New energy vehicle motor controller
Patent Information
- Application Number
- CN202522099927.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-29
- Publication Date
- 2026-10-09
- Estimated Expiration
- 2035-09-29
AI Technical Summary
[0003]如今，市面上的很多厂家，为了兼顾商用车的多重功能，会基于平台化开发出相对尺寸较大的控制器结构，同时其内部的很多元器件也会设计的比较大，导致电机控制器空间利用率大打折扣
本实用新型提供的新能源车用电机控制器中，由于上盖板、接线盖板分别和控制器箱体通过螺钉紧固，并形成一个内部腔体；滤波组件、薄膜电容、功率模块、电流传感器、以及驱动板、控制板、安规板、屏蔽板、定值电阻均安装在内部腔体中；金属线缆接头通过螺纹的方式安装在控制器箱体的侧面，并对穿过的整车正负极输入线缆、三相输出线缆进行屏蔽和支撑；整车正负极输入线缆与滤波组件的正负极铜排连接，三相输出线缆与三相输出铜排连接；功率模块设置有螺钉过孔，通过螺钉过孔与控制器箱体对应螺纹孔对中，并通过螺钉紧固；功率模块自带散热结构，并直接深入控制器水道的内部与冷却液直接接触，以达到散热的目的；同时功率模块与控制器箱体之间通过水道密封圈进行密封，以达到防止漏液的目的；因此本实用新型提供的新能源车用电机控制器，不仅结构紧凑、功率大、防护可靠，装配工艺简单，而且充分考虑了商用车电机控制器在高功率密度和结构小型化的要求，并采用了多种措施以有效提高电机控制器功率密度和结构尺寸。
Smart Images
Figure CN224844263U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of motor controller technology, and in particular to a motor controller for new energy vehicles. Background Technology
[0002] Currently, with the maturity of new energy passenger vehicles on the market, the new energy commercial vehicle market is also gradually opening up, and correspondingly, the types and sizes of commercial vehicle controllers are also flourishing.
[0003] Currently, many manufacturers on the market, in order to accommodate the multiple functions of commercial vehicles, develop relatively large controller structures based on platforms. Many of the internal components are also designed to be quite large, resulting in a significant reduction in the space utilization of the motor controller. However, for different vehicle models, not all functions of this platform-based controller are available. This means that a large motor controller structure built on a platform, which doesn't necessarily require a large external size, ends up occupying space without maximizing power density.
[0004] Therefore, how to provide a motor controller for new energy vehicles that is compact, highly integrated, has high power density, reliable protection, and simple assembly process has become a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content
[0005] The purpose of this utility model is to provide a motor controller for new energy vehicles, which has a compact structure, high power, reliable protection, and simple assembly process. It fully considers the requirements of commercial vehicle motor controllers for high power density and miniaturization, and adopts a variety of measures to effectively improve the power density and structural size of the motor controller.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: A motor controller for new energy vehicles includes: a controller housing, a top cover, a wiring cover, a metal cable connector, a filter assembly, a film capacitor, a power module, a water channel sealing ring, a current sensor, a three-phase output copper busbar, a drive board, a control board, a safety board, a shielding board, a low-voltage connector, and a fixed resistor. The upper cover plate and the wiring cover plate are fastened to the controller housing with screws, forming an internal cavity. The filter assembly, the thin-film capacitor, the power module, the current sensor, the drive board, the control board, the safety plate, the shielding plate, and the fixed resistor are all installed in the internal cavity. The metal cable connector is installed on the side of the controller housing by means of threads, and shields and supports the vehicle's positive and negative input cables and three-phase output cables passing through it. The vehicle's positive and negative input cables are connected to the positive and negative copper busbars of the filter assembly, and the three-phase output cables are connected to the three-phase output copper busbars. The power module is provided with screw through holes, which are aligned with the corresponding threaded holes of the controller housing and fastened with screws. The power module has its own heat dissipation structure and directly penetrates into the interior of the controller's water channel to directly contact the coolant for heat dissipation. At the same time, the power module and the controller housing are sealed by the water channel sealing ring to prevent leakage.
[0007] In practical applications, the filter assembly is integrally injection molded from positive and negative copper busbars arranged in a specific pattern. Each of the positive and negative copper busbars extends out a pin, and the plastic part integrates an embedded round nut, an insert support sleeve, a positioning pin, and a positioning hole. The filter assembly mates with the positioning pin of the controller housing through its positioning hole, and with the end face of its insert support sleeve mates with the end face of the BOSS post of the controller housing. Screws are used to fasten the filter assembly to the controller housing.
[0008] The safety plate is equipped with safety capacitors. It has screw holes for fixing the filter assembly, positioning holes, welding holes for fixing the safety capacitors, and welding holes for welding the positive and negative copper busbars. The leads of the safety capacitors pass through the welding holes in the safety plate and are fixed to the safety plate by welding. The safety plate's positioning holes correspond to the positioning pins of the filter assembly, and the welding holes of the positive and negative copper busbars on the safety plate fit over the protruding leads of the positive and negative copper busbars. Simultaneously, the screw holes on the safety plate correspond to the embedded round nuts of the filter assembly, and screws are used to fasten the safety plate to the filter assembly.
[0009] Specifically, the thin-film capacitor is formed by encapsulating a core cell, positive and negative input copper busbars, three-phase output copper busbars, epoxy resin, and a plastic shell. The positive and negative input copper busbars and the three-phase output copper busbars are fixed to the core cell by welding. The fixed copper busbar-core cell assembly is then encapsulated inside the plastic shell with epoxy resin to form the thin-film capacitor. The plastic housing of the thin-film capacitor integrates an embedded round nut, an insert support sleeve, and a positioning hole. The thin-film capacitor mates with the positioning pin of the controller housing through its positioning hole, and mates with the end face of the insert support sleeve of the controller housing through its end face. The filter assembly is fastened to the controller housing with screws. After completion, the positive and negative input copper busbars of the thin-film capacitor are fastened to the positive and negative output copper busbars of the filter assembly with screws. At the same time, the three-phase output copper busbars of the thin-film capacitor are fastened to the three-phase input terminals of the power module with screws.
[0010] Furthermore, the three-phase output copper busbars are respectively provided with a plurality of screw through holes; the three-phase output copper busbars pass through the reserved rectangular hole of the current sensor, and the screw through holes of the three-phase output copper busbars are aligned with the threaded hole of the current sensor and fastened with screws; the reserved screw through holes of the three-phase output copper busbars are aligned with the threaded hole of the power module and fastened with screws. The drive board is mounted above the power module; the drive board is provided with a number of welding holes and screw through holes, the power module is provided with a number of pins, the pins pass through the welding holes on the drive board and are fixed by welding process; at the same time, the screw through holes on the drive board are aligned with the reserved threaded bottom holes of the power module and are fastened with self-tapping screws.
[0011] Furthermore, a baffle is provided inside the controller housing between the drive board and the filter assembly to provide isolation and prevent the filter assembly from causing electromagnetic interference to the drive board signal. The shielding plate and the control plate are disposed above the drive board, and an electrical clearance is maintained between them.
[0012] Furthermore, the shielding plate is provided with several screw through holes and positioning holes; the controller housing is provided with BOOS posts and hexagonal studs at corresponding positions; the positioning holes of the shielding plate itself are matched with the positioning pins of the controller housing, and the screw through holes of the shielding plate are aligned with the female threaded holes of the hexagonal studs and fastened with screws.
[0013] Furthermore, the control board and the drive board are connected by a ribbon cable, and the shielding plate in the middle provides electromagnetic shielding for the drive board and the control board to prevent the high voltage signal on the drive board from interfering with the low voltage signal on the control board. The control board is equipped with the low-voltage connector, and the pins of the low-voltage connector are soldered to the pre-reserved soldering holes on the control board. The controller housing has an independent cavity, and after the control board is installed, the low-voltage connector is located within this independent cavity. The independent cavity has a through-hole on the side of the controller housing, and the output end of the low-voltage connector mates with this through-hole, extending out from the side of the controller housing. The shielding plate contacts the upper surface of an independently designed area inside the controller housing to isolate the low-voltage connector from the high-voltage components of the drive board, the filter assembly, and the thin-film capacitor, and to prevent high-voltage signals from interfering with the low-voltage signals on the control board.
[0014] Furthermore, the upper cover plate is provided with screw through holes and positioning holes. The positioning holes of the upper cover plate are matched with the reserved positioning pins of the controller housing, and the upper cover plate is fastened to the controller housing with screws. The upper cover plate and the controller housing are sealed with sealant to achieve the sealing level designed for the controller. The wiring cover is provided with positioning holes and screw through holes. The positioning holes of the wiring cover are matched with the reserved positioning pins of the controller housing, and the wiring cover is fastened to the controller housing with screws. The wiring cover and the controller housing are sealed with sealant to achieve the sealing level of the controller sealing design.
[0015] Furthermore, the waterway sealing ring and the sealing ring groove of the controller housing are correspondingly fitted; The wiring cover plate adopts an inverted structure.
[0016] Furthermore, an integrated heat dissipation channel is arranged at the bottom of the controller housing, and the heat dissipation channel is located on the bottom surface of the power module and the thin film capacitor to ensure the heat dissipation performance of the motor controller. The resolver module inside the controller is integrated into the control board, and the signal transmission between the controller and the motor is achieved through the internal pin of the low-voltage connector.
[0017] Compared with existing technologies, the new energy vehicle motor controller described in this utility model has the following advantages: In the new energy vehicle motor controller provided by this utility model, the upper cover plate and the wiring cover plate are fastened to the controller housing with screws, forming an internal cavity. The filter assembly, thin film capacitor, power module, current sensor, as well as the drive board, control board, safety board, shielding board, and fixed resistor are all installed in the internal cavity. The metal cable connector is installed on the side of the controller housing by means of threads, and shields and supports the vehicle's positive and negative input cables and three-phase output cables passing through it. The vehicle's positive and negative input cables are connected to the positive and negative copper busbars of the filter assembly, and the three-phase output cables are connected to the three-phase output copper busbars. The power module is provided with screws for... The hole is aligned with the corresponding threaded hole in the controller housing through a screw through hole and then fastened with screws. The power module has its own heat dissipation structure and directly penetrates into the interior of the controller's water channel to directly contact the coolant for heat dissipation. At the same time, the power module and the controller housing are sealed by a water channel sealing ring to prevent leakage. Therefore, the new energy vehicle motor controller provided by this utility model is not only compact in structure, high in power, and reliable in protection, and simple in assembly process, but also fully considers the requirements of commercial vehicle motor controllers for high power density and miniaturization, and adopts a variety of measures to effectively improve the power density and structural size of the motor controller. Attached Figure Description
[0018] Figure 1 An exploded view of the motor controller for new energy vehicles provided in this embodiment of the utility model; Figure 2 A schematic diagram of the filter component and safety plate in the motor controller for new energy vehicles provided in this embodiment of the utility model.
[0019] Figure label: 1-Controller housing; 2-Top cover; 3-Wiring cover; 4-Metal cable connector; 5-Filter assembly; 6-Film capacitor; 7-Power module; 8-Water channel sealing ring; 9-Current sensor; 10-Control board; 11-Safety board; 12-Shielding board; 13-Low voltage connector; 14-Fixed resistor; 51 - Positive and negative copper busbars; 511 - Copper busbar leads. Detailed Implementation
[0020] For ease of understanding, the new energy vehicle motor controller provided in the embodiments of this utility model will be described in detail below with reference to the accompanying drawings.
[0021] This utility model embodiment provides a motor controller for new energy vehicles, such as... Figure 1 and Figure 2As shown, it includes: controller housing 1, top cover 2, wiring cover 3, metal cable connector 4, filter assembly 5, film capacitor 6, power module 7, water channel sealing ring 8, current sensor 9, and three-phase output copper busbar, drive board, control board 10, safety board 11, shielding board 12, low voltage connector 13, and fixed resistor 14. The top cover 2 and the wiring cover 3 are fastened to the controller housing 1 with screws, forming an internal cavity. The filter assembly 5, the thin film capacitor 6, the power module 7, the current sensor 9, as well as the drive board, the control board 10, the safety board 11, the shielding board 12, and the fixed resistor 14 are all installed in the internal cavity. The metal cable connector 4 is installed on the side of the controller housing 1 by means of threads, and shields and supports the vehicle's positive and negative input cables and three-phase output cables that pass through it. The vehicle's positive and negative input cables are connected to the positive and negative copper busbars 51 of the filter assembly 5, and the three-phase output cables are connected to the three-phase output copper busbars. The power module 7 is provided with screw through holes, which are aligned with the corresponding threaded holes of the controller housing 1 and fastened with screws. The power module 7 has its own heat dissipation structure and directly penetrates into the interior of the controller's water channel to directly contact the coolant for heat dissipation. At the same time, the power module 7 and the controller housing 1 are sealed by the water channel sealing ring 8 to prevent leakage.
[0022] Compared with the prior art, the new energy vehicle motor controller described in this embodiment of the utility model has the following advantages: In the new energy vehicle motor controller provided in this embodiment, the upper cover plate 2 and the wiring cover plate 3 are fastened to the controller housing 1 with screws, forming an internal cavity; the filter assembly 5, thin film capacitor 6, power module 7, current sensor 9, as well as the drive board, control board 10, safety board 11, shielding board 12, and fixed resistor 14 are all installed in the internal cavity; the metal cable connector 4 is installed on the side of the controller housing 1 by means of threads, and shields and supports the vehicle's positive and negative input cables and three-phase output cables passing through it; the vehicle's positive and negative input cables are connected to the positive and negative copper busbars 51 of the filter assembly 5, and the three-phase output cables are connected to the three-phase output copper busbars; the power module... Block 7 is provided with screw through holes, which are aligned with the corresponding threaded holes of the controller housing 1 and fastened with screws. The power module 7 has its own heat dissipation structure and directly penetrates into the interior of the controller's water channel to directly contact the coolant for heat dissipation. At the same time, the power module 7 and the controller housing 1 are sealed by the water channel sealing ring 8 to prevent leakage. Therefore, the new energy vehicle motor controller provided by this utility model embodiment is not only compact in structure, high in power, reliable in protection, and simple in assembly process, but also fully considers the requirements of commercial vehicle motor controllers for high power density and miniaturization, and adopts a variety of measures to effectively improve the power density and structural size of the motor controller.
[0023] In practical applications, such as Figure 1 and Figure 2 As shown, the above-mentioned filter component 5 is integrally injection molded from positive and negative copper busbars 51 arranged in a certain manner; each of the positive and negative copper busbars 51 extends out a (copper busbar) pin 511, and the plastic part integrates an embedded round nut, an insert support sleeve, a positioning pin, and a positioning hole; the filter component 5 is engaged with the positioning pin of the controller housing 1 through its own positioning hole, and is engaged with the end face of the BOSS post of the controller housing 1 through its own insert support sleeve, and is fastened to the controller housing 1 with screws.
[0024] Among them, such as Figure 1 and Figure 2 As shown, safety capacitors are distributed on the safety plate 11. The safety plate 11 is provided with screw through holes for fixing to the filter assembly 5, positioning holes, welding holes for fixing the safety capacitors, and welding holes for welding to the positive and negative copper busbars. The leads of the safety capacitors pass through the welding holes of the safety plate 11 and are fixed to the safety plate 11 by welding. The safety plate 11 is matched with the positioning pins of the filter assembly 5 through its own positioning holes, and the positive and negative copper busbar welding holes of the safety plate 11 are fitted into the leads of the positive and negative copper busbars. At the same time, the screw through holes of the safety plate 11 correspond to the embedded round nuts of the filter assembly 5, and the safety plate 11 and the filter assembly 5 are fastened with screws.
[0025] Specifically, such as Figure 1 and Figure 2 As shown, the above-mentioned thin film capacitor 6 is formed by encapsulating a core cell, positive and negative input copper busbars, three-phase output copper busbars, epoxy resin, and a plastic shell. The positive and negative input copper busbars and the three-phase output copper busbars are fixed to the core cell by welding. The fixed copper busbar core cell assembly is encapsulated in the plastic shell with epoxy resin to form the thin film capacitor 6. The plastic housing of the film capacitor 6 integrates an embedded round nut, an insert support sleeve, and a positioning hole. The film capacitor 6 mates with the positioning pin of the controller housing 1 through its own positioning hole, and mates with the end face of the insert support sleeve of the controller housing 1 through its own end face. The filter assembly 5 is fastened to the controller housing 1 with screws. After completion, the positive and negative input copper busbars of the film capacitor 6 are fastened to the positive and negative output copper busbars of the filter assembly 5 with screws. At the same time, the three-phase output copper busbars of the film capacitor 6 are fastened to the three-phase input terminals of the power module 7 with screws.
[0026] Furthermore, such as Figure 1 and Figure 2As shown, the three-phase output copper busbars are provided with several screw through holes; the three-phase output copper busbars pass through the reserved rectangular hole of the current sensor 9, and the screw through holes of the three-phase output copper busbars are aligned with the threaded holes of the current sensor 9 and fastened with screws; the reserved screw through holes of the three-phase output copper busbars are aligned with the threaded holes of the power module 7 and fastened with screws. The driver board is mounted on top of the power module 7. The driver board has several welding holes and screw through holes. The power module 7 has several pins. The pins pass through the welding holes on the driver board and are fixed by welding. At the same time, the screw through holes on the driver board are aligned with the reserved threaded bottom holes of the power module 7 and are fastened with self-tapping screws.
[0027] Furthermore, such as Figure 1 and Figure 2 As shown, the controller housing 1 has a baffle wall located between the drive board and the filter assembly 5 to provide isolation and prevent electromagnetic interference from the filter assembly 5 to the drive board signal, thereby effectively improving the control EMC performance. A shielding plate 12 and a control plate 10 are provided above the aforementioned drive board, and the two are kept at an electrical clearance.
[0028] Furthermore, such as Figure 1 and Figure 2 As shown, the shielding plate 12 is provided with several screw through holes and positioning holes; the controller housing 1 is provided with BOOS post and hexagonal stud at the corresponding position; the positioning hole of the shielding plate 12 itself is matched with the positioning pin of the controller housing 1, and the screw through hole of the shielding plate 12 is aligned with the threaded hole of the female end of the hexagonal stud and is fastened with screws. Due to height limitations and casting process constraints, the strength of a cast BOSS column will be significantly reduced when the height-to-diameter ratio exceeds a certain range. In this case, the design uses a BOSS column with a hexagonal stud that meets the height-to-diameter ratio range to ensure strength and meet design requirements. When using it, first screw the male end of the hexagonal stud into the internal thread of the BOSS column, and then mate the female end of the hexagonal stud with the matching part.
[0029] Furthermore, such as Figure 1 and Figure 2 As shown, the control board 10 and the drive board are connected by a ribbon cable, and the drive board and the control board 10 are electromagnetically shielded by the shielding plate 12 in the middle to avoid the high voltage signal on the drive board from interfering with the low voltage signal on the control board 10, thereby further improving the control EMC performance. The control board 10 is equipped with a low-voltage connector 13, and the pins of the low-voltage connector 13 are soldered to the pre-reserved soldering holes of the control board 10. The controller housing 1 is equipped with an independent cavity, and the low-voltage connector 13 is located in the independent cavity after the control board 10 is installed. The independent cavity has a through hole on the side of the controller housing 1, and the output end of the low-voltage connector 13 is connected to the through hole of the controller housing 1 and extends out of the side of the controller housing 1. The shielding plate 12 contacts the upper surface of the independent area designed inside the controller housing 1, so as to isolate the low-voltage connector 13 from the high-voltage components of the drive board, filter assembly 5, and film capacitor 6, and to prevent the high-voltage signal from interfering with the low-voltage signal on the control board 10, thereby further improving the control EMC performance.
[0030] Furthermore, such as Figure 1 and Figure 2 As shown, the upper cover plate 2 is provided with screw through holes and positioning holes. The positioning holes of the upper cover plate 2 are matched with the reserved positioning pins of the controller housing 1, and the upper cover plate 2 is fastened to the controller housing 1 with screws. The upper cover plate 2 and the controller housing 1 are sealed with sealant to achieve the sealing level designed by the controller. The aforementioned wiring cover 3 is provided with positioning holes and screw through holes. The positioning holes of the wiring cover 3 are matched with the reserved positioning pins of the controller housing 1, and the wiring cover 3 is fastened to the controller housing 1 with screws. The wiring cover 3 and the controller housing 1 are sealed with sealant to achieve the sealing level of the controller sealing design.
[0031] Furthermore, such as Figure 1 and Figure 2 As shown, the waterway sealing ring 8 and the sealing ring groove of the controller housing 1 are correspondingly matched; The aforementioned wiring cover 3 adopts an inverted structure, which can be compatible with vehicles that have bottom wiring requirements, and can prevent moisture from remaining on the wiring cover 3 of the controller for a long time due to gravity. At the same time, it can effectively reduce the processing steps of the upper cover 2 and improve the overall strength and modality of the upper cover 2.
[0032] Furthermore, such as Figure 1 and Figure 2 As shown, the bottom of the controller housing 1 is provided with an integrated heat dissipation channel, which is located on the bottom surface of the power module 7 and the thin film capacitor 6 to ensure the heat dissipation performance of the motor controller. At the same time, the integrated channel can effectively reduce the space. The resolver module inside the controller is integrated into the control board 10, and the signal transmission between the controller and the motor is achieved through the internal pin of the low-voltage connector 13. The use of metal cable connector 4 can achieve a high degree of compatibility with the specifications of input and output cables, thereby effectively reducing the cost of use and ensuring that the performance of the controller is not affected by the cable.
[0033] 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 variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the protection scope of the claims.
Claims
1. A motor controller for new energy vehicles, characterized in that, include: Controller enclosure, top cover, wiring cover, metal cable connectors, filter components, film capacitors, power modules, water channel sealing rings, current sensors, three-phase output copper busbars, drive boards, control boards, safety boards, shielding boards, low-voltage connectors, and fixed resistors. The upper cover plate and the wiring cover plate are fastened to the controller housing with screws, forming an internal cavity. The filter assembly, the thin-film capacitor, the power module, the current sensor, the drive board, the control board, the safety plate, the shielding plate, and the fixed resistor are all installed in the internal cavity. The metal cable connector is installed on the side of the controller housing by means of threads, and shields and supports the vehicle's positive and negative input cables and three-phase output cables passing through it. The vehicle's positive and negative input cables are connected to the positive and negative copper busbars of the filter assembly, and the three-phase output cables are connected to the three-phase output copper busbars. The power module is provided with screw through holes, which are aligned with the corresponding threaded holes of the controller housing and fastened with screws. The power module has its own heat dissipation structure and directly penetrates into the interior of the controller's water channel to directly contact the coolant for heat dissipation. At the same time, the power module and the controller housing are sealed by the water channel sealing ring to prevent leakage.
2. The new energy vehicle motor controller according to claim 1, characterized in that, The filter assembly is integrally injection molded from positive and negative copper busbars arranged in a certain pattern. Each of the positive and negative copper busbars extends out a pin, and the plastic part integrates an embedded round nut, an insert support sleeve, a positioning pin, and a positioning hole. The filter assembly mates with the positioning pin of the controller housing through its own positioning hole, and mates with the end face of the BOSS post of the controller housing through its own insert support sleeve. At the same time, screws are used to fasten the filter assembly to the controller housing.
3. The new energy vehicle motor controller according to claim 2, characterized in that, Safety capacitors are distributed on the safety plate. The safety plate is provided with screw through holes for fixing the filter assembly, positioning holes, welding holes for fixing the safety capacitors, and welding holes for welding to the positive and negative copper busbars. The leads of the safety capacitors pass through the welding holes of the safety plate and are fixed to the safety plate by welding. The safety plate mates with the positioning pins of the filter assembly through its own positioning holes, and the positive and negative copper busbar welding holes of the safety plate fit into the leads of the positive and negative copper busbars. At the same time, the screw through holes of the safety plate correspond to the embedded round nuts of the filter assembly, and the safety plate is fastened to the filter assembly with screws.
4. The new energy vehicle motor controller according to claim 3, characterized in that, The thin-film capacitor is formed by encapsulating a core cell, positive and negative input copper busbars, three-phase output copper busbars, epoxy resin, and a plastic shell. The positive and negative input copper busbars and the three-phase output copper busbars are fixed to the core cell by welding. The fixed copper busbar-core cell assembly is then encapsulated inside the plastic shell with epoxy resin to form the thin-film capacitor. The plastic housing of the thin-film capacitor integrates an embedded round nut, an insert support sleeve, and a positioning hole. The thin-film capacitor mates with the positioning pin of the controller housing through its positioning hole, and mates with the end face of the insert support sleeve of the controller housing through its end face. The filter assembly is fastened to the controller housing with screws. After completion, the positive and negative input copper busbars of the thin-film capacitor are fastened to the positive and negative output copper busbars of the filter assembly with screws. At the same time, the three-phase output copper busbars of the thin-film capacitor are fastened to the three-phase input terminals of the power module with screws.
5. The new energy vehicle motor controller according to claim 4, characterized in that, The three-phase output copper busbars are provided with a number of screw through holes; the three-phase output copper busbars pass through the reserved rectangular holes of the current sensor, and the screw through holes of the three-phase output copper busbars are aligned with the threaded holes of the current sensor and fastened with screws; the reserved screw through holes of the three-phase output copper busbars are aligned with the threaded holes of the power module and fastened with screws. The drive board is mounted above the power module; the drive board is provided with a number of welding holes and screw through holes, the power module is provided with a number of pins, the pins pass through the welding holes on the drive board and are fixed by welding process; at the same time, the screw through holes on the drive board are aligned with the reserved threaded bottom holes of the power module and are fastened with self-tapping screws.
6. The new energy vehicle motor controller according to claim 5, characterized in that, The controller housing has a baffle wall located between the driver board and the filter assembly to provide isolation and prevent the filter assembly from causing electromagnetic interference to the driver board signal. The shielding plate and the control plate are disposed above the drive board, and an electrical clearance is maintained between them.
7. The new energy vehicle motor controller according to claim 6, characterized in that, The shielding plate is provided with several screw through holes and positioning holes; the controller housing is provided with BOOS posts and hexagonal studs at corresponding positions; the positioning holes of the shielding plate itself are matched with the positioning pins of the controller housing, and the screw through holes of the shielding plate are aligned with the threaded holes at the female end of the hexagonal studs and are fastened with screws.
8. The new energy vehicle motor controller according to claim 7, characterized in that, The control board and the drive board are connected by a ribbon cable, and the shielding plate in the middle provides electromagnetic shielding for the drive board and the control board to prevent the high voltage signal on the drive board from interfering with the low voltage signal on the control board. The control board is equipped with the low-voltage connector, and the pins of the low-voltage connector are soldered to the pre-reserved soldering holes on the control board. The controller housing has an independent cavity, and after the control board is installed, the low-voltage connector is located within this independent cavity. The independent cavity has a through-hole on the side of the controller housing, and the output end of the low-voltage connector mates with this through-hole, extending out from the side of the controller housing. The shielding plate contacts the upper surface of an independently designed area inside the controller housing to isolate the low-voltage connector from the high-voltage components of the drive board, the filter assembly, and the thin-film capacitor, and to prevent high-voltage signals from interfering with the low-voltage signals on the control board.
9. The new energy vehicle motor controller according to claim 8, characterized in that, The upper cover plate is provided with screw through holes and positioning holes. The positioning holes of the upper cover plate are matched with the reserved positioning pins of the controller housing, and the upper cover plate is fastened to the controller housing with screws. The upper cover plate and the controller housing are sealed with sealant to achieve the sealing level designed for the controller. The wiring cover is provided with positioning holes and screw through holes. The positioning holes of the wiring cover are matched with the reserved positioning pins of the controller housing, and the wiring cover is fastened to the controller housing with screws. The wiring cover and the controller housing are sealed with sealant to achieve the sealing level of the controller sealing design.
10. The new energy vehicle motor controller according to claim 9, characterized in that, The waterway sealing ring and the sealing ring groove of the controller housing are correspondingly matched; The wiring cover plate adopts an inverted structure.