A three-phase bottom-wired motor controller, electric drive assembly and vehicle

Abstract

The utility model provides a kind of three-phase bottom wiring motor controller, electric drive assembly and vehicle, including controller shell, radiator and electric control device, the bottom wall of controller shell is provided with phase hole, and the circumferential wall is provided with connecting hole, electric control device is set in device accommodating cavity, electric control device includes power circuit board, power tube, capacitor and three phase terminals, radiator is set in the top of controller shell and covers device accommodating cavity, power tube and capacitor are respectively connected with the heat conduction of radiator, and phase terminal extends towards bottom wall.The three phase leads of the case can be connected with phase terminal correspondingly, and cooperate with the connecting hole opened on circumferential wall, then the connecting tool is conveniently inserted from connecting hole, then the fixed connection of phase lead and phase terminal is conveniently completed, and the design of the case using bottom outlet line can reduce radial dimension, beneficial to the integration of equipment miniaturization.

Description

Technical Field

[0001] This utility model relates to the field of electrical control, and in particular to a three-phase bottom-connected motor controller, electric drive assembly, and vehicle. Background Technology

[0002] New energy vehicles are characterized by being environmentally friendly and less polluting because they do not burn gasoline or diesel fuel for power. With the vigorous promotion and application of new energy power generation such as hydropower, wind power, solar power and nuclear power, many new energy vehicles are gradually being promoted and applied, such as new energy electric cars, new energy electric buses, new energy electric trucks, new energy electric utility vehicles, new energy electric cleaning vehicles, new energy electric rail transit vehicles, new energy electric air vehicles and new energy electric shipping vehicles.

[0003] New energy vehicles are generally equipped with batteries, motor control devices, motors, and power generation devices. The power devices in the motor control device receive the direct current output from the battery and invert the direct current into alternating current to output to the motor. The motor then outputs rotational driving force to drive the power generation devices such as wheels and propellers, thereby propelling the vehicle forward.

[0004] Existing motor controllers require more space, are more expensive, and have complex installation processes. Currently, motor controllers integrated with motors are generally integrated on the outer radial circumference of the motor, which is relatively complex in terms of process, size, and installation space requirements. This poses layout difficulties in applications such as wheel-side drive high-speed motors or small-tonnage forklifts. In addition, the integrated motor and electronic control unit will cause the electronic control unit to overheat due to the heat conducted from the motor, affecting its performance. Conventional integrated motor and electronic control units require external relays, and the overall vehicle layout needs to design the collector mounting position and power supply cables, which is highly complex. Utility Model Content

[0005] The primary objective of this invention is to provide a three-phase bottom-wired motor controller.

[0006] The second objective of this invention is to provide an electric drive assembly having the aforementioned motor controller.

[0007] The third objective of this invention is to provide a vehicle having the aforementioned electric drive assembly.

[0008] To achieve the first objective of this utility model, it provides a three-phase bottom-connected motor controller, comprising a controller housing, a heat sink, and an electronic control device. The controller housing has a bottom wall and a peripheral wall, with the peripheral wall connected to the outer periphery of the bottom wall. The bottom wall and the peripheral wall form a device housing cavity. The bottom wall has three phase holes, and the peripheral wall has three connection holes, which communicate with the device housing cavity. The electronic control device is disposed within the device housing cavity and includes a power circuit board, multiple power transistors, multiple capacitors, and three phase terminals. The power transistors, capacitors, and phase terminals are respectively connected to the power circuit board. The heat sink is disposed on top of the controller housing and covers the device housing cavity. The power transistors and capacitors are thermally connected to the heat sink. The phase terminals extend towards the bottom wall, with each phase terminal located within a phase hole. Each phase terminal has a connection portion within its phase hole, and each connection hole is opposite to a connection portion.

[0009] As can be seen from the above scheme, by integrating the electronic control device into the controller housing and using a heat sink to cover the top of the controller housing, the power transistors and capacitors can conduct heat through the heat sink, thereby achieving heat dissipation from the top. Furthermore, the phase terminals extend towards the bottom wall and are located in the phase holes. When the motor controller is connected to the motor, the three phase leads can be connected to the phase terminals accordingly. With the connection holes opened from the peripheral wall, it is convenient for the connection tools to pass through the connection holes, thereby facilitating the fixed connection between the phase leads and the phase terminals. Moreover, the bottom-outlet design of this scheme can reduce the radial dimension, which is conducive to the miniaturization of the equipment integration.

[0010] A further proposed solution is that the inner wall of the phase hole is provided with an arc-shaped wall and a first straight wall located on both sides of the arc-shaped wall. The arc-shaped peripheral wall of the phase terminal is fitted with the arc-shaped wall with a clearance. The end of the phase terminal is provided with a second straight wall in the radial direction. The connecting part is provided on the second straight wall. The second straight wall is located between the two first straight walls. One second straight wall is opposite to one connecting hole.

[0011] As can be seen from the above, the phase terminal is positioned by the arc-shaped wall, while the phase leads are positioned by the second straight walls on both sides. With the phase leads positioned and connected to the first straight wall, the phase leads can be accurately connected and matched with the phase terminal.

[0012] A further proposed solution is to provide two limiting walls on the bottom wall between the connecting hole and the phase hole, with the two limiting walls located on the radial sides of the connecting hole respectively.

[0013] As can be seen from the above, the arrangement of two limiting walls can standardize the connection operation of the connecting tools and improve the safety of the connection operation.

[0014] A further solution is to install a sealing plug inside the connection hole.

[0015] A further improvement is to provide a retaining ring on the outer side of the connecting hole on the peripheral wall, with a retaining hole on the retaining ring, and a retaining block on the outer wall of the sealing plug, which engages with the retaining hole.

[0016] A further improvement is to provide a sealing ring on the outer periphery of the sealing plug, with the sealing ring having an interference fit with the inner wall of the connection hole.

[0017] As can be seen from the above, by setting a sealing plug in the connection hole, moisture can be prevented from entering the device housing cavity, and the locking block engages with the locking hole, which facilitates the installation and removal of the sealing plug. Furthermore, the interference fit of the sealing ring further improves the protection of the equipment.

[0018] A further proposed solution is to arrange the capacitors towards the heat sink, with the capacitors and phase terminals facing opposite directions, and multiple power transistors distributed on both sides of the capacitors.

[0019] As can be seen from the above, by arranging the capacitors towards the heat sink, and then connecting the top of the capacitors with the heat sink for thermal conduction, the heat conduction efficiency is improved, thus giving the electronic control better performance.

[0020] A further proposed solution is that the electronic control device includes a relay module, which comprises a relay circuit board and a relay. The relay is connected to the relay circuit board. The power circuit board has positive and negative terminals that extend towards the bottom wall. A through slot is provided through the bottom wall, through which the relay passes and is located within the device housing cavity. The relay circuit board is located on the bottom side of the bottom wall, and the positive terminal block on the relay circuit board is connected to the positive terminal.

[0021] As can be seen from the above, while ensuring the overall integration of the electronic control system, the relay module is also built-in, making the internal space utilization rate higher.

[0022] A further proposed solution is to have a supporting step on the inner wall of the perimeter wall, with the edge of the radiator located on the supporting step. A buckle is installed at the supporting step, which engages with the edge of the radiator. Adhesive is used to fill the space between the inner wall of the perimeter wall and the edge of the radiator.

[0023] As can be seen above, the radiator's edge is positioned by supporting steps and fixed by snap-fit, and the edge sealing is further improved by filling and potting glue.

[0024] A further alternative is to make the controller housing out of plastic.

[0025] As can be seen from the above, compared with metal casings, plastic casings can isolate heat conduction between the motor and the motor controller. In conjunction with the heat sink, the plastic casing not only ensures efficient heat conduction but also helps control costs.

[0026] To achieve the second objective of this utility model, this utility model provides an electric drive assembly, including a motor and a motor controller as described above; the rear cover of the motor is connected to the bottom wall, and the phase leads of the motor are respectively inserted into the phase holes and connected to the connecting part.

[0027] To achieve the third objective of this utility model, this utility model provides a means of transportation, including an electric drive assembly as described above.

[0028] As can be seen from the above scheme, the motor controller is arranged on the rear cover side of the motor. After the motor controller is connected to the rear cover of the motor, the phase lead can be connected to the phase terminal accordingly. With the help of the connection hole opened from the peripheral wall, it is convenient for the connection tool to pass through the connection hole, and then it is convenient to complete the fixed connection between the phase lead and the phase terminal. In addition, the design of the bottom of the electric controller can reduce the radial dimension, which is conducive to the miniaturization of the equipment integration. Attached Figure Description

[0029] Figure 1 This is a structural diagram of an embodiment of the electric drive assembly of this utility model.

[0030] Figure 2 This is a structural diagram of an embodiment of the electric drive assembly of this utility model from another perspective.

[0031] Figure 3 This is a structural diagram of an embodiment of the motor controller of this utility model.

[0032] Figure 4 This is an exploded view of an embodiment of the motor controller of this utility model.

[0033] Figure 5 This is a structural diagram of the electrical control device in an embodiment of the motor controller of this utility model.

[0034] Figure 6 This is a structural diagram of the power circuit board in an embodiment of the motor controller of this utility model.

[0035] Figure 7 This is a structural diagram of the controller housing in an embodiment of the motor controller of this utility model.

[0036] Figure 8 This is a cross-sectional view along the direction of the connecting hole in an embodiment of the electric drive assembly of this utility model.

[0037] Figure 9 This is a cross-sectional view of an embodiment of the electric drive assembly of this utility model along the arrangement direction of the phase terminals.

[0038] The above figures include the following reference numerals:

[0039] Motor 1, Rear cover 12, Phase lead 13, Motor controller 2, Controller housing 21, Heat sink 24, Electrical control device 23, Bottom wall 211, Peripheral wall 212, Device housing 210, Phase hole 213, Connection hole 216, Power circuit board 231, Power tube 232, Capacitor 233, Phase terminal 234, Arc wall 214, First straight wall 215, Second straight wall 235, Connecting part 236, Limiting wall 219, Sealing plug 26, Snap ring 217, Snap hole 218, Snap block 261, Sealing ring 262, Relay module 25, Relay circuit board 251, Relay 252, Positive terminal block 253, Positive terminal 237, Negative terminal 238, Through groove 220, Supporting step 2121, Buckle 2122.

[0040] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0041] Example of electric drive assembly and motor controller:

[0042] Reference Figures 1 to 9 The electric drive assembly includes a motor 1 and a motor controller 2. The output shaft 11 of the motor 1 extends from the front cover. The motor 1 has a rear cover 12 on the opposite side of the front cover in an axial direction. The motor controller 2 is located on the rear side of the rear cover 12 in an axial direction.

[0043] The motor controller 2 includes a controller housing 21, a heat sink 24, and an electronic control device 23. The controller housing 21 is provided with a bottom wall 211 and a peripheral wall 212. The peripheral wall 212 is arranged in a rectangular ring and is connected to the outer periphery of the bottom wall 211. The bottom wall 211 and the peripheral wall 212 form a device receiving cavity 210. The device receiving cavity 210 has an opening on the opposite side of the bottom wall 211. The bottom wall 211 is provided with three phase holes 213, a positive electrode hole 221, and a negative electrode hole 222. The three phase holes 213, the positive electrode hole 221, and the negative electrode hole 222 are staggered along the arrangement direction. The inner wall of the phase hole 213 is provided with an arc-shaped wall 214 and a first straight wall 215 located on both sides of the arc-shaped wall 214. The inner wall of the phase hole 213 is arranged in a U-shape.

[0044] The peripheral wall 212 has three connecting holes 216 that are intersecting along the arrangement direction. The phase hole 213 and the connecting holes 216 communicate with the device receiving cavity 210. One connecting hole 216 is opposite to one phase hole 213, and the axial direction of the connecting hole 216 is perpendicular to the axial direction of the phase hole 213. The bottom wall 211 has two limiting walls 219 between the connecting holes 216 and the phase holes 213. The two limiting walls 219 are located on both radial sides of the connecting hole 216.

[0045] The electronic control device 23 is disposed in the device housing cavity 210. The electronic control device 23 includes a power circuit board 231, multiple power transistors 232, multiple capacitors 233, three phase terminals 234, a positive terminal 237, a negative terminal 238, a relay module 25, and a control board 239. The multiple power transistors 232, multiple capacitors 233, positive terminal 237, negative terminal 238, and three phase terminals 234 are respectively connected to the power circuit board 231. The positive terminal 237, negative terminal 238, and three phase terminals 234 are staggered along the arrangement direction, and the positive terminal 237, negative terminal 238, and three phase terminals 234 all extend towards the bottom wall 211. Multiple capacitors 233 are arranged toward the heat sink 24, and the capacitors 233 and the phase terminals 234 are arranged in opposite directions. Multiple power transistors 232 are distributed on both sides of the capacitors 233. The control board 239 is mounted on the power circuit board 231 and has five through holes. Three phase terminals 234, the positive terminal 237, and the negative terminal 238 pass through the five through holes respectively.

[0046] The heat sink 24 is located on the top of the controller housing 21 and covers the device receiving cavity 210. The power transistor 232 and capacitor 233 are thermally connected to the heat sink 24. The outer surface of the heat sink 24 is provided with heat dissipation fins. The inner surface of the heat sink 24 is provided with two first heat-conducting surfaces 241 and a second heat-conducting surface 242. The two first heat-conducting surfaces 241 are located on both sides of the second heat-conducting surface 242. The top surfaces of multiple capacitors 233 are thermally connected to the second heat-conducting surface 242. The power transistor 232 is thermally connected to the first heat-conducting surface 24 and is connected between the heat sink 24 and the power transistor 232 by an elastic clip 2321, thereby achieving that the power transistor 232 is tightly pressed onto the heat sink 24.

[0047] The inner wall of the peripheral wall 212 is provided with a supporting step 2121. The edge of the radiator 24 is located on the supporting step 2121. A buckle 2122 is provided at the supporting step 2121. The buckle 2122 engages with the edge of the radiator 24. The space between the inner wall of the peripheral wall 212 and the edge of the radiator 24 is filled with potting compound to achieve a seal at the edge. The controller housing 21 is made of plastic.

[0048] A phase terminal 234 is located within a phase hole 213. The phase terminal 234 has a connecting portion 236 within the phase hole 213. The connecting portion 236 is arranged as a connecting hole. The arc-shaped peripheral wall 212 of the phase terminal 234 is clearance-fitted with the arc-shaped wall 214. The end of the phase terminal 234 is provided with a second straight wall 235 radially. The connecting portion 236 is disposed on the second straight wall 235. The second straight wall 235 is located between the two first straight walls 215. A connecting hole 216 is opposite to a connecting portion 236, and a second straight wall 235 is opposite to a connecting hole 216.

[0049] The relay module 25 includes a relay circuit board 251 and a relay 252. The relay 252 is connected to the relay circuit board 251. A through slot 220 is provided through the bottom wall 211. The relay 252 passes through the through slot 220 and is located in the device receiving cavity 210. The relay circuit board 251 is located on the bottom side of the bottom wall 211. The positive terminal block 253 on the relay circuit board 251 is connected to the positive terminal 237. The positive terminal 237 is located in the positive hole 221. The negative terminal 238 is located in the negative hole 222. A positive and negative terminal block 223 is also provided on the peripheral wall 212. The positive and negative terminal block 223 is used to connect to the external power cable. The negative cable is connected to the negative terminal 238, and the positive cable is connected to the positive input terminal of the relay circuit board 251.

[0050] When the rear cover 12 of the motor 1 is connected to the bottom wall 211, the motor 1 has a winding. The three phase leads 13 of the winding are respectively inserted into the phase holes 213 and connected to the connecting part 236, and are connected to the second straight wall 23. The phase leads 13 are also limited by the first straight walls 215 on both sides. They can be connected by connecting screws 132. The phase leads 13 can be arranged as copper busbars or wire lugs and are equipped with through holes. The connecting tool is inserted through the connecting hole, which facilitates the fixed connection between the phase leads and the phase terminals.

[0051] Each connection hole 216 is provided with a sealing plug 26. A retaining ring 217 is provided on the outer side of the connection hole 216 on the peripheral wall 212. The retaining ring 217 is provided with retaining holes 218 on both radial sides. The outer wall of the sealing plug 26 is provided with retaining blocks 261 on both radial sides. The retaining blocks 261 engage with the retaining holes 218. Furthermore, a sealing ring 262 is provided on the outer periphery of the sealing plug 26. The sealing ring 262 is press-fitted with the inner wall of the connection hole 216 to achieve sealing of the connection hole 216.

[0052] Example of a means of transportation:

[0053] The vehicle includes the electric drive assembly described above, and the electric drive assembly may integrate a transmission, or it may integrate a transmission, or it may not integrate a transmission. The vehicle may be a new energy electric car, a new energy electric bus, a new energy electric truck, a new energy electric cleaning vehicle, a new energy electric rail transit vehicle, a new energy electric flying vehicle, a new energy electric shipping vehicle, a new energy electric utility vehicle, a new energy aerial work platform, or a new energy small-tonnage forklift, etc.

[0054] As can be seen from the above, the motor controller is located on the rear cover side of the motor. After the motor controller is connected to the rear cover of the motor, the phase lead can be connected to the phase terminal accordingly. With the help of the connection hole opened from the peripheral wall, it is convenient for the connection tool to pass through the connection hole, and then it is convenient to complete the fixed connection between the phase lead and the phase terminal. In addition, the design of the bottom of the electric controller can reduce the radial dimension, which is conducive to the miniaturization of the equipment integration.

Claims

1. A three-phase bottom-wired motor controller, comprising a controller housing, a heat sink, and an electrical control device, characterized in that: The controller housing has a bottom wall and a peripheral wall. The peripheral wall is connected to the outer periphery of the bottom wall. The bottom wall and the peripheral wall form a device receiving cavity. The bottom wall has three phase holes, and the peripheral wall has three connection holes. The phase holes and the connection holes are respectively connected to the device receiving cavity. The electronic control device is disposed in the device housing cavity. The electronic control device includes a power circuit board, multiple power transistors, multiple capacitors, and three phase terminals. The multiple power transistors, multiple capacitors, and three phase terminals are respectively connected to the power circuit board. The heat sink is disposed on the top of the controller housing and covers the device receiving cavity. The power transistor and the capacitor are respectively thermally connected to the heat sink. The phase terminal extends toward the bottom wall. One phase terminal is located in one phase hole. The phase terminal is provided with a connection part in the phase hole. One connection hole is opposite to one connection part.

2. The motor controller according to claim 1, characterized in that: The inner wall of the phase hole is provided with an arc-shaped wall and a first straight wall located on both sides of the arc-shaped wall. The arc-shaped peripheral wall of the phase terminal is clearance-fitted with the arc-shaped wall. The end of the phase terminal is provided with a second straight wall in the radial direction. The connecting part is provided on the second straight wall. The second straight wall is located between the two first straight walls on both sides. One second straight wall is opposite to one connecting hole.

3. The motor controller according to claim 2, characterized in that: The bottom wall is provided with two limiting walls between the connecting hole and the phase hole, and the two limiting walls are respectively located on the radial sides of the connecting hole.

4. The motor controller according to claim 1, characterized in that: A sealing plug is provided inside the connection hole.

5. The motor controller according to claim 4, characterized in that: The peripheral wall is provided with a retaining ring on the outside of the connecting hole, the retaining ring is provided with a retaining hole, and the outer wall of the sealing plug is provided with a retaining block, the retaining block engaging with the retaining hole.

6. The motor controller according to claim 4, characterized in that: A sealing ring is provided on the outer periphery of the sealing plug, and the sealing ring is interference-fitted with the inner wall of the connecting hole.

7. The motor controller according to claim 1, characterized in that: The capacitor is arranged toward the heat sink, and the capacitor and the phase terminal are arranged in opposite directions. The multiple power transistors are distributed on both sides of the capacitor.

8. The motor controller according to claim 1, characterized in that: The electronic control device includes a relay module, which includes a relay circuit board and a relay. The relay is connected to the relay circuit board. The power circuit board is provided with a positive terminal and a negative terminal, which extend toward the bottom wall. A through groove is provided through the bottom wall, the relay passes through the through groove and is located in the device receiving cavity, the relay circuit board is located on the bottom side of the bottom wall, and the positive terminal block on the relay circuit board is connected to the positive terminal.

9. The motor controller according to any one of claims 1 to 8, characterized in that: The inner wall of the peripheral wall is provided with a supporting step, the edge of the radiator is located on the supporting step, a buckle is provided at the supporting step, the buckle engages with the edge of the radiator, and the space between the inner wall of the peripheral wall and the edge of the radiator is filled with potting compound.

10. The motor controller according to any one of claims 1 to 8, characterized in that: The controller housing is made of plastic.

11. An electric drive assembly, characterized in that, Includes a motor and a motor controller as described in any one of claims 1 to 10 above; The rear cover of the motor is connected to the bottom wall, and the three phase leads of the motor are respectively inserted into the phase holes and connected to the connecting part.

12. A means of transport, characterized in that, Includes the electric drive assembly as described in claim 11 above.

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