A power module, motor controller, electric drive assembly, and vehicle

Abstract

The application discloses a power module, a motor controller, an electric drive assembly and a vehicle. The power module comprises a shell and at least one magnetic core structure, and at least part of the at least one magnetic core structure is nested in the shell. In this way, the magnetic core does not need to be separately packaged with a shell and fixed, and the cost of the electric drive assembly comprising the power module provided by the application can be reduced.

Description

Technical Field

[0001] This application relates to the field of power electronics technology, and in particular to a power module, a motor controller, an electric drive assembly, and a vehicle. Background Technology

[0002] With the development of the new energy vehicle industry, market competition is becoming increasingly fierce, and the pressure to control costs is also increasing.

[0003] Currently, autonomous current sensors are commonly used in electronic control assemblies to monitor the magnitude and direction of the current flowing through the power module. On one hand, in the event of anomalies such as overcurrent, protection mechanisms can be triggered to prevent damage to the power module or other critical components. On the other hand, the real-time current data provided by the autonomous current sensor can be used to adjust the operating state of the power module to ensure output stability. The independent structural design of the autonomous current sensor gives it high flexibility and a wide range of applications. In range-extended electric vehicles, traditional technologies typically use two separate power modules, each generating independent three-phase currents. Therefore, each magnetic core requires its own plastic casing and mounting, resulting in a larger footprint. Utility Model Content

[0004] To address the aforementioned issues, this application provides a power module, a motor controller, an electric drive assembly, and a vehicle, which can reduce the size of the electric drive assembly while ensuring the performance of the current sensor.

[0005] The embodiments of this application disclose the following technical solutions:

[0006] In a first aspect, this application provides a power module, including a housing and at least one magnetic core structure, wherein at least a portion of the magnetic core structure is nested within the housing.

[0007] Optionally, the power module further includes at least one terminal, and the at least one terminal is provided with the magnetic core structure;

[0008] At least one of the terminals is at least partially nested within the housing.

[0009] Optionally, at least one of the terminals may have only one of the magnetic core structures;

[0010] At least a portion of each of the terminals is nested within the housing; and / or at least a portion of each of the core structures is nested within the housing.

[0011] Optionally, the magnetic core structure has a receiving cavity;

[0012] The terminal includes a first segment, wherein at least a portion of the first segment is located within the receiving cavity.

[0013] Optionally,

[0014] The terminal further includes a second terminal segment, wherein the first terminal segment and the second terminal segment are distributed along the length direction of the terminal, and the width of the first terminal segment is smaller than the width of the second terminal segment.

[0015] Optionally, the second segment of the terminal further includes a first sub-segment of the terminal, the first segment of the terminal and the first sub-segment of the terminal are distributed along the length direction of the terminal, the width of the first sub-segment of the terminal is greater than the width of the first segment of the terminal, and the first sub-segment of the terminal is provided with a connection hole.

[0016] Optionally, the second segment of the terminal further includes a second sub-segment of the terminal, the second segment of the terminal and the second sub-segment of the terminal are distributed along the length direction of the terminal, and the width of the second sub-segment of the terminal is greater than the width of the first segment of the terminal.

[0017] Optionally, the second segment of the terminal is located between the first segment of the terminal and the first segment of the terminal.

[0018] Optionally, the terminal further includes a third terminal segment connected to the first terminal segment, the third terminal segment being used to connect to the power submodule of the power module, and the width of the third terminal segment being greater than the width of the first terminal segment.

[0019] Optionally, the center line of the third segment of the terminal and the center line of the first segment of the terminal extend along the length direction of the terminal, and the center lines of the third segment of the terminal and the center lines of the first segment of the terminal are staggered in the width direction of the terminal.

[0020] Optionally, the power module includes at least two magnetic core structures, each magnetic core structure including a first magnetic core end disposed opposite to the circuit board, and a second magnetic core end disposed opposite to the first magnetic core end, wherein the first magnetic core ends of at least two magnetic core structures are disposed flush with each other and / or the second magnetic core ends of at least two magnetic core structures are disposed flush with each other.

[0021] Optionally, the power module includes a drive module for connection to a drive motor and a power generation module for connection to a generator motor.

[0022] Optionally, the magnetic core structure includes a first magnetic core end disposed opposite to the circuit board, and a second magnetic core end distributed opposite to the first magnetic core end;

[0023] At least one of the first magnetic core ends of the power generation module and at least one of the first magnetic core ends of the drive module are arranged flush with each other, and / or at least one of the second magnetic core ends of the power generation module and at least one of the second magnetic core ends of the drive module are arranged flush with each other.

[0024] Optionally, the power generation module includes at least two power sub-modules, and at least two of the power sub-modules share the same liner.

[0025] Optionally, the magnetic core structure includes a first magnetic core end for being disposed opposite to the circuit board, the first magnetic core end having an opening structure for accommodating at least a portion of the current sensor.

[0026] Optionally, the cross-sectional area of ​​at least one magnetic core structure of the drive module is larger than the cross-sectional area of ​​at least one magnetic core structure of the power generation module.

[0027] Optionally, the magnetic core structure of the drive module and the magnetic core structure of the power generation module each include width, thickness, and height, and the directions of the width, thickness, and height are perpendicular to each other, and at least one of the following conditions must be met:

[0028] The width of at least one magnetic core structure of the drive module is greater than the width of at least one magnetic core structure of the power generation module;

[0029] The thickness of at least one magnetic core structure of the drive module is greater than the thickness of at least one magnetic core structure of the power generation module.

[0030] Optionally, the height of at least one magnetic core structure of the drive module is equal to the height of at least one magnetic core structure of the power generation module.

[0031] Optionally, the width of the opening in the magnetic core structure is less than or equal to 6 mm.

[0032] Optionally, the height of the magnetic core structure is less than or equal to 21 mm.

[0033] Optionally, the height of the magnetic core structure is greater than or equal to 6 mm and less than or equal to 8 mm.

[0034] Optionally, the width of the magnetic core structure is greater than or equal to 12 mm and less than or equal to 15 mm.

[0035] Optionally, the distance between two adjacent terminals in the width direction is greater than or equal to 15 mm and less than or equal to 18 mm.

[0036] Optionally, the housing is injection molded.

[0037] Secondly, this application provides a motor controller, including the power module described in any embodiment of the first aspect.

[0038] Thirdly, embodiments of this application provide an electric drive assembly, including the motor controller described in the second aspect.

[0039] Fourthly, embodiments of this application provide a vehicle including the electric drive assembly described in the third aspect.

[0040] Compared with the prior art, this application has the following beneficial effects:

[0041] This application provides a power module in which at least one magnetic core structure and a housing are nested and connected. This eliminates the need for separate plastic coating and installation of the magnetic core, and can also reduce the cost of the electric drive assembly including the power module provided in this application. Attached Figure Description

[0042] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, 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.

[0043] Figure 1 A schematic diagram of the topology of a range-extended vehicle is shown.

[0044] Figure 2 A schematic diagram of the topology of the drive module and the power generation module in the prior art is shown;

[0045] Figure 3 A schematic diagram of the structure of a conventional power module in the prior art is shown;

[0046] Figure 4 This paper shows a schematic diagram of the structure of a power module provided in an embodiment of this application;

[0047] Figure 5 This illustration shows a structural diagram of a drive module and a power generation module in a power module according to an embodiment of this application;

[0048] Figure 6 This paper shows a top view of the magnetic core structure and busbar structure of a current sensor according to an embodiment of this application;

[0049] Figure 7 for Figure 6 A schematic diagram showing the dimensions of the core structure;

[0050] Figure 8 This illustration shows a front view of the magnetic core structure and busbar structure of a current sensor according to an embodiment of this application.

[0051] Figure 9 for Figure 4 A schematic diagram of the structure after removing the cover plate;

[0052] Figure 10 for Figure 9 Enlarged schematic diagram of part A in the middle;

[0053] Figure 11 for Figure 9 A schematic diagram of the structure of the second power terminal 200;

[0054] Figure 12 for Figure 9 A schematic diagram from the Y-axis perspective.

[0055] List of reference numerals in the attached diagram:

[0056] 1-Drive module; 2-Power generation module; 3-Housing; 31-Frame; 10-First power terminal group; 11-First current sensor; 20-Second power terminal group; 21-Second current sensor; 100-First power terminal; 110-Magnetic core structure of the first current sensor; 200-Second power terminal; 201-First segment of terminal; 202-Second segment of terminal; 2021-First sub-segment of terminal; 2021a-Connecting hole; 2022-Second sub-segment of terminal; 202 21-Protrusion; 203-Third segment of terminal; 210-Magnetic core structure of the second current sensor; 211-Receiving cavity; 212-Opening structure; 219-Current sensing chip; 261-First surface of outer rectangular cylinder; 262-Second surface of outer rectangular cylinder; 263-Third surface of outer rectangular cylinder; 264-Fourth surface of outer rectangular cylinder; 271-First surface of inner rectangular cylinder; 272-Second surface of inner rectangular cylinder; 273-Third surface of inner rectangular cylinder; 274-Fourth surface of inner rectangular cylinder;

[0057] 01-Wheel; 02-Range extender; 03-Power battery; 04-Engine; 05-Motor controller; 06-Inverter. Detailed Implementation

[0058] The power module, motor controller, electric drive assembly, and vehicle provided in this application can be used in the field of power electronics. The above is only an example and does not limit the application field of the power module, motor controller, electric drive assembly, and vehicle provided in this application.

[0059] The terms "first," "second," "third," and "fourth," etc., used in this application specification, claims, and drawings are used to distinguish different objects, not to limit a specific order.

[0060] In the embodiments of this application, the terms "as an example" or "for example" are used to indicate that they are examples, illustrations, or explanations. Any embodiment or design that is described as "as an example" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design options. Specifically, the use of terms such as "as an example" or "for example" is intended to present the relevant concepts in a specific manner.

[0061] The terminology used in the implementation section of this application is for the purpose of explaining specific embodiments of this application only, and is not intended to limit this application.

[0062] New energy vehicles include an electric drive system (or, more specifically, an electronic control system), which uses electric energy to propel the vehicle. Taking a range-extended electric vehicle as an example, its topology is as follows: Figure 1 As shown. The core component is the range extender 07, whose main function is to activate the range extender 07 when the power battery 03's charge drops to a certain level, causing the engine 04 to drive the generator M2 to generate electricity. Part of the generated electricity can be used to power the drive motor M1, and the other part can be used to charge the power battery 03. An inverter 06 is also installed between the drive motor M1 and the power battery 03.

[0063] Range-extended electric vehicles (REEVs) offer numerous advantages, including: for daily urban commutes, they can operate on pure electric power with zero emissions, reducing exhaust pollution and meeting environmental requirements. Furthermore, electric drive is more energy-efficient than gasoline drive, lowering energy consumption and operating costs.

[0064] Range-extended electric vehicles are equipped with an engine 04 as a range extender 07. When the battery is low, the engine can start to generate electricity to provide continuous power to the vehicle, avoiding the range anxiety problem caused by the limited driving range of pure electric vehicles and making long-distance travel more convenient.

[0065] In addition, range-extended electric vehicles also have the following advantages in terms of driving experience:

[0066] Pure electric drive: The range-extended topology is essentially a pure electric drive system. The vehicle's driving power is entirely provided by the electric motor (i.e., drive motor M1). The engine 04 does not directly participate in driving the vehicle, but plays the role of generating electricity. It starts when the power battery 03 is low on power, converting fuel into electrical energy to power drive motor M1 or charge power battery 03. This pure electric drive method makes the vehicle's power source singular and pure, consistent with the driving mode of pure electric vehicles, fundamentally ensuring the comfort of the driving experience.

[0067] Rapid power response: The characteristics of the drive motor M1 enable it to output maximum torque instantly. In range-extended electric vehicles, when the driver presses the accelerator pedal, the drive motor M1 responds immediately, rapidly delivering powerful output for quick starts and acceleration. This instantaneous power response is far superior to traditional gasoline vehicles, allowing the driver to experience a more direct and rapid surge of power. Whether in the frequent stop-and-go traffic of city driving or overtaking maneuvers on highways, it handles everything with ease, delivering a smooth driving experience.

[0068] No power interruption: During the operation of a range-extended vehicle, since it is always driven by the drive motor M1, there is no power interruption problem as seen in traditional gasoline vehicles when shifting gears. Whether driving at low or high speeds, the power output remains continuous and smooth. Even when the power battery 03 is low on charge and the engine 04 starts generating electricity, the system can ensure that the power output of the drive motor M1 is unaffected through precise control strategies, without any jerking or power interruption. This provides the driver with a consistently stable driving experience, improving driving comfort and safety.

[0069] However, in existing technologies, the electric drive assembly of range-extended electric vehicles includes components such as generator M2, drive motor M1, generator controller, and drive motor controller. Figure 1 The motor controller 05 shown includes a generator controller and a drive motor controller. The generator controller and drive motor controller are independent components, each with its own power supply (e.g., using diodes, IGBTs, SiC semiconductors for AC-DC conversion), current sensors, temperature sensors, motor rotor position sensors, and other sensors. Their weight, size, and cost are all relatively high, necessitating optimization.

[0070] Figure 2 This diagram illustrates the topology of the drive module and power generation module in an existing range-extended electric vehicle. (See also...) Figure 2 The drive module converts the DC power from the high-voltage battery into AC power to drive the drive motor M1, providing torque to rotate the wheel 01. The generator module converts the AC power output from the generator M2 into DC power to charge the high-voltage power battery 03 or to power the drive motor M1. Figure 3 This diagram illustrates the structural schematics of the drive module and power generation module in an existing range-extended electric vehicle. (For example...) Figure 3As shown, existing drive and power generation modules both use half-bridge modules as the smallest unit, with the three half-bridge modules from the left constituting the drive module and the three from the right constituting the power generation module. It's easy to see that the length along the arrangement of the half-bridge modules is relatively long. In existing technologies, the drive and power generation modules each have independent heat dissipation backplates. Because hybrid vehicles need to accommodate components such as the engine, generator, electronic control system, battery, fuel tank, and transmission system simultaneously, interior space is limited. Simply packaging the drive and power generation modules together without reducing their size will not reduce their space requirements; instead, it may lead to greater space waste and will not reduce production costs. Therefore, the integration of the drive and power generation modules requires not only integration but also miniaturization after integration.

[0071] As mentioned earlier, with the development of the new energy vehicle industry, market competition is becoming increasingly fierce, and the pressure to control costs is also increasing. As a crucial component of the vehicle, how to optimize the electronic control system from multiple aspects, including cost, space utilization, and performance, has become a widely concerned issue.

[0072] In the electronic control assembly, a current sensor is needed to monitor the magnitude and direction of the current in the power module. On the one hand, when an abnormality such as overcurrent occurs, a protection mechanism can be triggered to prevent damage to the power module or other critical components. On the other hand, the operating state of the power module can be adjusted based on the real-time current data provided by the autonomous current sensor to ensure the stability of the output. The autonomous current sensor is a current sensor whose magnetic core structure and chip are set separately.

[0073] In traditional solutions, current sensors typically exist as a separate component, including a magnetic core, coil, and other related parts. These components often require additional mounting and fixing devices such as plastic coating and screws to ensure their stability and safety. Not only does the complex assembly process lead to increased labor costs, but the materials required for each individual current sensor and its installation, such as plastic coating materials and fasteners, also increase manufacturing costs.

[0074] On the other hand, in order to meet the requirements of mechanical strength and electrical isolation, the overall structure of a standalone current sensor is usually bulky and occupies a lot of space, which is a significant disadvantage in applications with strict space requirements, such as new energy vehicles.

[0075] In addition, each current sensor requires a long connecting cable to connect to the power module, which can easily introduce electromagnetic interference and affect the stability and accuracy of the electronic control assembly.

[0076] In view of this, this application provides a power module comprising: an integrated drive module 1 and a power generation module 2, wherein the drive module 1 controls the drive motor of a hybrid vehicle, and the power generation module 2 controls the power generation device of the hybrid vehicle, such as... Figure 4 , 5 As shown. The drive module 1 includes terminals, which can be defined as first power terminals 100. Multiple first power terminals 100 form a first power terminal group 10, which is coupled to the drive motor during operation. At least one first power terminal 100 in the first power terminal group 10 can be equipped with a first current sensor 11. Specifically, in this embodiment, each first power terminal 100 is equipped with one first current sensor 11 for measuring the magnitude and direction of the current in the corresponding first power terminal 100. The power generation module 2 also includes terminals, which can be defined as second power terminals 200. Multiple second power terminals 200 form a second power terminal group 20, which is coupled to the range extender during operation. At least one second power terminal 100 in the second power terminal group 20 can be equipped with a second current sensor 21. Specifically, in this embodiment, each second power terminal 200 is equipped with one second current sensor 21 for measuring the magnitude and direction of the current in the corresponding second power terminal 200.

[0077] The power module also includes a housing 3 for encapsulating the drive module 1 and the power generation module 2. The first power terminal 100 and the second power terminal 200 each include a portion protruding from the outside of the housing 3 (which may be defined as the first portion) and a portion disposed on or inside the housing 3 (which may be defined as the second portion).

[0078] In an optional embodiment, the drive module 1 and the power generation module 2 are three-phase AC power modules. The first power terminal group 10 includes three first power terminals 100, which are used to transmit AC power U, V and W phases respectively. The second power terminal group 20 includes three second power terminals 200, which are used to transmit AC power U, V and W phases respectively.

[0079] According to the embodiments of this application, such as Figure 4 and Figure 5 As shown, in the power module provided in this embodiment, the drive module 1 and the power generation module 2 are arranged side by side, and the power generation module 2 is disposed on either side of the drive module 1. For example, as... Figure 4 and Figure 5 As shown, the power generation module 2 is located to the right of the drive module 1.

[0080] Drive module 1 transmits AC power through the first power terminal 100, realizing AC-DC conversion. Drive module 1 is used to invert or rectify power according to the driving state of the hybrid vehicle. For example, when the vehicle needs to accelerate, drive module 1 can convert the DC power output from the battery into AC power; when the vehicle needs to decelerate, the drive motor switches to generator mode, and drive module 1 rectifies the AC power into DC power. It should be understood that the hybrid vehicle in this application includes range-extended electric vehicles and dual-mode intelligent hybrid vehicles (DMI).

[0081] The power generation module 2 transmits AC power through the second power terminal 200 to achieve AC-DC conversion. The power generation module 2 is used to control the vehicle's range extender generator and plays a rectifier role, converting the AC power generated by the fuel generator into DC power to power the motor and / or battery.

[0082] In an optional embodiment, the drive module 1 and the power generation module 2 measure alternating current via current sensors. A first power terminal 100 connects the drive module 1 to the drive motor, and a first current sensor 11 is integrated on the first power terminal 100. A second power terminal 200 connects the power generation module 2 to the range extender, and a second current sensor 21 is integrated on the second power terminal 200. The current sensors include magnetic core structures. The magnetic core structure of the first current sensor 11 is defined as magnetic core structure 110, and the magnetic core structure of the second current sensor 21 is defined as magnetic core structure 210. The magnetic core structures 110 and 210 are used to concentrate the magnetic field, enhance the signal strength of the alternating current, and facilitate the measurement of its magnitude and direction by the first current sensor 11 and the second current sensor 21.

[0083] The housing 3 includes, for example, a portion for accommodating the drive module 1 and the power generation module 2, wherein a portion of the first power terminal 100 and the second power terminal 200 are encapsulated inside the housing 3, and the other portion is located outside the housing 3. In this embodiment, at least one magnetic core structure is nested within the housing 3, for example, at least a portion of the magnetic core structure is integrally injection molded with the housing 3, or the housing 3 is an injection molded structure, and at least a portion of the magnetic core structure is assembled and nested within the housing 3. Specifically, the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor are respectively integrated into the portions of the first power terminal 100 and the second power terminal 200 located inside the housing 3.

[0084] Therefore, in this application, the magnetic core structure of the current sensor is nested within the housing 3, thereby integrating the magnetic core structure into the power module and forming a compact overall structure. On the one hand, this reduces the need for external wiring, making the entire electronic control assembly more compact; on the other hand, it eliminates the need for additional plastic coating material and mounting screws for the autonomous current sensor, reducing not only material costs but also assembly steps, thus lowering overall production costs; furthermore, the magnetic core structure of the current sensor is nested within the corresponding power terminal, meaning the power terminal portion is located within the magnetic core structure cavity of the current sensor, reducing unnecessary connecting cables, thereby reducing electromagnetic interference, helping to maintain signal purity and stability, improving the accuracy of current monitoring results, and avoiding errors caused by long-distance transmission.

[0085] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present application.

[0086] In an optional embodiment, the drive module 1 includes three half-bridge circuits, and the power generation module 2 includes a three-phase full-bridge circuit. The three-phase full-bridge circuit is mounted on a substrate structure to integrate the second power terminal 200. At the same time, the second current sensor 21 is also integrated on the second power terminal 200, which helps to reduce the overall design cost of the power control and optimize the power control space.

[0087] See Figure 4 and Figure 5 This illustration shows a schematic diagram of a power module structure according to an embodiment of this application. The power module includes a drive module 1, a power generation module 2, and a housing 3. The drive module 1 includes three independent half-bridge units. Exemplarily, the three first power terminals 100 from left to right correspond to the U phase, V phase, and W phase, respectively. The power generation module 2 employs a full-bridge circuit, reducing the size along the arrangement direction of the drive module 1 and the power generation module 2. Exemplarily, for a three-phase AC signal... Figure 4In the full-bridge circuit, the three second power terminals 200 from left to right correspond to the U phase, V phase, and W phase, respectively. The main bodies of the drive module 1 and the power generation module 2 are encapsulated inside the housing 3. A portion of the first power terminal 100 is located inside the housing 3, and the other portion is located outside. The magnetic core structure 110 of the first current sensor is integrated onto the first power terminal 100 and located inside the housing 3. A portion of the second power terminal 200 is located inside the housing 3, and the other portion is located outside. The magnetic core 210 of the second current sensor is integrated onto the second power terminal 200 and located inside the housing 3.

[0088] In an optional embodiment, the power module includes an insulated-gate bipolar transistor (IGBT) chip. IGBTs can operate under high voltage and current conditions while maintaining low energy loss. They are controlled by gate voltage for turn-on and turn-off, are simple to operate, have fast switching speeds, and are easily integrated into complex control systems. They perform excellently in high-power, high-voltage, and high-current applications and are widely used in industrial drives and electric vehicles.

[0089] In the embodiments of this application, the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor are used to concentrate and guide the magnetic field generated by the measured current, thereby accurately monitoring the current. In an optional embodiment, both the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor can be designed with an opening structure 212. On the one hand, this facilitates a more uniform distribution of the magnetic field, reducing possible errors and interference; on the other hand, it can also increase the magnetic reluctance of the magnetic circuit, reduce the magnetic flux density, and prevent the magnetic core from saturating prematurely when handling large currents; furthermore, it can also improve the linearity of the current sensor, making the output more linear and improving measurement accuracy.

[0090] As an example, in the power module manufacturing process, the first power terminal 100 and the second power terminal 200 can be connected to the output terminals of the drive module 1 and the power generation module 2. Then, the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor are nested on the side of the first power terminal 100 near the drive module 1 and the side of the second power terminal 200 near the power generation module 2, respectively. Finally, the housing 3 is assembled and packaged to form an integrated power module.

[0091] In this embodiment, the housing 3 may include a frame 31, such as Figure 4As shown, the drive module 1 and the power generation module 2 are distributed along the X-direction. The first power terminal 100 and the second power terminal 200 are located on one side of the power module along the X-direction. The Y-direction is perpendicular to the X-direction, and the Z-direction is perpendicular to both the Y-direction and the X-direction. The drive module 1 and the power generation module 2 can be defined as forming the main body of the power module. The frame 31 can then be stacked on top of the main body of the power module along its height direction (i.e., the Z-direction). The frame 31 is connected to the edge of the main body of the power module, and the frame 31 is positioned approximately around the drive module 1 and the power generation module 2. The frame 31 can be located on one side of the main body of the power module along its height direction, between the main body of the power module and the circuit board 4 (shown in...). Figure 12 Between the frame 31 and the power module body, the frame 31 can be fixed with adhesive, and screws can also be used to further secure the connection, increasing its reliability. Figure 4 As shown, the main body of the power module is roughly rectangular, and therefore the frame 31 is also roughly rectangular. Since the first power terminal 100 and the second power terminal 200 are located on one side of the power module body in the Y direction, the frame 31, correspondingly, can be injection molded to connect the magnetic core structure and the AC side sub-terminals on the side closer to the first power terminal 100 and the second power terminal 200, to achieve a nested connection with the magnetic core structure. The frame 31 may also include multiple columns, each with a first connection hole. The height of the columns may be higher than the power generation module 2 and the drive module 1, so that they can be fixedly connected to the circuit board 4 by fasteners inserted into the first connection holes of the columns and the second connection holes on the circuit board 4. The fasteners are, for example, fastening screws. The housing 3 may also include a cover plate 32, which is located between the circuit board 4 and the drive module 1 and the power generation module 2, and serves to protect the drive module 1 and the power generation module 2.

[0092] More specifically, the frame 31 includes a first side and a second side arranged opposite each other along the Y direction. The first side is injection molded to connect magnetic core structures 110 and 120, as well as a first power terminal 100 and a second power terminal 200. The first power terminal 100 and the second power terminal 200 are AC side terminals. The second side of the frame 31 extends approximately to the position on the power module body where it connects to the DC side terminal. The housing 3 may also include a reinforcing rib extending along the direction from the first side to the second side. One end of the reinforcing rib is connected to the first side of the frame 31, and the other end is connected to the second side of the frame 31. The addition of the reinforcing rib can improve the strength of the frame 31.

[0093] The power module includes multiple bridge arms distributed along the X-direction. At least a portion of the reinforcing ribs of the frame 31 can be located between two adjacent bridge arms of the drive module 1, and between the drive module 1 and the power generation module 2. Multiple reinforcing ribs can be provided, with one reinforcing rib corresponding to each pair of adjacent bridge arms of the drive module 1. Since the power generation module 2 is relatively small in this embodiment, and the full-bridge circuit is arranged on a single substrate, there are no corresponding reinforcing ribs between the bridge arms of the power generation module 2. This arrangement strengthens the housing 3 without interfering with the bridge arms.

[0094] Thus, the drive module 1 and the power generation module 2, together with the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor, become an integral part of the power module during the production process. This achieves miniaturization and integration of the equipment, saves the space required for the magnetic core structure of the independent current sensor, and eliminates the need for separate plastic coating design and installation fixation of the magnetic core structure of the current sensor, thereby reducing the cost of the power module.

[0095] In this embodiment, the magnetic core structure of the current sensor is integrated into the power module to form a whole, and is encapsulated together inside the housing 3. While ensuring the performance of the current sensor, this makes the electronic control assembly, including the power module provided in this embodiment, more compact in design, reducing the size of the electronic control assembly and optimizing the electronic control space. In addition, there is no need to separately encapsulate and fix the magnetic core structure of the current sensor, which can also reduce the cost of the electronic control assembly, including the power module provided in this embodiment. The integration of the drive module 1, the power generation module 2, and the magnetic core structures 110 and 210 of its first current sensor can further reduce the size of the power module and the electronic control unit using the power module.

[0096] In the embodiments of this application, the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor may have the same or different dimensions. For example, the size of the magnetic core structure 110 of the first current sensor may be larger than the size of the magnetic core structure 210 of the second current sensor.

[0097] In the embodiments of this application, the magnetic core structure 110 of the first current sensor and the first power terminal 100 are nested together, and both can be nested within the housing 3. Similarly, the magnetic core structure 210 of the second current sensor and the second power terminal 200 are nested together, and both can be nested within the housing 3. The structures of the magnetic core structure 110 of the first current sensor and the magnetic core structure 210 of the second current sensor are substantially the same; the following description uses the magnetic core structure 210 of the second current sensor as an example. The magnetic core structure 210 of the second current sensor includes a receiving cavity 211, and a portion of the busbar 220 of the second power terminal 200 is disposed inside the receiving cavity 211. The second current sensor 21 may include a current sensing chip 219 (shown in…). Figure 8 The second current sensor has an opening structure 212 on its magnetic core structure 210 to accommodate a current sensing chip 219. The current sensing chip 219 is located at the opening structure 212 and is used to detect the magnitude and direction of the current passing through the second power terminal 200 based on the magnetic induction lines passing through the current sensing chip 219. It can be seen that the first current sensor 21 also includes a current sensing chip, and the magnetic core structure 110 of the first current sensor also has an opening structure to accommodate the current sensing chip of the first current sensor 21.

[0098] As an example, the second power terminal 200 in this embodiment may include a busbar 220, with a portion of the busbar 220 located in the receiving cavity 211 of the magnetic core structure 210 of the second current sensor. Therefore, the first power terminal 100 may also include a busbar, with a portion of the busbar located in the receiving cavity of the magnetic core structure 110 of the first current sensor. Both busbars can be made of copper. On one hand, copper has excellent electrical conductivity, which reduces energy loss and heat generation when transmitting large currents, improving the efficiency of the power module. On the other hand, copper also has excellent thermal conductivity, helping to quickly dissipate the heat generated by the current, maintaining a stable operating temperature and reducing the risk of overheating leading to performance degradation or damage. Furthermore, the busbar 220 is flat, compact, and occupies little space, contributing to a more compact structure for the power module. Thus, using a busbar 220 not only optimizes electrical performance but also enhances system reliability and safety, contributing to a compact and efficient electrical control solution.

[0099] In an optional embodiment, the second power terminals 200 of the power generation module 2 are disposed on the same substrate. To increase the spacing between the magnetic core structures 210 of the second current sensors and reduce crosstalk, in an optional embodiment, the magnetic core structure 210 of the second current sensor is a small core, that is, the size of the magnetic core structure 210 of the second current sensor is relatively small compared to the magnetic core structure 110 of the first current sensor. This allows the spacing between adjacent magnetic core structures 210 of the second current sensors to be increased after the bridge arms of the power generation module 2 are integrated on a substrate. For example, the cross-sectional area of ​​at least one magnetic core structure of the drive module 1 is larger than the cross-sectional area of ​​at least one magnetic core structure of the power generation module 2, and the cross-sectional area can be a cross-section in any of the Y, X, and Z directions.

[0100] The cross-sectional area of ​​at least one magnetic core structure of the driving module 1 mentioned above is greater than the cross-sectional area of ​​at least one magnetic core structure of the power generation module 2. Specifically, in this embodiment, the magnetic core structure of the driving module 1 and the magnetic core structure of the power generation module 2 respectively include width, thickness, and height. The width is the dimension in the X direction, the thickness is the dimension in the Y direction, and the height is the dimension in the Z direction. The directions of width, thickness, and height are perpendicular to each other, and at least one of the following two conditions must be met:

[0101] The width of at least one magnetic core structure of the drive module 1 is greater than the width of at least one magnetic core structure of the power generation module 2;

[0102] The thickness of at least one magnetic core structure of drive module 1 is greater than the thickness of at least one magnetic core structure of power generation module 2.

[0103] By designing the thickness or width, it is easy to make the magnetic core structure 210 of the second current sensor a small magnetic core. The height of at least one magnetic core structure of the drive module 1 can be equal to the height of at least one magnetic core structure of the power generation module 2, so that the magnetic core structures can be set flush, which facilitates the connection between the current sensor of the integrated power module and the circuit board 4.

[0104] Let's look again. Figures 6 to 8 , Figures 6 to 8 The diagram shows a top view and a front view of the nested structure formed by the magnetic core structure 210 of the second current sensor and the busbar 220 of the second power terminal 200, according to an embodiment of this application. Figure 7 yes Figure 6 A schematic diagram showing the dimensions of the magnetic core structure.

[0105] Specifically, in this embodiment, the busbar 220 has a rectangular cross-section, including a long side and a short side, and the core structure 210 has a rectangular annular cross-section, including an outer rectangular cylindrical surface and an inner rectangular cylindrical surface. An opening structure 212 is provided on the inner rectangular cylindrical surface. The outer rectangular cylindrical surface includes a first surface, a second surface, a third surface, and a fourth surface, wherein the first and fourth surfaces are opposite each other, and the second and third surfaces are opposite each other. The inner rectangular cylindrical surface includes an inner rectangular cylindrical surface first surface 271 that is substantially parallel to the first surface 261 of the outer rectangular cylindrical surface, an inner rectangular cylindrical surface second surface 272 that is substantially parallel to the second surface 262 of the outer rectangular cylindrical surface, an inner rectangular cylindrical surface third surface 273 that is substantially parallel to the third surface 263 of the outer rectangular cylindrical surface, and an inner rectangular cylindrical surface fourth surface 274 that is substantially parallel to the fourth surface 264 of the outer rectangular cylindrical surface.

[0106] An opening structure 212 is perpendicular to the first surface 261 of the outer rectangular cylinder and the first surface 271 of the inner rectangular cylinder, with its length direction parallel to the height direction of the outer rectangular cylinder, facilitating the placement of the current sensing chip 219 within it. The first surface 271, the second surface 272, the third surface 273, and the fourth surface 274 of the inner rectangular cylinder form a receiving cavity 211, which accommodates a portion of the second power terminal 200. The corresponding wall surface of the receiving cavity 211 does not contact the second power terminal 200, i.e., the second power terminal 200 and the inner rectangular cylinder do not contact each other, and are spaced apart.

[0107] Where AG is the width of the opening structure 212, tc is the height of the outer rectangular cylinder along the Y direction and the height of the inner rectangular cylinder along the Y direction, Lx is the width of the first face 271 and the fourth face 274 of the inner rectangular cylinder, Ly is the height of the second face 272 and the third face 273 of the inner rectangular cylinder, ec is the distance between the first face 261 of the outer rectangular cylinder and the first face 271 of the inner rectangular cylinder, and ech is the distance between the second face 262 of the outer rectangular cylinder and the second face 272 of the inner rectangular cylinder, the distance between the third face 263 of the outer rectangular cylinder and the third face 273 of the inner rectangular cylinder, and the distance between the fourth face 264 of the outer rectangular cylinder and the fourth face 274 of the inner rectangular cylinder. It can be seen that the distance between the fourth face 264 of the outer rectangular cylinder and the fourth face 274 of the inner rectangular cylinder can also be unequal to the distance between the third face 263 of the outer rectangular cylinder and the third face 273 of the inner rectangular cylinder.

[0108] In the embodiments of this application, in order to adjust the cross-sectional area of ​​the magnetic core structure 210 of the second current sensor, the dimensions of ec and ech can be the same or different.

[0109] In the embodiments of this application, the magnetic core structure 210 of the second current sensor is disposed between the PCBA and the heat dissipation substrate inside the housing 3, that is, between the circuit board 4 and the heat dissipation substrate 5, as can be seen from [reference]. Figure 12 understand.

[0110] In an optional embodiment, the distance between the first surface 261 and the fourth surface 264 of the outer rectangular cylinder is less than or equal to 21 mm, that is, the height of the magnetic core structure is less than or equal to 21 mm. When the distance is too large, it is difficult to accommodate the size of the magnetic core structure 210 between the PCBA and the heat sink, thereby affecting the overall size of the power module.

[0111] In an optional embodiment, the distance between the second surface 262 and the third surface 263 of the outer rectangular cylinder is greater than or equal to 12 mm and less than or equal to 15 mm, that is, the width of the magnetic core structure is greater than or equal to 12 mm and less than or equal to 15 mm. When the distance is too large, the distance between two adjacent terminals becomes too close, resulting in excessive coupling interference between adjacent terminals. When the distance is too small, the cross-sectional area of ​​the magnetic core structure 210 is too small, making it prone to magnetic saturation and unable to meet the requirements for measuring large currents.

[0112] In one optional embodiment, the height of the outer rectangular cylinder is greater than or equal to 6 mm and less than or equal to 8 mm, meaning the height of the magnetic core structure is greater than or equal to 6 mm and less than or equal to 8 mm. When the height is too small, the magnetic core structure 210 is prone to magnetic saturation, failing to meet the requirements for measuring larger currents. When the height is too large, the magnetic core structure 210 is difficult to accommodate inside the housing 3, thus affecting the overall size of the power module.

[0113] In an optional embodiment, the distance between two adjacent second power terminals 200 along the cross-sectional length of the busbar 220 is greater than or equal to 15 mm and less than or equal to 18 mm. When the distance is too large, the overall volume of the housing 3 increases, affecting the overall size of the power module. When the distance is too small, the spacing between the second power terminals 200 is too close, resulting in excessive coupling interference between adjacent terminals.

[0114] In an optional embodiment, the width AG of the opening structure 212 is less than or equal to 6 mm. When AG is too large, the area of ​​the opening structure 212 is too large, which can easily lead to magnetic leakage.

[0115] In an optional embodiment, the width Lx of the first inner rectangular cylindrical surface 271 and the width Lx of the third inner rectangular cylindrical surface 273 are less than or equal to 3 mm, and the width Ly of the second inner rectangular cylindrical surface 272 and the width Ly of the fourth inner rectangular cylindrical surface 274 are less than or equal to 9 mm. When Lx and Ly are too large, it will be difficult to accommodate the size of the magnetic core structure 210 between the PCBA and the heat sink substrate, thereby affecting the overall size of the power module.

[0116] In an optional embodiment, the spacing between the second surface 262 of the outer rectangular cylinder and the second surface 272 of the inner rectangular cylinder, the spacing between the third surface 263 of the outer rectangular cylinder and the third surface 273 of the inner rectangular cylinder, and the spacing between the fourth surface 264 of the outer rectangular cylinder and the fourth surface 274 of the inner rectangular cylinder are all equal, denoted as ech, where ech is less than or equal to 3 mm. When ech is too large, the distance between the PCBA and the heat sink increases, thereby affecting the overall size of the power module.

[0117] In the embodiments of this application, based on the aforementioned dimensional settings, and with the three half-bridge arms of the full-bridge structure of the power generation module 2 connected to the same liner structure, the dimensions of ech are mainly reduced. While ensuring that it can meet the current of more than 600A without magnetic saturation, the thickness is significantly reduced, effectively reducing interference between terminals and effectively lowering the height between the PCBA and the heat dissipation substrate.

[0118] Exemplarily, in one embodiment of this application, the magnetic core structure 210 has the following dimensions: the lengths of the first and fourth outer rectangular cylindrical surfaces 261 and 264 are 13 mm, the lengths of the second and third outer rectangular cylindrical surfaces 262 and 263 are 9 mm, tc=5.98 mm, ec=3 mm, ech=3 mm, and AG=6 mm. These dimensions effectively reduce the thickness of the magnetic core structure 210 while ensuring that magnetic saturation does not occur when a current of 600A or higher is supplied. This allows for a reduction in the spacing between the PCBA and the heat sink, thereby reducing the overall size of the power module and saving space. This can be combined with... Figure 12 It is understood that, due to the limited height between the circuit board 4 and the heat dissipation substrate 5, and the need to integrate into a power module with a smaller width, the size design of the magnetic core structure is limited. In this embodiment, the magnetic core structure 210 of the second current sensor is reasonably set so that it meets the requirements of the current sensor under the limited size space.

[0119] As an example, to ensure a necessary gap between the inner surface of the core structure 210 of the second current sensor for three-phase current and the second power terminal 200, the second core 210 can be designed as a rectangular annular core with an air gap (i.e., a core opening structure 212). The internal dimensions of the core structure 210 of the second current sensor are designed based on the width and thickness of the second power terminal 200. Based on requirements such as avoiding coupling interference between magnetic fields, the thickness ec of the side where the air gap is located can be widened or narrowed relative to the thickness ech of other parts of the core structure.

[0120] For example, when the spacing between phases can ensure low magnetic field coupling interference, the values ​​of ec and ech can be determined based on the maximum current value expected to be measured by the current sensor, so that the current value corresponding to the magnetic core structure 210 of the second current sensor exhibiting magnetic core saturation is greater than the maximum current value expected to be measured by the current sensor, thereby improving the accuracy and reliability of the current sensor measurement results.

[0121] In some embodiments, the housing 3 has a through hole at the position corresponding to the opening structure 212; the diameter of the through hole is less than or equal to the size of the opening structure 212. The current sensor chip 219 can be connected to an external circuit through the through hole to monitor the current passing through the power module.

[0122] The diameter of the through-hole on the housing 3 is less than or equal to the size of the opening structure 212, which reduces the impact of the housing structure on the performance of the current sensor. Furthermore, the through-hole design not only helps maintain the air pressure balance inside the housing 3 but also facilitates the smooth passage of magnetic field lines, further improving the sensitivity and accuracy of current detection. On the other hand, the presence of the through-hole also facilitates heat dissipation inside the housing 3, improving the stability and reliability of the device during long-term operation.

[0123] In addition, such as Figures 9 to 12 As shown, Figure 9 for Figure 4 A schematic diagram of the structure after removing the cover plate; Figure 10 for Figure 9 Enlarged diagram of part A in the middle; Figure 11 for Figure 9 A schematic diagram of the structure of the second power terminal 200; Figure 12 for Figure 9 A schematic diagram from the Y-axis perspective.

[0124] In this embodiment, the second power terminal 200 includes a first terminal segment 201, wherein at least a portion of the first terminal segment 201 is located in the receiving cavity 211. The second power terminal 200 also includes a second terminal segment 202, wherein the first terminal segment 201 and the second terminal segment 202 are distributed along the length direction of the second power terminal 200, and the width W1 of the first terminal segment 201 is smaller than the width of the second terminal segment 202, that is, the second power terminal 200 adopts an unequal width design, and the width is the dimension of the terminal along the X direction. With this configuration, the width of the receiving cavity 211 of the magnetic core structure 210 of the second current sensor is sufficient to accommodate the smaller width of the first terminal segment 201, so the width of the magnetic core structure 210 can be set to be smaller. This is beneficial for increasing the spacing between two adjacent magnetic core structures 210 of the second current sensor in the case of limited space, reducing interference, thereby allowing the power generation module 2 to have a smaller width, which is beneficial for multiple bridge arms of the power generation module 2 to share a single liner, and thus facilitates the miniaturization design of the entire power module.

[0125] The second segment 202 of the terminal may include a first sub-segment 2021 of the terminal. The first segment 201 and the first sub-segment 2022 of the terminal are distributed along the length direction of the terminal. The width W21 of the first sub-segment 2021 is greater than the width W1 of the first segment 201 of the terminal. The first sub-segment 2021 of the terminal is provided with a connecting hole 2021a. The first sub-segment 2021 of the terminal can be connected to other components by fasteners inserted into the connecting hole 2021a. The fasteners are, for example, screws. In this case, the first sub-segment 201 of the terminal is widened. On the one hand, this facilitates the arrangement of the connecting hole 2021a and ensures strength. On the other hand, the contact resistance at the connection point with the fastener is relatively large and the heat generation is relatively large. The widening of the first sub-segment 2021 of the terminal is beneficial for heat dissipation.

[0126] The second segment 202 of the terminal may further include a second sub-segment 2022. The first segment 201 and the second sub-segment 2022 of the terminal are distributed along the length direction of the terminal. The width W22 of the second sub-segment 2022 is greater than the width W1 of the first segment 201 of the terminal, that is, the width of the first segment 201 of the terminal is smaller, so as to be installed in the magnetic core structure 210. Specifically, the width W22 of the second sub-segment 2022 of the terminal is smaller than the width W21 of the first sub-segment 2021 of the terminal. Figure 11 In the middle, the second sub-segment 2022 of the terminal is located between the first segment 201 of the terminal and the first sub-segment 2021 of the terminal, connecting the first sub-segment 2021 of the terminal and the first segment 201 of the terminal, which can take into account both heat dissipation and current carrying capacity.

[0127] The narrower terminal segment 201 is easy to accommodate in the opening structure 212 of the small magnetic core. At the same time, when the second power terminal 200 and the housing 3 are nested together by injection molding, the space between the magnetic core structure 210 of the second current sensor and the terminal segment 201 will be filled with injection molding plastic. The injection molding plastic can be made of a material with a high heat dissipation coefficient, which can also provide better heat dissipation for the narrower terminal segment 201.

[0128] like Figure 10 , 11 As shown, the second power terminal 200 in this embodiment also includes a third terminal segment 203 connected to the first terminal segment 201. The third terminal segment 203 is used to connect to the power submodule of the power module, that is, to the bridge arm of the power module. The width W3 of the third terminal segment 203 is greater than the width W1 of the first terminal segment 201. That is, the first terminal segment 201 can be the part with the smallest width in the second power terminal 200. Figure 11In the second power terminal 200, the length is L, where the length of the first segment 201 is L1 and the length of the second sub-segment 2022 is L2. The width W3 of the third segment 203 is greater than the width W1 of the first segment 201 to ensure the necessary width for connection with the power submodule. The third segment 203 may include two connecting legs 2031 arranged along the width direction, with a spacing t between the two connecting legs 2031 in the width direction, and the two connecting legs 2031 are used for connection with the power submodule.

[0129] You can continue to refer to this. Figure 11 In this embodiment, the center line O1 of the third segment 203 and the center line O2 of the first segment 201 of the terminal extend along the length direction of the second power terminal 200. The length direction of the terminal is also the direction of current flow in the terminal, which is the Y direction in this embodiment. Furthermore, the center lines O1 of the third segment 203 and O2 of the first segment 201 of the terminal are staggered in the width direction of the second power terminal 200. Thus, as... Figure 9 As shown, even with a limited width for the power generation module 2, the connection between the third segment 203 of the terminal and the power sub-module on the power generation module 2 can be accommodated.

[0130] like Figure 11 As shown, the second segment 2022 of the terminal has a protrusion 20221 extending along the width direction of the terminal at the position where it connects with the first segment 201 of the terminal. When the second power terminal 200 and the magnetic core structure 210 of the second current sensor are integrally injection molded, the protrusion 20221 can be locked onto the magnetic core structure along the Y direction, increasing the reliability during injection molding.

[0131] The above embodiments describe a second power terminal 200 with an unequal width design and a matching small magnetic core, which is adapted to the design of a power generation module 2 integrated on a substrate. It can be seen that in this embodiment, the multiple bridge arms on the drive module 1 are not integrated on a substrate, and the space in the width direction is relatively wider. The first power terminal 100 can be designed with approximately equal width, and the magnetic core structure 110 of the first current sensor can also be set to be larger in size than the magnetic core structure 210 of the second current sensor.

[0132] The power module in this embodiment includes at least two magnetic core structures, including the magnetic core structure of the drive module 1 and the magnetic core structure of the power generation module 2. Each magnetic core structure of the power module is defined to include a first magnetic core end positioned opposite to the circuit board 4, and a second magnetic core end distributed opposite to the first magnetic core end, such as... Figure 12 As shown, the first and second magnetic core ends are distributed along the Z-direction, and the aforementioned opening structure 212 is disposed at the first magnetic core end. Specifically, the first magnetic core ends of at least two magnetic core structures of the power module are flush with each other, and / or the second magnetic core ends of at least two magnetic core structures are flush with each other. For example... Figure 12As shown, the current sensing chip 219 of the current sensor needs to be connected to the circuit board 4. When the first magnetic core end of the magnetic core structure is flush, the terminal that mates with the magnetic core structure is also flush, and the current sensing chip of the current sensor that mates with the terminal and the magnetic core structure is also flush, which facilitates a relatively flush connection with the circuit board 4. Similarly, the second magnetic core end of the magnetic core structure is flush in the height direction, which facilitates the connection with the heat sink 5.

[0133] This application also provides a motor controller, including any of the power modules described above.

[0134] This application also provides an electronic control assembly, including the motor controller described above.

[0135] Furthermore, this application also provides a vehicle including the electronic control assembly described above.

[0136] It should be noted that the various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to interchangeably. Each embodiment focuses on describing the differences from other embodiments. In particular, the descriptions of the motor controller, electric drive assembly, and vehicle embodiments are relatively simple because they are basically similar to the method embodiments; relevant parts can be referred to the descriptions in the method embodiments. The motor controller, electric drive assembly, and vehicle embodiments described above are merely illustrative. Units described as separate components may or may not be physically separate, and components indicated as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without creative effort.

[0137] The above description is merely one specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A power module, characterized in that, It includes a housing, at least one magnetic core structure and at least one terminal, at least a portion of the magnetic core structure is nested within the housing (3), and at least one terminal is provided with the magnetic core structure.

2. The power module according to claim 1, characterized in that, At least one of the terminals is at least partially nested within the housing (3).

3. The power module according to claim 2, characterized in that, At least one of the terminals is provided with only one of the magnetic core structures; At least a portion of each of the terminals is nested within the housing (3); and / or at least a portion of each of the magnetic core structures is nested within the housing (3).

4. The power module according to any one of claims 2-3, characterized in that, The magnetic core structure has a receiving cavity (211). The terminal includes a first segment (201), wherein at least a portion of the first segment (201) is located in the receiving cavity (211).

5. The power module according to claim 4, characterized in that, The terminal also includes a second terminal segment (202), wherein the first terminal segment (201) and the second terminal segment (202) are distributed along the length direction of the terminal, and the width of the first terminal segment (201) is smaller than the width of the second terminal segment (202).

6. The power module according to claim 5, characterized in that, The second segment (202) of the terminal also includes a first sub-segment (2021) of the terminal. The first segment (201) and the first sub-segment (2021) of the terminal are distributed along the length direction of the terminal. The width of the first sub-segment (2021) of the terminal is greater than the width of the first segment (201) of the terminal. The first sub-segment of the terminal is provided with a connecting hole (2022a).

7. The power module according to claim 6, characterized in that, The second segment (202) of the terminal also includes a second sub-segment (2022), the second segment (201) and the second sub-segment (2022) of the terminal are distributed along the length direction of the terminal, and the width of the second sub-segment (2022) of the terminal is greater than the width of the first segment (201) of the terminal.

8. The power module according to claim 7, characterized in that, The second sub-segment (2022) of the terminal is located between the first segment (201) of the terminal and the first sub-segment (2021) of the terminal.

9. The power module according to any one of claims 4-8, characterized in that, The terminal also includes a third terminal segment (203) connected to the first terminal segment (201), the third terminal segment (203) being used to connect to the power submodule of the power module, and the width of the third terminal segment (203) being greater than the width of the first terminal segment (201).

10. The power module according to claim 9, characterized in that, The center line (O1) of the third segment (203) of the terminal and the center line (O2) of the first segment (201) of the terminal extend along the length direction of the terminal, and the center line (O1) of the third segment (203) of the terminal and the center line (O2) of the first segment (201) of the terminal are staggered in the width direction of the terminal.

11. The power module according to any one of claims 1-10, characterized in that, The power module includes at least two magnetic core structures, each magnetic core structure including a first magnetic core end disposed opposite to the circuit board and a second magnetic core end disposed opposite to the first magnetic core end, the first magnetic core ends of at least two magnetic core structures being flush with each other and / or the second magnetic core ends of at least two magnetic core structures being flush with each other.

12. The power module according to any one of claims 1-11, characterized in that, The power module includes a drive module for connection to a drive motor and a power generation module for connection to a generator motor.

13. The power module according to claim 12, characterized in that, The magnetic core structure includes a first magnetic core end disposed opposite to the circuit board, and a second magnetic core end distributed opposite to the first magnetic core end; At least one of the first magnetic core ends of the power generation module and at least one of the first magnetic core ends of the drive module are arranged flush with each other, and / or at least one of the second magnetic core ends of the power generation module and at least one of the second magnetic core ends of the drive module are arranged flush with each other.

14. The power module according to claim 12 or 13, characterized in that, The power generation module includes at least two power sub-modules, and at least two of the power sub-modules share the same liner.

15. The power module according to any one of claims 1-10, characterized in that, The magnetic core structure includes a first magnetic core end for being disposed opposite to the circuit board, the first magnetic core end having an opening structure for accommodating at least a portion of the current sensor.

16. The power module according to claim 12, characterized in that, The cross-sectional area of ​​at least one magnetic core structure of the drive module is greater than the cross-sectional area of ​​at least one magnetic core structure of the power generation module.

17. The power module according to claim 16, characterized in that, The magnetic core structure of the drive module and the magnetic core structure of the power generation module each include width, thickness, and height, and the directions of width, thickness, and height are perpendicular to each other. At least one of the following conditions must be met: The width of at least one magnetic core structure of the drive module is greater than the width of at least one magnetic core structure of the power generation module; The thickness of at least one magnetic core structure of the drive module is greater than the thickness of at least one magnetic core structure of the power generation module.

18. The power module according to claim 17, characterized in that, The height of at least one magnetic core structure of the drive module is equal to the height of at least one magnetic core structure of the power generation module.

19. The power module according to any one of claims 1-18, characterized in that, The width of the opening in the magnetic core structure is less than or equal to 6 mm.

20. The power module according to any one of claims 1-19, characterized in that, The height of the magnetic core structure is less than or equal to 21 mm.

21. The power module according to claim 20, characterized in that, The height of the magnetic core structure is greater than or equal to 6 mm and less than or equal to 8 mm.

22. The power module according to any one of claims 1-21, characterized in that, The width of the magnetic core structure is greater than or equal to 12 mm and less than or equal to 15 mm.

23. The power module according to any one of claims 1-22, characterized in that, The distance between two adjacent terminals in the width direction is greater than or equal to 15mm and less than or equal to 18mm.

24. The power module according to any one of claims 1-23, characterized in that, The housing (3) is formed by injection molding.

25. A motor controller, characterized in that, Includes the power module as described in any one of claims 1-24.

26. An electric drive assembly, characterized in that, Includes the motor controller described in claim 25 above.

27. A vehicle, characterized in that, Includes the electric drive assembly described in claim 26 above.

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