A controller for an electric motor
Patent Information
- Application Number
- CN202522277910.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-28
- Publication Date
- 2026-09-22
- Estimated Expiration
- 2035-10-28
AI Technical Summary
进一步的，功率回路与信号回路的线缆可能长距离并行，导致强电与弱电间产生严重电磁干扰，影响采样精度与控制稳定性
[0024]提供了一种电机用控制器，包括壳体以及安装于壳体的驱动板、信号采集板、环形电容、高压滤波板、低压滤波板和第一端盖。其中，驱动板包括第一板主体和功率模块，功率模块设置有偶数块，多块功率模块绕第一板主体的周向边缘排布安装；信号采集板位于驱动板于第一方向的一侧，且与驱动板电性连接；环形电容位于驱动板背对信号采集板一侧，与功率模块通过铜排连接；高压滤波板内嵌于环形电容内；低压滤波板与驱动板电性连接，低压滤波板与高压滤波板于第一方向间隔设置；第一端盖与壳体固定，夹设于低压滤波板与高压滤波板之间。
Smart Images
Figure CN224790897U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of controller technology, and in particular to a controller for motors. Background Technology
[0002] Currently, motor controllers are developing towards higher power density and higher reliability. Existing controllers typically contain multiple functional modules, such as high-voltage filter boards, toroidal capacitors, driver boards, and signal acquisition boards. These modules are generally electrically connected using methods such as flying wires, independent wiring harnesses, or flexible PCBs.
[0003] However, complex wiring occupies a lot of space, hindering the miniaturization and compact design of controllers, and messy cables can easily lead to assembly errors. Discrete wiring harnesses introduce too many connection points and connectors, which not only increase contact resistance but also become potential failure points, reducing system reliability. Furthermore, power circuit and signal circuit cables may run in parallel over long distances, causing severe electromagnetic interference between high-voltage and low-voltage circuits, affecting sampling accuracy and control stability.
[0004] Therefore, there is an urgent need for a controller for motors to solve the above-mentioned technical problems. Utility Model Content
[0005] The purpose of this invention is to provide a controller for motors that is compact in structure, occupies little space, and reduces the connection paths between various functional modules.
[0006] To achieve this objective, the present invention adopts the following technical solution:
[0007] The controller for the motor includes a housing and a component mounted on the housing:
[0008] The drive board includes a first board body and power modules. An even number of power modules are provided, and multiple power modules are arranged and installed around the circumferential edge of the first board body.
[0009] The signal acquisition board is located on one side of the aforementioned driving board in the first direction and is electrically connected to the aforementioned driving board;
[0010] A ring capacitor is located on the side of the drive board opposite to the signal acquisition board and is connected to the power module via a copper busbar.
[0011] The high-voltage filter board is embedded within the aforementioned ring capacitor;
[0012] The low-voltage filter board is electrically connected to the aforementioned drive board, and the low-voltage filter board and the aforementioned high-voltage filter board are spaced apart in the aforementioned first direction;
[0013] The first end cap is fixed to the aforementioned housing and sandwiched between the aforementioned low-voltage filter plate and the aforementioned high-voltage filter plate.
[0014] As a preferred technical solution for the aforementioned motor controller, two high-voltage filter boards are provided, and an isolation wall is formed inside the aforementioned annular capacitor. The isolation wall separates the two aforementioned high-voltage filter boards on both sides of a second direction; the aforementioned first direction is perpendicular to the aforementioned second direction.
[0015] As a preferred technical solution for the aforementioned motor controller, it includes multiple power supply circuits, multiple control circuits, and multiple communication circuits. The multiple power supply circuits, the multiple control circuits, and the multiple communication circuits are all designed to be redundant with each other.
[0016] As a preferred technical solution for the aforementioned motor controller, the outer wall contour of the aforementioned housing is annular.
[0017] As a preferred technical solution for the aforementioned motor controller, the power module is in close contact with the inner wall of the housing, forming a surface contact between them.
[0018] As a preferred technical solution for the aforementioned motor controller, the power module is mounted on the inner wall of the aforementioned housing via a compression spring.
[0019] As a preferred technical solution for the aforementioned motor controller, it further includes a second end cover, which is located on the side of the low-voltage filter board opposite to the high-voltage filter board. The second end cover is provided with a communication interface and a power interface, and the high-voltage filter board and the low-voltage filter board are respectively connected to the communication interface and / or the power interface.
[0020] As a preferred technical solution for the aforementioned motor controller, the power module has a first copper busbar formed on the side facing the first main board. The edge of the first main board is provided with a clearance groove. The drive board also includes a phase line parallel copper busbar. The signal acquisition board includes a second main board. The circumferential edge of the second main board is provided with a clearance hole. One end of the phase line parallel copper busbar passes through the clearance groove and connects to the first copper busbar. The other end of the phase line parallel copper busbar is used to connect to the phase line fixing seat of the controller through a threaded fastener. The threaded fastener passes through the clearance hole. The clearance hole is provided with a current sensor for collecting the phase line current.
[0021] As a preferred technical solution for the aforementioned motor controller, the power module has a second copper busbar on the side facing away from the first main plate, and the second copper busbar is connected to the third copper busbar of the aforementioned annular capacitor.
[0022] As a preferred technical solution for the aforementioned motor controller, the aforementioned high-voltage filter board is installed inside the aforementioned annular capacitor using threaded fasteners.
[0023] The beneficial effects of this utility model are:
[0024] A controller for a motor is provided, including a housing and a drive board, a signal acquisition board, a ring capacitor, a high-voltage filter board, a low-voltage filter board, and a first end cover mounted on the housing. The drive board includes a first board body and power modules, with an even number of power modules arranged around the circumferential edge of the first board body. The signal acquisition board is located on one side of the drive board in a first direction and is electrically connected to the drive board. The ring capacitor is located on the side of the drive board opposite to the signal acquisition board and is connected to the power modules via a copper busbar. The high-voltage filter board is embedded within the ring capacitor. The low-voltage filter board is electrically connected to the drive board, and the low-voltage filter board and the high-voltage filter board are spaced apart in the first direction. The first end cover is fixed to the housing and sandwiched between the low-voltage filter board and the high-voltage filter board.
[0025] Along the first direction, the signal acquisition board, driver board, ring capacitor, high-voltage filter board, first end cover, and low-voltage filter board are arranged sequentially. The ring capacitor is located on the side of the driver board opposite to the signal acquisition board and is connected to the power module via a copper busbar; the ring capacitor is electrically connected to the driver board on the other side of the first direction, and the high-voltage filter board is installed inside the ring capacitor via filter copper busbar terminals. The first end cover isolates the high-voltage filter board from the low-voltage filter board. This design achieves a compact controller structure with a small footprint, and facilitates disassembly and maintenance during assembly. Attached Figure Description
[0026] Figure 1 This is an exploded view of the motor controller provided in this embodiment of the utility model;
[0027] Figure 2 This is a schematic diagram of the structure of the driver board provided in this embodiment of the utility model. Figure 1 ;
[0028] Figure 3 This is a schematic diagram of the structure of the driver board provided in this embodiment of the utility model. Figure 2 ;
[0029] Figure 4 This is a schematic diagram of the structure of the signal acquisition board provided in this embodiment of the utility model;
[0030] Figure 5 This is an assembly diagram of the phase line parallel copper busbar and the phase line mounting base provided in this embodiment of the utility model;
[0031] Figure 6 This is a schematic diagram of the structure of the ring capacitor provided in this embodiment of the utility model;
[0032] Figure 7 This is a schematic diagram of the high-voltage filter board provided in this embodiment of the utility model;
[0033] Figure 8This is a schematic diagram of the structure of the low-voltage filter board provided in this embodiment of the utility model.
[0034] In the picture:
[0035] 1. Shell;
[0036] 2. Drive board; 21. First board body; 211. Clearance groove; 22. Power module; 221. First copper busbar; 222. Second copper busbar; 23. Compression spring; 24a. First drive circuit; 24b. Second drive circuit; 25. Phase line parallel copper busbar;
[0037] 3. Signal acquisition board; 31a. First signal acquisition circuit; 31b. Second signal acquisition circuit; 32. Main body of the second board; 33. Current sensor;
[0038] 4. Ring capacitor; 41. Isolation wall; 42. Third copper busbar;
[0039] 5. High-voltage filter board; 51a. First high-voltage filter circuit; 51b. Second high-voltage filter circuit; 52. Filter copper busbar terminals;
[0040] 6. Low-voltage filter board; 61a. First low-voltage filter circuit; 61b. Second low-voltage filter circuit;
[0041] 71. First end cap; 72. Second end cap;
[0042] 8. Phase wire mounting bracket. Detailed Implementation
[0043] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.
[0044] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions. Moreover, "above," "on top of," and "over" the first feature in relation to the second feature includes the first feature directly above and diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "under," and "below" the first feature in relation to the second feature includes the first feature directly below and diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.
[0045] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0046] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.
[0047] like Figure 1 As for Figure 8As shown, this application provides a controller for a motor, including a housing 1 and a drive board 2, a signal acquisition board 3, a ring capacitor 4, a high-voltage filter board 5, a low-voltage filter board 6, and a first end cover 71 mounted on the housing 1. The drive board 2 includes a first board body 21 and power modules 22, with an even number of power modules 22 arranged around the circumferential edge of the first board body 21. The signal acquisition board 3 is located on one side of the drive board 2 in a first direction and is electrically connected to the drive board 2. The ring capacitor 4 is located on the side of the drive board 2 opposite to the signal acquisition board 3 and is connected to the power modules 22 via a copper busbar. The high-voltage filter board 5 is embedded within the ring capacitor 4. The low-voltage filter board 6 is electrically connected to the drive board 2, and the low-voltage filter board 6 and the high-voltage filter board 5 are spaced apart in the first direction. The first end cover 71 is fixed to the housing 1 and sandwiched between the low-voltage filter board 6 and the high-voltage filter board 5.
[0048] For example, along the first direction, the signal acquisition board 3, the driver board 2, the ring capacitor 4, the high-voltage filter board 5, the first end cover 71, and the low-voltage filter board 6 are arranged sequentially. The ring capacitor 4 is located on the side of the driver board 2 opposite to the signal acquisition board 3 and is connected to the power module 22 via a copper busbar; the ring capacitor 4 is electrically connected to the driver board 2 on the other side of the first direction, and the high-voltage filter board 5 is installed inside the ring capacitor 4 via the filter copper busbar terminal 52. The first end cover 71 isolates the high-voltage filter board 5 from the low-voltage filter board 6. This achieves a compact controller structure with a small footprint, and facilitates disassembly and maintenance during assembly.
[0049] For example, the driver board 2 is used to amplify the weak logic level signal emitted from the control terminal to a level sufficient to drive the voltage and current of the power device. For example, the driver board 2 is provided with a first driving circuit 24a and a second driving circuit 24b.
[0050] For example, the signal acquisition board 3 is a dedicated circuit board specifically designed for the high-precision and high-reliability acquisition, conditioning, isolation, and conversion of various analog and digital signals. For example, the signal acquisition board 3 includes a first signal acquisition circuit 31a and a second signal acquisition circuit 31b.
[0051] For example, the toroidal capacitor 4 is used to effectively filter out noise on the wires.
[0052] For example, the high-voltage filter board 5 and the low-voltage filter board 6 are designed to allow current / signals within a specific frequency range to pass through, while significantly attenuating or blocking components within other frequency ranges. For example, the high-voltage filter board 5 includes a first high-voltage filter circuit 51a and a second high-voltage filter circuit 51b. Illustratively, the low-voltage filter board 6 includes a first low-voltage filter circuit 61a and a second low-voltage filter circuit 61b.
[0053] Optionally, the ring capacitor 4 is a high-voltage support capacitor, which is composed of two independent, semi-circular capacitors, and the two capacitors share a metal casing.
[0054] Optionally, two high-voltage filter boards 5 are provided, and an isolation wall 41 is formed inside the annular capacitor 4. The isolation wall 41 separates the two high-voltage filter boards 5 on both sides of the second direction; the first direction is perpendicular to the second direction.
[0055] For example, a circular cavity is formed in the middle of the ring capacitor 4, and an isolation wall 41 is formed in the circular cavity. The isolation wall 41 is parallel to the first direction and divides the circular cavity into two sub-cavities distributed in sequence in the second direction. The second direction is perpendicular to the first direction. Two high-voltage filter plates 5 are placed in one-to-one correspondence with the two sub-cavities.
[0056] In this way, physical isolation between the two high-voltage filter boards 5 is achieved.
[0057] Optionally, the motor controller includes multiple power supply circuits, multiple control circuits, and multiple communication circuits. The power supply circuits, control circuits, and communication circuits are all redundantly designed.
[0058] For example, the redundant design of the power supply circuit ensures that if one power source fails, the other can immediately take over the entire load, guaranteeing uninterrupted power supply and continuous operation of the controller. Furthermore, the two power sources can come from different power grids or batteries, preventing system crashes caused by fluctuations, drops, or interruptions in a single power grid. The redundant design of the control circuit allows the backup control circuit to take over control in a very short time when the main control circuit fails, maintaining the continuity of the output signal and preventing production interruptions or equipment malfunctions. The two control circuits can monitor each other's operating status, enabling rapid self-diagnosis and fault location. The redundant design of the communication circuit ensures that if one communication circuit experiences an open circuit, short circuit, or interference, the other circuit can immediately take over the communication task, ensuring uninterrupted data exchange between the controller and the upper-level monitoring system and other devices.
[0059] Optionally, the outer wall of the housing 1 has an annular profile.
[0060] For example, since the edge contour of the motor housing is generally circular, in order to ensure that the controller and motor are assembled and their shapes can be adapted and the overall layout is symmetrical, the outer wall contour of the controller housing 1 is set to be circular.
[0061] Optionally, the power module 22 is tightly attached to the inner wall of the housing 1, forming a surface contact. This arrangement maximizes heat dissipation efficiency, ensuring that the junction temperature of the power module 22 remains within a safe range, thereby guaranteeing the reliability and output capability of the system.
[0062] Indicatively, with this configuration, the heat generated by the internal chip of power module 22 passes sequentially through the module substrate, thermally conductive interface material, and housing 1 before exchanging heat with the cooling medium. The close surface contact greatly increases the contact area for heat conduction, significantly reducing the thermal resistance from the module substrate to the housing 1. The lower the thermal resistance, the higher the heat dissipation efficiency, which also means that under the same losses, the junction temperature of the module will be lower.
[0063] Furthermore, if a gap exists between the power module 22 and the housing 1, localized hot spots will form. The temperature at these points is much higher than the average temperature, which is the starting point for thermal breakdown of the module. Surface contact ensures that heat can be evenly dissipated from the entire module substrate, avoiding localized overheating.
[0064] Furthermore, the power module 22 is typically heavy and may be subject to vibration. A tight surface contact with the housing 1 provides robust mechanical support, preventing the module from loosening or damaging the leads due to vibration.
[0065] Optionally, the power module 22 is mounted to the inner wall of the housing 1 via a compression spring 23. The compression spring 23 ensures that the power module 22 always tends to be pressed tightly against the inner wall of the housing 1. Since the power module 22 generates a large amount of heat during operation, and its substrate and housing 1 are made of different materials—typically copper or aluminum silicon carbide for the substrate and aluminum for the housing 1—their coefficients of thermal expansion differ. When the temperature changes, the expansion and contraction of the two materials are inconsistent. Compared to using threaded fasteners, the compression spring 23 provides a continuous and retractable clamping force. When the module and housing 1 experience relative displacement due to their different coefficients of thermal expansion, the compression spring 23 can compress or rebound, adapting to this change, thereby absorbing stress, maintaining the contact pressure within a safe range, and greatly extending the module's lifespan.
[0066] Optionally, the motor controller also includes a second end cover 72, which is located on the side of the low-voltage filter board 6 facing away from the high-voltage filter board 5. The second end cover 72 has a communication interface and a power interface, and the high-voltage filter board 5 and the low-voltage filter board 6 are respectively connected to the communication interface and / or the power interface.
[0067] For example, communication interfaces (such as RS485, CAN bus) and power interfaces are located on one side of the controller for easy installation and maintenance.
[0068] For example, the communication interface includes a low-voltage communication interface, the power interface includes a high-voltage power interface and a low-voltage power interface, the high-voltage filter board 5 is connected to the high-voltage power interface, and the low-voltage filter board 4 is connected to the low-voltage communication interface and the low-voltage power interface.
[0069] Optionally, the power module 22 has a first copper busbar 221 formed on the side facing the first board body 21. The edge of the first board body 21 is provided with a clearance groove 211. The drive board 2 also includes a phase line parallel copper busbar 25. The signal acquisition board 3 includes a second board body 32. The circumferential edge of the second board body 32 is provided with a clearance hole. One end of the phase line parallel copper busbar 25 passes through the clearance groove 211 and is connected to the first copper busbar 221. The other end of the phase line parallel copper busbar 25 is used to connect to the phase line fixing seat 8 of the controller through a threaded fastener. The threaded fastener passes through the clearance hole. The clearance hole is provided with a current sensor 33 for collecting the phase line current.
[0070] For example, the second plate body 32 is sandwiched between the phase line parallel copper busbar 25 and the phase line fixing seat 8.
[0071] In this way, the power module 22 and the signal acquisition board 3 can be connected through a relatively short path and with low inductance.
[0072] Optionally, the power module 22 has a second copper busbar 222 on the side facing away from the first board body 21, and the second copper busbar 222 is connected to the third copper busbar 42 of the ring capacitor 4.
[0073] In this way, the power module 22 and the toroidal capacitor 4 can be connected through a relatively short path and with low inductance.
[0074] Optionally, the high-voltage filter board 5 is installed inside the annular capacitor 4 using threaded fasteners.
[0075] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.
Claims
1. A controller for an electric motor, characterized in that, Includes a housing (1) and components mounted on the housing (1): The drive board (2) includes a first board body (21) and a power module (22). The power module (22) is provided with an even number of blocks, and multiple power modules (22) are arranged and installed around the circumferential edge of the first board body (21). The signal acquisition board (3) is located on one side of the drive board (2) in the first direction and is electrically connected to the drive board (2); A ring capacitor (4) is located on the side of the drive board (2) facing away from the signal acquisition board (3) and is connected to the power module (22) via a copper busbar; The high-voltage filter board (5) is embedded in the ring capacitor (4); The low-voltage filter board (6) is electrically connected to the drive board (2), and the low-voltage filter board (6) and the high-voltage filter board (5) are spaced apart in the first direction; The first end cap (71) is fixed to the housing (1) and sandwiched between the low-voltage filter plate (6) and the high-voltage filter plate (5).
2. The controller for a motor according to claim 1, characterized in that, Two high-voltage filter boards (5) are provided. An isolation wall (41) is formed inside the annular capacitor (4). The isolation wall (41) separates the two high-voltage filter boards (5) on both sides of a second direction. The first direction is perpendicular to the second direction.
3. The controller for a motor according to claim 2, characterized in that, It includes multiple power supply circuits, multiple control circuits, and multiple communication circuits. The multiple power supply circuits, the multiple control circuits, and the multiple communication circuits are all designed to be redundant with each other.
4. The controller for a motor according to claim 1, characterized in that, The outer wall of the shell (1) has a circular outline.
5. The controller for a motor according to claim 1, characterized in that, The power module (22) is in close contact with the inner wall of the housing (1), and the two form a surface contact.
6. The controller for a motor according to claim 4, characterized in that, The power module (22) is mounted on the inner wall of the housing (1) by a compression spring (23).
7. The controller for a motor according to claim 1, characterized in that, It also includes a second end cap (72), which is located on the side of the low-voltage filter board (6) facing away from the high-voltage filter board (5). The second end cap (72) has a communication interface and a power interface. The high-voltage filter board (5) and the low-voltage filter board (6) are respectively connected to the communication interface and / or the power interface.
8. The controller for a motor according to claim 1, characterized in that, The power module (22) has a first copper busbar (221) on one side facing the first board body (21). The edge of the first board body (21) is provided with a clearance groove (211). The drive board (2) also includes a phase line parallel copper busbar (25). The signal acquisition board (3) includes a second board body (32). The circumferential edge of the second board body (32) is provided with a clearance hole. One end of the phase line parallel copper busbar (25) passes through the clearance groove (211) and is connected to the first copper busbar (221). The other end of the phase line parallel copper busbar (25) is used to connect with the phase line fixing seat (8) of the controller through a threaded fastener. The threaded fastener passes through the clearance hole. The clearance hole is provided with a current sensor (33) for collecting the phase line current.
9. The controller for a motor according to claim 1, characterized in that, The power module (22) has a second copper busbar (222) on the side opposite to the first plate body (21), and the second copper busbar (222) is connected to the third copper busbar (42) of the annular capacitor (4).
10. The controller for a motor according to claim 1, characterized in that, The high-voltage filter board (5) is installed inside the annular capacitor (4) by threaded fasteners.