Integrated potting type motor controller

Abstract

The utility model provides a kind of integrated motor controller of potting, including shell, power module, capacitor, filter module and circuit board. First accommodating bin and second accommodating bin are formed with the shell inside. The power module of first accommodating bin and the capacitor and filter module of second accommodating bin are electrically connected in sequence, and the circuit board is arranged on the side of power module and capacitor. The potting piece is formed in the second accommodating bin by potting process, which fills the gap between capacitor, filter module and shell and seals them into one. The independent support of filter module is cancelled, the assembly process is simplified, and the cost and production cycle are significantly reduced. The potting piece also greatly improves the overall anti-vibration impact capacity and environmental sealing. At the same time, the excellent heat conduction performance of the potting piece efficiently conducts the heat of the components to the shell for dissipation, thereby comprehensively improving the compactness, reliability and service life of the controller.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicles, and in particular to an integrated potting motor controller. Background Technology

[0002] In the field of new energy vehicles, the motor controller, as the core actuator of the drive system, is of paramount importance in terms of performance and reliability. Its basic function is to accurately convert the DC power provided by the power battery into the three-phase AC power required by the drive motor, and to achieve precise control of the motor torque and speed by adjusting the output voltage and frequency. It is one of the core components of the vehicle.

[0003] However, the internal structure of existing common motor controllers still faces many challenges. To accommodate necessary components such as power modules, capacitors, and filter modules, multiple independent mechanical supports and fasteners are often used for assembly and fixation, resulting in a large number of parts and complex assembly processes, which restricts production efficiency and cost control. At the same time, the physical separation and air gaps between components not only limit the overall compactness and vibration resistance of the structure, but also make it difficult to efficiently dissipate internal heat, affecting power density and long-term reliability.

[0004] There are currently no good solutions to these problems. Utility Model Content

[0005] In order to overcome the above-mentioned technical defects, the purpose of this utility model is to provide a potting-integrated motor controller.

[0006] This utility model discloses a potted integrated motor controller, which includes a housing, a power module, a capacitor, a filter module, and a circuit board. The housing contains a first receiving compartment and a second receiving compartment connected in a first direction; a power module is fixed in the first receiving compartment; a capacitor and a filter module are fixed in the second receiving compartment; the power module, capacitor, and filter module are electrically connected in sequence; a circuit board is disposed on one side of the power module and capacitor in the second direction and is electrically connected to both the power module and the capacitor; the second direction is perpendicular to the first direction. A first electrical connector is provided between the capacitor and the filter module to enable electrical connection between the capacitor and the filter module; a second electrical connector is also provided on the side of the filter module away from the capacitor; one end of the second electrical connector is electrically connected to the filter module, and the other end extends to the outside of the housing so that other external components can be electrically connected to the filter module through the second electrical connector. The motor controller also includes a potting compound formed by filling the housing with potting material, filling the gap between the capacitor and filter module and the second receiving chamber, and sealing at least a portion of the capacitor and filter module inside.

[0007] Preferably, the housing further includes a sealing element; a clearance window is provided on the side of the housing away from the power module so that the second electrical connector extends out of the housing through the clearance window; The seal is disposed within the clearance window and is fixedly connected to both the housing and the second electrical connector; thereby fixing the second electrical connector relative to the housing and sealing at least a portion of the second electrical connector therein.

[0008] Preferably, the seal includes a first part and a second part that are fixedly connected to the housing, the first part being disposed on the side of the clearance window closer to the circuit board, and the second part being disposed on the side of the clearance window away from the circuit board; The first and second parts engage relative to each other in the second direction to fix the second electrical connector relative to the housing.

[0009] Preferably, the seal further includes a first guide surface and a second guide surface disposed opposite to each other in the third direction; the clearance window is correspondingly provided with a first guide groove and a second guide groove disposed opposite to each other in the third direction, so that the seal slides along the first guide groove and the second guide groove and is fixed inside the clearance window; The third direction is perpendicular to both the first and second directions.

[0010] Preferably, the first electrical connector and the filter module are fixed and electrically connected by laser welding.

[0011] Preferably, the thermal conductivity of the potting compound is 0.3 W / (m·K) to 3 W / (m·K).

[0012] Preferably, the motor controller further includes a first shielding plate, which is disposed between the power module, the capacitor and the circuit board to form a shielding space together with the housing, shielding the power module and the capacitor inside.

[0013] Preferably, an insulating member is further provided between the second electrical connector and the housing, with one side of the insulating member attached to the second electrical connector and the other side attached to the housing, so that the second electrical connector can exchange heat with the housing through the insulating member.

[0014] Preferably, the motor controller further includes a low-voltage interface, one end of which is electrically connected to the circuit board, and the other end extends out of the housing.

[0015] Preferably, the motor controller further includes a second shielding plate, which is disposed on the side of the circuit board away from the power module and together with the housing forms a shielding space to shield the low-voltage interface.

[0016] Compared with existing technologies, the above technical solution has the following advantages: 1. By integrating the capacitor and filter module into a single structural component through a potting process, the following advantages are achieved: First, it eliminates the original independent support component of the filter module, simplifying material management and directly reducing material and assembly costs. Simultaneously, merging multiple components into a single assembly step significantly shortens the production line assembly cycle and improves production efficiency. Second, the potted component greatly enhances the physical reliability of the controller: filling all gaps firmly binds the components together, giving it excellent vibration and shock resistance and completely preventing the corrosion of external contaminants, effectively improving its operational stability in vibration environments. Third, the thermal conductivity of the potted component is far superior to air, enabling rapid heat dissipation from the components to the housing, effectively preventing heat accumulation and thus improving the controller's power density and lifespan. 2. By using a dedicated seal, a reliable fixation and seal is provided for the second electrical connection extending to the outside of the housing, completely blocking the entry of contaminants. Furthermore, the seal is designed as a two-part interlocking structure with a guiding mechanism, greatly improving assembly efficiency and maintenance convenience, while ensuring the accuracy and durability of the seal. For the internal electrical connections, laser welding is used to form robust connection points with extremely low resistance, significantly improving the reliability and stability of the electrical connections and ensuring the long-term safety of the power transmission path. 3. By further limiting the thermal conductivity of the potting compound and adding insulating components, an efficient and insulated heat conduction path is established for the internal heating elements, effectively reducing their operating temperature and ensuring thermal reliability. Simultaneously, by setting up a first and second shielding plate, independent shielding spaces are constructed for the high-voltage side (power module, capacitor) and the low-voltage side, respectively, effectively constraining the radiation of internal high-frequency electromagnetic noise and protecting sensitive signals from interference, thereby significantly improving the overall controller's stable operation in complex electromagnetic environments. The integrated low-voltage interface also enhances the controller's functionality, providing a standardized interface for easy integration into the vehicle system for interaction. Attached Figure Description

[0017] Figure 1 An exploded view of the potted integrated motor controller provided in this application; Figure 2 A front view schematic diagram of the potted integrated motor controller provided in this application; Figure 3 for Figure 2 A schematic diagram of the structure with the circuit board and second shielding plate removed. Figure 4 for Figure 3 A schematic diagram of the structure for removing the potting compound; Figure 5 for Figure 4 A sectional view taken along section AA. Figure 6 for Figure 4 A sectional view taken along the middle section BB.

[0018] Attached reference numeral: 100, motor controller; 1. Shell; 11. First receiving compartment; 12. Second receiving compartment; 13. Clearance window; 131. First guide groove; 132. Second guide groove; 2. Power module; 3. Capacitor; 31. First electrical connector; 4. Filtering module; 41. Second electrical connector; 411. Insulating component; 5. Circuit board; 6. Potting components; 7. Seal; 71. First part; 72. Second part; 73. First guide surface; 74. Second guide surface; 81. First shielding plate; 82. Second shielding plate; 9. Low-voltage interface; x, first direction; z, second direction; y, third direction. Detailed Implementation

[0019] The advantages of this utility model are further illustrated below with reference to the accompanying drawings and specific embodiments.

[0020] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0021] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “a,” “the,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0022] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if," as used herein, can be interpreted as "when," "in response to determination," or "when," or "in the event of a determination." In the description of this utility model, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. 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.

[0023] In the description of this utility model, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "linking" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components. They can be direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0024] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrating this invention and has no specific meaning in itself. Therefore, "module" and "part" can be used interchangeably.

[0025] Please see Figures 1-4 , Figure 1 An exploded view of the potted integrated motor controller provided in this application; Figure 2 A front view schematic diagram of the potted integrated motor controller provided in this application; Figure 3 for Figure 2 A schematic diagram of the structure with the circuit board and second shielding plate removed. Figure 4 for Figure 3 A schematic diagram of the structure for removing potting compound.

[0026] like Figure 1 As shown, this utility model discloses a potted integrated motor controller 100, which includes a housing 1, a power module 2, a capacitor 3, a filter module 4, and a circuit board 5. The housing 1 has a first receiving compartment 11 and a second receiving compartment 12 connected in the first direction x; the power module 2 is fixed to the first receiving compartment 11; the capacitor 3 and the filter module 4 are fixed to the second receiving compartment 12; the power module 2, the capacitor 3 and the filter module 4 are electrically connected in sequence; the circuit board 5 is disposed on one side of the power module 2 and the capacitor 3 in the second direction z, and is electrically connected to both the power module 2 and the capacitor 3; the second direction z is perpendicular to the first direction x. A first electrical connector 31 is provided between capacitor 3 and filter module 4 so that capacitor 3 and filter module 4 are electrically connected; a second electrical connector 41 is also provided on the side of filter module 4 away from capacitor 3; one end of the second electrical connector 41 is electrically connected to filter module 4, and the other end extends to the outside of housing 1 so that other external components can be electrically connected to filter module 4 through the second electrical connector 41. The motor controller 100 also includes a potting compound 6, which is formed by filling the inside of the housing 1 with potting material, filling the gap between the capacitor 3 and the filter module 4 and the second receiving chamber 12, and sealing at least a portion of the capacitor 3 and the filter module 4 inside.

[0027] By integrating capacitor 3 and filter module 4 into a single structural component through a potting process, the following advantages are achieved: First, the original independent support component of filter module 4 is eliminated, simplifying material management and directly reducing material and assembly costs. Simultaneously, merging multiple components into a single assembly step significantly shortens the production line assembly cycle and improves production efficiency. Second, the potting compound 6 formed through potting greatly enhances the physical reliability of controller 100: potting compound 6 fills all gaps, firmly bonding the components together, giving it excellent vibration and impact resistance, and completely preventing the erosion of external contaminants, effectively improving its operational stability in vibration environments. Third, the thermal conductivity of potting compound 6 is far superior to air, enabling rapid heat dissipation from the components to the housing 1, effectively preventing heat accumulation, thereby improving the power density and service life of controller 100.

[0028] It should be noted that the specific types of power module 2, capacitor 3, and filter module 4 described herein are not limited. For example, power module 2 can be an IGBT module, capacitor 3 can be a thin-film capacitor, filter module 4 can be a CLC three-stage filter, and the magnetic ring can be a nanocrystalline plastic-encased magnetic ring. This application does not constitute any limitation.

[0029] The above is an explanation of the basic concept of this application. Those skilled in the art will understand that the motor controller 100 provided in this application may include more components to achieve more functions or meet higher functional requirements. This application does not make any limitations here.

[0030] Please see Figure 5 , Figure 5 for Figure 4 A sectional view taken along section AA.

[0031] like Figure 5 As shown, and in combination Figures 1-4 It is understood that, for example, in one possible implementation, the housing 1 further includes a seal 7; a clearance window 13 is provided on the side of the housing 1 away from the power module 2, so that the second electrical connector 41 extends out of the housing 1 through the clearance window 13; The sealing element 7 is disposed inside the clearance window 13 and is fixedly connected to both the housing 1 and the second electrical connector 41; thereby fixing the second electrical connector 41 relative to the housing 1 and sealing at least a portion of the second electrical connector 41 inside.

[0032] By providing a dedicated seal 7 at the housing clearance window 13, a complete sealing system can be formed with the housing 1, facilitating the filling of the second receiving chamber 12 to form the potting compound 6 and preventing external contaminants from entering. On the other hand, it also firmly fixes the second electrical connector 41 to the housing 1, preventing loosening or damage to the connection due to vibration.

[0033] Furthermore, such as Figure 5 As shown, the sealing element 7 includes a first part 71 and a second part 72 that are fixedly connected to the housing 1. The first part 71 is disposed on the side of the clearance window 13 close to the circuit board 5, and the second part 72 is disposed on the side of the clearance window 13 away from the circuit board 5. The first part 71 and the second part 72 engage relative to each other in the second direction z to fix the second electrical connector 41 relative to the housing 1.

[0034] The design of the seal 7 is a structure consisting of two interlocking parts. The first part 71 corresponds to the upper edge of the second electrical connector 41, and the second part 72 corresponds to the lower edge of the second electrical connector 41. This makes the installation and disassembly of the seal 7 simpler and improves the efficiency of production assembly and subsequent maintenance.

[0035] Furthermore, the seal 7 also includes a first guide surface 73 and a second guide surface 74 disposed opposite to each other in the third direction y; the clearance window 13 is correspondingly provided with a first guide groove 131 and a second guide groove 132 disposed opposite to each other in the third direction y, so that the seal 7 slides along the first guide groove 131 and the second guide groove 132 and is fixed inside the clearance window 13. The third direction y is perpendicular to both the first direction x and the second direction z. By providing mutually cooperating guide surfaces and guide grooves on the seal 7 and the clearance window 13, a clear path is provided for the installation of the seal 7. This guide structure can effectively prevent misalignment or tilting that may occur during assembly, ensuring that the seal 7 can quickly and accurately reach the predetermined installation position. This not only improves assembly efficiency but also ensures the fitting accuracy between the seal 7 and the housing 1 and the second electrical connector 41, thereby achieving optimal sealing performance.

[0036] Those skilled in the art will understand that the electromagnetic shielding effect can be further improved by adding structures to the motor controller 100.

[0037] For example, such as Figure 1 and Figure 2 As shown, in one possible implementation, the motor controller 100 further includes a first shielding plate 81, which is disposed between the power module 2, the capacitor 3 and the circuit board 5 to form a shielding space together with the housing 1, shielding the power module 2 and the capacitor 3 inside.

[0038] By setting up a first shielding plate 81, which together with the housing 1 forms a closed shielding space, the power module 2 and capacitor 3, which are strong interference sources, are surrounded. This structure can effectively constrain the high-frequency electromagnetic noise generated by these components and prevent it from radiating outwards and interfering with sensitive circuit boards 5 or other external devices. At the same time, it can also block the influence of external electromagnetic interference on internal power components to a certain extent, thereby significantly improving the electromagnetic compatibility of the motor controller 100 and ensuring its stable operation in complex electromagnetic environments.

[0039] The above is a structural description of the high-voltage side (capacitor 3, filter module 4) of the motor controller 100 provided in this application. The modular performance can be further enhanced by setting a low-voltage related structure in the motor controller 100.

[0040] like Figures 1-4 As shown, in one possible implementation, the motor controller 100 also includes a low-voltage interface 9. One end of the low-voltage interface 9 is electrically connected to the circuit board 5, and the other end extends outside the housing 1. By integrating the low-voltage interface 9, a standard and convenient connection channel is provided between the control circuit inside the controller 100 and external low-voltage devices (such as sensors, host computers, etc.). It achieves physical separation of strong and weak current interfaces, making wiring operations safer and clearer, and facilitating on-site installation and debugging. This design improves the functional integration of the controller 100, enabling it to be better integrated into the electrical system of a vehicle or industrial equipment for signal interaction and control.

[0041] In one possible implementation, the motor controller 100 further includes a second shielding plate 82, which is disposed on the side of the circuit board 5 away from the power module 2 and together with the housing 1 forms a shielding space to shield the low-voltage interface 9.

[0042] This can be understood as follows: The motor controller 100 has a separate second shielding plate 82 on the low-voltage side. The first shielding plate 81, the circuit board 5, and the second shielding plate 82 form a sandwich-shaped structure that is stacked in sequence, thereby completely separating the high-voltage shielding side and the low-voltage shielding side, thus ensuring the shielding performance of the high-voltage side and the low-voltage side respectively, and further improving the anti-interference capability and signal integrity of the entire system.

[0043] The above describes the possible structures of this application. Those skilled in the art will understand that the connection methods between the components are also not limited.

[0044] In one possible implementation, the first electrical connector 31 and the filter module 4 are fixed and electrically connected by laser welding. This avoids space waste caused by fasteners such as bolts and improves the space utilization of the motor controller 100.

[0045] It should be noted that all components in the motor controller 100 provided in this application rely on passive heat dissipation through heat exchange with the housing 1.

[0046] Please see Figure 6 , Figure 6 for Figure 4 A sectional view taken along the middle section BB.

[0047] Therefore, in one possible implementation, an insulating member 411 is further provided between the second electrical connector 41 and the housing 1. One side of the insulating member 411 is in contact with the second electrical connector 41, and the other side is in contact with the housing 1, so that the second electrical connector 41 can exchange heat with the housing 1 through the insulating member 411. This allows the filter module 4 to transfer heat to the housing 1 and dissipate it sequentially through the second electrical connector 41 and the insulating member 411, effectively reducing the operating temperature of the filter module 4 and the second electrical connector 41, avoiding performance degradation or damage due to excessive temperature rise, while ensuring electrical safety and improving the current carrying capacity and reliability of this key connecting component.

[0048] For cases where heat exchange is required between the potting compound 6 and the housing 1, improvements can also be made.

[0049] Understandably, the specific material of potting component 6 is not limited.

[0050] In one possible implementation, no thermally conductive material is added to the potting material forming the potting element 6. In this case, the thermal conductivity of the potting element 6 is 0.1 W / (m·K)~1 W / (m·K), which is still higher than that of air (0.024 W / (m·K)~0.026 W / (m·K), indicating better thermal conductivity.

[0051] In another possible implementation, the thermal conductivity of the potting compound 6 can be further improved by adding a thermally conductive material to the potting material, thereby enhancing the heat dissipation effect of the potting compound 6 on the capacitor 3 and the filter module 4. For example, the thermal conductivity of the potting compound 6 is 0.3 W / (m·K) to 3 W / (m·K), specifically 0.3 W / (m·K), 1 W / (m·K), 1.5 W / (m·K), 2 W / (m·K), 2.5 W / (m·K), or 3 W / (m·K). Those skilled in the art can determine the composition of the potting material as needed to adapt to different heat dissipation scenarios; this application does not impose any limitations here.

[0052] It should be noted that the embodiments of this utility model have better implementability and are not intended to limit this utility model in any way. Any person skilled in the art may use the above-disclosed technical content to change or modify it into equivalent effective embodiments. However, any modifications or equivalent changes and modifications made to the above embodiments based on the technical essence of this utility model without departing from the content of the technical solution of this utility model shall still fall within the scope of the technical solution of this utility model.

Claims

1. A potted integrated motor controller, characterized in that, The motor controller includes a housing, a power module, a capacitor, a filter module, and a circuit board; The housing contains a first and a second receiving compartment connected in a first direction. The power module is fixed to the first receiving compartment. The capacitor and the filter module are fixed to the second receiving compartment. The power module, the capacitor, and the filter module are electrically connected in sequence. The circuit board is disposed on one side of the power module and the capacitor in a second direction and is electrically connected to both the power module and the capacitor. The second direction is perpendicular to the first direction. A first electrical connector is provided between the capacitor and the filter module to electrically connect the capacitor and the filter module; a second electrical connector is also provided on the side of the filter module away from the capacitor; one end of the second electrical connector is electrically connected to the filter module, and the other end extends to the outside of the housing so that other external components can be electrically connected to the filter module through the second electrical connector; The motor controller further includes a potting compound formed by filling the interior of the housing with potting material, filling the gap between the capacitor and the filter module and the second receiving chamber, and sealing at least a portion of the capacitor and the filter module inside.

2. The potted integrated motor controller as described in claim 1, characterized in that, The housing also includes a sealing element; a clearance window is provided on the side of the housing away from the power module, so that the second electrical connector extends out of the housing through the clearance window; The sealing element is disposed inside the clearance window and is fixedly connected to both the housing and the second electrical connector; thereby fixing the second electrical connector relative to the housing and sealing at least a portion of the second electrical connector inside.

3. The potted integrated motor controller as described in claim 2, characterized in that, The sealing element includes a first part and a second part that are fixedly connected to the housing. The first part is disposed on the side of the clearance window closer to the circuit board, and the second part is disposed on the side of the clearance window away from the circuit board. The first part and the second part are engaged relative to each other in the second direction to fix the second electrical connector relative to the housing.

4. The potted integrated motor controller as described in claim 3, characterized in that, The sealing element further includes a first guide surface and a second guide surface disposed opposite to each other in the third direction; the clearance window is correspondingly provided with a first guide groove and a second guide groove disposed opposite to each other in the third direction, so that the sealing element slides along the first guide groove and the second guide groove and is fixed inside the clearance window; The third direction is perpendicular to both the first direction and the second direction.

5. The potted integrated motor controller as described in claim 1, characterized in that, The first electrical connector and the filter module are fixed and electrically connected by laser welding.

6. The potted integrated motor controller as described in claim 1, characterized in that, The thermal conductivity of the potting compound is 0.3 W / (m·K) to 3 W / (m·K).

7. The potted integrated motor controller as described in claim 1, characterized in that, The motor controller further includes a first shielding plate, which is disposed between the power module, the capacitor and the circuit board to form a shielding space together with the housing, shielding the power module and the capacitor inside.

8. The potted integrated motor controller as described in claim 1, characterized in that, An insulating member is also provided between the second electrical connector and the housing. One side of the insulating member is in contact with the second electrical connector, and the other side is in contact with the housing, so that the second electrical connector can exchange heat with the housing through the insulating member.

9. The potted integrated motor controller as described in claim 1, characterized in that, The motor controller also includes a low-voltage interface, one end of which is electrically connected to the circuit board, and the other end extends to the outside of the housing.

10. The potted integrated motor controller as described in claim 9, characterized in that, The motor controller also includes a second shielding plate, which is disposed on the side of the circuit board away from the power module and together with the housing forms a shielding space to shield the low-voltage interface.

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