Filter of direct-current power source, and electric drive controller and vehicle

Abstract

Disclosed in the present application are a filter of a direct-current power source, and an electric drive controller and a vehicle. The filter of a direct-current power source comprises a base, a power source charging copper bar, a power source positive copper bar, a power source negative copper bar and at least three stages of filtering assemblies, wherein the power source charging copper bar, the power source positive copper bar, the power source negative copper bar and the at least three stages of filtering assemblies are all assembled on the base, and the at least three stages of filtering assemblies are electrically connected to the power source charging copper bar, the power source positive copper bar and the power source negative copper bar, respectively.

Description

DC power supply filter, electric drive controller and automobile

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the China Patent Office on June 14, 2023, with application number 202310708072.0, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The embodiments of the present application relate to, but are not limited to, the field of filtering technology, and in particular to, but are not limited to, a DC power supply filter, an electric drive controller, and a vehicle. Background Art

[0004] Driven by the national dual-carbon strategy and supported by the industrialization of new energy, new energy vehicles have achieved rapid development, especially 800V high-voltage, high-power density electric drive controllers represented by third-generation wide-bandgap silicon carbide (SiC) power semiconductors, which have been widely used due to their advantages such as high switching frequency, low loss and good temperature resistance.

[0005] Summary of the Invention

[0006] The following is a summary of the subject matter described in detail herein. This summary is not intended to limit the scope of the claims. The present invention provides a filter, electric drive controller, and vehicle with a simple structure, compact layout, and small size for a DC power supply.

[0007] An embodiment of the present application provides a filter for a DC power supply, comprising: a base; a power charging copper bus assembled on the base; a power positive copper bus assembled on the base; a power negative copper bus assembled on the base; and at least three stages of filter components, wherein the at least three stages of filter components are assembled on the base and electrically connected to the power charging copper bus, the power positive copper bus, and the power negative copper bus, respectively.

[0008] In some embodiments, the base extends along a first direction and a second direction that are located in the same horizontal plane and intersect with each other; the power charging copper busbar includes a power charging copper busbar input end and a power charging copper busbar output end; the power positive copper busbar includes a power positive copper busbar input end and a power positive copper busbar output end; the power negative copper busbar includes a power negative copper busbar input end and a power negative copper busbar output end; wherein, the power charging copper busbar input end, the power positive copper busbar input end and the power negative copper busbar input end are extended side by side along the first direction, and the power charging copper busbar output end, the power positive copper busbar output end and the power negative copper busbar output end are extended side by side along the second direction.

[0009] In some embodiments, the power charging copper busbar input end, the power positive copper busbar input end, and the power negative copper busbar input end each have a height difference relative to the horizontal plane, and the height differences are different.

[0010] In some embodiments, the power charging copper busbar output end, the power positive copper busbar output end, and the power negative copper busbar output end have height differences relative to the horizontal plane, and the height differences are different.

[0011] In some embodiments, the height difference between the power charging copper bar input end and the power charging copper bar output end relative to the horizontal plane is different, the height difference between the power positive copper bar input end and the power positive copper bar output end relative to the horizontal plane is different, and the height difference between the power negative copper bar input end and the power negative copper bar output end relative to the horizontal plane is different.

[0012] In some embodiments, the power positive copper busbar is arranged relative to the power negative copper busbar and the power charging copper busbar close to the outer edge of the base.

[0013] In some embodiments, the power charging copper busbar is arranged near the inner middle area of ​​the base relative to the power positive copper busbar and the power negative copper busbar.

[0014] In some embodiments, the at least three-stage filter components include a first-stage filter component, a second-stage filter component, and a third-stage filter component, which are respectively mounted on the power charging copper bus, the power positive copper bus, and the power negative copper bus, and are respectively connected to the power charging copper bus, the power positive copper bus, and the power negative copper bus.

[0015] In some embodiments, the first-stage filter component is arranged relative to the second-stage filter component and the third-stage filter component, close to the power charging copper bus input terminal, the power positive copper bus input terminal and the power negative copper bus input terminal.

[0016] In some embodiments, the first-stage filter component is arranged to extend along the first direction, and the second-stage filter component and the third-stage filter component are arranged to be spaced apart along the second direction.

[0017] In some embodiments, the first-stage filter component is integrally formed and has a ring structure, and the power charging copper busbar input end, the power positive copper busbar input end, and the power negative copper busbar input end are all inserted into the first-stage filter component and extend from the first-stage filter component to the outside of the base.

[0018] In some embodiments, the second-stage filter assembly is a split structure, including an upper lobe of the second-stage filter assembly and a lower lobe of the second-stage filter assembly. The upper lobe of the second-stage filter assembly and the lower lobe of the second-stage filter assembly are plugged into each other up and down to be assembled above and below the power charging copper bus, the power positive copper bus and the power negative copper bus.

[0019] In some embodiments, the third-stage filter assembly is a split structure, including an upper lobe of a third-stage filter assembly and a lower lobe of a third-stage filter assembly. The upper lobe of the third-stage filter assembly and the lower lobe of the third-stage filter assembly are plugged into each other up and down to be assembled above and below the power charging copper bus, the power positive copper bus and the power negative copper bus.

[0020] In some embodiments, the first-stage filtering component includes an amorphous magnetic ring.

[0021] In some embodiments, the second-stage filtering component includes a ferrite ring.

[0022] In some embodiments, the third-stage filtering component includes a ferrite ring.

[0023] In some embodiments, the filter further includes a printed circuit board, which is covered on the top of the base; the printed circuit board is provided with a plurality of differential mode components, a plurality of common mode components and a plurality of DC support capacitor components on a side facing the base; the filter further includes a plurality of electrical connectors, which are respectively provided on the side of the power charging copper bus, the power positive copper bus and the power negative copper bus facing the printed circuit board, and extend upward from the top of the power charging copper bus, the power positive copper bus and the power negative copper bus, and are electrically connected to the plurality of differential mode components, the plurality of common mode components and the plurality of DC support capacitor components of the printed circuit board by upper and lower plugging.

[0024] In some embodiments, the filter further includes a grounding copper bus; one end of each of the plurality of differential mode components, the plurality of common mode components, and the plurality of DC support capacitor components is connected to the grounding copper bus, and the grounding copper bus is connected to a ground terminal.

[0025] In some embodiments, the plurality of differential mode components include at least one differential mode capacitor, and each of the differential mode capacitors is connected between two of the power charging copper bus, the power positive copper bus, and the power negative copper bus.

[0026] In some embodiments, the plurality of common-mode components include at least two common-mode capacitors, each of which is connected between one of the power positive copper bus, the power negative copper bus, and the power charging copper bus and a ground terminal.

[0027] In some embodiments, the filter further includes a current sensor disposed on the positive copper busbar of the power supply.

[0028] In some embodiments, the DC power supply comprises a DC boost power supply.

[0029] In some embodiments, the power positive copper busbar is a positive busbar copper busbar.

[0030] In some embodiments, the power supply negative copper busbar is a negative busbar copper busbar.

[0031] An embodiment of the present application further provides an electric drive controller, comprising a filter of a DC power supply as described in any one of the above embodiments.

[0032] An embodiment of the present application also provides a car, comprising the electric drive controller as described in the above embodiment.

[0033] The DC power supply filter, electric drive controller, and automobile of the embodiments of the present application are configured such that a power charging copper busbar, a power positive copper busbar, a power negative copper busbar, and at least three-stage filter components are installed on a base, and at least three-stage filter components are electrically connected to the power charging copper busbar, the power positive copper busbar, and the power negative copper busbar to simultaneously provide power to the motor drive and realize a filtering function on the basis of a voltage boost function. This can achieve a very high insertion loss capability, meet relatively stringent filtering requirements, and has a high degree of integration, a simple structure, a compact layout, a small size, and low maintenance costs.

[0034] Still other aspects will become apparent upon reading and understanding the accompanying drawings and detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] FIG1 is a circuit diagram of a filter circuit of a DC power supply according to an embodiment of the present application.

[0036] FIG2 is a schematic diagram showing the structure of a filter of a DC power supply according to an embodiment of the present application.

[0037] FIG3 is an exploded view of the filter of the DC power supply shown in FIG2 .

[0038] FIG4 is a schematic diagram showing a top view of the structure of the filter of the DC power supply shown in FIG2 .

[0039] FIG5 is a schematic diagram showing a partial structure of a filter of the DC power supply shown in FIG2 .

[0040] FIG6 is a schematic diagram showing a partial structure of a filter of the DC power supply shown in FIG2 .

[0041] FIG7 is a schematic diagram showing a partial structure of a filter of the DC power supply shown in FIG2 .

[0042] FIG8 is a schematic diagram showing a partial structure of a filter of the DC power supply shown in FIG2 .

[0043] Explanation of the accompanying symbols: 1-filter circuit, 2-filter, 10-positive DC bus, 101-positive DC bus input terminal, 102-positive DC bus output terminal, 11-negative DC bus, 111-negative DC bus input terminal, 112-negative DC bus output terminal, 12-charging line, 121-charging line input terminal, 122-charging line output terminal, 13-at least three-stage filter circuit, 131-first-stage filter magnetic ring, 132-second-stage filter magnetic ring, 133-third-stage filter magnetic ring, 14-DC support capacitor, CL1-CL3: first to third DC support capacitors, 15-differential mode circuit, CX1-CX3: first to third differential mode capacitors, 16-common mode circuit, CY1-CY12: first to twelfth common mode capacitors, 21-base, 22-power charging copper busbar, 221-power charging copper busbar input end, 222-power charging copper busbar output end, 23-power positive copper busbar, 231-power positive copper busbar input end, 232-power positive copper busbar output end, 24-power negative copper busbar, 241-power negative copper busbar input end, 242-power negative copper busbar output end, 25-at least three-stage filter components, 251-first-stage filter component, 252-second-stage filter component, 252a-second-stage filter component upper lobe, 252b-second-stage filter component lower lobe, 253-third-stage filter component, 253a-third-stage filter component upper lobe, 253b-third-stage filter component lower lobe, 26-printed circuit board, 27-electrical connector, 28-current sensor, X1-first direction, X2-second direction. DETAILED DESCRIPTION

[0044] Exemplary embodiments will be described in detail herein, with examples illustrated in the accompanying drawings. In the following description, when referring to the drawings, identical numerals in different figures represent identical or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments are not intended to represent all embodiments consistent with the present application. Rather, they are merely examples of devices consistent with certain aspects of the present application, as detailed in the appended claims.

[0045] The terms used in this application are for the purpose of describing specific embodiments only and are not intended to limit this application. Unless otherwise defined, technical or scientific terms used in this application should have the ordinary meaning understood by a person of ordinary skill in the art to which this application belongs. The terms "first," "second," and similar words used in this specification and claims do not denote any order, quantity, or importance, but are simply used to distinguish different components. Similarly, terms such as "a" or "an" do not denote a quantitative limitation, but rather indicate the presence of at least one. If only "a" is referred to, this will be separately stated. "Multiple" or "several" means two or more. Unless otherwise indicated, terms such as "front," "rear," "lower," and / or "upper" are for convenience only and are not limited to a single position or spatial orientation. Terms such as "include" or "comprising" mean that the elements or objects listed before "include" or "comprising" include the elements or objects listed after "include" or "comprising" and their equivalents, and do not exclude other elements or objects. "Connected" or "connected" and similar words are not limited to physical or mechanical connections, but can also include electrical connections, whether direct or indirect. As used in this specification and the appended claims, the singular forms "a," "the," and "the" are intended to include the plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

[0046] 800V high-voltage, high-power-density electric drive controllers, typified by third-generation wide-bandgap silicon carbide (SiC) power semiconductors, have seen widespread adoption due to their high switching frequency, low losses, and excellent temperature resistance. However, this has also led to more serious electromagnetic interference (EMI) issues. The high-speed switching of SiC power semiconductors in electric drive controllers generates high du / dt voltage and di / dt current rates, generating EMI. EMI primarily consists of radiated and conducted interference. Radiated interference refers to electromagnetic waves generated by the product, which disrupt the normal operation of electronic equipment through spatial interference. Conducted interference refers to interference sources, in the form of voltage and current, that affect other electronic equipment through coupling paths conducted by high- and low-voltage wiring harnesses. Interference can be further categorized as differential-mode interference and common-mode interference, with common-mode interference being the primary factor causing electric drive controllers to fail to meet regulatory requirements. Conventional DC power supply filters, however, suffer from significant stray inductance and high insertion loss. Their inflexible structure and output susceptibility to high-frequency coupling lead to substandard performance and high maintenance costs in high-frequency bands, hindering their widespread application on a platform-based basis.

[0047] Embodiments of the present application provide a DC power supply filter, an electric drive controller, and a vehicle. The DC power supply filter includes a base, a charging busbar, a positive busbar, a negative busbar, and at least three filter components. The charging busbar, the positive busbar, the negative busbar, and the at least three filter components are assembled to the base, and the at least three filter components are electrically connected to the charging busbar, the positive busbar, and the negative busbar, respectively.

[0048] The DC power supply filter, electric drive controller, and automobile of the embodiments of the present application are configured such that a power charging copper busbar, a power positive copper busbar, a power negative copper busbar, and at least three-stage filter components are installed on a base, and at least three-stage filter components are electrically connected to the power charging copper busbar, the power positive copper busbar, and the power negative copper busbar to simultaneously provide power to the motor drive and perform a filtering function on the basis of a voltage boost function. These devices can achieve high resistance to insertion loss and meet relatively stringent filtering requirements. Furthermore, they have high integration, simple structure, compact layout, small size, and low maintenance costs.

[0049] FIG1 is a circuit diagram of a filter circuit of a DC power supply according to an embodiment of the present application. As shown in FIG1 , the filter circuit 1 of the DC power supply includes a positive DC bus 10, a negative DC bus 11, a charging line 12, and at least three filter circuits 13. The positive DC bus 10 includes a positive DC bus input terminal 101 and a positive DC bus output terminal 102. The negative DC bus 11 includes a negative DC bus input terminal 111 and a negative DC bus output terminal 112. The charging line 12 includes a charging line input terminal 121 and a charging line output terminal 122. The at least three filter circuits 13 are respectively connected between the positive DC bus input terminal 101 and the positive DC bus output terminal 102, between the negative DC bus input terminal 111 and the negative DC bus output terminal 112, and between the charging line input terminal 121 and the charging line output terminal 122.

[0050] In this embodiment, by integrating the charging line and the DC bus (positive DC bus, negative DC bus), and providing at least three-stage filtering circuits 13 between the input and output ends of the integration, it is possible to simultaneously provide power for the motor drive and realize the filtering function on the basis of the boost function, thereby achieving a high resistance to insertion loss, thereby meeting more stringent filtering requirements.

[0051] In the embodiment shown in FIG1 , at least three stages of filtering circuit 13 include a first-stage filtering magnetic ring 131, a second-stage filtering magnetic ring 132, and a third-stage filtering magnetic ring 133. The first-stage filtering magnetic ring 131, the second-stage filtering magnetic ring 132, and the third-stage filtering magnetic ring 133 are sequentially connected in intervals between the positive DC bus input terminal 101 and the positive DC bus output terminal 102, between the negative DC bus input terminal 111 and the negative DC bus output terminal 112, and between the charging line input terminal 121 and the charging line output terminal 122. The first-stage filtering magnetic ring 131 is used to eliminate low-frequency electromagnetic interference. The second-stage filtering magnetic ring 132 and the third-stage filtering magnetic ring 133 are used to eliminate high-frequency electromagnetic interference. The intervals between the first-stage filtering magnetic ring 131, the second-stage filtering magnetic ring 132, and the third-stage filtering magnetic ring 133 allow for simultaneous power supply for the motor drive and filtering in addition to the boost function. This provides high insertion loss resistance and meets stringent filtering requirements.

[0052] In the embodiment shown in FIG1 , the first-stage filter magnetic ring 131 is positioned closer to the positive DC bus input terminal 101, the negative DC bus input terminal 111, and the charging line input terminal 121, relative to the second-stage filter magnetic ring 132 and the third-stage filter magnetic ring 133. Because the input terminals of the positive DC bus 10, the negative DC bus 11, and the charging line 12 are subject to significant low-frequency electromagnetic interference, this embodiment positions the first-stage filter magnetic ring 131 closer to the positive DC bus input terminal 101, the negative DC bus input terminal 111, and the charging line input terminal 121 to eliminate low-frequency electromagnetic interference and ensure signal stability and reliability.

[0053] In the embodiment shown in FIG1 , the at least three-stage filter circuit 13 further includes a plurality of DC link capacitors 14, which are respectively connected between the positive DC bus 10 and the ground terminal GND, between the negative DC bus 11 and the ground terminal GND, and between the charging line 12 and the ground terminal GND. In the embodiment shown in FIG1 , the connection points between the plurality of DC link capacitors 14 and the positive DC bus 10, the negative DC bus 11, and the charging line 12 are respectively located between the third-stage filter magnetic ring 133 and the positive DC bus output terminal 102, the third-stage filter magnetic ring 133 and the negative DC bus output terminal 112, and the third-stage filter magnetic ring 133 and the charging line output terminal 122.

[0054] The multiple DC link capacitors 14 of this embodiment smooth and filter the output voltages of the positive DC bus 10, negative DC bus 11, and charging line 12, keeping voltage fluctuations on the charging line 12 and DC bus (positive DC bus 10, negative DC bus 11) within an acceptable range. DC link capacitors 14 offer advantages such as high voltage and current resistance, low impedance, low inductance, minimal capacitance loss, low leakage current, and safety and reliability.

[0055] For example, in the embodiment shown in FIG1 , the plurality of DC link capacitors 14 may specifically include a first DC link capacitor CL1, a second DC link capacitor CL2, and a third DC link capacitor CL3. The first DC link capacitor CL1 is connected between the positive DC bus 10 and the ground terminal GND, the second DC link capacitor CL2 is connected between the negative DC bus 11 and the ground terminal GND, and the third DC link capacitor CL3 is connected between the charging line 12 and the ground terminal GND. The first DC link capacitor CL1 can smooth and filter the output voltage of the positive DC bus 10, keeping voltage fluctuations on the positive DC bus 10 within an allowable range, suppressing ripple and preventing backflow. The second DC link capacitor CL2 can smooth and filter the output voltage of the negative DC bus 11, keeping voltage fluctuations on the negative DC bus 11 within an allowable range, suppressing ripple and preventing backflow. The third DC link capacitor CL3 can smooth and filter the output voltage of the charging line 12, keeping voltage fluctuations on the charging line 12 within an allowable range, suppressing ripple and preventing backflow.

[0056] In the embodiment shown in FIG1 , one end of each of the DC link capacitors 14 is connected to the ground terminal GND. This connection method is flexible. In other embodiments, one end of each of the DC link capacitors 14 can also be connected to the same ground terminal GND. This connection method provides a relatively more stable and reliable ground terminal.

[0057] In the embodiment shown in FIG1 , the at least three-stage filter circuit 13 may further include at least one differential-mode circuit 15, connected between each of the positive DC bus 10, the negative DC bus 11, and the charging line 12. In the embodiment shown in FIG1 , the differential-mode circuit 15 includes at least one differential-mode capacitor CX. In some embodiments, each differential-mode capacitor is connected between two of the positive DC bus 10, the negative DC bus 11, and the charging line 12. This configuration improves the performance of eliminating differential-mode interference signals.

[0058] For example, in the embodiment shown in Figure 1, the differential mode capacitor CX may specifically include a first differential mode capacitor CX1, a second differential mode capacitor CX2, and a third differential mode capacitor CX3. Among them, the first differential mode capacitor CX1 is connected between the positive DC bus 10 and the charging line 12, and is used to eliminate the differential mode interference between the positive DC bus 10 and the charging line 12. The second differential mode capacitor CX2 is connected between the negative DC bus 11 and the charging line 12, and is used to eliminate the differential mode interference between the negative DC bus 11 and the charging line 12. The third differential mode capacitor CX3 is connected between the positive DC bus 10 and the negative DC bus 11, and is used to eliminate the differential mode interference between the positive DC bus 10 and the negative DC bus 11.

[0059] In the embodiment shown in FIG1 , the connection points between the differential-mode circuit 15 and the positive DC bus 10, the negative DC bus 11, and the charging line 12 are located between the first-stage filter magnetic ring 131 and the second-stage filter magnetic ring 132. This arrangement reduces mutual interference between the first-stage filter magnetic ring 131 and the second-stage filter magnetic ring 132.

[0060] In the embodiment shown in FIG1 , at least three stages of filtering circuits 13 may further include one or more common-mode circuits 16, which are respectively connected between the positive DC bus 10 and the ground terminal GND, between the negative DC bus 11 and the ground terminal GND, and between the charging line 12 and the ground terminal GND. In the embodiment shown in FIG1 , the connection points of the common-mode circuit 16 with the positive DC bus 10, the negative DC bus 11, and the charging line 12 are respectively located between the first-stage filtering magnetic ring 131 and the second-stage filtering magnetic ring 132, and between the second-stage filtering magnetic ring 132 and the third-stage filtering magnetic ring 133. In the embodiment shown in FIG1 , the common-mode circuit 16 includes at least two common-mode capacitors CY. In some embodiments, each of the common-mode capacitors is connected between the positive DC bus 10, the negative DC bus 11, and the charging line 12 and the ground terminal. This arrangement can improve the performance of eliminating common-mode interference.

[0061] For example, in the embodiment shown in Figure 1, the common-mode capacitor CY whose connection point at the non-ground end is located between the first-stage filter magnetic ring 131 and the second-stage filter magnetic ring 132 may specifically include: a first common-mode capacitor CY1 and a second common-mode capacitor CY2, connected between the negative DC bus 11 and the ground terminal GND, for eliminating common-mode interference between the negative DC bus 11 and the ground terminal GND; a third common-mode capacitor CY3 and a fourth common-mode capacitor CY4, connected between the positive DC bus 10 and the ground terminal GND, for eliminating common-mode interference between the positive DC bus 10 and the ground terminal GND; and a fifth common-mode capacitor CY5 and a sixth common-mode capacitor CY6, connected between the charging line 12 and the ground terminal GND, for eliminating common-mode interference between the charging line 12 and the ground terminal GND.

[0062] For another example, in the embodiment shown in Figure 1, the common-mode capacitor CY whose non-ground connection point is located between the second-stage filter magnetic ring 132 and the third-stage filter magnetic ring 133 may specifically include: a seventh common-mode capacitor CY7 and an eighth common-mode capacitor CY8, connected between the negative DC bus 11 and the ground terminal GND, for eliminating common-mode interference between the negative DC bus 11 and the ground terminal GND; a ninth common-mode capacitor CY9 and a tenth common-mode capacitor CY10, connected between the positive DC bus 10 and the ground terminal GND, for eliminating common-mode interference between the positive DC bus 10 and the ground terminal GND; and an eleventh common-mode capacitor CY11 and a twelfth common-mode capacitor CY12, connected between the charging line 12 and the ground terminal GND, for eliminating common-mode interference between the charging line 12 and the ground terminal GND.

[0063] In addition, in the embodiment shown in FIG1 , one end of each of the common-mode circuits 16 is connected to the ground terminal GND, which is a flexible connection method. In other embodiments, one end of each of the common-mode circuits 16 can be connected to the same ground terminal GND. In this connection method, the ground terminal is relatively more stable and reliable.

[0064] In the embodiment shown in FIG1 , the first-stage filter magnetic ring 131 may include an amorphous magnetic ring. Amorphous magnetic rings are magnetic components made of amorphous materials that effectively suppress low-frequency interference signals. Depending on the material of the amorphous material used, they can be categorized as iron-based amorphous, cobalt-based amorphous, and so on. In this embodiment, the amorphous magnetic ring can be replaced with a ring of different shapes and materials to achieve the desired inductance, depending on the actual filtering requirements of different products.

[0065] In the embodiment shown in FIG1 , the second-stage filter magnetic ring 132 may include a ferrite magnetic ring. In the embodiment shown in FIG1 , the third-stage filter magnetic ring 133 may also include a ferrite magnetic ring, for example, made of a ferrite material (Mn-Zn). Ferrite magnetic rings have a good suppressive effect on high-frequency interference signals.

[0066] The embodiment of the present application also provides a filter 2 of a DC power supply, in which the filter circuit 1 of the DC power supply shown in the embodiment of FIG1 is provided. The DC power supply may include a DC boost power supply (Boost boost power supply). The filter 2 integrates the charging line 12 and the DC bus (positive DC bus 10, negative DC bus 11) into one piece by providing the filter circuit 1 of the DC power supply shown in the embodiment of FIG1, and provides at least three-stage filter circuits 13 between the input and output ends of the integration, which can simultaneously provide power for the motor drive and realize the filtering function on the basis of the boost function, and can achieve a high resistance to insertion loss, thereby meeting the more stringent filtering requirements.

[0067] FIG2 is a schematic diagram of the structure of an embodiment of a DC power supply filter 2 of the present application. FIG3 is an exploded view of the DC power supply filter 2 shown in FIG2 . FIG4 is a schematic diagram of the structure of the DC power supply filter 2 shown in FIG2 from above. FIG5 is a schematic diagram of a portion of the structure of the DC power supply filter 2 shown in FIG2 . FIG6 is a schematic diagram of a portion of the structure of the DC power supply filter 2 shown in FIG2 . FIG7 is a schematic diagram of a portion of the structure of the DC power supply filter 2 shown in FIG2 . FIG8 is a schematic diagram of a portion of the structure of the DC power supply filter 2 shown in FIG2 . As shown in FIG2 to FIG8 , the DC power supply filter 2 includes a base 21 , a power charging busbar 22 , a power positive busbar 23 , a power negative busbar 24 , and at least three filter assemblies 25 . The power charging busbar 22 , the power positive busbar 23 , the power negative busbar 24 , and the at least three filter assemblies 25 are all mounted on the base 21 . The base 21 is provided with a storage space for accommodating the power charging busbar 22 , the power positive busbar 23 , the power negative busbar 24 , and the at least three filter assemblies 25 . At least three filter components 25 are electrically connected to the power charging copper busbar 22, the power positive copper busbar 23, and the power negative copper busbar 24. In this embodiment, the power positive copper busbar 23 can be a positive busbar copper busbar. The power negative copper busbar 24 can be a negative busbar copper busbar.

[0068] In this embodiment, the power charging copper bus 22, the power positive copper bus 23, the power negative copper bus 24, and at least three-stage filter components 25 are all installed on the base 21, and the at least three-stage filter components 25 are electrically connected to the power charging copper bus 22, the power positive copper bus 23, and the power negative copper bus 24 to simultaneously provide power to the motor drive and realize a filtering function on the basis of a boost function. This can achieve a high resistance to insertion loss and meet relatively stringent filtering requirements. It also has a high degree of integration, a simple structure, a compact layout, a small size, and low maintenance costs.

[0069] In the embodiment shown in conjunction with Figures 2 to 3 and Figures 7 to 8, the base 21 extends along a first direction X1 and a second direction X2 that are located in the same plane and intersect with each other. In this embodiment, the first direction X1 and the second direction X2 may be arranged to intersect perpendicularly. The power charging copper busbar 22 includes a power charging copper busbar input end 221 and a power charging copper busbar output end 222 that are interconnected. In this embodiment, the power charging copper busbar input end 221 and the power charging copper busbar output end 222 are both bent and connected to the filter assembly 25. The power positive copper busbar 23 includes a power positive copper busbar input end 231 and a power positive copper busbar output end 232 that are interconnected. The power positive copper busbar input end 231 and the power positive copper busbar output end 232 are both bent and connected to the filter assembly 25. The power negative copper busbar 24 includes a power negative copper busbar input end 241 and a power negative copper busbar output end 242 that are interconnected. The power negative copper busbar input end 241 and the power negative copper busbar output end 242 are both bent and connected to the filter assembly 25. Furthermore, as shown in Figures 2 to 8, the charging busbar input terminal 221, the positive busbar input terminal 231, and the negative busbar input terminal 241 extend side by side along a first direction X1, and the charging busbar output terminal 222, the positive busbar output terminal 232, and the negative busbar output terminal 242 extend side by side along a second direction X2. This combination of parallel and vertically stacked busbar placement allows for compatibility with various spatial configurations by adjusting the busbar bending angle, resulting in a simple structure, high integration, compact layout, and low maintenance costs.

[0070] In the embodiments shown in conjunction with Figures 2 to 3 and Figures 7 to 8, the power charging copper busbar input terminal 221, the power positive copper busbar input terminal 231, and the power negative copper busbar input terminal 241 each have a height difference relative to the plane in which the first direction X1 and the second direction X2 are located, and the height differences are different. In this embodiment, it is assumed that the plane in which the first direction X1 and the second direction X2 are located is a horizontal plane. The power charging copper busbar input terminal 221, the power positive copper busbar input terminal 231, and the power negative copper busbar input terminal 241 each have a height difference relative to the horizontal plane, and the height differences can be different from each other. This arrangement can prevent mutual interference between the input signals of the power charging copper busbar input terminal 221, the power positive copper busbar input terminal 231, and the power negative copper busbar input terminal 241, making the input signals stable and reliable.

[0071] In the embodiments shown in conjunction with Figures 2 to 3 and Figures 7 to 8, the power charging copper busbar output terminal 222, the power positive copper busbar output terminal 232, and the power negative copper busbar output terminal 242 have a height difference relative to the plane in which the first direction X1 and the second direction X2 are located, and the height difference is different. In this embodiment, it is assumed that the plane in which the first direction X1 and the second direction X2 are located is a horizontal plane. The power charging copper busbar output terminal 222, the power positive copper busbar output terminal 232, and the power negative copper busbar output terminal 242 each have a height difference relative to the horizontal plane, and the height difference can be different from each other. This arrangement can prevent mutual interference between the output signals of the power charging copper busbar output terminal 222, the power positive copper busbar output terminal 232, and the power negative copper busbar output terminal 242, making the output signals stable and reliable.

[0072] In the embodiments shown in conjunction with Figures 2 to 3 and Figures 7 to 8, the charging busbar input 221, the positive busbar input 231, and the negative busbar input 241 have height differences relative to the charging busbar output 222, the positive busbar output 232, and the negative busbar output 242, respectively, in the planes along the first direction X1 and the second direction X2. In this embodiment, it is assumed that the plane along the first direction X1 and the second direction X2 is a horizontal plane. The charging busbar input 221 may have a height difference relative to the charging busbar output 222 on this horizontal plane. The positive busbar input 231 may have a height difference relative to the positive busbar output 232 on this horizontal plane. The negative busbar input 241 may have a height difference relative to the negative busbar output 242 on this horizontal plane. This arrangement further prevents signal interference and ensures more stable and reliable signal transmission.

[0073] In the embodiments shown in conjunction with Figures 2 to 3 and Figures 7 to 8, the positive power copper bar 23 can be arranged near the outer edge of the base 21 relative to the negative power copper bar 24 and the power charging copper bar 22, while the power charging copper bar 22 can be arranged near the inner middle area of ​​the base 21 relative to the positive power copper bar 23 and the power negative copper bar 24. For example, the positive power copper bar 23, the negative power copper bar 24, and the power charging copper bar 22 can be arranged sequentially from the edge to the middle area of ​​the base 21. In addition, the positive power copper bar input end 231 and the positive power copper bar output end 232 can extend in two directions, respectively. For example, the positive power copper bar input end 231 extends along a first direction X1, while the positive power copper bar output end 232 extends along a second direction X2. Similarly, the negative power copper bar input end 241 and the negative power copper bar output end 242 can also extend in two directions respectively (the negative power copper bar input end 241 is along the first direction X1, and the negative power copper bar output end 242 is along the second direction X2), and the power charging copper bar input end 221 and the power charging copper bar output end 222 can also extend in two directions respectively (the power charging copper bar input end 221 is along the first direction X1, and the power charging copper bar output end 222 is along the second direction X2).

[0074] In this embodiment, by adopting two perpendicular directions to set copper bars, the space of the curved part can be fully utilized, and through the structural design of the parallel laminated copper bars, parallel means parallel when projected onto the horizontal plane, and laminated means there are different height differences relative to the horizontal plane, which can maximize the laminated length range of the positive copper bar 23, the negative copper bar 24 and the charging copper bar 22, so that the magnetic fields of the positive copper bar 23, the negative copper bar 24 and the charging copper bar 22 cancel each other out, which can effectively reduce the stray inductance. And this layout method makes the structure simple, the layout compact, the integration high and the volume small. It should be noted that an isolation component (not shown) is provided between adjacent copper bars for isolation to prevent electrical connection between adjacent copper bars.

[0075] In the embodiment shown in combination with Figures 3, 5 to 7, at least three-stage filter components 25 include a first-stage filter component 251, a second-stage filter component 252 and a third-stage filter component 253, which are respectively mounted on the power charging copper bus 22, the power positive copper bus 23 and the power negative copper bus 24, and are respectively connected to the power charging copper bus 22, the power positive copper bus 23 and the power negative copper bus 24.

[0076] In conjunction with Figure 1, the first-stage filter component 251 shown in Figures 2 to 8 can be a first-stage filter magnetic ring 131, and the first-stage filter magnetic ring 131 can be an amorphous magnetic ring. The second-stage filter component 252 can be a second-stage filter magnetic ring 132, and the third-stage filter component 253 can be a third-stage filter magnetic ring 133. The second-stage filter magnetic ring 132 and the third-stage filter magnetic ring 133 can be ferrite magnetic rings. The first-stage filter component 251 is used to eliminate low-frequency electromagnetic interference. The second-stage filter component 252 and the third-stage filter component 253 are used to eliminate high-frequency electromagnetic interference. With this arrangement, it is possible to simultaneously power the motor drive and realize the filtering function on the basis of the boost function, and achieve a high resistance to insertion loss, thereby meeting more stringent filtering requirements.

[0077] In the embodiment shown in conjunction with Figures 5 and 7 , the first-stage filter assembly 251 is positioned closer to the power charging busbar input terminal 221, the power positive busbar input terminal 231, and the power negative busbar input terminal 241, relative to the second-stage filter assembly 252 and the third-stage filter assembly 253. Because the input terminals of the power charging busbar 22, the power positive busbar 23, and the power negative busbar 24 are subject to a significant amount of low-frequency electromagnetic interference, positioning the first-stage filter assembly 251 closer to the power charging busbar input terminal 221, the power positive busbar input terminal 231, and the power negative busbar input terminal 241 can eliminate low-frequency electromagnetic interference and ensure signal stability and reliability.

[0078] In the embodiments shown in Figures 3, 5, and 7, the first-stage filter assembly 251 is arranged to extend along a first direction X1, and the second-stage filter assembly 252 and the third-stage filter assembly 253 are arranged to be spaced apart along a second direction X2. This arrangement is compatible with the load's spatial structure, resulting in a compact layout and preventing mutual interference between the first-stage filter assembly 251, the second-stage filter assembly 252, and the third-stage filter assembly 253.

[0079] In the embodiment shown in combination with Figures 3, 5 to 7, the first-stage filter component 251 is integrally formed and has a ring structure. The power charging copper busbar input terminal 221, the power positive copper busbar input terminal 231 and the power negative copper busbar input terminal 241 can all be passed through the first-stage filter component 251 and extend from the first-stage filter component 251 to the outside of the base 21.

[0080] In the embodiment shown in conjunction with Figures 2 to 8, the second-stage filter assembly 252 can be a split structure, including a second-stage filter assembly upper lobe 252a and a second-stage filter assembly lower lobe 252b. The second-stage filter assembly upper lobe 252a and the second-stage filter assembly lower lobe 252b can be plugged in and out to be assembled above and below the power charging copper bus 22, the power positive copper bus 23, and the power negative copper bus 24.

[0081] In the embodiment shown in conjunction with Figures 2 to 8, the third-stage filter assembly 253 can also be a split structure, including a third-stage filter assembly upper lobe 253a and a third-stage filter assembly lower lobe 253b. The third-stage filter assembly upper lobe 253a and the third-stage filter assembly lower lobe 253b can be plugged in and out to be assembled above and below the power charging copper bus 22, the power positive copper bus 23, and the power negative copper bus 24.

[0082] To accommodate complex spatial configurations, the first-stage filter assembly 251 is assembled parallel to the input end of the copper busbar, and the magnetic ring dimensions can be adjusted to accommodate varying spatial dimensions. The second-stage filter assembly 252 and the third-stage filter assembly 253 are assembled in sections, orthogonal to the assembly direction of the first-stage filter assembly 251. This arrangement allows for flexible magnetic ring configuration, balances structural dimensions, and facilitates platform-based application.

[0083] In the embodiment shown in conjunction with Figures 2 to 3, the filter 2 may further include a printed circuit board 26, which is covered on the top of the base 21. The printed circuit board 26 is assembled on the top of the base 21. On the one hand, it allows the power charging copper bus 22, the power positive copper bus 23, the power negative copper bus 24, and at least three-stage filter components 25 to be assembled in the base 21 and fixed and stable. On the other hand, it allows the power positive copper bus 23, the power negative copper bus 24, and at least three-stage filter components 25 to be electrically connected to the printed circuit board 26. The electrical connection is stable and reliable, and the signal transmission is stable. In this embodiment, the printed circuit board 26 is used instead of the traditional direct connection method of the capacitor pins, which can not only facilitate the capacitor layout, but also reduce the parasitic resistance and inductance through the wider traces on the printed circuit board 26.

[0084] This embodiment is based on the structure of parallel stacked copper bars and vertically placed, and adopts screws and printed circuit board 26 to lock and take out electricity, which is convenient for installation and disassembly. This embodiment selects and designs protection measures from the system level, including magnetic rings, Y capacitors (CX capacitors), and X capacitors (CY capacitors) to prevent structural damage. In this embodiment, the side of the printed circuit board 26 facing the base 21 is provided with multiple differential mode components (not shown), multiple common mode components (not shown) and multiple DC support capacitor components (not shown). In conjunction with Figure 1, the DC support capacitor component can be a DC support capacitor 14, which is respectively connected between the power charging copper bar 22 and the ground terminal, between the power positive copper bar 23 and the ground terminal, and between the power negative copper bar 24 and the ground terminal. The differential mode component can be the differential mode capacitor of the differential mode circuit 15. The differential mode component includes at least one differential mode capacitor, each differential mode capacitor is connected between two of the power charging copper bar 22, the power positive copper bar 23 and the power negative copper bar 24. The common mode component can be the common mode capacitor of the common mode circuit 16. The common-mode assembly includes at least two common-mode capacitors, each connected between the positive power busbar 23, the negative power busbar 24, and one of the charging busbars 22, and the ground terminal. In addition, the printed circuit board 26 may also include other components, which are not limited in this application. In this embodiment, multiple differential-mode components, multiple common-mode components, and multiple DC link capacitor components are incorporated into the filter 2. This internal arrangement reduces the product's height, resulting in a compact structure and a smaller size.

[0085] In conjunction with the embodiments shown in Figures 3, 7, and 8, the filter 2 may further include a plurality of electrical connectors 27, which are respectively arranged on the side of the power charging copper bus 22, the power positive copper bus 23, and the power negative copper bus 24 facing the printed circuit board 26, and extend upward from the top of the power charging copper bus 22, the power positive copper bus 23, and the power negative copper bus 24, and are plugged and electrically connected to the multiple differential mode components, multiple common mode components, and multiple DC support capacitor components of the printed circuit board 26. In this embodiment, the electrical connector 27 can be a plug-in copper bus, which is integrally formed with the power charging copper bus 22, the power positive copper bus 23, and the power negative copper bus 24. In this embodiment, by providing multiple plug-in copper buses, on the one hand, the structural layout is compact and the molding process is simple, and on the other hand, plug-in connection with the components on the printed circuit board 26 is achieved, the signal is stable, and it is easy to assemble. In this embodiment, the electrical connector 27 can be a copper pin bar, which is different from the traditional bolt fixing, which can not only ensure the flow capacity but also achieve the filtering effect.

[0086] In the present embodiment, the filter 2 may also include a grounding copper bar (not shown). One end of multiple differential mode components, multiple common mode components and multiple DC support capacitor assemblies is connected to the grounding copper bar, and the grounding copper bar is connected to the ground terminal. In some embodiments, the differential mode component is connected to the housing ground via a Y capacitor. In this way, one end of the grounding of multiple differential mode components, multiple common mode components and multiple DC support capacitor assemblies can be concentrated and connected to the grounding copper bar, which is convenient for connection and maintenance on the one hand, and has a large grounding area and a stable grounding signal on the other hand. In addition, in combination with the actual space, multiple channels are connected to the same grounding copper bar, and by multi-point parallel connection to the ground, the length of the common mode grounding line is minimized, the grounding impedance is reduced, and it is beneficial to filter out high-frequency clutter; multiple channels are connected in parallel separately to the common ground, and the structural design is simple, saving space. In the present embodiment, the filter grounding of the common mode capacitor and the product fixed hole position are integrated into the design, which can reduce the number of fixed holes and further reduce the volume.

[0087] In the embodiments shown in Figures 2 to 4 and 7 , the filter 2 may further include a current sensor 28, located on the positive power supply busbar 23. Current sensor 28 is used to detect the current flowing through the positive power supply busbar 23, or more accurately, the current flowing through the DC bus circuit. This provides real-time monitoring of the DC bus circuit current, ensuring safety and reliability. In this embodiment, the filter 2 may also include a voltage sensor, achieving a high level of integration.

[0088] The embodiment of the present application also provides an electric drive controller, including a filter 2 of a DC power supply as shown in the embodiments of Figures 2 to 8 above. The electric drive controller of this embodiment is provided with a filter 2 of a DC power supply as shown in the embodiments of Figures 2 to 8 above. This embodiment mainly improves the differential / common mode interference problem caused by the high voltage, high switching frequency and wide bandgap power module operation of the electric drive controller. Under the premise of ensuring performance, size and cost, at least three stages of filters 2 are distributed in the electric drive controller. The first stage filter component 251, the second stage filter component 252 and the third stage filter component 253 are externally placed to facilitate material formula adjustment, and the common mode capacitor of the common mode component, the differential mode capacitor of the differential mode component and the DC support capacitor of the DC support capacitor component are internally placed to facilitate structural integration and achieve good electromagnetic compatibility design target requirements. The electric drive controller is selected from the entire control system level without changing the size, realizing flexible configuration of design topology and structural optimization, while ensuring reliability, and is conducive to platform-based promotion and application. It can be applied to front-wheel drive and rear-wheel drive, dual-motor and four-motor system solutions. An embodiment of the present application also provides an automobile, including an electric drive controller as in the above embodiment, which is stable and reliable, can meet good electromagnetic compatibility design target requirements, has better stability, better safety, and better compatibility, and is conducive to platform-based promotion and application.

[0089] The above descriptions are some embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application shall be included in the scope of protection of the present application.

Claims

1. A filter for a DC power supply, comprising: Base; A power charging copper busbar, assembled on the base; A positive copper busbar of the power supply is assembled on the base; A negative copper busbar of the power supply, assembled on the base; and At least three-stage filter components are assembled on the base and are electrically connected to the power charging copper bus, the power positive copper bus and the power negative copper bus respectively.

2. The filter of the DC power supply according to claim 1, wherein: The base extends along a first direction and a second direction which are located in the same horizontal plane and intersect with each other; The power charging copper bar comprises a power charging copper bar input end and a power charging copper bar output end; The power supply positive copper bar comprises a power supply positive copper bar input end and a power supply positive copper bar output end; The power supply negative copper bar comprises a power supply negative copper bar input end and a power supply negative copper bar output end; The power charging copper bar input terminal, the power positive copper bar input terminal and the power negative copper bar input terminal are arranged side by side along the first direction, and The power charging copper bar output end, the power positive copper bar output end and the power negative copper bar output end are arranged side by side and extend along the second direction.

3. The filter of the DC power supply according to claim 2, wherein: The power charging copper bar input end, the power positive copper bar input end and the power negative copper bar input end respectively have height differences relative to the horizontal plane, and the height differences are different; and / or The power charging copper bar output end, the power positive copper bar output end and the power negative copper bar output end have a height difference relative to the horizontal plane, and the height difference is different; The height difference between the power charging copper bar input end and the power charging copper bar output end relative to the horizontal plane is different, the height difference between the power positive copper bar input end and the power positive copper bar output end relative to the horizontal plane is different, and the height difference between the power negative copper bar input end and the power negative copper bar output end relative to the horizontal plane is different.

4. The filter of the DC power supply according to claim 2, wherein: The power positive copper bar is arranged opposite to the power negative copper bar and the power charging copper bar is arranged close to the outer edge of the base; and / or The power charging copper bar is arranged in the middle area of ​​the inner side of the base relative to the power positive copper bar and the power negative copper bar.

5. The filter of the DC power supply according to claim 2, wherein: The at least three-stage filter components include a first-stage filter component, a second-stage filter component and a third-stage filter component, which are respectively mounted on the power charging copper bar, the power positive copper bar and the power negative copper bar, and are respectively connected to the power charging copper bar, the power positive copper bar and the power negative copper bar.

6. The filter of the DC power supply according to claim 5, wherein: The first-stage filter component is arranged relative to the second-stage filter component and the third-stage filter component is close to the power charging copper bar input end, the power positive copper bar input end and the power negative copper bar input end.

7. The filter of the DC power supply according to claim 5, wherein: The first-stage filter component is arranged to extend along the first direction, The second-stage filter components and the third-stage filter components are arranged to be spaced apart along the second direction.

8. The filter of the DC power supply according to claim 5, wherein: The first-stage filter assembly is integrally formed and has a ring structure, and the power charging copper bar input end, the power positive copper bar input end, and the power negative copper bar input end are all arranged in the first-stage filter assembly and extend from the first-stage filter assembly to the outside of the base; and / or The second-stage filter assembly is a split structure, including an upper lobe of the second-stage filter assembly and a lower lobe of the second-stage filter assembly, and the upper lobe of the second-stage filter assembly and the lower lobe of the second-stage filter assembly are plugged together up and down to be assembled above and below the power charging copper bus, the power positive copper bus and the power negative copper bus; and / or The third-stage filter assembly is a split structure, including an upper lobe of a third-stage filter assembly and a lower lobe of a third-stage filter assembly. The upper lobe of the third-stage filter assembly and the lower lobe of the third-stage filter assembly are plugged together up and down to be assembled above and below the power charging copper bus, the power positive copper bus and the power negative copper bus.

9. The filter of the DC power supply according to claim 5, wherein: The first-stage filter assembly includes an amorphous magnetic ring; and / or The second-stage filter component includes a ferrite ring; and / or The third-stage filter component includes a ferrite ring.

10. The filter of the DC power supply according to claim 1, wherein: The filter further comprises: A printed circuit board is covered on the top of the base; a side of the printed circuit board facing the base is provided with a plurality of differential mode components, a plurality of common mode components and a plurality of DC support capacitor components; A plurality of electrical connectors are respectively arranged on the side of the power charging copper bar, the power positive copper bar and the power negative copper bar facing the printed circuit board, and extend upward from the top of the power charging copper bar, the power positive copper bar and the power negative copper bar, and are electrically connected to the plurality of differential mode components, the plurality of common mode components and the plurality of DC support capacitor components of the printed circuit board by upper and lower plugging.

11. The filter of the DC power supply according to claim 10, wherein: The filter also includes a grounding copper busbar; One ends of the plurality of differential mode components, the plurality of common mode components and the plurality of DC support capacitor components are all connected to the grounding copper bus, and the grounding copper bus is connected to a ground terminal.

12. The filter of the DC power supply according to claim 10, wherein: The plurality of differential mode components include at least one differential mode capacitor, each of the differential mode capacitors being connected between two of the power charging copper bar, the power positive copper bar and the power negative copper bar; and / or The plurality of common-mode components include at least two common-mode capacitors, each of which is connected between one of the power positive copper bus, the power negative copper bus, and the power charging copper bus and a ground terminal; and / or The filter also includes a current sensor, which is arranged on the positive copper busbar of the power supply.

13. The filter of the DC power supply according to claim 10, wherein: The DC power supply includes a DC boost power supply; The power supply positive copper bar is a positive busbar copper bar; and / or The power supply negative copper bar is a negative busbar copper bar.

14. An electric drive controller, comprising a filter of a DC power supply as claimed in any one of claims 1 to 13.

15. A vehicle comprising the electric drive controller according to claim 14.

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