Motor controller and vehicle

Abstract

This application provides a motor controller and a vehicle, belonging to the field of automotive parts technology. The motor controller includes a housing and a cooling structure. The housing includes at least a first accommodating cavity and a second accommodating cavity spaced apart. The first accommodating cavity is used to install a SiC module structure, and the second accommodating cavity is used to install a capacitor module structure, the capacitor module structure including a capacitor core and a filter assembly. The cooling structure includes a water-cooling channel located inside the housing, and an inlet pipe and an outlet pipe located on the housing. The water-cooling channel includes a module water-cooling channel, a side cooling channel, and a capacitor water-cooling channel connected sequentially. The module water-cooling channel is located at the bottom of the first accommodating cavity, the capacitor water-cooling channel is located at the bottom of the second accommodating cavity, and the side cooling channel is located between the first and second accommodating cavities. The motor controller provided by this application effectively reduces the operating temperature of the capacitor, reduces the risk of capacitor over-temperature failure, and improves the reliability and stability of the motor controller.

Description

Technical Field

[0001] This application belongs to the field of automotive parts technology, and more specifically, relates to a motor controller and a vehicle. Background Technology

[0002] The capacitors in the automotive motor controller are mainly used to reduce the voltage spikes generated when the SIC module is turned off, so that the bus voltage remains relatively smooth under the action of the SIC module switching.

[0003] With the increasing power of motors, the current capacity of controllers is constantly improving, leading to a continuous increase in ripple current and severe capacitor overheating. Capacitor heat dissipation has become a key focus in capacitor design and application.

[0004] Currently, the most common way to arrange capacitors is to place the capacitors and SiC modules horizontally. Traditional controller modules can only reduce the operating temperature of the capacitors by adding water cooling to the controller housing that is close to the capacitor mounting surface. This does not directly address the heat-concentrated areas of the capacitor. Adding cooling channels on the back of the capacitor also increases the overall height of the controller. Furthermore, the heat dissipation effect is poor when only the controller housing is used for water cooling, especially in hybrid vehicles where the ambient temperature is high. The capacitors are at higher risk of overheating and failure due to poor heat dissipation. Utility Model Content

[0005] The purpose of this application is to provide a motor controller and vehicle that effectively improves heat dissipation performance without increasing the overall height of the controller.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows: Firstly, embodiments of this application provide a motor controller, comprising: The housing includes at least a first accommodating cavity and a second accommodating cavity spaced apart; the first accommodating cavity is used to install a SiC module structure, and the second accommodating cavity is used to install a capacitor module structure, the capacitor module structure including a capacitor core and a filter component; The cooling structure includes a water-cooling channel located inside the housing, and an inlet pipe and an outlet pipe located on the housing. The water-cooling channel includes a module water-cooling channel, a side cooling channel, and a capacitor water-cooling channel connected in sequence. The module water-cooling channel is located at the bottom of the first accommodating cavity, the capacitor water-cooling channel is located at the bottom of the second accommodating cavity, and the side cooling channel is located between the first accommodating cavity and the second accommodating cavity.

[0007] The beneficial effects of the motor controller provided in this application are as follows: Compared with the prior art, this application adopts the method of dividing the area inside the housing to separate the capacitor module structure and the SIC module structure, and then uses the method of setting a sandwich flow channel at the bottom of the housing to achieve separate water cooling of the capacitor module structure and the SIC module structure by means of the water inlet pipe and water outlet pipe opened on the housing.

[0008] The cooling structure includes an inlet pipe, an outlet pipe, and a water-cooling channel. When the cooling system is working, water flows in through the inlet pipe, first passing through the module water-cooling channel located at the bottom of the first accommodating cavity to cool the SiC module structure. Then, the water flows through the side cooling channel to the capacitor water-cooling channel at the bottom of the second accommodating cavity to cool the capacitor module structure, carrying away the heat generated by the capacitor core and filter components. Finally, the water flows out through the outlet pipe, completing the entire cooling cycle.

[0009] This application separates the heat-generating SiC module structure and capacitor module structure into different accommodating cavities by setting a first and a second accommodating cavity, thus preventing heat concentration. Simultaneously, the water-cooling channel is designed as a segmented structure, with different segments placed at the bottom of the accommodating cavities of the SiC module structure and capacitor module structure, enabling targeted cooling of these structures. This allows the water-cooling channel to directly act on the heat-concentrated areas, improving heat dissipation. The water-cooling channel proposed in this application effectively reduces the operating temperature of the capacitor, decreasing the risk of overheating failure due to poor heat dissipation, and improving the reliability and stability of the motor controller. This advantage is particularly pronounced in high-temperature environments, such as in hybrid vehicles.

[0010] In one possible implementation, the inlet pipe and the outlet pipe are respectively located on both sides of the housing; the module water cooling channel and the capacitor water cooling channel form a zigzag water cooling structure by means of the side cooling channel.

[0011] In the above technical solution, the zigzag water-cooling structure extends the flow path and residence time of the cooling medium in the shell through the guiding and buffering effect of the side cooling channels, ensuring the heat exchange area between the cooling medium and the heat-generating components, and ensuring that the cooling medium fully absorbs the heat of the SIC module structure in the module water-cooling channel and fully absorbs the heat of the capacitor module structure in the capacitor water-cooling channel, so as to improve the heat dissipation uniformity of the capacitor module structure.

[0012] In one possible implementation, the heights of the module water-cooling channel, the side cooling channel, and the capacitor water-cooling channel decrease sequentially.

[0013] In the above technical solution, the depth of the first accommodating cavity is less than the depth of the second accommodating cavity. To improve its cooling effect, the heights of the three water-cooling channels are set to decrease sequentially. The side cooling channel, to balance the heat dissipation effect of both and considering the smoothness of the water-cooling channel, is set at a height that fits against the lower end of the module's water-cooling channel. It not only cools the housing but is also located in the middle of the side of the second accommodating cavity. While cooling the housing and the first accommodating cavity, it also cools the capacitors within the second accommodating cavity, thus optimizing the heat dissipation efficiency of the entire cooling system.

[0014] In one possible implementation, the first accommodating cavity includes: A capacitor mounting cavity is provided to house the capacitor core. A filter mounting cavity is provided to house the filter assembly; The capacitor mounting cavity and the filter mounting cavity are connected by a connecting slot, which allows copper busbars to pass through. The capacitor water-cooling channel is located below the capacitor mounting cavity.

[0015] In the above technical solution, the first accommodating cavity is divided into a capacitor mounting cavity and a filter mounting cavity, which are used to accommodate the capacitor core and the filter assembly, respectively. This makes the internal structure of the motor controller clearer and more compact, avoiding mutual interference and collisions, and improving the overall performance and service life of the motor controller. Since the capacitor core is the main heat-generating component, separating it from the filter assembly for independent heat dissipation and cooling also prevents a large amount of heat generated by the capacitor from flowing to the filter assembly, thus affecting the use of the filter assembly.

[0016] In one possible implementation, the capacitor mounting cavity extends along the length of the housing, and a mounting gap is formed between the capacitor mounting cavity and the first accommodating cavity, with the side cooling channel located within the mounting gap.

[0017] In the above technical solution, when the cooling medium flows through this part in the zigzag flow path, it will directly contact the high-temperature air in the gap and the side wall of the cavity, and quickly absorb the heat in the installation gap.

[0018] In one possible implementation, the filter mounting cavity and the first accommodating cavity are located on the same side of the capacitor mounting cavity; the water outlet pipe is located below the filter mounting cavity.

[0019] In the above technical solution, the filter installation cavity and the first accommodating cavity are set on the same side of the capacitor installation cavity, which makes the module water cooling channel and the water outlet pipe approximately in a straight line. This allows the cooling medium to cover the entire module installation space during the flow process, improving the overall heat dissipation effect and enhancing the reliability and stability of the motor controller.

[0020] In one possible implementation, the capacitor water cooling channel includes an inlet and an outlet protruding toward one side of the side cooling channel, the inlet being located below the side cooling channel and the outlet being located above the outlet pipe; and the outlet having a cooling chamber located below the connecting groove.

[0021] In the above technical solution, after the cooling medium absorbs heat from the capacitor core in the capacitor water cooling channel, it flows to the water outlet and fills the cooling cavity at the same time as the water is discharged. The cooling medium directly absorbs the heat conducted by the connecting slot and the copper busbar through the wall of the cooling cavity.

[0022] In one possible implementation, the housing further includes a wiring cavity located on the side of the filter mounting sub-cavity away from the capacitor mounting sub-cavity, with the input copper busbar of the filter assembly exposed within the wiring cavity.

[0023] In the above technical solution, the wiring cavity is located on the side of the filter mounting cavity away from the capacitor mounting cavity, away from the main heat source, to avoid the input copper busbar being affected by the high temperature of the capacitor.

[0024] In one possible implementation, an inlet buffer tank and an outlet buffer tank are respectively provided at both ends of the module water cooling channel, the outlet of the module water cooling channel is located at the bottom of the outlet buffer tank, and a downwardly inclined guide surface is provided on the outside of the outlet of the module water cooling channel.

[0025] In the above technical solution, the inlet buffer tank has a large volume, which can alleviate the impact force of the cooling medium at the inlet and prevent the formation of local high-speed zones due to the small cross-section of the channel when the cooling medium enters the module water-cooling channel, thus ensuring the flow stability of the cooling medium. The outlet buffer tank, as a buffer structure, collects the cooling medium in the module water-cooling channel, allowing the cooling medium to flow smoothly before being discharged from the outlet at the bottom, thus avoiding the generation of eddies.

[0026] Secondly, embodiments of this application also provide a vehicle that employs the aforementioned motor controller.

[0027] The above technical solution includes all the beneficial effects of the motor controller. By arranging the water-cooling channels within the motor controller, the risk of capacitor overheating failure is reduced, and the reliability and stability of the motor controller are improved. This, in turn, ensures the reliability and stability of the entire vehicle during operation, especially in hybrid vehicles and other environments with higher temperatures, where the advantages are even more pronounced. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 A three-dimensional structural diagram of the motor controller provided in the embodiments of this application from a first angle; Figure 2 A three-dimensional structural diagram of the motor controller provided in an embodiment of this application from a second angle; Figure 3 A top view of the motor controller provided in an embodiment of this application; Figure 4 A top view of the housing of the motor controller provided in an embodiment of this application; Figure 5 A bottom view of the housing of the motor controller provided in an embodiment of this application; Figure 6 For along Figure 5 A cross-sectional view along line AA in the middle.

[0030] In the diagram: 100, shell; 101, inlet pipe; 102, outlet pipe; 200. First accommodating cavity; 201. Modular water cooling channel; 202. Inlet buffer tank; 203. Outlet buffer tank; 300. Capacitor mounting chamber; 301. Connecting slot; 302. Filter mounting chamber; 303. Wiring chamber; 304. Capacitor water cooling channel; 305. Water inlet; 306. Water outlet; 307. Capacitor core; 308. Filter assembly; 309. Wiring copper busbar; 310. Input copper busbar; 311. Cooling chamber; 312. Side cooling channel. Detailed Implementation

[0031] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0032] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or indirectly on the other element. It should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this application 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, and therefore should not be construed as a limitation of this application.

[0033] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a few" means two or more, unless otherwise explicitly specified.

[0034] Please refer to the following: Figures 1 to 6 The motor controller provided in this application will now be described. The motor controller includes a housing 100 and a cooling structure; the housing 100 includes at least a first accommodating cavity 200 and a second accommodating cavity spaced apart; the first accommodating cavity 200 is used to install a SiC module structure, and the second accommodating cavity is used to install a capacitor module structure, the capacitor module structure including a capacitor core 307 and a filter component 308; the cooling structure includes a water-cooling channel disposed inside the housing 100, and a water inlet pipe 101 and a water outlet pipe 102 disposed on the housing 100; the water-cooling channel includes a module water-cooling channel 201, a side cooling channel 312 and a capacitor water-cooling channel 304 connected in sequence, the module water-cooling channel 201 is disposed at the bottom of the first accommodating cavity 200, the capacitor water-cooling channel 304 is disposed at the bottom of the second accommodating cavity, and the side cooling channel 312 is disposed between the first accommodating cavity 200 and the second accommodating cavity.

[0035] Compared with the prior art, the motor controller provided in this application has at least two accommodating cavities horizontally spaced within the housing 100. The first accommodating cavity 200 is used to install the SiC module structure, and the second accommodating cavity is used to install the capacitor module structure. The capacitor module structure includes a capacitor core 307 and a filter component 308. The first accommodating cavity 200 and the second accommodating cavity are separated, and the spacing effect of the first accommodating cavity 200 and the second accommodating cavity is used to separate the SiC module structure and the capacitor core 307, thereby separating the two sets of heat-generating devices.

[0036] Unlike the prior art which adds heat dissipation channels to the outside of the housing 100, this application uses the method of dividing the housing 100 into regions to separate the capacitor module structure and the SIC module structure. Then, by setting up a mezzanine flow channel at the bottom of the housing 100, the water inlet pipe 101 and water outlet pipe 102 opened on the housing 100 are used to achieve separate water cooling for the capacitor module structure and the SIC module structure.

[0037] The cooling structure includes an inlet pipe 101, an outlet pipe 102, and a water-cooling channel. When the cooling system is working, the inlet pipe 101 introduces external cooling medium (such as water) into the water-cooling channel inside the housing 100. The cooling medium first passes through the module water-cooling channel 201 to cool the SIC module structure in the first accommodating cavity 200. Then, the cooling medium passes through the side cooling channel 312 to further absorb heat between the first and second accommodating cavities, and simultaneously cools the SIC module structure and the capacitor module structure. Finally, the cooling medium enters the capacitor water-cooling channel 304 to cool the capacitor module structure in the second accommodating cavity. The cooled medium flows out of the housing 100 through the outlet pipe 102, completing one cooling cycle.

[0038] The motor controller provided in this application has the following advantages compared with the prior art: (1) By setting the first accommodating cavity 200 and the second accommodating cavity with intervals, the SIC module structure and the capacitor module structure with serious heat generation are respectively placed in different accommodating cavities and isolated from each other to avoid heat concentration.

[0039] (2) Unlike the traditional method of cooling heat dissipation through water cooling only through the controller housing, the cooling structure of this motor controller is set as a segmented structure of water cooling channel. By setting different segments of water cooling channel at the bottom of the housing cavity of the SIC module structure and the capacitor module structure respectively, targeted cooling and temperature reduction of the SIC module structure and the capacitor module structure can be achieved, so that the water cooling channel can directly act on the heat concentration part and improve the heat dissipation effect. The water cooling channel proposed in this application effectively reduces the operating temperature of the capacitor, reduces the risk of capacitor failure due to overheating caused by poor heat dissipation, and improves the reliability and stability of the motor controller. Especially in the case of high ambient temperature such as hybrid vehicles, the advantages are more obvious.

[0040] (3) A side cooling channel 312 is provided between the first accommodating cavity 200 and the second accommodating cavity. The side cooling channel 312 can dissipate heat from the first accommodating cavity 200 and the second accommodating cavity at the same time, so that the heat between the first accommodating cavity 200 and the second accommodating cavity can also be effectively transferred and dissipated, further improving the overall heat dissipation performance of the controller, making the temperature of each component more balanced, and helping to extend the service life of the motor controller.

[0041] (4) By rationally arranging water cooling channels inside the housing 100, and utilizing the height difference between the various parts of the housing 100 structure, the module water cooling channel 201, the side cooling channel 312 and the capacitor water cooling channel 304 are connected in sequence, thus avoiding the problem of increasing the overall height of the controller by adding a separate heat dissipation channel on the outside of the housing 100 on the back of the capacitor. This makes the controller structure more compact and saves space.

[0042] Optionally, the housing 100 has a top cover at the upper end and a bottom plate at the lower end, but the top cover and bottom plate are not shown in the figure.

[0043] In some embodiments, such as Figures 1 to 5 As shown, the water inlet pipe 101 and the water outlet pipe 102 are respectively located on both sides of the housing 100; the module water cooling channel 201 and the capacitor water cooling channel 304 form a zigzag water cooling structure with the help of the side cooling channel 312.

[0044] By placing the water inlet pipe 101 and the water outlet pipe 102 on the side of the housing 100, the space occupied above and below the housing 100 is avoided, thus reducing the height space occupied by the housing 100. Furthermore, the positions of the side-mounted water inlet pipe 101 and water outlet pipe 102 can be determined based on the location of the heat dissipation core area, making positioning convenient.

[0045] In this application, the module water-cooling channel 201, the side cooling channel 312, and the capacitor water-cooling channel 304 are all cooling channels arranged along the length of the housing 100. The module water-cooling channel 201 flows towards the outlet pipe 102, then enters the side cooling channel 312, which flows towards the inlet pipe 101, causing the cooling water to return to the side closest to the inlet pipe 101, and then enters the capacitor water-cooling channel 304, which flows towards the outlet pipe 102 until its outlet end connects with the outlet pipe 102. This zigzag-shaped water-cooling channel ensures that the cooling medium can flow unidirectionally without backflow, and fully covers the SiC module structure and the capacitor module. Furthermore, while guiding the cooling medium to flow in the opposite direction, the side cooling channel 312 is located between the first and second accommodating cavities, simultaneously balancing heat dissipation from both sides. During the passage of the cooling medium, it simultaneously dissipates heat from the side walls of the first and second accommodating cavities, while preventing heat transfer from the high-temperature environment on both sides through the middle.

[0046] Traditional straight-line water-cooling channels are prone to problems such as rapid cooling medium flow and insufficient local heat dissipation. However, the zigzag-shaped water-cooling structure, through the guiding and buffering effect of the side cooling channels 312, extends the flow path and residence time of the cooling medium within the housing 100, ensuring the heat exchange area between the cooling medium and the heat-generating components. This ensures that the cooling medium fully absorbs the heat from the SiC module structure within the module water-cooling channel 201 and the capacitor module structure within the capacitor water-cooling channel 304, thereby improving the heat dissipation uniformity of the capacitor module structure. Furthermore, the side cooling channels 312 eliminate the need for additional cooling structures in the height direction of the housing 100, avoiding the problem of increasing the overall height of the housing 100. In some embodiments, such as Figures 1 to 5 As shown, the heights of the module water-cooling channel 201, the side cooling channel 312, and the capacitor water-cooling channel 304 decrease sequentially.

[0047] The depth of the first accommodating cavity 200 is less than the depth of the second accommodating cavity. In order to improve its cooling effect, the height of the three water-cooling channels is set to decrease sequentially. However, each water-cooling channel extends horizontally.

[0048] The modular water-cooling channel 201 is located at the bottom of the first accommodating cavity 200, and the capacitor water-cooling channel 304 is located at the bottom of the second accommodating cavity. They are used to cool the first accommodating cavity 200 and the second accommodating cavity, respectively. The side cooling channel 312, in order to balance the heat dissipation effect of both and to consider the smoothness of the water-cooling channel, is set at a height that fits the lower end of the modular water-cooling channel 201. It not only cools the housing 100, but is also located in the middle of the side of the second accommodating cavity. While cooling the housing 100 and the first accommodating cavity 200, it also cools the capacitor in the second accommodating cavity, thereby optimizing the heat dissipation efficiency of the entire cooling system.

[0049] In addition, the design of the cooling channel height decreasing in sequence allows the cooling medium to gradually adapt to the changes in the channel during the flow process, reducing pressure loss caused by sudden changes in channel height; and it can better adapt to the internal spatial layout of the housing 100, making the structure of the entire motor controller more compact.

[0050] In some embodiments, such as Figures 1 to 4 As shown, the second accommodating cavity includes a capacitor mounting sub-cavity 300 and a filter mounting sub-cavity 302; the capacitor mounting sub-cavity 300 is used to accommodate the capacitor core 307; the filter mounting sub-cavity 302 is used to accommodate the filter assembly 308; the capacitor mounting sub-cavity 300 and the filter mounting sub-cavity 302 are connected by a connecting slot 301, which allows the copper busbar 309 to pass through; the capacitor water cooling channel 304 is located below the capacitor mounting sub-cavity 300.

[0051] During operation, the electrical signal generated by the capacitor core 307 passes through the connecting slot 301 via the copper busbar 309 and is transmitted to the filter assembly 308 in the filter mounting cavity 302. The filter assembly 308 filters the electrical signal transmitted from the copper busbar 309 to remove noise and interference signals, and then transmits the clean signal to the subsequent circuit modules.

[0052] As the main heat-generating component, the capacitor core 307 transfers its heat primarily through the bottom of the capacitor mounting cavity 300 to the lower capacitor water-cooling channel 304, where it is specifically cooled. The filter assembly 308 also generates heat during operation. This heat is dissipated into the surrounding air through the wall of the filter mounting cavity 302, and some heat may also be transferred to the capacitor mounting cavity 300 through the connecting groove 301, where it is absorbed by the cooling medium of the capacitor water-cooling channel 304.

[0053] The second accommodating cavity is divided into a capacitor mounting cavity 300 and a filter mounting cavity 302, which respectively house the capacitor core 307 and the filter assembly 308. This makes the internal structure of the motor controller clearer and more compact, avoiding mutual interference and collisions, and improving the overall performance and service life of the motor controller. Since the capacitor core 307 is the main heat-generating component, separating it from the filter assembly 308 for independent heat dissipation also prevents a large amount of heat generated by the capacitor from flowing to the filter assembly 308, thus avoiding affecting the use of the filter assembly 308.

[0054] In some embodiments, such as Figure 4 As shown, the capacitor mounting cavity 300 extends along the length of the housing 100, and a mounting gap is formed between the capacitor mounting cavity 300 and the first accommodating cavity 200. The side cooling channel 312 is located within the mounting gap.

[0055] The capacitor core 307 is installed within the capacitor mounting cavity 300, which extends along the length of the housing 100. During operation, the heat generated by the capacitor core 307 is evenly distributed along the length of the capacitor mounting cavity 300, preventing localized heat accumulation. The capacitor mounting cavity 300 is directly attached to the structure of the housing 100. Heat is transferred to the housing 100 via the capacitor mounting cavity 300, and then from the outer wall of the housing 100 to the surrounding air. Additionally, heat is transferred through the bottom of the capacitor mounting cavity 300 to the capacitor water-cooling channel 304 below.

[0056] The mounting gap formed between the capacitor mounting cavity 300 and the first accommodating cavity 200 provides mounting space for the side cooling channel 312. When the cooling medium flows through this gap in the zigzag flow path, it directly contacts the high-temperature air in the gap and the side wall of the cavity, quickly absorbing the heat in the mounting gap and preventing the heat accumulated in the mounting gap from being conducted back to the first accommodating cavity 200 and the second accommodating cavity.

[0057] Optionally, the capacitor mounting cavity 300 and the first accommodating cavity 200 are separated by a partition, the side cooling channel 312 is located at the lower end of the partition, and the outer wall of the side cooling channel 312 is connected to the partition.

[0058] In some embodiments, such as Figure 4 As shown, the filter mounting cavity 302 and the first accommodating cavity 200 are located on the same side of the capacitor mounting cavity 300; the water outlet pipe 102 is located below the filter mounting cavity 302.

[0059] The cooling medium flows in from the inlet pipe 101, passes through the module water cooling channel 201, the side cooling channel 312 and the capacitor water cooling channel 304, dissipates heat from the SIC module and the capacitor module, and then flows out from the outlet pipe 102 located below the filter mounting cavity 302.

[0060] As a secondary heat-generating component, the filter assembly 308 also generates some heat, as does the heat generated during the operation of the capacitor module. This heat is conducted through the capacitor mounting cavity 300 to the lower capacitor water-cooling channel 304, and some heat is also transferred to the filter mounting cavity 302. Therefore, by placing the water outlet pipe 102 below the filter assembly 308, the cooling medium can effectively carry away the heat from the filter mounting cavity 302 during its outflow, thereby achieving comprehensive heat dissipation for the entire capacitor module structure.

[0061] By placing the filter mounting cavity 302 and the first accommodating cavity 200 on the same side of the capacitor mounting cavity 300, the module water cooling channel 201 and the water outlet pipe 102 can be approximately in a straight line, so that the cooling medium covers the entire module installation space during the flow process, improving the overall heat dissipation effect and improving the reliability and stability of the motor controller.

[0062] In addition, the depth of the filter mounting cavity 302 is less than the depth of the capacitor mounting cavity 300. The water outlet pipe 102 is located below the filter mounting cavity 302, which avoids the problem of increased overall height of the controller caused by the water outlet pipe 102, saves installation space, and meets the requirements of the automotive and other fields for miniaturization and lightweighting of the controller.

[0063] In some embodiments, such as Figure 5As shown, the capacitor water cooling channel 304 includes a water inlet 305 and a water outlet 306 protruding towards the side of the side cooling channel 312. The water inlet 305 is located below the side cooling channel 312, and the water outlet 306 is located above the water outlet pipe 102. The water outlet 306 has a cooling chamber located below the connecting groove 301.

[0064] To avoid the inclined setting of the connecting channel and the occupation of space, the water inlet 305 is extended to the lower part of the outlet side of the side cooling channel 312, forming a vertical connecting structure at the outlet end of the side cooling channel 312, reducing the resistance of the cooling medium to bypass the side cooling channel 312, and ensuring that the medium enters the capacitor water cooling channel 304 at a stable flow rate.

[0065] The capacitor core 307 and the filter assembly 308 are electrically connected through the copper busbar 309 in the connecting groove 301. The connecting groove 301 is higher than the bottom of the capacitor mounting cavity 300 and the bottom of the filter mounting cavity 302. The bottom of the connecting groove 301 can be close to the copper busbar 309 to improve heat transfer. Since the copper busbar 309 in the connecting groove 301 connects the capacitor core 307 and the filter assembly 308, local heat concentration is likely to occur in the connecting groove 301. Therefore, an upwardly extending cooling chamber is provided in the water outlet 306 of the capacitor water cooling channel 304. The cooling chamber is located below the connecting groove 301 and is used to cool the connecting groove 301 and the copper busbar 309.

[0066] After the cooling medium dissipates heat from the capacitor core 307 in the capacitor water cooling channel 304, it flows to the water outlet 306 and fills the cooling cavity at the same time as the water is discharged. The cooling medium directly absorbs the heat conducted by the connecting groove 301 and the wiring copper busbar 309 through the wall of the cooling cavity.

[0067] The water outlet 306 is located below the water outlet pipe 102, so that the capacitor water cooling channel 304 and the water outlet pipe 102 form a vertical connection structure. The medium can directly enter the water outlet pipe 102 through the water outlet 306 without the need for additional turning or guiding structures, reducing the flow resistance of the medium at the outlet end and ensuring the smoothness of the entire cooling cycle.

[0068] Optionally, the depth of the water outlet 306 is greater than the depth of other parts of the capacitor water cooling channel 304, but less than the depth of the cooling chamber. The water inlet end of the water outlet pipe 102 extends into the inner cavity of the water outlet 306, and a water inlet notch is provided on the side wall of the water outlet pipe 102.

[0069] In some embodiments, such as Figure 4 As shown, the housing 100 also includes a wiring cavity 303, which is located on the side of the filter mounting cavity 302 away from the capacitor mounting cavity 300, and the input copper busbar 310 of the filter assembly 308 is exposed in the wiring cavity 303.

[0070] The independent wiring cavity 303 can reduce electromagnetic interference introduced during external wiring and prevent interference signals from being conducted to the filter component 308 through the input copper busbar 310. In addition, the wiring cavity 303 is located on the side of the filter mounting cavity 302 away from the capacitor mounting cavity 300, away from the main heat source, and avoids the input copper busbar 310 being affected by the high temperature of the capacitor.

[0071] The input copper busbar 310 includes a positive input copper busbar 310 and a negative input copper busbar 310.

[0072] In addition, a three-phase output assembly is provided on the side of the first accommodating cavity 200 away from the capacitor mounting sub-cavity 300.

[0073] In some embodiments, such as Figure 4 As shown, the two ends of the modular water cooling channel 201 are respectively provided with an inlet buffer tank 202 and an outlet buffer tank 203. The outlet of the modular water cooling channel 201 is located at the bottom of the outlet buffer tank 203, and a downwardly inclined guide surface is provided on the outside of the outlet of the modular water cooling channel 201.

[0074] The water inlet end of the modular water cooling channel 201 is connected to the water inlet pipe 101. A downwardly recessed water inlet buffer trough 202 and a water outlet buffer trough 203 are respectively set at both ends of the modular water cooling channel 201. The water inlet buffer trough 202 plays a buffering role for the cooling medium entering it.

[0075] The outer side of the outlet is provided with a downward-sloping guide surface, which can guide the cooling medium smoothly into the outlet after entering the outlet buffer tank 203. The downward-sloping guide surface can make the cooling water flow out more smoothly, avoiding the formation of eddies or backflow at the outlet, thereby improving the efficiency of the cooling water flow and enhancing the heat dissipation effect.

[0076] Both the inlet buffer tank 202 and the outlet buffer tank 203 extend along the width direction of the housing 100, and their width directions are consistent with the length direction of the housing 100. Before the cooling medium enters the module water-cooling channel 201 from the inlet pipe 101, it first enters the inlet buffer tank 202. The inlet buffer tank 202 has a large volume, which can alleviate the inlet impact force of the cooling medium and prevent the formation of local high-speed zones due to the small cross-section of the channel within the module water-cooling channel 201, thus ensuring the flow stability of the cooling medium. Under the action of the inlet buffer tank 202, the cooling medium flows evenly through the module water-cooling channel 201, ensuring the cooling effect on the SiC module structure.

[0077] The water outlet buffer tank 203 serves as a buffer structure, collecting the cooling medium from the module's water cooling channel 201. After the cooling medium flows smoothly, it is discharged from the bottom outlet, thus preventing the generation of eddies.

[0078] The inlet buffer tank 202 has an inclined guide surface on the side away from the inlet pipe 101, and the outlet buffer tank 203 has an inclined guide surface on the side closer to the inlet pipe 101. The inclined guide surfaces can guide the water flow smoothly.

[0079] Based on the same inventive concept, this application also provides a vehicle that uses the above-mentioned motor controller.

[0080] Compared with the prior art, the vehicle provided in this application has all the beneficial effects of a motor controller. By arranging the water-cooling channels within the motor controller, the risk of capacitor overheating failure is reduced, and the reliability and stability of the motor controller are improved. This, in turn, ensures the reliability and stability of the entire vehicle during operation, especially in hybrid vehicles and other applications with higher ambient temperatures, where the advantages are even more pronounced.

[0081] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An electric motor controller characterized by, include: The housing (100) includes at least a first accommodating cavity (200) and a second accommodating cavity spaced apart. The first accommodating cavity (200) is used to install a SiC module structure, and the second accommodating cavity is used to install a capacitor module structure. The capacitor module structure includes a capacitor core (307) and a filter component (308). The cooling structure includes a water cooling channel disposed inside the housing (100), an inlet pipe (101) and an outlet pipe (102) disposed on the housing (100); The water cooling channel includes a module water cooling channel (201), a side cooling channel (312), and a capacitor water cooling channel (304) connected in sequence. The module water cooling channel (201) is located at the bottom of the first accommodating cavity (200), the capacitor water cooling channel (304) is located at the bottom of the second accommodating cavity, and the side cooling channel (312) is located between the first accommodating cavity (200) and the second accommodating cavity.

2. The motor controller as described in claim 1, characterized in that, The inlet pipe (101) and the outlet pipe (102) are respectively located on both sides of the housing (100); the module water cooling channel (201) and the capacitor water cooling channel (304) form a zigzag water cooling structure by means of the side cooling channel (312).

3. The motor controller as described in claim 1, characterized in that, The heights of the module water-cooling channel (201), the side cooling channel (312), and the capacitor water-cooling channel (304) decrease sequentially.

4. The motor controller as described in claim 1, characterized in that, The first accommodating cavity (200) includes: A capacitor mounting cavity (300) is provided for accommodating the capacitor core (307); A filter mounting cavity (302) is provided for accommodating the filter assembly (308); The capacitor mounting cavity (300) and the filter mounting cavity (302) are connected by a connecting slot (301), which allows a copper busbar (309) to pass through. The capacitor water cooling channel (304) is located below the capacitor mounting cavity (300).

5. The motor controller as described in claim 4, characterized in that, The capacitor mounting cavity (300) extends along the length of the housing (100), and a mounting gap is formed between the capacitor mounting cavity (300) and the first accommodating cavity (200). The side cooling channel (312) is located within the mounting gap.

6. The motor controller as described in claim 4, characterized in that, The filter mounting cavity (302) and the first accommodating cavity (200) are located on the same side of the capacitor mounting cavity (300); the water outlet pipe (102) is located below the filter mounting cavity (302).

7. The motor controller as described in claim 4, characterized in that, The capacitor water cooling channel (304) includes a water inlet (305) and a water outlet (306) protruding towards the side cooling channel (312). The water inlet (305) is located below the side cooling channel (312), and the water outlet (306) is located above the water outlet pipe (102). The water outlet (306) has a cooling chamber located below the connecting groove (301).

8. The motor controller as described in claim 4, characterized in that, The housing (100) also includes a wiring cavity (303), which is located on the side of the filter mounting sub-cavity (302) away from the capacitor mounting sub-cavity (300), and the input copper busbar (310) of the filter assembly (308) is exposed in the wiring cavity (303).

9. The motor controller as described in claim 1, characterized in that, The two ends of the modular water-cooling channel (201) are respectively provided with an inlet buffer tank (202) and an outlet buffer tank (203). The outlet of the modular water-cooling channel (201) is located at the bottom of the outlet buffer tank (203), and a downwardly inclined guide surface is provided on the outside of the outlet of the modular water-cooling channel (201).

10. A vehicle, characterized in that, The motor controller described in any one of claims 1-9 is used.

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