An electric vehicle motor controller

Abstract

The utility model relates to an electric automobile motor controller, including controller casing, the heat conduction pad, support and the fuse, magnetic ring, positive copper row, negative copper row, ground copper row and filter board of installing in support are equipped in controller casing, support is installed on controller casing through the mounting surface, the fuse is connected with positive copper row, and positive copper row and negative copper row pass through magnetic ring, and ground copper row is welded with filter board, filter board is fixed on the support and is located between support and controller casing, and one side welding filter capacitor of filter board, the other side welding discharge resistance, heat conduction pad is installed between discharge resistance and controller casing and is contacted with controller casing. Compared with prior art, the utility model has discharge resistance and filter capacitor integration on the same filter board, and discharge resistance, fuse and DC filter are integrated in the same component, effectively improve the integration of motor controller DC side component, thereby compress the whole machine volume and so on advantage.

Description

Technical Field

[0001] This utility model relates to electric vehicles, and more particularly to an electric vehicle motor controller. Background Technology

[0002] The motor controller is one of the core components of an electric vehicle. Due to the limited space available for its placement within the vehicle, the controller must be compact in structure, size, and weight. The high-voltage DC terminal of an electric vehicle motor controller typically includes a DC filter, discharge resistor, and fuse. These components are usually independently assembled inside the controller housing, resulting in low integration levels, inconvenient assembly, and an excessively large controller size that fails to meet the vehicle's internal assembly space requirements.

[0003] like Figure 1 As shown, in conventional motor controllers, the discharge resistor is typically a separate device fixed to the housing, with its two ends connected to the positive and negative copper busbars respectively via wiring harnesses. This type of discharge resistor is inherently expensive, and since it is not integrated with the DC filter, it occupies considerable space, leading to inconvenient component assembly, a larger overall controller size, and increased overall cost.

[0004] like Figure 2 As shown, the filter capacitors on the DC filter are directly fixed to the filter bracket using potting compound. The two leads of the filter capacitors are soldered to the leads on two corresponding copper busbars (which may be the positive, negative, or ground busbars). This design is characterized by a large number of leads on the copper busbars, leading to a complex structure and increased manufacturing costs. Furthermore, the relatively large number of filter capacitors and their dispersed assembly locations, coupled with the non-standardized soldering structure between the filter capacitors and the copper busbar leads, makes automated soldering difficult. Currently, manual soldering is commonly used, resulting in poor assembly consistency and low assembly efficiency.

[0005] Existing technology CN220190839U discloses an adjustable filter structure, including interconnected filter components, copper busbar components, and discharge resistors. The filter components include a filter bracket and a first filter magnetic ring and two magnetic ring brackets mounted on the filter bracket. Each magnetic ring bracket contains a second filter magnetic ring. The copper busbar components pass through the magnetic ring brackets and are mounted on the filter bracket. The filter bracket also has a first pair of Y capacitors and a second pair of Y capacitors. The portion of the filter bracket that mounts the magnetic ring brackets has semi-cylindrical concave stripes; the bottom of the magnetic ring brackets has wavy convex stripes corresponding to the semi-cylindrical concave stripes, and the back of the magnetic ring brackets has an elliptical small concave structure. This mainly achieves the purpose of convenient assembly and disassembly and saving potting compound. However, the integration level of this prior art still needs to be improved.

[0006] In summary, designing a highly integrated electric vehicle motor filter is a technical problem that needs to be solved. Utility Model Content

[0007] The purpose of this invention is to overcome the shortcomings of the existing technology in terms of low integration and to provide an electric vehicle motor controller.

[0008] The objective of this utility model can be achieved through the following technical solutions.

[0009] According to one aspect of this utility model, an electric vehicle motor controller is provided, including a controller housing. The controller housing contains a thermal pad, a bracket, and a fuse, a magnetic ring, a positive copper busbar, a negative copper busbar, a grounding copper busbar, and a filter board mounted on the bracket. The bracket is mounted on the controller housing via a mounting surface. The fuse is connected to the positive copper busbar, and the positive and negative copper busbars pass through the magnetic ring. The grounding copper busbar is welded to the filter board. The filter board is fixed to the bracket and located between the bracket and the controller housing. A filter capacitor is welded to one side of the filter board, and a discharge resistor is welded to the other side. The thermal pad is installed between the discharge resistor and the controller housing and is in contact with the controller housing.

[0010] As a preferred technical solution, the bracket is provided with a magnetic ring potting groove, a fuse mounting base, and a copper busbar through hole; the magnetic ring potting groove is located on the side of the bracket; the fuse mounting base is located on the side opposite to the mounting surface, and the copper busbar through hole penetrates the mounting surface and the side opposite to the mounting surface of the bracket; The number of magnetic rings is the same as the number of magnetic ring potting slots, and the magnetic rings are installed in the magnetic ring potting slots; the fuse is installed in the fuse mounting base; the positive copper busbar and the negative copper busbar pass through the copper busbar through hole.

[0011] As a preferred technical solution, the magnetic ring potting groove includes a primary magnetic ring potting groove and a secondary magnetic ring potting groove located on two opposite sides of the support; the magnetic ring includes a primary magnetic ring and a secondary magnetic ring respectively installed in the primary magnetic ring potting groove and the secondary magnetic ring potting groove.

[0012] As a preferred technical solution, the positive copper busbar includes a primary positive copper busbar and a secondary positive copper busbar, and the negative copper busbar includes a primary negative copper busbar and a secondary negative copper busbar. The primary positive copper busbar and the primary negative copper busbar are fixed on the side of the bracket opposite to the mounting surface and are respectively connected to the secondary positive copper busbar and the secondary negative copper busbar. The secondary positive copper busbar and the secondary negative copper busbar pass through the copper busbar through holes on the side of the bracket; the fuse is connected to the primary positive copper busbar.

[0013] As a preferred technical solution, the secondary positive copper busbar, the secondary negative copper busbar, and the grounding copper busbar are provided with pins, which pass through the filter board and are soldered to the filter board.

[0014] As a preferred technical solution, the grounding copper busbar includes a primary grounding copper busbar and a secondary grounding copper busbar, both of which are fixed on the mounting surface of the bracket.

[0015] As a preferred technical solution, the controller further includes a positive electrode transfer copper busbar and a negative electrode transfer copper busbar. The positive electrode transfer copper busbar and the negative electrode transfer copper busbar are fixed on the side of the bracket opposite to the mounting surface and pass through the bracket. One end is connected to the positive copper busbar and the negative copper busbar respectively, and the other end is connected to the filter board through pins.

[0016] As a preferred technical solution, there are multiple filter capacitors and magnetic rings, and the number of filter capacitors is the same as the number of magnetic rings.

[0017] As a preferred technical solution, the filter capacitor includes a primary filter capacitor and a secondary filter capacitor, and both the primary filter capacitor and the secondary filter capacitor include one or more X capacitors and one or more Y capacitors; the discharge resistor is multiple and the multiple discharge resistors are connected in series.

[0018] As a preferred technical solution, the thermal pad contains a polyimide film.

[0019] Compared with the prior art, the present invention has the following beneficial effects.

[0020] 1) This utility model integrates the discharge resistor and filter capacitor on the same filter board, and also integrates the discharge resistor, fuse, and DC filter into the same component, effectively improving the integration of the DC side components of the motor controller, thereby reducing the overall size. The magnetic ring and filter capacitor can filter out high-frequency noise and voltage fluctuations in the DC power supply, ensuring a stable DC voltage supplied to the motor controller. The thermal pad is located between the discharge resistor and the controller housing and is in contact with the controller housing, transferring the heat from the discharge resistor to the controller housing.

[0021] 2) The magnetic ring of this utility model can be multiple. The primary filter capacitor and the secondary filter capacitor both include one or more X capacitors and one or more Y capacitors. The X capacitors and Y capacitors can be adjusted according to specific EMC requirements, and the application range is wide.

[0022] 3) This utility model uses multiple small-value discharge resistors connected in series and integrated on the filter board, which has the advantages of lower cost and simpler assembly compared to a large-value discharge resistor that is fixed separately on the box.

[0023] 4) The thermal pad of this utility model has an internal polyimide film (PI film) to prevent the thermal pad from being punctured, which would lead to poor insulation. Attached Figure Description

[0024] Figure 1This is a schematic diagram of the structure of a conventional motor controller in the prior art.

[0025] Figure 2 This is a schematic diagram of the structure of a filter component in the prior art.

[0026] Figure 3 This is a schematic diagram of the first structure inside the controller housing of this utility model.

[0027] Figure 4 This is a schematic diagram of the second structure inside the controller housing of this utility model.

[0028] Figure 5 This is a schematic diagram of the first structure of the bracket of this utility model.

[0029] Figure 6 This is a schematic diagram of the second structure of the bracket of this utility model.

[0030] Figure 7 This is a schematic diagram of the first surface structure of the filter plate of this utility model.

[0031] Figure 8 This is a schematic diagram of the second surface structure of the filter plate of this utility model.

[0032] The numbers in the diagram are as follows: 1. Thermal pad; 2. Bracket; 20. Primary magnetic ring potting groove; 21. Secondary magnetic ring potting groove; 22. Fuse mounting bracket; 23. Secondary copper busbar perforation; 24. Adapter copper busbar perforation; 3. Fuse; 40. Primary magnetic ring; 41. Secondary magnetic ring; 50. Primary positive copper busbar; 51. Secondary positive copper busbar; 60. Primary negative copper busbar; 61. Secondary negative copper busbar; 70. Primary grounding copper busbar; 71. Secondary grounding copper busbar; 8. Filter board; 80. Primary filter capacitor. 81. Secondary filter capacitor; 82. Discharge resistor; 90. Positive terminal connecting copper busbar; 91. Negative terminal connecting copper busbar; 101. Existing discharge resistor; 102. Existing DC filter; 103. Existing fuse; 104. Existing first grounding copper busbar; 105. Existing secondary filter capacitor; 106. Existing positive copper busbar; 107. Existing positive copper busbar pin; 108. Existing primary filter capacitor; 109. Existing second grounding copper busbar; 110. Existing negative copper busbar. Detailed Implementation

[0033] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present utility model. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present utility model.

[0034] This utility model provides an electric vehicle motor controller, including a controller housing, such as... Figure 3 and Figure 4 As shown, a thermal pad 1 and a bracket 2 are installed inside the controller housing. A fuse 3, a magnetic ring, a positive copper busbar, a negative copper busbar, a grounding copper busbar, a transition copper busbar, and a filter board 8 are mounted on the bracket 2. The magnetic ring includes a primary magnetic ring 40 and a secondary magnetic ring 41; the positive copper busbar includes a primary positive copper busbar 50 and a secondary positive copper busbar 51; the negative copper busbar includes a primary negative copper busbar 60 and a secondary negative copper busbar 61; the grounding copper busbar includes a primary grounding copper busbar 70 and a secondary grounding copper busbar 71; and the transition copper busbar includes a positive transition copper busbar 90 and a negative transition copper busbar 91. The magnetic ring and filter capacitor shown in the figure have two stages (primary and secondary). However, in actual implementation, the number of stages for the magnetic ring and filter capacitor can be adjusted according to specific EMC (Electromagnetic Compatibility) requirements, and can be primary, secondary, tertiary, etc., as long as the number of stages remains consistent.

[0035] like Figure 5 and Figure 6 As shown, the bracket 2 is provided with a magnetic ring potting groove, a fuse mounting base 22, and copper busbar through holes. The magnetic ring potting groove includes a primary magnetic ring potting groove 20 and a secondary magnetic ring potting groove 21. The copper busbar through holes include a secondary copper busbar through hole 23 and a transition copper busbar through hole 24. The primary magnetic ring potting groove 20 and the secondary magnetic ring potting groove 21 are located on the front and rear sides of the bracket 2, respectively. The copper busbar through hole penetrates through the top surface of the bracket 2, connecting the top and bottom surfaces. The secondary copper busbar through hole 23 is close to the secondary magnetic ring potting groove 21 and penetrates through the front side of the bracket 2. The fuse mounting base 22 is located at the top of the bracket 2.

[0036] The primary magnetic ring 40 and the secondary magnetic ring 41 are respectively encapsulated in the primary magnetic ring encapsulation groove 20 and the secondary magnetic ring encapsulation groove 21 of the bracket 2. The secondary positive copper busbar 51 and the secondary negative copper busbar 61 pass through the secondary copper busbar through hole 23 located on the rear side of the bracket 2. The positive and negative adapter copper busbars 90 and 91 are installed on the top surface of the bracket 2 and pass through the bracket 2, so that the copper busbar pins protrude from the bottom surface of the bracket 2. The primary negative copper busbar 60 and the primary positive copper busbar 50 are fixed on the top surface of the bracket 2 and are respectively connected to the secondary positive copper busbar 51 and the secondary negative copper busbar 61. The fuse 3 is fixed in the fuse mounting base 22 of the bracket 2, and one end of the fuse 3 is connected to the primary positive copper busbar 50. The primary grounding copper busbar 70 and the secondary grounding copper busbar 71 are both fixed on the bottom surface of the bracket 2.

[0037] The filter board 8 is fixed to the bottom of the bracket 2 with its front side facing down. The secondary positive copper busbar 51, the secondary negative copper busbar 61, the primary grounding copper busbar 70 and the secondary grounding copper busbar 71 are all equipped with pins. The pins must pass through the filter board 8 and be welded to the filter board 8.

[0038] like Figure 7 and Figure 8 As shown, the front of the filter board 8 is soldered with a primary filter capacitor 80 and a secondary filter capacitor 81, and each stage of the filter capacitor includes several X capacitors and Y capacitors; the back of the filter board 8 is soldered with several discharge resistors 82. Each stage of the filter capacitor in the figure has two pairs of Y capacitors and one X capacitor. However, in actual implementation, the number and specifications of the Y and X capacitors in each stage of the filter capacitor can be adjusted according to specific EMC (Electromagnetic Compatibility) requirements.

[0039] The thermal pad 1 is placed directly below the discharge resistor 82, with its other side pressed against the controller housing, thereby transferring the heat from the discharge resistor 82 to the controller housing. The interior of the thermal pad 1 has a PI film (polyimide film) to prevent the thermal pad 1 from being punctured, which would lead to poor insulation.

[0040] The installation process of this utility model is as follows: First, the primary magnetic ring 40 and the secondary magnetic ring 41 are respectively encapsulated in the primary magnetic ring encapsulation groove 20 and the secondary magnetic ring encapsulation groove 21 of the bracket 2 using potting compound.

[0041] After the adhesive has cured, fix the positive electrode adapter copper busbar 90 and the negative electrode adapter copper busbar 91 from the front of the bracket 2 with screws, and make the copper busbar pins protrude from the bottom of the bracket 2.

[0042] The primary negative copper busbar 60 and the primary positive copper busbar 50 are fixed to the top surface of the bracket 2 with screws, and connected to the secondary positive copper busbar 51 and the secondary negative copper busbar 61 respectively.

[0043] The primary grounding copper busbar 70 and the secondary grounding copper busbar 71 are fixed to the bottom of the bracket 2 with screws.

[0044] With the front of the filter board 8 facing down, fix it to the bottom of the bracket 2 with screws, and ensure that the pins of all secondary positive copper busbars 51, secondary negative copper busbars 61, primary grounding copper busbars 70 and secondary grounding copper busbars 71 pass through the filter board 8. Then, solder these pins onto the filter board 8.

[0045] Install fuse 3 in fuse mounting bracket 22 of bracket 2, and then connect one end of fuse 3 to primary positive copper busbar 50 with screws.

[0046] In this embodiment, the magnetic ring is fixed to the bracket 2 by potting adhesive. However, in actual implementation, the magnetic ring can also be fixed by dispensing adhesive, or it can be encapsulated inside the bracket 2 during mass production.

[0047] In operation, the DC bus passes through the first-stage magnetic ring 40 and is connected to the first-stage positive copper busbar 50 and the first-stage negative copper busbar 60 respectively. The DC power from the electric vehicle battery pack passes sequentially through the two-stage magnetic rings and two-stage filter capacitors of the DC filter, allowing the DC filter to filter out high-frequency noise and voltage fluctuations in the DC power supply, ensuring a stable DC voltage supplied to the motor controller. The discharge resistor 82 can quickly release the energy stored in the capacitor after the motor controller is powered off. This avoids safety hazards caused by high voltage remaining in the capacitor during maintenance or repair, ensuring personnel safety. The fuse 3 is connected to a branch line of the DC bus and is an overcurrent protection device. When an overload or short circuit occurs in the circuit, the fuse 3 will automatically melt, cutting off the circuit and protecting the motor controller and other electrical components from damage.

[0048] This invention employs multiple small-resistance discharge resistors 82 connected in series and integrated onto a filter board 8. Compared to the existing technology that uses a large-resistance discharge resistor 82 separately fixed to the housing and requires wiring harnesses to connect to the positive and negative copper busbars, this design offers advantages such as lower cost and simpler assembly. The discharge resistor 82 and the filter capacitor are integrated onto the same filter board 8, and the discharge resistor 82, fuse 3, and DC filter are integrated into the same component, effectively improving the integration of the DC-side components of the motor controller and thus reducing the overall size of the device.

[0049] The above description is merely a specific embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this utility model, and these modifications or substitutions should all be covered within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. An electric vehicle motor controller, comprising a controller housing, characterized in that, The controller housing contains a heat-conducting pad (1), a bracket (2), and a fuse (3), a magnetic ring, a positive copper busbar, a negative copper busbar, a grounding copper busbar, and a filter plate (8) mounted on the bracket (2). The bracket (2) is mounted on the controller housing via a mounting surface. The fuse (3) is connected to the positive copper busbar. The positive and negative copper busbars pass through the magnetic ring. The grounding copper busbar is welded to the filter plate (8). The filter plate (8) is fixed on the bracket (2) and located between the bracket (2) and the controller housing. One side of the filter plate (8) is welded with a filter capacitor, and the other side is welded with a discharge resistor (82). The heat-conducting pad (1) is installed between the discharge resistor (82) and the controller housing and is in contact with the controller housing.

2. The electric vehicle motor controller according to claim 1, characterized in that, The bracket (2) is provided with a magnetic ring potting groove, a fuse mounting seat (22) and a copper busbar through hole; the magnetic ring potting groove is located on the side of the bracket (2); the fuse mounting seat (22) is located on the side opposite to the mounting surface, and the copper busbar through hole penetrates the mounting surface and the side opposite to the mounting surface of the bracket (2); The number of magnetic rings is the same as the number of magnetic ring potting slots, and the magnetic rings are installed in the magnetic ring potting slots; the fuse (3) is installed in the fuse mounting base (22); the positive copper busbar and the negative copper busbar pass through the copper busbar through hole.

3. An electric vehicle motor controller according to claim 2, characterized in that, The magnetic ring potting groove includes a primary magnetic ring potting groove (20) and a secondary magnetic ring potting groove (21) located on two opposite sides of the bracket (2); the magnetic ring includes a primary magnetic ring (40) and a secondary magnetic ring (41) installed in the primary magnetic ring potting groove (20) and the secondary magnetic ring potting groove (21) respectively.

4. An electric vehicle motor controller according to claim 2, characterized in that, The positive copper busbar includes a primary positive copper busbar (50) and a secondary positive copper busbar (51), and the negative copper busbar includes a primary negative copper busbar (60) and a secondary negative copper busbar (61). The primary positive copper busbar (50) and the primary negative copper busbar (60) are fixed on the side of the bracket (2) opposite to the mounting surface and are respectively connected to the secondary positive copper busbar (51) and the secondary negative copper busbar (61). The secondary positive copper busbar (51) and the secondary negative copper busbar (61) pass through the copper busbar through hole on the side of the bracket (2). The fuse (3) is connected to the primary positive copper busbar (50).

5. An electric vehicle motor controller according to claim 4, characterized in that, The secondary positive copper busbar (51), the secondary negative copper busbar (61) and the grounding copper busbar are provided with pins, which pass through the filter plate (8) and are soldered to the filter plate (8).

6. An electric vehicle motor controller according to claim 1, characterized in that, The grounding copper busbar includes a primary grounding copper busbar (70) and a secondary grounding copper busbar (71), both of which are fixed on the mounting surface of the bracket (2).

7. An electric vehicle motor controller according to claim 1, characterized in that, The controller also includes a positive electrode transfer copper busbar (90) and a negative electrode transfer copper busbar (91). The positive electrode transfer copper busbar (90) and the negative electrode transfer copper busbar (91) are fixed on the side of the bracket (2) opposite to the mounting surface and pass through the bracket (2). One end is connected to the positive copper busbar and the negative copper busbar respectively, and the other end is connected to the filter board (8) through pins.

8. An electric vehicle motor controller according to claim 1, characterized in that, The filter capacitors and magnetic rings are both multiple, and the number of filter capacitors is the same as the number of magnetic rings.

9. An electric vehicle motor controller according to claim 8, characterized in that, The filter capacitors include a primary filter capacitor (80) and a secondary filter capacitor (81), and both the primary filter capacitor (80) and the secondary filter capacitor (81) include one or more X capacitors and one or more Y capacitors; the discharge resistors (82) are multiple and multiple discharge resistors (82) are connected in series.

10. An electric vehicle motor controller according to claim 1, characterized in that, The thermal pad (1) contains a polyimide film.

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