A motor controller structure

Abstract

The utility model discloses a kind of motor controller structures, the shell inside motor controller is equipped with power module, capacitor module, filter module, control circuit board, waterway structure is embedded on the inner wall of the shell, the waterway structure both ends connect the water tap of shell left and right sides, two The water tap is symmetrically arranged, the power module is fixed on the waterway structure above between water tap, the power module is covered with isolation plate, the power module is filled with heat-conducting silicone grease between waterway structure.The utility model's motor controller structure power module generates heat when working, by heat-conducting silicone grease between it and shell is transferred to shell with waterway, finally by cooling fluid flowing in waterway, complete heat dissipation;Isolation plate is blocked by physical isolation and grounding treatment, electromagnetic radiation generated when power module works is prevented to spread to control circuit board, guarantee control signal stable transmission.

Description

Technical Field

[0001] This utility model relates to the field of motor control technology. Background Technology

[0002] Electric motors are widely used in various industries such as new energy vehicles and new energy ship power. For example, the published document with authorization announcement number CN204633668U, application publication date of 2015-09-09, and patent name "An Automobile Motor Controller" discloses an automobile motor controller, which includes a housing, diodes, several power modules and several relays. The power modules are connected in parallel and convert the externally input DC power into AC power for output. It also includes a DC composite bus and an AC composite bus. The DC composite bus connects the relays and diodes on the DC input side of the power modules to the power modules, and the AC composite bus connects the relays on the AC output side of the power modules to the power modules.

[0003] As a core component that works with a motor, the performance of the motor controller directly affects the motor's operating performance. Currently, conventional motor controllers have the following characteristics: For products such as new energy vehicles that are sensitive to installation space, the motor controller is large in size, which will reduce the available space inside the vehicle; For products with low space sensitivity, such as ships and commercial vehicles, the size of the motor controller has little impact on the internal space of the equipment. However, from the perspective of cost control, it is still necessary to minimize its size while meeting functional requirements. However, with the increasing power of electrical components such as motors, electrical components will interfere with each other due to electromagnetic radiation. The current conventional layout design of motor controllers can no longer meet the requirements of anti-interference. Furthermore, since the precision requirements of current electrical control equipment are higher, such interference will affect the precision of electrical control. Therefore, it is necessary to design a new structural layout for motor controllers. Summary of the Invention

[0004] The technical problem to be solved by this utility model is to realize a controller structure that makes the motor controller work more reliably through reasonable layout and structural design.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a motor controller structure, wherein the motor controller housing is provided with a power module, a capacitor module, a filter module, and a control circuit board, a water channel structure is embedded in the inner wall of the housing, the two ends of the water channel structure are connected to the water nozzles on the left and right sides of the housing, the two water nozzles are symmetrically arranged, the power module is fixed above the water channel structure between the water nozzles, the power module is covered with an isolation plate, the power module is fixed above the water channel of the housing by bolts, and thermally conductive silicone grease is filled between the power module and the water channel structure.

[0006] Both the isolation plate and the waterway structure are made of aluminum. The control circuit board is fixed in the groove above the isolation plate. The two sides of the isolation plate are turned up, and the cross-section is U-shaped, forming a groove to wrap the control circuit board. The isolation plate separates the power module and the control circuit board.

[0007] The isolation plate has an H-shaped cross-section, forming a structure with grooves on both sides. The grooves below the isolation plate and the water channel structure form a shielding layer that completely encloses the power module.

[0008] The isolation plate is in contact with water channel structures on both sides, and thermally conductive silicone grease is filled between the isolation plate and the power module.

[0009] The capacitor module is fixed inside the housing on one side of the power module, and the copper busbar, filter module, and terminal block are fixed inside the housing on the other side of the power module. The terminal block is connected to the gland on the side of the housing.

[0010] The housing consists of a device compartment with an opening at the top and a cover plate covering the device compartment. The device compartment and the cover plate are provided with corresponding fixing holes. The fixing holes are provided with bolts to connect and fix the device compartment and the cover plate. The part of the device compartment and the cover plate in contact is provided with a rubber gasket.

[0011] The motor controller is a motor controller for new energy vehicles or a motor controller for new energy ships.

[0012] The heat generated by the power module during operation of the motor controller structure of this utility model is transferred to the housing with water channels through the thermal grease applied between the power module and the housing, and is finally carried away by the coolant flowing in the water channels, thus completing the heat dissipation; the isolation plate, through physical isolation and grounding, blocks the electromagnetic radiation generated by the power module during operation from propagating to the control circuit board, ensuring stable transmission of control signals. Attached Figure Description

[0013] The following is a brief explanation of the content and markings in each of the accompanying drawings in this utility model specification: Figure 1 This is a schematic diagram of the motor controller structure; Figure 2This is the internal electrical schematic diagram of the motor controller; The markings in the above diagrams are as follows: 1. Terminal block; 2. Filter module; 3. Copper busbar; 4. Control circuit board; 5. Power module; 6. Isolation board; 7. Water tap; 8. Capacitor module; 9. Gland; 10. Current sensor. Detailed Implementation

[0014] The following description, with reference to the accompanying drawings, details the specific implementation of this utility model, including the shape and structure of each component, the relative positions and connections between the parts, the function and working principle of each part, the manufacturing process, and the operation and use methods. This will help those skilled in the art to have a more complete, accurate, and in-depth understanding of the inventive concept and technical solution of this utility model.

[0015] The internal components of the motor controller of this utility model can be configured as needed, but the core power module 5, capacitor module 8, filter module 2, and control circuit board 4 are definitely present. The electrical connection between these components can be done in the existing way or designed according to product needs. The components are connected by wire harnesses, wires or copper busbars 3. If it is necessary to pass through some components (such as isolation plate 6), it can be done by roughly passing the wire. The specific electrical connection method is not the protection content of this utility model and will not be described in detail.

[0016] Core component composition: Power Module 5: As the main heat source and power output unit, it integrates power devices such as IGBT (Insulated Gate Bipolar Transistor) and diodes, and is responsible for inverting DC voltage into adjustable AC voltage; Capacitor module 8: Used for filtering and energy storage, providing a stable operating voltage for power module 5; Filtering module 2: Used to filter the current transmitted by the input and output copper busbars 3 to reduce current fluctuations; Control circuit board 4: integrates MCU (microcontroller unit), sensor interface, communication interface, etc., and is responsible for receiving external commands and outputting weak control signals; Isolation plate 6: Made of aluminum, used to isolate strong signals from weak signals and reduce electromagnetic interference; Housing: It has a water channel structure for mounting various components and heat dissipation, and coolant can be introduced into the water channel; Shielded wire: Used to transmit weak control signals output by control circuit board 4, reducing interference during signal transmission; Copper busbar 3: Equipped with a filter component, used to connect the external power supply to capacitor module 8.

[0017] An embedded water channel structure runs along the bottom of the casing, with each end connecting to a water inlet 7 on the left and right sides of the casing. One water inlet 7 is an inlet, and the other is an outlet. The power module 5 is fixed to the water channel structure between the water inlets 7. Since the water level is lowest at the inlet, it is fixed closer to the inlet to ensure priority cooling and improve cooling efficiency. The power module 5 is bolted to the center area above the casing's water channel, with thermal grease applied between them to ensure efficient heat transfer. The capacitor module 8 is located behind the power module 5 and connects directly to its input terminal via pins for voltage transmission. An isolation plate 6 is mounted above the power module 5 via a support structure on the casing, maintaining a certain distance from it. The control circuit board 4 is mounted above the isolation plate 6 using a rivet nut. The isolation plate 6 employs a bent design to separate the input copper busbar 3 with the filter components from the power module 5. Both the isolation plate 6 and the water channel structure are made of aluminum. The cross-section of the isolation plate 6 is n-shaped, with grooves on the lower surface. The grooves on the lower surface of the isolation plate 6 and the water channel structure form a shielding layer that completely encloses the power module 5. The isolation plate 6 and the water channel structure can be used together to achieve full enclosure and isolation, improving the isolation effect. The two sides of the isolation plate 6 contact the water channel structure. Thermal grease is filled between the isolation plate 6 and the power module 5, which can also be used for heat dissipation. The isolation plate 6 absorbs the heat from the upper surface of the power module 5 and transfers it to the water channel structure, further improving the heat dissipation effect.

[0018] The internal layout of the housing is as follows: the capacitor module 8 is fixed inside the housing on one side of the power module 5, while the copper busbar 3, filter module 2, and terminal block 1 are fixed inside the housing on the other side of the power module 5. The terminal block 1 is connected to the gland 9 on the side of the housing. The control circuit board 4 is fixed to the upper surface of the isolation plate 6. The isolation plate 6 can be configured with upward folding structures on both sides to form U-shaped grooves (the isolation plate 6 can be configured with both U-shaped and N-shaped cross-sections, forming an overall H-shape with grooves on both sides to protect the control circuit board 4 and the power module 5). The isolation plate 6 separates the power module 5 and the control circuit board 4. The grooves on the upper surface of the isolation plate 6 also protect and isolate the control circuit board 4 and assist in heat dissipation. The control circuit board 4 is connected to the signal input terminal of the power module 5 through shielded wires to achieve control signal transmission. The terminal block 1 is located on the outside of the housing, isolating the internal structure of the motor controller from the external wiring points, facilitating external wiring connections. Terminal block 1 isolates the internal structure of the motor controller from the external wiring points, which not only facilitates the installation and disassembly of external wiring, but also prevents collisions and damage to internal components during external wiring, thus providing protection.

[0019] The housing consists of a top-opening component compartment and a cover plate covering the component compartment. The two parts facilitate the installation of components. The component compartment and the cover plate have corresponding fixing holes, and bolts are installed in the fixing holes to connect and fix the component compartment and the cover plate. Rubber gaskets are provided at the contact parts of the component compartment and the cover plate to enhance the protective capability of the housing.

[0020] The motor controller is for new energy vehicles or new energy ships. Its operation involves an external power supply connected to a capacitor module 8 via an input copper busbar 3 with a filter. The capacitor module 8 filters and stores the input voltage, then transmits a stable DC voltage to the power module 5 via the copper busbar 3. The control circuit board 4 receives external control signals (such as motor speed and steering commands), processes them through the MCU, and outputs a weak control signal (PWM pulse signal). This signal is transmitted to the signal input terminal of the power module 5 via a shielded wire. The power module 5, based on the received control signal, inverts the DC voltage from the capacitor module 8 into an AC voltage with adjustable voltage and frequency, and outputs it to the motor via the output copper busbar 3, driving the motor to operate according to the command. The heat generated by the power module 5 during operation is transferred to the water-channeled housing via thermal grease applied between it and the housing, and finally carried away by the coolant flowing within the water channels, completing heat dissipation. The isolation plate 6, through physical isolation and grounding, prevents electromagnetic radiation generated by the power module 5 during operation from propagating to the control circuit board 4, ensuring stable transmission of control signals.

[0021] This utility model of motor controller structure can be applied to the power system of new energy vehicles and new energy ships. It is a core control component that is matched with the motor and can be used to adjust the motor's operating state to ensure the motor works stably and efficiently.

[0022] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A motor controller structure, wherein the motor controller housing contains a power module, a capacitor module, a filter module, and a control circuit board, characterized in that: A water channel structure is embedded in the inner wall of the housing. The two ends of the water channel structure are connected to water nozzles on the left and right sides of the housing. The two water nozzles are symmetrically arranged. The power module is fixed above the water channel structure between the water nozzles. The power module is covered with an isolation plate. Thermal grease is filled between the power module and the water channel structure.

2. The motor controller structure according to claim 1, characterized in that: Both the isolation plate and the waterway structure are made of aluminum. The control circuit board is fixed in the groove above the isolation plate. The two sides of the isolation plate are turned up, and the cross-section is U-shaped, forming a groove to wrap the control circuit board. The isolation plate separates the power module and the control circuit board.

3. The motor controller structure according to claim 2, characterized in that: The isolation plate has an H-shaped cross-section, forming a structure with grooves on both sides. The grooves below the isolation plate and the water channel structure form a shielding layer that completely encloses the power module.

4. The motor controller structure according to claim 3, characterized in that: The isolation plate is in contact with water channel structures on both sides, and thermally conductive silicone grease is filled between the isolation plate and the power module.

5. The motor controller structure according to any one of claims 1-4, characterized in that: The capacitor module is fixed inside the housing on one side of the power module. The filter module is used to filter the current transmitted by the input and output copper busbars. The copper busbars, filter module, and terminal block are fixed inside the housing on the other side of the power module. The terminal block is connected to the gland on the side of the housing.

6. The motor controller structure according to claim 5, characterized in that: The housing consists of a device compartment with an opening at the top and a cover plate covering the device compartment. The device compartment and the cover plate are provided with corresponding fixing holes. The fixing holes are provided with bolts to connect and fix the device compartment and the cover plate. The part of the device compartment and the cover plate in contact is provided with a rubber gasket.

7. The motor controller structure according to claim 1 or 6, characterized in that: The motor controller is a motor controller for new energy vehicles or a motor controller for new energy ships.

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