Motor controller and switched reluctance motor using the same

Abstract

The utility model discloses a kind of motor controller and switch reluctance motor using it, comprising: electric control box, it has accommodating cavity;Circuit mainboard, it at least includes the substrate for being fixed in accommodating cavity and several components and parts arranged on substrate;Capacitor assembly, it includes the capacitor board for being erected above substrate and at least one electrolytic capacitor fixed on capacitor board;Wherein the capacitor board and substrate form the overhead interval for accommodating component and part between it.The utility model can improve the effective utilization of the space above circuit mainboard by double-layer overhead layout structure, thereby to improve the utilization ratio of the depth direction of the accommodating cavity of electric control box. Therefore, without expanding the length and width size of electric control box, the assembly demand for electrolytic capacitor can be met.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, and in particular to a motor controller and a switched reluctance motor using the same. Background Technology

[0002] Motor speed regulation relies heavily on the motor controller. The circuit board of an AC motor controller consists of two parts: a power conversion circuit and a motor control circuit. The power conversion circuit primarily converts AC power to DC power, filters, and stabilizes it, transforming the fluctuating AC voltage from the power grid into a stable DC voltage usable for motor excitation. This circuit offers two options: with and without electrolytic capacitors. The electrolytic capacitor-free option is suitable for low-voltage, low-current, and low-power applications. Generally, the electrolytic capacitor option is used when the motor voltage, current, and power are higher.

[0003] When using solutions with electrolytic capacitors, the large size of these capacitors places certain demands on the controller layout design (such as the design of the heat sink and the control box) and the controller's installation space. For example, the capacitor layout scheme in the new energy vehicle motor controller disclosed in announcement number CN218920676U involves several capacitors fixedly mounted on the main circuit board via a lead-connection mechanism. This complex mechanism cannot meet the design requirements for the large electrolytic capacitors. Furthermore, if large electrolytic capacitors are directly mounted on the main circuit board along with other components, it directly increases the overall length and / or width of the main circuit board, thus increasing the external length and / or width of the corresponding control box. A control box of this size may not be suitable for applications with limited installation space.

[0004] Based on the above, for large electrolytic capacitors, a new layout and assembly structure needs to be designed to determine how to rationally arrange their assembly in the controller. Utility Model Content

[0005] The primary objective of this invention is to provide a motor controller that addresses the technical problem of optimizing the assembly structure of large-volume electrolytic capacitors.

[0006] The second objective of this invention is to provide a switched reluctance motor to solve the technical problem of optimizing the assembly structure of the motor controller used in it for large-volume electrolytic capacitors.

[0007] The motor controller of this utility model is implemented as follows: A motor controller includes: an electrical control box having a receiving cavity; The circuit board includes at least a substrate for fixing in a housing cavity and several components disposed on the substrate. A capacitor assembly includes a capacitor plate for mounting on a substrate and at least one electrolytic capacitor fixed on the capacitor plate; wherein an overhead space for accommodating components is formed between the capacitor plate and the substrate.

[0008] In an optional embodiment of this invention, the substrate is provided with at least one protruding connecting post; and The capacitor plate is adapted to be connected to the connecting post via a first fastener.

[0009] In an optional embodiment of this invention, at least one support column is provided within the receiving cavity; and The substrate is fixed to the support column by a second fastener.

[0010] In an optional embodiment of this utility model, at least one supporting column is further provided inside the receiving cavity; The support column has a first support step formed on the end face of the substrate facing away from the capacitor plate.

[0011] In an optional embodiment of this invention, the supporting column is further formed with a second supporting step suitable for supporting the end face of the capacitor plate facing the substrate; and The substrate has through holes suitable for the second support step to pass through.

[0012] In optional embodiments of this invention, both the first and second supporting steps are annular structures; and The outer diameter of the second support step is smaller than the outer diameter of the first support step.

[0013] In an optional embodiment of this utility model, the capacitor plate is an L-shaped plate, and two electrolytic capacitors are fixed on the capacitor plate; and Each of the electrolytic capacitors is provided with electronic leads, and the substrate is designed with wire connection holes for mating with the electronic leads.

[0014] In an optional embodiment of this invention, the motor controller further includes a heat sink that cooperates with the motherboard; The heat sink includes at least a rectifier bridge heat sink and a power component heat sink arranged side by side and spaced apart.

[0015] In an optional embodiment of this invention, the heat sink further includes an additional heat sink that is detachably connected to both the rectifier bridge heat sink and the power component heat sink; and The rectifier bridge heat sink and the power component heat sink are respectively provided with mating holes for connecting additional heat sinks.

[0016] The switched reluctance motor of this invention is implemented as follows: A switched reluctance motor includes: the motor controller.

[0017] By adopting the above technical solution, this utility model has the following beneficial effects: The motor controller and the switched reluctance motor using it separate the large electrolytic capacitor from other components. The electrolytic capacitor is placed on a capacitor plate, while other components are placed on a substrate. The capacitor plate is then mounted on the substrate of the circuit board. This double-layered, elevated structure improves the effective utilization of the space above the circuit board, thereby increasing the utilization rate of the depth direction of the control box's housing. Therefore, the assembly requirements for the electrolytic capacitor can be met without increasing the length and width of the control box. Furthermore, the capacitor assembly is detachably connected to the circuit board. Based on this structure, the placement of the electrolytic capacitor will not interfere with or affect other components. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the internal structure of the motor controller of this utility model; Figure 2 This is an exploded structural diagram of the electrical control box, circuit board, and capacitor assembly of the motor controller of this utility model. Figure 3 for Figure 2 Enlarged view of part A; Figure 4 This is a schematic diagram of the cooperation structure between the capacitor assembly and the main circuit board of the motor controller of this utility model. Figure 5 This is a schematic diagram of the cooperation structure between the capacitor board and the main circuit board of the capacitor assembly of the motor controller of this utility model. Figure 6 This is a schematic diagram of the electrical circuit board of the motor controller of this utility model; Figure 7 This is a schematic diagram showing the cooperation structure between the capacitor assembly and the circuit board of the motor controller of this utility model and the supporting column.

[0019] In the diagram: 1. Control box; 11. Support column; 12. Support column; 21. Substrate; 22. Components; 23. Connecting column; 24. Wire connection hole; 25. Through hole; 31. Capacitor plate; 32. Electrolytic capacitor; 33. Limiting hole; 34. Electronic lead; 4. First fastener; 51. First support step; 52. Second support step; 53. Limiting column; 6. Second fastener; 71. Rectifier bridge heat sink; 72. Power component heat sink; 73. Connecting hole; 74. Additional heat sink. Detailed Implementation

[0020] To make the contents of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0021] Example 1: Please see Figures 1 to 7 As shown, this embodiment provides a motor controller, including: an electrical control box 1 with a certain depth of receiving cavity, and a circuit board and capacitor assembly disposed in the receiving cavity of the electrical control box 1.

[0022] Generally speaking, the circuit board includes at least a substrate 21 for fixing within the receiving cavity and several components 22 disposed on the substrate 21; it should be noted that the several components 22 here do not include electrolytic capacitors 32. The capacitor assembly includes a capacitor plate 31 mounted above the substrate 21 and at least one electrolytic capacitor 32 fixed on the capacitor plate 31; wherein an overhead space for accommodating the components 22 is formed between the capacitor plate 31 and the substrate 21. Based on this, a double-layer overhead layout structure is formed for the capacitor assembly and the circuit board. Thus, the double-layer overhead layout structure improves the effective utilization of the space above the circuit board, thereby increasing the utilization rate of the depth direction of the receiving cavity of the control box 1. Therefore, the assembly requirements for the electrolytic capacitors 32 can be met without increasing the length and width dimensions of the control box 1.

[0023] Next, let's discuss the circuit board in detail. It mainly consists of two parts: a power conversion circuit and a motor control circuit. The power conversion circuit includes relays, transformers, rectifier bridges, and power-on resistors; the motor control circuit includes an MCU, freewheeling diodes, IGBTs, and half-bridge drivers. It should be noted that the power conversion circuit and motor control circuit can utilize any mature existing technology. This embodiment does not modify these technologies, and therefore, its specific structure and implementation principle are not limited in this embodiment.

[0024] Secondly, the way the circuit board and the housing are fitted together: Referring to the accompanying drawings, in one optional embodiment, at least one support post 11 is provided within the receiving cavity; and the base plate 21 is fixedly connected to the support post 11 by a second fastener 6. The second fastener 6 may be, for example, but not limited to, a screw; that is, the support post 11 has a pre-drilled threaded inner hole for mates with the screw, and the base plate 21 has a second through hole suitable for the second fastener 6 to pass through. For example, if the electrical control box 1 is generally rectangular, a support post 11 is provided at each of two inner corners of the electrical control box 1, and the two support posts 11 are located at two adjacent inner corners.

[0025] Based on the above structure, at least one support column 12 is provided in the receiving cavity. Two support columns 12 can be provided here, and two support columns 11 are provided at two other adjacent inner corners of the electrical control box 1. A first support step 51 is formed on the support column 12 to support the end face of the substrate 21 facing away from the capacitor plate 31.

[0026] Next, we will explain the connection method between capacitor plate 31 and substrate 21: Generally, the substrate 21 has at least one protruding connecting post 23; and the capacitor plate 31 is adapted to be connected to the connecting post 23 via a first fastener 4. The first fastener 4 may be, for example, but not limited to, a screw. In this regard, the connecting post 23 has a pre-set threaded inner hole for mating with the screw, and the capacitor plate 31 has a first through hole for the first fastener 4 to pass through.

[0027] Based on the above structure, in the first optional implementation, the capacitor plate 31 can be fixed relative to the substrate 21 by a plurality of connecting posts 23 arranged at intervals.

[0028] In a second alternative implementation, to simplify the assembly of the capacitor plate 31 and the substrate 21, a support post 12 can be used to assist in fixing the capacitor plate 31. Specifically, the support post 12 is also formed with a second support step 52 suitable for supporting the end face of the capacitor plate 31 facing the substrate 21; and the substrate 21 is provided with a through hole 25 suitable for the second support step 52 to pass through. The through hole 25 is suitable for forming a clearance fit with the outer wall surface of the second support step 52. In this case, only one connecting post 23 can be provided, and the bottom support of the capacitor plate 31 can be simultaneously achieved by the two support posts 12 used to support the substrate 21 in the receiving cavity of the electrical control box 1. This structure means that the support post 12 in this embodiment can achieve a dual-purpose effect, thus simplifying the internal structure of the overall motor control box. Furthermore, the design of the support post 12 can also improve the efficiency of the assembly process between the circuit board and the electrical control box 1, as well as the efficiency of the assembly process between the capacitor plate 31 and the circuit board.

[0029] Of course, it should be noted that, in order to improve the fit between the support column 12 and the capacitor plate 31, a limiting post 53 is integrally formed on the support column 12, and the limiting post 53 is designed on the side end of the second support step 52 facing away from the first support step 51. Correspondingly, a limiting hole 33 is provided on the capacitor plate 31 to allow the limiting post 53 to pass through. The limiting hole 33 and the limiting post 53 are suitable for forming a clearance fit.

[0030] Based on the above, it should also be noted that, in order for the support column 12 of this embodiment to simultaneously support the substrate 21 and the capacitor plate 31, the first support step 51 and the second support step 52 in this embodiment are both annular structures; and the outer diameter of the second support step 52 is smaller than the outer diameter of the first support step 51.

[0031] Next, referring to the attached diagram, an alternative implementation is given: the capacitor plate 31 is an L-shaped plate, and two electrolytic capacitors 32 are fixed on the capacitor plate 31. Based on this structure, on the one hand, the requirement of setting two electrolytic capacitors 32 can be met, and on the other hand, the utilization rate of the upper space of the circuit board can be reasonably made.

[0032] It is also necessary to explain that the connection between the capacitor plate 31 and the circuit board is only a matter of layout and orientation. The electrical connection between the electrolytic capacitor 32 and the circuit board is achieved in the following way: each electrolytic capacitor 32 is equipped with an electronic lead 34, and the substrate 21 is designed with wire connection holes 24 for mating with the electronic lead 34. The electronic lead 34 here can be bent and deformed, thus improving the convenience and smoothness of its mating operation with the substrate 21.

[0033] Next, it should be noted that the motor controller in this embodiment also includes a heat sink that works with the motherboard; the heat sink includes at least a rectifier bridge heat sink 71 and a power component heat sink 72 arranged side by side and spaced apart.

[0034] Based on the above structure, the heat sink also includes an additional heat sink 74 that is detachably connected to both the rectifier bridge heat sink 71 and the power component heat sink 72; and each of the rectifier bridge heat sink 71 and the power component heat sink 72 has a pre-set mating hole 73 for mating with the additional heat sink 74. The mating hole 73 can be fitted with screws to achieve the detachable connection between the additional heat sink 74 and the rectifier bridge heat sink 71 and the power component heat sink 72. The additional heat sink 74 is added when the temperature rise of the controller power component 22 is too high. The additional heat sink 74 can meet the heat dissipation requirements through, for example, but not limited to, multiple heat dissipation fins.

[0035] In summary, for the motor control box of this embodiment, the double-layer overhead layout structure improves the effective utilization of the space above the circuit board, thereby increasing the utilization rate of the depth direction of the receiving cavity of the control box 1. Therefore, the assembly requirements for the electrolytic capacitor 32 can be met without increasing the length and width of the control box 1.

[0036] Example 2: Based on the motor controller of Embodiment 1, this embodiment provides a switched reluctance motor, including the motor controller of Embodiment 1.

[0037] The above specific embodiments further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above are only specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

[0038] In the description of this utility model, it should be understood that the terms indicating orientation or positional relationship are based on the orientation or positional relationship shown in the drawings and are only for the convenience of describing this utility model 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 utility model.

[0039] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0040] In the description of this utility model, 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, or the orientation or positional relationship commonly used when the product of this utility model is in use. They are only for the convenience of describing this utility model 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 utility model. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0041] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0042] In this invention, unless otherwise expressly specified and limited, "above or below" the first feature may include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on" the first feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the first feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

Claims

1. An electric motor controller characterized by, include: An electrical control box, which has a receiving cavity; The circuit board includes at least a substrate for fixing in a housing cavity and several components disposed on the substrate. A capacitor assembly includes a capacitor plate for mounting on a substrate and at least one electrolytic capacitor fixed on the capacitor plate; wherein an overhead space for accommodating components is formed between the capacitor plate and the substrate.

2. The motor controller of claim 1, wherein, The substrate is provided with at least one protruding connecting post; and The capacitor plate is adapted to be connected to the connecting post via a first fastener.

3. The motor controller of claim 1, wherein, The receiving cavity is provided with at least one support column; and The substrate is fixed to the support column by a second fastener.

4. The motor controller according to claim 2 or 3, characterized in that, The containment cavity is also provided with at least one support column; The support column has a first support step formed on the end face of the substrate facing away from the capacitor plate.

5. The motor controller according to claim 4, characterized in that, The supporting column is also formed with a second supporting step suitable for supporting the end face of the capacitor plate facing the substrate; and The substrate is provided with through holes suitable for the second support step to pass through.

6. The motor controller according to claim 5, characterized in that, Both the first and second support steps are annular structures; and The outer diameter of the second support step is smaller than the outer diameter of the first support step.

7. The motor controller according to claim 1 or 2, characterized in that, The capacitor plate is L-shaped, and two electrolytic capacitors are fixed on the capacitor plate; and Each of the electrolytic capacitors is provided with electronic leads, and the substrate is designed with wire connection holes for mating with the electronic leads.

8. The motor controller according to claim 1 or 2, characterized in that, The motor controller also includes a heat sink that works with the motherboard; The heat sink includes at least a rectifier bridge heat sink and a power component heat sink arranged side by side and spaced apart.

9. The motor controller of claim 8, wherein, The heat sink also includes an additional heat sink that is detachably coupled to both the rectifier bridge heat sink and the power component heat sink; and The rectifier bridge heat sink and the power component heat sink are respectively provided with mating holes for connecting additional heat sinks.

10. A switched reluctance motor, characterized in that, include: The motor controller as described in any one of claims 1 to 9.

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