Motor controller and electric drive assembly

Abstract

The application discloses a motor controller and an electric drive assembly. The motor controller comprises a shell, a first power assembly, a second power assembly and an alternating current output assembly. Three output ports of the first power assembly are used to output three-phase current to one motor, and three output ports of the second power assembly are used to output three-phase current to another motor. The alternating current output assembly comprises a first insulating shell, a first output copper bar group and a second output copper bar group. The first insulating shell comprises a first insulating part and a second insulating part connected with each other. Six independent mounting channels are arranged in the first insulating shell. The first output copper bar group comprises three first output copper bars, and the second output copper bar group comprises three second output copper bars. The three first output copper bars and the three second output copper bars are arranged in the six mounting channels in a one-to-one correspondence. The motor controller can improve the integration of the motor controller and facilitate the arrangement of double motors.

Description

Technical Field

[0001] This utility model relates to the field of vehicle technology, and in particular to a motor controller and electric drive assembly. Background Technology

[0002] With increasing global emphasis on environmental protection and sustainable development, the market demand for electric vehicles (including electric cars and electric motorcycles) as green transportation tools continues to grow. The power system is a core component of an electric vehicle, mainly composed of key components such as batteries, motors, and motor controllers. Among these, the motor, as the actuator that converts electrical energy into mechanical energy, directly determines the vehicle's power, efficiency, and reliability.

[0003] To continuously improve the performance and energy efficiency of electric vehicles and meet users' demands for higher power and better power distribution, the industry has begun to widely adopt dual-motor drive systems. These systems, through the coordinated operation of two motors, can achieve higher total power density and possess more flexible and precise power distribution capabilities.

[0004] In existing dual-motor system designs, the corresponding motor controllers typically have three or two sets of AC output copper busbars to correspond to the two motors respectively. This design requires each AC output copper busbar to have its own fixing and insulation structure, which increases the number of components, makes the internal wiring complex, occupies a large space and has low integration. Furthermore, the dispersed AC copper busbars will increase the space occupied when connected to the two motors, which is not conducive to the arrangement of dual motors and the overall system efficiency is low. Utility Model Content

[0005] The purpose of this utility model is to provide a motor controller and electric drive assembly that can improve the integration of the motor controller and facilitate the spatial arrangement of dual motors.

[0006] On one hand, this utility model provides a motor controller for driving dual motors, the motor controller comprising: shell; A first power component and a second power component are disposed within the housing. Both the first power component and the second power component have three output ports. The three output ports of the first power component are used to output three-phase current to one of the motors, and the three output ports of the second power component are used to output three-phase current to the other motor. An AC output assembly, comprising a first insulating housing, a first output copper busbar group, and a second output copper busbar group, wherein the first insulating housing comprises a first insulating part and a second insulating part connected to each other, the first insulating part and the second insulating part being arranged at an angle, the first insulating part extending at least partially into the housing, and the second insulating part being located outside the first insulating part; The first insulating housing has six independent mounting channels. The first end of each of the six mounting channels is located on the side of the first insulating part facing the output port, and the second end of each of the six mounting channels is located on the second insulating part. The first output copper busbar group includes three first output copper busbars, and the second output copper busbar group includes three second output copper busbars. Each first output copper busbar and each second output copper busbar is correspondingly inserted into one of the six mounting channels. One end of each of the three first output copper busbars is connected to one of the three output ports of the first power component, and one end of each of the three second output copper busbars is connected to one of the three output ports of the second power component.

[0007] In one exemplary embodiment of this disclosure, the six mounting channels are a first mounting channel, a second mounting channel, a third mounting channel, a fourth mounting channel, a fifth mounting channel, and a sixth mounting channel. The second ends of the first mounting channel to the third mounting channel and the second ends of the fourth mounting channel to the sixth mounting channel are located on opposite sides of the second insulating portion. One end of each of the three first output copper busbars passes through the second ends of the first mounting channel to the third mounting channel, and one end of each of the three second output copper busbars passes through the second ends of the fourth mounting channel to the sixth mounting channel.

[0008] In one exemplary embodiment of this disclosure, the second ends of the first to third mounting channels and the second ends of the fourth to sixth mounting channels are all spaced apart along the length direction of the second insulating portion.

[0009] In one exemplary embodiment of this disclosure, the first ends of the first to sixth mounting channels are spaced apart along the length direction of the first insulating portion; The three output ports of the first power component are respectively configured to correspond one-to-one with the first end of the first to third mounting channels, and the three output ports of the second power component are respectively configured to correspond one-to-one with the first end of the fourth to sixth mounting channels.

[0010] In one exemplary embodiment of this disclosure, the first ends of the first to sixth mounting channels are arranged sequentially along the length direction of the first insulating portion; The second ends of the first to third mounting channels are arranged sequentially along the length of the second insulating portion, and the distance between the second ends of the first to third mounting channels and the first insulating portion gradually increases. The second ends of the fourth to sixth mounting channels are arranged sequentially along the length of the second insulating portion, and the distance between the second ends of the fourth to sixth mounting channels and the first insulating portion gradually decreases.

[0011] In one exemplary embodiment of this disclosure, a mounting groove is provided on the side of the housing for the first insulating portion to extend into; The first insulating housing further includes a connecting portion disposed around the first insulating portion, the connecting portion abutting against and being detachably connected to the side of the housing.

[0012] In one exemplary embodiment of this disclosure, the first insulating portion extends along the length direction of the housing, the second insulating portion extends along the width direction of the housing, and the second insulating portion is connected to the middle portion of the first insulating portion.

[0013] In one exemplary embodiment of this disclosure, the first power component includes a first power module and a first adapter, and the second power component includes a second power module and a second adapter. The first power module has three output ports, and the second power module has three output ports. The three output ports of the first power module and the three output ports of the second power module are spaced apart along the length direction of the first insulating portion. The first adapter includes three first adapter copper busbars. The first ends of the three first adapter copper busbars are used to connect one-to-one with the three output ports of the first power module, and the second ends of the three first adapter copper busbars are used to connect one-to-one with the three first output copper busbars. The second adapter includes three second adapter copper busbars. The first ends of the three second adapter copper busbars are used to connect one-to-one with the three output ports of the second power module, and the second ends of the three second adapter copper busbars are used to connect one-to-one with the three second output copper busbars. Along the length of the first insulating portion, the distance between the second ends of adjacent first transition copper busbars is smaller than the distance between their corresponding first ends, and the distance between the second ends of adjacent second transition copper busbars is smaller than the distance between their corresponding first ends.

[0014] In one exemplary embodiment of this disclosure, the motor controller further includes a second insulating housing, which has six independent receiving channels along the length of the first insulating portion, and the three first transition copper busbars and the three second transition copper busbars are respectively inserted into the six receiving channels.

[0015] On the other hand, the present invention also provides an electric drive assembly, including the motor controller and two motors, the second insulating part extending between the two motors, and the first output copper busbar group and the second output copper busbar group being electrically connected to the two motors respectively.

[0016] As can be seen from the above technical solution, the beneficial effects of this utility model are as follows: In this application, an AC output component is provided, comprising a first insulating housing, a first output copper busbar group, and a second output copper busbar group. The first insulating housing includes a first insulating part and a second insulating part, with six mounting channels within the first insulating part. Three first output copper busbars from the first output copper busbar group and three second output copper busbars from the second output copper busbar group are respectively inserted into these six mounting channels, thus integrating the first and second output copper busbar groups into a single unit. The use of a single first insulating housing to fix and insulate each output copper busbar improves the integration of the motor controller, reduces internal space occupation, and minimizes the number of components used. Furthermore, since one end of both the first and second output copper busbar groups extends through the second insulating part, the output ends of the first and second output copper busbar groups are concentrated together, facilitating insertion between two motors. This reduces the space occupied when connecting to the two motors, simplifies the arrangement of the two motors, and ultimately improves the overall system efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the motor controller in this embodiment.

[0018] Figure 2 This is a schematic diagram of the structure of the motor controller after the upper housing is hidden in this embodiment.

[0019] Figure 3 This is a schematic diagram of the structure of the motor controller after the first insulating shell is hidden in this embodiment.

[0020] Figure 4 This is a schematic diagram of the AC output component in this embodiment.

[0021] Figure 5 This is a schematic diagram of the AC output component from another direction in this embodiment.

[0022] Figure 6 This is a side view of the AC output component in this embodiment.

[0023] Figure 7 yes Figure 6 A cross-sectional view along the AA direction.

[0024] Figure 8 This is an assembly diagram of the second insulating shell, the first adapter, and the second adapter in this embodiment.

[0025] Figure 9 This is a top view of the second insulating shell, the first adapter, and the second adapter in this embodiment.

[0026] Figure 10 yes Figure 9 Cross-sectional view along the BB direction.

[0027] Figure 11 This is an assembly diagram of the motor controller and the motor in this embodiment.

[0028] The annotations in the attached figures are explained as follows: Motor controller 1, housing 10, upper housing 101, lower housing 102, mounting slot 103, first power component 11, first power module 110, first adapter 111, first adapter copper busbar 1111, second power component 12, second power module 120, second adapter 121, second adapter copper busbar 1211, AC output component 13, first insulating housing 130, first insulating part 1301, second insulating part 1302, first mounting channel 1303, second mounting channel 1304, third mounting channel 130 5. Fourth mounting channel 1306, fifth mounting channel 1307, sixth mounting channel 1308, connecting part 1309, first output copper busbar group 131, first output copper busbar 1310, second output copper busbar group 132, second output copper busbar 1320, connecting ear 133, second insulating shell 14, receiving channel 140, first receiving channel 1401, second receiving channel 1402, third receiving channel 1403, fourth receiving channel 1404, fifth receiving channel 1405, sixth receiving channel 1406, motor 2. Detailed Implementation

[0029] Typical embodiments embodying the features and advantages of this utility model will be described in detail in the following description. It should be understood that this utility model can have various variations in different embodiments, all of which do not depart from the scope of this utility model, and the descriptions and illustrations therein are for illustrative purposes only and not intended to limit this utility model.

[0030] In the description of this application, it should be understood that, in the embodiments shown in the accompanying drawings, the indications of direction or positional relationships (such as up, down, left, right, front, and back, etc.) are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. These descriptions are appropriate when these elements are in the positions shown in the accompanying drawings. If the description of the positions of these elements changes, these directional indications also change accordingly.

[0031] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0032] See Figures 1 to 10 On one hand, this utility model embodiment provides a motor controller 1 for driving dual motors 2. The motor controller 1 includes a housing 10, a first power component 11, a second power component 12, and an AC output component 13. The first power component 11 and the second power component 12 are disposed within the housing 10. The three output ports of the first power component 11 are used to output three-phase current to one of the motors 2, and the three output ports of the second power component 12 are used to output three-phase current to the other motor 2. The AC output component 13 includes a first insulating housing 130, a first output copper busbar group 131, and a second output copper busbar group 132. The first insulating housing 130 includes a first insulating part 1301 and a second insulating part 1302 connected to each other. The first insulating part 1301 and the second insulating part 1302 are arranged at an included angle. The first insulating part 1301 at least partially extends into the housing 10, and the second insulating part 1302 is located outside the first insulating part 1301. The housing 130 has six independent mounting channels. The first end of each of the six mounting channels is located on the side of the first insulating part 1301 facing the output port, and the second end of each of the six mounting channels is located on the second insulating part 1302. The first output copper busbar group 131 includes three first output copper busbars 1310, and the second output copper busbar group 132 includes three second output copper busbars 1320. Each first output copper busbar 1310 and each second output copper busbar 1320 is correspondingly installed in the six mounting channels. One end of each of the three first output copper busbars 1310 is connected to one of the three output ports of the first power component 11, and one end of each of the three second output copper busbars 1320 is connected to one of the three output ports of the second power component 12.

[0033] In this utility model, by setting up an AC output component 13, the AC output component 13 includes a first insulating housing 130, a first output copper busbar group 131, and a second output copper busbar group 132. The first insulating housing 130 includes a first insulating part 1301 and a second insulating part 1302. The first insulating part 1301 is provided with six mounting channels, and the three first output copper busbars 1310 in the first output copper busbar group 131 and the three second output copper busbars 1320 in the second output copper busbar group 132 are respectively passed through the six mounting channels, so that the first output copper busbar group 131 and the second output copper busbar group 132 are integrated together. By setting up a single first insulating housing 130 to fix and insulate each output copper busbar, the integration of the motor controller 1 is improved, the internal space occupancy is reduced, and the number of components used is reduced. Meanwhile, since one end of the first output copper busbar group 131 and the second output copper busbar group 132 both protrude through the second insulating part 1302, the output ends of the first output copper busbar group 131 and the second output copper busbar group 132 are concentrated together, so that they can be inserted between the two motors 2, reducing the space occupied when connecting with the two motors 2, facilitating the arrangement of the two motors 2, and thus improving the overall efficiency of the system.

[0034] The motor controller 1 in the embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0035] See Figures 1 to 3 The motor controller 1 includes a housing 10, a first power component 11, a second power component 12, and an AC output component 13.

[0036] The housing 10 has an internal installation space for accommodating and installing other components of the motor controller 1. The housing 10 can be a rectangular parallelepiped, a cube, or other irregularly shaped structure. To facilitate the installation of the motor controller 1, the housing 10 may include an upper housing 101 and a lower housing 102, which are detachably connected and enclose the installation space of the housing 10.

[0037] In this embodiment, the first power component 11 is disposed inside the housing 10. The first power component 11 has three output ports. The three output ports of the first power component 11 are connected to one of the two motors 2 and are used to output three-phase current to drive the motor 2 to operate. Each output port is used to output one of the V-phase current, W-phase current and U-phase current.

[0038] In this embodiment, the second power component 12 is disposed inside the housing 10. The second power component 12 has three output ports. The three output ports of the second power component 12 are connected to another motor 2 in the dual motors 2 and are used to output three-phase current to drive the motor 2 to operate. Each output port is used to output one of the V-phase current, W-phase current and U-phase current.

[0039] For motor controller 1, it first receives DC power from battery module. After DC power enters first power component 11 and second power component 12, first power component 11 and second power component 12 convert DC power into three-phase AC power according to the instructions of control unit, and output the three-phase AC power to the corresponding motor 2 through AC output component 13.

[0040] In this embodiment, the AC output assembly 13 includes a first insulating housing 130, a first output copper busbar assembly 131, and a second output copper busbar assembly 132. The first insulating housing 130 is used to mount the first output copper busbar assembly 131 and the second output copper busbar assembly 132, so that the first output copper busbar assembly 131 and the second output copper busbar assembly 132 are centrally mounted within the first insulating housing 130, forming a single unit. The first insulating housing 130 ensures the electrical insulation and mechanical strength of the first output copper busbar assembly 131 and the second output copper busbar assembly 132.

[0041] The first output copper busbar group 131 includes three first output copper busbars 1310 corresponding to the transmission of three-phase current. The first output copper busbars 1310 can be flat copper strip structures, which are conducive to the transmission of large currents. One end of each of the three first output copper busbars 1310 is connected to one of the three output ports of the first power component 11, and the other end of each of the three first output copper busbars 1310 is connected to one of the motors 2, so that the first power component 11 transmits three-phase current to the corresponding motor 2 through the first output copper busbar group 131. The three first output copper busbars 1310 respectively transmit one of the V-phase current, W-phase current and U-phase current.

[0042] The second output copper busbar group 132 includes three second output copper busbars 1320 corresponding to the transmission of three-phase current. The structure of the second output copper busbars 1320 can be the same as that of the first output copper busbar 1310, and it can be a flat copper strip structure, which is conducive to the transmission of large current. One end of the three second output copper busbars 1320 is connected to the three output ports of the second power component 12 in a one-to-one correspondence, and the other end of the three second output copper busbars 1320 is connected to another motor 2, so that the second power component 12 transmits the three-phase current to the corresponding motor 2 through the second output copper busbar group 132. The three second output copper busbars 1320 respectively transmit one of the V-phase current, W-phase current and U-phase current.

[0043] join Figures 4 to 7In this embodiment, the first insulating shell 130 includes a first insulating part 1301 and a second insulating part 1302 connected to each other. The first insulating part 1301 and the second insulating part 1302 are arranged at an included angle, which can be an acute angle, an obtuse angle, or a right angle. The first insulating shell 130 can be made of a plastic material with high temperature resistance and good insulation properties, such as PBT (Polybutylene terephthalate) or PA (Polyamide), to ensure electrical insulation and structural strength.

[0044] In this embodiment, the included angle between the first insulating part 1301 and the second insulating part 1302 is a right angle, such that the first insulating part 1301 and the second insulating part 1302 are perpendicularly connected. The second insulating part 1302 can be connected to the end of the first insulating part 1301 or to the middle of the first insulating part 1301. In this embodiment, the second insulating part 1302 is perpendicularly connected to the middle of the first insulating part 1301, making the first insulating housing 130 have an overall T-shaped structure. The first insulating part 1301 extends at least partially into the outer shell 10, and the second insulating part 1302 is located outside the first insulating part 1301, that is, outside the outer shell 10. The first insulating part 1301 can extend along the length direction of the outer shell 10, and the second insulating part 1302 can extend along the width direction of the outer shell 10, both forming a long strip structure. The first insulating part 1301 is installed on the side of the outer shell 10, which makes it easier for the second insulating part 1302 to extend between the two motors 2.

[0045] In this embodiment, the first insulating part 1301 and the second insulating part 1302 can be integrally injection molded to form the first insulating shell 130.

[0046] In this embodiment, the first insulating housing 130 is detachably mounted to the outer casing 10. The first insulating housing 130 may further include a connecting portion 1309 surrounding the first insulating portion 1301. The connecting portion 1309 may be annular to enclose the first insulating portion 1301. The connecting portion 1309 has multiple first screw holes. The side of the outer casing 10 has a mounting groove 103 for the first insulating portion 1301 to extend into, and multiple second screw holes corresponding to the positions of the first screw holes. When installing the first insulating housing 130, a portion of the first insulating portion 1301 extends from the mounting groove 103 into the outer casing 10 until the connecting portion 1309 abuts against the side of the outer casing 10. The connecting portion 1309 is screwed onto the side of the outer casing 10 by bolts passing through the first and second screw holes, thus achieving a detachable connection between the connecting portion 1309 and the outer casing 10, i.e., enabling the detachable installation of the first insulating housing 130 and the outer casing 10. The first insulating housing 130 and the outer housing 10 are connected by screws, which not only facilitates the installation and disassembly of both, but also ensures that the first insulating housing 130 is firmly connected to the outer housing 10 due to the connection of multiple bolt fasteners, thus improving the connection stability.

[0047] In this embodiment, the first insulating housing 130 is detachably installed onto the upper housing 101 via the connecting part 1309. The mounting groove 103 is fully formed on the side of the upper housing 101, which facilitates installation and removal while improving sealing.

[0048] Of course, in some embodiments, the connecting part 1309 and the side of the outer shell 10 can also be bonded and fixed by high-strength adhesive.

[0049] In this embodiment, the connecting portion 1309 can be integrally injection molded with the first insulating portion 1301. A plurality of first screw holes can be spaced apart circumferentially along the connecting portion 1309, thereby improving the connection stability between the connecting portion 1309 and the outer casing 10.

[0050] In this embodiment, the first insulating housing 130 has six independent mounting channels. The first end of each mounting channel is located on the side of the first insulating part 1301 facing the output port, and the second end of each mounting channel is located on the second insulating part 1302. It can be understood that each mounting channel has a first segment and a second segment that are interconnected. The first segment is located within the first insulating part 1301, and the second segment is located within the second insulating part 1302. The first end and the second end of the mounting channel refer to their two ends in their extending direction. Three first output copper busbars 1310 and three second output copper busbars 1320 are correspondingly installed in the six mounting channels, ensuring that each first output copper busbar 1310 and second output copper busbar 1320 is isolated and independent from each other, preventing contact. The mounting channels provide electrical insulation and mounting fixation for the first output copper busbars 1310 and second output copper busbars 1320.

[0051] In this embodiment, a first insulating housing 130 is provided, with six independent mounting channels within it for mounting the first output copper busbar 1310 and the second output copper busbar 1320. This integrates the first output copper busbar group 131 and the second output copper busbar group 132 with the first insulating housing 130. By using a single first insulating housing 130 to fix and insulate each output copper busbar, the integration of the motor controller 1 is improved, internal space occupancy is reduced, and the number of components used is reduced. Furthermore, since one end of each of the first output copper busbar 1310 and the second output copper busbar 1320 protrudes through a mounting channel on the second insulating part 1302, the output ends of each of the first output copper busbar 1310 and the second output copper busbar 1320 extend from the second insulating part 1302, facilitating their insertion between the two motors 2. This reduces the space occupied when connecting to the two motors 2, simplifies the arrangement of the two motors 2, and ultimately improves the overall system efficiency.

[0052] In this embodiment, the extension direction of the first output copper busbar 1310 can be consistent with the extension direction of its corresponding mounting channel, and the extension direction of the second output copper busbar 1320 can be consistent with the extension direction of its corresponding mounting channel, so that the first output copper busbar 1310 and the second output copper busbar 1320 can be tightly fitted into their corresponding mounting channels.

[0053] See Figure 7 In this embodiment, for ease of explanation, the six mounting channels are designated as a first mounting channel 1303, a second mounting channel 1304, a third mounting channel 1305, a fourth mounting channel 1306, a fifth mounting channel 1307, and a sixth mounting channel 1308. The second ends of the first mounting channels 1303 to the third mounting channels 1305 and the second ends of the fourth to sixth mounting channels 1308 are located on opposite sides of the second insulating portion 1302. That is, the second ends of the first mounting channels 1303 to the third mounting channels 1305 are located on the same side of the second insulating portion 1302, and the second ends of the fourth mounting channels 1306 to the sixth mounting channels 1308 are located on the same side of the second insulating portion 1302, and are positioned opposite to the second ends of the first mounting channels 1303 to the third mounting channels 1305.

[0054] One end of each of the three first output copper busbars 1310 extends from the second end of the first mounting channel 1303 to the third mounting channel 1305, respectively, for connection to one of the motors 2. One end of each of the three second output copper busbars 1320 extends from the second end of the fourth mounting channel 1306 to the sixth mounting channel 1308, respectively, for connection to the other motor 2. Because the second ends of the first mounting channels 1303 to the third mounting channel 1305 and the second ends of the fourth mounting channels 1306 to the sixth mounting channel 1308 are positioned opposite each other, the three first output copper busbars 1310 and the three second output copper busbars 1320 can extend from opposite sides of the second insulating part 1302. This reduces the likelihood of interference between the first output copper busbar group 131 and the second output copper busbar group 132 when connecting to the two motors 2, making wiring easier and facilitating connection to each motor 2.

[0055] Of course, in some embodiments, the second ends of the first mounting channel 1303 to the sixth mounting channel 1308 can be opened on the same side of the second insulating part 1302, and the three first output copper busbars 1310 and the three second output copper busbars 1320 can arbitrarily pass through the first to the sixth mounting channels 1308.

[0056] In this embodiment, the second ends of the first mounting channel 1303 to the third mounting channel 1305 located on the same side of the second insulating portion 1302 can be spaced apart along the width direction of the second insulating portion 1302 or along the length direction of the second insulating portion 1302. The second ends of the fourth mounting channel 1306 to the sixth mounting channel 1308 located on the same side of the second insulating portion 1302 can be spaced apart along the width direction of the second insulating portion 1302 or along the length direction of the second insulating portion 1302. The length direction of the second insulating portion 1302 is perpendicular to the first insulating portion 1301. When the second ends of the first mounting channel 1303 to the sixth mounting channel 1308 are spaced apart along the length of the second insulating part 1302, one end of each of the three first output copper busbars 1310 and the three second output copper busbars 1320 can be spaced out along the length of the second insulating part 1302. The spatial hierarchy of each first output copper busbar 1310 and second output copper busbar 1320 is more distinct, and it is also easier to connect them one by one with the corresponding adapter copper busbar group on the motor 2.

[0057] In this embodiment, the second ends of the first mounting channel 1303 to the third mounting channel 1305 and the second ends of the fourth mounting channel 1306 to the sixth mounting channel 1308 can be disposed on both sides of the bottom width direction of the second insulating part 1302. After the first output copper busbar 1310 and the second output copper busbar 1320 pass through the second end of the mounting channel, they extend in a direction away from each other and form connecting ears 133 for corresponding connection with the corresponding adapter copper busbar group of the motor 2.

[0058] In this embodiment, the first ends of the first mounting channel 1303 to the sixth mounting channel 1308 are spaced apart along the length direction of the first insulating portion 1301, so that after the first ends of the first output copper busbar group 131 and the second output copper busbar group 132 pass through the first insulating portion 1301, they are also spaced apart along the length direction of the first insulating portion 1301. The first output copper busbar group 131 and the second output copper busbar group 132 are clearly spatially distinct, which facilitates connection with the output ports of the first power component 11 and the second power component 12.

[0059] In this embodiment, the first power component 11 and the second power component 12 can be arranged side by side along the length of the housing 10 to make the most of the space inside the housing 10 for installing the first power component 11 and the second power component 12, thereby improving the space utilization rate inside the housing 10. The three output ports of the first power component 11 and the three output ports of the second power component 12 can be spaced apart along the length of the housing 10. The three output ports of the first power component 11 are respectively arranged in a one-to-one correspondence with the first ends of the first mounting channels 1303 to the third mounting channels 1305, so that one end of the three first output copper busbars 1310 can be connected to the three output ports of the first power component 11 in a one-to-one correspondence. The three output ports of the second power component 12 are respectively arranged in a one-to-one correspondence with the first ends of the fourth mounting channels 1306 to the sixth mounting channels 1308, so that one end of the three second output copper busbars 1320 can be connected to the three output ports of the second power component 12 in a one-to-one correspondence.

[0060] In this embodiment, the first ends of the first mounting channels 1303 to the sixth mounting channels 1308 are arranged sequentially along the length direction of the first insulating portion 1301. That is, in the direction from one end to the other in the length direction of the first insulating portion 1301, the first ends of the first mounting channels 1303, the second mounting channels 1304, the third mounting channels 1305, the fourth mounting channels 1306, the fifth mounting channels 1307, and the sixth mounting channels 1308 are arranged alternately in sequence.

[0061] The second ends of the first mounting channels 1303 to the third mounting channels 1305 are arranged sequentially along the length of the second insulating portion 1302, and the distance between the second ends of the first mounting channels 1303 to the third mounting channels 1305 and the first insulating portion 1301 gradually increases. The second ends of the fourth mounting channels 1306 to the sixth mounting channels 1308 are arranged sequentially along the length of the second insulating portion 1302, and the distance between the second ends of the fourth mounting channels 1306 to the sixth mounting channels 1308 and the first insulating portion 1301 gradually decreases.

[0062] Taking the first mounting channel 1303 and the second mounting channel 1304 as examples, since they are arranged in sequence, in the length direction of the first insulating portion 1301, the first end of the first mounting channel 1303 is farther away from the second insulating portion 1302 than the first end of the second mounting channel 1304, while in the length direction of the second insulating portion 1302, the second end of the first mounting channel 1303 is closer to the first insulating portion 1301 than the second end of the second mounting channel 1304. Therefore, in general, by setting it up in the above manner, the lengths of the first installation channel 1303 and the second installation channel 1304 will be basically the same. Similarly, for the first installation channel 1303 to the sixth installation channel 1308, the lengths of the first installation channel 1303 to the sixth installation channel 1308 will be basically the same. This will result in the lengths of the first output copper busbar 1310 and the second output copper busbar 1320 passing through them being set to be basically the same. The electrical parameters such as the resistance and inductance values ​​of the first output copper busbar 1310 and the second output copper busbar 1320 with the same length will be close to the same. The impedance difference during three-phase current transmission will become extremely small, thereby making the three-phase current transmitted by the first output copper busbar group 131 and the second output copper busbar group 132 more balanced, and the two motors 2 will run more smoothly.

[0063] In this embodiment, along the width direction of the second insulating portion 1302, the second sections of the first mounting channel 1303 to the sixth mounting channel 1308 are stacked together, and adjacent mounting channels share one sidewall. Along the thickness direction of the first insulating portion 1301, the first sections of the first mounting channel 1303 to the third mounting channel 1305 are stacked together, and the first sections of the fourth mounting channel 1306 to the sixth mounting channel 1308 are stacked together.

[0064] See Figure 1 , Figures 8 to 10 In this embodiment, the first power component 11 includes a first power module 110 and a first adapter 111. The first power module 110 is the actuator of the first power component 11, used to convert direct current into alternating current. The first power module 110 has three output ports, which are used to output three-phase current. The first adapter 111 is used to connect the output ports of the first power module 110 and the first output copper busbar group 131, so that the three-phase current is transmitted from the first power module 110 to the first output copper busbar group 131, and finally to the corresponding motor 2.

[0065] In this embodiment, the first adapter 111 includes three first adapter copper busbars 1111. The first ends of the three first adapter copper busbars 1111 are used to connect one-to-one with the three output ports of the first power module 110, and the second ends of the three first adapter copper busbars 1111 are used to connect one-to-one with the three first output copper busbars 1310. The three first adapter copper busbars 1111 are used to transmit one of the U-phase current, W-phase current, and V-phase current, respectively. It should be noted that the first end and the second end of the first adapter copper busbar 1111 refer to the two ends in its length direction, and the second ends of the three first adapter copper busbars 1111 constitute the three output ports of the first power component 11.

[0066] In this embodiment, the second power component 12 includes a second power module 120 and a second adapter 121. The second power module 120 is the actuator of the second power component 12, used to convert direct current into alternating current. The second power module 120 has three output ports, which are used to output three-phase current. The second adapter 121 is used to connect the output ports of the second power module 120 and the second output copper busbar group 132, so that the three-phase current is transmitted from the second power module 120 to the second output copper busbar group 132, and finally to the corresponding motor 2.

[0067] In this embodiment, the second adapter 121 includes three second adapter copper busbars 1211. The first ends of the three second adapter copper busbars 1211 are used to connect one-to-one with the three output ports of the second power module 120, and the second ends of the three second adapter copper busbars 1211 are used to connect one-to-one with the three second output copper busbars 1320. The three second adapter copper busbars 1211 are used to transmit one of the U-phase current, W-phase current, and V-phase current, respectively. It should be noted that the first and second ends of the second adapter copper busbars 1211 refer to their two ends in the length direction, and the second ends of the three second adapter copper busbars 1211 constitute the three output ports of the second power component 12.

[0068] In this embodiment, the three output ports of the first power module 110 are spaced apart along the length of the first insulating portion 1301, such that the connection between the three output ports of the first power module 110 is parallel to the connection between the first ends of the three first output copper busbars 1310. Along the length of the first insulating portion 1301, the second ends of the three first transition copper busbars 1111 are converging relative to their first ends, such that the distance between the second ends of adjacent first transition copper busbars 1111 is smaller than the distance between their corresponding first ends. Thus, the arrangement of the first transition copper busbars 1111 makes the arrangement of the three output ports of the first power module 11 more compact, and the first ends of the first output copper busbar group 131 also become more compact, ultimately saving space inside the housing 10.

[0069] Similarly, in this embodiment, the three output ports of the second power module 120 are spaced apart along the length of the first insulating portion 1301, such that the connection between the three output ports of the second power module 120 is parallel to the connection between the first ends of the three second output copper busbars 1320. Along the length of the first insulating portion 1301, the second ends of the three second transition copper busbars 1211 are in a convergent state relative to their first ends, such that the distance between the second ends of adjacent second transition copper busbars 1211 is smaller than the distance between their corresponding first ends. Thus, the arrangement of the second transition copper busbars 1211 makes the arrangement of the three output ports of the second power component 12 more compact, and the first ends of the second output copper busbar group 132 also become more compact, ultimately saving space within the housing 10.

[0070] In this embodiment, the motor controller 1 further includes a second insulating housing 14. The second insulating housing 14 has six independent receiving channels 140 along the length direction of the first insulating part 1301. Three first transition copper busbars 1111 and three second transition copper busbars 1211 are respectively inserted into the six receiving channels. By setting the second insulating housing 14 to integrate the first transition copper busbars 1111 and the second transition copper busbars 1211 together, the insulation and fixing structures of each are not set separately, thus improving the integration.

[0071] In this embodiment, both the first transition copper busbar 1111 and the second transition copper busbar 1211 can be flat copper strip structures, which is beneficial for transmitting large currents. The extension direction of the first transition copper busbar 1111 can be consistent with the extension direction of its corresponding receiving channel 140, and the extension direction of the second transition copper busbar 1211 can be consistent with the extension direction of its corresponding receiving channel 140, so that the first transition copper busbar 1111 and the second transition copper busbar 1211 are tightly fitted in their corresponding receiving channels 140.

[0072] In this embodiment, the second insulating shell 14 can be made of a plastic material with high temperature resistance and good insulation properties, such as PBT and PA, to ensure electrical insulation and structural strength.

[0073] In this embodiment, for ease of description, the six receiving channels 140 are respectively the first receiving channel 1401, the second receiving channel 1402, the third receiving channel 1403, the fourth receiving channel 1404, the fifth receiving channel 1405, and the sixth receiving channel 1406. The first to sixth receiving channels 1406 are arranged sequentially along the length of the first insulating part 1301. Three first transition copper busbars 1111 are correspondingly inserted into the first to third receiving channels 1403, and three second transition copper busbars 1211 are correspondingly inserted into the fourth to sixth receiving channels 1406. This allows the first power module 110 and the second power module 120 to transmit three-phase current to the AC output component 13 through the first transition copper busbars 1111 and the second transition copper busbars 1211, respectively. The wiring is neat and does not interfere with each other.

[0074] In this embodiment, the second end of the first adapter copper busbar 1111 and the first end of the first output copper busbar 1310 can be fixedly connected by bolts to ensure stable current transmission between them. Similarly, the second end of the second adapter copper busbar 1211 and the first end of the second output copper busbar 1320 can be fixedly connected by bolts to ensure stable current transmission between them.

[0075] See Figure 11 On the other hand, this utility model embodiment also provides an electric drive assembly, which includes a motor controller 1 and two motors 2 as described in any of the above embodiments. The second insulating part 1302 of the motor controller 1 extends between the two motors 2. The first output copper busbar group 131 and the second output copper busbar group 132 are electrically connected to the two motors 2 respectively, so that the motor controller 1 can output three-phase current to the two motors 2 respectively to control the operation of the two motors 2.

[0076] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0077] For ease of explanation, the above description has been provided in conjunction with specific embodiments. However, the above exemplary discussion is not intended to be exhaustive or to limit the embodiments to the specific forms disclosed above. Various modifications and variations can be obtained based on the above teachings. The selection and description of the above embodiments are for the purpose of better explaining the principles and practical applications, thereby enabling those skilled in the art to better utilize the described embodiments and various different variations of embodiments suitable for specific use considerations.

Claims

1. A motor controller for driving dual motors (2), characterized in that, The motor controller (1) includes: Outer shell (10); The first power component (11) and the second power component (12) are disposed within the housing (10). Both the first power component (11) and the second power component (12) have three output ports. The three output ports of the first power component (11) are used to output three-phase current to one of the motors (2), and the three output ports of the second power component (12) are used to output three-phase current to the other motor (2). An AC output assembly (13) includes a first insulating housing (130), a first output copper busbar group (131), and a second output copper busbar group (132). The first insulating housing (130) includes a first insulating part (1301) and a second insulating part (1302) connected to each other. The first insulating part (1301) and the second insulating part (1302) are arranged at an angle. The first insulating part (1301) extends at least partially into the housing (10), and the second insulating part (1302) is located outside the first insulating part (1301). The first insulating housing (130) has six independent mounting channels. The first end of each of the six mounting channels is located on the side of the first insulating part (1301) facing the output port. The second end of each of the six mounting channels is located on the second insulating part (1302). The first output copper busbar group (131) includes three first output copper busbars (1310), and the second output copper busbar group (132) includes three second output copper busbars (1320). Each of the first output copper busbars (1310) and the second output copper busbars (1320) is inserted into the six mounting channels in a one-to-one correspondence. One end of each of the three first output copper busbars (1310) is connected to one of the three output ports of the first power component (11), and one end of each of the three second output copper busbars (1320) is connected to one of the three output ports of the second power component (12).

2. The motor controller according to claim 1, characterized in that, The six mounting channels are a first mounting channel (1303), a second mounting channel (1304), a third mounting channel (1305), a fourth mounting channel (1306), a fifth mounting channel (1307), and a sixth mounting channel (1308). The second ends of the first mounting channel (1303) to the third mounting channel (1305) and the second ends of the fourth mounting channel (1306) to the sixth mounting channel (1308) are located on opposite sides of the second insulating part (1302). One end of each of the three first output copper busbars (1310) passes through the second ends of the first mounting channel (1303) to the third mounting channel (1305), and one end of each of the three second output copper busbars (1320) passes through the second ends of the fourth mounting channel (1306) to the sixth mounting channel (1308).

3. The motor controller according to claim 2, characterized in that, The second ends of the first to third mounting channels (1305) and the second ends of the fourth to sixth mounting channels (1308) are all spaced apart along the length direction of the second insulating part (1302).

4. The motor controller according to claim 3, characterized in that, The first ends of the first to sixth mounting channels (1308) are spaced apart along the length direction of the first insulating part (1301); The three output ports of the first power component (11) are respectively configured to correspond one-to-one with the first end of the first to third mounting channels (1305), and the three output ports of the second power component (12) are respectively configured to correspond one-to-one with the first end of the fourth to sixth mounting channels (1308).

5. The motor controller according to claim 4, characterized in that, The first ends of the first to sixth mounting channels (1308) are arranged sequentially along the length of the first insulating part (1301); The second ends of the first to third mounting channels (1305) are arranged sequentially along the length direction of the second insulating part (1302), and the distance between the second ends of the first to third mounting channels (1305) and the first insulating part (1301) gradually increases; The second ends of the fourth to sixth mounting channels (1308) are arranged sequentially along the length of the second insulating part (1302), and the distance between the second ends of the fourth to sixth mounting channels (1308) and the first insulating part (1301) gradually decreases.

6. The motor controller according to claim 1, characterized in that, The outer casing (10) has a mounting groove (103) on its side for the first insulating part (1301) to extend into. The first insulating housing (130) further includes a connecting portion (1309) disposed around the first insulating portion (1301), the connecting portion (1309) abutting against and being detachably connected to the side of the housing (10).

7. The motor controller according to claim 1, characterized in that, The first insulating portion (1301) extends along the length direction of the outer shell (10), the second insulating portion (1302) extends along the width direction of the outer shell (10), and the second insulating portion (1302) is connected to the middle part of the first insulating portion (1301).

8. The motor controller according to claim 1, characterized in that, The first power component (11) includes a first power module (110) and a first adapter (111), and the second power component (12) includes a second power module (120) and a second adapter (121). The first power module (110) has three output ports, and the second power module (120) has three output ports. The three output ports of the first power module (110) and the three output ports of the second power module (120) are spaced apart along the length direction of the first insulating part (1301). The first adapter (111) includes three first adapter copper busbars (1111), the first end of the three first adapter copper busbars (1111) is used to connect one-to-one with the three output ports of the first power module (110), and the second end of the three first adapter copper busbars (1111) is used to connect one-to-one with the three first output copper busbars (1310). The second adapter (121) includes three second adapter copper busbars (1211). The first end of the three second adapter copper busbars (1211) is used to connect one-to-one with the three output ports of the second power module (120), and the second end of the three second adapter copper busbars (1211) is used to connect one-to-one with the three second output copper busbars (1320). Along the length direction of the first insulating portion (1301), the distance between the second ends of adjacent first transition copper busbars (1111) is smaller than the distance between their corresponding first ends, and the distance between the second ends of adjacent second transition copper busbars (1211) is smaller than the distance between their corresponding first ends.

9. The motor controller according to claim 8, characterized in that, The motor controller (1) also includes a second insulating housing (14), which has six independent receiving channels (140) along the length of the first insulating part (1301). The three first transition copper busbars (1111) and the three second transition copper busbars (1211) are respectively inserted into the six receiving channels (140).

10. An electric drive assembly, characterized in that, The device includes a motor controller (1) as described in any one of claims 1 to 9 and two motors (2), wherein the second insulating part (1302) extends between the two motors (2), and the first output copper busbar group (131) and the second output copper busbar group (132) are electrically connected to the two motors (2) respectively.

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