Filter integration structure of electric drive all-in-one system and electric drive all-in-one system thereof

Abstract

The utility model discloses a filter integrated structure of electric drive all -in -one system and electric drive all -in -one system, include: electric drive filter, electric drive filter includes magnetic core, filter capacitance and wiring copper bar, the positive and negative pole conductor of wiring copper bar passes through the magnetic core to form the first common mode inductance, and filter capacitance is connected in parallel between the positive and negative pole of wiring copper bar, first wire and second wire, and the first wire and second wire's first end are electrically connected on the positive and negative pole of wiring copper bar respectively, and the conductor part of first wire and second wire passes through the internal space of magnetic core in common, and winds around magnetic core several turns to form the second common mode inductance, and the end of first wire and second wire is used to connect to the high -voltage direct -current input end of OBCDCDC module. Through first wire and second wire share the magnetic core of electric drive filter and wind multiple turns to form its own common mode inductance, share filter capacitance of electric drive filter simultaneously, realized the cross -module depth integration of magnetic core and two big core filter element of capacitance.

Description

Technical Field

[0001] This utility model relates to the field of electric drive system technology, specifically to a filter integration structure for an all-in-one electric drive system and the all-in-one electric drive system thereof. Background Technology

[0002] As electric vehicle drive systems evolve towards multi-integration, modules such as motor controllers, on-board chargers (OBC), and DC-DC converters (DCDC) are being integrated into the same assembly housing to improve system power density and reduce overall vehicle costs. Under this integration trend, the high-voltage DC ports of each module are typically designed to share the same battery interface to achieve a compact structure and simplified connections.

[0003] However, due to significant differences between motor controllers and OBCs / DCDCs in terms of operating current and filter inductor parameters, integrating their filters faces numerous challenges. Specifically, motor controllers typically operate at currents exceeding 150A, requiring filter inductors in the tens of microhenries, often employing single-turn common-mode inductor structures; while OBCs and DCDCs generally have high-voltage DC currents below 20A, requiring inductors in the hundreds of microhenries, often using multi-turn symmetrical winding methods. Furthermore, there are significant differences in core size, material selection, and structural layout, leading to traditional designs where motor controllers and OBC / DCDC filters are still designed and installed as independent components, failing to achieve true integration.

[0004] To address the aforementioned issues, Chinese invention patent CN120433729A discloses a multi-stage filter structure for the DC end. This structure, through the combination of primary and secondary filter fixing components and the coordinated arrangement of PCBA board grounding with magnetic rings and cores, aims to reduce the spatial volume of the filter structure and improve EMC performance. While this solution optimizes filter layout and heat dissipation to some extent, it primarily targets the filtering needs of a single module or similar modules. It does not address the issue of filter sharing and integration between motor controllers and heterogeneous modules such as OBC / DCDC, thus failing to fundamentally solve the problems of numerous filters, large space occupation, and high cost in multi-functional systems.

[0005] Therefore, how to achieve a high degree of integration between the motor controller and the OBC / DCDC filter while ensuring the EMC performance of each module has become an urgent technical problem to be solved in the design of electric drive all-in-one systems. Utility Model Content

[0006] In a first aspect, to solve the above-mentioned technical problems, this utility model provides a filter integration structure for an electric drive all-in-one system, comprising: An electric drive filter includes a magnetic core, a filter capacitor, and a copper busbar. The positive and negative conductors of the copper busbar pass through the magnetic core to form a first common-mode inductor, and the filter capacitor is connected in parallel between the positive and negative terminals of the copper busbar. The first wire and the second wire have their beginning ends electrically connected to the positive and negative terminals of the copper busbar, respectively. The conductor portions of the first wire and the second wire pass through the internal space of the magnetic core and are wound around the magnetic core several times to form a second common-mode inductor. The ends of the first wire and the second wire are used to connect to the high-voltage DC input terminal of the OBC / DCDC module.

[0007] Furthermore, the first and second wires are wound symmetrically around the magnetic core.

[0008] Furthermore, the number of turns of the first and second conductors is determined based on the target inductance value required by the OBC / DCDC module.

[0009] Furthermore, the first and second conductors are enameled wires or silicone wires with an outer insulating layer.

[0010] Furthermore, the electric drive filter also includes an injection-molded housing, and the magnetic core, filter capacitor, and wiring copper busbar are encased within the injection-molded housing.

[0011] Furthermore, the first and second wires are connected to the copper busbar via access points provided on the injection-molded housing.

[0012] Furthermore, the magnetic core is made of ferrite or nanocrystals.

[0013] A second aspect of this utility model provides an all-in-one electric drive system, including the aforementioned filter integration structure.

[0014] Compared with the prior art, the present invention has the following beneficial effects: This invention achieves deep cross-module integration of the two core filtering components, the magnetic core and the capacitor, by sharing the magnetic core of the electric drive filter with the first and second wires and winding multiple turns to form its own common-mode inductance, while also sharing the filter capacitor of the electric drive filter. This results in the beneficial effects of reducing product volume and structural size, reducing the number of parts and thus reducing material and assembly costs, while ensuring the EMC filtering performance of each module. Attached Figure Description

[0015] Figure 1 This is an isometric view of an embodiment of the present utility model; Figure 2 This is a rear view of an embodiment of the present utility model.

[0016] In the picture: 11. Magnetic core; 12. Filter capacitor; 13. Copper busbar; 14. Injection molded housing; 21. First conductor; 22. Second conductor. Detailed Implementation

[0017] To make the technical solutions and effects of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings in the embodiments. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0018] This utility model aims to provide a filter integration structure for an all-in-one electric drive, OCB, and DC-DC system. It overcomes the inherent differences between the motor controller and the OBC / DCDC module (not shown in the figure) in terms of operating current, required filter inductance value, and magnetic core structure. Through a new physical structure, the two originally separate filters are integrated into a compact component in the all-in-one electric drive system, thereby eliminating the disadvantages of large system size, large number of parts, and high cost caused by separate design.

[0019] Please see Figure 1-2 The filter integration structure of this all-in-one electric drive system mainly includes an electric drive filter, a first wire 21, and a second wire 22. The electric drive filter includes a magnetic core 11, a filter capacitor 12, and a copper busbar 13. The copper busbar 13 is used to connect an external high-voltage DC power supply to the load and includes a positive conductor and a negative conductor. The positive and negative conductors of the copper busbar 13 pass through the magnetic core 11 to form a first common-mode inductor, and the filter capacitor 12 is connected in parallel between the positive and negative terminals of the copper busbar 13.

[0020] Preferably, the magnetic core 11 is toroidal; its material is ferrite or nanocrystal.

[0021] In this scheme, the first ends of the first wire 21 and the second wire 22 are electrically connected to the positive and negative terminals of the copper busbar 13, respectively; the conductor portions of the first wire 21 and the second wire 22 pass through the internal space of the magnetic core 11 and are wound around the magnetic core 11 several times to form a second common mode inductor; the ends of the first wire 21 and the second wire 22 are used to connect to the high voltage DC input terminal of the OBC / DCDC module.

[0022] Preferably, the first conductor 21 and the second conductor 22 are enameled wires or silicone wires with an outer insulating layer.

[0023] In a further embodiment, the first wire 21 and the second wire 22 are wound symmetrically on the magnetic core 11, and the number of turns of the first wire 21 and the second wire 22 are determined according to the target inductance value required by the OBC / DCDC module.

[0024] In a further embodiment, the electric drive filter also includes an injection-molded housing 14, with the magnetic core 11, filter capacitor 12, and wiring copper busbar 13 encased within the injection-molded housing 14, serving to provide insulation, support, and fixation.

[0025] In this design, the first ends of the first wire 21 and the second wire 22 are connected to the copper busbar 13 via access points on the injection-molded housing 14, allowing direct power draw from the DC busbar of the electric drive. After the first wire 21 and the second wire 22 are connected, their conductor portions are not directly led to the OBC / DCDC module, but instead first pass through the same internal space of the magnetic core 11. Subsequently, they are wound side-by-side or symmetrically around the magnetic post of the magnetic core 11 multiple times, and finally their ends are led out and connected to the high-voltage DC input terminal of the OBC / DCDC module.

[0026] The technical principle of this utility model is: Regarding the shared use of magnetic core 11: The magnetic core 11 simultaneously serves two circuits with different current levels and inductance requirements. For the electric drive circuit, the copper busbar 13 passes through the magnetic core 11 in a single turn, forming the first common-mode inductor, which has a relatively small inductance value and primarily suppresses high-frequency common-mode interference generated by the electric drive. For the OBC / DCDC circuit, the first wire 21 and the second wire 22 are symmetrically wound in multiple turns on the same magnetic core 11. Based on the principle that inductance is proportional to the square of the number of turns N, a larger inductance value is cleverly achieved by winding multiple turns on the same magnetic core, forming the second common-mode inductor to meet the filtering requirements of the OBC / DCDC module for a larger inductance value. This fundamentally eliminates the need for a separate magnetic core in the original OBC / DCDC module, achieving hardware resource sharing.

[0027] Regarding shared capacitors: Since the first wire 21 and the second wire 22 draw power directly from the copper busbar 13, the filter capacitor 12 connected in parallel to the copper busbar 13 is shared by the electric drive circuit and the OBC / DCDC circuit, providing DC support and filtering for both circuits. This eliminates the need for the original independent filter capacitor in the OBC / DCDC module, further reducing the number of components and lowering costs.

[0028] This solution achieves a high degree of filter integration at the physical level through the shared structure of the magnetic core and capacitor. Its direct effect is to reduce the size and weight of the entire filter component, contributing to increased power density in the all-in-one electric drive system; simultaneously, by eliminating one magnetic core and one set of capacitors, both material and assembly costs are reduced.

[0029] This utility model also protects an all-in-one electric drive system, which includes the aforementioned filter integration structure, motor controller module, and OBC / DCDC module. The DC input terminal of the motor controller module is connected to a copper busbar, and the DC input terminal of the OBC / DCDC module is connected to the ends of the first wire 21 and the second wire 22. All modules are integrated into a single assembly housing, forming a compact, efficient, and low-cost electric drive system.

[0030] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A filter integration structure for an all-in-one electric drive system, characterized in that, include: An electric drive filter includes a magnetic core (11), a filter capacitor (12), and a copper busbar (13). The positive and negative conductors of the copper busbar (13) pass through the magnetic core (11) to form a first common-mode inductor. The filter capacitor (12) is connected in parallel between the positive and negative terminals of the copper busbar (13). The first wire (21) and the second wire (22) are electrically connected to the positive and negative terminals of the copper busbar (13), respectively. The conductor portions of the first wire (21) and the second wire (22) pass through the internal space of the magnetic core (11) and are wound around the magnetic core (11) several times to form a second common-mode inductor. The ends of the first wire (21) and the second wire (22) are used to connect to the high-voltage DC input terminal of the OBC / DCDC module.

2. The filter integration structure of the electric drive all-in-one system according to claim 1, characterized in that, The first conductor (21) and the second conductor (22) are wound symmetrically on the magnetic core (11).

3. The filter integration structure of the electric drive all-in-one system according to claim 1 or 2, characterized in that, The number of turns of the first conductor (21) and the second conductor (22) is determined according to the target inductance value required by the OBC / DCDC module.

4. The filter integration structure of the electric drive all-in-one system according to claim 1, characterized in that, The first conductor (21) and the second conductor (22) are enameled wires or silicone wires with an outer insulating layer.

5. The filter integration structure of the electric drive all-in-one system according to claim 1, characterized in that, The electric drive filter also includes an injection-molded housing (14), in which the magnetic core (11), the filter capacitor (12), and the wiring copper busbar (13) are encased.

6. The filter integration structure of the electric drive all-in-one system according to claim 5, characterized in that, The first ends of the first conductor (21) and the second conductor (22) are connected to the copper busbar (13) through access points provided on the injection-molded housing (14).

7. The filter integration structure of the electric drive all-in-one system according to claim 1, characterized in that, The magnetic core (11) is made of ferrite or nanocrystal.

8. An all-in-one electric drive system, characterized in that, Includes the filter integration structure as described in any one of claims 1 to 7.

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