of the motor controller, and the second welding area is welded to the connecting busbar.

8. The motor controller according to claim 2, characterized in that, The cross-sectional area of ​​the grounding terminal is between 4 square millimeters and 6 square millimeters.

9. The motor controller according to claim 1, characterized in that, The mounting housing has an isolation plate located between the two safety capacitors. The isolation plate extends along the second direction and along the third direction; wherein the first direction, the second direction, and the third direction are mutually perpendicular.

10. A vehicle, characterized in that, The vehicle includes the motor controller according to any one of claims 1-9.

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