Motor controller

Abstract

The utility model provides a kind of motor controller, for example including shell assembly, multiple power units and busbar assembly. Shell assembly is configured with accommodating cavity;Multiple power units are arranged in accommodating cavity;Busbar assembly includes multiple ac busbars, and multiple ac busbars are electrically connected one by one with multiple power units. Each ac busbar includes main plate partially located in accommodating cavity and multiple connecting plates located in accommodating cavity, and the plate thickness of main plate is greater than the plate thickness of each connecting plate, and each connecting plate includes first end and second end, and main plate includes connecting end and lead-out end, and the connecting end of main plate is electrically connected with each second end of multiple connecting plates, and the lead-out end of main plate extends outward from accommodating cavity and is exposed outside shell assembly, and each first end of multiple connecting plates is electrically connected with corresponding power unit. In this way, ac busbar can have better large current carrying capacity under the premise of considering the connection quality with the lead-out terminal of power module.

Description

Technical Field

[0001] This utility model relates to the field of power electronic device technology, and in particular to a motor controller. Background Technology

[0002] In the automotive field, the motor controller is a key component in new energy electric vehicles that converts the direct current (DC) from the power battery into the alternating current (AC) required to drive the motor; it belongs to the electric drive system of electric vehicles. Typically, a motor controller includes a housing, a power module housed within the housing, and an AC busbar electrically connected to the power module. However, to facilitate electrical connection (e.g., soldering) with the leads of the power module, the AC busbar needs to be close in thickness to achieve good soldering quality. This results in a thinner AC busbar, leading to poor high-current carrying capacity. Utility Model Content

[0003] In view of this, the present invention provides a motor controller that enables the AC busbar to have better high current carrying capacity while taking into account the connection quality with the lead-out terminals of the power module.

[0004] Specifically, an embodiment of this utility model provides a motor controller including a housing assembly, multiple power units, and a busbar assembly; the housing assembly is configured with a receiving cavity; the multiple power units are disposed within the receiving cavity; the busbar assembly includes multiple AC busbars, which are electrically connected to the multiple power units one-to-one; wherein each AC busbar includes a main plate partially located within the receiving cavity and multiple connecting plates located within the receiving cavity, the thickness of the main plate is greater than the thickness of each connecting plate, each connecting plate includes a first end and a second end, the main plate includes a connecting end and a lead-out end, the connecting end of the main plate is electrically connected to each of the second ends of the multiple connecting plates, and the lead-out end of the main plate extends outward from the receiving cavity and is exposed outside the housing assembly, and each of the first ends of the multiple connecting plates is electrically connected to the corresponding power unit.

[0005] The above embodiments of this utility model can have the following beneficial effects: by setting each AC busbar to include a main plate and multiple connecting plates, and the thickness of the main plate is greater than the thickness of each connecting plate, that is, by adopting a combination design of a thick main plate and a thin connecting plate, the thickness of the connecting plate is close to or equal to the thickness of the lead-out terminals of the power module in the power unit to achieve high-quality electrical connection, such as welding or sintering, while the thick main plate has better high current carrying capacity. In this way, the AC busbar can achieve the purpose of having better high current carrying capacity while taking into account the connection quality with the lead-out terminals of the power module. Attached Figure Description

[0006] The specific embodiments of this utility model will now be described in detail with reference to the accompanying drawings.

[0007] Figure 1 This is a three-dimensional structural diagram of a motor controller provided for an embodiment of the present utility model.

[0008] Figure 2 for Figure 1 The diagram shows a combined structure of multiple power units, multiple AC buses, and a heat sink for the motor controller.

[0009] Figure 3A for Figure 2 An enlarged view of the area within the dashed circle.

[0010] Figure 3B This is a schematic diagram showing the connection relationship between two power modules in a single power module group.

[0011] Figure 4 for Figure 1 The diagram shows an exploded view of the motor controller.

[0012] Figure 5A for Figure 1 The diagram shows the three-dimensional structure of the motor controller after the cover has been removed.

[0013] Figure 5B for Figure 1 The diagram shows the three-dimensional structure of the motor controller after removing the cover, drive control circuit board, and AC busbar insulation.

[0014] Figure 5C for Figure 1 The diagram shows a three-dimensional structure of the motor controller after removing the housing assembly, drive control circuit board, AC busbar insulator and first DC busbar insulator.

[0015] Figure 6A and Figure 6B A schematic diagram of the three-dimensional structure of the busbar at different angles.

[0016] Figure 6C This is a schematic diagram of the exploded structure of the AC busbar.

[0017] Figure 7A This is a three-dimensional structural diagram of the first DC busbar.

[0018] Figure 7B for Figure 7A The side view of the first DC busbar shown.

[0019] Figure 8 for Figure 1 The diagram shows a cross-section and enlarged view of a portion of the structure of the motor controller.

[0020] Figure 9 This is a three-dimensional structural diagram of the heat sink. Detailed Implementation

[0021] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0022] To enable those skilled in the art to better understand the technical solutions of this utility model, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model.

[0023] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0024] It should also be noted that the division of multiple embodiments in this utility model is only for the convenience of description and should not constitute a special limitation. Features in various embodiments can be combined and referenced in each other without contradiction.

[0025] See Figure 1 , Figure 2 , Figures 3A-3B , Figure 4 , Figures 5A-5C and Figures 6A-6C The present invention provides a motor controller comprising a housing assembly CA, multiple power units PU, and a busbar assembly BBA.

[0026] The housing assembly CA is equipped with a receiving cavity CAA, and multiple power units PU are housed within the receiving cavity CAA. The busbar assembly BBA includes multiple AC busbars 5, which are electrically connected to the multiple power units PU one-to-one. Figure 2The diagram shows three power units PU and three AC busbars 5 as illustrative examples, but the embodiments of this utility model are not limited thereto.

[0027] As described above, each AC busbar 5 includes a main body plate 51 partially located within the accommodating cavity CAA and multiple connecting plates 52 located within the accommodating cavity CAA. The thickness t1 of the main body plate 52 is greater than the thickness t2 of each connecting plate 52. Each connecting plate 52 includes a first end 52A and a second end 52B. The main body plate 51 includes a connecting end 51A and a lead-out end 51B. The connecting end 51A of the main body plate 51 is electrically connected to each of the second ends 52B of the multiple connecting plates 52, and the lead-out end 51B of the main body plate 51 extends outward from the accommodating cavity CAA and is exposed outside the housing assembly CA. Each of the first ends 52A of the multiple connecting plates 52 is electrically connected to the corresponding power unit PU (see reference). Figure 2 and Figure 3A ).

[0028] As can be seen from the above, this embodiment sets each AC busbar 5 to include a main plate 51 and multiple connecting plates 52, and the thickness t1 of the main plate 51 is greater than the thickness t2 of each connecting plate 52. That is, it adopts a combination design of a thick main plate 51 and a thin connecting plate 52. The thickness t2 of the connecting plate 52 is close to or equal to the thickness of the lead-out terminals of the power module in the power unit PU to achieve high-quality electrical connection, such as welding. The thick main plate 51 has better high current carrying capacity. In this way, the AC busbar can achieve the purpose of having better high current carrying capacity while taking into account the connection quality with the lead-out terminals of the power module.

[0029] In some embodiments, see Figure 4 and Figures 6A-6C Each connecting plate 52 has a narrow end 52A and a wide end 52B. This allows the narrow end to pass through other components, such as busbar insulators, and to connect electrically with the second lead 105 of the upper arm power module 100U and the first lead of the lower arm power module 100L in the power module group PG. For example, the narrow end can be welded to the first lead of the lower arm power module 100L, and the sidewall of the narrow end may or may not contact the sidewall of the second lead 105 of the upper arm power module 100U. The wide end facilitates a high-quality connection with the main plate 51, such as welding, and promptly disperses the large current from the narrow end to the main plate 51. Furthermore, as an example, the main plate 51 is a bent plate, and each connecting plate 52 is a bent plate. The bending arrangement facilitates the connection between the main plate and the connecting plate, the connection between the connecting plate and the power module, and the exposure of the main plate.

[0030] In some embodiments, see Figure 2 , Figures 3A-3B , Figure 4 and Figures 6A-6CEach power unit (PU) includes at least one power module group (PG). Figure 2 (The illustration shows a single power unit PU comprising three power module groups PG as an example.) Each power module group PG includes an upper arm power module 100U and a lower arm power module 100L. Each of the upper arm power module 100U and the lower arm power module 100L includes: a first lead terminal 104 located on a first side in a first direction B1, a second lead terminal 105 located on a second side in the first direction B1 opposite to the first side, and at least one control terminal, such as a first control terminal 106 and a second control terminal 107, located on the second side in the first direction B1. In each power module group PG, the second lead terminal 105 of the upper arm power module 100U overlaps with and is electrically connected to the first lead terminal 104 of the lower arm power module 100L. Furthermore, in each AC busbar 5, the connection end 51A of the main plate 51 extends to form a plurality of connection claws 510 corresponding one-to-one with the plurality of connection plates 52. The second end 52B of each connection plate 52 is electrically connected to the corresponding connection claw 510. The second lead terminal 105 of the upper bridge arm power module 100U and the first lead terminal of the lower bridge arm power module 100L in each power module group PG of each power unit PU are electrically connected to the first end 52A of a connection plate 52 of the corresponding AC busbar 5. For example, the first lead terminal of the lower bridge arm power module 100L in each power module group PG is welded or sintered to the first end 52A of a connection plate 52 of the corresponding AC busbar 5. The second lead terminal 105 of the upper bridge arm power module 100U in each power module group PG may or may not be in contact with the first end 52A of a connection plate 52 of the corresponding AC busbar 5. It should be noted that if they are in contact, there will be a better electrical connection effect, thereby further improving the electrical performance. Here, the design of multiple connecting claws 510 facilitates the connection and positioning between each connecting plate 52 and the main plate 51.

[0031] In some embodiments, see Figure 1 , Figure 2 , Figures 3A-3B , Figure 4 and Figures 5A-5C The motor controller also includes: a drive control circuit board 10, a bus capacitor 17, and a DC input terminal 3.

[0032] The drive control circuit board 10 is disposed within the accommodating cavity CAA and is electrically connected to at least one control terminal, such as the first control terminal 106, of the upper bridge arm power module 100U and the lower bridge arm power module 100L in each of the multiple power units PU. For example, the drive control circuit board 10 may include an MCU control circuit, a power module drive circuit, a signal sampling circuit, a low-voltage power conversion circuit, a communication circuit, and other related control systems. Furthermore, in addition to being electrically connected to the first control terminal 106, the drive control circuit board 10 may also be electrically connected to the second control terminal 107, the first DC bus voltage sampling terminal, and the second DC bus voltage sampling terminal. Furthermore, the busbar assembly BBA also includes a first DC busbar 13 (e.g., a positive DC busbar) and a second DC busbar 15 (e.g., a negative DC busbar). The first DC busbar 13 is disposed within the housing cavity CAA and is electrically connected to the first lead-out terminal 104 of the upper arm power module 100U in each power module group PG of the multiple power units PU. The second DC busbar 15 is disposed within the housing cavity CAA and is electrically connected to the second lead-out terminal 105 of the lower arm power module 100L in each power module group PG of the multiple power units PU. In addition, a bus capacitor 17 is disposed within the housing cavity CAA and is electrically connected to the first DC busbar 13 and the second DC busbar 15. Furthermore, the DC input terminal 3 is fixed to the housing assembly CA and is electrically connected to the bus capacitor 17.

[0033] As mentioned above, the motor controller is a key component in new energy electric vehicles that converts the DC power from the power battery into AC power required for the drive motor, and belongs to the electric drive system of electric vehicles. Currently, flagship models from various automakers are demanding increasingly higher output power for individual motors, rising from approximately 200kW two years ago to 580kW today. As the power supply device for the motor, the motor controller's output AC power needs to be significantly increased accordingly. However, a large portion of A-class cars, even A0-class cars and microcars, have power requirements of only around 100kW or even tens of kilowatts. Therefore, the power range requirement for motor controllers in new energy vehicles is roughly between 30kW and 580kW. The motor controller in this embodiment breaks through the size limitations of existing large-size packaged products, allowing multiple power modules (PGs) to be connected in parallel via a first DC bus and a second DC bus. The number of power modules can be flexibly configured according to different vehicle classes to achieve different power and current output capabilities.

[0034] In some embodiments, see Figure 1 , Figure 2 , Figures 3A-3B , Figure 4 , Figures 5A-5C and Figures 6A-6CThe motor controller includes multiple current sensors 19, which are disposed within the accommodating cavity CAA. The housing assembly CA includes a housing 1 and a cover 2 detachably disposed on the top side 1U of the housing 1. The housing 1 and the cover 2 together enclose the accommodating cavity CA. At least a portion of the AC busbars 5 have their leads 51B passing through the multiple current sensors 19 and extending outward to the bottom side 1B of the housing 1, which is exposed to the top side 1U. The DC input terminal 3 is fixed to the side wall of the housing 1 that connects the top side 1U and the bottom side 1B. For example, there are three AC busbars 5, such as the U-phase AC busbar, V-phase AC busbar, and W-phase AC busbar. Correspondingly, there can also be three current sensors 19, which are electrically connected to the drive control circuit board 10. Thus, the leads 51B of the U-phase AC busbar, V-phase AC busbar, and W-phase AC busbar pass through the three current sensors 19 one-to-one. Of course, it can be understood that there can also be two current sensors 19, and correspondingly, the leads 51B of the U-phase AC busbar and W-phase AC busbar pass through these two current sensors 19 one-to-one. In this embodiment, by setting the current sensors 19, the amplitude and phase of the AC current can be detected in real time, providing accurate feedback signals for motor control, and quickly identifying current abnormalities (such as overcurrent, phase loss, etc.), and taking timely protective measures to prevent damage to the motor or controller. In addition, by setting the DC input terminal 3 on the side wall of the housing 1 and exposing the leads 51B of each AC busbar 5 to the bottom side 1B of the housing 1, this positional design facilitates the external electrical connection of the motor controller.

[0035] In some embodiments, see Figure 1 and Figure 5A The motor controller also includes an external control terminal 4, which is fixed to the housing assembly CA and exposed outside the housing assembly CA. The external control terminal 4 is electrically connected to the drive control circuit board 10 and is located on the same side of the housing assembly CA as the DC input terminal 3. Compared to the high input voltage of the DC input terminal 3, the external control terminal 4 in this embodiment can also be called a low-voltage control terminal, which is mainly used to realize functions such as communication, wake-up, and interlocking. In addition, the positional relationship between the external control terminal 4 and the DC input terminal 3 facilitates external electrical connections.

[0036] In some embodiments, see Figure 4 and Figures 5A-5CThe motor controller also includes an input filter component 9, which is disposed within the accommodating cavity CAA and electrically connected between the DC input terminal 3 and the bus capacitor 17. For example, the input filter component 9 includes an X capacitor, a Y capacitor, and a filter magnetic ring. The X capacitor is connected in parallel between the positive and negative DC inputs, the Y capacitor is connected in parallel between the positive or negative DC input and ground, and the filter magnetic ring is connected in series between the positive and negative DC input lines. The input filter component 9 helps suppress interference.

[0037] In some embodiments, see Figure 1 , Figure 2 , Figures 3A-3B , Figure 4 and Figures 5A-5C The busbar assembly BBA also includes busbar insulating components such as a first DC busbar insulator 12, a second DC busbar insulator 14, and an AC busbar insulator 11. The first DC busbar insulator 12 is disposed within the accommodating cavity CAA and located between the first DC busbar 13 and the plurality of AC buses 5. The second DC busbar insulator 14 is disposed within the accommodating cavity CAA and located between the second DC busbar 15 and the first DC busbar 13. The AC busbar insulator 11 is disposed within the accommodating cavity CAA and located between the plurality of AC buses 5 and the drive control circuit board 10. The at least one of the upper bridge arm power modules 100U of each power module group PG of the plurality of power units PU is also present. Control terminals, such as the first control terminal 106 and at least one control terminal of the lower bridge arm power module 100L, pass sequentially through the second DC bus insulator 14, the first DC bus 13, the first DC bus insulator 12, and the AC bus insulator 11 before being electrically connected to the drive control circuit board 10. Each AC bus passes sequentially through the first DC bus insulator 12, the first DC bus 13, and the second DC bus insulator 14 before being electrically connected to the second lead-out terminal 105 of the upper bridge arm power module 100U and the first lead-out terminal 104 of the lower bridge arm power module 100L of each power module group PG in the corresponding power unit PU. In this embodiment, the arrangement of the first DC bus insulator 12, the second DC bus insulator 14, and the AC bus insulator 11 facilitates electrical insulation between related components to avoid short circuit problems.

[0038] In some embodiments, see Figures 7A-7B and Figure 8The first DC bus 13 includes a main body and a plurality of desaturation pins 131 integrally formed with the main body and extending toward the drive control circuit board 10. The plurality of desaturation pins 131 are electrically connected to the drive control circuit board 10. Compared with the prior art where the desaturation pins are set on the bus capacitor, this embodiment flexibly utilizes the main body of the first DC bus 13, bending out small pins for short-circuit desaturation detection, reducing the design and manufacturing difficulty and cost of the bus capacitor. Moreover, the desaturation pins and the main body are integrally formed, which can reduce the processing steps and make the connection between the desaturation pins and the main body more stable and reliable, resulting in better signal transmission. However, it should be noted that in some other embodiments, the plurality of desaturation pins 131 and the main body may not be integrally formed, i.e., they may be separate structures. For example, the plurality of desaturation pins 131 may be connected together by welding or snap-fitting.

[0039] In some embodiments, see Figure 2 , Figures 5A-5C , Figures 7A-7B and Figure 8The body of the first DC busbar 13 along the first direction B1 includes a main body 130, a first bending step 132, and a second bending step 133 connected in sequence. The main body 130 is provided with a plurality of desaturation pins 131, a plurality of first through holes HL1, and a plurality of second through holes HL2. The upper bridge arm power modules 100U of each power module group PG of the plurality of power units PU are correspondingly arranged with the plurality of first through holes HL1 one by one, and the lower bridge arm power modules 100L of each power module group PG of the plurality of power units PU are correspondingly arranged with the plurality of second through holes HL2 one by one. At least one control terminal, such as a first control terminal 106 (or even a second control terminal), of the upper bridge arm power module 100U of each power module group PG of each power unit PU is provided with the following: 107) After passing through the corresponding first through hole HL1, it is electrically connected to the drive control circuit board 10. At least one control terminal, such as the first control terminal 106 (or even the second control terminal 107), of the lower bridge arm power module 100L of each power module group PG of each power unit PU passes through the corresponding second through hole HL2 and is electrically connected to the drive control circuit board 10. The first bending step 132 is attached to the upper surface of the upper bridge arm power module 100U of each power module group PG of the multiple power units PU facing the first DC bus 12. The second bending step 133 is attached to the first lead-out terminal 104 of the upper bridge arm power module 100U of each power module group PG of the multiple power units PU and is electrically connected to the first lead-out terminal 104. In this embodiment, the desaturation pin 131 can be formed by cutting a small groove in the body of the first DC bus 13 and bending it out, without the need for additional component welding. Each desaturation pin 131 passes through the first DC bus insulation 12 and the AC bus insulation 11 and is electrically connected to the relevant short-circuit protection function circuit of the drive control circuit board 10. The bottom of the first bend step 132 is in close contact with the upper surface of the upper arm power module 100U, which can reduce the stray inductance of the system. The second bend step 133 is in close contact with the first lead terminal 104 of the upper arm power module 100U for electrical connection, such as by welding or sintering.

[0040] In some embodiments, see Figure 1 , Figure 2 , Figure 4 and Figure 9The motor controller also includes a radiator 18, a cooling fluid inlet 6, and a cooling fluid outlet 7. The radiator 18 is disposed within the accommodating cavity CAA and together with the housing assembly CA, forms a cooling fluid receiving space CAC. The cooling fluid inlet 6 and the cooling fluid outlet 7 are both connected to the cooling fluid receiving space CAC. The upper bridge arm power module 100U and the lower bridge arm power module 100L of each power module group PG of the multiple power units PU are fixed on the radiator 18. The surface of the radiator 18 facing away from the upper bridge arm power module 100U and the lower bridge arm power module 100L of each power module group PG of the multiple power units PU are provided with a plurality of spaced-apart pin fins 181 and strip reinforcing ribs 182 surrounded by the plurality of pin fins 181. The plurality of pin fins 181 and the strip reinforcing ribs 182 are located in the cooling fluid receiving space CAC, and the cooling fluid inlet 6 and the cooling fluid outlet 7 are located on opposite sides of the housing assembly CA along the length direction of the strip reinforcing ribs 182. In this embodiment, the strip reinforcing rib 182 is, for example, at the same height as each pin fin 181. Since the heat transfer of the upper bridge arm power module 100U and the lower bridge arm power module 100L is mainly concentrated on both sides of the strip reinforcing rib 182, the strip reinforcing rib 182 can split the cooling fluid, such as cooling water, on both sides, increase the effective flow rate of cooling water at the bottom of the power module, and improve the cooling efficiency. At the same time, the strip reinforcing rib 182 can enhance the strength of the radiator 18 in the length direction, avoiding the deformation of the traditional all-pin fin structure in large-size radiators due to temperature and water pressure cycles, which would lead to an increase in module thermal resistance and affect the lifespan of the power module.

[0041] In some embodiments, see Figure 2 and Figures 3A-3BEach of the upper arm power module 100U and lower arm power module 100L in each power module group PG of each power unit PU includes a first lead 105A and a second lead 105B spaced apart in a second direction B2 different from the first direction B1. At least one control terminal, such as a first control terminal 106 or even a second control terminal 107, is located between the first lead 105A and the second lead 105B in the second direction B2 and is spaced apart from both the first lead 105A and the second lead 105B. In each power module group PG, the first lead 105A and the second lead 105B of the upper arm power module 100U overlap the first lead 104 of the lower arm power module 100L and are electrically connected to the first lead 104 of the lower arm power module 100L. Furthermore, the connection point 104M of each power module group PG in each power unit PU, which is electrically connected to the corresponding AC bus 5, is located on the first lead-out terminal 104 of the lower bridge arm power module 100U in the power module group PG, and in the second direction B2, it is located between the first lead-out portion 105A and the second lead-out portion 105B of the upper bridge arm power module 100U in the power module group PG. The connection point 104M of each power module group PG in each power unit PU is electrically connected to the first end 52A of a connection plate 52 of the corresponding AC bus 5.

[0042] In this embodiment, the second lead-out terminal 105 is divided into two parts to form a first lead-out portion 105A and a second lead-out portion 105B. This two-part configuration allows space for arranging at least one control terminal, such as the first control terminal 106 or even the second control terminal 107. This allows the at least one control terminal to be positioned closer to the package 103 compared to the prior art, and the first lead-out terminal 104 to be shorter in the first direction B1. Consequently, each power module group PG can have a shorter main circuit length, for example... Figure 3B The 74.85mm shown represents a reduction of approximately 9.5mm compared to the approximately 84mm main circuit length of a traditional power module with control terminals placed on one side relative to the source leads. This results in a reduction of approximately 3nH in the total stray inductance of the main circuit, a reduction of approximately 30%. Furthermore, from... Figure 3BIt can also be seen that the first lead-out terminal 104 can be provided with an avoidance notch (not labeled in the figure) to shorten the length of the main circuit. Furthermore, the connection point 104M of the power module group PG that is electrically connected to the AC busbar 5 is located in the second direction B2 between the first lead-out portion 105A and the second lead-out portion 105B of the upper bridge arm power module 100U in the power module group PG, and is located on the first lead-out terminal 104 of the lower bridge arm power module 100L in the power module group PG. That is, the AC lead-out position can be located at the center of the upper bridge arm power module 100U and the lower bridge arm power module 100L. This optimized design of the AC lead-out position makes the current distribution more symmetrical and improves the current sharing effect.

[0043] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. A motor controller, characterized in that, include: The housing assembly is equipped with a receiving cavity; Multiple power units are disposed within the accommodating cavity, and The busbar assembly includes multiple AC busbars, which are electrically connected to the multiple power units one by one. Each AC busbar includes a main plate partially located within the accommodating cavity and a plurality of connecting plates located within the accommodating cavity. The thickness of the main plate is greater than the thickness of each connecting plate. Each connecting plate includes a first end and a second end. The main plate includes a connecting end and a lead-out end. The connecting end of the main plate is electrically connected to each of the second ends of the plurality of connecting plates, and the lead-out end of the main plate extends outward from the accommodating cavity and is exposed outside the housing assembly. Each of the first ends of the plurality of connecting plates is electrically connected to the corresponding power unit.

2. The motor controller according to claim 1, characterized in that, The first end of each of the connecting plates is a narrow end and the second end is a wide end; and / or, The main plate is a bent plate, and each of the connecting plates is a bent plate.

3. The motor controller according to claim 2, characterized in that, Each power unit includes at least one power module group, and each power module group includes an upper arm power module and a lower arm power module. Each of the upper arm power module and the lower arm power module includes: a first lead terminal located on a first side in a first direction, a second lead terminal located on a second side in the first direction opposite to the first side, and at least one control terminal located on the second side in the first direction. In each power module group, the second lead terminal of the upper arm power module is connected to and electrically connected to the first lead terminal of the lower arm power module. In each of the AC busbars, the connecting end of the main plate extends to form a plurality of connecting claws corresponding one-to-one with the plurality of connecting plates, and the second end of each of the connecting plates is electrically connected to the corresponding connecting claw; the second lead terminal of the upper bridge arm power module and the first lead terminal of the lower bridge arm power module in each of the power module groups in each of the power units are electrically connected to the first end of a connecting plate of the corresponding AC busbar.

4. The motor controller according to claim 3, characterized in that, The motor controller also includes a drive control circuit board, a bus capacitor, and a DC input terminal; The drive control circuit board is disposed in the accommodating cavity and is electrically connected to at least one control terminal of the upper bridge arm power module and at least one control terminal of the lower bridge arm power module in each of the power module groups of the plurality of power units. The busbar assembly further includes a first DC busbar and a second DC busbar. The first DC busbar is disposed in the accommodating cavity and is electrically connected to the first lead-out terminal of the upper arm power module in each of the power module groups in the plurality of power units. The second DC busbar is disposed in the accommodating cavity and is electrically connected to the second lead-out terminal of the lower arm power module in each of the power module groups in the plurality of power units. The bus capacitor is disposed within the accommodating cavity and is electrically connected to both the first DC bus and the second DC bus. The DC input terminal is fixed on the housing assembly and is electrically connected to the bus capacitor.

5. The motor controller according to claim 4, characterized in that, The motor controller further includes multiple current sensors disposed within the accommodating cavity; the housing assembly includes a housing and a cover detachably disposed on the top side of the housing, the housing and the cover together enclosing the accommodating cavity; at least a portion of the AC busbars have their lead-out ends passing through the multiple current sensors and extending outward to the bottom side of the housing assembly opposite to the top side; the DC input terminal is fixed to the side wall of the housing connected between the top side and the bottom side. And / or, The motor controller also includes an external control terminal, which is fixed to the housing assembly and exposed outside the housing assembly, and is electrically connected to the drive control circuit board and located on the same side of the housing assembly as the DC input terminal; And / or, The motor controller further includes an input filter component, which is disposed within the accommodating cavity and electrically connected between the DC input terminal and the bus capacitor.

6. The motor controller according to claim 4, characterized in that, The busbar assembly further includes a first DC busbar insulator, a second DC busbar insulator, and an AC busbar insulator. The first DC busbar insulator is disposed within the accommodating cavity and located between the first DC busbar and the plurality of AC buses. The second DC busbar insulator is disposed within the accommodating cavity and located between the second DC busbar and the first DC busbar. The AC busbar insulator is disposed within the accommodating cavity and located between the plurality of AC buses and the drive control circuit board. At least one control terminal of the upper arm power module and at least one control terminal of the lower arm power module of each power module group of the plurality of power units passes sequentially through the second DC busbar insulator, the first DC busbar, the first DC busbar insulator, and the AC busbar insulator and is electrically connected to the drive control circuit board. Each AC busbar passes sequentially through the first DC busbar insulator, the first DC busbar, and the second DC busbar insulator and is electrically connected to the second lead-out terminal of the upper arm power module and the first lead-out terminal of the lower arm power module of each power module group in the corresponding power unit.

7. The motor controller according to claim 4, characterized in that, The first DC bus includes a body and a plurality of desaturation pins that are integral with the body and extend toward the drive control circuit board. The plurality of desaturation pins are electrically connected to the drive control circuit board.

8. The motor controller according to claim 7, characterized in that, The body comprises a main body portion, a first bending step, and a second bending step connected sequentially along the first direction. The main body portion is provided with a plurality of desaturation pins, a plurality of first through holes, and a plurality of second through holes. The upper bridge arm power modules of each power module group of the plurality of power units are correspondingly arranged with the plurality of first through holes, and the lower bridge arm power modules of each power module group of the plurality of power units are correspondingly arranged with the plurality of second through holes. At least one control terminal of the upper bridge arm power module of each power module group of each power unit passes through the corresponding first through hole and is electrically connected to the drive control circuit board. At least one control terminal of the lower bridge arm power module of each power module group of each power unit passes through the corresponding second through hole and is electrically connected to the drive control circuit board. The first bending step is attached to the upper surface of the upper bridge arm power module of each power module group of the plurality of power units facing the first DC busbar, and the second bending step is attached to the first lead-out terminal of the upper bridge arm power module of each power module group of the plurality of power units and is electrically connected to the first lead-out terminal.

9. The motor controller according to claim 3, characterized in that, It also includes a radiator, a cooling fluid inlet and a cooling fluid outlet. The radiator is disposed in the accommodating cavity and together with the housing assembly forms a cooling fluid receiving space. The cooling fluid inlet and the cooling fluid outlet are both connected to the cooling fluid receiving space. The upper bridge arm power module and the lower bridge arm power module of each of the power module groups of the plurality of power units are fixed on the heat sink. The surface of the heat sink opposite to the upper bridge arm power module and the lower bridge arm power module of each of the power module groups of the plurality of power units is provided with a plurality of spaced needles and strip reinforcing ribs surrounded by the plurality of needles. The plurality of needles and the strip reinforcing ribs are located in the cooling fluid receiving space. The cooling fluid inlet and the cooling fluid outlet are respectively located on opposite sides of the housing assembly in the length direction of the strip reinforcing ribs.

10. The motor controller according to any one of claims 3 to 9, characterized in that, The second lead-out terminal of each of the upper arm power module and the lower arm power module in each power module group of each power unit includes a first lead-out portion and a second lead-out portion spaced apart in a second direction different from the first direction. The at least one control terminal is located between the first lead-out portion and the second lead-out portion in the second direction and is spaced apart from both the first lead-out portion and the second lead-out portion. In each power module group, the first lead-out portion and the second lead-out portion of the upper arm power module overlap the first lead-out terminal of the lower arm power module and are electrically connected to the first lead-out terminal of the lower arm power module. The connection point of each power module group in each power unit, which is electrically connected to the corresponding AC busbar, is located on the first lead-out terminal of the lower bridge arm power module in the power module group and in the second direction between the first lead-out portion and the second lead-out portion of the upper bridge arm power module in the power module group. The connection point of each power module group in each power unit is electrically connected to the first end of a connection plate of the corresponding AC busbar.

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