Motor controller, powertrain, and vehicle

Abstract

The present application relates to the technical field of motor controllers, and in particular to a motor controller, a powertrain, and a vehicle. The motor controller comprises a circuit board, a plurality of power modules, a middle partition plate, two cooling liquid pipes, and a capacitor module; each power module comprises at least one power tube; the circuit board is used for controlling the on and off of each power tube; the middle partition plate comprises an internal flow channel and two flow channel openings; the two cooling liquid pipes are communicated with the internal flow channel by means of the two flow channel openings, respectively; in a first direction, the plurality of power modules are arranged between the circuit board and the middle partition plate, the middle partition plate and the capacitor module are stacked, the middle partition plate comprises two side surfaces disposed opposite to each other, and the two flow channel openings are disposed spaced part in one side surface of the middle partition plate; and in a second direction, the power modules or the capacitor module is arranged between the two cooling liquid pipes. The middle partition plate in the motor controller provided by the present application integrates the functions of heat dissipation and power module installation, so that the motor controller has a compact structure and a high integration level.

Description

Motor controller, powertrain and vehicle

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the State Intellectual Property Office of China on August 16, 2023, with application number 202311041499.6 and application name “A Motor Controller, Powertrain and Vehicle”, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the technical field of motor controllers, and in particular to a motor controller, a powertrain, and a vehicle. Background Art

[0004] The motor controller is a core component for controlling electric vehicles. As electric vehicles increasingly demand higher power density from their motors, the number of components within the motor controller is also increasing. However, existing motor controllers have a low degree of integration, resulting in large motor controllers and cumbersome disassembly and assembly during rework or repair. Therefore, a new motor controller with high integration and a smaller size is urgently needed.

[0005] Summary of the Invention

[0006] The embodiments of the present application provide a motor controller, a powertrain, and a vehicle. The motor controller has a compact layout, high integration, and occupies a small space.

[0007] In a first aspect, a motor controller is provided, comprising a circuit board, multiple power modules, a middle partition, two coolant pipes, and a capacitor module. The middle partition comprises an internal flow channel, two flow channel openings, and two side surfaces. The two flow channel openings are spaced apart on one side surface, and the two coolant pipes are connected to the internal flow channel through the two flow channel openings. Along a first direction, the circuit board, multiple power modules, the middle partition, and the two capacitor modules are stacked. Multiple power modules are arranged between one side surface of the middle partition of the circuit board. Along a second direction, the power modules or the capacitor modules are arranged between the two coolant pipes. In this embodiment, the capacitor module is used to filter direct current (DC) and output the filtered DC power to the power module, which converts the DC power into alternating current (AC) and outputs the AC power to the motor. The circuit board is used to control the opening and closing of at least one power tube included in the power module and to control the parameters of the AC power converted by the power module. Coolant is introduced into the internal flow channel of the middle partition through the coolant pipe to dissipate heat from the power module and the capacitor module. The center baffle incorporates a heat dissipation function, further enhancing the integration of the motor controller and facilitating its miniaturization. Furthermore, when coolant is passed through the coolant pipe, it also dissipates heat from the capacitor module or power module, accelerating the heat dissipation process.

[0008] In one embodiment, the middle partition includes multiple mounting windows. These mounting windows are spaced apart along the second direction on the other side of the middle partition. Each mounting window is used to secure a power module, and each mounting window communicates with the internal flow channel. In this manner, multiple power modules are integrated into the other side of the middle partition through the mounting windows on the middle partition, thereby improving the integration of the middle partition and miniaturizing the motor controller.

[0009] In one embodiment, the middle partition includes two rows of circuit board supports for securing the circuit boards. These two rows of circuit board supports are located on the other side of the middle partition, on the same side of the middle partition as the multiple mounting windows. Along a third direction, the two rows of circuit board supports are arranged opposite each other on either side of the multiple mounting windows. The circuit boards are secured by the two rows of circuit board supports on the middle partition, further increasing the integrated functionality of the middle partition, improving the integration of the motor controller, and thereby miniaturizing the motor controller.

[0010] In the above embodiment, each row of circuit board supports includes four circuit board supports spaced apart along the second direction, with the spacing between two adjacent circuit board supports being greater than the aperture of each mounting window. This allows the circuit board supports to further compress the edges of each power module when securing the circuit board to the middle partition.

[0011] In one embodiment, each power module includes multiple DC input copper bars, one AC output copper bar, and multiple power signal terminals. The multiple DC input copper bars are spaced apart along the second direction. Along the third direction, multiple DC input copper bars and one AC output copper bar are arranged on both sides of the power end. Each DC input copper bar is used to connect a power tube and a capacitor module. Multiple power signals extend along the first direction, and the power signal terminals are inserted into the circuit board to achieve electrical connection between the power module and the circuit board. The circuit board sends a control signal to the power module through the power signal terminals, enabling the power module to achieve the AC / DC conversion function.

[0012] In one embodiment, the motor controller includes a Hall assembly, which is fixed to the other side of the middle partition. The Hall assembly includes multiple Hall sensors and multiple copper busbar connectors, and the multiple Hall sensors are arranged along the second direction on the other side of the middle partition. Each Hall core includes a core through-hole, and each core through-hole is used to pass a copper busbar connector. The copper busbar connector is used to connect to the power tube and the motor to transmit alternating current to the motor. When the copper busbar connector passes through the core through-hole, a gap exists between the copper busbar connector and the inner wall of the core through-hole.

[0013] In one embodiment, the Hall assembly includes a Hall fixed plate. The middle partition includes at least one row of Hall support members arranged along a second direction, the at least one row of Hall support members arranged on another side of the middle partition, and the at least one row of Hall support members used to fix the Hall fixed plate. The Hall fixed plate extends parallel to the second direction, and a plurality of Hall cores are fixed to the Hall fixed plate along the second direction.

[0014] In the above embodiment, the Hall assembly is fixed by the Hall support member of the middle partition, so that the integrated function of the middle partition is further increased, thereby improving the integration of the motor controller and miniaturizing the motor controller.

[0015] In one embodiment, a capacitor module includes a capacitor housing, a capacitor core, and multiple DC output copper bars. The capacitor housing accommodates the capacitor core. The multiple DC output copper bars are spaced apart along a second direction and electrically connect the capacitor core to the power transistor. To reduce parasitic capacitance, at least one DC output copper bar has an S-shape or a U-shape projected along the first direction.

[0016] In one embodiment, a DC output copper busbar includes a welding section, a plurality of bending sections, and a lead-out section, wherein the plurality of bending sections are sequentially connected between the welding section and the lead-out end. The welding section is used to electrically connect to a DC input copper busbar of a power module, and the lead-out section is used to electrically connect to a capacitor core. The bending direction of at least one of the plurality of bending sections is different from the bending direction of at least one bending section, which can reduce the mechanical stress of the welding section included in the output copper busbar, improve the stability of the connection between the output copper busbar and the input copper busbar, and thereby improve the stability of the operation of the motor controller.

[0017] In one embodiment, the plurality of bending sections include a first bending section, and the first bending section includes two first connecting sections. One first connecting section is used to connect to the welding section, and another first connecting section is used to connect to another bending section. The angle between one first connecting section and the other first connecting section faces one power module. This allows for greater installation space on the side of the capacitor module facing the power module, facilitating device layout. Alternatively, the angle between one first connecting section and the other first connecting section faces away from one power module. This prevents the two first connecting sections and the other bending section from protruding from the capacitor module, thereby improving the compactness of the motor controller.

[0018] In one embodiment, the welding section, the first connecting section, and the DC input copper busbar are stacked along the first direction, thereby reducing parasitic capacitance.

[0019] In one embodiment, the plurality of bending sections include a second bending section, and the second bending section includes two second connecting sections. One second connecting section is used to connect to the lead-out section, and another second connecting section is used to connect to another bending section. The angle between one second connecting section and another second connecting section is oriented toward one power module. This allows for a larger installation space for the capacitor module on the side facing the power module, facilitating the layout of the components. The angle between one second connecting section and another second connecting section is oriented away from one power module. This prevents the two second connecting sections from protruding from the capacitor module, thereby improving the compactness of the motor controller.

[0020] In one embodiment, in order to protect the circuit board, the motor controller includes a protective cover. Along a first direction, the protective cover is located on a side of the circuit board away from the power module and covers the circuit board.

[0021] In a second aspect, embodiments of the present application provide a powertrain. The powertrain includes an electric motor and a motor controller according to any technical solution of the first aspect, the motor controller being electrically connected to the electric motor. The motor controller is configured to convert direct current (DC) power provided by a power supply into alternating current (AC) power and output the AC power to the electric motor.

[0022] In a third aspect, embodiments of the present application provide a vehicle. The vehicle includes a vehicle body, an engine, and the motor controller described in any technical solution of the first aspect, or the powertrain described in the second aspect. The motor or powertrain is mounted on the vehicle body and is used to drive the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG1 is a schematic structural diagram of a vehicle provided in one embodiment of the present application;

[0024] FIG2 is a schematic diagram of an application scenario of a powertrain provided in one embodiment of the present application;

[0025] FIG3 is an overall assembly diagram of a motor controller provided in an embodiment of the present application;

[0026] FIG4 is an exploded view of a motor controller provided in an embodiment of the present application;

[0027] FIG5 is a schematic structural diagram of a middle partition in a motor controller provided in an embodiment of the present application;

[0028] FIG6 is an exploded view of FIG5 ;

[0029] FIG7 is a bottom view of FIG5;

[0030] FIG8 is a schematic structural diagram of a main board of a middle partition in a motor controller provided in an embodiment of the present application;

[0031] FIG9 is a schematic structural diagram of a cover plate of a middle partition in a motor controller provided in an embodiment of the present application;

[0032] FIG10 is a schematic diagram of the structure of a capacitor module in a motor controller provided by an embodiment of the present application;

[0033] FIG11 is a schematic diagram of the structure of the capacitor module and the power module in the motor controller provided by the embodiment of the present application;

[0034] FIG12 is a side view of FIG11 ;

[0035] FIG13 is another side view of the coordination of a capacitor module and a power module in a motor controller provided by an embodiment of the present application;

[0036] FIG14 is another side view of the coordination of a capacitor module and a power module in a motor controller provided by an embodiment of the present application;

[0037] FIG15 is a schematic structural diagram of a medium-voltage plate in a motor controller according to an embodiment of the present application;

[0038] FIG16 is a schematic diagram of a structure of a motor controller provided in an embodiment of the present application;

[0039] FIG17 is another structural diagram of a motor controller provided in an embodiment of the present application.

[0040] Figure numerals: 1-vehicle; 11-wheel; 12-vehicle load; 13-external power supply; 2-powertrain; 20-power module; 21-power battery; 22-motor; 3-motor controller; 30-middle partition; 30a-flow channel opening; 30b-installation window; 30c-positioning hole; 30d-mainboard; 30e-cover plate; 300-circuit board support; 301-pressure plate fixing member; 302-Hall support member; 303-capacitor module connector; 304-cold liquid holding tank; 305-positioning plate; 306-positioning groove; 307-partition plate; 310-cooling liquid pipe; 32-power module; 320-power tube; 321-DC input copper bus; 322-AC output copper bus; 323-power signal Terminal; 33-circuit board; 330-circuit board fixing hole; 34-capacitor module; 340-capacitor housing; 341-capacitor core; 342-DC output copper busbar; 3420-slot; 3421-welding section; 3422-bending section; 3422a-first bending section; 3422b-second bending section; 34220-first connecting section; 34221-second connecting section; 3423-lead-out section; 343-positioning part; 344-insulating plate; 35-pressing plate assembly; 350-pressing plate; 3500-pressing plate fixing hole; 351-insulating paper; 36-protective cover; 37-Hall assembly; 370-Hall fixing plate; 371-Hall core; 372-copper busbar connector; 373-connecting copper busbar. DETAILED DESCRIPTION

[0041] In order to make the purpose, technical solutions and advantages of this application clearer, this application will be further described in detail below with reference to the accompanying drawings.

[0042] The motor controller is a core component for controlling electric vehicles. As electric vehicles increasingly demand higher power density from their motors, the number of components within the motor controller is also increasing. However, existing motor controllers have a low degree of integration, resulting in large motor controllers and cumbersome disassembly and assembly during rework or repair. Therefore, a new motor controller with high integration and a smaller size is urgently needed.

[0043] The terms used in the following embodiments are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the specification and appended claims of this application, the singular expressions "a", "an", "said", "above", "the", and "this" are intended to also include expressions such as "one or more", unless the context clearly indicates otherwise.

[0044] References to "one embodiment" or "some embodiments" in this specification mean that a particular feature, structure, or characteristic described in conjunction with that embodiment is included in one or more embodiments of the present application. Thus, phrases such as "in one embodiment," "in some embodiments," "in other embodiments," and "in yet other embodiments" appearing in various places in this specification do not necessarily refer to the same embodiment, but rather mean "one or more but not all embodiments," unless otherwise specifically emphasized. The terms "including," "comprising," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0045] Please refer to Figure 1, which is a structural schematic diagram of a vehicle 1 provided in an embodiment of the present application. In one implementation, the vehicle 1 includes a vehicle body 10, wheels 11 and a powertrain 2. The powertrain 2 is installed on the vehicle body 10 and is used to supply power to the vehicle load 12 and drive the wheels 11 to rotate.

[0046] In this embodiment, vehicle 1 refers to a wheeled vehicle 1 that is driven or towed by a power unit and is used for passengers on roads, for transporting goods, and for performing special engineering operations. Vehicles 1 include electric vehicles (EVs), battery electric vehicles (BEVs), hybrid electric vehicles (HEVs), range-extended electric vehicles (REEVs), plug-in hybrid electric vehicles (PHEVs), and new energy vehicles.

[0047] Please refer to Figure 2, which is a schematic diagram of the powertrain 2 provided in an embodiment of the present application. In one implementation, the powertrain 2 includes a power module 20, a power battery 21, a motor controller 3 and an electric motor 22.

[0048] In this embodiment, the power module 20 receives power from the external power source 13 and charges the power battery 21. The external power source 13 can be an AC power grid, an AC charging station, or a DC charging station. The power battery 21 supplies power to the electric motor 22 via the motor controller 3. The motor controller 3 is electrically connected to the electric motor 22. The motor controller 3 is configured to convert the DC power provided by the power battery 21 into AC power. The electric motor 22 receives this AC power and converts it into kinetic energy to drive the wheels 11.

[0049] In one embodiment, a power module 20 is electrically connected to the vehicle load 12. The power module 20 is configured to supply power to the vehicle load 12. The power module 20 may be a power distribution unit or an onboard charger. The vehicle load 12 includes at least one of a compressor, a battery heating module, a seat heating module, and a DC low-voltage power supply.

[0050] Figure 3 is an overall assembly diagram of the motor controller provided in an embodiment of the present application, and Figure 4 is an exploded diagram of the motor controller provided in an embodiment of the present application. Referring to Figures 3 and 4, the motor controller includes a circuit board 33, multiple power modules 32, a middle partition 30, two coolant pipes 310, a capacitor module 34, a pressure plate assembly 35, a protective cover 36 and a Hall assembly 37.

[0051] Among them, the capacitor module 34 is used to filter the direct current and output the filtered direct current to the power module 32. The power module 32 converts the direct current into alternating current and outputs it to the motor. The circuit board 33 is used to control the conduction and shutdown of multiple switching tubes in the multiple power modules 32, and control the parameters of the alternating current converted by the power module 32. The Hall component 37 is used to detect the parameters of the alternating current output by the multiple power modules 32, and transmit the detected alternating current parameters to the circuit board 33. The middle partition 30 is used to fix one or more of the circuit board 33, multiple power modules 32, two coolant pipes 310, the capacitor module 34, the pressure plate assembly 35, the protective cover 36 or the Hall component 37.

[0052] In one embodiment, a circuit board 33, a pressure plate assembly 35, multiple power modules 32, a middle separator 30, and a capacitor module 34 are stacked and arranged along a first direction X. Two coolant pipes 310 are connected to the side of the middle separator 30 facing the capacitor module 34. A Hall element 37 is mounted on the side of the middle separator 30 facing the power module 32. A protective cover 36 covers the circuit board 33 to prevent damage from external components or external forces.

[0053] FIG5 is a schematic diagram of the structure of the middle partition in the motor controller provided by an embodiment of the present application. Referring to FIG4 and FIG5, the middle partition 30 includes a plurality of installation windows 30b. The plurality of installation windows 30b are spaced apart and distributed on one side of the middle partition 30 along the second direction Y.

[0054] In one embodiment, the plurality of mounting windows 30b are located on a side of the middle partition 30 facing away from the capacitor module.

[0055] Each installation window 30b is used to fix a power module 32. Each installation window 30b is connected to the internal flow channel of the middle partition 30 so that the heat generated by the power module 32 during operation can be quickly dissipated through the installation window 30b, ensuring the stability of the operation of the power module 32.

[0056] In one embodiment, the power module 32 is installed in each installation window 30b, and a sealing ring may be installed between the power module 32 and the installation window 30b to improve the sealing of the power module installed in the installation window 30b and prevent coolant leakage.

[0057] In the embodiment of the present application, the shape of each installation window 30b includes a rectangle, a circle, a diamond, etc. In one embodiment, the shape of each installation window 30b can be the same or different.

[0058] Continuing with Figures 4 and 5 , the middle partition 30 includes two rows of circuit board supports 300. In one embodiment, the two rows of circuit board supports 300 and the plurality of mounting windows 30b are located on the same side of the middle partition 30. Along the third direction Z, the two rows of circuit board supports 300 are arranged opposite each other on either side of the plurality of mounting windows 30b and are used to secure the circuit boards 33.

[0059] In one embodiment, the plurality of mounting windows 30 b are located between two rows of circuit board supports 300 .

[0060] In the embodiment of the present application, the circuit board 33 can be fixed by the circuit board support 300 of the middle partition 30, so that the integrated function of the middle partition 30 is further increased to improve the integration of the motor controller and thus miniaturize the motor controller.

[0061] In one embodiment, each row of circuit board supports 300 includes four circuit board supports 300, which are spaced apart along the second direction Y. The spacing between two adjacent circuit board supports 300 is greater than the aperture of each mounting window 30b. In the projection of the second direction Y, a mounting window 30b is arranged between two adjacent circuit board supports 300. Because the circuit boards and power modules are stacked along the first direction X, the circuit boards 33 can be mounted on the middle partition 30 via the circuit board supports 300. The four circuit board supports 300 surrounding each mounting window 30b can compress the corners of each mounting window 30b, thereby improving the compactness of each power module 32 installed in the mounting window 30b.

[0062] Continuing with Figures 4 and 5 , the middle partition 30 includes two rows of pressure plate fixing members 301, which are used to secure the pressure plate assembly 35 to the middle partition 30. In one embodiment, the two rows of pressure plate fixing members 301, the circuit board support member 300, and the installation window 30b are mounted on the same side of the middle partition 30. The two rows of pressure plate fixing members 301 are arranged opposite each other on either side of the plurality of installation windows 30b along the second direction Y. Along the first direction X, the plurality of power modules 32 are arranged between the pressure plate assembly 35 and the middle partition 30. The pressure plate fixing members 301 secure the pressure plate assembly 35 to the middle partition 30, thereby improving the stability of the power modules installed in the installation windows and preventing coolant leakage.

[0063] In the embodiment of the present application, the pressure plate assembly 35 can be fixed by the pressure plate fixing piece 301 of the middle partition 30, so that the integrated function of the middle partition 30 is further increased to improve the integration of the motor controller and further miniaturize the motor controller.

[0064] Continuing to refer to Figures 4 and 5, the middle partition 30 includes two rows of positioning holes 30c. In one embodiment, each row of positioning holes 30c includes a plurality of positioning holes 30c spaced apart along the second direction Y. Along the third direction Z, two positioning holes 30c are arranged between at least partially opposite two circuit board supports 300. Two positioning holes 30c are arranged between each two adjacent installation windows 30b, and the two positioning holes 30c are spaced apart along the third direction. The connector passes through the pressure plate assembly 35 and cooperates with the positioning holes 30c. During the process of fixing the pressure plate assembly, the connector and the pressure plate fixing member 301 can press each corner of each installation window 30b to further improve the stability of the connection between the pressure plate assembly and the middle partition 30, and can also press the power module 32. In one embodiment, the cooperation between the connector and the positioning hole 30c can also be understood as a pressure plate fixing member.

[0065] Continuing to refer to Figures 4 and 5, the middle partition 30 includes at least one row of Hall support members 302 arranged along the second direction. The Hall support members 302, the pressure plate fixing member 301, the installation window 30b and the circuit board support member 300 are all located on the same side of the middle partition 30. Each row of Hall support members 302 includes at least two Hall support members 302, and the Hall support members 302 are used to fix the Hall assembly to the middle partition 30 to improve the integration of the middle partition 30 and miniaturize the motor controller. In one embodiment, the middle partition 30 includes a capacitor module connector 303 for connecting to the capacitor module to increase the stability of the capacitor module when it is matched with the middle partition 30.

[0066] FIG6 is an exploded view of FIG5 . Referring to FIG5 and FIG6 , the middle partition 30 includes a main board 30d and a cover plate 30e. In one embodiment, the main board 30d is made of aluminum alloy and is a sealed aluminum alloy die-casting. Along the first direction X, the main board 30d has a first surface and a second surface facing each other, and the cover plate 30e is integrally formed with the second surface of the main board 30d by friction welding. The first surface of the main board 30d is used to integrate the above-mentioned multiple installation windows 30b, two rows of circuit board supports 300, at least one row of Hall support members 302, and two rows of pressure plate fixing members 301. Among them, the first surface of the main board 30d includes two rows of positioning holes 30c. Along the second direction, the two rows of positioning holes 30c are arranged between two adjacent installation windows 30b. Along the third direction, the two rows of positioning holes 30c are arranged between the two rows of circuit board supports 300. The capacitor module connector 303 is integrated into the side of the main board 30d. The side surface is a connection surface of the main board 30d for connecting the first surface and the second surface. Along the first direction X, the capacitor module connector 303 extends toward one side of the cover plate 30e.

[0067] FIG7 is a bottom view of a central partition in a motor controller according to an embodiment of the present application, FIG8 is a schematic structural diagram of a mainboard of the central partition in a motor controller according to an embodiment of the present application, and FIG9 is a schematic structural diagram of a cover plate of the central partition in a motor controller according to an embodiment of the present application. Continuing with FIG6 to FIG9 , the second side of mainboard 30d includes a cooling liquid tank 304. The edge of cooling liquid tank 304 is located at the edge of mainboard 30d, thereby increasing the capacity of cooling liquid tank 304 and ensuring effective heat dissipation. A positioning plate 305 is integrated into the second side of mainboard 30d. Positioning plate 305 is located in cooling liquid tank 304. One end of positioning plate 305 is connected to one side wall of cooling liquid tank 304, and the other end of positioning plate 305 extends toward the side of the other side wall of cooling liquid tank 304. Positioning plate 305 is not connected to the other side wall of cooling liquid tank 304. Positioning plate 305 is spaced apart from the other side wall of cooling liquid tank 304, so that positioning plate 305 divides cooling liquid tank 304 into two interconnected portions. The side of the cover plate 30e facing the main plate 30d includes a positioning slot 306 and at least one partition plate 307. The positioning slot 306 extends through the cover plate 30e along a first direction X. Along a second direction Y, the at least one partition plate 307 is spaced apart from the positioning slot 306. Two flow channel openings 30a on the main plate 30d are located on either side of the partition plate 307 and the positioning slot 306. Two coolant pipes 310 communicate with the two flow channel openings 30a, thereby increasing the distance between the two coolant pipes 310 and increasing the cooling efficiency of the middle partition 30.

[0068] In one embodiment, the cover plate 30e is secured to the second surface of the main board 30d by friction welding. The positioning groove 306 engages the positioning plate 305 by snapping. The cover plate 30e is completely positioned within the coolant reservoir 304, and the edges of the coolant reservoir 304 are completely sealed by friction welding, thereby forming an internal flow channel between the cover plate 30e and the second surface of the main board 30d. The internal flow channel communicates with each mounting window 30b, and the coolant within the internal flow channel is supplied and discharged through two coolant pipes 310. This ensures that the coolant remains in the internal flow channel for a long time, allowing for sufficient heat exchange with other components. Two partition plates 307 can be provided, parallel to each other and extending in the second direction Y to slow the flow of coolant within the internal flow channel. In this embodiment, the height of the partition plates 307 along the first direction X is the same as the coverage of the positioning plate 305 to ensure the tightness of the internal flow channel formed after the cover plate 30e is welded to the main board 30d.

[0069] In one embodiment, in order to improve the heat dissipation performance of the middle partition 30 to the capacitor module 34 , a thermal pad may be provided between the cover plate 30 e and the capacitor module 34 .

[0070] In one embodiment, the two flow channel openings 30a may be shaped like a circle, rectangle, diamond, or other irregular shape. The diameter of the inlet of the flow channel opening 30a may be larger than the diameter of the outlet, allowing the coolant to remain in the internal flow channel for a longer time, thereby improving heat exchange efficiency. The diameter of the inlet of the flow channel opening 30a may be smaller than the diameter of the outlet, allowing the coolant to remain in the internal flow channel for a relatively shorter time, allowing the coolant to enter the internal flow channel quickly.

[0071] In one embodiment, the shape of the coolant pipe 310 including the coolant channel may be cylindrical or prismatic, etc. The diameter of the coolant pipe 310 is larger than the flow channel opening 30a to improve the sealing performance of the connection between the coolant pipe 310 and the flow channel opening 30a.

[0072] Continuing with Figure 4 , each power module 32 includes at least one power transistor 320. A circuit board 33 controls the on / off switching of each power transistor 320, enabling the power modules 32 to perform AC / DC conversion. The power modules 32 are mounted to the central baffle 30 through mounting windows. The central baffle 30 dissipates heat from the power transistors 320, ensuring stable operation.

[0073] In one embodiment, the power module 32 includes a plurality of power tubes 320. The plurality of power tubes 320 in the power module 32 are used to form a three-phase bridge arm circuit. Among them, the plurality of power tubes 320 in the power module 32 are arranged flatly along the second direction Y on the side of the middle partition 30 away from the capacitor module 34. Exemplarily, each power module 32 includes two power tubes 320, and every two power tubes 320 constitute a one-phase bridge arm circuit. Both ends of each phase bridge arm circuit are electrically connected to the capacitor module 34. In one embodiment, the two power tubes 320 are arranged flatly in two rows along the second direction Y. In one embodiment, the two power tubes 320 are arranged flatly in a single row in the second direction Y.

[0074] In one embodiment, multiple power modules 32 are used to form a three-phase bridge arm circuit. The multiple power modules 32 are arranged flatly along the second direction. Exemplarily, the motor controller 3 includes three power modules 32. Each power module 32 forms a single-phase bridge arm circuit. Both ends of each phase bridge arm circuit are electrically connected to the capacitor module 34.

[0075] Each power module 32 includes an upper-arm switching transistor and a lower-arm switching transistor. Each of the upper-arm switching transistors and the lower-arm switching transistor includes at least one power transistor 320. In one embodiment, each power module 32 includes two power transistors 320. The two power transistors 320 respectively constitute the upper-arm switching transistor and the lower-arm switching transistor of a phase arm circuit.

[0076] In one embodiment, the power transistor 320 includes at least one of an insulated gate bipolar transistor (IGBT) or a metal-oxide-semiconductor field-effect transistor (MOS). In one embodiment, the power transistor 320 includes a silicon carbide metal-oxide-semiconductor field-effect transistor (SiC MOSFET) or a silicon-insulated-gate bipolar transistor (Si IGBT).

[0077] In this embodiment, multiple power modules 32 are arranged flatly along the second direction on the surface of the middle partition 30. Compared to the arrangement in which multiple power modules 32 are stacked and arranged between the pressure plate assembly 35 and the middle partition 30 along the first direction, this solution helps to reduce the length of the motor controller 3 in the first direction, effectively utilizes the installation area of ​​the middle partition 30, and thus realizes a miniaturized design of the motor controller.

[0078] In one embodiment, each power module has a heat dissipation toothed portion (not shown) on the side facing the middle baffle. The side of the power module with the heat dissipation toothed portion is sealed to the mounting window via a sealing ring to ensure that the middle baffle can dissipate heat from the power module and prevent coolant leakage, thereby preventing damage to other components.

[0079] In one embodiment, the power module and the middle partition can be pre-assembled to make the parts inside the motor controller modular. When the motor controller needs to be reworked or repaired, there is no need to disassemble and assemble the parts one by one, thereby achieving rapid assembly and disassembly of the motor controller and reducing the difficulty and cost of operation.

[0080] 4, each power module 32 comprises a plurality of DC input copper bars 321 and a plurality of AC output copper bars 322. A plurality of DC input copper bars 321 are spaced apart along the second direction. Along the third direction, a plurality of DC input copper bars 321 and an AC output copper bar 322 are arranged on both sides of the power tube 320. Each DC input copper bar 321 is used to connect a power tube 320 and a capacitor module 34, and the power tube 320 and the capacitor module 34 are electrically connected by the DC input copper bars 321. Direct current is transmitted to the power tube 320 from the capacitor module 34 via the DC input copper bars 321. A plurality of DC input copper bars 321 extend toward the outside of the middle partition plate 30 so that the DC input copper bars 321 are electrically connected to the capacitor module 34.

[0081] In the embodiment of the present application, the number of DC input copper busbars 321 included in each power module 32 is 3, and the number of AC output copper busbars included in each power module 32 is 1. In other embodiments, the number of DC input copper busbars 321 included in each power module may be another positive integer, and those skilled in the art may adjust this number based on actual needs, and this application does not impose any limitation on this.

[0082] Continuing with Figure 4 , the power module 32 includes a power signal terminal 323. The power signal terminal 323 is located on the side of the power module 32 opposite the DC input busbar 321 and extends toward the circuit board 33. In one embodiment, the power signal terminal 323 is a pin that is inserted into the circuit board to establish an electrical connection between the power module 32 and the circuit board 33. The circuit board 33 sends a control signal to the power module 32 via the power signal terminal 323, enabling the power module 32 to perform AC / DC conversion.

[0083] Continuing with reference to FIG4 , the capacitor module 34 is used to transmit and adjust DC power, including but not limited to smoothing the voltage so that the voltage remains relatively smooth when the switching devices in the power module 32 are switched. The capacitor module 34 can also reduce the inductance parameters, weaken the peak voltage, absorb the high pulse current of the motor controller 3, and prevent the voltage from being overcharged and the influence of the transient voltage on the motor controller 3.

[0084] FIG10 is a schematic diagram of the structure of the capacitor module in the motor controller provided by the present application, and FIG11 is a schematic diagram of the structure of the capacitor module and the power module in the motor controller provided by the present application. Referring to FIG4, FIG10 and FIG11, the capacitor module 34 includes a capacitor core 341, a capacitor housing 340 and multiple DC output copper bars 342. The capacitor housing 340 includes multiple positioning portions 343, which are used to cooperate with the capacitor module connector 303 included in the middle partition to fix the capacitor housing 340 to the middle partition 30. The capacitor housing 340 is used to accommodate the capacitor core 341, and a DC output copper bar 342 is used to connect a power tube 320. The multiple DC output copper bars 342 are arranged along the second direction Y on the side of the capacitor module 34 facing the middle partition 30, and the orthographic projections of the DC output copper bars 342 and the middle partition 30 on the mounting surface of the capacitor module 34 do not overlap. Among them, the mounting surface of the capacitor module 34 is the surface of the capacitor housing 340 facing the power module 32. The DC input copper busbar 321 is electrically connected to the DC output copper busbar 342. The power transistor 320 is electrically connected to the capacitor module 34 via the DC input copper busbar 321 and the DC output copper busbar 342. DC power is transmitted from the capacitor module 34 to the power transistor 320 via the DC output copper busbar 342 and the DC input copper busbar 321.

[0085] In one embodiment, the mounting surface of the capacitor module 34 can be understood as the side of the capacitor housing 340 facing the middle partition 30. The DC output copper bus 342 extends out of the mounting surface along a first direction, and the DC output copper bus 342 does not overlap with the orthographic projection of the mounting surface of the power tube 320. The DC input copper bus 321 extends from the power tube along a third direction Z, wherein the third direction Z is perpendicular to the first direction X and the second direction Y, respectively, and the DC input copper bus 321 and the DC output copper bus 342 overlap in the first direction X. It can be understood that the DC input copper bus 321 is arranged along the horizontal direction (third direction Z), and the DC output copper bus 342 is arranged along the second direction Y. The DC input copper bus 321 and the DC output copper bus 342 are fixedly connected by laser welding.

[0086] In one embodiment, a plurality of DC output copper bars 342 form three groups of DC output copper bars 342. Each group of DC output copper bars 342 includes two positive output copper bars 342 and one negative output copper bar 342. Along the second direction Y, one negative output copper bar 342 is located between two positive output copper bars 342. It can be understood that, among the three DC output copper bars 342 included in each group of DC output copper bars 342, the DC output copper bar 342 located in the middle along the second direction Y is the negative DC output copper bar 342, and the DC output copper bar 342 located in the middle along the second direction Y is the positive output copper bar 342.

[0087] Continuing with reference to Figures 10 and 11, the capacitor module includes three insulating plate groups. Each insulating plate group includes three insulating plates 344 spaced apart along a third direction, two positive output copper bars 342 are located between two adjacent insulating plates 344 among the three insulating plates 344, and one negative output copper bar 342 is located between two other adjacent insulating plates 344. The two positive output copper bars 342 and one negative output copper bar 342 are both connected to the capacitor core 341, and at least one of the two positive output copper bars 342 and one negative output copper bar 342 has an S-shape or U-shape projection along the first direction to reduce parasitic inductance. In one embodiment, in order to reduce the stress of the negative output copper bar 342, the negative output copper bar 342 includes a slot 3420, which extends along the first direction X. It is worth mentioning that in order to reduce the stress of the positive output copper bar 342, the positive output copper bar 342 may also be provided with a slot 3420 extending along the first direction X.

[0088] In an embodiment of the present application, the projections of two positive output copper bars 342 and one negative output copper bar 342 along the first direction can be S-shaped or U-shaped at the same time, or the projections of the two positive output copper bars 342 along the first direction are S-shaped. The projection of one negative output copper bar 342 along the first direction X is U-shaped. Or, the projections of the two positive output copper bars 342 along the first direction X are U-shaped, and the projection of one negative output copper bar 342 along the first direction X is S-shaped. The connection ends of the two positive output copper bars 342 and one negative output copper bar 342 and the DC input copper bar include welding sections, which are stacked on the DC input copper bar 321 along the first direction and fixedly connected by laser welding to achieve electrical connection between the capacitor module and the power module.

[0089] FIG12 is a side view of FIG11 , and FIG12 illustrates an insulating plate. In one embodiment, the DC output copper busbar includes a welding section 3421, an extension section 3423, and a plurality of bent sections 3422 sequentially connected between the welding section 3421 and the extension section 3423. The welding section 3421 is used to electrically connect a DC input copper busbar 321, and the extension section 3423 is used to electrically connect the capacitor core. Along a first direction X, a DC input copper busbar 321 facing the side of the capacitor module 34 and a welding section 3421 facing the side of a DC input copper busbar 321 are fixedly connected by laser welding. It can be understood that a DC output copper busbar 342 and a welding section 3421 are stacked along the first direction, and the side of the DC input copper busbar 321 facing the capacitor module 34 is parallel to the side of the welding section 3421 facing the DC input copper busbar 321 to reduce parasitic inductance.

[0090] In one embodiment, the plurality of bending segments 3422 include a first bending segment 3422a, which includes two first connecting segments 34220. One first connecting segment 34220 is configured to connect to the welding segment 3421, and the other first connecting segment 34220 is configured to connect to the other bending segment 3422. The angle between one first connecting segment 34220 and the other first connecting segment 34220 is directed toward one power module 32.

[0091] In one embodiment, the angle between one first connecting segment 34220 and another first connecting segment 34220 can be 90 degrees. The first connecting segment 34220 and the other first connecting segment 34220 are arranged perpendicularly to each other. A first connecting segment 34220 is located in the extension direction of the welding segment 3421 and is connected to the welding segment 3421. At least a portion of a first connecting segment 34220 and a DC input copper busbar 321 are stacked along the second direction. During the welding process of a DC output copper busbar 342 and a DC input copper busbar 321, at least a portion of a first connecting segment 34220 included in a DC output copper busbar 342 can also be connected to the DC input copper busbar 321 via laser welding. This increases the stacking length between the DC output copper busbar 342 and the DC input copper busbar 321, further reducing parasitic inductance.

[0092] In one embodiment, the angle between one first connecting section 34220 and another first connecting section 34220 is oriented toward one power module 32, and this angle may be less than 90 degrees. One first connecting section 34220 connected to the welding section 3421 faces the side of the DC input copper busbar 321 and is stacked with the side of the DC input copper busbar 321 facing the capacitor module 34. The other first connecting section 34220 is connected to the first connecting section 34220 and extends toward one side of the power module 32. This increases the stacking area of ​​the DC output copper busbar and the DC input copper busbar along the first direction X, thereby reducing parasitic inductance.

[0093] In the above-mentioned embodiment, the angle of another bending section 3422 is toward a power module 32, and the angle of another bending section 3422 is greater than 90 degrees. The bending direction of at least one bending section 3422 in a plurality of bending sections 3422 is different from the bending direction of at least another bending section 3422. In this embodiment, it can be understood that the bending direction of the first bending section 3422a is relative to the bending direction of another bending section 3422, so that the projection of the welding section 3421 of the DC output copper bus 342 and the plurality of bending sections 3422 in the first direction is U-shaped, and the opening of the U is toward the power module 32. The DC output copper bus 342 includes a U-shaped bending portion with an opening toward the power module, which can reduce parasitic capacitance, and can also reduce the stress of the DC output copper bus 342 and the DC input copper bus 321 during laser welding, thereby improving the stability of the electrical connection between the power module 32 and the capacitor module 34.

[0094] FIG13 is another side view of the combination of a capacitor module and a power module in a motor controller provided by an embodiment of the present application. Referring to FIG13 , the plurality of bending segments 3422 include a first bending segment 3422a and another bending segment 3422. The first bending segment 3422a includes two first connecting segments 34220, one first connecting segment 34220 is used to connect to the welding segment 3421, and the other first connecting segment 34220 is used to connect to the other bending segment 3422. The angle between the first connecting segment 34220 and the other first connecting segment 34220 deviates from one power module 32. The bending angle of the other bending segment 3422 also deviates from one power module 32, and the bending direction of the other bending segment 3422 is opposite to the bending direction of the first bending segment 3422a. In one embodiment, the angle at which one first connecting section 34220 and another first connecting section 34220 face away from the power module 32 is less than or equal to 90 degrees, and the angle at which the other bending section 3422 faces away from the power module 32 is greater than 90 degrees. This ensures that the projection of the welding section 3421 and the plurality of bending sections 3422 included in the DC output copper busbar 342 in the second direction is U-shaped. The opening of the U-shape faces away from one side of the power module 32. It can be understood that the output copper busbar 342 includes a U-shaped bending portion with an opening facing away from the power module 32, which is used to reduce parasitic capacitance. It can also reduce the stress of the DC output copper busbar and the DC input copper busbar during laser welding, thereby improving the stability of the electrical connection between the power module 32 and the capacitor module 34.

[0095] FIG14 is another side view of the cooperation between the capacitor module and the power module in a motor controller provided by an embodiment of the present application. Referring to FIG13 , the plurality of bending segments 3422 include a second bending segment 3422b, and the second bending segment 3422b includes two second connecting segments 34221, one second connecting segment 34221 is used to connect the lead-out segment 3423, and the other second connecting segment 34221 is used to connect the other bending segment 34222. The angle between one second connecting segment 34221 and the other second connecting segment 34221 is toward or away from the power module 32. FIG14 shows that the angle between one second connecting segment 34221 and the other second connecting segment 34221 is toward the power module 32, and the angle is greater than 90 degrees. In one embodiment, the plurality of bending segments include two first bending segments 3422a and two second bending segments 3422b. One end of a first bending section 3422a is connected to the welding section 3421, and the other end is connected to another first bending section 3422a. One end of a second bending section 3422b is connected to the lead-out section 3423, and the other end is connected to another second bending section 3422b. Another second bending section is used to connect to another first bending section. Continuing with reference to Figure 10, the angle of the second bending section 3422b is toward the power module, and the two second bending sections 3422b are projected in the second direction into a U-shape with the opening facing the power module. The angle of the two first bending sections 3422a is away from the power module, and the two first bending sections 3422a are projected in the second direction into a U-shape with the opening facing away from the power module. The two first bending sections 3422a and the two second bending sections 3422b are projected in the second direction into an approximately S-shape.

[0096] In the above embodiment, the projections of the two second bent segments 3422b in the second direction are U-shaped with the opening facing away from the power module, and the projections of the two first bent segments 3422a in the second direction are U-shaped with the opening facing the power module. The projections of the two first bent segments 3422a and the two second bent segments 3422b in the second direction also form a substantially S-shaped shape.

[0097] Continuing with Figure 4 , the pressure plate assembly 35 is positioned between the power module 32 and the circuit board 33. The pressure plate assembly 35 is connected to the middle partition 30 via the pressure plate fastener 301. During the connection process between the pressure plate assembly 35 and the middle partition 30 via the pressure plate fastener 301, the pressure plate assembly 35 presses the power module 32, thereby increasing the stability of the connection between the power module 32 and the middle partition 30 and preventing coolant leakage between the power module 32 and the middle partition 30.

[0098] Figure 15 is a structural diagram of the pressure plate in the motor controller provided in an embodiment of the present application. Continuing to refer to Figures 4 and 15, the pressure plate assembly 35 includes a pressure plate 350 and insulating paper 351. Along the first direction X, the pressure plate 350 is located on the side of the power module 32 away from the middle partition, and the insulating paper 351 is located between the pressure plate 350 and the circuit board 33. The pressure plate 350 includes a plurality of pressure plate fixing holes 3500, and the plurality of pressure plate fixing holes 3500 are distributed along the edge of the pressure plate 350. Along the first direction, the height of the pressure plate fixing piece is the same as the height of the power module 32 after being stacked on the middle partition, or the height of the pressure plate fixing piece is slightly smaller than the height of the power module 32 after being stacked on the middle partition, so as to ensure that after the pressure plate 350 is fixed to the middle partition, it can not only limit the position of the power module 32 along the first direction, but also enable the power module 32 to be fastened to the middle partition to prevent leakage between the power module 32 and the middle partition. In one embodiment, some of the pressure plate fixing holes 3500 correspond to the positioning holes included in the middle partition 30 , and the connecting members pass through the pressure plate fixing holes 3500 and are connected to the positioning holes to improve the tightness of the connection between the pressure plate 350 and the middle partition 30 .

[0099] In the embodiment of the present application, the insulating paper 351 can be fixed to the side of the pressure plate 350 facing the circuit board 33 by bonding. The provision of the insulating paper 351 is beneficial to reducing electrical interference between the power module 32 and the circuit board 33.

[0100] Continuing with reference to Figure 4, the Hall assembly 37 includes a Hall fixed plate 370. The Hall fixed plate 370 includes a plurality of connection holes, and the plurality of connection holes are used to cooperate with the Hall support member 302 to fix the Hall fixed plate 370 on the middle partition plate 30. The Hall fixed plate 370 has a fixing portion for fixing the Hall core 371, and the plurality of fixing portions are arranged at intervals along the second direction Y. Each Hall core 371 includes a core through-hole, and a copper busbar connector 372 is provided in the core through-hole of each Hall core 371. There is a gap between the copper busbar connector 372 and the inner wall of the core through-hole. The copper busbar connector 372 is respectively connected to a plurality of AC output copper buses 322 and the motor. The DC power transmitted by the capacitor module 34 is converted into AC power by the power module 32, and the AC power is transmitted to the motor through the copper busbar connector 372.

[0101] In one embodiment, the copper busbar connector 372 and the AC output copper busbar 322 can be connected via a connecting copper busbar 373 , and the provision of the connecting copper busbar 373 can improve the convenience of connecting the copper busbar connector 372 and the AC output copper busbar 322 .

[0102] Continuing with reference to Figure 4, a circuit board fixing hole 330 is provided at the edge of the circuit board 33. The circuit board support 300 is inserted into the circuit board fixing hole 330 along the first direction X to achieve a fixed connection between the middle partition 30 and the edge of the circuit board 33. The middle partition 30 and the circuit board 33 are fixedly connected, so that the positions of the power module 32 and the pressure plate assembly 35 located between the middle partition 30 and the circuit board 33 are also relatively fixed, limiting the displacement of the power module 32 and the pressure plate assembly 35 in the first direction, thereby making the overall structure of the motor controller 3 stable. When the external environment applies external force to the motor controller 3, the power module and the pressing module will not easily undergo relative displacement inside the motor controller. Accordingly, the circuit board will not easily undergo displacement relative to the middle partition, which is conducive to the motor controller 3 operating in a stable state. In one embodiment, a signal interface is provided on the circuit board, and the signal interface is used to electrically connect to an external controller for receiving external control signals to control the parameters of the power module converting alternating current.

[0103] Figure 16 is a front view of the circuit board 33, multiple power modules 32, the middle partition 30, two coolant pipes 310 and the capacitor module 34 in Figure 4. Referring to Figures 3 and 11, the middle partition 30 includes an internal flow channel, two flow channel openings 30a and two oppositely distributed side surfaces. The two flow channel openings 30a are spaced apart and distributed on one side surface B of the two side surfaces. The two coolant pipes 310 are connected to the internal flow channel through the two flow channel openings 30a respectively. Along the first direction X, the multiple power modules 32 are arranged between the other side surface A of the circuit board 33 and the middle partition 30, the capacitor module 34 is stacked with the middle partition 30, and the circuit board 33 is located on the side of the middle partition 30 away from the capacitor module 34.

[0104] In the motor controller provided by the above embodiment of the present application, the coolant enters the internal flow channel of the middle partition 30 through two coolant pipes 310. The internal flow channel can dissipate heat to the capacitor module 34 stacked with the middle partition 30, as well as to the power module 32 located between the other side A of the middle partition 30 and the circuit board 33. Along the second direction Y, the capacitor module 34 is located between the two coolant pipes 310. The coolant in the two coolant pipes 310 can cool the capacitor module 34 located between the two coolant pipes 310, so that the capacitor module 34 can be cooled quickly. In the embodiment of the present application, the middle partition 30 integrates the function of a radiator. The middle partition 30 includes a Hall support 302, a pressure plate fixing 301, an installation window 30b and a circuit board support 300. All components in the motor controller are connected to the middle partition, which makes the motor controller more integrated and is conducive to the miniaturization of the motor controller.

[0105] Figure 17 is a front view of another arrangement of a circuit board 33, multiple power modules 32, a middle partition 30, two coolant pipes 310, and a capacitor module 34 in a motor controller provided in an embodiment of the present application. Referring to Figure 17, the middle partition includes a side surface B and another side surface A, and one side surface B and the other side surface A are opposite to each other along a first direction X. The capacitor module, the middle partition, the power module, and the circuit board are stacked along the first direction, and the capacitor module 34 is located on the other side surface A of the middle partition. Among them, the middle partition 30 includes an internal flow channel and two flow channel openings 30a. Along the second direction Y, the two flow channel openings 30a are spaced apart and distributed on one side surface B of the two sides. The two coolant pipes 310 are connected to the internal flow channel through the two flow channel openings 30a.

[0106] In this embodiment, the coolant enters the internal flow channel of the middle partition 30 through two coolant tubes 310. The internal flow channel can dissipate heat to the capacitor module 34 stacked with the middle partition 30, as well as to the power module 32 located between the middle partition 30 and the circuit board 33. Along the second direction Y, the power module 32 is arranged between the two coolant tubes 310. The coolant in the two coolant tubes 310 can cool the power module 32 located between the two coolant tubes 310, allowing the power module 32 to cool down quickly. The middle partition 30 integrates the function of a radiator, which makes the motor controller more integrated and is conducive to the miniaturization of the motor controller.

[0107] It is worth mentioning that, since the height of the power module 32 is smaller than the height of the capacitor module 34, the height of the coolant tube 310 is greater than or equal to the height of the power module 32 or the capacitor module 34 in the height direction of the power module 32 and the capacitor module 34. The power module 32 is located between the two coolant tubes 310. Compared to when the capacitor module 34 is located between the two coolant tubes, the power module 32 located between the two coolant tubes 310 can shorten the length of the coolant tube along the power module 32 or the capacitor module 34, thereby reducing the thickness of the motor controller along the height direction of the power module 32 or the capacitor module 34.

[0108] In addition, in each of the above-mentioned embodiments, the first direction X, the second direction Y, and the third direction Z may be perpendicular to each other. The perpendicularity defined in the embodiments of the present application is not limited to an absolute perpendicular intersection relationship (an angle of 90 degrees). It allows for non-absolute perpendicular intersection relationships caused by factors such as assembly tolerance, design tolerance, and the influence of structural flatness. It allows for errors in a small angle range. For example, the assembly error range of 80 to 100 degrees can be understood as a vertical relationship.

[0109] Obviously, those skilled in the art may make various changes and modifications to the present application without departing from the scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include these modifications and variations.

Claims

1. A motor controller, characterized in that: The motor controller includes a circuit board, a plurality of power modules, a middle partition, two coolant pipes and a capacitor module, each of the power modules includes at least one power tube, the circuit board is used to control the conduction and shutdown of each power tube, the middle partition includes an internal flow channel and two flow channel openings, the two coolant pipes are connected to the internal flow channel through the two flow channel openings respectively, wherein: Along the first direction, the plurality of power modules are arranged between the circuit board and the middle partition, the middle partition and the capacitor module are stacked, the middle partition includes two side surfaces that are arranged opposite to each other, and the two flow channel openings are spaced and distributed on one side surface of the middle partition; Along the second direction, the power module or the capacitor module is arranged between the two cooling liquid pipes.

2. The motor controller according to claim 1, characterized in that: The middle partition includes a plurality of installation windows, each of which is used to fix one of the power modules and to communicate with the internal flow channel, wherein: Along the second direction, the plurality of installation windows are distributed at intervals on the other side surface of the middle partition plate.

3. The motor controller according to claim 2, characterized in that: The middle partition includes two rows of circuit board support members, the two rows of circuit board support members are used to fix the circuit board, and the two rows of circuit board support members are distributed on the other side of the middle partition, wherein: Along the third direction, the two rows of circuit board support members are arranged opposite to each other on both sides of the plurality of installation windows.

4. The motor controller according to claim 3, characterized in that: The motor controller includes a pressure plate assembly, and the middle partition includes two rows of pressure plate fixing members, and the two rows of pressure plate fixing members are used to fix the pressure plate assembly and the middle partition, wherein: Along the first direction, the plurality of power modules are arranged between the pressure plate assembly and the middle partition plate; Along the second direction, the two rows of pressure plate fixing members are distributed on the other side surface of the middle partition plate and are arranged relatively on both sides of the plurality of installation windows.

5. The motor controller according to claim 3 or 4, characterized in that: Each row of the circuit board supports comprises four circuit board supports, wherein: Along the second direction, the four circuit board supporting members in each row of the circuit board supporting members are arranged at intervals, and a distance between two adjacent circuit board supporting members is greater than a hole diameter of each installation window.

6. The motor controller according to any one of claims 1 to 5, characterized in that: Each of the power modules includes a plurality of DC input copper bars and an AC output copper bar, and each of the DC input copper bars is used to connect one of the power tubes and the capacitor module, wherein: Along the second direction, a plurality of the DC input copper bars are arranged; Along the third direction, the plurality of DC input copper bars and one AC output copper bar are arranged on both sides of the power tube.

7. The motor controller according to any one of claims 1 to 5, characterized in that: The motor controller includes a Hall assembly, the Hall assembly includes a plurality of Hall sensors and a plurality of copper busbar connectors, the plurality of Hall sensors are distributed at intervals along the second direction on the other side of the middle partition, wherein: Each of the Hall cores comprises a core through hole, and each of the core through hole is used to pass a copper busbar connector, and the copper busbar connector is used to connect with the power tube.

8. The motor controller according to claim 7, characterized in that: The Hall assembly includes a Hall fixing plate, which is used to fix the multiple Hall sensors. The middle partition includes at least one row of Hall support members arranged along the second direction. The Hall support members are distributed on the other side of the middle partition, and the Hall support members are used to fix the Hall fixing plate.

9. The motor controller according to any one of claims 1 to 8, characterized in that: The capacitor module includes a capacitor housing, a capacitor core and a plurality of DC output copper bars, wherein the capacitor housing is used to accommodate the capacitor core, and the plurality of DC output copper bars are used to be electrically connected to the capacitor core and the power tube, wherein: A projection shape of at least one of the DC output copper bars along the first direction includes an S shape or a U shape.

10. The motor controller according to claim 9, characterized in that: The DC output copper busbar comprises a welding section, a plurality of bending sections and a lead-out section, wherein the plurality of bending sections are sequentially connected between the welding section and the lead-out end, wherein: The welding section is used to electrically connect a DC input copper busbar of the power module, the bending direction of at least one bending section among the multiple bending sections is different from the bending direction of at least one bending section, and the lead-out section is used to electrically connect the capacitor core.

11. The motor controller according to claim 10, characterized in that: The plurality of bending segments include a first bending segment, the first bending segment includes two first connecting segments, wherein: One of the first connecting segments is used to connect the welding segment, and another of the first connecting segments is used to connect another of the bending segments. The angle between the one first connecting segment and the other first connecting segment is toward or away from the one power module.

12. The motor controller according to claim 10, characterized in that: The welding section, the first connecting section and the DC input copper bus are respectively stacked and arranged along the first direction.

13. The motor controller according to any one of claims 8 to 12, characterized in that: The plurality of bending segments include a second bending segment, the second bending segment includes two second connecting segments, wherein: One of the second connecting sections is used to connect the lead-out section, and another of the second connecting sections is used to connect the other bending section. The angle between the one second connecting section and the other second connecting section is directed toward or away from the one power module.

14. A powertrain, characterized in that: The powertrain includes an electric motor and a motor controller according to any one of claims 1 to 13, wherein the motor controller is used to drive the electric motor.

15. A vehicle, characterized in that: The vehicle comprises an electric motor and a motor controller as claimed in any one of claims 1 to 13 for driving the electric motor, or comprises a powertrain as claimed in claim 14, wherein: The electric motor or the powertrain is used to drive the vehicle.

Images