Double-electric-control bus capacitor laminated copper bar structure of electric vehicle

Abstract

The utility model relates to mechanical technical field discloses a kind of double electric control busbar capacitor laminated copper bar structure of electric vehicle, including injection molding insulator, DC-LINK positive copper bar, DC-LINK positive and negative copper bar interlayer insulation paper, DC-LINK negative copper bar, main capacitor group, X capacitor, Y capacitor one and Y capacitor two;The DC-LINK positive copper bar and DC-LINK negative copper bar are arranged in parallel lamination, the DC-LINK positive and negative copper bar interlayer insulation paper is located between DC-LINK positive copper bar and DC-LINK negative copper bar, the injection molding insulator is wrapped the outside of DC-LINK positive copper bar, DC-LINK positive and negative copper bar interlayer insulation paper and DC-LINK negative copper bar;The main capacitor group is respectively welded with DC-LINK positive copper bar, DC-LINK negative copper bar by main capacitor busbar welding foot welding.In the utility model, DC-LINK positive and negative copper bar "several" character-shaped lamination design, reduce ESL by staggered layout, reduce electromagnetic interference, improve electric energy transmission efficiency;Three-dimensional layout saves electric control system space, optimizes magnetic field coupling, reduces loss.

Description

Technical Field

[0001] This utility model relates to the field of mechanical technology, and in particular to a stacked copper busbar structure for dual electronic control busbar capacitors in electric vehicles. Background Technology

[0002] Against the backdrop of the rapid development of the global electric vehicle industry, market competition is becoming increasingly fierce. High performance and low energy consumption have become the watershed of industry technology. In order to improve vehicle power performance, reliability and adaptability to special scenarios, dual electric control systems have become the mainstream technology direction in the industry due to their precise torque distribution, redundant control and multi-mode driving capabilities. In the design of dual electric control systems, reducing product size and improving integration are among the core objectives. The equivalent series inductance (ESL) of the inverter circuit directly affects the electromagnetic compatibility, switching losses and reliability of the system. The smaller the ESL, the better the dynamic response and stability of the system. Therefore, how to reduce ESL and achieve compact design by optimizing the DC-Link capacitor busbar structure has become a technical challenge that the industry urgently needs to overcome.

[0003] Traditional dual-control DC-Link capacitor busbars often employ a separate or single-layer copper busbar structure. This design has significant drawbacks: firstly, separate busbars result in high overall ESL due to dispersed circuit wiring, easily leading to voltage spikes and electromagnetic interference under high-frequency operating conditions; secondly, single-layer structures are difficult to modularly integrate, resulting in large busbar volumes that cannot meet the miniaturization requirements of automotive systems. To address these issues, this invention proposes a stacked copper busbar structure integrating dual-control DC-Link. Through the staggered stacking of multiple copper busbars and the coupling design of positive and negative buses, the high performance and compactness of the control system can be achieved from a structural perspective. Utility Model Content

[0004] To overcome the above shortcomings, this utility model provides a stacked copper busbar structure for dual electronic control busbar capacitors in electric vehicles, aiming to improve the problem of insufficient space utilization in existing stacked copper busbar structures for dual electronic control busbar capacitors in electric vehicles.

[0005] To achieve the above objective, the present utility model provides the following technical solution: a laminated copper bar structure for dual electronic control bus capacitors of electric vehicles, comprising an injection-molded insulator, a DC-LINK positive copper bar, insulating paper between DC-LINK positive and negative copper bars, a DC-LINK negative copper bar, a main capacitor bank, an X capacitor, a first Y capacitor and a second Y capacitor; the DC-LINK positive copper bar and the DC-LINK negative copper bar are arranged in parallel and laminated, the insulating paper between DC-LINK positive and negative copper bars is disposed between the DC-LINK positive copper bar and the DC-LINK negative copper bar, and the injection-molded insulator wraps the outer sides of the DC-LINK positive copper bar, the insulating paper between DC-LINK positive and negative copper bars and the DC-LINK negative copper bar; the main capacitor bank is welded to the DC-LINK positive copper bar and the DC-LINK negative copper bar respectively through main capacitor busbar welding pins; the X capacitor is connected to the DC-LINK positive copper bar and the DC-LINK negative copper bar respectively through an X capacitor and busbar positive electrode welding pin, and an X capacitor and busbar negative electrode welding pin; the first Y capacitor and the second Y capacitor are connected to the DC-LINK positive copper bar and the DC-LINK negative copper bar respectively through Y capacitor busbar welding pins, and are grounded through Y capacitor and ground wire connection pins; a DC power supply is connected to the DC-LINK positive copper bar and the DC-LINK negative copper bar through the positive and negative terminals for DC power input to the capacitor assembly, and the DC-LINK capacitor output positive electrode and the DC-LINK capacitor output negative electrode are connected to the power module through the adapter copper bars for outputting the positive and negative electrodes from the DC-LINK capacitor to the power module.

[0006] Further, the DC-LINK positive copper bar is provided with a DC-LINK positive Y capacitor grounding position, a DC-LINK positive copper bar main capacitor welding position, and a DC-LINK positive copper bar Y capacitor welding position, and the DC-LINK negative copper bar is provided with a DC-LINK negative Y capacitor grounding position, a DC-LINK negative copper bar and X capacitor welding position, a DC-LINK negative copper bar Y capacitor welding position, and a DC-LINK negative copper bar main capacitor welding position, which are used for realizing welding and fixing with the corresponding capacitors and the main capacitor bank.

[0007] Further, the DC-LINK positive copper bar and the DC-LINK negative copper bar adopt a "Π"-shaped laminated structure, and are arranged in a staggered manner to form a multi-layer current loop, so as to reduce the equivalent series inductance of the inverter loop.

[0008] Further, the connection mode between the main capacitor bank and the DC-LINK positive copper bar and the DC-LINK negative copper bar is soldering or laser welding, so as to form a low-impedance electrical connection.

[0009] Further, the insulating paper between the positive and negative DC-LINK copper bars is made of an insulating material with low dielectric constant and high voltage resistance, which is used to reduce the parasitic capacitance and electric field coupling between the positive DC-LINK copper bar and the negative DC-LINK copper bar.

[0010] Further, the injection-molded insulator is made of a high-temperature resistant, high-insulation polymer material, which is used for electrical isolation and mechanical protection of the positive DC-LINK copper bar and the negative DC-LINK copper bar.

[0011] The utility model has the following beneficial effects: 1. In the utility model, the "several"-shaped laminated design of the positive and negative DC-LINK copper bars reduces ESL through staggered layout, reduces electromagnetic interference, and improves power transmission efficiency; the three-dimensional layout saves the space of the electric control system, optimizes magnetic field coupling, and reduces losses.

[0012] 2. In the utility model, insulating materials such as insulating paper or plastic are used for filling insulation to adapt to different scenarios, the insulating paper precisely controls the capacitance and electric field, and other materials fill the special-shaped space; combined with the injection molding process, the insulation gap is eliminated, partial discharge is avoided, and the safety of the electric control system is ensured. Brief Description of the Drawings

[0013] Figure 1 is a schematic diagram of the main structure of a laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 2 is a schematic diagram of the injection-molded insulator structure of the laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 3 is Figure 2 an enlarged view of part A in; Figure 4 is a schematic diagram of the positive DC-LINK copper bar structure of the laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 5 is a schematic assembly diagram of the laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 6 is a schematic diagram of the main structure of the laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 7 is a schematic diagram of the positive DC-LINK copper bar structure of the laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 8 is a schematic diagram of the main capacitor group structure of the laminated copper bar structure for a dual electric control bus capacitor of an electric vehicle proposed by the utility model; Figure 9This is a schematic diagram of the DC-LINK negative electrode copper busbar structure of a dual electronic control bus capacitor stacked copper busbar structure for electric vehicles proposed in this utility model. Figure 10 This is a schematic diagram of the X and Y capacitor structures of a stacked copper busbar capacitor structure for a dual-control busbar in an electric vehicle proposed in this utility model.

[0014] Legend: 1. Injection-molded insulator; 2. DC-LINK positive copper busbar; 3. Insulating paper between DC-LINK positive and negative copper busbars; 4. DC-LINK negative copper busbar; 5. DC power input to capacitor bank positive and negative terminals; 6. Adapter copper busbar from DC-LINK capacitor output to power module positive and negative terminals; 7. Main capacitor bank; 8. DC-LINK capacitor output positive terminal; 9. DC-LINK capacitor output negative terminal; 10. Y capacitor one; 11. X capacitor; 12. Y capacitor two; 13. Main capacitor busbar soldering pins; 14. Y capacitor busbar soldering pins; 15. Y capacitor ground connection pin; 16. X capacitor positive terminal soldering pin; 17. X capacitor negative terminal soldering pin; 18. DC-LINK positive Y capacitor grounding point; 19. DC-LINK positive copper busbar main capacitor soldering point; 20. DC-LINK positive copper busbar Y capacitor soldering point; 21. DC-LINK negative copper busbar and X capacitor soldering point; 22. DC-LINK negative Y capacitor grounding point; 23. DC-LINK negative copper busbar Y capacitor soldering point; 24. DC-LINK negative copper busbar main capacitor soldering point. Detailed Implementation

[0015] 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 embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0016] Reference Figure 1-10This utility model provides an embodiment of a dual-control busbar capacitor stacked copper busbar structure for electric vehicles, comprising an injection-molded insulator 1, a DC-LINK positive copper busbar 2, insulating paper 3 between the DC-LINK positive and negative copper busbars, a DC-LINK negative copper busbar 4, a main capacitor group 7, an X capacitor 11, a Y capacitor 10, and a Y capacitor 12; the DC-LINK positive copper busbar 2 and the DC-LINK negative copper busbar 4 are stacked in parallel, the insulating paper 3 between the DC-LINK positive and negative copper busbars is disposed between the DC-LINK positive copper busbar 2 and the DC-LINK negative copper busbar 4, and the injection-molded insulator 1 wraps around the outside of the DC-LINK positive copper busbar 2, the insulating paper 3 between the DC-LINK positive and negative copper busbars, and the DC-LINK negative copper busbar 4; the main capacitor group 7 is connected to the DC-LINK busbar via the main capacitor busbar welding pins 13. -LINK positive copper busbar 2 and DC-LINK negative copper busbar 4 are soldered; X capacitor 11 is connected to DC-LINK positive copper busbar 2 and DC-LINK negative copper busbar 4 respectively through X capacitor to busbar positive soldering pin 16 and X capacitor to busbar negative soldering pin 17; Y capacitor 10 and Y capacitor 2 12 are connected to DC-LINK positive copper busbar 2 and DC-LINK negative copper busbar 4 respectively through Y capacitor busbar soldering pin 14, and grounded through Y capacitor to ground wire connection pin 15; DC power supply is input to capacitor collector positive and negative terminals 5 and connected to DC-LINK positive copper busbar 2 and DC-LINK negative copper busbar 4; DC-LINK capacitor output positive terminal 8 and DC-LINK capacitor output negative terminal 9 are connected to the power module through DC-LINK capacitor output to the power module positive and negative terminal adapter copper busbar 6; Specifically, the DC power supply is input to the capacitor bank 5, which is connected to the DC-LINK positive copper busbar 2 and the DC-LINK negative copper busbar 4. Then, the power is output through the DC-LINK capacitor to the power module's positive and negative transfer copper busbar 6, and then transferred to the power module. The "U"-shaped stacked structure of the DC-LINK positive and negative copper busbars forms multiple current loops through staggered arrangement, reducing the equivalent series inductance (ESL), minimizing losses and voltage spikes during high-frequency current transmission, and ensuring efficient and stable power transmission. Electromagnetic interference suppression: X capacitor 11 is connected between the DC-LINK positive and negative copper busbars to suppress differential-mode interference; Y capacitors 10 and 12 are connected to the DC-LINK positive and negative copper busbars and ground respectively, mainly suppressing common-mode interference. These three, together with the main capacitor bank 7, form a filter circuit, working together to filter high-frequency harmonics and electromagnetic interference in the DC bus, improving the system's power efficiency. Magnetic compatibility (EMC) is ensured to prevent interference with the normal operation of other electronic devices in electric vehicles. The insulating paper 3 between the positive and negative copper busbars of the DC-LINK and the injection-molded insulator 1 provide electrical isolation from both internal and external perspectives. The insulating paper 3 uses a low dielectric constant and high voltage withstand performance to prevent short circuits or electric field coupling between the positive and negative copper busbars. The injection-molded insulator 1 wraps around the outside of the copper busbars, not only isolating them from contact with external conductive materials but also providing mechanical protection, enhancing structural stability, and ensuring safe operation of the system under complex conditions. Components such as the main capacitor group 7, X capacitor 11, and Y capacitor are connected to the DC-LINK positive and negative copper busbars through their respective soldering pins, forming a modular circuit structure. This connection method ensures clear division of labor and close collaboration among components, facilitating assembly and disassembly, as well as later maintenance and repair, while ensuring stable and reliable electrical connections throughout the entire circuit system.

[0017] Working principle: The DC-LINK positive copper busbar 2 and the DC-LINK negative copper busbar 4 are processed into a "几"-shaped laminated structure, which are arranged in a staggered manner to form a multi-layer current loop. The insulating paper 3 between the DC-LINK positive and negative copper busbars is laid between the DC-LINK positive copper busbar 2 and the DC-LINK negative copper busbar 4. The insulating paper can be made of a material with low dielectric constant and high voltage resistance as required, so as to ensure effective electrical isolation between the positive and negative copper busbars and complete the preliminary assembly of the laminated structure. Using the tin soldering or laser welding process, the main capacitor assembly 7 is respectively welded to the corresponding welding positions of the DC-LINK positive copper busbar 2 and the DC-LINK negative copper busbar 4 through the main capacitor busbar welding pins 13; in the same welding manner, the X capacitor 11 is connected to the DC-LINK positive and negative copper busbars by using the X capacitor and busbar positive welding pin 16 and the X capacitor and busbar negative welding pin 17; through the Y capacitor busbar welding pin 14, the first Y capacitor 10 and the second Y capacitor 12 are respectively welded to the DC-LINK positive and negative copper busbars, and the Y capacitors are grounded through the Y capacitor and ground wire connection pin 15, so as to ensure that each capacitor element and the copper busbars form a low-impedance and stable electrical connection. The assembled copper busbars and capacitor assembly are integrally placed into a mold, and an injection molding process is adopted to make a polymer material with high temperature resistance and high insulation performance perform injection molding around the copper busbars and the capacitor elements, so as to form an injection-molded insulator 1, which wraps the outer sides of the DC-LINK positive copper busbar 2, the insulating paper 3 between the DC-LINK positive and negative copper busbars and the DC-LINK negative copper busbar 4, so as to realize all-round electrical isolation and mechanical protection for the copper busbars. At the same time, check whether the insulating paper is damaged or displaced to ensure reliable internal insulation. The transition copper busbars 5 for the positive and negative poles of the capacitor assembly for DC power input and the transition copper busbars 6 for the positive and negative poles of the power module for DC-LINK capacitor output are respectively connected to the corresponding positions of the DC-LINK positive and negative copper busbars to complete the overall connection of the circuit. Finally, electrical performance tests are carried out on the assembled structure, including insulation resistance test, voltage withstand test, ESL measurement, filtering effect verification, etc., to ensure that it meets the working requirements of the dual electronic control system of the electric vehicle.

[0018] Finally, it should be noted that the above description is only the preferred embodiment of the present utility model, and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still make modifications to the technical solutions recorded in the foregoing embodiments, or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present utility model shall all be included in the protection scope of the present utility model.

Claims

1. A stacked copper busbar structure for dual electronic control bus capacitors in electric vehicles, characterized in that: comprising an injection-molded insulator (1), a DC-LINK positive copper busbar (2), an insulating paper between the DC-LINK positive and negative copper busbars (3), a DC-LINK negative copper busbar (4), a main capacitor bank (7), an X capacitor (11), a first Y capacitor (10) and a second Y capacitor (12); the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) are arranged in parallel and stacked, the insulating paper between the DC-LINK positive and negative copper busbars (3) is disposed between the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4), and the injection-molded insulator (1) wraps the outer sides of the DC-LINK positive copper busbar (2), the insulating paper between the DC-LINK positive and negative copper busbars (3) and the DC-LINK negative copper busbar (4); the main capacitor bank (7) is respectively welded to the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) through the main capacitor busbar welding pins (13); the X capacitor (11) is respectively connected to the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) through the X capacitor and busbar positive electrode welding pin (16) and the X capacitor and busbar negative electrode welding pin (17); the first Y capacitor (10) and the second Y capacitor (12) are respectively connected to the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) through the Y capacitor busbar welding pins (14), and are grounded through the Y capacitor and ground wire connection pin (15); A DC power supply is connected to the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) through the positive and negative electrodes (5) for DC power input to the capacitor assembly, and the DC-LINK capacitor output positive electrode (8) and the DC-LINK capacitor output negative electrode (9) are connected to the power module through the adapter copper busbar (6) for output from the DC-LINK capacitor to the positive and negative electrodes of the power module.

2. The electric vehicle dual-control bus capacitor stacked copper busbar structure according to claim 1, characterized in that: The DC-LINK positive copper busbar (2) is provided with a DC-LINK positive Y capacitor grounding position (18), a DC-LINK positive copper busbar main capacitor welding position (19), and a DC-LINK positive copper busbar Y capacitor welding position (20), and the DC-LINK negative copper busbar (4) is provided with a DC-LINK negative Y capacitor grounding position (22), a DC-LINK negative copper busbar and X capacitor welding position (21), a DC-LINK negative copper busbar Y capacitor welding position (23), and a DC-LINK negative copper busbar main capacitor welding position (24), which are used to realize welding and fixing with the corresponding capacitors and the main capacitor bank (7).

3. The electric vehicle dual-control bus capacitor stacked copper busbar structure according to claim 1, characterized in that: The DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) adopt a "several"-shaped stacked structure, and a multi-layer current loop is formed by staggered arrangement to reduce the equivalent series inductance (ESL) of the inverter loop.

4. The electric vehicle dual-control bus capacitor stacked copper busbar structure according to claim 1, characterized in that: The connection mode of the main capacitor bank (7) with the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4) is soldering or laser welding, so as to form a low-impedance electrical connection.

5. The electric vehicle dual-control bus capacitor stacked copper busbar structure according to claim 1, characterized in that: The insulating paper (3) between the positive and negative copper busbars of the DC-LINK uses an insulating material with low dielectric constant and high voltage resistance to reduce the parasitic capacitance and electric field coupling between the positive copper busbar (2) and the negative copper busbar (4) of the DC-LINK.

6. The electric vehicle dual-control bus capacitor stacked copper busbar structure according to claim 1, characterized in that: The injection-molded insulator (1) is made of a high-temperature resistant and high-insulation polymer material and is used to provide electrical isolation and mechanical protection for the DC-LINK positive copper busbar (2) and the DC-LINK negative copper busbar (4).

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