Electric vehicle drive motor controller

Abstract

The utility model relates to motor controller technical field discloses a kind of electric automobile drive motor controllers, comprising: shell;Inverter brick module, set in the inside of the shell;Boost module, set in the inside of the shell, and with the inverter brick module parallel distribution;Input module, fixedly penetrate in the shell, one end is connected with external high-voltage bus, the other end is used to be connected with the input end of the inverter brick module and the boost module;Output module, fixedly penetrate in the shell, one end is connected with the output end of the inverter brick module and the boost module, the other end is used to be connected with external motor.Adopt inverter brick module, can effectively improve the integration of shell internal structure, facilitate to carry out ageing test;While, in the internal integration boost module of shell, and with inverter brick module share part input and output, while further improving the integration of shell inside, effectively improve charging efficiency.

Description

Technical Field

[0001] This utility model relates to the field of motor controller technology, and specifically to an electric vehicle drive motor controller. Background Technology

[0002] The drive motor controller of an electric vehicle, often referred to as an "inverter," is the "heart" of the electric vehicle. It directly converts the high-voltage direct current from the power battery into precisely controlled alternating current to drive the motor.

[0003] Currently, the common 400V platform controller structure on the market has low charging efficiency, and the controller assembly needs to be tested during testing, which is complex and inefficient. Utility Model Content

[0004] The purpose of this invention is to overcome the problems of low charging efficiency and complex testing in the existing technology, and to provide an electric vehicle drive motor controller that has the functions of high charging efficiency and convenient testing.

[0005] To achieve the above objectives, this utility model provides an electric vehicle drive motor controller, comprising: case; The inverter brick module is located inside the housing; The boost module is located inside the housing and is distributed in parallel with the inverter brick module; The input module is fixedly inserted through the housing, with one end connected to the external high-voltage busbar and the other end used to connect to the input terminals of the inverter brick module and the boost module. The output module is fixedly inserted through the housing, with one end connected to the output end of the inverter brick module and the boost module, and the other end used to connect to an external motor.

[0006] Optionally, the input module includes: The first high-voltage busbar is connected at one end to the positive input of the inverter brick module at the other end. The second high-voltage busbar is connected at one end to the negative input terminal of the inverter brick module and the negative input terminal of the boost module. The third high-voltage busbar is connected at one end to the positive input of the boost module.

[0007] Optionally, the input module further includes: The first filtering module is located inside the input module, with one end connected to the other end of the input module; The second filter module is located at the end of the first filter module away from the input module and is connected to the output terminal of the first filter module. The output terminal of the second filter module is connected to the input terminals of the inverter module and the boost module.

[0008] Optionally, the first filtering module and the second filtering module include LC filters.

[0009] Optionally, the inverter brick module includes: A waterway base plate is disposed at the inner bottom of the housing; A thin-film capacitor is disposed at the inner bottom of the waterway substrate and is connected to the output terminal of the second filter module; A SiC module is disposed in the middle of the water channel substrate, and the input terminal of the SiC module is connected to the output terminal of the thin film capacitor. A drive board is disposed on top of the water channel substrate, and the input end of the drive board is connected to the output end of the SIC module.

[0010] Optionally, the inverter brick module further includes: The water inlet is fixedly inserted through one side of the housing and communicates with one end of the water channel formed by the housing and the water channel base plate; The water outlet is fixedly inserted through the other side of the housing and communicates with the other end of the water channel formed by the housing and the water channel base plate.

[0011] Optionally, the output module includes a three-phase mounting bracket, which is fixedly inserted through the housing. The input end of the three-phase mounting bracket is connected to the output end of the SIC module, and the output end of the three-phase mounting bracket is used to connect to an external motor.

[0012] Optionally, the boost module includes: A boost converter copper busbar is connected at one end to the output terminal of the thin film capacitor; The relay has its input terminal connected to the other end of the boost converter copper busbar and its output terminal connected to the neutral point of the three-phase fixed base.

[0013] Optionally, the inverter brick module further includes a bus current sensor, which is disposed on the water channel substrate and connected to the thin film capacitor.

[0014] Optionally, it also includes a controller cover, which cooperates with the housing to form a sealed structure.

[0015] Through the above technical solution, the electric vehicle drive motor controller provided by this utility model can effectively improve the integration of the internal structure of the housing by adopting an inverter brick module, which facilitates aging tests and simplifies assembly. At the same time, the boost module is integrated inside the housing and shares some inputs and outputs with the inverter brick module, which further improves the integration of the housing and also increases the output voltage of the controller, effectively improving charging efficiency. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the external structure of an electric vehicle drive motor controller according to one embodiment of the present invention; Figure 2 This is a schematic diagram of the inverter brick module in an electric vehicle drive motor controller according to one embodiment of the present invention; Figure 3 This is a schematic diagram of the internal structure of an electric vehicle drive motor controller according to one embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of a three-phase mounting base in an electric vehicle drive motor controller according to one embodiment of the present invention.

[0017] Explanation of reference numerals in the attached figures 1. Housing; 2. Controller cover; 3. Junction box cover; 4. First high-voltage busbar; 5. Second high-voltage busbar; 6. Third high-voltage busbar; 7. Outlet nozzle; 8. Drive board; 9. Thin-film capacitor; 10. Water channel substrate; 11. Busbar current sensor; 12. Three-phase mounting bracket; 13. SiC module; 14. First filter module; 15. Second filter module; 16. Boost converter copper busbar; 17. Inlet nozzle; 18. Relay. Detailed Implementation

[0018] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the scope of the present invention.

[0019] Figure 1 This is a schematic diagram of the structure of an electric vehicle drive motor controller according to one embodiment of the present invention; Figure 2 This is a schematic diagram of the inverter brick module in an electric vehicle drive motor controller according to one embodiment of the present invention; Figure 3 This is a schematic diagram of the internal structure of an electric vehicle drive motor controller according to one embodiment of the present invention; Figure 4 This is a schematic diagram of the structure of a three-phase mounting bracket in an electric vehicle drive motor controller according to one embodiment of the present invention. Figures 1 to 4The electric vehicle drive motor controller may include a housing 1, an inverter module, a boost module, an input module, and an output module.

[0020] The inverter module is housed inside housing 1, and the boost module is also housed inside housing 1, distributed in parallel with the inverter module. The input module is fixedly inserted through housing 1, with one end connected to the external high-voltage busbar and the other end connected to the input terminals of both the inverter module and the boost module. The output module is also fixedly inserted through housing 1, with one end connected to the output terminals of both the inverter module and the boost module, and the other end connected to an external motor.

[0021] By integrating the inverter brick module (film capacitor 9, SiC module 13, driver board 8, etc.) inside the housing 1, a high degree of integration can be achieved within the housing 1. Furthermore, using the inverter brick module simplifies the process; only the inverter brick module needs to be tested when aging tests are required on the controller. The input module connects to the external high-voltage bus, allowing external 800V DC power to be input to the inverter brick module, converted to AC power, and then supplied to the external motor via the output module. The boost module is also integrated within the housing 1, distributed alongside the inverter brick module, and shares some input and output components with it, enabling it to form a boost circuit with the high-voltage bus and motor.

[0022] Traditional 400V platform controller structures commonly found in the market suffer from low charging efficiency and require complex and inefficient testing of the entire controller assembly. In this embodiment of the invention, an inverter brick module is used, which improves the integration within the housing 1, facilitates aging tests, and is easy to assemble. Furthermore, integrating a boost module within the housing 1, sharing input and output sections with the inverter brick module, further enhances the integration within the housing 1 while boosting the high-voltage platform, effectively improving charging efficiency, saving copper wire usage, and reducing the controller's weight.

[0023] In this embodiment of the present invention, such as Figure 1 As shown, the input module may include a first high-voltage bus 4, a second high-voltage bus 5, and a third high-voltage bus 6.

[0024] The other end of the first high-voltage bus 4 is connected to the positive input of the inverter brick module, the other end of the second high-voltage bus 5 is connected to the negative input of the inverter brick module and the negative input of the boost module, and the other end of the third high-voltage bus 6 is connected to the positive input of the boost module.

[0025] The input bus adopts an IPT three-core structure. The first high-voltage bus 4 and the second high-voltage bus 5 serve as the inputs to the inverter brick module, while the third high-voltage bus 6 and the second high-voltage bus 5 serve as the inputs to the boost module. The inverter brick module and the boost module share the negative terminal. The first high-voltage bus 4, the second high-voltage bus 5, and the third high-voltage bus 6 are sealed to the housing 1 using a radial sealing ring.

[0026] In this embodiment of the present invention, such as Figure 3 As shown, the input module may also include a first filtering module 14 and a second filtering module 15.

[0027] The first filter module 14 is located inside the input module, and one end of the first filter module 14 is connected to the other end of the input module. The second filter module 15 is located at the end of the first filter module 14 away from the input module and is connected to the output end of the first filter module 14. The output end of the second filter module 15 is connected to the input ends of the inverter module and the boost module.

[0028] The first filtering module 14 and the second filtering module 15 may include LC filters. Specifically, the controller has an EMC rating of Class 5. Due to the large number of filtering capacitors, the capacitor cores are encapsulated within the plastic shell of the magnetic ring mounting base, saving on capacitor housings and reducing costs. The controller's filtering structure employs a two-stage filtering approach. For high-voltage isolation, a baffle design is used inside the housing 1.

[0029] In this embodiment of the present invention, such as Figure 2 as well as Figure 3 As shown, the inverter brick module may include a water channel substrate 10, a thin film capacitor 9, a SiC module 13, a driver board 8, a water inlet 17, and a water outlet 7.

[0030] A water channel substrate 10 is disposed at the inner bottom of the housing 1. A thin-film capacitor 9 is disposed at the inner bottom of the water channel substrate 10 and connected to the output terminal of the second filter module 15. A SiC module 13 is disposed in the middle of the water channel substrate 10, and the input terminal of the SiC module 13 is connected to the output terminal of the thin-film capacitor 9. A drive board 8 is disposed at the top of the water channel substrate 10, and the input terminal of the drive board 8 is connected to the output terminal of the SiC module 13. A water inlet 17 is fixedly inserted through one side of the housing 1 and communicates with one end of the water channel formed by the housing 1 and the water channel substrate 10. A water outlet 7 is fixedly inserted through the other side of the housing 1 and communicates with the other end of the water channel formed by the housing 1 and the water channel substrate 10.

[0031] The thin-film capacitor 9, SiC module 13, and driver board 8 are arranged from bottom to top. The inverter brick module is connected to the housing 1 by five bolts on the water channel substrate 10. The water channel substrate 10 and the housing 1 cooperate to form a cooling water channel. The inlet nozzle 17 and outlet nozzle 7 are located at the two ends of the cooling water channel to circulate coolant inside the cooling water channel, thereby improving the heat dissipation performance of the thin-film capacitor 9, SiC module 13, etc. Specifically, the water channel substrate 10 is sleeved on the outside of the thin-film capacitor 9 to serve as the outer shell of the thin-film capacitor 9, saving the outer shell of the thin-film capacitor 9, reducing the number of components, and saving costs. The SiC module 13 and the thin-film capacitor 9 are connected by a copper busbar welding process, which can reduce stray inductance in the circuit. In addition, the inlet nozzle 17 is sealed to the housing 1 by a sealing ring end face seal, and the outlet nozzle 7 is sealed to the housing 1 by a sealing ring radial seal.

[0032] In this embodiment of the present invention, such as Figure 2 as well as Figure 4 As shown, the output module may include a three-phase mounting bracket 12.

[0033] The three-phase mounting bracket 12 is fixedly inserted through the housing 1. The input end of the three-phase mounting bracket 12 is connected to the output end of the SIC module 13. The output end of the three-phase mounting bracket 12 is used to connect to an external motor.

[0034] The three-phase mounting bracket 12 is connected to an external motor and is used to output phase current to provide three-phase power to the motor. The three-phase mounting bracket 12 and the housing 1 are sealed with FIPG end face sealing technology.

[0035] In this embodiment of the present invention, such as Figure 3 As shown, the boost module may include a boost converter busbar 16 and a relay 18.

[0036] One end of the boost converter copper busbar 16 is connected to the output terminal of the film capacitor 9, the input terminal of the relay 18 is connected to the other end of the boost converter copper busbar 16, and the output terminal is connected to the neutral point of the three-phase fixed base 12. Specifically, the third high-voltage busbar 6, the second high-voltage busbar 5, the first filter module 14, the second filter module 15, the boost converter copper busbar 16, and the relay 18 cooperate to form a boost module, which enters the motor to form a high-voltage circuit for the boost module. In addition, all the above components are fastened to the housing 1 with bolts.

[0037] In this embodiment of the present invention, such as Figure 2 As shown, the inverter brick module may also include a bus current sensor 11. Specifically, the bus current sensor 11 is mounted on the water channel substrate 10 and connected to the thin-film capacitor 9. Specifically, the bus current sensor 11 is connected to the negative copper busbar of the thin-film capacitor 9 via an M4 bolt for detecting the bus current.

[0038] In this embodiment of the present invention, such as Figure 1 As shown, it may also include a controller cover 2. Specifically, the controller cover 2 and the housing 1 cooperate to form a sealing structure. The seal between the controller cover 2 and the housing 1 is achieved using a FIPG end-face seal process.

[0039] In this embodiment of the present invention, such as Figure 1 As shown, it may also include a junction box cover 3, which is disposed on the controller cover 2, and the junction box cover 3 and the controller cover 2 are sealed with CIPG end face sealing technology.

[0040] In this embodiment of the present invention, the high-voltage current flow inside the controller is divided into two parts. The first part: the bus current is filtered by the first filter module 14 and the second filter module 15, and then buffered by the film capacitor 9 to supply DC power to the SIC module 13. After passing through the silicon carbide, the three-phase power is output to the three-phase fixed base 12, and finally flows into the motor to form the MCU high-voltage circuit. The second part: the bus current is filtered by the first filter module 14 and the second filter module 15, and then filtered by the film capacitor 9 to enter the boost converter copper busbar 16. After passing through the relay 18 and the neutral point copper busbar in the three-phase fixed base 12, it finally enters the motor to form the boost module high-voltage circuit.

[0041] Through the above technical solution, the electric vehicle drive motor controller provided by this utility model can effectively improve the integration of the internal structure of the housing 1 by adopting an inverter brick module, which facilitates aging tests and is easy to assemble. At the same time, the boost module is integrated inside the housing 1 and shares some inputs and outputs with the inverter brick module, which further improves the integration of the housing 1 and also increases the output voltage of the controller, effectively improving the charging efficiency.

[0042] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0043] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A drive motor controller for an electric vehicle, characterized in that, include: case; The inverter brick module is located inside the housing; The boost module is located inside the housing and is distributed in parallel with the inverter brick module; The input module is fixedly inserted through the housing, with one end connected to the external high-voltage busbar and the other end used to connect to the input terminals of the inverter brick module and the boost module. The output module is fixedly inserted through the housing, with one end connected to the output end of the inverter brick module and the boost module, and the other end used to connect to an external motor.

2. The electric vehicle drive motor controller according to claim 1, characterized in that, The input module includes: The first high-voltage busbar is connected at one end to the positive input of the inverter brick module at the other end. The second high-voltage busbar is connected at one end to the negative input terminal of the inverter brick module and the negative input terminal of the boost module. The third high-voltage busbar is connected at one end to the positive input of the boost module.

3. The electric vehicle drive motor controller according to claim 1, characterized in that, The input module further includes: The first filtering module is located inside the input module, with one end connected to the other end of the input module; The second filter module is located at the end of the first filter module away from the input module and is connected to the output terminal of the first filter module. The output terminal of the second filter module is connected to the input terminals of the inverter module and the boost module.

4. The electric vehicle drive motor controller according to claim 3, characterized in that, The first filtering module and the second filtering module include LC filters.

5. The electric vehicle drive motor controller according to claim 3, characterized in that, The inverter brick module includes: A waterway base plate is disposed at the inner bottom of the housing; A thin-film capacitor is disposed at the inner bottom of the waterway substrate and is connected to the output terminal of the second filter module; A SiC module is disposed in the middle of the water channel substrate, and the input terminal of the SiC module is connected to the output terminal of the thin film capacitor. A drive board is disposed on top of the water channel substrate, and the input end of the drive board is connected to the output end of the SIC module.

6. The electric vehicle drive motor controller according to claim 5, characterized in that, The inverter brick module also includes: The water inlet is fixedly inserted through one side of the housing and communicates with one end of the water channel formed by the housing and the water channel base plate; The water outlet is fixedly inserted through the other side of the housing and communicates with the other end of the water channel formed by the housing and the water channel base plate.

7. The electric vehicle drive motor controller according to claim 5, characterized in that, The output module includes a three-phase mounting base, which is fixedly inserted through the housing. The input end of the three-phase mounting base is connected to the output end of the SIC module, and the output end of the three-phase mounting base is used to connect to an external motor.

8. The electric vehicle drive motor controller according to claim 7, characterized in that, The boost module includes: A boost converter copper busbar is connected at one end to the output terminal of the thin film capacitor; The relay has its input terminal connected to the other end of the boost converter copper busbar and its output terminal connected to the neutral point of the three-phase fixed base.

9. The electric vehicle drive motor controller according to claim 5, characterized in that, The inverter brick module also includes a bus current sensor, which is disposed on the water channel substrate and connected to the thin film capacitor.

10. The electric vehicle drive motor controller according to claim 1, characterized in that, It also includes a controller cover, which cooperates with the housing to form a sealed structure.

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