Motor controller and powertrain

Abstract

The present application relates to the technical field of motor controllers, and in particular to a motor controller and a powertrain. The motor controller comprises a liquid-cooling heat-dissipation device and an integrated assembly. The liquid-cooling heat-dissipation device is used for cooling a plurality of power modules, the power modules each comprising at least one power tube; and the integrated assembly comprises an integrated housing and a capacitor core, the integrated housing being used for accommodating the capacitor core. The integrated housing comprises two coolant through holes, the two coolant through holes being respectively configured to be connected to the liquid-cooling heat-dissipation device. In a first direction, the liquid-cooling heat-dissipation device and the integrated housing are stacked, and the coolant through holes each pass through the integrated housing. In a second direction, the gap between the two coolant through holes is less than the length of the liquid-cooling heat-dissipation device. In a third direction, the diameter of each coolant through hole is less than the width of the liquid-cooling heat-dissipation device. The motor controller of the present application has a compact layout and occupies a small space.

Description

Motor controller and powertrain

[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 31, 2023, with application number 202311134486.3 and application name “Motor Controller and Powertrain”, 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 and a powertrain. Background Art

[0004] At present, electric vehicles represented by pure electric and hybrid vehicles are becoming more and more popular among consumers, and the interior space and comfort of electric vehicles are also constantly increasing. The motor controller in the electric vehicle is used to convert the DC power provided by the power battery into AC power to power the drive motor, thereby using the drive motor to drive the wheels of the electric vehicle.

[0005] However, the motor controller has a large number of parts and the connection relationships between the various parts are complex, which makes the assembly process of the motor controller complicated, resulting in large gaps between the various components in the motor controller, and thus resulting in a larger size of the motor controller.

[0006] Summary of the Invention

[0007] The embodiments of the present application provide a motor controller and a powertrain, wherein the motor controller has a compact layout, high integration, and occupies a small space.

[0008] In a first aspect, the present application provides a motor controller comprising multiple power modules, a liquid-cooled heat sink, and an integrated assembly. The liquid-cooled heat sink is used to cool the multiple power modules, each of which includes at least one power transistor. The integrated assembly includes an integrated housing and a capacitor core. The integrated housing accommodates the capacitor core and includes two coolant holes for communication with the liquid-cooled heat sink. The liquid-cooled heat sink and the integrated housing are stacked in a first direction, with each coolant hole extending through the integrated housing. In a second direction, the spacing between the two coolant holes is less than the length of the liquid-cooled heat sink. In a third direction, the diameter of the coolant holes is less than the width of the liquid-cooled heat sink. In this embodiment, the integrated assembly is used to filter direct current (DC) power and output the filtered DC power to the power modules. The power modules convert the DC power to alternating current (AC) power and output the AC power to the motor. Both coolant holes extend through the integrated housing. When refrigerant passes through the two coolant holes, they dissipate heat from the capacitor core, thereby providing the integrated housing with heat dissipation functionality and improving the compactness of the motor controller. The spacing between the two coolant holes is smaller than the length of the liquid cooling radiator. This ensures that the refrigerant in the coolant holes is transported to the liquid cooling radiator without the need for additional piping or components. This makes the motor controller more compact and facilitates miniaturization. Furthermore, the diameter of each coolant hole is smaller than the width of the liquid cooling radiator, minimizing the possibility of refrigerant leakage during transmission and improving the stability of the motor controller.

[0009] In one embodiment, the integrated housing includes a first surface and a second surface opposite to each other along a first direction. The first surface includes two rows of fixing columns and two rows of supporting columns, and each row of fixing columns includes a plurality of fixing columns. Each row of supporting columns includes a plurality of supporting columns. Along the second direction, a plurality of fixing columns in each row of fixing columns are arranged at intervals, and the two rows of fixing columns are used to fix the liquid-cooled radiator. Along the second direction, a plurality of supporting columns in each row of supporting columns are arranged at intervals, and the two rows of supporting columns are used to fix the circuit board. Along the third direction, the two rows of supporting columns are arranged at intervals, and the two rows of fixing columns are arranged at intervals between the two rows of supporting columns. To improve the compactness of the integrated housing including the components. The spacing between the two rows of fixing columns is less than the width of the liquid-cooled radiator. To ensure that the liquid-cooled radiator can be mounted on the first surface of the integrated housing through the fixing columns.

[0010] In one embodiment, the integrated assembly includes multiple Hall cores. The first surface includes multiple mounting slots, which are spaced apart along the second direction, and each mounting slot is used to mount a Hall core. In this manner, the Hall core can be fixed in the mounting slot by bonding or other means. The Hall core is mounted in the integrated housing, thereby improving the functionality of the integrated housing and facilitating the miniaturization of the motor controller. It can also be understood that the Hall core is fixed in the mounting slot in an integrated manner.

[0011] In one embodiment, the integrated assembly includes a plurality of copper busbar connectors. Each copper busbar connector is commonly used to electrically connect a power module. Each Hall core includes a core through-hole, each core through-hole being adapted to receive a copper busbar connector along the three directions. A gap exists between the copper busbar connector and the inner wall of the core through-hole along the first direction and the second direction.

[0012] In one embodiment, the motor controller includes a filter and a grounding structure. The second surface includes a filter cavity, which is used to accommodate the filter. The opening of the filter cavity is oriented in a first direction. The grounding structure is electrically connected to the side of the filter facing away from the liquid cooling radiator and protrudes from the filter cavity in the first direction. When the integrated assembly is installed in the lower housing, the grounding structure can contact the lower housing to improve the stability of the filter installed in the filter cavity. The filter can filter the direct current flowing into the capacitor core. The filter is integrated into the integrated housing through the filter cavity to improve the integration of the motor controller.

[0013] In one embodiment, the motor controller includes a circuit board configured to control the operation of power transistors within multiple power modules. The circuit board is configured to control the switching of the power transistors within the power modules and to control the parameters of the AC power converted by the power modules. In this embodiment, each Hall effect core is arranged between two adjacent support pillars along the second direction, thereby improving the compactness of the device on the first side of the integrated housing.

[0014] In one embodiment, the circuit board includes an isolation zone, multiple power tube signal terminal connection areas, a power supply circuit assembly installation area, a control circuit assembly, and a control signal interface installation area. Along the second direction, the power supply circuit assembly installation area, the control circuit assembly installation area, and the control signal interface installation area are spaced apart in sequence, and the multiple power tube signal terminal connection areas are spaced apart in sequence. Along the third direction, the multiple power tube signal terminal connection areas are distributed on one side of the isolation zone, and the power supply circuit assembly installation area, the control circuit assembly installation area, and the control signal interface installation area are distributed on the other side of the isolation zone. In this manner, the isolation zone divides the circuit board into two areas, which can improve the utilization of the circuit board space. It can also reduce interference between the areas on both sides of the isolation zone. This allows more devices to be integrated on the circuit board, reducing the number of circuit boards in the motor controller.

[0015] In one embodiment, the motor controller includes a control signal interface, a power supply circuit, and a control circuit. The control signal interface is used to receive control signals, the control circuit is used to control the power transistors in multiple power modules based on the control signals, and the power supply circuit is used to receive direct current and power the control circuit. The controller signal interface enables information exchange between the motor controllers. The control circuit assembly mounting area is used to mount the circuit assembly of the control circuit, the control signal interface mounting area is used to mount the control signal interface, and the power supply circuit assembly mounting area is used to mount the circuit assembly of the power supply circuit. This implements a single circuit board controller for the entire motor controller.

[0016] In one embodiment, the motor controller includes two clamping members, each of which is used to engage and secure the liquid-cooled radiator and the integrated housing along a first direction. The clamping member includes two ends. Along the first direction, the two ends are arranged opposite each other, and the integrated housing and the liquid-cooled radiator are fixed between the two ends. The clamping member includes a clearance hole, and the clearance hole is used to avoid the coolant through-hole. Securing the liquid-cooled radiator to the integrated housing using the clamping members can improve the convenience of securing the power module and the liquid-cooled radiator to the integrated housing. The clearance hole ensures the smooth flow of the coolant through-hole.

[0017] In one embodiment, a liquid-cooled heat sink is used to secure multiple power modules. Along a first direction, the multiple power modules are stacked on the liquid-cooled heat sink. Along a second direction, the multiple power modules are spaced apart. This can be understood as laying the multiple power modules flat on the side of the liquid-cooled heat sink facing away from the integrated housing to reduce the size of the motor controller along the first direction.

[0018] In one embodiment, the motor controller includes an upper housing and a lower housing, with a liquid cooling radiator and integrated components stacked and arranged between the upper and lower housings along a first direction. The lower housing includes two coolant channels, each of which is connected to two coolant through-holes to provide refrigerant to the coolant through-holes. The coolant channels also enhance heat absorption and provide heat dissipation. The upper and lower housings house other components of the motor controller.

[0019] In one embodiment, the lower housing includes two coolant openings, each for communicating with a coolant through-hole. Each coolant opening is oriented in a first direction. In a second direction, the distance between the two coolant openings is less than the length of the liquid-cooled radiator. In a third direction, the diameter of each coolant opening is less than the width of the liquid-cooled radiator, thereby facilitating communication between the coolant openings and the coolant through-holes.

[0020] In one embodiment, the lower housing includes two coolant ports, each of which is configured to communicate with a coolant opening via a coolant channel. Each coolant opening is oriented along a third direction, and the spacing between the two coolant openings along a second direction is less than the length of the liquid-cooled radiator. The coolant ports are configured to direct external refrigerant through the coolant opening and the coolant opening to the liquid-cooled radiator, thereby providing a cooling source for the liquid-cooled radiator.

[0021] In one embodiment, the upper housing includes a control signal connector mounting hole and a plurality of DC connector mounting holes. The control signal connector mounting hole is used to mount a control signal connector, which is used to receive a control signal, and the opening of the signal connector faces along the second direction. The provision of the control signal connector mounting hole facilitates electrical connection between the control signal connector and the control signal interface. The plurality of DC connector mounting holes are respectively used to mount a plurality of DC connectors, and the openings of the plurality of DC connector mounting holes face at least one of the first direction and the second direction, and the plurality of DC connectors are respectively used to transmit direct current. The plurality of DC connector mounting holes facilitate electrical connection of the plurality of DC connectors to the filter. The control signal connector mounting hole facilitates electrical connection of the control signal connector to the control signal interface on the circuit board.

[0022] In a second aspect, embodiments of the present application provide a powertrain. The powertrain includes a motor and a motor controller according to any technical solution of the first aspect, the motor controller being electrically connected to the 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 motor. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0024] FIG2 is a schematic diagram of a vehicle and a powertrain according to an embodiment of the present application;

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

[0026] FIG3a is an explosion diagram of FIG3;

[0027] FIG3 b is another explosion diagram of FIG3 ;

[0028] FIG4 is another schematic diagram of a motor controller provided in an embodiment of the present application;

[0029] FIG4a is an explosion diagram of FIG4 ;

[0030] FIG5 is another schematic diagram of a motor controller provided in an embodiment of the present application;

[0031] FIG6 is a top view of FIG5;

[0032] FIG7 is another schematic diagram of an integrated component according to an embodiment of the present application;

[0033] FIG8 is a schematic diagram of a Hall core in an integrated component according to an embodiment of the present application;

[0034] FIG9 is a schematic diagram of a liquid cooling radiator and a power module in an embodiment of the present application;

[0035] FIG10 is a top view of a liquid cooling radiator and a power module in an embodiment of the present application;

[0036] FIG11 is a bottom view of the liquid cooling radiator and the power module in an embodiment of the present application;

[0037] FIG12 is a schematic diagram of a circuit board in an embodiment of the present application;

[0038] FIG13 is another schematic diagram of a circuit board according to an embodiment of the present application;

[0039] FIG14 is a schematic diagram of an upper housing of a motor controller provided in an embodiment of the present application;

[0040] FIG15 is a bottom view of FIG14;

[0041] FIG16 is another schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application;

[0042] FIG17 is another schematic diagram of a motor controller provided in an embodiment of the present application;

[0043] FIG18 is a bottom view of FIG17;

[0044] FIG19 is a schematic diagram of the clamping member in FIG17 .

[0045] Figures: 1-vehicle; 10-vehicle body; 11-wheel; 12-vehicle load; 13-external power supply; 2-powertrain; 20-power module; 21-power battery; 22-motor; 3-motor controller; 30-integrated component; 301-integrated housing; 302-capacitor core; 3010-support column; 3011a, 3011b-limiting members; 30110-positioning groove; 3012-fixing column; 3013, 3013a, 3013b-cooling liquid through hole; 3014-Hall core; 30140-core through hole; 30141-opening; 3015 - copper busbar connector; 3016 - mounting slot; 3017 - filter cavity; 303 - DC output terminal; 31 - liquid cooling radiator; 310 - radiator fixing hole; 311 - cooling liquid inlet; 312 - cooling liquid outlet; 32 - power module; 320 - power tube; 321 - DC power input terminal; 322 - AC power output terminal; 323 - power tube signal terminal; 33 - circuit board; 33a - metal trace; 33b - lower partition; 33c - power supply circuit component installation area; 33d - control circuit component installation area; 33e - control signal interface installation area; 33 0-power tube signal terminal connection area; 3300-power tube signal terminal interface; 331-fixing hole; 332-isolation belt; 333-control signal interface; 334-control circuit; 335-power supply circuit; 34-filter module; 340-filter; 341-DC transmission element; 342-grounding structure; 35-clamping piece; 350-upper clamping part; 3500-upper connecting plate; 3501-upper pressure plate; 3502-guide plate; 351-lower clamping part; 3510-lower connecting plate; 3511-lower pressure plate; 3512-buckle; 352-main body; 35 20-connecting section; 3521-weight reduction hole; 353-avoidance; 36-upper shell; 360-sub-side plate; 3600-convex edge; 3601-control signal connector mounting hole; 361-DC connector mounting hole; 362-control signal shielding protrusion; 3620-annular protrusion; 363-DC shielding protrusion; 364-connecting plate; 3640-positioning hole; 37-lower shell; 370-coolant channel; 371-coolant opening; 372-coolant interface; 373-AC connector mounting hole; 38-three-phase copper busbar assembly; 39-control signal connector. DETAILED DESCRIPTION

[0046] 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.

[0047] The motor controller is a core component that controls the electric powertrain in electric vehicles. Currently, electric vehicles, represented by pure electric and hybrid vehicles, are becoming increasingly popular among consumers, and the interior space and comfort of electric vehicles are also constantly increasing. The motor controller in an electric vehicle is used to convert the DC power provided by the power battery into AC power to power the drive motor, which in turn drives the wheels of the electric vehicle.

[0048] However, the large number of parts in a motor controller and the complex connections between them complicate assembly, leading to large gaps between components and, consequently, a large motor controller size. This large size is detrimental to overall vehicle layout, and during rework or repair, the internal components must be disassembled one by one, making assembly and disassembly cumbersome.

[0049] In existing technology, motor controllers typically use high-speed communication protocols for signal transmission to increase the signal transmission rate of electronic controllers. However, using high-speed communication protocols for signal transmission requires a protective structure within the motor controller. This installation complicates assembly of the motor controller and further increases the number of parts required. This results in a larger motor controller after assembly, which is detrimental to the overall vehicle layout. Therefore, a highly integrated, compact motor controller is urgently needed.

[0050] 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.

[0051] 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.

[0052] In the present application, the first direction X, the second direction Y, and the third direction Z are perpendicular to each other. It should be noted that the perpendicularity defined in the embodiments of the present application is not limited to an absolute intersection angle of 90 degrees. It allows for a relationship that is not absolutely perpendicular due to factors such as assembly tolerance, design tolerance, and the influence of structural flatness, and allows for errors in a small angle range. For example, 80 to 100 degrees can be understood as a perpendicular relationship within the assembly error range.

[0053] Figure 1 is a schematic diagram of the vehicle provided in this application. Referring to Figure 1 , vehicle 1 includes a vehicle body 10, wheels 11, a power battery 21, and a powertrain 2. Powertrain 2 is mounted on vehicle body 10, and power battery 21 supplies power to powertrain 2. Powertrain 2 is used to drive wheels 11 of vehicle 1. In one embodiment, vehicle 1 includes wheels 11 and powertrain 2. Powertrain 2 is used to drive wheels 11 of vehicle 1.

[0054] In this application, vehicle 1 includes an electric vehicle (EV), a battery electric vehicle (BEV), a hybrid electric vehicle (HEV), a range extended electric vehicle (REEV), a plug-in hybrid electric vehicle (PHEV) or a new energy vehicle (NEV).

[0055] Figure 2 is a schematic diagram of a vehicle and powertrain according to an embodiment of the present application. As shown in Figures 1 and 2 , a vehicle 1 includes a vehicle body 10 , wheels 11 , a power battery 21 , a power module 20 , an onboard load 12 , and a powertrain 2 .

[0056] In one embodiment, the powertrain 2 includes a motor controller 3 and a motor 22. Referring to Figure 2 , the power battery 21 supplies power to the motor 22 via the motor controller 3. The motor controller 3 is configured to convert the direct current (DC) power provided by the power battery 21 into alternating current (AC). The motor 22 receives this AC power and converts it into kinetic energy to drive the wheels 11.

[0057] In one embodiment, the power module 20 is used to receive power from the external power source 13 and charge the power battery 21. In one embodiment, the power module 20 is used to supply power to the vehicle-mounted load 12.

[0058] In this application, the external power source 13 can be an AC grid, an AC charging station, or a DC charging station. The power module 20 can be a power distribution unit or an onboard charger. The onboard load 12 includes at least one of a compressor, a battery heating module, a seat heating module, and a DC low-voltage power supply.

[0059] FIG3 is a schematic diagram of a motor controller provided in an embodiment of the present application. FIG3a is an exploded schematic diagram of FIG3. FIG3b is another exploded schematic diagram of FIG3. FIG4 is another schematic diagram of a motor controller provided in an embodiment of the present application. FIG4a is an exploded schematic diagram of FIG4. FIG5 is another schematic diagram of a motor controller provided in an embodiment of the present application. FIG7 is another schematic diagram of an integrated component in an embodiment of the present application. FIG6 is a top view of FIG5. For ease of explanation, please refer to FIG3, FIG3a, FIG3b, FIG4a, FIG5, FIG6 and FIG7.

[0060] In one embodiment, the motor controller 3 includes an integrated assembly 30, a liquid-cooled heat sink 31, multiple power modules 32, a circuit board 33, a filter module 34, an upper housing 36, a lower housing 37, a three-phase copper busbar assembly 38, and a control signal connector 39. The upper housing 36 and the lower housing 37 combine to form a housing for the motor controller 3. The housing is used to accommodate the integrated assembly 30, the liquid-cooled heat sink 31, multiple power modules 32, the circuit board 33, the filter module 34, and the three-phase copper busbar assembly 38.

[0061] In one embodiment, the upper housing 36 includes a control signal connector mounting hole 3601 and multiple DC connector mounting holes 361. The control signal connector mounting hole 3601 is used to mount a control signal connector 39. The control signal connector mounting hole 3601 opens in the second direction X. The control signal connector 39 is used to connect to an external signal transmission line. The control signal connector 39 opens in the first direction X. The multiple DC connector mounting holes 361 open in at least one of the first direction X and the second direction Y. The multiple DC connector mounting holes 361 are respectively used to mount multiple DC connectors.

[0062] In one embodiment, the lower housing 37 includes two coolant ports 372 and an AC connector mounting hole 373. The two coolant ports 372 are used to connect to the liquid-cooled radiator 31 and transmit coolant to dissipate heat from the circuit board 33, multiple power modules 32, integrated components 30, and filter modules 34 in the motor controller 3. The openings of the two coolant ports 372 are oriented along the third direction Z. The AC connector mounting hole 373 is used to install an AC connector, which is used to electrically connect the three-phase AC power transmission line and the three-phase copper busbar assembly 38. The opening of the AC connector mounting hole 373 is oriented along the second direction Y.

[0063] In one embodiment, the housing of the motor controller 3 includes an upper housing 36 and a lower housing 37. As shown in Figures 3, 3a, and 3b, along the second direction Y, AC connector mounting holes 373 are arranged on one side of the housing of the motor controller 3, and multiple DC connector mounting holes 361 are arranged on the other side of the housing of the motor controller 3. Along the second direction, the AC connector mounting holes 373 are arranged on one side of the lower housing 37, and the multiple DC connector mounting holes 361 are arranged on the other side of the upper housing 36.

[0064] In one embodiment, the circuit board 33, multiple power modules 32, the liquid-cooled heat sink 31, and the integrated assembly 30 are stacked along a first direction X. In one embodiment, the liquid-cooled heat sink 31 and the integrated assembly 30 are stacked along the first direction X between the upper housing 36 and the lower housing 37. In one embodiment, multiple power modules 32 are arranged between the liquid-cooled heat sink 31 and the circuit board 33 along the first direction X. In one embodiment, each power module 32 is stacked with the circuit board 33 along the first direction X.

[0065] In this embodiment, the integrated assembly 30 includes an integrated housing 301 and a capacitor core 302. The integrated housing 301 is used to accommodate the capacitor core 302.

[0066] In one embodiment, each power module 32 includes at least one power transistor 320. In one embodiment, the power transistors 320 of multiple power modules 32 are used to form a three-phase bridge circuit. The ends of each phase bridge circuit are electrically connected to the capacitor core 302 in the integrated assembly 30, and the midpoint of each phase bridge circuit is used to output AC power to drive the motor 22.

[0067] In one embodiment, each power module 32 includes at least one power transistor 320. In one embodiment, the power transistors 320 of multiple power modules 32 are used to form a three-phase bridge circuit. The ends of each phase bridge circuit are electrically connected to the capacitor core 302 in the integrated assembly 30, and the midpoint of each phase bridge circuit is used to output AC power to drive the motor 22.

[0068] In one embodiment, the filter module 34 includes a filter 340, a DC transmission element 341, and a grounding structure 342. The filter 340 is used to electrically connect the capacitor core 302 in the integrated assembly 30. The DC transmission element 341 is used to receive the DC power output from the power battery 21 via one or more DC connectors installed in the DC connector mounting holes 361. The filter 340 is used to receive the DC power from the DC transmission element 341.

[0069] In the present application, the DC power output by the power battery 21 is transmitted to the filter 340 and the capacitor core 302 via the DC transmission element 341. The filter 340 and the capacitor core 302 are used to reduce the harmonics in the DC power. The three-phase bridge arm circuit composed of the circuit board 33 and multiple power modules 32 receives DC power and outputs AC power to drive the motor 22. Among them, the circuit board 33 is used to control the operation of the power tube 320 in the power module 32. The circuit board 33 receives a control signal through the control signal connector 39 to control the parameters of the AC power output by the inverter circuit. The AC power output by the three-phase bridge arm circuit is transmitted to the three-phase winding of the motor 22 through the three-phase copper busbar assembly 38 and the AC connector fixed by the AC connector mounting hole 373.

[0070] In one embodiment, the integrated housing 301 includes two cooling liquid holes. In one embodiment, the liquid cooling radiator 31 includes a cooling liquid inlet 311 and a cooling liquid outlet 312. The two cooling liquid holes of the integrated housing 301 are used to connect the cooling liquid inlet 311 and the cooling liquid outlet 312 respectively.

[0071] Referring to Figures 4a, 5, and 6, the two coolant holes are coolant hole 3013a and coolant hole 3013b. Along a first direction X, coolant hole 3013a and coolant hole 3013b extend through integrated housing 301. The projections of coolant holes 3013a and 3013b do not overlap with the projection of capacitor core 302. The refrigerant pipes from coolant holes 3013a and 3013b do not need to circumvent capacitor core 302, improving installation convenience.

[0072] Along the second direction Y, the cooling liquid through hole 3013a and the cooling liquid through hole 3013b are arranged at intervals, and the capacitor core 302 is located between the cooling liquid through hole 3013a and the cooling liquid through hole 3013b. When the coolant enters the cooling liquid through hole 3013a and the cooling liquid through hole 3013b, it can dissipate heat and cool down the capacitor core 302.

[0073] In one embodiment, the coolant holes 3013a and 3013b are greater than the length of the capacitor core 302 along the first direction X. In one embodiment, the spacing between the coolant holes 3013a and 3013b along the second direction Y is less than the length of the liquid-cooled heat sink 31. The refrigerant passes through the coolant holes 3013a and 3013b, with the capacitor core 302 located between the coolant holes 3013a and 3013b, thereby cooling the capacitor core 302.

[0074] In one embodiment, along the third direction Z, the apertures of the cooling liquid through hole 3013a and the cooling liquid through hole 3013b are smaller than the width of the liquid-cooled radiator 31 to ensure that the cooling liquid through hole 3013a and the cooling liquid through hole 3013b are less likely to leak when flowing into the liquid-cooled radiator 31.

[0075] In one embodiment, the diameter of the cooling liquid through hole 3013a and the diameter of the cooling liquid through hole 3013b are larger than the cooling liquid inlet and the cooling liquid outlet of the liquid-cooled radiator 31, thereby improving the sealing between the cooling liquid through hole 3013a and the cooling liquid through hole 3013b and the cooling liquid inlet and the cooling liquid outlet of the liquid-cooled radiator 31.

[0076] 4a, 5, and 6, the coolant inlet and outlet of the liquid-cooled radiator 31 are connected to the coolant through-hole 3013a and the coolant through-hole 3013b, respectively. For example, the coolant is delivered to the liquid-cooled radiator 31 through the coolant through-hole 3013a, and the coolant in the liquid-cooled radiator 31 flows out through the other coolant through-hole 3013b.

[0077] In the present application, integrated housing 301 integrates coolant through-holes 3013a and 3013b. The process of coolant transmission through coolant through-holes 3013a and 3013b can dissipate heat from capacitor core 302, thus enabling integrated housing 301 to dissipate heat from capacitor core 302. Furthermore, the integration of coolant through-holes 3013a and 3013b into integrated housing 301 can improve the integration of the motor controller and facilitate miniaturization of the motor controller.

[0078] In one embodiment, the shapes of the coolant through-holes 3013a and 3013b are waist-shaped, circular, rectangular, or diamond-shaped. In one embodiment, sealing rings are provided between the coolant through-holes 3013a and 3013b and the coolant inlet and outlet of the liquid-cooled radiator 31 to ensure sealing between the coolant through-holes 3013a and 3013b and the coolant inlet and outlet of the liquid-cooled radiator 31.

[0079] In one embodiment, the lower housing 37 includes two coolant channels and two coolant openings 371 , each of which is connected to a coolant through-hole. As shown in FIG3a , each coolant opening 371 is oriented along a first direction X. Along a second direction Y, the distance between the two coolant openings 371 is less than the length of the liquid-cooled radiator 31 . Along a third direction Z, the diameter of each coolant opening 371 is less than the width of the liquid-cooled radiator 31 . This facilitates communication between the coolant openings 371 and the coolant through-holes, further preventing coolant leakage.

[0080] In one embodiment, the lower housing 37 includes two coolant ports 372, each of which is configured to communicate with a coolant opening 371 via a coolant channel 370. As shown in FIG3a , each coolant opening 371 is oriented along the third direction Z, and the distance between the two coolant openings 371 along the second direction Y is less than the length of the liquid-cooled radiator 31. The coolant ports 372 are configured to direct external coolant through a coolant channel 370 and a coolant opening 371 to the liquid-cooled radiator 31, thereby providing coolant to the liquid-cooled radiator 31.

[0081] The two coolant interfaces 372, the two coolant channels 370, and the two coolant openings 371 form two pipes that provide a cooling source for the liquid-cooled radiator 31. The inlets of the two pipes are connected to the side wall of the lower housing 37, and the outlets of the two pipes are connected to the coolant inlet and coolant outlet of the liquid-cooled radiator 31, respectively.

[0082] In one embodiment, referring to Figures 4a, 5, and 6, the integrated housing 301 includes a first surface A and a second surface B that are opposite to each other along a first direction X. The first surface A of the integrated housing 301 can be understood as the side of the integrated housing 301 facing the circuit board 33, and the second surface B of the integrated housing 301 can be understood as the side of the integrated housing 301 facing away from the circuit board 33.

[0083] The first surface A of the integrated housing 301 includes a stopper 3011a and a stopper 3011b. The stoppers 3011a and 3011b are spaced apart on the surface of the integrated housing 301. The coolant through hole 3013a and the coolant through hole 3013b are located between the stoppers 3011a and 3011b.

[0084] Referring to Figures 4a, 5, and 6, stoppers 3011a and 3011b are arranged on either side of the coolant through-holes 3013a and 3013b along the second direction. The space between the two spaced-apart stoppers 3011a and 3011b is used to mount the liquid-cooled radiator 31. The stoppers 3011a and 3011b restrict movement of the liquid-cooled radiator 31 perpendicular to the first direction X and the second direction Y. The stoppers 3011a and 3011b also restrict movement of the liquid-cooled radiator 31 along the third direction Z, thereby improving the stability of the liquid-cooled radiator 31 integrated into the integrated housing 301.

[0085] In one embodiment, the first surface A of the integrated housing 301 includes two rows of fixing posts 3012. Continuing with Figures 4a, 5, and 6, the two rows of fixing posts 3012 are spaced apart and arranged between the stopper 3011a and the stopper 3011b, which are used to fix the liquid cooling radiator 31.

[0086] In one embodiment, two rows of fixing posts 3012, stoppers 3011a, and stoppers 3011b are located on the same side of the integrated housing 301. Each row of fixing posts 3012 includes a plurality of fixing posts 3012 spaced apart along the second direction. Along the first direction X, the two rows of fixing posts 3012 are spaced apart along the third direction Z, and the two rows of fixing posts 3012 are used to secure the liquid cooling radiator 31.

[0087] In one embodiment, referring to FIG. 4 a , FIG. 5 and FIG. 6 , along the third direction Z, two rows of fixing posts 3012 are arranged at intervals.

[0088] In one embodiment, each row of fixing columns 3012 includes four fixing columns 3012 arranged along the second direction Y. Referring to Figures 4a, 5, and 6, a mounting area is formed between every four fixing columns 3012. The multiple mounting areas are used to mount the liquid-cooled radiator 31. Along the second direction Y, one mounting area at one end corresponds to the coolant through-hole 3013a, and one mounting area at the other end corresponds to the coolant through-hole 3013b. The coolant inlet and coolant outlet of the liquid-cooled radiator 31 can correspond to the coolant through-hole 3013a and the coolant through-hole 3013b, respectively.

[0089] In the present application, the integrated housing 301 is integrated with the fixing columns 3012 , and the liquid cooling radiator 31 is fixed to the integrated housing 301 through the fixing columns 3012 , thereby improving the integration of the integrated housing 301 .

[0090] In one embodiment, the first side A of the integrated housing 301 includes two rows of support columns 3010. Referring to Figures 4a, 5, and 6, the two rows of support columns 3010, the two rows of fixing columns 3012, and the stoppers 3011a and 3011b are located on the same side of the integrated housing 301. Along the second direction Y, the two rows of support columns 3010 are arranged on opposite sides of the two rows of fixing columns 3012.

[0091] In one embodiment, two rows of support columns 3010 are arranged on opposite sides of the liquid-cooled heat sink 31 or power module 32. The two rows of support columns 3010 are used to secure the circuit board 33. In this application, the integrated housing 301, by integrating two rows of support columns 3010, makes the motor controller 3 compact and highly integrated, facilitating the miniaturization of the motor controller 3 and reducing the difficulty and cost of disassembling and assembling its internal components.

[0092] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the second direction Y. Along the third direction Z, the stoppers 3011a and 3011b each integrate a row of support columns 3010. Accordingly, along the first direction X, the height of the support columns 3010 is greater than the height of the fixing columns 3012, thereby reducing the size of the integrated housing 301 in the first direction X.

[0093] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the first direction X. Along the third direction Z, each support column 3010 is fixed to the first surface A of the integrated housing 301 through a stopper 3011 a and a stopper 3011 b.

[0094] In one embodiment, each row of support columns 3010 includes a plurality of support columns 3010 spaced apart along the second direction Y. Along the third direction Z, two rows of support columns 3010 are spaced apart, and two rows of fixing columns 3012 are spaced apart between the two rows of support columns 3010. The spacing between the two rows of fixing columns 3012 is less than the width of the liquid-cooled radiator 31. Accordingly, along the first direction X, the height of the support columns 3010 is also greater than the height of the fixing columns 3012, thereby reducing the size of the integrated housing 301 in the first direction X.

[0095] In one embodiment, the integrated assembly 30 includes a plurality of Hall cores 3014 and a plurality of copper busbar connectors 3015. One end of the copper busbar connector 3015 is used to electrically connect to a power tube 320 to output the alternating current of the power module 32.

[0096] In one embodiment, the first surface A of the integrated housing 301 includes a plurality of mounting slots 3016 spaced apart along the second direction Y. Each mounting slot 3016 is configured to receive a Hall effect core 3014. FIG8 is a schematic diagram illustrating the structure of the Hall effect core in the integrated assembly according to an embodiment of the present application. Referring to FIG5 , FIG6 , FIG7 , and FIG8 , the mounting slots 3016, two rows of support posts 3010, two rows of fixing posts 3012, and the stoppers 3011a and 3011b are located on the same side of the integrated housing 301.

[0097] In one embodiment, the Hall cores 3014 are fixed to the mounting slots 3016 by bonding, so that the plurality of Hall cores 3014 are arranged at intervals along the second direction Y.

[0098] In one embodiment, the limiting member 3011 a includes a mounting groove 3016 , and the Hall core 3014 is bonded to the mounting groove 3016 of the limiting member 3011 a .

[0099] In one embodiment, the Hall core 3014 includes a core through hole 30140 , and the axis of the core through hole 30140 is perpendicular to the first direction X and the second direction Y. Each core through hole 30140 is used to pass a copper busbar connector 3015 .

[0100] In one embodiment, the Hall core 3014 includes an opening 30141. The opening faces away from the integrated housing 301 along the first direction X. The opening 30141 communicates with the core through-hole 30140. The opening 30141 is configured to accommodate a detection device. The detection device is configured to detect current flowing through the copper busbar connector 3015 or voltage across the copper busbar connector 3015.

[0101] 5, 6, and 8, the copper busbar connector 3015 is disposed through the magnetic core through-hole 30140, and there is no electrical connection between the copper busbar connector 3015 and the Hall core 3014. In this application, a gap exists between the copper busbar connector 3015 and the inner wall of the magnetic core through-hole 30140 in the first direction X and the second direction Y to ensure the stability of the AC power output through the copper busbar connector 3015.

[0102] In one embodiment, the plurality of Hall cores 3014 are spaced apart along the second direction Y. In one embodiment, the stopper 3011a includes the plurality of Hall cores 3014. Exemplarily, the plurality of Hall cores 3014 are integrally formed with the stopper 3011a. In one embodiment, the Hall cores 3014 can be made of a magnetic material such as silicon steel or nickel core.

[0103] In one embodiment, along the second direction Y, a Hall core 3014 is arranged between two adjacent support pillars 3010 to improve space utilization of the first surface A of the integrated housing 301 .

[0104] In one embodiment, the integrated component 30 includes a plurality of DC output terminals 303. The plurality of DC output terminals 303 are spaced apart along the second direction Y. Referring to Figures 4a, 5, and 6, the plurality of DC output terminals 303 form three groups of DC output terminals 303. The three groups of DC output terminals 303 are respectively used to correspond to three power modules 32. One end of each group of DC output terminals 303 is electrically connected to a power transistor 320 in a power module 32, and the other end of each group of DC output terminals 303 is electrically connected to the capacitor core 302.

[0105] In one embodiment, each set of DC output terminals 303 is arranged opposite one copper busbar connector 3015. Along the second direction Y, the projection of one copper busbar connector 3015 lies within the projection of the set of DC output terminals 303. This ensures that the copper busbar connector 3015 does not occupy additional space in the second direction Y, thereby improving the compactness of the motor controller. Along the first direction X, the height of the DC output terminals 303 is smaller than the height of the copper busbar connector 3015, facilitating electrical connection between the DC output terminals 303 and one copper busbar connector 3015 and the power module.

[0106] In one embodiment, each set of DC output terminals 303 includes two positive DC output terminals and one negative DC output terminal. Along the second direction Y, one negative DC output terminal is arranged between the two positive DC output terminals.

[0107] In one embodiment, the side of the limiting member 3011a facing the limiting member 3011b includes a plurality of positioning grooves 30110 , and the plurality of positioning grooves 30110 are arranged at intervals along the second direction Y. A portion of the copper busbar connector 3015 is fixed to the positioning groove 30110 .

[0108] In the above embodiment, the integrated shell 301 can integrate two coolant holes 3013a, 3013b, two limit members 3011a, 3011b, two rows of support columns 3010, two rows of fixed columns 3012 and a Hall core 3014, so that the structural layout of the motor controller 3 is compact and highly integrated, which is conducive to realizing the miniaturization design of the motor controller 3 and reducing the difficulty and cost of disassembly and assembly of the internal parts of the motor controller.

[0109] Continuing with Figure 7 , in one embodiment, the filter module 34 includes a filter 340, a DC transmission element 341, and a grounding structure 342. The first surface of the integrated housing 301 is used to secure the liquid-cooled heat sink 31 and the circuit board 33, while the second surface is used to mount the filter 340. The second surface B of the integrated housing 301 includes a filter cavity 3017 for mounting the filter 340.

[0110] In one embodiment, the filter 340 is mounted on the second surface of the integrated housing 301 through a filter cavity 3017. Referring to Figures 3b and 7, the second surface B of the integrated housing 301 includes a filter cavity 3017. The filter cavity 3017 is used to mount the filter 340.

[0111] In one embodiment, the grounding structure 342 is electrically connected to the filter 340 and protrudes from the filter cavity 3017 along the first direction X. Referring to Figures 3b and 8 , the grounding structure 342 is mounted on the filter 340 and protrudes from the second surface of the integrated housing 301. The grounding structure 342 is electrically connected to the side of the filter 340 facing away from the liquid-cooled heat sink 31 and protrudes from the filter cavity 3017 along the first direction X. Along the second direction Y, the length of the filter 340 is shorter than the length of the second surface of the integrated housing 301.

[0112] In the present application, the grounding structure 342 is electrically connected to the filter 340, facing away from the liquid-cooled radiator 31, and protrudes from the filter cavity 3017 along the first direction X. The integrated housing 301 is mounted on the lower housing 37, and the grounding structure 342 can abut against the bottom surface of the lower housing, thereby improving the stability of the filter module installed in the integrated housing 301. In addition, the grounding structure 342 protruding from the second surface also ensures that the grounding structure 342 is in contact with the lower housing 37, improving the operational stability of the filter module 34.

[0113] In one embodiment, the second side B of the integrated housing 301 includes a first side a, a second side b, a third side c, and a fourth side d. The first side a is disposed opposite the second side b, and the third side c is disposed opposite the fourth side d. The copper busbar connector 3015 partially protrudes from the integrated housing 301. Coolant holes 3013a and 3013b are located between the first side a and the second side b, with coolant hole 3013a near the fourth side d and coolant hole 3013b near the third side c. The spacing between coolant holes 3013a and 3013b is large enough to ensure the installation of the capacitor core. Coolant holes 3013a and 3013b are located on both sides of the integrated housing 301, facilitating the integration of components such as the mounting slot 3016, support column 3010, and fixing column 3012 into the integrated housing 301.

[0114] In one embodiment, the filter cavity 3017 is arranged between the coolant through-hole 3013a and the copper busbar connector 3015. It can be understood that after the filter 340 is installed in the integrated housing 301, the filter 340 is located between the coolant through-hole 3013a and the copper busbar connector 3015. One end of the DC transmission element 341 is connected to the filter 340, and the other end of the DC transmission element 341 is located on one side of the fourth side d. The other end of the DC transmission element 341 extends toward the first surface of the integrated housing 301, thereby minimizing interference between the DC transmission element 341 and the copper busbar connector 3015. Because the DC output terminal 303 and the copper busbar connector 3015 are arranged opposite each other and the DC transmission element 341 is positioned away from the DC output terminal 303, the DC transmission element 341 interferes less with the DC output terminal 303 than with the copper busbar connector 3015.

[0115] In one embodiment, the filter cavity 3017 is arranged between the coolant through hole 3013b and the copper busbar connector 3015 along the third direction Z. As shown in FIG7 , the filter 340 is installed in the filter cavity 3017 of the integrated housing 301 , and the filter 340 is located between the coolant through hole 3013b and the copper busbar connector 3015 .

[0116] In one embodiment, one end of the DC transmission element 341 is electrically connected to the filter 340, and the other end of the DC transmission element 341 is electrically connected to the DC connector. As shown in FIG8 , the other end of the DC transmission element 341 is located on one side of the third side c and extends along the second direction Y toward the first surface of the integrated housing 301, thereby reducing interference between the DC transmission element 341 and the copper busbar connector 3015.

[0117] In one embodiment, the DC transmission component 341 and the signal connector 39 are arranged relative to each other along the second direction Y. As shown in FIG3 a and FIG8 , the DC transmission component 341 and the signal connector 39 are arranged along the second direction Y on both sides of the liquid-cooled radiator 31 , thereby reducing interference of the DC transmission component 341 on the signal connector 39 .

[0118] Figure 9 is a schematic diagram of the liquid-cooled radiator and power module in an embodiment of the present application. Figure 10 is a top view of the liquid-cooled radiator and power module in an embodiment of the present application. Figure 11 is a bottom view of the liquid-cooled radiator and power module in an embodiment of the present application.

[0119] In one embodiment, a plurality of power modules 32 are fixed to a liquid-cooled radiator 31. Along a first direction X, the plurality of power modules 32 are stacked and arranged on the liquid-cooled radiator 31, and along a second direction Y, the plurality of power modules 32 are arranged at intervals. Referring to Figures 4a, 9, 10, and 11, the power modules 32 are arranged at intervals on the surface of the liquid-cooled radiator 31 along the second direction Y. In the present application, the plurality of power modules 32 are arranged flat on the surface of the liquid-cooled radiator 31 along the second direction Y, which is beneficial for reducing the length of the motor controller 3 in the first direction X, effectively utilizing the installation area of ​​the liquid-cooled radiator 31, and thus enabling a miniaturized design of the motor controller.

[0120] In one embodiment, the power tubes 320 of multiple power modules 32 are used to form a three-phase bridge arm circuit. The two ends of the bridge arm of each phase bridge arm circuit are used to electrically connect to the capacitor core 302, and the midpoint of the bridge arm of each phase bridge arm circuit is used to output alternating current. Exemplarily, the motor controller 3 includes three power modules 32. Each power module 32 includes a single-phase bridge arm circuit. Each power module 32 includes at least one bridge arm circuit. Each bridge arm circuit includes two power tubes 320. The two power tubes 320 respectively constitute the upper bridge arm switch tube and the lower bridge arm switch tube of the single-phase bridge arm circuit.

[0121] 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).

[0122] In one embodiment, each power module 32 includes multiple DC power input terminals 321, one AC power output terminal 322, and multiple power transistor signal terminals 323. The DC power input terminal 321 is electrically connected to the capacitor core 302 via the DC output terminal 303. The power transistor signal terminal 323 is electrically connected to the circuit board 33. The AC power output terminal 322 is electrically connected to the copper busbar connector 3015. The power transistor signal terminal 323 is electrically connected to the power transistor 320 in the power module 32.

[0123] In one embodiment, the multiple DC power input terminals 321 of each power module 32 are arranged on one side of the power module 32 along the third direction Z. The multiple power tube signal terminals 323 and one AC power output terminal 322 of each power module 32 are arranged on the other side of the power module 32 along the third direction Z. Along the second direction Y, the multiple AC power output terminals 322 of the multiple power modules 32 are arranged in sequence and spaced apart.

[0124] As shown in Figures 8 and 9, each power module 32 includes three DC power input terminals 321, one AC power output terminal 322, and multiple power tube signal terminals 323. For example, each power module 32 includes twelve power tubes 320 and twelve power tube signal terminals 323. Six power tubes 320 constitute the upper-arm switching tubes of a single-phase bridge arm circuit, and the remaining six power tubes 320 constitute the lower-arm switching tubes of a single-phase bridge arm circuit. The twelve power tube signal terminals 323 are respectively used to electrically connect the control terminals of the twelve power tubes 320.

[0125] As shown in Figures 9 and 10, the three DC power input terminals 321 of each power module 32 are arranged on one side of the power module 32 along the third direction Z. The one AC power output terminal 322 and multiple power tube signal terminals 323 of each power module 32 are arranged on the other side of the power module 32 along the third direction Z.

[0126] The nine DC power input terminals 321 of the three power modules 32 are arranged on one side along the third direction Z. Along the second direction Y, the nine DC power input terminals 321 of the three power modules 32 are arranged at intervals along the second direction Y. The three AC power output terminals 322 and twelve power tube signal terminals 323 of the three power modules 32 are arranged on the other side along the third direction Z. Along the second direction Y, the three AC power output terminals 322 of the three power modules 32 are arranged at intervals.

[0127] Each DC power input terminal 321 extends away from the power module 32 along the third direction Z to facilitate electrical connection between the DC power input terminal 321 and the capacitor core 302. The AC power output terminal 322 of each power module 32 extends away from the power module 32 along the third direction Z to facilitate electrical connection to the copper busbar connector 3015. The power transistor signal terminal 323 of each power module 32 extends away from the power module 32 along the first direction X to facilitate electrical connection to the circuit board 33.

[0128] In one embodiment, the power tube signal terminal 323 is a pin. The power tube signal terminal 323 is inserted into the circuit board 33 to realize the electrical connection between the power module 32 and the circuit board 33. The circuit board 33 transmits the control signal to the power tube 320 in the power module 32 through the power tube signal terminal 323. In one embodiment, the liquid-cooled radiator 31 includes two rows of radiator fixing holes 310. As shown in Figures 10 and 11, each row of radiator fixing holes 310 includes four radiator fixing holes 310. Along the second direction Y, the four radiator fixing holes 310 are arranged at intervals, and in the two rows of radiator fixing holes 310, a power module 32 is arranged between the four oppositely arranged radiator fixing holes 310. The four radiator fixing holes 310 are used to cooperate with four fixing columns so that the liquid-cooled radiator 31 is stably installed on the integrated housing 301.

[0129] Figure 12 is a schematic diagram of a circuit board according to an embodiment of the present application. Figure 13 is another schematic diagram of a circuit board according to an embodiment of the present application. As shown in Figures 12 and 13, circuit board 33 includes an isolation strip 332, a plurality of power transistor signal terminal connection areas 330, a power supply circuit assembly mounting area 33c, a control circuit assembly mounting area 33d, and a control signal interface mounting area 33e.

[0130] Along the second direction Y, the power supply circuit component installation area 33c, the control circuit component installation area 33d, and the control signal interface installation area 33e are sequentially spaced apart, and the plurality of power tube signal terminal connection areas 330 are sequentially spaced apart.

[0131] Along the third direction Z, multiple power tube signal terminal connection areas 330 are distributed on one side of the isolation zone 332 , and the power supply circuit component installation area 33c , the control circuit component installation area 33d and the control signal interface installation area 33e are distributed on the other side of the isolation zone 332 .

[0132] The control circuit assembly mounting area 33d is used to mount the circuit components of the control circuit 334, the control signal interface mounting area 33e is used to mount the control signal interface 333, and the power supply circuit assembly mounting area 33c is used to mount the circuit components of the power supply circuit 335. The control signal interface 333 is used to receive control signals, the control circuit 334 is used to control the power transistors 320 in the multiple power modules 32 according to the control signals, and the power supply circuit 335 is used to receive DC power and supply power to the control circuit 334.

[0133] As shown in FIG13 , the control signal interface mounting area 33e is located at the edge of the circuit board 33. As shown in FIG3a , the control signal interface 333 is located at the edge of the circuit board 33, which facilitates the electrical connection between the control signal connector and the control signal interface 333, reduces interference of other circuits on the control signal, and improves the reliability of the motor controller 3.

[0134] In the present application, the isolation strip 332 is arranged in the middle of the circuit board 33 to improve the utilization rate of the circuit board 33, and the signal interference between the power supply circuit component installation area 33c and the control circuit component installation area 33d arranged on one side of the isolation strip 332 and the multiple power tube signal terminal connection areas 330 arranged on the other side.

[0135] In one embodiment, the circuit board 33 includes a plurality of fixing holes 331 , each of which is used to fix the circuit board 33 . Referring to FIG12 and FIG13 , the plurality of fixing holes 331 are provided at an edge of the circuit board 33 .

[0136] A plurality of fixing holes 331 respectively penetrate the circuit board 33 along the first direction X. The plurality of fixing holes 331 are used to cooperate with the plurality of support columns 3010 so that the circuit board 33 is fixed to the integrated housing 301 through the support columns.

[0137] Along the second direction Y, the distance between two adjacent fixing holes 331 is greater than the distance between two adjacent power tube signal terminal connection areas 330, so that the support column 3010 avoids the power tube signal terminal 323 of the power module 32, avoiding affecting the electrical connection between the power tube signal terminal 323 and the circuit board 33, thereby improving the reliability of the motor controller 3.

[0138] Along the third direction Z, the distance between two adjacent fixing holes 331 is greater than the width of the isolation belt 332 , so as to avoid affecting the isolation effect of the isolation belt 332 , thereby improving the reliability of the motor controller 3 .

[0139] In one embodiment, referring to FIG. 11 , FIG. 12 and FIG. 13 , each power tube signal terminal connection area 330 includes three rows of power tube signal terminal interfaces 3300 , which are used to electrically connect to the power signal terminals 323 in the power module.

[0140] 12 and 13 , each row of power tube signal terminal interfaces 3300 includes three power tube signal terminal interfaces 3300. Each power tube signal terminal interface 3300 is used to electrically connect a power tube signal terminal of a power tube to achieve signal transmission between the circuit board 33 and the power module.

[0141] Along the first direction X, each power tube signal terminal interface 3300 penetrates the circuit board 33 to ensure that the power tube signal terminals are electrically connected to the circuit board 33 through the power tube signal terminal interface 3300 in the first direction X. Along the second direction Y, the three power tube signal terminal interfaces 3300 in each row of power tube signal terminal interfaces 3300 are arranged at intervals. Along the third direction Z, the three rows of power tube signal terminal interfaces 3300 in each power tube signal terminal connection area 330 are arranged at intervals.

[0142] In the present application, multiple rows of power tube signal terminal interfaces 3300 of multiple power modules 32 are spaced apart, multiple rows of power tube signal terminal interfaces 3300 of the same power module 32 are spaced apart, and multiple power tube signal terminal interfaces 3300 in the same row of power tube signal terminal interfaces 3300 are spaced apart, which can improve the signal stability of the power tube signal terminal interface 3300 of each power tube 320 in each power module 32.

[0143] Figure 14 is a schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application. Figure 15 is a bottom view of Figure 14. Figure 16 is another schematic diagram of the upper housing of the motor controller provided in an embodiment of the present application.

[0144] In one embodiment, the upper housing 36 includes a control signal shielding protrusion 362 and a control signal connector mounting hole 3601. The control signal connector mounting hole 3601 is used to mount a control signal connector 39. The control signal connector 39 is used to transmit control signals to the control signal interface 333.

[0145] 3a, 14, 15 and 16, along the first direction X, the extension direction of the control signal shielding protrusion 362 is toward the circuit board 33, and the projection of the control signal shielding protrusion 362 at least partially surrounds the control signal interface 333 to ensure that the control signal interface 333 is located in the shielding cavity formed by the control signal shielding protrusion 362 and the circuit board 33.

[0146] Along the second direction Y, the projection of the control signal shielding protrusion 362 covers the projection of the control signal connector mounting hole 3601. The control signal connector mounting hole 3601 passes through the upper shell 36, which can ensure that the control signal connector 39 and the control signal connector mounting hole 3601 are electrically connected to the control signal interface 333 located in the control signal shielding protrusion 362.

[0147] In the present application, the control signal shielding protrusion 362 is integrally formed with the upper shell 36 . In the motor controller 3 , there is no need to independently set up a shielding structure for shielding the control signal interface 333 , which can simplify assembly and reduce costs.

[0148] In one embodiment, the circuit board 33 includes metal traces 33a and a lower partition 33b. As shown in Figures 3, 3a, 12, and 15, the control signal interface 333 and the lower partition 33b are located at the edge of the circuit board 33. In one embodiment, the area enclosed by the metal traces 33a on the circuit board 33 is larger than the area of ​​the control signal interface 333.

[0149] In one embodiment, the metal trace 33a is located on the side of the circuit board 33 facing the upper housing 36. As shown in Figures 3a and 13, the upper housing 36 is stacked on the circuit board 33, and the control signal shielding protrusion 362 is electrically connected to the metal trace 33a of the circuit board 33. Along the first direction X, the lower partition 33b corresponds to the control signal shielding protrusion 362, and the lower partition 33b is electrically connected to the metal trace 33a. The metal trace 33a, the lower partition 33b, the control signal shielding protrusion 362, and the upper housing 36 connected to the control signal shielding protrusion 362 form a shielding cavity, which can improve the shielding effect of shielding the control signal interface 333 and the control signal connector 39, thereby improving the reliability of the motor controller 3.

[0150] In one embodiment, the two ends of the control signal shielding protrusion 362 are respectively fixedly connected to the two sides of the control signal connector mounting hole 3601. Along the second direction Y, the projection of the control signal shielding protrusion 362 surrounds the projection of the control signal interface 333. Along the third direction Z, the two ends of the control signal shielding protrusion 362 are arranged on both sides of the control signal connector mounting hole 3601. The control signal shielding protrusion 362 covers the projection of the control signal connector mounting hole 3601, and the control signal connector 39 passes through the control signal connector mounting hole 3601 and is electrically connected to the control signal interface 333 located in the control signal shielding protrusion 362.

[0151] In one embodiment, the control signal shielding protrusion 362 includes an annular protrusion 3620 and a relief opening. Along the first direction X, the projection of the annular protrusion 3620 surrounds the projection of the control signal interface 333. When the annular protrusion 3620 is electrically connected to the circuit board 33, the annular protrusion 3620 completely covers the control signal interface 333. Along the second direction Y, the relief opening passes through the annular protrusion 3620, and the projection of the relief opening covers the projection of the control signal connector mounting hole 3601. The control signal connector 39 passes through the control signal connector mounting hole 3601 and the relief opening and is electrically connected to the control signal interface 333 located in the annular protrusion 3620. The control signal connector 39 is electrically connected to the control signal interface 333, and the control signal connector 39 is electrically connected to the control signal interface 333 via a transmission line.

[0152] In one embodiment, the annular protrusion 3620 is a panel with two open ends formed by a plurality of sub-panels. The panel may be projected in the first direction X in a circular, rectangular, diamond or other irregular shape.

[0153] In one embodiment, the upper housing 36 includes a plurality of sub-side panels 360 extending toward one side of the lower housing 37. The sub-side panels 360 are sequentially connected in pairs. Along the second direction Y, the spacing between the control signal interface 333 and two connected sub-side panels 360 is smaller than the spacing between the control signal interface 333 and the other sub-side panels 360.

[0154] In one embodiment, one of the two connected sub-side panels 360 includes a control signal connector mounting hole 3601. As shown in Figures 3, 3a, 12, 13, and 15, the distance between the control signal interface 333 and the two connected sub-side panels is smaller than the distance between the control signal interface 333 and the other sub-side panels. One of the two connected sub-side panels includes a control signal connector mounting hole 3601, and the distance between the control signal shielding protrusion 362 and the sub-side panel having the control signal connector mounting hole 3601 is small, making it easier for the control signal connector to be electrically connected to the control signal interface 333 through the control signal connector mounting hole and the control signal shielding protrusion.

[0155] In one embodiment, the upper shell 36 includes a plurality of raised edges 3600 , which are used to be fixedly connected to the lower shell 37 .

[0156] In one embodiment, the upper housing 36 includes a DC shielding protrusion 363 and a plurality of DC connector mounting holes 361. The DC shielding protrusion 363 extends in a first direction X, toward the circuit board 33. The openings of the plurality of DC connector mounting holes 361 face at least one of the first direction X and the second direction Y.

[0157] As shown in Figure 14 , the DC shielding protrusions 363 and the control signal shielding protrusions 362 extend in the same direction. As shown in Figures 3 and 3a , and in conjunction with Figure 14 , the projection of the DC shielding protrusions 363 along the first direction X at least partially surrounds the projections of the multiple DC connector mounting holes 361 . In this application, the integrated DC shielding protrusions 363 and the control signal shielding protrusions 362 on the upper housing 36 not only reduce electrical interference but also simplify assembly of the motor controller 3 .

[0158] As shown in FIG14 , at least one of the plurality of DC connector mounting holes 361 is located on the secondary side plate 360. The opening of the at least one DC connector mounting hole 361 located on the secondary side plate 360 ​​is oriented along the first direction X. As shown in FIG15 , the opening of at least one of the plurality of DC connector mounting holes 361 is oriented along the second direction Y.

[0159] In one embodiment, the upper housing 36 includes a connecting plate 364. As shown in Figures 3a, 14, and 16, the connecting plate 364 is fixed to the side of the sub-side plate 360, located on the control signal connector mounting hole 3601, facing away from the control signal shielding protrusion 362 along the second direction. The connecting plate 364 includes a positioning hole 3640. The positioning hole 3640 mates with the control signal connector mounting hole 3601 along the second direction Y, thereby improving the stability of the connection between the control signal connector 39 and the upper housing 36.

[0160] Figure 17 is another schematic diagram of a motor controller according to an embodiment of the present application. Figure 18 is a bottom view of Figure 17 , and Figure 19 is a schematic diagram of the clamping member in Figure 17 . In one embodiment, the motor controller 3 includes a clamping member 35 .

[0161] The integrated shell 301 includes multiple Hall cores 3014 arranged along the second direction Y, and two rows of support columns 3010, each row of support columns 3010 includes multiple support columns 3010 arranged at intervals along the second direction Y, and multiple Hall cores 3014 are located on the side of one row of support columns 3010 away from the other row of support columns 3010.

[0162] As shown in FIG17 , the liquid cooling radiator 31 is stacked on the integrated housing 301 along a first direction X. A plurality of power modules 32 are arranged on the surface of the liquid cooling radiator 31 along a second direction Y. The liquid cooling radiator 31 is located between two rows of support columns 3010 .

[0163] In one embodiment, along the first direction X, the clamping member 35 includes two opposite ends, and the integrated housing 301 and the liquid-cooling radiator 31 are fixed between the two ends of the clamping member 35 .

[0164] In one embodiment, one end of the clamping member 35 abuts against the surface of the power module 32 facing away from the liquid-cooled radiator 31, and the other end of the clamping member 35 abuts against the side of the integrated shell 301 facing away from the liquid-cooled radiator 31, so as to fix the liquid-cooled radiator 31 and the power module 32 to the integrated shell 301.

[0165] In the present application, the clamping member 35 fixes the liquid cooling radiator 31 and the integrated housing 301 along the first direction X, which can improve the structural stability of the motor controller, simplify the assembly process of the motor controller 3, and also facilitate the disassembly of the liquid cooling radiator 31 for maintenance.

[0166] As shown in Figures 18 and 19 , the integrated housing 301 includes two coolant holes 3013. The clamping member 35 includes a clearance opening 353, which is used to clear the coolant holes 3013. As shown in Figure 18 , the clamping member 35 is fixed to the liquid-cooled radiator 31 and the integrated housing 301. The clearance opening 353 prevents the clamping member 35 from interfering with the coolant holes 3013.

[0167] In one embodiment, the motor controller 3 includes two clamping members 35. As shown in FIG17 , the two clamping members 35 respectively engage with two power modules 32 located at the leading and trailing ends. The leading end refers to the first one along the arrangement of the power modules 32, and the trailing end refers to the last one along the arrangement of the power modules 32.

[0168] In one embodiment, the clamping member 35 includes a main body 352, an upper engaging portion 350, and a lower engaging portion 351. The upper engaging portion 350 and the lower engaging portion 351 are connected to both ends of the main body 352. Along the first direction X, the upper engaging portion 350 and the lower engaging portion 351 are located on the same side of the main body 352. The upper engaging portion 350 is used to engage and secure with the side of the power module 32 located at the head end or tail end that faces away from the liquid-cooled radiator 31, and the lower engaging portion 351 is used to engage and secure with the side of the integrated housing 301 that faces away from the liquid-cooled radiator 31. The upper engaging portion 350 includes an upper connecting plate 3500, an upper pressure plate 3501, and a guide plate 3502. The upper connecting plate 3500 connects the upper pressure plate 3501 to the main body 352. The guide plate 3502 is connected to the side of the upper pressure plate 3501 that faces away from the upper connecting plate 3500. The guide plate 3502 extends to a side away from the lower engaging portion 351 . When the clamping member 35 fixes the power module 32 at the head end or the tail end to the integrated housing 301 , the guide plate 3502 included in the clamping member 35 can play a guiding role.

[0169] Along the first direction X, the distance between the upper connecting plate 3500 and the lower engaging portion 351 is greater than the distance between the upper pressing plate 3501 and the lower engaging portion 351. The distance between the guide plate 3502 and the lower engaging portion 351 is also greater than the distance between the upper pressing plate 3501 and the lower engaging portion 351. It can be understood that the upper connecting plate 3500, the upper pressing plate 3501, and the guide plate 3502 are sequentially connected, forming a substantially U-shape, with the U-shaped opening facing away from the lower engaging portion 351. Along the first direction X, the distance between the upper pressing plate 3501 and the lower engaging portion 351 is less than the distance between the power module 32, the liquid-cooled radiator 31, and the integrated housing 301 facing away from the liquid-cooled radiator 31, ensuring that the upper pressing plate 3501 and the lower engaging portion 351 can stably secure the liquid-cooled radiator 31 and the power module 32 to the integrated housing 301.

[0170] The lower engaging portion 351 includes a lower connecting plate 3510, a lower pressing plate 3511, and a buckle 3512. The lower connecting plate 3510, the lower pressing plate 3511, and the buckle 3512 are connected in sequence. Along the first direction X, the spacing between the upper pressing plate 3501 and the lower pressing plate 3511 is smaller than the spacing between the power module 32, the liquid-cooled radiator 31, and the integrated housing 301 away from the liquid-cooled radiator 31. This ensures that the upper pressing plate 3501 and the lower pressing plate 3511 can stably fix the liquid-cooled radiator 31 and the power module 32 to the integrated housing 301. The buckle 3512 can be engaged with an edge of the integrated housing 301 facing away from the power module 32 to improve the stability of the connection between the power module 32, the liquid-cooled radiator 31, and the integrated housing 301.

[0171] In one embodiment, the escape opening 353 is formed on one lower engaging portion 351 to separate the lower engaging portion 351 into two parts. Alternatively, each clamping member 35 includes two identical lower engaging portions 351 , and the gap between the two lower engaging portions 351 serves as the escape opening 353 .

[0172] The main body 352 includes multiple connecting segments 3520. The angle between two adjacent connecting segments 3520 is greater than or equal to 90 degrees, giving the main body 352 a roughly U-shaped shape. Each connecting segment 3520 includes at least one reinforcing rib, which serves to increase the strength of the main body. Furthermore, to reduce the weight of the clamping member 35, the main body 352 includes multiple weight-reducing holes 3521 that extend through the main body 352.

[0173] The above are only specific embodiments of the present application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.

Claims

1. A motor controller, characterized in that: The motor controller includes a liquid cooling radiator and an integrated component, wherein the liquid cooling radiator is used to cool a plurality of power modules, each of which includes at least one power tube, and the integrated component includes an integrated housing and a capacitor core, wherein the integrated housing is used to accommodate the capacitor core, and the integrated housing includes two cooling liquid through holes, wherein the two cooling liquid through holes are respectively used to connect the liquid cooling radiator, wherein: Along the first direction, the liquid cooling radiator and the integrated shell are stacked and arranged, and each of the cooling liquid through holes penetrates the integrated shell; Along the second direction, the distance between the two cooling liquid through holes is smaller than the length of the liquid cooling radiator; Along the third direction, the diameter of each of the cooling liquid through holes is smaller than the width of the liquid cooling radiator.

2. The motor controller according to claim 1, characterized in that: The integrated housing comprises a first surface and a second surface opposite to each other along the first direction, the first surface comprises two rows of fixing columns and two rows of supporting columns, each row of the fixing columns comprises a plurality of fixing columns, and each row of the supporting columns comprises a plurality of supporting columns, wherein: Along the second direction, the plurality of fixing columns in each row of the fixing columns are arranged at intervals, and the plurality of supporting columns in each row of the supporting columns are arranged at intervals; Along the third direction, the two rows of support columns are arranged at intervals, the two rows of fixing columns are arranged at intervals between the two rows of support columns, and the spacing between the two rows of fixing columns is smaller than the width of the liquid cooling radiator.

3. The motor controller according to claim 2, characterized in that: The integrated component includes a plurality of Hall cores, the first surface includes a plurality of mounting grooves, the plurality of mounting grooves are arranged at intervals along the second direction, and each of the mounting grooves is used to mount one of the Hall cores.

4. The motor controller according to claim 3, characterized in that: The integrated component includes a plurality of copper busbar connectors, each of which is commonly used to electrically connect one of the power modules, and each of the Hall cores includes a core through hole, each of which is used to penetrate one of the copper busbar connectors along the third direction.

5. The motor controller according to claim 2, characterized in that: The motor controller includes a filter and a grounding structure, the second surface includes a filter cavity, the filter cavity is used to accommodate the filter, the opening of the filter cavity is oriented along the first direction, and the grounding structure is electrically connected to a side of the filter away from the liquid-cooled radiator and protrudes from the filter cavity along the first direction.

6. The motor controller according to claim 4, characterized in that: The motor controller includes a circuit board, and the circuit board is used to control the operation of the power tubes in the multiple power modules, wherein: Along the second direction, each of the Hall cores is arranged between two adjacent support pillars.

7. The motor controller according to claim 6, characterized in that: The circuit board includes an isolation belt, a plurality of power tube signal terminal connection areas, a power supply circuit component installation area, a control circuit component installation area, and a control signal interface installation area, wherein: Along the second direction, the power supply circuit component installation area, the control circuit component installation area, and the control signal interface installation area are sequentially spaced and distributed, and the plurality of power tube signal terminal connection areas are sequentially spaced and distributed; Along the third direction, the plurality of power tube signal terminal connection areas are distributed on one side of the isolation zone, and the power supply circuit component installation area, the control circuit component installation area and the control signal interface installation area are distributed on the other side of the isolation zone.

8. The motor controller according to claim 7, characterized in that: The motor controller includes a control signal interface, a power supply circuit and a control circuit, wherein the control signal interface is used to receive a control signal, the control circuit is used to control the power tubes in the multiple power modules according to the control signal, and the power supply circuit is used to receive direct current and supply power to the control circuit, wherein: The control circuit component installation area is used to install the circuit component of the control circuit, the control signal interface installation area is used to install the control signal interface, and the power supply circuit component installation area is used to install the circuit component of the power supply circuit.

9. The motor controller according to any one of claims 1 to 8, characterized in that: The motor controller includes two clamping members, each of which is used to clamp and fix the liquid cooling radiator and the integrated housing along the first direction, and the clamping member includes two ends, wherein: Along the first direction, the two ends are arranged opposite to each other, the integrated housing and the liquid-cooled radiator are fixed between the two ends, and the clamping member includes an avoidance opening, and the avoidance opening is used to avoid the cooling liquid through hole.

10. The motor controller according to any one of claims 1 to 9, characterized in that: The liquid cooling radiator is used to fix the multiple power modules, wherein: Along the first direction, the multiple power modules are stacked and arranged with the liquid cooling radiator respectively; Along the second direction, the multiple power modules are arranged at intervals.

11. The motor controller according to any one of claims 1 to 10, characterized in that: The motor controller includes an upper shell and a lower shell. The liquid-cooled radiator and the integrated component are stacked between the upper shell and the lower shell along the first direction. The lower shell includes two coolant channels, and the two coolant channels are respectively used to connect the two coolant through holes.

12. The motor controller according to claim 11, characterized in that: The lower shell includes two coolant openings, each of which is used to communicate with one of the coolant through holes, and each of the coolant openings is directed in the following direction: Along the second direction, the distance between the two cooling liquid openings is smaller than the length of the liquid cooling radiator; Along the third direction, a diameter of each of the coolant openings is smaller than a width of the liquid-cooled radiator.

13. The motor controller according to claim 12, characterized in that: The lower shell includes two coolant interfaces, each of which is used to connect to a coolant opening through a coolant channel, each of the coolant openings is oriented along the third direction, and the spacing between the two coolant openings along the second direction is less than the length of the liquid-cooled radiator.

14. The motor controller according to claim 11, characterized in that: The upper housing includes a control signal connector mounting hole and a plurality of DC connector mounting holes, wherein: The control signal connector mounting hole is used to mount a control signal connector, the control signal connector is used to receive a control signal, and the opening of the signal connector faces along the second direction; The plurality of DC connector mounting holes are respectively used to mount a plurality of DC connectors, the opening directions of the plurality of DC connector mounting holes include at least one of the first direction and the second direction, and the plurality of DC connectors are respectively used to transmit direct current.

15. A powertrain, characterized in that: The powertrain includes a motor and a motor controller as described in any one of claims 1 to 14, and the motor controller is used to drive the motor.

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