Controller and vehicle

Abstract

This application provides a controller and a vehicle. The controller includes a capacitor module and a power control module electrically connected to the capacitor module. The capacitor module includes a first busbar and a second busbar. The first busbar includes a first base, and the second busbar includes a second base disposed opposite to the first base. The first base has a first side facing away from the second base. The second base has a second side facing away from the first base. One end of the first base is bent toward the first side to form an extension. The end of the extension away from the first base is bent toward the side facing away from the first base to form a first molded portion. The end of the second base near the extension is bent toward the second side to form a second molded portion. The first molded portion and the second molded portion form a capacitor mounting space. By providing the extension, the volume of the capacitor mounting space is increased, the size of the capacitor core that can be installed in the controller is increased, the instantaneous current that the controller can provide is increased, and the performance of the controller is improved.

Description

Technical Field

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

[0002] With the continuous development of vehicle technology, new energy vehicles are becoming increasingly popular. As the core drive component of new energy vehicles, the performance requirements for electric drive systems are constantly increasing. Controllers, as key control units within electric drive systems, also face higher demands in terms of integration, operating efficiency, and reliability.

[0003] The controller has internal space for accommodating capacitors. Currently, this space is too small, limiting the capacity of the capacitors and making it difficult to meet the controller's demands for instantaneous high currents, thus reducing the response speed of the electric drive unit. Utility Model Content

[0004] This application provides a controller and a vehicle to solve related technical problems.

[0005] This application provides a controller, including: a capacitor module and a power control module; the capacitor module includes a first busbar and a second busbar; the power control module includes a first conductive end plate and a second conductive end plate; the first busbar is electrically connected to the first conductive end plate, and the second busbar is electrically connected to the second conductive end plate; the first busbar includes a first base, and the second busbar includes a second base disposed opposite to the first base; the first base has a first side facing away from the second base; the second base has a second side facing away from the first base; one end of the first base is bent toward the first side to form an extension; the end of the extension away from the first base is bent toward the side facing away from the first base to form a first molded portion; the end of the second base near the extension is bent toward the second side to form a second molded portion; the first molded portion and the second molded portion form a capacitor mounting space.

[0006] By adding an extension section, the volume of the capacitor mounting space is increased, the size of the capacitor core that can be installed in the controller is increased, the instantaneous current that the controller can provide is increased, the controller performance is improved, and the response speed of the electric drive device is increased.

[0007] Furthermore, the end of the first base away from the extension is bent toward the first side to form a first overlapping plate, and the end of the second base away from the second forming portion is bent toward the first side to form a second overlapping plate; the power control module is disposed on the second side. This arrangement reduces the area of ​​the current loop formed by the capacitor module and the power module, thereby reducing stray inductance and further improving the performance of the controller.

[0008] Furthermore, the capacitor module includes a housing and a bracket, one end of the bracket abutting against the housing, and the other end of the bracket abutting against the first and second overlapping plates; the power control module is disposed on the second side; the first conductive end plate is electrically connected to the first overlapping plate; the second conductive end plate is electrically connected to the second overlapping plate. By setting the bracket to support the first and second overlapping plates, the installation strength of the first and second overlapping plates is improved, thereby improving the overall structural strength of the controller.

[0009] Furthermore, the first overlapping plate and / or the second overlapping plate are connected to the bracket pins. By providing a pin connection structure, the overlapping plates can be positioned during installation, improving assembly efficiency. At the same time, the installation strength of the overlapping plates is further improved.

[0010] Furthermore, the first overlapping plate and / or the second overlapping plate are provided with a first positioning part, and the bracket is provided with a second positioning part. One of the first positioning part and the second positioning part is a notch, and the other is a protrusion. Using the notch and protrusion structure for positioning further improves the installation efficiency of the overlapping plate, and the structure is simple and easy to manufacture.

[0011] Furthermore, the first and / or second overlapping plates are provided with support plates on their sides, and the bracket is provided with a pair of clamping parts, which respectively clamp the two sides of the support plate. By providing the clamping parts and support plates, the overlapping plates can be positioned and reinforced, thereby further improving assembly efficiency and structural strength.

[0012] Furthermore, the support plate is provided with positioning holes, and the bracket is provided with positioning posts that mate with the positioning holes. By providing positioning holes on the support plate, the positioning efficiency of the overlapping plate is further improved, and the assembly speed is accelerated.

[0013] Furthermore, the bracket is equipped with a tooling positioning structure. By providing a tooling positioning structure on the bracket, the bracket can serve as an installation reference during controller assembly, thereby improving the overall assembly efficiency of the controller.

[0014] Furthermore, the first busbar is welded and fixed to the first conductive end plate, and the first conductive end plate is provided with a first stress relief hole; and / or, the second busbar is welded and fixed to the second conductive end plate, and the second conductive end plate is provided with a second stress relief hole. By providing stress relief holes, the deformation of the conductive end plate during the welding process can be reduced, the connection strength between the conductive end plate and the busbar can be improved, and the two can be electrically connected normally.

[0015] Furthermore, the first base includes a first thick segment and a first thin segment, wherein the thickness of the first thick segment is greater than the thickness of the first thin segment; and / or, the second base includes a second thick segment and a second thin segment, wherein the thickness of the second thick segment is greater than the thickness of the second thin segment. By providing the thick segment, the resistance of the busbar is reduced, thereby reducing heat generation. By providing the thin segment, the busbar is made easier to bend, improving manufacturing efficiency.

[0016] Furthermore, the first thick segment and the second thin segment are aligned, and the first thin segment and the second thick segment are aligned. This arrangement ensures the uniformity of the busbar's dimensions, avoids areas that are too thick, and improves space utilization.

[0017] This application also provides a vehicle including the aforementioned controller. Because the controller of this application can provide a larger instantaneous current, it speeds up the vehicle's response rate, thereby improving the user experience.

[0018] 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 specification. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this specification and, together with the description, serve to explain the principles of this specification.

[0020] Figure 1 This is a structural diagram of a controller according to an exemplary embodiment of this application;

[0021] Figure 2 yes Figure 1 A structural diagram of the first and second busbars in the middle;

[0022] Figure 3 yes Figure 1 Partial structural diagram of the controller;

[0023] Figure 4 yes Figure 3 Enlarged view of part A in the image;

[0024] Figure 5 yes Figure 3 Enlarged view of part B in the image.

[0025] Reference numerals in the attached figures: Capacitor module 10; First busbar 11; First side 110; First base 111; Extension 112; First forming part 113; First section 1131; Second section 1132; First overlapping plate 114; First thick section 115; First thin section 116; Second busbar 12; Second side 120; Second base 121; Second forming part 122; Second overlapping plate 123; Second thick section 124; Second thin section 125; Capacitor mounting space 13; Housing 14; Mounting lug 141; Bracket 15; Clamping part 151; Tooling positioning structure 152; Pin 16; First positioning part 171; Second positioning part 172; Support plate 173; Positioning hole 174; Power control module 20; First conductive end plate 21; First stress relief hole 211; Second conductive end plate 22; Second stress relief hole 221; Insulating component 30. Detailed Implementation

[0026] The technical solutions in the embodiments (or "implementations") of this application will be clearly and completely described herein with reference to the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements.

[0027] If the embodiments of this application contain terms relating to directional indications or positional relationships (such as up, down, left, right, front, back, inside, outside, top, bottom, center, vertical, horizontal, longitudinal, transverse, length, width, counterclockwise, clockwise, axial, radial, circumferential, etc.), such terms are only used to explain the relative positional relationships and movements between components in a specific posture (as shown in the attached figures); if the specific posture changes, the directional indications or positional relationships will also change accordingly. Furthermore, the terms "first" and "second" used in the embodiments of this application are only for descriptive convenience and should not be construed as indicating or implying relative importance.

[0028] The controller has an internal space for accommodating capacitors. Currently, this space is too small, limiting the capacity of the capacitors and making it difficult to meet the controller's demands for instantaneous high currents, thus affecting the response speed of the electric drive system. This application provides a controller and a vehicle to solve these technical problems.

[0029] like Figure 1 As shown, this application provides a controller, including a capacitor module 10 and a power control module 20. The power control module 20 is electrically connected to the capacitor module 10. The power control module 20 is used to control an electric drive device. The capacitor module 10 includes a first busbar 11 and a second busbar 12. The polarities of the first busbar 11 and the second busbar 12 are opposite. Please refer to the following: Figure 2 As shown, an insulating element 30 can be installed between the first busbar 11 and the second busbar 12 to prevent electrical conduction.

[0030] The first busbar 11 includes a first base 111, and the second busbar 12 includes a second base 121. The first base 111 and the second base 121 are disposed opposite to each other. The first base 111 is provided with a first side 110 facing away from the second base 121. The second base 121 is provided with a second side 120 facing away from the first base 111.

[0031] One end of the first base 111 is bent toward the first side 110 to form an extension 112. The end of the extension 112 away from the first base 111 is bent toward the side opposite to the first base 111 to form a first molded portion 113. The end of the second base 121 near the extension 112 is bent toward the second side 120 to form a second molded portion 122. The first molded portion 113 and the second molded portion 122 form a capacitor mounting space 13.

[0032] By providing the extension section 112, the volume of the capacitor mounting space 13 is expanded, the size of the capacitor core that can be installed in the controller is increased, the instantaneous current that the controller can provide is increased, the performance of the controller is improved, and the response speed of the electric drive device is increased.

[0033] The first forming part 113 includes a first portion 1131 and a second portion 1132. The first portion 1131 is formed by bending from the extension portion 112. The second portion 1132 is formed by bending from the first portion 1131. The first portion 1131, the second portion 1132 and the second forming part 122 together form a square capacitor mounting space 13 for mounting capacitor cores.

[0034] The end of the first base 111 away from the extension 112 is bent toward the first side 110 to form a first overlapping plate 114, and the end of the second base 121 away from the second forming part 122 is bent toward the first side 110 to form a second overlapping plate 123. The power control module 20 is disposed on the second side 120. To accommodate the overlapping requirements of the power control module 20, the first overlapping plate 114 and the second overlapping plate 123 are staggered in the height direction.

[0035] Since the power control module 20 is located on the second side 120, and the first lap plate 114 and the second lap plate 123 are bent toward the first side 110, the current on the first busbar 11 and the second busbar 12 will be limited at the bend of the first lap plate 114 and the second lap plate 123, thereby reducing the area of ​​the formed current loop (as shown by the dotted line in the figure), reducing the stray inductance generated by the current loop, reducing interference to the controller, and improving the performance of the controller.

[0036] The first base 111 includes a first thick segment 115 and a first thin segment 116. The thickness of the first thick segment 115 is greater than the thickness of the first thin segment 116. The second base 121 includes a second thick segment 124 and a second thin segment 125. The thickness of the second thick segment 124 is greater than the thickness of the second thin segment 125.

[0037] The first thick section 115 reduces the resistance of the first busbar 11, thereby reducing its heat generation. The second thick section 124 reduces the resistance of the second busbar 12, thereby reducing its heat generation. The first thin section 116 makes the first busbar 11 easier to bend, improving its manufacturing efficiency. The second thin section 125 makes the second busbar 12 easier to bend, improving its manufacturing efficiency.

[0038] The first thick section 115 is aligned with the second thin section 125. The first thin section 116 is aligned with the second thick section 124. This arrangement ensures the uniformity of the busbar structure in terms of dimensions, avoids areas that are too thick, and improves space utilization.

[0039] The number of first busbars 11 can be two, and the number of second busbars 12 can be two accordingly. Correspondingly, the number of power control modules 20 can be two to control both types of electrical components. Each first busbar 11 may include three first contact plates 114, and each second busbar may include three second contact plates 123 to output three-phase AC power.

[0040] Please refer to the following: Figure 3 As shown, the capacitor module 10 includes a housing 14 and a bracket 15. The housing 14 is provided with a mounting boss 141 for fixing the capacitor module 10. An extension 112, a first molding portion 113, and a second molding portion 122 can be disposed inside the housing 14. A first base portion 111 and a second base portion 121 extend out of the housing 14. One end of the bracket 15 abuts against the housing 14, and the other end of the bracket 15 abuts against the first overlapping plate 114 and the second overlapping plate 123.

[0041] By setting bracket 15 to support the first overlapping plate 114 and the second overlapping plate 123, the installation strength of the first overlapping plate 114 and the second overlapping plate 123 is improved, thereby improving the overall structural strength of the controller.

[0042] The bracket 15 is provided with pins 16. At least one of the first overlapping plate 114 and the second overlapping plate 123 is connected to the bracket 15 with a pin. By providing a pin connection structure, the overlapping plates can be positioned during installation, improving assembly efficiency. At the same time, the installation strength of the overlapping plates is further improved.

[0043] Please refer to the following: Figure 4As shown, at least one of the first overlapping plate 114 and the second overlapping plate 123 is provided with a first positioning part 171, and the bracket is provided with a second positioning part 172. One of the first positioning part 171 and the second positioning part 172 is a notch, and the other is a protrusion. The positioning is achieved by using the notch and protrusion structure, which further improves the installation efficiency of the overlapping plate, and the structure is simple and easy to manufacture.

[0044] Please refer to the following: Figure 5 As shown, at least one of the first overlapping plate 114 and the second overlapping plate 123 has a support plate 173 on its side. The bracket 15 is provided with a pair of clamping parts 151, which clamp the two sides of the support plate 173 respectively. By providing the clamping parts 151 and the support plate 173, the overlapping plates can be positioned and reinforced, thereby further improving assembly efficiency and structural strength.

[0045] The support plate 173 is provided with positioning holes 174, and the bracket 15 is provided with positioning posts (not shown) that are installed in conjunction with the positioning holes 174. By providing positioning holes 174 on the support plate 173, the positioning efficiency of the overlapping plate is further improved, and the assembly speed is accelerated.

[0046] like Figure 3 As shown, the bracket 15 is provided with a tooling positioning structure 152 for fixing the bracket 15 to a positioning fixture. Specifically, the tooling positioning structure 152 can be a positioning hole. By providing the tooling positioning structure 152 on the bracket 15, the bracket 15 can serve as an installation reference during controller assembly, thereby improving the overall assembly efficiency of the controller.

[0047] like Figure 1 As shown, the power control module 20 includes a first conductive end plate 21 and a second conductive end plate 22. A first busbar 11 is welded and fixed to the first conductive end plate 21, and the first conductive end plate 21 is provided with a first stress relief hole 211. A first overlapping plate 114 is welded and fixed to the first conductive end plate 21. A second busbar 12 is welded and fixed to the second conductive end plate 22, and the second conductive end plate 22 is provided with a second stress relief hole 221.

[0048] By setting stress relief holes, the deformation of the conductive end plate during the welding process can be reduced, the connection strength between the conductive end plate and the busbar can be improved, and the two can conduct electricity normally.

[0049] A second aspect of this application provides a vehicle including the aforementioned controller. Because the controller of this application can provide a larger instantaneous current, it accelerates the vehicle's response rate, thereby improving the user experience.

[0050] It should be noted that the technical solutions or features described in the above embodiments can be combined or supplemented with each other without conflict. The scope of protection of this application is not limited to the precise structures described in the above embodiments and shown in the accompanying drawings; all modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A controller characterized by, include: A capacitor module and a power control module electrically connected to the capacitor module; the capacitor module includes a first busbar and a second busbar. The first busbar includes a first base, and the second busbar includes a second base disposed opposite to the first base; the first base is provided with a first side facing away from the second base; the second base is provided with a second side facing away from the first base; One end of the first base is bent toward the first side to form an extension; the end of the extension away from the first base is bent toward the side opposite to the first base to form a first forming part; the end of the second base near the extension is bent toward the second side to form a second forming part; the first forming part and the second forming part form a capacitor mounting space.

2. The controller of claim 1, wherein, The first base portion is bent toward the first side at one end away from the extension portion to form a first overlapping plate, and the second base portion is bent toward the first side at one end away from the second forming portion to form a second overlapping plate; the power control module is disposed on the second side.

3. The controller of claim 2, wherein, The capacitor module includes a housing and a bracket, one end of the bracket abuts against the housing, and the other end of the bracket abuts against the first overlapping plate and the second overlapping plate.

4. The controller of claim 3, wherein, The first overlapping plate and / or the second overlapping plate are connected to the bracket pins.

5. The controller of claim 3, wherein, The first overlapping plate and / or the second overlapping plate are provided with a first positioning part, and the bracket is provided with a second positioning part. One of the first positioning part and the second positioning part is a notch and the other is a protrusion.

6. The controller according to claim 3, characterized in that, The first overlapping plate and / or the second overlapping plate are provided with support plates on their sides, and the bracket is provided with a pair of clamping parts, which respectively clamp the two sides of the support plate.

7. The controller according to claim 6, characterized in that, The support plate is provided with positioning holes, and the bracket is provided with positioning posts that cooperate with the positioning holes for installation.

8. The controller according to claim 3, characterized in that, The bracket is equipped with a tooling positioning structure.

9. The controller according to claim 1, characterized in that, The power control module includes a first conduction terminal board and a second conduction terminal board; The first busbar is welded and fixed to the first conductive end plate, and the first conductive end plate is provided with a first stress relief hole; and / or, the second busbar is welded and fixed to the second conductive end plate, and the second conductive end plate is provided with a second stress relief hole.

10. The controller according to claim 1, characterized in that, The first base includes a first thick segment and a first thin segment, wherein the thickness of the first thick segment is greater than the thickness of the first thin segment; and / or, the second base includes a second thick segment and a second thin segment, wherein the thickness of the second thick segment is greater than the thickness of the second thin segment.

11. The controller according to claim 10, characterized in that, The first thick segment and the second thin segment are aligned.

12. A vehicle, characterized in that, include: The controller as described in any one of claims 1-11.

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