Integrated pure electric vehicle motor controller assembly

Abstract

The utility model discloses an integrated pure electric vehicle motor controller assembly, including controller casing, the high pressure area, low pressure area and power area of mutual shielding are separated in controller casing, filter assembly, power brick and three -phase copper row assembly are equipped in high pressure area in proper order, and control panel is equipped in low pressure area, and power brick is equipped in power area, OBC connector, high voltage branch connector and DCDC connector are equipped with in the side of controller casing close to power brick, the control panel with power brick and power brick all are connected through the wire of arranging, is used to the transmission control signal to power brick and power brick, the first high -voltage input of the battery assembly output end outside controller casing is connected on filter assembly, and the first high -voltage output of power brick input terminal electricity is connected, and the second high -voltage output of high voltage branch connector's input terminal electricity is connected, and the third high -voltage output of power brick input terminal connection.

Description

Technical Field

[0001] This utility model relates to the field of automotive motor control, specifically to an integrated pure electric vehicle motor controller assembly. Background Technology

[0002] With the rapid development of new energy vehicles and the increasing maturity of related technologies, the interior space of automobiles is becoming more and more compact. Miniaturization, lightweighting, and integration have become the mainstream directions for the development of new energy vehicles. As a core component of new energy vehicles, the market demand for integrated, low-cost, and high-efficiency motor controllers is becoming increasingly strong. The power battery of an electric vehicle converts high-voltage DC power into AC power through a power module to supply the motor for drive. To provide a stable and interference-free current, EMC filtering components need to be installed in the power supply unit. Simultaneously, to reduce wiring and achieve vehicle-wide power supply for all electrical components, multiple connectors and high / low voltage current conversion modules need to be added to the motor controller to supply power to other electrical components in the vehicle, resulting in a large number of electrical components in the power supply unit. Therefore, how to provide a compact, small-sized motor controller that can be installed in various vehicle models has become an urgent problem to be solved. Summary of the Invention

[0003] In view of the above-mentioned shortcomings of the existing technology, the purpose of this utility model is to provide an integrated pure electric vehicle motor controller assembly, which solves the problem that if the motor controller needs to supply power to multiple automotive electrical components, there are many electrical devices to be installed, resulting in a large size of the motor controller and making it unsuitable for assembly in various vehicle models.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: An integrated pure electric vehicle motor controller assembly includes a controller housing. Within the housing are mutually shielded high-voltage, low-voltage, and power supply areas, located on the same side and adjacent to the high-voltage area. The high-voltage area contains a filter assembly, a power supply module, and a three-phase copper busbar assembly. The low-voltage area contains a control board, and the power supply area contains a power supply module. A first connector for external power supply to the control board is located on the side of the controller housing near the control board. An OBC connector, a high-voltage branch connector, and a DC-DC connector are located on the side of the controller housing near the power supply module. The control board is connected to the power supply module and the power supply module. All components are connected via ribbon cables to transmit control signals to the power brick and power supply brick. The filter assembly has a first high-voltage input terminal, a first high-voltage output terminal, a second high-voltage output terminal, and a third high-voltage output terminal. The first high-voltage input terminal is connected to the battery assembly output terminal outside the controller housing, and then electrically connected to the power brick via the first high-voltage output terminal, from which the power brick outputs high-voltage electricity to the three-phase copper busbar assembly. The second high-voltage output terminal is electrically connected to the input terminal of the high-voltage branch connector, and the third high-voltage output terminal is connected to the input terminal of the power supply brick, and then electrically connected to the OBC connector input terminal and the DC-DC connector input terminal via the power supply brick's interface. This design, with shielding partitions within the housing according to the different functions of each component, effectively avoids signal interference between devices, improves controller reliability, and makes the internal structure of the controller clearer, facilitating platform design and mass production. The power supply brick and power brick are integrated from multiple parts according to their functions. This integrated design allows for refined structural design and a smaller controller size, enabling compatibility with more vehicle models. Meanwhile, the power brick and power supply brick design allows for platform-based design, reducing production line investment and enabling large-scale mass production, thereby lowering production costs. After the external battery assembly and filter assembly are electrically connected, high-voltage electricity is transmitted to the power brick through the first high-voltage output terminal. Finally, the three-phase copper busbar assembly outputs the high-voltage electricity to the vehicle's motor. Simultaneously, the control board sends commands to the power brick, which converts the received two-phase DC power into three-phase AC power, which is then output as current by the three-phase copper busbar assembly. The control board also transmits control signals according to the vehicle ECU's control commands, adjusting the output power and ultimately changing the motor's output power. The filter assembly also directly outputs high-voltage electricity to the high-voltage risk connector through the second high-voltage output terminal, ultimately powering the vehicle's air conditioning. The power supply brick is also connected to the control board via a ribbon cable. It receives control signals from the control board, converts the high voltage to low voltage, and outputs it to the OBC and DC-DC connectors to provide low-voltage electricity to the vehicle battery or other components. The various components are installed in separate sections within the housing, with each connector positioned close to the input terminal, resulting in a reasonable layout, compact structure, and small overall size.

[0005] Furthermore, the controller housing includes a main electrical control housing and a sealing cover plate mounted on the main electrical control housing. Multiple partitions are fixedly connected to the main electrical control housing, dividing it into a high-voltage area, a low-voltage area, and a power supply area. This allows the cover plate to be repeatedly removed from the main electrical control housing, ensuring an internal seal and facilitating the installation of various components. Simultaneously, the partitions separate the main electrical control housing, achieving zoned partitioning.

[0006] Furthermore, the main housing, cover plate, and partition of the electronic control system are all made of metal or a material with a metal shielding layer. In this way, the material with the metal shielding layer can achieve signal shielding, preventing signal interference between the various devices.

[0007] Furthermore, the power brick is mainly composed of a power module, a drive board, a bus capacitor, and a current sensor integrated into a single unit. This high level of integration, combining the bus capacitor, current sensor, and power module, ensures a platform-based and modular product design, facilitating large-scale mass production, while also reducing investment in assembly lines, optimizing production line structure, and lowering assembly costs.

[0008] Furthermore, the power module is a SiC power module. This use of a SiC high-voltage module allows for higher voltage withstand, more accurate control, and effectively improved controller efficiency.

[0009] Furthermore, the power supply unit primarily integrates an OBC module, a DCAC module, and a DCDC module into a single unit. This integration of OBC (On-Board Charger), DCAC (DC-to-AC converter, typically referring to an inverter), and DCDC (DC-to-DC converter) functions into a single unit improves the energy efficiency of electric vehicles (EVs) and reduces the number and weight of components. The configured OBC, DCAC, and DCDC modules can convert AC and DC power to meet the power demands of different electrical systems in the vehicle.

[0010] Furthermore, a fast-charging boost interface is also provided next to the three-phase copper busbar assembly, which is connected to its three-phase power supply. This fast-charging boost interface enables the 400V power supply pile to power the 800V battery pack. Attached Figure Description

[0011] Figure 1 This is a diagram showing the internal structure of the motor controller assembly after the electronic control cover has been removed in the embodiment. Figure 2 This is a top view of the motor controller assembly in the embodiment; Figure 3 This is a circuit diagram of an existing fast-charging boost circuit. Detailed Implementation

[0012] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this utility model provided in the accompanying drawings is not intended to limit the scope of the claimed utility model, but merely represents selected embodiments of the utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.

[0013] It should be noted that similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. 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 figures, or the orientation or positional relationship commonly used when the product 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. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. In addition, the terms "horizontal," "vertical," etc., do not indicate that the component is required to be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted. In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" 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 of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0014] like Figure 1 , Figure 2As shown, this report provides an integrated pure electric vehicle motor controller assembly, including a controller housing 1. Within the controller housing 1, there are mutually shielded high-voltage, low-voltage, and power supply areas, with the low-voltage and power supply areas located on the same side and adjacent to the high-voltage area. Within the high-voltage area, a filter assembly 2, a power supply brick 3, and a three-phase copper busbar assembly 4 are sequentially arranged. Within the low-voltage area, a control board 5 is arranged, and within the power supply area, a power supply brick 6 is arranged. On the controller housing 1, near the control board 5, is a first connector 112 for connecting an external power source to the control board 5. On the side of the controller housing 1 near the power supply brick 6, there are an OBC connector 7, a high-voltage branch connector 9, and a DC-DC connector 8. The control board 5 and... Power brick 3 and power supply brick 6 are connected by ribbon cables to transmit control signals to each other. The filter assembly 2 has a first high-voltage input terminal, a first high-voltage output terminal, a second high-voltage output terminal, and a third high-voltage output terminal. The first high-voltage input terminal is connected to the battery assembly output terminal outside the controller housing 1, and is electrically connected to power brick 3 via the first high-voltage output terminal, from which power brick 3 outputs high-voltage electricity to the three-phase copper busbar assembly 4. The second high-voltage output terminal is electrically connected to the input terminal of the high-voltage branch connector 9, and the third high-voltage output terminal is connected to the input terminal of power supply brick 6, and is electrically connected to the input terminals of OBC connector 7 and DC-DC connector 8 via the connector of power supply brick 6. In this way, the housing is partitioned according to the different functional modules installed. This design facilitates the installation of each component by technicians and effectively avoids signal interference between devices, improving the reliability of the controller. Both power supply brick 6 and power brick 3 are integrated from multiple parts, reducing the installation space and controller size to accommodate more vehicle models. Meanwhile, the power brick 3 and power supply brick 6 are designed for platformization, reducing production line investment and enabling large-scale mass production, thereby lowering production costs. After the external battery assembly is electrically connected to the filter assembly 2, high-voltage electricity is transmitted to the power brick 3 through the first high-voltage output terminal. Finally, the three-phase copper busbar assembly 4 outputs the high-voltage electricity to the vehicle motor. Simultaneously, the control board 5 sends commands to the power brick 3, which converts the received two-phase DC power into three-phase AC power, which is then output by the three-phase copper busbar assembly 4. The control board 5 also transmits control signals according to the vehicle ECU's control commands, adjusting the output power and ultimately changing the motor's output power. The filter assembly 2 also directly outputs high-voltage electricity to the high-voltage risk connector through the second high-voltage output terminal, ultimately powering the vehicle's air conditioning. The power supply brick 6 is also connected to the control board 5 via a ribbon cable. After receiving control signals from the control board 5, it converts the high voltage to low voltage and outputs it to the OBC connector 7 and the DC-DC connector 8, providing low-voltage electricity to the vehicle battery or other components. The various components inside the housing are installed in separate sections, and each connector is placed close to the input end, resulting in a reasonable layout, compact structure, and small overall size.

[0015] Furthermore, the controller housing 1 includes an electrical control main housing 11 and an electrical control cover 12 sealed and mounted on the electrical control main housing 11. Multiple partitions 111 are fixedly connected to the electrical control main housing 11, dividing it into a high-voltage area, a low-voltage area, and a power supply area. Thus, the electrical control cover 12 is detachably and sealed to the electrical control main housing 11, facilitating the installation of various components. Simultaneously, the partitions 111 divide the electrical control main housing 11 into zones.

[0016] Furthermore, the main housing 11, the cover 12, and the partition 111 are all made of metal or a material with a metal shielding layer. This provides high strength from the metal and effective signal shielding from the metal shielding layer.

[0017] Furthermore, the power brick 3 mainly integrates a power module, a drive board, a bus capacitor, and a current sensor into a single unit. This high level of integration, combined with the bus capacitor and current sensor, reduces the amount of installation work required.

[0018] Furthermore, the power module is a SiC power module. This use of a SiC high-voltage module allows for higher voltage withstand, more accurate control, and effectively improved controller efficiency.

[0019] Furthermore, the power supply brick 6 mainly integrates an OBC module, a DCAC module, and a DCDC module into a single unit. This integration of OBC (On-Board Charger), DCAC (DC-to-AC converter, typically referring to an inverter), and DCDC (DC-to-DC converter) functions into one unit improves the energy efficiency of electric vehicles (EVs) and reduces the number and weight of components. The provided OBC, DCAC, and DCDC modules can convert AC and DC power to meet the different electrical needs of the vehicle.

[0020] Furthermore, a fast-charging boost interface is also provided next to the three-phase copper busbar assembly 4, which is connected to its three-phase power supply. This fast-charging boost interface enables the 400V power supply pile to power the 800V battery pack. Specifically, fast-charging boost is a current technology. The principle of fast-charging boost is to use the motor's own inductance to replace the Boost circuit inductance, and the power module to replace the Boost circuit diodes, forming three parallel Boost circuits. By adjusting the duty cycle and frequency of the three-phase power module switches, the voltage of the charging pile is boosted.

[0021] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and not to limit the technical solutions. Those skilled in the art should understand that any modifications or equivalent substitutions to the technical solutions of this utility model that do not depart from the spirit and scope of this technical solution should be covered within the scope of the claims of this utility model.

Claims

1. An integrated pure electric vehicle motor controller assembly, comprising a controller housing, characterized in that, The controller housing contains mutually shielded high-voltage, low-voltage, and power supply areas, with the low-voltage and power supply areas located on the same side and adjacent to the high-voltage area. The high-voltage area contains a filter assembly, a power supply module, and a three-phase copper busbar assembly in sequence. The low-voltage area contains the control board, and the power supply area contains the power supply module. On the controller housing, near the control board, is a first connector for external power supply to the control board. On the controller housing, near the power supply module, are an OBC connector, a high-voltage branch connector, and a DC-DC connector. The control board is connected to both the power supply module and the power supply module via ribbon cables for power supply to... The power brick and power supply brick transmit control signals. The filter assembly is equipped with a first high-voltage input terminal, a first high-voltage output terminal, a second high-voltage output terminal, and a third high-voltage output terminal. The first high-voltage input terminal is connected to the output terminal of the battery assembly outside the controller housing. After being electrically connected to the power brick through the first high-voltage output terminal, the power brick outputs high-voltage electricity to the three-phase copper busbar assembly. The second high-voltage output terminal is electrically connected to the input terminal of the high-voltage branch connector. After the third high-voltage output terminal is connected to the input terminal of the power supply brick, it is electrically connected to the input terminals of the OBC connector and the DC-DC connector through the plug interface of the power supply brick.

2. The integrated pure electric vehicle motor controller assembly according to claim 1, characterized in that, The controller housing includes an electrical control main housing and an electrical control cover plate sealed on the electrical control main housing. Multiple partitions are fixedly connected to the electrical control main housing inside the electrical control main housing, and the partitions divide the electrical control main housing into the high voltage area, the low voltage area and the power supply area.

3. The integrated pure electric vehicle motor controller assembly according to claim 2, characterized in that, The main housing, cover plate, and partition of the electronic control system are all made of metal or materials with a metal shielding layer.

4. The integrated pure electric vehicle motor controller assembly according to claim 1, 2, or 3, characterized in that, The power brick is mainly composed of a power module, a driver board, a bus capacitor, and a current sensor integrated into a single unit.

5. The integrated pure electric vehicle motor controller assembly according to claim 4, characterized in that, The power module is a SiC power module.

6. The integrated pure electric vehicle motor controller assembly according to claim 1, 2, 3, or 5, characterized in that, The power supply brick is mainly composed of an OBC module, a DCAC module, and a DCDC module integrated into one unit.

7. The integrated pure electric vehicle motor controller assembly according to claim 6, characterized in that, Next to the three-phase copper busbar assembly, there is also a fast-charging boost interface that is connected to its three-phase power supply.

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