All-in-one power supply device, power assembly, and electric vehicle

Abstract

Embodiments of the present application provide an all-in-one power supply device, a power assembly, and an electric vehicle. The all-in-one power supply device comprises a recess-shaped housing and an integrated capacitor filtering module. The integrated capacitor filtering module is used for integrating a bus capacitor, an EMC filtering assembly, and two first connecting copper busbars. The bus capacitor and the EMC filtering assembly filter high-voltage direct currents received by the two first connecting copper busbars. The recess-shaped housing is further used for fixing a high-voltage connector. The two first connecting copper busbars are respectively used for being directly and fixedly connected to two high-voltage lap-join copper busbars of the high-voltage connector and are respectively electrically connected to a positive electrode and a negative electrode of a power battery by means of the two high-voltage lap-join copper busbars. The integrated capacitor filtering module is directly lap-joined with the high-voltage connector, without using too many cables and adapter copper busbars, thereby simplifying the circuit layout in the power supply device, reducing the assembly difficulty, and further improving the integration level of the power supply device and the deep integration between the electrical components in the power supply device.

Description

All-in-one power supply device, powertrain and electric vehicle

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on March 19, 2024, with application number 202410317038.5 and application name “Multi-in-one power supply device, powertrain and electric vehicle”, the entire contents of which are incorporated by reference into this application. Technical Field

[0002] The present application relates to the technical field of electric vehicles, and in particular to an all-in-one power supply device, a power assembly and an electric vehicle. Background Art

[0003] The power battery of an electric vehicle converts high-voltage direct current into alternating current through a power supply device and supplies it to the motor to drive the motor. In order to provide a stable current with less interference, EMC filter components and bus capacitors need to be installed in the power supply device, resulting in a large number of electromagnetic devices in the power supply device, a large number of components on the input side of the power supply device, and complex switching times and assembly processes. Summary of the Invention

[0004] The present application provides an all-in-one power supply device, a powertrain, and an electric vehicle.

[0005] In the first aspect, the present application provides an all-in-one power supply device, which includes a slot-shaped housing and a motor controller, wherein the slot-shaped housing is used to accommodate the electrical components of the motor controller, and the electrical components of the motor controller include a capacitor filter integrated module. Wherein, a capacitor filter integrated module is used to integrate a busbar capacitor, an EMC filter assembly and two first connection copper bars, a busbar capacitor receives the high-voltage direct current output by the power battery through the two first connection copper bars, and filters the high-voltage direct current received by the two first connection copper bars through an EMC filter assembly. The slot-shaped housing is also used to fix a high-voltage connector, a high-voltage connector includes a power battery connection terminal and two high-voltage lap copper bars, a power battery connection terminal is used to electrically connect the power battery through a power connection line, a portion of each first connection copper bar is stacked with a high-voltage lap copper bar, and a portion of the two first connection copper bars is used to directly fix and connect the two high-voltage lap copper bars and electrically connect the positive and negative poles of the power battery through the two high-voltage lap copper bars.

[0006] In the embodiment of the present application, the trough-shaped housing is integrally die-cast, improving the structural stability of the power supply. The trough-shaped housing accommodates and supports the electrical components of the motor controller. The capacitor filter integrated module is used to filter out harmonic interference, common-mode interference, differential-mode interference, and stabilize current and voltage.

[0007] In an embodiment of the present application, a capacitor filter integrated module is used to integrate a busbar capacitor, an EMC filter component and two first connecting copper bars. A busbar capacitor, an EMC filter component and a first connecting copper bar are integrated into a capacitor filter integrated module, so that the capacitor filter integrated module has filtering and voltage stabilization functions, and can also improve the integration level of a capacitor filter integrated module, reduce the wiring harness and transfer copper bar layout in a capacitor filter integrated module, and is conducive to the miniaturized layout of the power supply device.

[0008] In an embodiment of the present application, a busbar capacitor receives the high-voltage direct current output by the power battery through two first connecting copper bars, and filters the high-voltage direct current received by the two first connecting copper bars through an EMC filter component. When the high-voltage direct current from the power battery passes through a busbar capacitor, the busbar capacitor can provide ripple current when the power supply device drives the motor, reducing the bus current fluctuation of the entire vehicle, thereby reducing the bus voltage ripple of the entire vehicle. When the high-voltage direct current from the power battery passes through an EMC filter component, the EMC filter component can eliminate differential mode interference and common mode interference in the current signal and reduce harmonic interference in the current signal.

[0009] In an embodiment of the present application, the high-voltage connector is an independent component, which includes a power battery connection terminal and two high-voltage copper bars. A high-voltage connector is used to electrically connect the power battery and a capacitor filter integrated module of the motor controller. A power battery connection terminal is used to electrically connect the power battery through a power connection line, output the high-voltage direct current in the power battery through the two high-voltage copper bars to the two first connecting copper bars of a capacitor filter integrated module, thereby transmitting the high-voltage direct current to a capacitor filter integrated module of the motor controller.

[0010] In an embodiment of the present application, each first connecting copper busbar is stacked with a high-voltage bonding copper busbar, which is beneficial for each first connecting copper busbar to fully contact with a high-voltage bonding copper busbar to conduct power. It is also beneficial for each first connecting copper busbar and a high-voltage bonding copper busbar to not occupy too much space of the power supply device along the first direction, which is beneficial for the miniaturized layout of the power supply device.

[0011] In an embodiment of the present application, the two first connecting copper bars are respectively used to directly and fixedly connect the two high-voltage lap copper bars, so that the direct electrical connection between the power battery and the power supply device only needs to be achieved through the two high-voltage lap copper bars of a high-voltage connector, avoiding the use of excessive cables and adapter copper bars when electrically connecting the power battery to the motor controller, which is conducive to simplifying the wiring layout within the power supply device, simplifying the installation process, reducing the difficulty of assembly, and also helping to save materials and reduce production costs. The two first connecting copper bars are electrically connected to the positive and negative poles of the power battery through the two high-voltage lap copper bars, which is conducive to the power supply device to realize the charging and discharging functions between the power battery.

[0012] In one embodiment, the all-in-one power supply device also includes an on-board charger, and the groove-shaped housing is also used to accommodate the electrical components of the on-board charger. The electrical components of the on-board charger include a circuit board, and the circuit board is used to fix multiple electrical components of the power conversion circuit in the on-board charger. The power conversion circuit is used to convert the external power supply and output high-voltage direct current to charge the power battery. Each first connecting copper bar includes a first bonding copper bar and a second bonding copper bar. The first bonding copper bar of each first connecting copper bar is stacked with a high-voltage bonding copper bar. In addition, along the stacking direction of the first bonding copper bar and the high-voltage bonding copper bar of each first connecting copper bar, each second bonding copper bar is stacked with a circuit board. The two second bonding copper bars are used to directly fix and connect to a circuit board and receive the high-voltage direct current output by the power conversion circuit through a circuit board.

[0013] In the embodiment of the present application, the trough-shaped housing accommodates and supports the electrical components of the on-board charger. A single circuit board supports multiple electrical components of the power conversion circuit in the on-board charger, allowing the electrical components of the on-board charger to conduct current to the power battery through the single circuit board, thereby charging the power battery.

[0014] In an embodiment of the present application, a circuit board is used to fix multiple electrical components of the power conversion circuit in the vehicle charger. The power conversion circuit is used to convert the external power supply and output high-voltage direct current to charge the power battery. The external power supply can be an AC power supply. The vehicle charger converts the high-voltage AC power into high-voltage direct current and then charges the power battery, thereby realizing that the power battery can discharge the power supply device and the power supply device can also charge the power battery.

[0015] In the embodiment of the present application, each first connecting copper busbar includes a first bonding busbar and a second bonding busbar. Current flows sequentially through the first bonding busbar, an EMC filter assembly, and a busbar capacitor. The second bonding busbar enables electrical connection between the power battery and the electrical components of the onboard charger, promoting deep integration between the electrical components within the power supply device and improving the integration and fusion of the power supply device.

[0016] In the embodiment of the present application, along the stacking direction of the first connecting copper bar and a high-voltage connecting copper bar, each second connecting copper bar is stacked with a circuit board, so that each second connecting copper bar has a larger contact area with the circuit board, thereby achieving electrical connection between each second connecting copper bar and the circuit board. The stacking arrangement of each second connecting copper bar and the circuit board also helps to reduce the space occupied by each second connecting copper bar and the circuit board along the second direction, which is conducive to the miniaturization of electrical components in the power supply device.

[0017] In the embodiment of the present application, the stacking direction of the first bonding copper bar and a high-voltage bonding copper bar along each first connecting copper bar is parallel to the height direction of the power supply device and parallel to the thickness direction of a circuit board.

[0018] In the embodiment of the present application, two second bonding copper bars are used to directly and fixedly connect a circuit board and receive the high-voltage direct current output by the power conversion circuit through the circuit board. Only two second bonding copper bars are used to realize the electrical connection between the electrical components of the vehicle charger and the power battery, thereby reducing the use of external wiring harnesses, copper bars, and adapters, simplifying the wiring layout within the power supply device, reducing the installation difficulty, and also reducing production costs.

[0019] In one embodiment, each first connecting copper bar also includes a transmission copper bar, one section of each transmission copper bar is embedded in the shell of a capacitor filter integrated module and is electrically connected to a bus capacitor and an EMC filter component, and the other section of each transmission copper bar is used to fixedly connect a first strapping copper bar and a second strapping copper bar.

[0020] In an embodiment of the present application, a section of each transmission copper bar is embedded in the housing of a capacitor filter integrated module and electrically connected to a busbar capacitor and an EMC filter assembly, so that the current inputted into the capacitor filter integrated module by the first connection copper bar is filtered, common-mode interference, differential-mode interference, and harmonic interference are eliminated. Another section of each transmission copper bar is used to fix a first lap copper bar and a second lap copper bar, and the high-voltage direct current in the power battery is transmitted to an EMC filter assembly and a busbar capacitor through a first lap copper bar and another section of a transmission copper bar. A circuit board of an on-board charger receives the high-voltage direct current outputted by the power conversion circuit and realizes charging of the power battery through a second lap copper bar and a first lap copper bar, strengthening the connection between a first lap copper bar, a transmission copper bar, and a second lap copper bar. A first lap copper bar, a transmission copper bar, and a second lap copper bar are integrated into one, which is conducive to improving the integration degree of the power supply device and simplifying the circuit layout in the power supply device.

[0021] In one embodiment, the direction in which the two first overlapping copper bars are arranged in parallel intersects with the direction in which the two second overlapping copper bars are arranged in parallel, and each second overlapping copper bar includes a bending section and a fixed section, one end of a fixed section is used to electrically connect to a circuit board, and the other end of a fixed section is fixedly connected to a first overlapping copper bar through a bending section, and the bending direction of a bending section is from a fixed section toward the bottom of the groove of the groove-shaped shell.

[0022] In an embodiment of the present application, the direction in which the two first overlapping copper bars are arranged in parallel intersects the direction in which the two second overlapping copper bars are arranged in parallel, and the two first overlapping copper bars and the two second overlapping copper bars are arranged in parallel in different directions, respectively. Compared with arranging the two first overlapping copper bars and the two second overlapping copper bars in parallel in the same direction, a space for a capacitor filter integrated module is saved in the direction in which the two first overlapping copper bars are arranged in parallel and the direction in which the two second overlapping copper bars are arranged in parallel. It should be noted that the direction in which the two first overlapping copper bars are arranged in parallel is the same as the second direction, and the direction in which the two second overlapping copper bars are arranged in parallel is the same as the first direction, and the first direction and the second direction are perpendicular to each other, which is conducive to the first overlapping copper bar receiving the charge from the power battery along the first direction, which is conducive to reducing power loss, and is conducive to the second overlapping copper bar and a circuit board of the on-board charger being stacked along the third direction, so as to realize the electrical connection between the second overlapping copper bar and the electrical components of the on-board charger.

[0023] In an embodiment of the present application, each second copper strapping busbar includes a bent section and a fixed section. Each bent section is used to connect to a first copper strapping busbar. One end of a fixed section is used to electrically connect to a circuit board. One end of a fixed section is fixed to a circuit board. One end of a fixed section receives current from a bent section and transmits it to a circuit board. The other end of a fixed section is fixedly connected to a first copper strapping busbar via a bent section. The other end of a fixed section receives current from a first copper strapping busbar and transmits it to a bent section, which in turn transmits it to a circuit board.

[0024] In an embodiment of the present application, a second overlapping copper busbar is stacked with a circuit board, and a bending direction of a bent section is from a fixed section toward the bottom of the trough of the trough-shaped housing. This facilitates the bent section of the second overlapping copper busbar to receive current from a first overlapping copper busbar along the third direction and conduct it to a circuit board. The bending direction of a bent section is from a fixed section toward the bottom of the trough of the trough-shaped housing. Compared to a case where the bent section and the fixed section of the second overlapping copper busbar are arranged flat along the second direction, this facilitates reducing the space occupied by the bent section of the second overlapping copper busbar in the second direction.

[0025] In an embodiment of the present application, when the power battery discharges the power supply device, the current passes through a high-voltage connector, a first overlapping copper busbar, the other end of a bent section, one end of a bent section, a fixed section, and a circuit board in sequence to power the electrical components of the vehicle charger. When the power supply device charges the power battery, the current passes through an external power supply in sequence to a circuit board, a fixed section, one end of a bent section, the other end of a bent section, a first overlapping copper busbar, and finally to a high-voltage connector to charge the power battery.

[0026] In one embodiment, the electrical components of the on-board charger further include another EMC filter assembly for filtering the high-voltage direct current output or received by the on-board charger. A circuit board, a filter capacitor of the other EMC filter assembly, and the bottom of the slot of the slot-shaped housing are stacked in sequence along the stacking direction of the first connecting copper busbar and a high-voltage connecting copper busbar of each first connecting copper busbar.

[0027] In an embodiment of the present application, another EMC filter component is used to filter the high-voltage direct current output or received by the vehicle charger, that is, when the power battery discharges the vehicle charger, the other EMC filter component filters the high-voltage direct current in the power battery and transmits it to the electrical components of the vehicle charger. The other EMC filter component can also filter the high-voltage direct current in the vehicle charger and transmit it to the power battery when the vehicle charger charges the power battery, which is beneficial to reduce signal interference during the current transmission process.

[0028] In an embodiment of the present application, along the stacking direction of the first lap copper bar of each first connecting copper bar and a high-voltage lap copper bar, a circuit board, a filter capacitor of another EMC filter assembly, and the bottom of the slot of the slot-shaped housing are stacked in sequence, and the filter capacitor of another EMC filter assembly is arranged below a circuit board along the third direction, making full use of the space within the power supply device and facilitating the miniaturization of the power supply device. It should be noted that the stacking direction of the first lap copper bar of each first connecting copper bar and a high-voltage lap copper bar is in the same direction as the third direction.

[0029] In one embodiment, the two high-voltage copper busbars are also used to house a filter magnetic ring of another EMC filter assembly. Along the length of any one of the high-voltage copper busbars, a filter magnetic ring is arranged between the housing of a capacitor filter integrated module and a side wall of the slot-shaped housing.

[0030] In an embodiment of the present application, a filter magnetic ring of another EMC filter component is sleeved on two high-voltage strapping copper bars, which can filter the current passing through the two high-voltage strapping copper bars. It is also beneficial to improve the integration of a filter magnetic ring of another EMC filter component with other electrical components in the power supply device, without occupying too much space outside the slot-shaped shell of the power supply device, so that the power supply device can be miniaturized.

[0031] In an embodiment of the present application, along the length direction of any high-voltage lap copper busbar, a filter magnetic ring is arranged between the housing of a capacitor filter integrated module and a side wall of the slot-shaped housing, providing installation space for a filter magnetic ring of another EMC filter assembly, which can improve the integration of a filter magnetic ring of another EMC filter assembly with other electrical components in the power supply device, and can also not occupy too much space outside the slot-shaped housing of the power supply device, so that the power supply device is miniaturized. A filter magnetic ring is arranged outside the housing of a capacitor filter integrated module, which is also beneficial to reduce the electrical interference between a filter magnetic ring and a capacitor filter integrated module, and improve the electromagnetic compatibility of the power supply device. It should be noted that the length direction of any high-voltage lap copper busbar is in the same direction as the first direction.

[0032] In an embodiment of the present application, when the current in the power battery is transmitted into the power supply device through a high-voltage connector, a filter magnetic ring of another EMC filter component eliminates the harmonic interference in the current signal, and then transmits the current that reduces the interference to a capacitor filter integrated module through the first overlapping copper bar of the first connection copper bar, and an EMC filter component in a capacitor filter integrated module further eliminates the interference signal of the current. Alternatively, the current that eliminates the harmonic interference signal through a filter magnetic ring of another EMC filter component is transmitted to a circuit board through the second overlapping copper bar of the first connection copper bar, and the interference signal of the current is further eliminated through the filter capacitor of another EMC filter component in a circuit board, and the accurate current signal can be transmitted to the electrical components of the on-board charger, which is conducive to improving the electromagnetic compatibility of the power supply device. Alternatively, the current signal of the electrical components of the on-board charger is filtered by the filter capacitor of another EMC filter component, and then transmitted to the second overlapping copper bar and the first overlapping copper bar of the first connection copper bar through a circuit board, filtered by a filter magnetic ring of another EMC filter component, and transmitted to a high-voltage connector, and then charged the power battery, and the accurate current signal can be transmitted to the power battery, improving the electromagnetic compatibility of the power supply device.

[0033] In one embodiment, the bottom of the trough-shaped housing is used to secure a filter capacitor of another EMC filter assembly and a capacitor filter integrated module. The bottom of the trough-shaped housing includes a shielding protrusion, which is used to securely connect the bottom of the trough-shaped housing and two sidewalls arranged oppositely along the length direction of any high-voltage copper busbar. A filter magnetic ring and a capacitor filter integrated module are arranged on one side of a shielding protrusion along the arrangement direction of the two high-voltage copper busbars, and a filter capacitor of another EMC filter assembly is arranged on the other side of a shielding protrusion.

[0034] In an embodiment of the present application, the bottom of the groove of the groove-shaped shell is used to fix the filter capacitor of another EMC filter component and a capacitor filter integrated module. The groove-shaped shell also provides support for the filter capacitor of another EMC filter component and a capacitor filter integrated module, which can improve the stability of the power supply device.

[0035] In an embodiment of the present application, a shielding protrusion is used to fix the bottom of the groove of the groove-shaped shell and the two side walls arranged oppositely along the length direction of any high-voltage lap copper busbar. A shielding protrusion divides the space inside the groove-shaped shell into two installation areas. The shielding protrusion separates the motor controller and the vehicle charger. The shielding protrusion has the function of isolating the electrical components of the motor controller and the electrical components of the vehicle charger from electrical interference.

[0036] In an embodiment of the present application, along the arrangement direction of the two high-voltage overlapping copper bars, a filter magnetic ring and a capacitor filter integrated module are arranged on one side of a shielding protrusion, and the filter capacitor of another EMC filter assembly is arranged on the other side of a shielding protrusion, that is, a filter magnetic ring, a capacitor filter integrated module and the filter capacitor of another EMC filter assembly are electrically isolated, which is conducive to the separate filtering of the filter magnetic ring and the capacitor filter integrated module and the filter capacitor of another EMC filter assembly, which is conducive to improving the electromagnetic compatibility within the power supply device. It should be noted that the arrangement direction of the two high-voltage overlapping copper bars is in the same direction as the second direction.

[0037] In one embodiment, a capacitor filter integrated module is also used to integrate three pairs of second connection copper bars, and the electrical components of the motor controller also include a three-phase power module, a three-phase power module is used to electrically connect the three pairs of second connection copper bars, and a three-phase power module is used to convert the high-voltage direct current received by a bus capacitor into three-phase alternating current. Wherein, along the length direction of any high-voltage overlapping copper bar, two first connection copper bars and three pairs of second connection copper bars are arranged at intervals on both sides of the shell of a capacitor filter integrated module, and a filter magnetic ring, a capacitor filter integrated module and a three-phase power module are arranged in sequence at the bottom of the slot of the slot-shaped shell. Along the arrangement direction of the two high-voltage overlapping copper bars, a three-phase power module, a filter magnetic ring and a capacitor filter integrated module are arranged on the same side of a shielding protrusion.

[0038] In an embodiment of the present application, a capacitor filter integrated module is further integrated with three pairs of second connecting copper bars, thereby increasing the integration level of the capacitor filter integrated module. The electrical components of the motor controller also include a three-phase power module. The three pairs of second connecting copper bars are used to transmit current from the capacitor filter integrated module to the three-phase power module, which converts high-voltage direct current from a bus capacitor into three-phase alternating current.

[0039] In an embodiment of the present application, along the length direction of any high-voltage lap copper bar, two first connecting copper bars and three pairs of second connecting copper bars are arranged at intervals on both sides of the housing of a capacitor filter integrated module, and the electrical components in the housing of a capacitor filter integrated module are electrically connected to the power battery and the three-phase power module respectively through the two first connecting copper bars and the three pairs of second connecting copper bars, thereby improving the integration of the power supply device. Along the length direction of any high-voltage lap copper bar, two first connecting copper bars and three pairs of second connecting copper bars are arranged at intervals on both sides of the housing of a capacitor filter integrated module, which is conducive to the two first connecting copper bars and the three pairs of second connecting copper bars working independently, reducing electrical interference between the two.

[0040] In an embodiment of the present application, the bottom of the groove of the groove-shaped housing provides a space for installing and fixing a filter magnetic ring, a capacitor filter integrated module and a three-phase power module, and also provides support for a filter magnetic ring, a capacitor filter integrated module and a three-phase power module. Along the length direction of any high-voltage lap copper busbar, a filter magnetic ring, a capacitor filter integrated module and a three-phase power module are arranged in sequence at the bottom of the groove of the groove-shaped housing, which is conducive to the regular arrangement of electrical components in the power supply device, and is also conducive to the current passing through a filter magnetic ring, a capacitor filter integrated module and a three-phase power module in sequence, filtering and current conversion are carried out in sequence, and the power flow is transmitted to the three-phase group of the motor along the first direction to drive the motor, which is conducive to reducing power loss and improving the overall performance of the power supply device.

[0041] In one embodiment, the trough-shaped housing includes a first mounting hole for securing a high-voltage connector. The first mounting hole extends through a side wall of the trough-shaped housing along the length of any high-voltage copper busbar, and the distance between the first mounting hole and the capacitor core of a busbar capacitor is greater than the length of any high-voltage copper busbar.

[0042] In an embodiment of the present application, along the length direction of any high-voltage lap copper busbar, a first mounting hole penetrates a side wall of the slot-shaped shell, so that a high-voltage connector is installed in a first mounting hole along the first direction, which is beneficial to reducing the space occupied by a high-voltage connector in the power supply device along the second direction.

[0043] In an embodiment of the present application, along the length direction of any high-voltage strapping copper busbar, the distance between a first mounting hole and the capacitor core of a busbar capacitor is greater than the length of any high-voltage strapping copper busbar, providing sufficient installation space for the first strapping copper busbars of two high-voltage strapping copper buses of a high-voltage connector and two first connecting copper buses of a capacitor filter integrated module.

[0044] In one embodiment, the trough-shaped housing further includes a second mounting hole for securing a winding connector, which is used to electrically connect a three-phase power module of a motor controller to a three-phase winding of a motor. A second mounting hole extends through the bottom of the trough-shaped housing along the stacking direction of each first connecting copper bar and a high-voltage bridging copper bar. Alternatively, a second mounting hole extends through another side wall of the trough-shaped housing along the length of any high-voltage bridging copper bar, with one side wall aligned opposite the other.

[0045] In an embodiment of the present application, a second mounting hole provides space for the installation and fixation of a winding connector, a winding connector is used to connect a three-phase power module and the three-phase winding of a motor, and a winding connector transmits the high-voltage alternating current converted by the three-phase power module to the three-phase winding of a motor through a winding connector to drive the motor.

[0046] In an embodiment of the present application, along the stacking direction of each first connecting copper bar and a high-voltage lap copper bar, that is, along the stacking direction of the first lap copper bar of each first connecting copper bar and a high-voltage lap copper bar, a second mounting hole passes through the bottom of the slot of the slot-shaped shell, so that a winding connector is arranged in a second mounting hole along a third direction, which is beneficial for a winding connector to conduct current to a three-phase winding of a motor with a shorter path. In addition, a second mounting hole passing through the bottom of the slot along the third direction is beneficial for a winding connector to be arranged in the slot-shaped shell along the third direction, and is also beneficial for a winding connector to not occupy too much space of the power supply device along the first direction and the second direction, thereby facilitating the miniaturization of the power assembly. It should be noted that the stacking direction of each first connecting copper bar and a high-voltage lap copper bar is in the same direction as the third direction.

[0047] In an embodiment of the present application, a second mounting hole extends through another side wall of the trough-shaped housing, allowing a winding connector to be arranged in the trough-shaped housing along a first direction. This facilitates the winding connector not to excessively occupy space of the power supply device along the second and third directions, thereby facilitating a compact layout of the power assembly. Along the length direction of any high-voltage lap copper busbar, one side wall is arranged relative to the other side wall, facilitating the relative arrangement of a first mounting hole on one side wall and a second mounting hole on the other side wall, thereby facilitating a regular arrangement of the mounting holes on the trough-shaped housing.

[0048] In an embodiment of the present application, along the length direction of any high-voltage overlapping copper busbar, a second mounting hole penetrates the other side wall of the slot-shaped shell, which is conducive to a winding connector transmitting the high-voltage alternating current converted by the three-phase power module to the three-phase winding of a motor through a winding connector along the power flow to drive the motor, which is conducive to reducing power loss and improving the overall performance of the power supply device.

[0049] In one embodiment, the all-in-one power supply device further includes a high-voltage power supply module and an on-board charger, the high-voltage power supply module being used to power at least one of the compressor or the PTC, and the trough-shaped housing further including a third mounting hole and a fourth mounting hole. A third mounting hole is used to fix a high-voltage power supply connector, and a high-voltage power supply connector is used to electrically connect at least one of the compressor or the PTC and a high-voltage power supply module. A fourth mounting hole is used to fix an AC input connector, and an AC input connector is used to electrically connect the on-board charger and an external power supply. Along the length direction of any high-voltage bonding copper busbar, a third mounting hole and a fourth mounting hole respectively penetrate a side wall. Along the arrangement direction of the two high-voltage bonding copper busbars, a first mounting hole, a third mounting hole, and a fourth mounting hole are sequentially spaced apart on a side wall.

[0050] In the embodiment of the present application, a high-voltage power supply connector is used to connect to the compressor, so that the power supply device is electrically connected to the compressor to power the compressor, and a high-voltage power supply connector is used to connect to the PTC to power the PTC. An AC input connector is used to electrically connect the on-board charger and the external power supply, transmitting the AC power from the external power supply to the on-board charger of the power supply device through the AC input connector, and then charging the power battery.

[0051] In an embodiment of the present application, a high-voltage power supply module includes multiple copper bars, and the high-voltage power supply module can also be called a power distribution module.

[0052] In an embodiment of the present application, a third mounting hole extends through the slot-shaped housing in the first direction, allowing a high-voltage power supply connector to be mounted and fixed to the third mounting hole in the first direction. A fourth mounting hole extends through the slot-shaped housing in the first direction, allowing an AC input connector to be mounted and fixed to the fourth mounting hole in the first direction. This eliminates the need to arrange excessive cables when connecting an AC input connector connected to an AC power source and a high-voltage power supply connector connected to a compressor and a PTC to electrical components within the power supply device, thereby simplifying the connection lines between the power supply device and the AC power source and the compressor and PTC, making the wiring of the electric vehicle more concise.

[0053] In an embodiment of the present application, a power supply device integrates the functions of charging and discharging a power battery, driving a motor, and supplying power to a compressor and a PTC. A high-voltage connector, an AC input connector, and a high-voltage power supply connector for connecting the power battery, AC power supply, and compressor are respectively fixed to a first mounting hole, a third mounting hole, and a fourth mounting hole of a slotted housing of the power supply device, thereby increasing the integration of the power supply device. The fourth mounting hole and the third mounting hole are arranged on the same side as the first mounting hole, thereby regularizing the openings on the slotted housing and arranging the AC input connector, the high-voltage power supply connector, and the high-voltage connector in a regular manner within the power supply device. This further increases the integration of the power supply device, facilitating reduction in the space occupied by the power supply device along the second direction, allowing other sides of the slotted housing to be used for mounting other connectors or electrical components, facilitating miniaturization and diversification of the power supply device and powertrain, and enabling the high-voltage DC power transmitted by the high-voltage connector to be transmitted to the high-voltage power supply connector via a shorter path, thereby reducing transmission losses.

[0054] In an embodiment of the present application, a first mounting hole, a third mounting hole, and a fourth mounting hole are arranged in sequence on a side wall along the arrangement direction of two high-voltage overlapping copper bars, so that a high-voltage connector is spaced from an AC input connector, thereby avoiding electrical interference between high-voltage direct current and alternating current, and improving the safety performance of charging and discharging of the power supply device.

[0055] In one embodiment, the all-in-one power supply device further includes a low-voltage power supply module, which is used to power an on-board low-voltage load. The output voltage of the low-voltage power supply module is less than the output voltage of the power battery. The trough-shaped housing further includes a fifth mounting hole. Along the length direction of any high-voltage lap copper busbar, a fifth mounting hole extends through another side wall, and the other side wall is arranged opposite to a side wall. The fifth mounting hole is used to secure a low-voltage power supply connector, which is used to electrically connect a low-voltage power supply module to an on-board low-voltage load.

[0056] In an embodiment of the present application, a fifth mounting hole is used to secure a low-voltage power supply connector, which is used to electrically connect a low-voltage power supply module to an on-board low-voltage load. The low-voltage power supply module includes a DC-DC converter, which converts high-voltage DC power to low-voltage DC power. The DC-CDC converter includes at least one of a capacitor, an inductor, and a power switch. The low-voltage power supply connector is used to transmit the low-voltage DC power from the low-voltage power supply module to an on-board low-voltage load to power the on-board low-voltage load.

[0057] In an embodiment of the present application, along the length direction of any high-voltage lap copper busbar, a fifth mounting hole penetrates another side wall, so that a low-voltage power supply connector is mounted and fixed to the trough-shaped housing along the first direction, reducing the space occupied by the low-voltage power supply connector in the trough-shaped housing along the second and third directions. Along the length direction of any high-voltage lap copper busbar, another side wall is arranged relative to a side wall, so that a fifth mounting hole and a first mounting hole are arranged relative to each other, which is conducive to the regular arrangement of a low-voltage power supply connector and a high-voltage connector in the power supply device. In addition, it is also conducive to the current output from the power battery to the power supply device through a high-voltage connector, and output from a low-voltage power supply module of the power supply device to an on-board low-voltage load along the first direction, so that the entire power flow path flows along the first direction, making the power flow path smoother and reducing losses.

[0058] In one embodiment, the all-in-one power supply device further includes a cover plate and a vehicle controller. The cover plate is configured to cooperate with the trough-shaped housing to form a receiving space. One of the cover plate and the bottom of the trough-shaped housing includes a sixth mounting hole extending through the cover plate and the bottom of the trough-shaped housing along the stacking direction of each first connecting copper busbar and a high-voltage lap copper busbar. The sixth mounting hole is configured to secure a signal connector. The vehicle controller is configured to receive external control signals via the signal connector and to control the motor controller via signal cables housed in the receiving space.

[0059] In an embodiment of the present application, a cover plate is used to cover the trough-shaped shell, and cooperates with the trough-shaped shell to form a accommodating space. The accommodating space provides installation space for a motor controller, an on-board charger, a high-voltage power supply module, a low-voltage power supply module and a vehicle controller.

[0060] In an embodiment of the present application, a sixth mounting hole extends through the bottom of the trough-shaped housing, allowing a signal connector to be connected to a vehicle controller along the third direction. This facilitates the signal connector not occupying excessive space in the power supply device in the third and second directions. A vehicle controller is configured to receive external control signals via a signal connector and to control a motor controller via a signal connection line housed in a receiving space, thereby facilitating regulation and control of the motor controller by the vehicle controller. The location of the vehicle controller outside the trough-shaped housing facilitates the relatively independent and normal operation of electrical components within the trough-shaped housing and the vehicle controller, thereby reducing electrical interference.

[0061] In an embodiment of the present application, a cover plate includes a sixth mounting hole extending through the cover plate along the stacking direction of a portion of each first connecting copper busbar and a high-voltage lap copper busbar. The sixth mounting hole is used to secure a signal connector, and a vehicle controller is used to receive external control signals via the signal connector and to control a motor controller via a signal connection line housed in a receiving space. In an embodiment of the present application, when the signal connector needs to exit from the top of the power supply device, the sixth mounting hole can be provided in the cover plate.

[0062] In a second aspect, the present application provides a powertrain, which includes a motor and a power supply device as described above, wherein a three-phase power module of the power supply device is used to be connected to the three-phase winding of the motor.

[0063] In an embodiment of the present application, the capacitor filter integrated module in the power supply device is used to receive the high-voltage direct current transmitted by the power battery, and convert the high-voltage direct current into high-voltage alternating current in the three-phase power module and transmit it to the three-phase winding of the motor to drive the motor to rotate.

[0064] On the third aspect, the present application provides an electric vehicle, which includes a frame, a power battery and the powertrain as described above. The frame is used to fix the power battery and the powertrain. The powertrain also includes a reducer. A power battery connection terminal of a high-voltage connector is used to electrically connect the power battery through a power connection line, and the motor is used to drive the wheels of the electric vehicle through the reducer.

[0065] In an embodiment of the present application, the motor includes a motor shaft, a motor stator and a motor rotor, and the motor rotor is fixedly mounted on the motor shaft. The reducer includes a gear assembly, an input shaft and an output shaft. The high-voltage direct current in the power battery is transmitted into the power supply device through a power connection line via a power battery connection terminal of a high-voltage connector. The two first connecting copper bars of the capacitor filter integrated module receive the high-voltage direct current and transmit it to the three-phase power module. The high-voltage direct current is converted into high-voltage alternating current through the three-phase power module, and then transmitted to the three-phase winding of the motor. After receiving the alternating current, the motor stator drives the motor rotor to rotate, thereby driving the motor shaft to rotate. The motor shaft of the motor is used to be connected to the input shaft of the reducer in transmission. The input shaft receives the power transmitted by the motor shaft of the motor and transmits the power to the output shaft through the gear assembly to drive the wheels of the electric vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments of the present application will be described below.

[0067] FIG1 is a schematic structural diagram of an electric vehicle provided in an embodiment of the present application;

[0068] FIG2 is a schematic structural diagram of a powertrain according to an embodiment of the present application;

[0069] FIG3a is a schematic structural diagram of a power supply device provided in an embodiment of the present application;

[0070] FIG3 b is another schematic structural diagram of a power supply device provided in an embodiment of the present application;

[0071] FIG4 is another schematic structural diagram of a power supply device provided in an embodiment of the present application;

[0072] FIG5 is a cross-sectional view of a power supply device provided in an embodiment of the present application;

[0073] FIG6 is a schematic structural diagram of a high-voltage connector provided in an embodiment of the present application;

[0074] FIG7 is a partial enlarged view of the M1 portion in FIG3a;

[0075] FIG8 is a schematic structural diagram of a capacitor filter integrated module provided in an embodiment of the present application;

[0076] FIG9 is another structural diagram of a capacitor filter integrated module provided in an embodiment of the present application;

[0077] FIG10 is an exploded view of a capacitor filter integrated module provided in an embodiment of the present application;

[0078] FIG11 is another structural diagram of a capacitor filter integrated module provided in an embodiment of the present application;

[0079] FIG12 is a partial enlarged view of the M2 portion in FIG9 ;

[0080] FIG13 is another structural diagram of a capacitor filter integrated module provided in an embodiment of the present application;

[0081] FIG14 is another structural diagram of the capacitor filter integrated module provided in an embodiment of the present application. DETAILED DESCRIPTION

[0082] The technical solutions in the embodiments of the present application will be described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments.

[0083] For ease of understanding, the English abbreviations and related technical terms involved in the embodiments of this application are explained and described below.

[0084] EMC: The abbreviation of Electro Magnetic Compatibility. EMC refers to the ability of electronic products or electrical equipment to work normally according to design requirements in a specified electromagnetic environment.

[0085] PTC: The abbreviation of Positive Temperature Coefficient, which means positive temperature coefficient. PTC in the car refers to the car heater.

[0086] DCDC: DC stands for Direct Current. DCDC refers to a device that converts a DC power source of one voltage level to a DC power source of another voltage level. DCDCs are categorized by voltage level: step-up power supplies and step-down power supplies. For example, a DCDC converter is a component used to convert high-voltage DC power to low-voltage DC power.

[0087] Parallel: This term is understood to mean essentially parallel, not limited to absolute parallelism or a 180-degree angle. Even angles less than or greater than 180 degrees due to factors such as assembly tolerances, design tolerances, and process tolerances are considered essentially parallel.

[0088] Perpendicular: This term is understood to mean essentially perpendicular, not limited to an absolute perpendicular intersection or a 90-degree angle. Angles less than or greater than 90 degrees due to factors such as assembly tolerances, design tolerances, and process tolerances also fall within the definition of essentially perpendicular.

[0089] First direction X, second direction Y, third direction Z: the first direction is perpendicular to the second direction and the third direction, the second direction is perpendicular to the first direction and the third direction, the third direction is perpendicular to the first direction and the second direction, and the third direction is parallel to the height direction of the power supply device.

[0090] In order to simplify the circuit arrangement of the power supply device and improve electromagnetic compatibility, an embodiment of the present application provides an all-in-one power supply device including a slot-shaped housing and a motor controller, which is used to convert high-voltage direct current into alternating current and provide the alternating current to the motor to drive the motor. The slot-shaped housing is used to accommodate the electrical components of the motor controller, and the electrical components of the motor controller include a capacitor filter integrated module. Among them, a capacitor filter integrated module is used to integrate a bus capacitor, an EMC filter component and two first connecting copper bars, so that the bus capacitor, the EMC filter component and the first connecting copper bar are arranged more compactly. A bus capacitor receives the high-voltage direct current output by the power battery through two first connecting copper bars, and filters the high-voltage direct current received by the two first connecting copper bars through an EMC filter component. The trough-shaped shell is also used to fix a high-voltage connector. A high-voltage connector includes a power battery connection terminal and two high-voltage lap copper bars. A power battery connection terminal is used to electrically connect the power battery through a power connection line. Each first connection copper bar is stacked with a high-voltage lap copper bar. The two first connection copper bars are respectively used to directly fix and connect the two high-voltage lap copper bars and electrically connect the positive and negative poles of the power battery through the two high-voltage lap copper bars. By integrating two first connection copper bars in a capacitor filter integrated module, an electrical connection between a capacitor filter integrated module and a power battery is achieved without the need for excessive cables and transfer copper bars, which simplifies the circuit layout in the power supply device, reduces the difficulty of assembly, and is also conducive to improving the integration of the power supply device and the deep integration between the electrical components in the power supply device. By using an EMC filter component for filtering and voltage stabilization, the three-phase winding of the motor can receive accurate current signals from the power battery, thereby improving the electromagnetic compatibility of the power supply device.

[0091] The all-in-one power supply device provided in the embodiment of the present application is applied to a powertrain, and the powertrain is applied to an electric vehicle to improve the overall performance of the electric vehicle.

[0092] Please refer to Figures 1 and 2. Figure 1 is a schematic diagram of the structure of an electric vehicle 1 provided in one embodiment of the present application, and Figure 2 is a schematic diagram of the structure of a powertrain 4 provided in one embodiment of the present application. In one embodiment, the electric vehicle 1 includes a frame 2, a power battery 3, and a powertrain 4. The frame 2 is used to fix the power battery 3 and the powertrain 4. In this embodiment of the present application, the electric vehicle 1 refers to a wheeled device driven or towed by a power device. In this embodiment of the present application, the powertrain 4 is used to receive power from the power battery 3 and to drive the wheels 5.

[0093] In one embodiment, the powertrain 4 includes a power supply 10, a motor 30, and a reducer 20. As shown in Figure 2, in this embodiment of the present application, the power supply 10 and the motor 30 are electrically connected. The power supply 10 is used to receive high-voltage direct current (DC) power from the power battery 3, convert the DC power into high-voltage AC power, and transmit it to the motor 30, thereby driving the motor 30 to rotate. The motor 30 is in transmission connection with the reducer 20, and the motor 30 drives the reducer 20 to rotate.

[0094] In an embodiment of the present application, the motor 30 includes a motor shaft (not shown), a motor stator (not shown) and a motor rotor (not shown). The reducer 20 includes a gear assembly (not shown), an input shaft and an output shaft (not shown). The motor rotor in the motor 30 is fixedly sleeved on the motor shaft, and the motor stator drives the motor rotor to rotate after receiving alternating current, thereby driving the motor shaft to rotate. The motor shaft of the motor 30 is used to be connected to the input shaft of the reducer 20 in a transmission manner. The input shaft receives the power transmitted by the motor shaft of the motor 30 and transmits the power to the output shaft through the gear assembly, driving the wheels 5 of the electric vehicle 1 to travel.

[0095] In an embodiment of the present application, the power supply device 10 is used to charge and discharge the power battery 3 and to drive the motor 30. The power supply device 10 is used to receive high-voltage direct current (DC) transmitted by the power battery 3, and convert the high-voltage DC into high-voltage AC to transmit to the motor 30, thereby driving the motor 30 to rotate. In one embodiment, the power supply device 10 is used to receive AC power and convert the AC power into DC power to charge the power battery 3. The AC power includes mains electricity or residential AC power. In one embodiment, the power supply device 10 receives high-voltage DC power and provides DC power to the power battery 3 for charging.

[0096] Please refer to Figures 3a, 3b, 4 and 5. Figure 3a is a structural schematic diagram of the power supply device 10 provided in one embodiment of the present application, Figure 3b is another structural schematic diagram of the power supply device 10 provided in an embodiment of the present application, Figure 4 is another structural schematic diagram of the power supply device 10 provided in an embodiment of the present application, and Figure 5 is a cross-sectional view of the power supply device 10 provided in an embodiment of the present application.

[0097] As shown in FIG. 3 a , in one embodiment, the power supply device 10 includes a motor controller 101 , an on-board charger 102 , a power distribution module 105 and a vehicle controller 103 .

[0098] The motor controller 101 is known as the Motor Control Unit (MCU). In one embodiment, the motor controller 101 receives high-voltage direct current (HVDC) from the power battery 3 and converts it into high-voltage alternating current (HVAC) for transmission to the three-phase windings (not shown) of the motor 30, thereby driving the rotor and motor shaft of the motor 30.

[0099] In one embodiment, the motor controller 101 includes a capacitor filter integrated module 140 and a three-phase power module 150. As shown in FIG3a , the capacitor filter integrated module 140 is used to filter out harmonic interference, common-mode interference, differential-mode interference, and stabilize current and voltage. The three-phase power module 150 receives high-voltage direct current (DC) output from the capacitor filter integrated module 140 and converts the high-voltage DC into high-voltage alternating current (AC). The three-phase power module 150 transmits the high-voltage AC to the motor 30 to drive the motor 30.

[0100] In one embodiment, the capacitor filter integrated module 140 includes a pair of first connecting copper bars 143 and three pairs of second connecting copper bars 144. As shown in Figure 3a, a pair of first connecting copper bars 143 is used to connect the power battery 3, and three pairs of second connecting copper bars 144 are used to connect the three-phase power module 150. The capacitor filter integrated module 140 receives the high-voltage direct current of the power battery 3 through the first connecting copper bar 143, and transmits the high-voltage direct current to the three-phase power module 150 from the second connecting copper bar 144. The three-phase power module 150 converts the high-voltage direct current into high-voltage alternating current, and transmits the high-voltage alternating current to the three-phase winding (not shown) of the motor 30 to drive the motor 30 to rotate. The power battery 3 is electrically connected to the capacitor filter integrated module 140 of the power supply device 10 through a pair of first connecting copper bars 143, without the need to use too many external cables or transfer copper bars, thereby simplifying the circuit layout and improving the integration of the power supply device 10.

[0101] In one embodiment, the capacitor filter integrated module 140 and the three-phase power module 150 are arranged along the first direction Y, which facilitates the electrical connection between the three-phase power module 150 and the capacitor filter integrated module 140 through the second connecting copper bus 144, effectively shortening the space occupied by the power supply device 10 along the first direction Y.

[0102] The on-board charger 102 is called an On-Board Charger (OBC). In one embodiment, the on-board charger 102 is used to transfer current from an external power source to charge the power battery 3 or power the vehicle's loads. The external power source can be an AC grid, an AC charging station, or a DC charging station. In one embodiment, the on-board charger 102 includes a power conversion circuit that converts the external power source into high-voltage DC power for charging the power battery 3. The power conversion circuit includes multiple power switches.

[0103] Among them, the high-voltage distribution module 105 is responsible for the power distribution and management in the high-voltage system of the electric vehicle 1, providing the entire vehicle with functions such as charging and discharging control, high-voltage component power-on control, circuit overload and short-circuit protection, high-voltage sampling, and low-voltage control, protecting and monitoring the operation of the high-voltage system.

[0104] The vehicle control unit (VCU) 103 is a vehicle control unit (VCU). In one embodiment, the VCU 103 is responsible for normal vehicle operation, brake energy feedback, energy routing and network routing for the vehicle's drive system and power battery 3, fault diagnosis and handling, and vehicle status monitoring.

[0105] In one embodiment, the power supply device 10 includes a trough-shaped housing 110, two circuit boards 111, 112 (as shown in FIG3a), a heat sink 107 (as shown in FIG5) and a cover plate 170. The trough-shaped housing 110 and the cover plate 170 enclose a receiving space, and the receiving space is used to receive the two circuit boards 111, 112 and the electrical components of the motor controller 101 and the on-board charger 102 carried on the two circuit boards 111, 112. In the embodiment of the present application, the trough-shaped housing 110 of the power supply device 10 is integrally die-cast to improve the structural stability of the power supply device 10. The trough-shaped housing 110 accommodates the electrical components of the motor controller 101 and the on-board charger 102, and the trough-shaped housing 110 also provides support for the electrical components of the motor controller 101 and the on-board charger 102.

[0106] In one embodiment, the bottom 160 of the trough-shaped housing 110 includes a first flow channel 121 and a second flow channel 122 (as shown in FIG4 ). The first flow channel 121 and the second flow channel 122 are interconnected. The first flow channel 121 includes two sub-flow channels 121 a and 121 b. The first flow channel 121, a circuit board 111, and the heat sink 107 are stacked in sequence along the third direction Z. The two sub-flow channels 121 a and 121 b of the first flow channel 121 are arranged adjacent to each other along the second direction X. One circuit board 111 is used to carry the electrical components of the on-board charger 102, and the other circuit board 112 is used to carry the electrical components of the motor controller 101.

[0107] In the embodiment of the present application, one of the sub-channels 121a of the first channel 121 and the radiator 107 are used to cool the electrical components of the on-board charger 102 carried by a circuit board 111, another sub-channel 121b of the first channel 121 is used to cool the capacitor filter integrated module 140 of the motor controller 101 carried by another circuit board 112, and the second channel 122 is used to cool the three-phase power module 150 of the motor controller 101 carried by another circuit board 112. Sandwiching a circuit board 111 between the first channel 121 and the radiator 107 allows the coolant in the first channel 121 and the radiator 107 to simultaneously dissipate heat from the electrical components of the on-board charger 102 on the circuit board 111, thereby improving heat dissipation efficiency and enhancing the cooling effect of the coolant on the power supply device 10.

[0108] In one embodiment, a circuit board 111 is also used to support the electrical components of the DC-DC converter 104 and the vehicle controller 103. As shown in Figure 3a, along the second direction X, the motor controller 101 and the vehicle controller 103 are spaced apart, and the motor controller 101 and the DC-DC converter 104 are also spaced apart. This facilitates the motor controller 101 and the DC-DC converter 104 to operate relatively independently from the vehicle controller 103. The DC-DC converter 104 is used to convert high-voltage DC power into low-voltage DC power to power low-voltage loads. The DC-DC converter 104 is also referred to as a low-voltage power supply module.

[0109] In one embodiment, the trough-shaped housing 110 includes a liquid inlet 114g on its peripheral sidewalls, and a liquid outlet 114h on its bottom 160. As shown in FIG4 , the liquid inlet 114g is used to connect the radiator 107 and the first flow channel 121. The liquid inlet 114g is used to input coolant from the vehicle cooling system into the power supply device 10. The liquid outlet 114h is used to output the coolant from the power supply device 10 through the external cooling pipe 109 connected to the liquid outlet 114h. The coolant is also input into the heat exchanger (not shown) from the liquid inlet of the heat exchanger, where it exchanges heat with the cooling oil.

[0110] In one embodiment, the slotted housing 110 includes a plurality of mounting holes, to which a plurality of electrical connectors are fixed. As shown in Figures 3a and 4, the plurality of electrical connectors include a high-voltage connector 171, a winding connector 172, a high-voltage power connector 173, an AC input connector 174, a low-voltage power connector 175, and a signal connector 176.

[0111] The high-voltage connector 171 is used to electrically connect the power supply device 10 to the power battery 3 .

[0112] The winding connector 172 is used to connect the three-phase power module 150 and the three-phase winding of the motor, so that the power supply device 10 converts the DC power in the power battery 3 into AC power and outputs it to the three-phase winding of the motor 30 to drive the motor 30 to run.

[0113] The AC input connector 174 is used to connect to an AC power source. Exemplarily, the AC power source is an AC charging station or an AC power grid.

[0114] Low-voltage power connector 175 is used to connect a low-voltage load to DCDC converter 104 of power supply device 10. The low-voltage load includes at least one of a low-voltage battery, lights, wipers, air conditioner, audio system, USB port, instrument panel, and control display. For example, the low-voltage battery can also power other low-voltage loads.

[0115] The signal connector 176 is used to connect the vehicle load and the vehicle controller 103. The signal connector 176 is used to enable the vehicle controller 103 to transmit control signals to the power supply device 10 to optimize the energy distribution and operation of the vehicle.

[0116] The high-voltage power supply connector 173 is used to connect at least one of the PTC or the compressor. The PTC is also called a heater or a car heater. The heater is used to heat the entire vehicle. The heater is used to heat the seats, including heating the front seats, rear seats or middle seats. In some embodiments, when the electric vehicle 1 is a motorhome, the heater can also heat the seats and lying positions in the motorhome. After the heater raises the temperature of the entire vehicle, it can also perform defrosting and demisting.

[0117] In one embodiment, the housings of the high-voltage power connector 173 connected to the compressor and the high-voltage power connector 173 connected to the heater are integrated into a single structure. The high-voltage power connector 173 for the compressor and the high-voltage power connector 173 for the heater share a single housing, which improves the integration of the power supply device 10 and facilitates the deep integration of the power supply device 10 and the powertrain 4. Furthermore, sharing a single housing reduces the number of circuits within the power supply device 10, saving materials and reducing production costs.

[0118] The all-in-one power supply device 10 provided in an embodiment of the present application will be described in detail below.

[0119] Please refer to Figures 6 to 9. Figure 6 is a structural schematic diagram of a high-voltage connector 171 provided in an embodiment of the present application. Figure 7 is a partial enlarged view of the M1 part in Figure 3a. Figure 8 is a structural schematic diagram of the capacitor filter integrated module 140 provided in an embodiment of the present application. Figure 9 is another structural schematic diagram of the capacitor filter integrated module 140 provided in an embodiment of the present application.

[0120] As shown in FIG8 , in one embodiment, a capacitor filter integrated module 140 is used to integrate a busbar capacitor 141, an EMC filter assembly 142, a pair of first connecting copper bars 143, and three pairs of second connecting copper bars 144. A pair of first connecting copper bars 143 includes two first connecting copper bars 143, and each pair of second connecting copper bars 144 includes two second connecting copper bars 144. A busbar capacitor 141 receives the high-voltage direct current output by the power battery 3 through the two first connecting copper bars 143, and filters the high-voltage direct current received by the two first connecting copper bars 143 through an EMC filter assembly 142.

[0121] In an embodiment of the present application, a capacitor filter integrated module 140 is used to integrate a bus capacitor 141, an EMC filter component 142, a pair of first connecting copper bars 143 and three pairs of second connecting copper bars 144. A bus capacitor 141, an EMC filter component 142, a pair of first connecting copper bars 143 and three pairs of second connecting copper bars 144 are integrated into a capacitor filter integrated module 140, so that the capacitor filter integrated module 140 has filtering and voltage stabilization functions, and can also improve the integration of a capacitor filter integrated module 140, reduce the wiring harness and transfer copper bar layout in a capacitor filter integrated module 140, and is conducive to the miniaturized layout of the power supply device 10.

[0122] In an embodiment of the present application, a bus capacitor 141 receives the high-voltage direct current output by the power battery 3 through two first connecting copper bars 143, and filters the high-voltage direct current received by the two first connecting copper bars 143 through an EMC filter component 142. When the high-voltage direct current in the power battery 3 passes through a bus capacitor 141, the bus capacitor 141 can provide ripple current when the power supply device 10 drives the motor 30, reducing the bus current fluctuation of the entire vehicle, thereby reducing the bus voltage ripple of the entire vehicle. When the high-voltage direct current in the power battery 3 passes through an EMC filter component 142, the EMC filter component 142 can eliminate differential mode interference and common mode interference in the current signal and reduce harmonic interference in the current signal.

[0123] In one embodiment, the trough-shaped housing 110 is also used to secure a high-voltage connector 171. As shown in FIG6 , a high-voltage connector 171 includes a power battery connection terminal 171a and two high-voltage copper bridges 171b. The power battery connection terminal 171a is used to electrically connect to the power battery 3 via a power connection line. As shown in FIG7 , each first copper bridge 143 is stacked with a high-voltage copper bridge 171b. The two first copper bridges 143 are respectively used to directly and securely connect the two high-voltage copper bridges 171b and electrically connect the positive and negative electrodes of the power battery 3 via the two high-voltage copper bridges 171b.

[0124] In an embodiment of the present application, as shown in Figure 6, the high-voltage connector 171 is an independent component, and the high-voltage connector 171 includes a power battery connection terminal 171a and two high-voltage lap copper bars 171b. A high-voltage connector 171 is used to electrically connect the power battery 3 and a capacitor filter integrated module 140 of the motor controller 101. A high-voltage connector 171 includes a power battery connection terminal 171a and two high-voltage lap copper bars 171b, and a power battery connection terminal 171a is used to electrically connect the power battery 3 through a power connection line, and output the high-voltage direct current in the power battery 3 through the two high-voltage lap copper bars 171b to the two first connection copper bars 143 of a capacitor filter integrated module 140, thereby transmitting the high-voltage direct current to a capacitor filter integrated module 140 of the motor controller 101.

[0125] In the embodiment of the present application, each first connecting copper bar 143 is stacked with a high-voltage bonding copper bar 171b, which is beneficial for each first connecting copper bar 143 to fully contact and conduct power with a high-voltage bonding copper bar 171b. It is also beneficial for each first connecting copper bar 143 and a high-voltage bonding copper bar 171b to not occupy too much space of the power supply device 10 along the first direction Y, thereby facilitating the miniaturization of the power supply device 10.

[0126] In an embodiment of the present application, the two first connecting copper bars 143 are respectively used to directly and fixedly connect the two high-voltage lap copper bars 171b, so that the direct electrical connection between the power battery 3 and the power supply device 10 can be achieved only through the two high-voltage lap copper bars 171b of a high-voltage connector 171, avoiding the use of excessive cables and transfer copper bars when the power battery 3 is electrically connected to the motor controller 101, which is conducive to simplifying the wiring layout within the power supply device 10, simplifying the installation process, reducing the difficulty of assembly, and also helping to save materials and reduce production costs. The two first connecting copper bars 143 are electrically connected to the positive and negative poles of the power battery 3 through the two high-voltage lap copper bars 171b, making it easier for the power supply device 10 to realize the charging and discharging functions between the power battery 3 and the power battery 3.

[0127] In one embodiment, each first connecting copper bar 143 includes a transmission copper bar 1400, a first bonding copper bar 1410, and a second bonding copper bar 1420. As shown in FIG7 , the first bonding copper bar 1410 of each first connecting copper bar 143 is stacked with a high-voltage bonding copper bar 171b. Along the stacking direction Z of the first bonding copper bar 1410 and the high-voltage bonding copper bar 171b of each first connecting copper bar 143, each second bonding copper bar 1420 is stacked with a circuit board 111. The two second bonding copper bars 1420 are used to directly and fixedly connect to a circuit board 111 and receive high-voltage direct current output by the power conversion circuit through the circuit board 111.

[0128] In an embodiment of the present application, a circuit board 111 is used to fix multiple electrical components of the power conversion circuit in the vehicle charger 102. The power conversion circuit is used to convert the external power supply and output high-voltage direct current to charge the power battery 3. The external power supply can be an AC power supply. The vehicle charger 102 converts the high-voltage AC power into high-voltage direct current and then charges the power battery 3, thereby achieving not only the power battery 3 can discharge the power supply device 10, but the power supply device 10 can also charge the power battery 3.

[0129] In the embodiment of the present application, as shown in FIG9 , each first connecting copper busbar 143 includes a transmission copper busbar 1400, a first bonding copper busbar 1410, and a second bonding copper busbar 1420. A transmission copper busbar 1400 electrically connects a first bonding copper busbar 1410 to a bus capacitor 141 and an EMC filter assembly 142. Current sequentially passes through a first bonding copper busbar 1410, a transmission copper busbar 1400, an EMC filter assembly 142, and a bus capacitor 141. The second bonding copper busbar 1420 makes it possible to electrically connect the power battery 3 to the electrical components of the on-board charger 102, thereby promoting the deep integration of the electrical components within the power supply device 10 and improving the integration and fusion of the power supply device 10.

[0130] In the embodiment of the present application, along the stacking direction Z of the first bonding copper bar 1410 and a high-voltage bonding copper bar 171b of each first connecting copper bar 143, each second bonding copper bar 1420 is stacked with a circuit board 111. This facilitates greater contact area between each second bonding copper bar 1420 and a circuit board 111, facilitating electrical connection between each second bonding copper bar 1420 and a circuit board 111. The stacking of each second bonding copper bar 1420 and a circuit board 111 also helps reduce the space occupied by each second bonding copper bar 1420 and a circuit board 111 along the second direction X, facilitating the miniaturized arrangement of electrical components within the power supply device 10.

[0131] In the embodiment of the present application, the stacking direction Z of the first bonding copper bar 1410 and the one high-voltage bonding copper bar 171b along each first connecting copper bar 143 is parallel to the height direction of the power supply device and to the thickness direction of each circuit board 111, 112. In one embodiment, the first bonding copper bar 1410 and the high-voltage bonding copper bar 171b are flat copper bars, and the stacking direction Z of the first bonding copper bar 1410 and the one high-voltage bonding copper bar 171b along each first connecting copper bar 143 is parallel to the thickness direction of the first bonding copper bar 1410 and the high-voltage bonding copper bar 171b.

[0132] In the embodiment of the present application, two second bonding copper bars 1420 are used to directly and fixedly connect a circuit board 111 and receive the high-voltage direct current output by the power conversion circuit through a circuit board 111. Only two second bonding copper bars 1420 are used to realize the electrical connection between the electrical components of the vehicle charger 102 and the power battery 3, reducing the use of external wiring harnesses, copper bars, and adapters, simplifying the wiring layout within the power supply device 10, reducing the installation difficulty, and also reducing production costs.

[0133] In one embodiment, the first bonding copper bars 1410 of the two first connecting copper bars 143 are respectively used to directly and fixedly connect the two high-voltage bonding copper bars 171b and receive the high-voltage direct current output by the power battery 3 through the two high-voltage bonding copper bars 171b and a power battery connection terminal 171a.

[0134] As shown in FIG7 , in the embodiment of the present application, the first bonding copper bars 1410 of the two first connecting copper bars 143 are directly fixedly connected to the two high-voltage bonding copper bars 171b, which helps to reduce the connection harness and adapter copper bars between the capacitor filter integrated module 140 and the power battery 3, simplifies the wiring layout within the power supply device 10, and simplifies the assembly process. This facilitates the first bonding copper bars 1410 of the two first connecting copper bars 143 to directly receive the high-voltage direct current output by the power battery 3 from the two high-voltage bonding copper bars 171b and the one power battery connection terminal 171a.

[0135] In one embodiment, the trough-shaped housing 110 includes a trough bottom 160 and four sidewalls 113a, 113b, 113c, and 113d. The trough bottom 160 of the trough-shaped housing 110 includes a shielding protrusion 161. The shielding protrusion 161 is used to securely connect the trough bottom 160 of the trough-shaped housing 110 and two sidewalls 113a and 113b that are arranged opposite each other along the length direction Y of any high-voltage copper busbar 171b. As shown in Figures 3a and 3b, a shielding protrusion 161, a side wall 113c, and part of the side walls 113b and 113a between the shielding protrusion 161 and the side wall 113c enclose an electric control accommodating chamber 131, and a shielding protrusion 161, a side wall 113d, and part of the side walls 113b and 113a between the shielding protrusion 161 and the side wall 113d enclose an on-board charging accommodating chamber 132, wherein the electric control accommodating chamber 131 and the on-board charging accommodating chamber 132 are adjacently arranged along the second direction X, the electric control accommodating chamber 131 is used to accommodate a capacitor filter integrated module 140 and a three-phase power module 150 of the motor controller 101, and the on-board charging accommodating chamber 132 is used to accommodate electrical components of the on-board charger 102, the power distribution module 105, the vehicle controller 103, and the DCDC converter 104.

[0136] In the embodiment of the present application, the bottom 160 of the trough-shaped housing 110 includes a shielding protrusion 161. The shielding protrusion 161 can be continuous or intermittent along the second direction Y, both of which can shield electrical signals. In the embodiment of the present application, the shielding protrusion 161 is connected to the bottom 160 of the trough-shaped housing 110 and also serves to increase the strength of the trough-shaped housing 110 of the power supply device 10, thereby improving the structural stability of the power supply device 10. The second direction Y is parallel to the length direction Y of any high-voltage copper busbar 171b.

[0137] In the embodiment of the present application, the electronic control housing chamber 131 provides space for mounting and fixing a capacitor filter integrated module 140 and a three-phase power module 150 of the motor controller 101, and the on-board charging housing chamber 132 provides space for mounting and fixing the electrical components of the on-board charger 102. The electronic control housing chamber 131 and the on-board charging housing chamber 132 in the trough-shaped housing 110 are arranged adjacent to each other along the second direction X, thereby reducing the space occupied by the power supply device 10 along the first direction Y and the third direction Z. The trough-shaped housing 110 is also divided into two large housing and installation areas, which facilitates the regular arrangement of the electrical components within the power supply device 10 and reduces electrical interference between the electrical components.

[0138] In one embodiment, one circuit board 111 is housed in the onboard charging cavity 132, and another circuit board 112 is housed in the electrical control cavity 131. The other circuit board 112 securely connects a capacitor filter integrated module 140 and a three-phase power module 150 in the motor controller 101. As shown in FIG3a , one circuit board 111 and the other circuit board 112 are arranged adjacent to each other in a first direction Y, facilitating the regular arrangement of the electrical components of the motor controller 101 and the onboard charger 102 within the power supply device 10 along the first direction Y.

[0139] In one embodiment, the electrical components of the onboard charger 102 further include another EMC filter assembly 180, which is used to filter the high-voltage direct current output or received by the onboard charger 102. As shown in Figures 3a and 3b, along the stacking direction Z of the first bonding copper bus 1410 of each first connecting copper bus 143 and a high-voltage bonding copper bus 171b, a circuit board 111, a filter capacitor 181 of another EMC filter assembly 180, and the slot bottom 160 of the slot-shaped housing 110 are stacked in sequence.

[0140] In an embodiment of the present application, another EMC filter component 180 includes multiple filter capacitors 181. Another EMC filter component 180 is used to filter the high-voltage direct current output or received by the on-board charger 102. That is, when the power battery 3 discharges the on-board charger 102, the other EMC filter component 180 can filter the high-voltage direct current in the power battery 3 and transmit it to the electrical components of the on-board charger 102. When the on-board charger 102 charges the power battery 3, the other EMC filter component 180 can also filter the high-voltage direct current in the on-board charger 102 and transmit it to the power battery 3, which helps to reduce signal interference during the current transmission process.

[0141] In an embodiment of the present application, the bottom 160 of the trough-shaped housing 110 is used to fix the filter capacitor 181 of another EMC filter assembly 180, and a circuit board 111 is electrically connected to the filter capacitor 181 of the other EMC filter assembly 180. Along the stacking direction Z of the first lap copper bar 1410 of each first connecting copper bar 143 and a high-voltage lap copper bar 171b, a circuit board 111, the filter capacitor 181 of another EMC filter assembly 180, and the bottom 160 of the trough-shaped housing 110 are stacked in sequence, and the filter capacitor 181 of another EMC filter assembly 180 is arranged below a circuit board 111 along the third direction Z (as shown in FIG3b ), making full use of the space within the power supply device 10 and facilitating the miniaturization of the power supply device 10. It should be noted that the stacking direction Z of the first lap copper bar 1410 of each first connecting copper bar 143 and a high-voltage lap copper bar 171b is in the same direction as the third direction Z.

[0142] As shown in FIG. 3 b , in one embodiment, multiple filter capacitors 181 of another EMC filter assembly 180 are directly soldered to a circuit board 111 , which helps to simplify the cable arrangement in the power supply device 10 and reduce assembly difficulty.

[0143] In one embodiment, the power supply device 10 further includes a third filter assembly 190. As shown in FIG3a , a capacitor filter integrated module 140, a three-phase power module 150, and a third filter assembly 190 are sequentially arranged along a first direction Y. In this embodiment of the present application, the third filter assembly 190 is used to isolate and eliminate common-mode interference in the high-voltage alternating current transmitted by the three-phase power module 150, thereby facilitating the three-phase power module 150 to transmit accurate current signals to the three-phase windings of the motor 30, thereby driving the motor 30.

[0144] In one embodiment, the two high-voltage copper busbars 171b are also used to house a filter magnetic ring 182 of another EMC filter assembly 180. As shown in FIG3b , along the length direction Y of any high-voltage copper busbar 171b, a filter magnetic ring 182 is arranged between the housing 145 of a capacitor filter integrated module 140 and a side wall 113a of the slot-shaped housing 110.

[0145] In the embodiment of the present application, a filter magnetic ring 182 of another EMC filter component 180 is sleeved on two high-voltage strapping copper bars 171b, which is convenient for filtering the current passing through the two high-voltage strapping copper bars 171b. It is also beneficial to improve the integration of a filter magnetic ring 182 of another EMC filter component 180 with other electrical components in the power supply device 10, and it is also convenient to not occupy too much space outside the slot-shaped shell 110 of the power supply device 10, thereby facilitating the miniaturization of the power supply device 10.

[0146] In the embodiment of the present application, along the length direction Y of any high-voltage lap copper bar 171b, a filter magnetic ring 182 is arranged between the housing 145 of a capacitor filter integrated module 140 and a side wall 113a of the slot-shaped housing 110, providing installation space for a filter magnetic ring 182 of another EMC filter assembly 180, thereby facilitating the improvement of the integration of a filter magnetic ring 182 of another EMC filter assembly 180 with other electrical components in the power supply device 10, and also facilitating the miniaturization of the power supply device 10 by not occupying too much space outside the slot-shaped housing 110 of the power supply device 10. Arranging a filter magnetic ring 182 outside the housing 145 of a capacitor filter integrated module 140 is also beneficial for reducing electrical interference between a filter magnetic ring 182 and a capacitor filter integrated module 140, thereby improving the electromagnetic compatibility of the power supply device 10.

[0147] It should be noted that the length direction Y of any high-voltage copper busbar 171 b is in the same direction as the first direction Y.

[0148] In an embodiment of the present application, when the current in the power battery 3 is transmitted into the power supply device 10 through a high-voltage connector 171, a filter magnetic ring 182 of another EMC filter component 180 eliminates harmonic interference in the current signal, and then transmits the current with reduced interference to a capacitor filter integrated module 140 through the first overlapping copper bus 1410 of the first connecting copper bus 143. An EMC filter component 142 in a capacitor filter integrated module 140 further eliminates the interference signal of the current, facilitating the transmission of accurate current to the three-phase power module, so that the high-voltage direct current received by the three-phase power module is filtered twice, thereby improving the stability of the drive motor operation. Alternatively, the current from which harmonic interference signals are eliminated by a filter magnetic ring 182 of another EMC filter component 180 is transmitted to a circuit board 111 through the second overlapping copper bar 1420 of the first connecting copper bar 143, and the interference signal of the current is further eliminated by the filter capacitor 181 of another EMC filter component 180 in the circuit board 111, thereby facilitating the transmission of accurate current signals to the electrical components of the on-board charger 102, which is beneficial for improving the electromagnetic compatibility of the power supply device 10. Alternatively, the current signals of the electrical components of the on-board charger 102 are filtered by the filter capacitor 181 of another EMC filter component 180, and then transmitted to the second overlapping copper bar 1420 and the first overlapping copper bar 1410 of the first connecting copper bar 143 through a circuit board 111, filtered by a filter magnetic ring 182 of another EMC filter component 180, and transmitted to a high-voltage connector 171, thereby charging the power battery 3, thereby facilitating the transmission of accurate current signals to the power battery 3, and improving the electromagnetic compatibility of the power supply device 10.

[0149] In one embodiment, the bottom 160 of the trough-shaped housing 110 is used to secure a filter capacitor 181 of another EMC filter assembly 180 and a capacitor filter integrated module 140. As shown in FIG3 a , along the arrangement direction X of the two high-voltage copper busbars 171 b , a filter magnetic ring 182 and a capacitor filter integrated module 140 are arranged on one side of a shielding protrusion 161 , while the filter capacitor 181 of the other EMC filter assembly 180 is arranged on the other side of the shielding protrusion 161 .

[0150] In an embodiment of the present application, the bottom 160 of the trough-shaped shell 110 is used to fix the filter capacitor 181 of another EMC filter component 180 and a capacitor filter integrated module 140. The trough-shaped shell 110 also provides support for the filter capacitor 181 of another EMC filter component 180 and a capacitor filter integrated module 140, thereby improving the stability of the power supply device 10.

[0151] In the embodiment of the present application, a shielding protrusion 161 is used to fix the groove bottom 160 of the groove-shaped shell 110 and the two side walls 113a and 113b arranged oppositely along the length direction Y of any high-voltage lap copper bus 171b. A shielding protrusion 161 divides the space inside the groove-shaped shell 110 into two installation areas. The shielding protrusion 161 separates the motor controller 101 and the vehicle charger 102. The shielding protrusion 161 has the function of isolating the electrical components of the motor controller 101 from the electrical components of the vehicle charger 102 from electrical interference.

[0152] In an embodiment of the present application, along the arrangement direction X of the two high-voltage overlapping copper bars 171b, a filter magnetic ring 182 and a capacitor filter integrated module 140 are arranged on one side of a shielding protrusion 161, and the filter capacitor 181 of another EMC filter component 180 is arranged on the other side of a shielding protrusion 161, that is, a filter magnetic ring 182, a capacitor filter integrated module 140 and a filter capacitor 181 of another EMC filter component 180 are electrically isolated, which is beneficial for filtering a filter magnetic ring 182 and a capacitor filter integrated module 140 and a filter capacitor 181 of another EMC filter component 180 separately, which is beneficial for improving the electromagnetic compatibility within the power supply device 10.

[0153] It should be noted that the arrangement direction X of the two high-voltage copper busbars 171 b is the same as the second direction X.

[0154] In one embodiment, a capacitor filter integrated module 140 is further used to integrate three pairs of second connection copper bars 144 (as shown in FIG8 ). The electrical components of the motor controller 101 also include a three-phase power module 150 (as shown in FIG3 a ). A three-phase power module 150 is used to electrically connect the three pairs of second connection copper bars 144. A three-phase power module 150 is used to convert the high-voltage direct current received by a bus capacitor 141 into three-phase alternating current. As shown in FIG3 a , along the length direction Y of any high-voltage lap copper bar 171 b, two first connection copper bars 143 and three pairs of second connection copper bars 144 are spaced apart on both sides of the housing 145 of a capacitor filter integrated module 140. A filter magnetic ring 182, a capacitor filter integrated module 140, and a three-phase power module 150 are sequentially arranged at the bottom 160 of the slot-shaped housing 110. Along the arrangement direction X of the two high-voltage copper busbars 171 b , a three-phase power module 150 , a filter magnetic ring 182 and a capacitor filter integrated module 140 are arranged on the same side of a shielding protrusion 161 .

[0155] In the embodiment of the present application, a capacitor filter integrated module 140 is also used to integrate three pairs of second connecting copper bars 144, thereby improving the integration level of the capacitor filter integrated module 140. The electrical components of the motor controller 101 also include a three-phase power module 150. The three pairs of second connecting copper bars 144 are used to transmit the current in the capacitor filter integrated module 140 to the three-phase power module 150. The three-phase power module 150 converts the high-voltage direct current from a bus capacitor 141 into three-phase alternating current, which is then transmitted to the three-phase winding of the motor 30 to drive the motor 30.

[0156] In the embodiment of the present application, along the length direction Y of any high-voltage lap copper busbar 171b, two first connecting copper buses 143 and three pairs of second connecting copper buses 144 are arranged at intervals on both sides of the shell 145 of a capacitor filter integrated module 140. The electrical components in the shell 145 of a capacitor filter integrated module 140 are electrically connected to the power battery 3 and the three-phase power module 150 respectively through the two first connecting copper buses 143 and the three pairs of second connecting copper buses 144, thereby improving the integration of the power supply device 10. Along the length direction Y of any high-voltage lap copper bar 171b, two first connecting copper bars 143 and three pairs of second connecting copper bars 144 are arranged at intervals on both sides of the shell 145 of a capacitor filter integrated module 140, which is conducive to the two first connecting copper bars 143 and the three pairs of second connecting copper bars 144 working independently, reducing electrical interference between the two. In addition, it is also beneficial for the current in the power battery 3 to be transmitted along the power flow in the first direction Y to the winding of the motor 30, driving the motor 30, which is conducive to reducing power loss and improving the overall performance of the power supply device 10.

[0157] In the embodiment of the present application, the bottom 160 of the groove-shaped housing 110 provides a fixed installation space for a filter magnetic ring 182, a capacitor filter integrated module 140 and a three-phase power module 150, and also provides support for a filter magnetic ring 182, a capacitor filter integrated module 140 and a three-phase power module 150. Along the length direction Y of any high-voltage lap copper bus 171b, a filter magnetic ring 182, a capacitor filter integrated module 140 and a three-phase power module 150 are arranged in sequence at the bottom 160 of the groove-shaped housing 110, which is conducive to the regular arrangement of electrical components in the power supply device 10, and is also conducive to the current passing through a filter magnetic ring 182, a capacitor filter integrated module 140 and a three-phase power module 150 in sequence, filtering and current conversion in sequence, and transmitting the power flow along the first direction Y to the motor 30 winding to drive the motor 30, which is conducive to reducing power loss and improving the overall performance of the power supply device 10.

[0158] In one embodiment, the trough-shaped housing 110 includes a first mounting hole 114a, which is used to secure a high-voltage connector 171. As shown in FIG3b , along the length direction Y of any high-voltage copper busbar 171b, the first mounting hole 114a extends through a side wall 113a of the trough-shaped housing 110. As shown in FIG7 , the distance between the first mounting hole 114a and the capacitor core 141a of a busbar capacitor 141 is greater than the length of any high-voltage copper busbar 171b.

[0159] In the embodiment of the present application, along the length direction Y of any high-voltage lap copper busbar 171b, a first mounting hole 114a passes through a side wall 113a of the trough-shaped shell 110, so that a high-voltage connector 171 can be installed in a first mounting hole 114a along the first direction Y, which is beneficial to reducing the space occupied by a high-voltage connector 171 on the power supply device 10 along the second direction X.

[0160] As shown in Figure 7, in an embodiment of the present application, along the length direction Y of any high-voltage strapping copper busbar 171b, the distance between a first mounting hole 114a and the capacitor core 141a of a bus capacitor 141 is recorded as L1, and the length of any high-voltage strapping copper busbar 171b is recorded as L2, L1>L2, which provides sufficient installation space for two high-voltage strapping copper buses 171b of a high-voltage connector 171 and the first strapping copper busbar 1410 of two first connecting copper buses 143 of a capacitor filtering integrated module 140.

[0161] As shown in Figures 7 and 9, in one embodiment, along the first direction Y, the distance between a first mounting hole 114a and the capacitor core 141a of a bus capacitor 141 is greater than the length of any high-voltage strapping copper busbar 171b, and the distance between a first mounting hole 114a and the capacitor core 141a of a bus capacitor 141 is less than the sum of the lengths of a first strapping copper busbar 1410, a transmission copper busbar 1400, and any high-voltage strapping copper busbar 171b.

[0162] In an embodiment of the present application, the distance between a first mounting hole 114a and the capacitor core 141a of a bus capacitor 141 is greater than the length of any high-voltage strapping copper busbar 171b, so that the capacitor core 141a of a bus capacitor 141 is electrically connected to a high-voltage strapping copper busbar 171b through a transmission copper busbar 1400 and a first strapping copper busbar 1410. The distance between a first mounting hole 114a and the capacitor core 141a of a bus capacitor 141 is less than the sum of the lengths of a first bridging copper busbar 1410, a transmission copper busbar 1400, and any high-voltage bridging copper busbar 171b, that is, the copper busbar circuit portion formed as a whole along the first direction Y by a first bridging copper busbar 1410, a transmission copper busbar 1400, and any high-voltage bridging copper busbar 171b is inserted into the capacitor core 141a of a bus capacitor 141 of a capacitor filter integrated module 140, thereby realizing the electrical connection between the power battery 3 and the bus capacitor 141, facilitating the reduction of the use of additional transfer copper buses or cables, and helping to improve the integration of a capacitor filter integrated module 140, thereby improving the integration of the power supply device 10. Alternatively, a first lap copper bus 1410 and a high-voltage lap copper bus 171b are overlapped along the third direction Z so that the distance between the capacitor filter integrated module 140 and a first mounting hole 114a of the slot-shaped shell 110 is closer, making the component arrangement more compact, which is conducive to the miniaturization of the power supply device 10.

[0163] In one embodiment, the trough-shaped housing 110 further includes a second mounting hole 114b, which is used to secure a winding connector 172. The winding connector 172 is used to electrically connect a three-phase power module 150 of the motor controller 101 to a three-phase winding of the motor 30. As shown in FIG3a , a second mounting hole 114b extends through the bottom 160 of the trough-shaped housing 110 along the stacking direction Z between each first connecting copper bar 143 and a high-voltage bridging copper bar 171b.

[0164] In an embodiment of the present application, a second mounting hole 114b provides space for the installation and fixation of a winding connector 172. A winding connector 172 is used to connect a three-phase power module 150 and the three-phase winding of the motor 30. A winding connector 172 transmits the high-voltage alternating current converted by the three-phase power module 150 to the three-phase winding of the motor 30 through a winding connector 172 to drive the motor 30.

[0165] In the embodiment of the present application, along the stacking direction Z of each first connecting copper bar 143 and a high-voltage bridging copper bar 171b, that is, along the stacking direction Z of the first bridging copper bar 1410 of each first connecting copper bar 143 and a high-voltage bridging copper bar 171b, a second mounting hole 114b penetrates the slot bottom 160 of the slot-shaped housing 110, facilitating the arrangement of a winding connector 172 in the second mounting hole 114b along the third direction Z. This facilitates the winding connector 172 to conduct current to the three-phase winding of the motor 30 via a shorter path. In addition, the second mounting hole 114b penetrating the slot bottom 160 along the third direction Z facilitates the arrangement of the winding connector 172 in the slot-shaped housing 110 along the third direction Z. It also facilitates the winding connector 172 not occupying excessive space in the power supply device 10 along the first direction Y and the second direction X, thereby facilitating the miniaturization of the power assembly 4.

[0166] It should be noted that the stacking direction Z of each first connecting copper bar 143 and a high-voltage bridging copper bar 171 b is the same as the third direction Z.

[0167] As shown in FIG3b , in one embodiment, along the length direction Y of any high-voltage copper busbar 171b , a second mounting hole 114b penetrates the other side wall 113b of the trough-shaped housing 110 , and one side wall 113a is arranged opposite to the other side wall 113b .

[0168] In the embodiment of the present application, a second mounting hole 114b passes through another side wall 113b of the trough-shaped housing 110, facilitating the arrangement of a winding connector 172 in the trough-shaped housing 110 along the first direction Y. This facilitates the arrangement of the winding connector 172 within the trough-shaped housing 110 without excessively occupying space on the power supply device 10 along the second direction X and the third direction Z, thereby facilitating the miniaturization of the power assembly 4. Along the length direction Y of any high-voltage lap copper busbar 171b, one side wall 113a is arranged opposite the other side wall 113b, facilitating the arrangement of a first mounting hole 114a on one side wall 113a opposite a second mounting hole 114b on the other side wall 113b, thereby facilitating the regular arrangement of the mounting holes on the trough-shaped housing 110.

[0169] In an embodiment of the present application, along the length direction Y of any high-voltage lap copper busbar 171b, a second mounting hole 114b penetrates the other side wall 113b of the trough-shaped shell 110, which is conducive to a winding connector 172 transmitting the high-voltage alternating current converted by the three-phase power module 150 to the three-phase winding of a motor 30 along the power flow through a winding connector 172, driving the motor 30, which is conducive to reducing power loss and improving the overall performance of the power supply device 10.

[0170] In one embodiment, the all-in-one power supply device 10 further includes a high-voltage power supply module 105 and an on-board charger 102, wherein the high-voltage power supply module 105 is used to power at least one of the compressor or the heater. As shown in FIG3a , the trough-shaped housing 110 further includes a third mounting hole 114c and a fourth mounting hole 114d. Among them, a third mounting hole 114c is used to fix a high-voltage power supply connector 173, and a high-voltage power supply connector 173 is used to electrically connect at least one of the compressor or the heater and a high-voltage power supply module 105. As shown in FIG4 , a fourth mounting hole 114d is used to fix an AC input connector 174, and an AC input connector 174 is used to electrically connect the on-board charger 102 and an external power supply. As shown in FIG3a , along the length direction Y of any high-voltage bonding copper busbar 171b, a third mounting hole 114c and a fourth mounting hole 114d respectively penetrate a side wall 113a. Along the arrangement direction X of the two high-voltage copper busbars 171 b , a first mounting hole 114 a , a third mounting hole 114 c , and a fourth mounting hole 114 d are sequentially arranged at intervals on a side wall 113 a .

[0171] In this embodiment of the present application, a high-voltage power supply connector 173 is used to connect to the compressor, so that the power supply device 10 is electrically connected to the compressor to power the compressor. A high-voltage power supply connector 173 is used to connect to the heater to power the heater. An AC input connector 174 is used to electrically connect the on-board charger 102 and an external power source, transmitting the AC power from the external power source to the on-board charger 102 of the power supply device 10 through the AC input connector 174, and then charging the power battery 3.

[0172] In the embodiment of the present application, a high-voltage power supply module 105 includes multiple copper busbars, and the high-voltage power supply module 105 can also be called a power distribution module.

[0173] In the embodiment of the present application, a third mounting hole 114c passes through the groove-shaped housing 110 along the first direction Y, facilitating the installation and fixation of a high-voltage power supply connector 173 to the third mounting hole 114c along the first direction Y. A fourth mounting hole 114d passes through the groove-shaped housing 110 along the first direction Y, facilitating the installation and fixation of an AC input connector 174 to the fourth mounting hole 114d along the first direction Y. This eliminates the need to arrange excessive cables when connecting an AC input connector 174 connected to the AC power source and a high-voltage power supply connector 173 connected to the compressor and heater to the electrical components within the power supply device 10, thereby simplifying the connection lines between the power supply device 10 and the AC power source and the compressor and heater, and making the wiring of the electric vehicle 1 simpler.

[0174] In the embodiment of the present application, the power supply device 10 integrates the functions of charging and discharging the power battery 3, driving the motor 30, and supplying power to the compressor and heater. A high-voltage connector 171, an AC input connector 174, and a high-voltage power supply connector 173 for connecting the power battery 3, the AC power supply, and the compressor are respectively fixed to a first mounting hole 114a, a third mounting hole 114c, and a fourth mounting hole 114d of the grooved housing 110 of the power supply device 10, making the power supply device 10 more integrated. A fourth mounting hole 114d, a third mounting hole 114c and a first mounting hole 114a are arranged on the same side, so that the openings on the groove-shaped shell 110 are regular, and it is also convenient for an AC input connector 174, a high-voltage power supply connector 173 and a high-voltage connector 171 to be arranged regularly in the power supply device 10. It can also make the power supply device 10 more integrated, which is beneficial to reducing the space occupied by the power supply device 10 along the second direction X, so that the other side surfaces of the groove-shaped shell 110 can be used to install other connectors or electrical components, which is beneficial to the miniaturization and diversification of the power supply device 10 and the powertrain 4. It can also enable the high-voltage direct current transmitted by the high-voltage connector 171 to be transmitted to the high-voltage power supply connector 173 via a shorter path, thereby reducing transmission loss.

[0175] In the embodiment of the present application, a first mounting hole 114a, a third mounting hole 114c and a fourth mounting hole 114d are arranged in sequence on a side wall 113a along the arrangement direction X of the two high-voltage overlapping copper bars 171b, so that a high-voltage connector 171 is separated from an AC input connector 174, thereby avoiding electrical interference between high-voltage direct current and alternating current, and improving the charging and discharging safety performance of the power supply device 10.

[0176] In one embodiment, the all-in-one power supply device 10 also includes a low-voltage power supply module 106, as shown in Figure 3a. The low-voltage power supply module 106 is used to power a low-voltage load on a vehicle (not shown). The output voltage of the low-voltage power supply module 106 is less than the output voltage of the power battery 3. The grooved housing 110 also includes a fifth mounting hole 114e. As shown in Figure 4, along the length direction Y of any high-voltage lap copper busbar 171b, a fifth mounting hole 114e passes through another side wall 113b, and the other side wall 113b is arranged opposite to a side wall 113a. A fifth mounting hole 114e is used to fix a low-voltage power supply connector 175, and a low-voltage power supply connector 175 is used to electrically connect a low-voltage power supply module 106 to a low-voltage load on a vehicle.

[0177] In this embodiment of the present application, a fifth mounting hole 114e is used to secure a low-voltage power connector 175. Low-voltage power connector 175 is used to electrically connect a low-voltage power supply module 106 to an onboard low-voltage load. Low-voltage power supply module 106 includes a DC-DC converter 104, which converts high-voltage DC power to low-voltage DC power. DCDC converter 104 includes at least one of a capacitor, an inductor, and a power switch. Low-voltage power connector 175 is used to transmit the low-voltage DC power from low-voltage power supply module 106 to an onboard low-voltage load, thereby powering the onboard low-voltage load.

[0178] In the embodiment of the present application, along the length direction Y of any high-voltage copper busbar 171b, a fifth mounting hole 114e penetrates the other side wall 113b, facilitating the installation and fixation of a low-voltage power connector 175 to the trough-shaped housing 110 along the first direction Y, thereby reducing the space occupied by the low-voltage power connector 175 in the trough-shaped housing 110 along the second direction X and the third direction Z. Along the length direction Y of any high-voltage copper busbar 171b, the other side wall 113b is arranged opposite the one side wall 113a, so that the fifth mounting hole 114e and the first mounting hole 114a are arranged opposite each other. This facilitates the regular arrangement of the low-voltage power connector 175 and the high-voltage connector 171 in the power supply device 10. Furthermore, it facilitates the current output from the power battery 3 to the power supply device 10 via the high-voltage connector 171, and is output from a low-voltage power supply module 106 of the power supply device 10 to an on-vehicle low-voltage load along the first direction Y, ensuring that the entire power flow path flows along the first direction Y, making the power flow path smoother and reducing losses.

[0179] In one embodiment, the all-in-one power supply device 10 further includes a cover plate 170 and a vehicle controller 103 (as shown in FIG3 a). As shown in FIG5 , the cover plate 170 is used to cooperate with the trough-shaped housing 110 to form a receiving space 130. The bottom 160 of the trough-shaped housing 110 includes a sixth mounting hole 114f. As shown in FIG4 , along the stacking direction Z of a portion 1431 of each first connecting copper busbar 143 and a high-voltage lap copper busbar 171b, a sixth mounting hole 114f passes through the bottom 160 of the trough-shaped housing 110. The sixth mounting hole 114f is used to fix a signal connector 176. The vehicle controller 103 is used to receive external control signals through a signal connector 176 and to control the motor controller 101 through a signal connection line accommodated in a receiving space 130.

[0180] In an embodiment of the present application, a cover plate 170 is used to cover the trough-shaped shell 110, and cooperates with the trough-shaped shell 110 to form a accommodating space 130. The accommodating space 130 provides installation space for the motor controller 101, the vehicle charger 102, a high-voltage power supply module 105, a low-voltage power supply module 106 and a vehicle controller 103.

[0181] In the embodiment of the present application, a sixth mounting hole 114f passes through the bottom 160 of the groove of the groove-shaped housing 110 (as shown in FIG4 ), facilitating connection of a signal connector 176 to a vehicle controller 103 along the third direction Z, which is beneficial for the signal connector 176 not to occupy too much space of the power supply device 10 in the third direction Z and the second direction X. A vehicle controller 103 is used to receive external control signals through a signal connector 176 and to control the motor controller 101 through a signal connection line accommodated in a receiving space 130, facilitating adjustment and control of the motor controller 101 by the vehicle controller 103. A vehicle controller 103 is located outside the groove-shaped housing 110, which is beneficial for the electrical components in the groove-shaped housing 110 and the vehicle controller 103 to operate normally and relatively independently, thereby reducing electrical interference.

[0182] In one embodiment, a cover plate 170 includes a sixth mounting hole 114f (not shown), which extends through the cover plate 170 along the stacking direction Z between a portion 1431 of each first connecting copper busbar 143 and a high-voltage lap copper busbar 171b. The sixth mounting hole 114f is used to secure a signal connector 176. A vehicle controller 103 is used to receive external control signals via the signal connector 176 and to control the motor controller 101 via a signal connection line housed in a receiving space 130. In this embodiment of the present application, when the signal connector 176 needs to exit from the top of the power supply device 10, the sixth mounting hole 114f can be provided in the cover plate 170.

[0183] The capacitor filter integrated module 140 provided in the embodiment of the present application is described in detail below in conjunction with Figures 8, 9, and 10 to 14. Figure 10 is an exploded view of the capacitor filter integrated module 140 provided in the embodiment of the present application, Figure 11 is another structural schematic diagram of the capacitor filter integrated module 140 provided in the embodiment of the present application, Figure 12 is a partial enlarged view of the M2 portion in Figure 9, Figure 13 is another structural schematic diagram of the capacitor filter integrated module 140 provided in the embodiment of the present application, and Figure 14 is another structural schematic diagram of the capacitor filter integrated module 140 provided in the embodiment of the present application.

[0184] In one embodiment, the housing 145 of the capacitor filter integrated module 140 includes a receiving slot 146, as shown in Figures 8 and 10. The receiving slot 146 is used to accommodate the capacitor core 141a of the bus capacitor 141 and the electrical components of an EMC filter assembly 142. As shown in Figure 9, a pair of first connecting copper bars 143 are used to receive high-voltage direct current. A portion 1431 of each first connecting copper bar 143 is embedded in the housing 145 and electrically connected to at least one of the capacitor core 141a of the bus capacitor 141 or the electrical components of an EMC filter assembly 142. The other portion 1432 of each first connecting copper bar 143 is exposed on a side 145a of the housing 145. Each pair of second connecting copper bars 144 is used to output high-voltage direct current after filtering and voltage stabilization. A portion 1441 of each second connecting copper bar 144 is used to be embedded in the shell 145 and to electrically connect to the capacitor core 141a of the bus capacitor 141 or at least one of the electrical components of an EMC filter assembly 142. The other portion 1442 of each second connecting copper bar 144 is used to be exposed on the other side 145b of the shell 145. The one side 145a and the other side 145b of the shell 145 are arranged relative to each other along the first direction Y.

[0185] In an embodiment of the present application, the shell 145 of the capacitor filter integrated module 140 includes a receiving groove 146, which is used to accommodate the capacitor core 141a of the bus capacitor 141 and the electrical components of an EMC filter component 142. It is also beneficial to electrically isolate the capacitor core 141a of the bus capacitor 141 and the electrical components of an EMC filter component 142 in the receiving groove 146 from other electrical components outside the receiving groove 146, reduce electrical interference, and facilitate the normal operation of the capacitor core 141a of the bus capacitor 141 and the electrical components of an EMC filter component 142.

[0186] In the embodiment of the present application, the bus capacitor 141 and an EMC filter component 142 are integrated into the receiving groove 146 of the capacitor filter integrated module 140, which is conducive to fully utilizing the space within the receiving groove 146 of the capacitor filter integrated module 140, improving the integration and space utilization of the capacitor filter integrated module 140, and is conducive to miniaturization of the power supply device 10. It can also simplify the circuit, reduce the difficulty of assembly, and reduce production costs. If a separate DC bus capacitor module and a separate electromagnetic compatibility filter and EMC filter module are used in the power supply device 10, it is easy to cause more electrical components in the power supply device 10, reduce space utilization, and make the assembly of the whole machine complicated, which does not conform to the development trend of miniaturization and low cost of the power supply device 10.

[0187] In an embodiment of the present application, a pair of first connecting copper bars 143 are used to receive high-voltage direct current, and a portion 1431 of each first connecting copper bar 143 is used to be embedded in a housing 145 and to be electrically connected to at least one of the capacitor core 141a of the bus capacitor 141 or an electrical component of an EMC filter assembly 142, and another portion 1432 of each first connecting copper bar 143 is used to be exposed to a side 145a of the housing 145, so that a portion 1431 of each first connecting copper bar 143 can be integrated into the receiving groove 146 of the capacitor filter integrated module 140, while the other portion 1432 can be connected to the power battery 3, which is beneficial to improving the integration of the capacitor filter integrated module 140 and also beneficial to reducing the copper bars required for the electrical connection between the capacitor filter integrated module 140 and the power battery 3.

[0188] In an embodiment of the present application, each pair of second connecting copper bars 144 is used to output high-voltage direct current after filtering and voltage stabilization, and a portion 1441 of each second connecting copper bar 144 is used to be embedded in the housing 145 and to be electrically connected to the capacitor core 141a of the bus capacitor 141 or at least one of the electrical components of an EMC filter assembly 142, and another portion 1442 of each second connecting copper bar 144 is used to be exposed on the other side 145b of the housing 145, so that a portion 1441 of each second connecting copper bar 144 can be integrated into the receiving groove 146 of the capacitor filter integrated module 140, while the other portion 1442 can be electrically connected to the three-phase power module 150, thereby facilitating the transmission of the high-voltage direct current in the capacitor filter integrated module 140 to the three-phase power module 150 for conversion. One side 145a and the other side 145b of the shell 145 are arranged relative to each other along the first direction Y, so that a pair of first connecting copper bars 143 and three pairs of second connecting copper bars 144 are arranged regularly in the capacitor filter integrated module 140 and work relatively independently of each other, which is conducive to reducing electrical interference.

[0189] In the embodiment of the present application, the housing 145 of the capacitor filter integrated module 140 integrates a bus capacitor 141, an EMC filter component 142, a first connecting copper bar 143 for electrically connecting the capacitor core 141a of the bus capacitor 141 or a portion 1431 of at least one of the electrical components of the EMC filter component 142, and a second connecting copper bar 144 for being embedded in the housing 145 and for electrically connecting the capacitor core 141a of the bus capacitor 141 or a portion 1441 of at least one of the electrical components of the EMC filter component 142. These four parts are fixedly integrated into the housing 145 of the capacitor filter integrated module 140 without the need for additional cables or copper bars for connection, which is conducive to improving the integration of the capacitor filter integrated module 140. Exemplarily, the bus capacitor 141, an EMC filter component 142, a portion 1431 of the first connecting copper bar 143, and a portion 1441 of the second connecting copper bar 144 can be welded or screwed to the interior of the housing 145 of the capacitor filter integrated module 140.

[0190] As shown in Figures 8 and 9, in one embodiment, the other portions 1442 of the six second connecting copper bars 144 are spaced apart along the second direction X on the other side 145b of the housing 145. The housing 145 includes a first side wall 145c and a second side wall 145d arranged opposite each other along the second direction X. The busbar capacitor 141 includes two groups of capacitor cores 1412 and 1413, each group of capacitor cores 1412 and 1413 including at least one capacitor core 141a. In the first direction Y, the length of one group of capacitor cores 1413 is greater than the length of the other group of capacitor cores 1412. Along the second direction X, one group of capacitor cores 1413 and the other group of capacitor cores 1412 are sequentially arranged between the first side wall 145c and the second side wall 145d. The space between one group of capacitor cores 1413 and the second side wall 145d is used to accommodate electrical components of an EMC filter assembly 142 and portions 1431 of two first connecting copper bars 143.

[0191] In the embodiment of the present application, the capacitor filter integrated module 140 includes three pairs of second connecting copper bars 144, a pair of second connecting copper bars 144 includes two second connecting copper bars 144, and the other parts 1442 of the six second connecting copper bars 144 are arranged at intervals on the other side 145b of the shell 145 along the second direction X, which is beneficial for each second connecting copper bar 144 to be free from electrical interference from other second connecting copper bars 144, and is beneficial for electrical connection with the three-phase power module on the other side 145b of the shell 145.

[0192] In the embodiment of the present application, the housing 145 includes a first side wall 145c and a second side wall 145d that are arranged opposite each other along the second direction X. This facilitates electrical isolation of the electrical components within the housing 145 of the capacitor filter integrated module 140 from other electrical components within the power supply device 10 along the second direction X, thereby reducing electrical interference from other electrical components on the electrical components within the housing 145 of the capacitor filter integrated module 140. The first side wall 145c and the second side wall 145d can also provide support for the housing 145, thereby facilitating the stability of the housing 145.

[0193] In an embodiment of the present application, the bus capacitor 141 includes two groups of capacitor cores 1412 and 1413. Each group of capacitor cores 1412 and 1413 includes at least one capacitor core 141a. The capacitor core 141a can convert the current input by the power battery 3 into ripple current, reduce the bus current fluctuation of the entire vehicle, thereby reducing the bus voltage ripple of the entire vehicle and smoothing the voltage.

[0194] As shown in Figure 9, in an embodiment of the present application, one group of capacitor cores 1413 includes two capacitor cores 141a, and the other group of capacitor cores 1412 includes one capacitor core 141a. Along the first direction Y, the length of one group of capacitor cores 1413 is recorded as L3, and the length of the other group of capacitor cores 1412 is recorded as L4, L3>L4, L4 is smaller, and L3 is larger, so that the other group of capacitor cores 1412 has space relative to the group of capacitor cores 1413 along the first direction Y and the second direction X for accommodating part of the electrical components of an EMC filter assembly 142 and a part 1431 of the two first connecting copper bars 143, so that the layout inside the shell 145 is more compact, the space utilization inside the shell 145 is improved, and the integration of the capacitor filter integrated module 140 is improved.

[0195] In the embodiment of the present application, along the second direction X, one group of capacitor cores 1413 and another group of capacitor cores 1412 are sequentially arranged between the first side wall 145c and the second side wall 145d. That is, one group of capacitor cores 1413 and the other group of capacitor cores 1412 are isolated within the housing 145, which helps reduce electrical interference from other electrical components outside the housing 145 on the two groups of capacitor cores 141a, allowing the two groups of capacitor cores 141a to operate smoothly. The space between one group of capacitor cores 1413 and the second side wall 145d is used to accommodate the electrical components of an EMC filter assembly 142 and a portion 1431 of the two first connecting copper bars 143, so that the space within the accommodating groove 146 is fully utilized, which helps to reduce the overall volume of the capacitor filter integrated module 140.

[0196] In one embodiment, the electrical components of an EMC filter assembly 142 include multiple filter capacitors 142a, as shown in Figures 8 and 9. The multiple filter capacitors 142a are arranged between a group of capacitor cores 1413 and a second sidewall 145d. Along a first direction Y, the multiple filter capacitors 142a are arranged on the same side of another group of capacitor cores 1412. Along a second direction X, the two filter capacitors 142b and 142c are spaced apart. The other portion 1432 of each first connecting copper busbar 143 is arranged between the two filter capacitors 142b and 142c.

[0197] In an embodiment of the present application, multiple filter capacitors 142a can eliminate differential-mode interference and common-mode interference during current conduction. Multiple filter capacitors 142a are arranged between a group of capacitor cores 1413 and the second side wall 145d, so that the space between a group of capacitor cores 1413 and the second side wall 145d can be fully utilized, which is convenient for improving the space utilization rate within the shell 145 and is conducive to reducing the overall volume of the capacitor filter integrated module 140.

[0198] In the embodiment of the present application, multiple filter capacitors 142a are arranged on the same side of another group of capacitor cores 1412 along the first direction Y, which is conducive to fully utilizing the space of another group of capacitor cores 1412 along the first direction Y in the shell 145, thereby improving the space utilization rate in the shell 145 and reducing the overall volume of the capacitor filter integrated module 140.

[0199] In the embodiment of the present application, the two filter capacitors 142 b and 142 c are arranged at intervals along the second direction X, so as to facilitate electrical isolation of the two filter capacitors 142 b and 142 c and reduce electrical interference between the two filter capacitors 142 b and 142 c.

[0200] In the embodiment of the present application, the other part 1432 of each first connecting copper busbar 143 is arranged in the interval between the two filter capacitors 142b and 142c, which can fully utilize the space generated by the interval between the two filter capacitors 142b and 142c in the second direction X, so that the other part 1432 of each first connecting copper busbar 143 and the two filter capacitors 142b and 142c are arranged compactly, thereby improving the space utilization of the housing 145, facilitating the improvement of the integration of the capacitor filter integrated module 140, and reducing the volume of the capacitor filter integrated module 140.

[0201] In one embodiment, multiple filter capacitors 142a in an EMC filter assembly 142 are directly welded to the housing 145, which helps to reduce the wiring harness and copper bus connection design connected to the multiple filter capacitors 142a and reduces assembly links.

[0202] In one embodiment, the bottom 146a of the receiving groove 146 further includes two shielding protrusions 146b and 146c. As shown in Figures 9 to 11, the two shielding protrusions 146b and 146c are arranged between the first side wall 145c and the second side wall 145d along the second direction X. In the second direction X, one filter capacitor 142b is arranged between a group of capacitor cores 1413 and one shielding protrusion 146b, and another filter capacitor 142c is arranged between another shielding protrusion 146c and the second side wall 145d.

[0203] In the embodiment of the present application, the bottom 146a of the receiving groove 146 further includes two shielding protrusions 146b and 146c. The two shielding protrusions 146b and 146c enhance the structural strength of the receiving groove 146 and improve the stability of the housing 145. Along the second direction X, the two shielding protrusions 146b and 146c are arranged between the first side wall 145c and the second side wall 145d, thereby forming multiple electrically isolated regions within the housing 145 along the second direction X. This facilitates the installation and fixation of the electrical components of the capacitor filter integrated module 140 within the housing 145 in separate regions, thereby reducing electrical interference between the electrical components.

[0204] In an embodiment of the present application, along the second direction X, a filter capacitor 142b is arranged between a group of capacitor cores 1413 and a shielding protrusion 146b, and another filter capacitor 142c is arranged between another shielding protrusion 146c and the second side wall 145d. The space between a group of capacitor cores 1413 and a shielding protrusion 146b provides the possibility for the arrangement of a filter capacitor 142b, and the space between another shielding protrusion 146c and the second side wall 145d provides the possibility for the arrangement of another filter capacitor 142c. In an embodiment of the present application, along the second direction X, a group of capacitor cores 1413, a filter capacitor 142b, a shielding protrusion 146b, another shielding protrusion 146c, another filter capacitor 142c, and a second side wall 145d are arranged in sequence, and the two shielding protrusions 146b and 146c electrically isolate one filter capacitor 142b from another filter capacitor 142c, thereby reducing electrical interference between one filter capacitor 142b and another filter capacitor 142c.

[0205] As shown in Figures 9 and 11, in one embodiment, the side of a shielding protrusion 146b facing away from the receiving groove 146 includes a grounding protrusion 1451, the side of the first sidewall 145c facing away from the receiving groove 146 includes a fixing protrusion 1453, and the side of the second sidewall 145d facing away from the receiving groove 146 includes another grounding protrusion 1452 and another fixing protrusion 1454. One grounding protrusion 1451 is used to electrically connect to one filter capacitor 142b, and the other grounding protrusion 1452 is used to electrically connect to another filter capacitor 142c. Each fixing protrusion 145e or grounding protrusion 145f includes a through hole for accommodating a fixing member. Along the second direction X, the protrusion direction of one grounding protrusion 1451 and one fixing protrusion 1453 is opposite to the protrusion direction of the other grounding protrusion 1452 and the other fixing protrusion 1454.

[0206] In the embodiment of the present application, a shielding protrusion 146b includes a grounding protrusion 1451 on the side facing away from the receiving groove 146, a first side wall 145c includes a fixing protrusion 1453 on the side facing away from the receiving groove 146, and a second side wall 145d includes another grounding protrusion 1452 and another fixing protrusion 1454 on the side facing away from the receiving groove 146. A grounding protrusion 1451 and another grounding protrusion 1452 are used to achieve grounding of some electrical components in the capacitor filter integrated module 140, which is beneficial for eliminating common-mode interference. A fixing protrusion 1453 and another fixing protrusion 1454 are respectively connected and fixed to the first side wall 145c and the second side wall 145d, which is beneficial for a fixing protrusion 1453 and another fixing protrusion to fix the housing 145 to another circuit board 112 or the groove-shaped housing 110 in the power supply device 10, and to install and fix the capacitor filter integrated module 140 to the power supply device 10, thereby improving the integration of the power supply device 10.

[0207] In the embodiment of the present application, a grounding protrusion 1451 is used to electrically connect a filter capacitor 142b, so that a grounding protrusion 1451 can ground a filter capacitor 142b, and another grounding protrusion 1452 is used to electrically connect another filter capacitor 142c, so that another grounding protrusion 1452 can ground another filter capacitor 142c. Each fixing protrusion 145e or grounding protrusion 145f includes a through hole for accommodating a fixing member to pass through. The through hole of each fixing protrusion 145e facilitates the passage of a fixing member to install and fix the capacitor filter integrated module 140 to another circuit board 112 or a slot-shaped housing 110. The through hole of each grounding protrusion 145f facilitates the passage of a fixing member to fix the ground wire to the housing 145.

[0208] In the embodiment of the present application, along the second direction X, the protruding directions of one grounding protrusion 1451 and one fixing protrusion 1453 are opposite to the protruding directions of another grounding protrusion 1452 and another fixing protrusion 1454, so that one grounding protrusion 1451, one fixing protrusion 1453, another grounding protrusion 1452 and another fixing protrusion 1454 are arranged regularly on the shell 145, so that one fixing protrusion 1453 and another fixing protrusion 1454 fix the shell 145 along the second direction X, so that one grounding protrusion 1451 and another grounding protrusion 1452 realize grounding of one filter capacitor 142b and another filter capacitor 142c along the second direction X.

[0209] In one embodiment, the two first connecting copper bars 143 each include a transmission copper bar 1400, a first bonding copper bar 1410, and a second bonding copper bar 1420. As shown in FIG12 , each transmission copper bar 1400 is used to connect a first bonding copper bar 1410 and a second bonding copper bar 1420. The first bonding copper bar 1410 of each first connecting copper bar 143 is used to electrically connect to the power battery 3, and the second bonding copper bar 1420 of each first connecting copper bar 143 is used to electrically connect to the high-voltage DC terminal of the on-board charger 102 (as shown in FIG3 a). Along the first direction Y, the width of the first bonding copper bar 1410 is greater than the width of the second bonding copper bar 1420.

[0210] In the embodiment of the present application, each transmission copper bus 1400 is used to connect a first bonding copper bus 1410 and a second bonding copper bus 1420, and the first bonding copper bus 1410 of each first connecting copper bus 143 is used to electrically connect the power battery 3, so that the high-voltage direct current in the power battery 3 passes through the first bonding copper bus 1410 of a first connecting copper bus 143a, the transmission copper bus 1400, and a first connecting copper bus 143a for electrically connecting the capacitor core 141a of the bus capacitor 141 or a portion 1431 of at least one of the electrical components of an EMC filter assembly 142, transmitting the current to the capacitor core 141a or the electrical components of an EMC filter assembly 142.

[0211] In the embodiment of the present application, the second bonding copper bar 1420 of each first connecting copper bar 143 is used to electrically connect to the high-voltage DC terminal of the vehicle charger 102, so that the current in the power battery 3 is transmitted to the high-voltage DC terminal of the vehicle charger 102 through a first bonding copper bar 1410 and a second bonding copper bar 1420 of a first connecting copper bar 143a to power the electrical components of the vehicle charger 102, and also facilitates the electrical components of the vehicle charger 102 to receive current from an external power source and pass the current through the high-voltage DC terminal of the vehicle charger 102, a second bonding copper bar 1420, and a first bonding copper bar 1410 to charge the power battery 3.

[0212] In the embodiment of the present application, as shown in FIG12 , along the first direction Y, the width of the first overlapping copper busbar 1410 is denoted as L5, and the width of the second overlapping copper busbar 1420 is denoted as L6. L5>L6. A larger L5 facilitates meeting the high-current conduction requirements of the first overlapping copper busbar 1410 connected to the power battery 3, and also helps reduce the resistance of the high-voltage DC power from the power battery 3 to the capacitor filter integrated module 140. The current flowing between the high-voltage DC terminal of the on-board charger 102 and the second overlapping copper busbar 1420 is relatively small, so a smaller L6 can meet the power supply requirements, saving materials and reducing production costs.

[0213] In one embodiment, each of the first connecting copper bus 143, the first bonding copper bus 1410 and the second bonding copper bus 1420 include a fixing through-hole 1411 and a fixing through-hole 1425, respectively. As shown in FIG12 , the diameter of the fixing through-hole 1411 of the first bonding copper bus 1410 is larger than the diameter of the fixing through-hole 1425 of the second bonding copper bus 1420.

[0214] In the embodiment of the present application, the first bonding copper bar 1410 and the second bonding copper bar 1420 of each first connecting copper bar 143 include a fixing through-hole 1411 and a fixing through-hole 1425, respectively. The fixing through-hole 1411 of the first bonding copper bar 1410 is used to be fixedly connected to the high-voltage bonding copper bar 171b of a high-voltage connector 171, thereby electrically connecting the first bonding copper bar 1410 to the power battery 3. The fixing through-hole 1425 of the second bonding copper bar 1420 is used to be fixedly connected to a circuit board 111 of the on-board charger 102, thereby electrically connecting the first bonding copper bar 1410 to the electrical components of the on-board charger 102.

[0215] In the embodiment of the present application, the aperture of one fixing through hole 1411 is relatively large, which is conducive to fixing the first overlapping copper busbar, which is wider along the first direction Y, to the housing 145, so that the installation and fixation of the first overlapping copper busbar 1410 is more stable. The aperture of one fixing through hole 1425 is relatively small, which is conducive to connecting the second overlapping copper busbar 1420, which is narrower along the first direction Y, to a circuit board 111 (as shown in Figure 3b) of the vehicle charger 102.

[0216] In one embodiment, a section 1401 of each transmission copper busbar 1400 is embedded in a housing 145 of a capacitor filter integrated module 140 and electrically connected to a bus capacitor 141 and an EMC filter component 142, and another section 1402 of each transmission copper busbar 1400 is used to fixedly connect a first bonding copper busbar 1410 and a second bonding copper busbar 1420.

[0217] As shown in Figure 12, in an embodiment of the present application, a section 1401 of each transmission copper busbar 1400 is embedded in the shell 145 of a capacitor filter integrated module 140 and is electrically connected to a bus capacitor 141 and an EMC filter component 142 to filter the current input into the capacitor filter integrated module 140 by the first connecting copper busbar 143, eliminate common-mode interference, differential-mode interference, and reduce harmonic interference. The other section 1402 of each transmission copper bar 1400 is used to fixedly connect a first strapping copper bar 1410 and a second strapping copper bar 1420. The high-voltage direct current in the power battery 3 is transmitted to an EMC filter component 142 and a bus capacitor 141 through a first strapping copper bar 1410 and the other section 1402 of a transmission copper bar 1400. A circuit board 111 of the on-board charger 102 receives the high-voltage direct current output by the power conversion circuit, and can charge the power battery 3 through a second strapping copper bar 1420 and a first strapping copper bar 1410. That is, the connection between a first strapping copper bar 1410, a transmission copper bar 1400, and a second strapping copper bar 1420 is strengthened, and a first strapping copper bar 1410, a transmission copper bar 1400, and a second strapping copper bar 1420 are integrated into one, which is beneficial to improving the integration of the power supply device 10 and also beneficial to simplifying the line layout within the power supply device 10.

[0218] In one embodiment, each transmission copper bus 1400 further includes a bifurcated segment 1403. As shown in FIG12 , one segment 1401, another segment 1402, and the bifurcated segment 1403 of the transmission copper bus 1400 are sequentially connected. The bifurcated segment 1403 includes two segments, one end of the two segments is connected as a whole and connected to the other segment 1402, and the other ends of the two segments are separated. The two segments are respectively used to form a first overlapping copper bus 1410 and a second overlapping copper bus 1420.

[0219] In an embodiment of the present application, each transmission copper bus 1400 is connected and integrated with a first overlapping copper bus 1410 and a second overlapping copper bus 1420 through a forked section 1403, so that each transmission copper bus 1400 is integrated with a first overlapping copper bus 1410 and a second overlapping copper bus 1420 into an integrated large copper bus, and plays the function of directly electrically connecting the power battery 3 with the electrical components of the motor controller 101 and the electrical components of the vehicle charger 102 at the same time, thereby improving the integration of a capacitor filter integrated module 140, realizing a simple connection between the power battery 3 and the motor controller 101 and the vehicle charger 102 in the power supply device 10, greatly simplifying the layout of the wiring harness cables, copper buses and adapters in the power supply device 10, and facilitating the miniaturization of the power supply device 10.

[0220] In one embodiment, the direction X in which the two first overlapping copper bars 1410 are arranged in parallel intersects with the direction Y in which the two second overlapping copper bars 1420 are arranged in parallel. As shown in FIG13 , each second overlapping copper bar 1420 includes a bending section 1421 and a fixed section 1422. One end 1423 of a fixed section 1422 is used to electrically connect to a circuit board 111. The other end 1424 of a fixed section 1422 is fixedly connected to a first overlapping copper bar 1410 through a bending section 1421. The bending direction of a bending section 1421 is from a fixed section 1422 toward the bottom 160 of the trough-shaped shell 110.

[0221] In the embodiment of the present application, the direction X in which the two first overlapping copper bars 1410 are arranged in parallel intersects with the direction Y in which the two second overlapping copper bars 1420 are arranged in parallel. The two first overlapping copper bars 1410 and the two second overlapping copper bars 1420 are arranged in parallel along different directions respectively. Compared with arranging the two first overlapping copper bars 1410 and the two second overlapping copper bars 1420 in parallel in the same direction, the space of the capacitor filter integrated module 140 along the direction X in which the two first overlapping copper bars 1410 are arranged in parallel and the direction Y in which the two second overlapping copper bars 1420 are arranged in parallel is saved. It should be noted that the direction X in which the two first strapping copper bars 1410 are arranged in parallel is in the same direction as the second direction X, and the direction Y in which the two second strapping copper bars 1420 are arranged in parallel is in the same direction as the first direction Y. The first direction Y and the second direction X are perpendicular to each other. This is beneficial for the first strapping copper bar 1410 to receive charge from the power battery 3 along the first direction Y, which is beneficial for reducing power loss, and is beneficial for the second strapping copper bar 1420 and a circuit board 111 of the on-board charger 102 to be stacked along the third direction Z, thereby realizing electrical connection between the second strapping copper bar 1420 and the electrical components of the on-board charger 102.

[0222] In the embodiment of the present application, each second copper strapping busbar 1420 includes a bent section 1421 and a fixed section 1422. Each bent section 1421 is used to connect to a first copper strapping busbar 1410. One end 1423 of a fixed section 1422 is used to electrically connect to a circuit board 111. One end 1423 of a fixed section 1422 is fixed to a circuit board 111. One end 1423 of a fixed section 1422 receives current from a bent section 1421 and transmits it to a circuit board 111. The other end 1424 of a fixed section 1422 is fixedly connected to a first copper strapping busbar 1410 through a bent section 1421. The other end 1424 of a fixed section 1422 receives current from a first copper strapping busbar 1410 and transmits it to a bent section 1421, and then transmits it to a circuit board 111.

[0223] In the embodiment of the present application, the second bonding copper busbar 1420 is stacked with a circuit board 111, and the bending direction of one bent section 1421 is from a fixed section 1422 toward the bottom 160 of the trough-shaped housing 110. This facilitates the bent section 1421 of the second bonding copper busbar 1420 to receive current from a first bonding copper busbar 1410 and conduct it to the circuit board 111 along the third direction Z. The bending direction of one bent section 1421 is from a fixed section 1422 toward the bottom 160 of the trough-shaped housing 110. Compared to a case where the bent section 1421 and the fixed section 1422 of the second bonding copper busbar 1420 are arranged flat along the second direction X, this facilitates reducing the space occupied by the bent section 1421 of the second bonding copper busbar 1420 in the second direction X.

[0224] In the embodiment of the present application, when the power battery 3 discharges the power supply device 10, the current passes through a high-voltage connector 171, a first overlapping copper bus 1410, the other end 1424 of a bent section 1421, one end 1423 of a bent section 1421, a fixed section 1422, and a circuit board 111 to power the electrical components of the vehicle charger 102. When the power supply device 10 charges the power battery 3, the current passes through an external power source to a circuit board 111, a fixed section 1422, one end 1423 of a bent section 1421, the other end 1424 of a bent section 1421, a first overlapping copper bus 1410, and finally to a high-voltage connector 171 to charge the power battery 3.

[0225] In one embodiment, the fixed section 1422 of each second bonding copper busbar 1420 is connected to a first bonding copper busbar 1410 via a bent section 1421. As shown in Figures 13 and 14, along the third direction Z, the transmission copper busbars 1500 of one first connection copper busbar 143a are stacked and spaced apart between the bottom 146a of the receiving slot 146 (as shown in Figure 10) and the transmission copper busbar 1600 of another first connection copper busbar 143b, and the first bonding copper busbar 1410 of one first connection copper busbar 143a is spaced apart and partially stacked between the bottom 146a of the receiving slot 146 and the fixed section 1422 of the second bonding copper busbar 1420 of another first connection copper busbar 143b (as shown in Figure 14).

[0226] In the embodiment of the present application, along the third direction Z, the transmission copper busbars 1500 of one first connecting copper busbar 143a are stacked and spaced apart between the bottom 146a of the receiving slot 146 and the transmission copper busbar 1600 of another first connecting copper busbar 143b, thereby reducing electrical interference between the transmission copper busbar 1500 of one first connecting copper busbar 143a and the transmission copper busbar 1600 of another first connecting copper busbar 143b. Along the third direction Z, the bottom 146a of the receiving slot 146, the transmission copper busbar 1500 of one first connecting copper busbar 143a, and the transmission copper busbar 1600 of another first connecting copper busbar 143b are stacked and spaced apart, which helps reduce the space occupied by the receiving slot 146 along the second direction X and facilitates the miniaturization of the capacitor filter integrated module 140 and the power supply device 10.

[0227] In the embodiment of the present application, along the third direction Z, the first overlapping copper bar 1410 of a first connecting copper bar 143a is spaced and partially stacked between the bottom 146a of the accommodating groove 146 and the fixed section 1422 of the second overlapping copper bar 1420 of another first connecting copper bar 143b. Compared with the first overlapping copper bar 1410 of a first connecting copper bar 143a and the fixed section 1422 of the second overlapping copper bar 1420 of another first connecting copper bar 143b being arranged flatly along the first direction Y, the space occupied by the first overlapping copper bar 1410 of a first connecting copper bar 143a and the fixed section 1422 of the second overlapping copper bar 1420 of another first connecting copper bar 143b in the capacitor filter integrated module 140 along the first direction Y is reduced.

[0228] Along the third direction Z, the transmission copper bus 1500 of a first connecting copper bus 143a is stacked and spaced apart between the bottom 146a of the accommodating groove 146 and the transmission copper bus 1600 of another first connecting copper bus 143b. The first overlapping copper bus 1410 of a first connecting copper bus 143a is spaced apart and partially stacked between the bottom 146a of the accommodating groove 146 and the fixed section 1422 of the second overlapping copper bus 1420 of another first connecting copper bus 143b. This facilitates the staggered stacking arrangement between the first connecting copper bus 143a and the other first connecting copper bus 143b, greatly utilizing the space within the housing 145 of the capacitor filter integrated module 140, improving space utilization, facilitating improving the integration of the capacitor filter integrated module 140, and reducing the overall volume of the capacitor filter integrated module 140, which is conducive to the miniaturized layout of the power supply device 10.

[0229] In one embodiment, along the third direction Z, the distance between the first strapping copper bus 1410 of one first connecting copper bus 143a and the fixed section 1422 of the second strapping copper bus 1420 of another first connecting copper bus 143b is greater than the distance between the transmission copper bus 1500 of one first connecting copper bus 143a and the transmission copper bus 1600 of another first connecting copper bus 143b.

[0230] In the embodiment of the present application, as shown in Figure 14, along the third direction Z, the interval between the first overlapping copper bar 1410 of one first connecting copper bar 143a and the fixed section 1422 of the second overlapping copper bar 1420 of another first connecting copper bar 143b is recorded as L7, and the interval between the transmission copper bar 1500 of one first connecting copper bar 143a and the transmission copper bar 1600 of the other first connecting copper bar 143b is recorded as L8. L7>L8, L7 is larger, that is, the fixed section 1422 of the second overlapping copper bar 1420 of the other first connecting copper bar 143b is arranged at a higher position relative to the bottom 146a of the accommodating groove 146 along the third direction Z, which facilitates the electrical connection between the fixed section 1422 of the second overlapping copper bar 1420 of the other first connecting copper bar 143b and a circuit board 111 of the on-board charger, which is arranged at a higher position relative to the bottom 160 of the groove-shaped housing 110 along the third direction Z. L8 is relatively small, which is beneficial for the transmission copper bar 1500 of one first connecting copper bar 143a and the transmission copper bar 1600 of another first connecting copper bar 143b to be stacked along the third direction Z. They can occupy less space of the capacitor filter integrated module 140 along the third direction Z, thereby facilitating the integration of the capacitor filter integrated module 140 and miniaturization of the capacitor filter integrated module 140.

[0231] In one embodiment, along the third direction Z, the distance between the first overlapping copper bus 1410 of another first connecting copper bus 143b and the bottom 146a of the accommodating groove 146 is less than or equal to the distance between the transmission copper bus 1600 of another first connecting copper bus 143b and the bottom 146a of the accommodating groove 146, and is greater than the distance between the transmission copper bus 1500 of one first connecting copper bus 143a and the bottom 146a of the accommodating groove 146.

[0232] In the embodiment of the present application, as shown in Figure 14, along the third direction Z, the distance between the first overlapping copper bus 1410 of another first connecting copper bus 143b and the bottom 146a of the accommodating groove 146 is recorded as L9, the distance between the transmission copper bus 1600 of another first connecting copper bus 143b and the bottom 146a of the accommodating groove 146 is recorded as L10, and the distance between the transmission copper bus 1500 of one first connecting copper bus 143a and the bottom 146a of the accommodating groove 146 is recorded as L11. L9≤L10, L9 is relatively small, which is conducive to the first bonding copper bar 1410 of another first connecting copper bar 143b directly bonding with the high-voltage bonding copper bar 171b of the high-voltage connector 171; L9>L11, L11 is relatively small, which is conducive to a section of the transmission copper bar 1600 of another first connecting copper bar 143b and one end of the transmission copper bar 1500 of one first connecting copper bar 143a being embedded in the bus capacitor, facilitating the electrical connection between another first connecting copper bar 143b and one first connecting copper bar 143a and the capacitor core 141a of the bus capacitor 141 and the electrical components of an EMC filter component 142. It is also beneficial to arrange the transmission copper bus 1600 of another first connecting copper bus 143b, the transmission copper bus 1500 of one first connecting copper bus 143a, and the bottom 146a of the accommodating groove 146 in an interval-stacked manner along the third direction Z, which is beneficial for the first lap copper bus 1410 of another first connecting copper bus 143b and the transmission copper bus 1500 of one first connecting copper bus 143a to reduce the space occupied by the accommodating groove 146 along the third direction Z, thereby improving the space utilization rate of the accommodating groove 146, facilitating the integration of the capacitor filter integrated module 140, and miniaturizing the capacitor filter integrated module 140.

[0233] It should be noted that, in order to clearly illustrate the dimensional relationship, the reference numeral 146a in Figure 14 is used to indicate the bottom of the receiving groove 146. Specifically, the bottom 146a of the receiving groove 146 is shown as 146a in Figure 10.

[0234] In one embodiment, the electrical components of an EMC filter assembly 142 further include a filter magnetic ring 142 d . As shown in FIG13 , the transmission copper bus 1400 of each first connecting copper bus 143 passes through a filter magnetic ring 142 d .

[0235] In the embodiment of the present application, a filter magnetic ring 142d is used to filter out harmonic interference in the current signal transmitted by the transmission copper bus 1400 of each first connecting copper bus 143, thereby improving the electromagnetic compatibility of the power supply device 10. Integrating multiple filter capacitors 142a and a filter magnetic ring 142d into the capacitor filter integrated module 140 to filter out the current interference signal generated in the power supply device 10 is beneficial for the three-phase power module 150 to obtain an accurate current signal transmitted from the capacitor filter integrated module 140, and is also beneficial for the three-phase power module 150 to receive current with a stable voltage. The simultaneous integration of multiple filter capacitors 142a and a filter magnetic ring 142d into the capacitor filter integrated module 140 is also beneficial for improving the integration and reliability of the power supply device 10.

[0236] In one embodiment, the housing 145 further includes an insulating potting layer 145g. As shown in FIG11 , the insulating potting layer 145g is used to cover the capacitor core 141a of the busbar capacitor 141 within the receiving slot 146, multiple filter capacitors 142a of an EMC filter assembly 142, a portion 1431 of each first connecting copper busbar 143, and a portion 1441 of each second connecting copper busbar 144. A filter magnetic ring 142d, and the first and second connecting copper busbars 1410 and 1420 of each first connecting copper busbar 143 are exposed from the insulating potting layer 145g.

[0237] In the embodiment of the present application, the insulating glue layer 145g has insulating properties, can block current, and can also shield electrical interference signals. In conjunction with Figures 9 and 11, the insulating glue layer 145g fixes the capacitor core 141a of the busbar capacitor 141, multiple filter capacitors 142a of an EMC filter assembly 142, a portion 1431 of each first connecting copper busbar 143, and a portion 1441 of each second connecting copper busbar 144 within the receiving groove 146, thereby enhancing the strength of the receiving groove 146 and the housing 145, and improving the structural stability of the power supply device 10.

[0238] In the embodiment of the present application, the insulating glue potting layer 145g is used to cover the capacitor core 141a of the bus capacitor 141 in the accommodating slot 146, multiple filter capacitors 142a of an EMC filter assembly 142, a portion 1431 of each first connecting copper bar 143, and a portion 1441 of each second connecting copper bar 144, thereby reducing electrical interference from other electrical components in the power supply device 10 to the capacitor core 141a of the bus capacitor 141 in the accommodating slot 146, multiple filter capacitors 142a of an EMC filter assembly 142, a portion 1431 of each first connecting copper bar 143, and a portion 1441 of each second connecting copper bar 144, thereby ensuring the normal operation of the capacitor core 141a of the bus capacitor 141 in the accommodating slot 146, multiple filter capacitors 142a of an EMC filter assembly 142, a portion 1431 of each first connecting copper bar 143, and a portion 1441 of each second connecting copper bar 144, thereby ensuring the stable operation of the power supply device 10.

[0239] In the embodiment of the present application, the insulating glue potting layer 145g seals the capacitor core 141a of the bus capacitor 141, multiple filter capacitors 142a of an EMC filter component 142, a portion 1431 of each first connecting copper bus 143 and a portion 1441 of each second connecting copper bus 144 in the accommodating groove 146, which is beneficial to improving the integration of the capacitor filter integrated module 140.

[0240] In the embodiment of the present application, a filter magnetic ring 142d is exposed from the insulating glue potting layer 145g and is used to filter the current in the transmission copper busbar exposed from the insulating glue potting layer 145g. The first lap copper busbar 1410 of each first connecting copper busbar 143 is exposed from the insulating glue potting layer 145g, which facilitates the electrical connection between the first lap copper busbar 1410 of each first connecting copper busbar 143 and the power battery 3, ensuring that the current input by the power battery 3 can smoothly pass through the first lap copper busbar 1410 of the first connecting copper busbar into the capacitor core 141a of the busbar capacitor 141 and the multiple filter capacitors 142a of an EMC filter assembly 142, and then be output from the second connecting copper busbar 144 to the three-phase power module 150, so that the current transmitted by the power battery 3 can be smoothly conducted and low-interference signals are transmitted to the three-phase windings of the motor 30, driving the motor 30 to operate stably. The second connecting copper bar 1420 of each first connecting copper bar 143 is exposed from the insulating glue potting layer 145g, so that each first connecting copper bar 143 and the second connecting copper bar 1420 can be electrically connected to the electrical components of the vehicle charger 102, thereby ensuring that the current input by the power battery 3 can be smoothly transmitted to the electrical components of the vehicle charger 102 through the second connecting copper bar 1420, or the current of the external power supply received by the electrical components of the vehicle charger 102 can be transmitted to the first connecting copper bar 1410 through the second connecting copper bar 1420, thereby charging the power battery 3.

[0241] In one embodiment, the capacitor filter integrated module 140 further includes a rubber shield 147. As shown in FIG11 , in this embodiment of the present application, the rubber shield 147 is used to isolate the insulating glue potting layer 145g and a filter magnetic ring 142d, thereby reducing electrical interference between the filter magnetic ring 142d and the capacitor core 141a of the busbar capacitor 141 in the receiving slot 146 and the multiple filter capacitors 142a of the EMC filter assembly 142, thereby ensuring that the capacitor filter integrated module 140 performs its filtering and current interference signal elimination functions normally.

[0242] In one embodiment, the shell 145 includes a capacitor accommodating groove 145h, a magnetic ring accommodating groove 145i and a copper busbar accommodating groove 145j. As shown in Figure 10, the capacitor accommodating groove 145h, the magnetic ring accommodating groove 145i and the copper busbar accommodating groove 145j are arranged in sequence along the first direction Y. The capacitor accommodating groove 145h is used to accommodate a busbar capacitor 141, multiple filter capacitors 142a of an EMC filter component 142 and an insulating glue layer 145g. The magnetic ring accommodating groove 145i is used to accommodate a filter magnetic ring 142d of an EMC filter component 142. The copper busbar accommodating groove 145j is used to accommodate a first overlapping copper busbar 1410 of two first connecting copper buses 143. There is an opening between the capacitor accommodating groove 145h and the magnetic ring accommodating groove 145i. The glue baffle 147 is used to seal the opening to prevent it from being exposed when the capacitor accommodating groove 145h is filled with insulating glue.

[0243] In one embodiment, the copper busbar accommodating slot 145j includes a notch along the first direction Y away from the capacitor accommodating slot 145h. The notch facilitates the high-voltage strapping copper busbar 171b of the high-voltage connector 171 to be directly strapped to the first strapping copper busbar 1410 of the first connecting copper busbar 143.

[0244] The above is a detailed introduction to the multi-in-one power supply device, powertrain and electric vehicle provided in the embodiments of the present application. Specific examples are used in this article to illustrate the principles and embodiments of the present application. The description of the above embodiments is only used to help understand the method of the present application and its core idea; at the same time, for general technical personnel in this field, based on the ideas of the present application, there will be changes in the specific embodiments and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. An all-in-one power supply device, characterized in that: The all-in-one power supply device includes a slot-shaped housing and a motor controller, wherein the slot-shaped housing is used to accommodate the electrical components of the motor controller, and the electrical components of the motor controller include a capacitor filter integrated module, wherein: The capacitor filter integrated module is used to integrate a bus capacitor, an EMC filter component and two first connecting copper bars, wherein the bus capacitor receives the high-voltage direct current output by the power battery through the two first connecting copper bars, and filters the high-voltage direct current received by the two first connecting copper bars through the EMC filter component; The trough-shaped shell is also used to fix a high-voltage connector, which includes a power battery connection terminal and two high-voltage strapping copper bars. The power battery connection terminal is used to electrically connect the power battery through a power connection line. A portion of each of the first connection copper bars is stacked with a high-voltage strapping copper bar. The portions of the two first connection copper bars are respectively used to directly fix the connection to the two high-voltage strapping copper bars and electrically connect the positive and negative electrodes of the power battery through the two high-voltage strapping copper bars.

2. The all-in-one power supply device according to claim 1, characterized in that: The all-in-one power supply device also includes an on-board charger. The groove-shaped housing is further used to accommodate the electrical components of the on-board charger. The electrical components of the on-board charger include a circuit board. The circuit board is used to fix multiple electrical components of the power conversion circuit in the on-board charger. The power conversion circuit is used to convert the external power supply and output high-voltage direct current to charge the power battery. Each of the first connecting copper bars includes a first bonding copper bar and a second bonding copper bar. The first bonding copper bar of each first connecting copper bar is stacked with one of the high-voltage bonding copper bars, wherein: Along the stacking direction of the first strapping copper bar of each first connecting copper bar and one of the high-voltage strapping copper bars, each of the second strapping copper bars is stacked with the one circuit board, and the two second strapping copper bars are used to directly and fixedly connect to the one circuit board and receive the high-voltage direct current output by the power conversion circuit through the one circuit board.

3. The all-in-one power supply device according to claim 2, characterized in that: Each of the first connecting copper bars also includes a transmission copper bar, one section of each of the transmission copper bars is embedded in the housing of the capacitor filter integrated module and electrically connected to the bus capacitor and the EMC filter component, and the other section of each of the transmission copper bars is used to fixedly connect one of the first bonding copper bars and one of the second bonding copper bars.

4. The all-in-one power supply device according to claim 3, characterized in that: The direction in which the two first overlapping copper bars are arranged in parallel intersects with the direction in which the two second overlapping copper bars are arranged in parallel. Each of the second overlapping copper bars includes a bending section and a fixed section. One end of the fixed section is used to electrically connect to the circuit board, and the other end of the fixed section is fixedly connected to one of the first overlapping copper bars through the bending section. The bending direction of the bending section is from the fixed section toward the bottom of the groove of the groove-shaped shell.

5. The all-in-one power supply device according to any one of claims 2 to 4, characterized in that: The electrical components of the on-board charger further include another EMC filter component, which is used to filter the high-voltage direct current output or received by the on-board charger, wherein: Along the stacking direction of the first bonding copper bar and one of the high-voltage bonding copper bars of each of the first connecting copper bars, the circuit board, the filter capacitor of the other EMC filter assembly, and the bottom of the slot of the slot-shaped housing are stacked in sequence.

6. The all-in-one power supply device according to claim 5, characterized in that: The two high-voltage copper bars are also used to sleeve a filter magnetic ring of another EMC filter assembly, wherein: Along the length direction of any one of the high-voltage lap copper bars, the filtering magnetic ring is arranged between the housing of the capacitor filtering integrated module and a side wall of the slot-shaped housing.

7. The all-in-one power supply device according to claim 6, characterized in that: The bottom of the trough-shaped housing is used to fix the filter capacitor of the other EMC filter assembly and the capacitor filter integrated module. The bottom of the trough-shaped housing includes a shielding protrusion, and the shielding protrusion is used to fix the bottom of the trough-shaped housing and two side walls arranged oppositely along the length direction of any one of the high-voltage lap copper bars, wherein: Along the arrangement direction of the two high-voltage overlapping copper bars, the filtering magnetic ring and the capacitor filtering integrated module are arranged on one side of the shielding protrusion, and the filtering capacitor of the other EMC filtering component is arranged on the other side of the shielding protrusion.

8. The all-in-one power supply device according to claim 7, characterized in that: The capacitor filter integrated module is further used to integrate three pairs of second connecting copper bars. The electrical components of the motor controller also include a three-phase power module. The three-phase power module is used to electrically connect the three pairs of second connecting copper bars. The three-phase power module is used to convert the high-voltage direct current received by the bus capacitor into three-phase alternating current, wherein: Along the length direction of any one of the high-voltage bridging copper bars, the two first connecting copper bars and the three pairs of second connecting copper bars are arranged at intervals on both sides of the housing of the capacitor filter integrated module, and the filter magnetic ring, the capacitor filter integrated module and the three-phase power module are arranged in sequence at the bottom of the slot of the slot-shaped housing; Along the arrangement direction of the two high-voltage overlapping copper bars, the three-phase power module, the filter magnetic ring and the capacitor filter integrated module are arranged on the same side of the shielding protrusion.

9. The all-in-one power supply device according to any one of claims 1 to 8, characterized in that: The groove-shaped housing includes a first mounting hole, and the first mounting hole is used to fix the high-voltage connector, wherein: Along the length direction of any one of the high-voltage copper busbars, the first mounting hole passes through a side wall of the trough-shaped shell, and the distance between the first mounting hole and the capacitor core of the busbar capacitor is greater than the length of any one of the high-voltage copper busbars.

10. The all-in-one power supply device according to claim 9, characterized in that: The trough-shaped housing further includes a second mounting hole, the second mounting hole being used to fix a winding connector, the winding connector being used to electrically connect a three-phase power module of the motor controller and a three-phase winding of a motor, wherein: Along the stacking direction of each of the first connecting copper bars and one of the high-voltage lap copper bars, the second mounting hole passes through the bottom of the slot-shaped housing; or, Along the length direction of any one of the high-voltage copper busbars, the second mounting hole passes through the other side wall of the trough-shaped housing, and the one side wall is arranged opposite to the other side wall.

11. The all-in-one power supply device according to claim 9, wherein: The all-in-one power supply device further includes a high-voltage power supply module and an on-board charger, wherein the high-voltage power supply module is used to power at least one of the compressor or the PTC, and the groove-shaped housing further includes a third mounting hole and a fourth mounting hole, wherein: The third mounting hole is used to fix a high-voltage power supply connector, and the high-voltage power supply connector is used to electrically connect at least one of the compressor or the PTC and the high-voltage power supply module; The fourth mounting hole is used to fix an AC input connector, and the AC input connector is used to electrically connect the vehicle charger and an external power supply; Along the length direction of any one of the high-voltage copper busbars, the third mounting hole and the fourth mounting hole respectively penetrate through the side wall; Along the arrangement direction of the two high-voltage copper busbars, the first mounting hole, the third mounting hole, and the fourth mounting hole are sequentially arranged at intervals on the side wall.

12. The all-in-one power supply device according to claim 9, wherein: The all-in-one power supply device further includes a low-voltage power supply module, which is used to power an on-board low-voltage load. The output voltage of the low-voltage power supply module is lower than the output voltage of the power battery. The groove-shaped housing further includes a fifth mounting hole, wherein: Along the length direction of any one of the high-voltage copper busbars, the fifth mounting hole passes through another side wall, and the other side wall is arranged opposite to the one side wall; The fifth mounting hole is used to fix a low-voltage power supply connector, and the low-voltage power supply connector is used to electrically connect a low-voltage power supply module and the vehicle-mounted low-voltage load.

13. The all-in-one power supply device according to any one of claims 1 to 12, further comprising a cover plate and a vehicle controller, the cover plate being configured to cooperate with the trough-shaped housing to form a receiving space, one of the cover plate and the bottom of the trough-shaped housing comprising a sixth mounting hole, the sixth mounting hole penetrating one of the cover plate and the bottom of the trough-shaped housing along a stacking direction of each of the first connecting copper busbars and one of the high-voltage lap copper busbars, wherein: The sixth mounting hole is used to fix a signal connector, and the vehicle controller is used to receive an external control signal through the signal connector and to control the motor controller through a signal connection line accommodated in the accommodating space.

14. A powertrain, characterized in that: The powertrain includes a motor and a power supply device as described in any one of claims 1 to 13, wherein the three-phase power module of the power supply device is used to be connected to the three-phase winding of the motor.

15. An electric vehicle, characterized in that: The electric vehicle includes a frame, a power battery and a powertrain as described in claim 14, the frame is used to fix the power battery and the powertrain, the powertrain also includes a reducer, the power battery connection terminal of the high-voltage connector is used to electrically connect the power battery through a power connection line, and the motor is used to drive the wheels of the electric vehicle through the reducer.

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