Electric motor controller and cable output structure thereof, and electric motor driving system

Abstract

An electric motor controller and a cable output structure thereof, and an electric motor driving system. The cable output structure of the electric motor controller comprises: a housing (10), which comprises at least one mounting tube (110) penetrating the housing in a direction of thickness; a terminal (200), which runs through the mounting tube; a sealing assembly (300), which is configured to seal a gap between the housing and a shell (51) of the electric motor controller, as well as a gap between the terminal and the mounting tube; and a choke ring (400), which is arranged in the housing and surrounds the periphery of the mounting tube. The cable output structure meets the sealing requirements of the electric motor controller and realizes a filtering function for high-frequency harmonic waves generated by a high-voltage circuit, the overall volume is reduced, and thus the internal structure of the electric motor controller is more compact, thereby realizing miniaturization requirements of the electric motor controller.

Description

Motor controller and its outgoing wiring structure, motor drive system Technical Field

[0001] This application relates to, but is not limited to, a motor controller and its output structure, and a motor drive system. Background Technology

[0002] As the most crucial component of electric vehicles, the electric motor drive system's performance directly impacts the widespread adoption and application of electric vehicles. With the increasing power density requirements of new energy vehicle motors, the voltage demanded by the motor drive system is constantly rising, leading to higher EMC performance requirements for the motor.

[0003] After the electric motor and motor controller of an electric vehicle are assembled, they need to meet the high-voltage safety requirements of the entire vehicle. Therefore, a sealing design is incorporated into the motor controller housing to meet the sealing requirements of the inverter housing. In addition, to reduce the abnormal energy loss of the motor caused by the high-frequency harmonics of the high-voltage current output by the inverter, as well as the impact on the EMC performance of the entire motor, a choke ring design is usually used at the three-phase output terminals of the inverter to weaken the influence of high-frequency harmonics.

[0004] In existing technologies, the sealing components that meet the sealing requirements of the motor controller output terminals and the choke ring structure that reduces interference from high-frequency harmonics are usually designed independently. Such designs are structurally complex and occupy more space inside the motor controller, making it difficult to meet the miniaturization requirements of motors and motor controllers.

[0005] Summary of the Invention

[0006] This application provides a wiring structure for a motor controller, which includes:

[0007] A housing, the housing including at least one mounting tube penetrating the housing;

[0008] At least one terminal, said terminal passing through the mounting tube;

[0009] A sealing assembly for sealing the gap between the housing and the outer casing of the motor controller, and the gap between the terminal and the mounting tube;

[0010] At least one choke ring is disposed within the housing and surrounds the outer periphery of the mounting tube.

[0011] Optionally, the sealing assembly includes at least one first sealing ring and at least one second sealing ring, the first sealing ring surrounding the mounting tube and sandwiched between the housing and the outer shell, and the second sealing ring sleeved on the outer periphery of the terminal and sandwiched between the terminal and the inner wall of the mounting tube.

[0012] Optionally, the circumferential surface of the terminal is provided with a second limiting groove, and the second sealing ring is partially embedded in the second limiting groove.

[0013] Optionally, all of the mounting tubes are surrounded by the first sealing ring, wherein one of the first sealing rings surrounds at least one of the mounting tubes.

[0014] Optionally, all of the mounting tubes are surrounded by a choke ring, wherein one of the choke rings surrounds at least one of the mounting tubes.

[0015] Optionally, the housing has an internal accommodating cavity, and the housing further includes a partition disposed in the accommodating cavity. The partition cooperates with the mounting tube to divide the space of the accommodating cavity other than the mounting tube into an annular groove and a hollow groove, and the choke ring is embedded in the annular groove.

[0016] Optionally, one side surface of the housing has an opening communicating with the accommodating cavity; the choke ring is embedded in the annular groove through the opening.

[0017] Optionally, the housing is a one-piece structure.

[0018] Optionally, the housing may be made of engineering plastics.

[0019] Optionally, the choke ring includes an iron core and an insulating layer, wherein the insulating layer covers the iron core;

[0020] The insulating layer is made of an adhesive material, and the choke ring is bonded to the housing through the insulating layer.

[0021] Embodiments of this application also provide a motor controller, which includes the outgoing wiring structure of any of the motor controllers provided by this invention, and the motor controller further includes:

[0022] The housing has an internal mounting chamber, and the surface of the housing has a wire passage hole communicating with the mounting chamber; the wiring structure of the motor controller is installed inside the housing, and the terminals protrude from the wire passage hole;

[0023] An inverter is installed inside the housing and has a number of electrical connectors corresponding to the terminals, the electrical connectors being fixedly connected to the terminals one-to-one.

[0024] Embodiments of this application also provide a motor drive system, which includes the output wiring structure of any of the motor controllers provided by this invention, and the motor drive system further includes:

[0025] The motor body includes a rotor assembly and a stator assembly. The stator assembly is disposed around the central axis of the motor body on the outer periphery of the rotor assembly, and the stator assembly is electrically connected to the terminals.

[0026] One of the above technical solutions has the following advantages or beneficial effects: This application adopts an integrated structure in which the sealing component and the choke ring are installed in the housing, so that the outgoing structure can simultaneously meet the sealing requirements of the motor controller and realize the filtering function of high-frequency harmonics generated by the high-voltage circuit, thereby reducing the overall volume and making the internal structure of the motor controller more compact, realizing the miniaturization requirement of the motor controller. The reduced size of the motor controller can reduce the space occupied in the car, thereby increasing the interior space of the car body, providing space for the comfort design of the car body, and improving the ride comfort. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0028] Figure 1 is a schematic diagram of the outgoing wiring structure of a motor controller according to an embodiment of this application.

[0029] Figure 2 is a schematic diagram of the outgoing cable structure of a motor controller provided according to an embodiment of this application from another perspective.

[0030] Figure 3 is an exploded structural diagram of the wiring structure of a motor controller according to an embodiment of this application.

[0031] Figure 4 is an exploded view of the wiring structure of a motor controller according to an embodiment of this application.

[0032] Figure 5 is a cross-sectional view of the wiring structure of a motor controller according to an embodiment of this application.

[0033] Figure 6 is a schematic diagram of the motor controller's outgoing wiring structure installed in the lower housing according to an embodiment of this application.

[0034] Figure 7 is a schematic diagram of a motor controller provided according to an embodiment of this application.

[0035] In the diagram: 10-Housing; 100-Housing body; 1001-Lead-out surface; 1002-Inlet surface; 10021-Opening; 101-Accommodation cavity; 1011-Annular groove; 1012-Hollowed groove; 110-Mounting tube; 120-Mounting base; 130-Partition; 140-First limiting groove; 200-Terminal; 201-Inner connection end; 210-First screw hole; 220-Second screw hole; 230-Second limiting groove; 300-Sealing assembly; 310-First sealing ring; 320-Second sealing ring; 400-Choke ring; 410-Core; 420-Insulation layer; 51-Outer shell; 511-Lower shell; 512-Upper shell; 5121-Wire passage hole; 52-Inverter; 521-Electrical connector. Detailed Implementation

[0036] The technical solutions of the embodiments of this application will now be described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0037] As shown in Figures 1 to 4, an embodiment of the present application provides a wiring structure for a motor controller, including: a housing 10, terminals 200, a sealing assembly 300, and a choke ring 400. The housing 10 is an integral structure, comprising a housing body 100, a mounting tube 110, and a mounting base 120. The housing body 100 has a thickness direction W, and an accommodating cavity 101 is located inside the housing body 100. One surface of the housing body 100 with respect to its thickness direction W is a lead-out surface 1001, and the other surface is an inlet surface 1002. The wiring structure of the motor controller of the present application is installed inside the housing of the motor controller. The lead-out surface 1001 of the housing body 100 faces the external circuit, and the inlet surface 1002 of the housing body 100 faces the internal circuit of the motor controller. The housing body 100 has an opening 10021 on its inlet surface 1002 that communicates with the accommodating cavity 101. The opening 10021 is used to allow the choke ring 400 to pass through during installation, and to reduce the materials required in production and the overall weight of the application while ensuring the mechanical strength of the housing 10, so as to meet the lightweight requirements of the application.

[0038] This application adopts an integrated structure in which the sealing component 300 and the choke ring 400 are installed in the housing 10, so that the outgoing structure can simultaneously meet the sealing requirements of the motor controller and achieve the filtering function of high-frequency harmonics generated by the high-voltage circuit, reducing the overall volume, thereby making the internal structure of the motor controller more compact, realizing the miniaturization requirement of the motor controller, and increasing the interior space of the carriage.

[0039] As shown in Figures 3 and 4, the mounting tube 110 is a hollow tubular structure that penetrates the housing body 100 along the thickness direction W. The mounting tube 110 is used to mount the terminals 200. In the thickness direction W, the height of the mounting tube 110 is greater than the height of the housing body 100, so that both ends of the mounting tube 110 protrude from the lead-out surface 1001 and the lead-in surface 1002 of the housing body 100. The mounting tube 110 protruding from the surface of the housing body 100 plays a positioning role during installation, ensuring that the mounting tube 110 is at least partially embedded in the positioning hole or connection hole on the housing 51 of the motor controller, facilitating positioning and installation during the process. Furthermore, adjacent mounting tubes 110 are spaced apart to meet the requirement of mutual electrical insulation between the terminals 200 installed in the mounting tubes 110. In this embodiment, the motor adapted to the output structure of the motor controller is a three-phase motor; therefore, the number of terminals 200 and mounting tubes 110 corresponding to the three phases of the motor is three. In other embodiments, the number of mounting tubes 110 and terminals 200 is set according to the number of phases of the motor, such as two or four, etc., and no specific limitation is made here.

[0040] The housing body 100 also includes a partition 130 disposed within the accommodating cavity 101. The partition 130 cooperates with the mounting tube 110 to divide the space of the accommodating cavity 101 excluding the mounting tube 110 into an annular groove 1011 and a hollow groove 1012. Both the annular groove 1011 and the hollow groove 1012 communicate with the opening 10021. An annular choke ring 400 is installed in the annular groove 1011. The housing 10 has a reference plane 1 perpendicular to the thickness direction W. The orthographic projection of each mounting tube 110 onto the reference plane 1 is located within the area enclosed by the orthographic projection of the choke ring 400 onto the reference plane 1. That is, the mounting tube 110 and the hollow groove 1012 are both disposed within the surrounding range of the annular groove 1011, and the space between adjacent mounting tubes 110 forms the hollow groove 1012. This hollow groove 1012 reduces the material required for the production of the housing 10 and lowers the overall weight of this application, thus meeting the lightweight requirements of this application.

[0041] At least four mounting bases 120 are evenly arranged on the outer periphery of the housing body 100 and connected to the housing body 100. Each mounting base 120 has a fixing hole 121 extending through it in the thickness direction W, for screws to pass through the fixing hole 121 to fix the present application in the housing 51 of the motor controller.

[0042] In this embodiment, the housing 10 is manufactured by a one-piece injection molding process. The material of the housing 10 is engineering plastic. Compared with the machining process commonly used in the prior art, the one-piece injection molding process has a lower production cost. Moreover, engineering plastic has the advantages of light weight, high mechanical strength, good heat resistance and good electrical insulation, so that the housing 10 meets the requirements of lightweight motor drive system, high temperature resistance and electrical insulation in high voltage circuit, and improves the vibration resistance of the housing 10.

[0043] Referring to Figure 5, which shows a cross-sectional view of a motor controller according to an embodiment of this application, in this embodiment, the terminal 200 is a cylindrical structure adapted to the mounting hole. The terminal 200 passes through the mounting tube 110, and the axial length of the terminal 200 is greater than the axial length of the mounting tube 110, so that both ends of the terminal 200 at least partially protrude from both ends of the mounting hole, so as to facilitate the connection and installation of the terminal 200 with external circuits or internal circuits of the motor controller. The end faces of the two ends of the terminal 200 are respectively provided with a first screw hole 210 and a second screw hole 220 extending into them along their axial direction, for screws to pass through through holes on electrical connectors (such as copper busbars) and engage with the first screw hole 210 or the second screw hole 220, so that the electrical connector is electrically connected to the terminal 200. At least one second limiting groove 230 is provided on the outer peripheral surface of the terminal 200, which surrounds the peripheral surface of the terminal 200, and the second limiting groove 230 is used to install the second sealing ring 320 in the sealing assembly 300. In this embodiment, there are two second limiting grooves 230. In other embodiments, the number of second limiting grooves 230 may be one or more depending on the sealing requirements, and no specific limitation is made here.

[0044] In this embodiment, the terminal 200 is made of pure copper. Pure copper terminals 200 have the advantages of good conductivity, low heat generation, corrosion resistance, and easy shaping. In other embodiments, the terminal 200 may be made of aluminum, silver, or other conductive materials, and no specific limitation is made here.

[0045] Furthermore, the end of terminal 200 near the inlet surface 1002 is an inner connection end 201, and the radial cross-section of the inner connection end 201 is approximately elliptical. When installed on the housing 51 of the motor controller, the inner connection end 201 is embedded in a limiting hole that matches its shape. The limiting hole serves a positioning function, and at the same time, the limiting hole cooperates with the inner connection end 201 to prevent the terminal 200 from rotating around its own axis during the screw engagement process, which would prevent the screw from tightly engaging with the first screw hole 210 or the second screw hole 220, thus causing poor connection between the terminal 200 and the electrical connector.

[0046] Referring again to Figure 5, the sealing assembly 300 includes a first sealing ring 310 and a second sealing ring 320. The first sealing ring 310 is used for sealing between the present application and the housing 51 of the motor controller, and the second sealing ring 320 is used for sealing between the terminal 200 and the mounting tube 110. The first sealing ring 310 is an annular structure made of elastic material and is disposed on the lead-out surface 1001 of the housing body 100, sleeved on the outer periphery of the mounting tube 110. Correspondingly, a first limiting groove 140 corresponding to the first sealing ring 310 is provided on the lead-out surface 1001 of the housing body 100, and the first sealing ring 310 is partially embedded in the first limiting groove 140. When the present application is installed in the electrical controller, one side of the first sealing ring 310 with respect to the thickness direction W abuts against the housing body 100, and the other side abuts against the housing 51 of the motor controller, thereby achieving a seal between the present application and the housing 51 of the motor controller.

[0047] In this embodiment, a first sealing ring 310 is provided on the outer periphery of each mounting tube 110. In other embodiments, a sealing ring 310 surrounds all mounting tubes 110, which is not specifically limited here.

[0048] The second sealing ring 320 is an annular structure made of elastic material. The second sealing ring 320 is embedded in the second limiting groove 230 on the outer peripheral surface of the terminal 200. When the terminal 200 is installed on the mounting ring, the second sealing ring 320 is sandwiched in the annular gap between the terminal 200 and the mounting tube 110. The outer ring side of the second sealing ring 320 abuts against the inner wall of the mounting tube 110, and the inner ring side of the second sealing ring 320 abuts against the groove wall and the bottom of the second limiting groove 230 of the terminal 200, so as to achieve a seal between the terminal 200 and the mounting tube 110. It should also be noted that during the installation process, the second sealing ring 320 is first installed on the outer periphery of the terminal 200 and partially embedded in the second limiting groove 230, and then the terminal 200 is inserted into the mounting tube 110. During the installation of the terminal 200, the second limiting groove 230 limits the second sealing ring 320, preventing the second sealing ring 320 from sliding on the outer periphery of the terminal 200 during the installation process. This ensures that the second sealing ring 320 can be accurately installed in the pre-installation position, thereby preventing poor sealing between the terminal 200 and the mounting tube 110.

[0049] Referring to Figures 4 and 5, the choke ring 400 has a ring structure, and the shape of the annular groove 1011 is adapted to the choke ring 400. The choke ring 400 is integrally embedded in the annular groove 1011. The structure of this application, in which a single choke ring 400 surrounds all terminals 200, simplifies the production process and reduces production costs. The choke ring 400 includes an iron core 410 and an insulating layer 420 covering the iron core 410. The insulating layer 420 is an adhesive material, and the choke ring 400 is bonded to the annular groove 1011 through the insulating layer 420 to prevent the choke ring 400 from falling out of the annular groove 1011 due to vehicle vibration. The choke ring 400 filters the high-frequency harmonics generated in the high-voltage circuit of this application, reducing the interference of high-frequency harmonics on other electrical components, thereby improving the EMC performance of the motor drive system.

[0050] For example, EMC (Electromagnetic Compatibility) refers to the ability of a device or system to operate in its electromagnetic environment without causing intolerable electromagnetic interference to any other device in that environment.

[0051] In this embodiment, a single choke ring 400 surrounds all terminals 200 within the mounting tubes 110. In other embodiments, each mounting tube 110 may be surrounded by a separate choke ring 400, which is not specifically limited here.

[0052] It should be noted that the three terminals 200 in this embodiment are arranged in a curved shape, that is, the arrangement directions of the three terminals 200 are not in a straight line. The choke ring 400 is an irregular ring structure adapted to the layout of the terminals 200, so that each terminal 200 is adjacent to the choke ring 400 on both sides in at least one direction in the plane where the choke ring 400 is located, so as to ensure the filtering effect of the choke ring 400 on the high-frequency harmonics in the high-voltage circuit.

[0053] Referring to Figures 6 and 7, this application also discloses a motor controller, which includes the aforementioned motor controller output structure. The motor controller further includes a housing 51 and a transformer. The housing 51 has an internal mounting chamber and includes an upper shell 512 and a lower shell 511 opposite each other in the thickness direction W, forming the mounting chamber. The motor controller output structure and the inverter 52 are both mounted on the lower shell 511. Three through holes 5121, corresponding one-to-one with terminals 200, are provided on the upper shell 512 at positions corresponding to the motor controller output structure. The mounting tube 110 and terminals 200 are at least partially embedded in the through holes 5121. In the thickness direction W, the through holes 5121, projected onto the reference plane 1, are accommodated within the area surrounded by the first sealing ring 310 projected onto the reference plane 1, and the first sealing ring 310 abuts against the upper shell 512. The inverter 52 has three electrical connectors 521 that correspond one-to-one with the terminals 200. Screws pass through the electrical connectors 521 and engage with the second screw hole 220 to connect the electrical connection to the terminals 200.

[0054] On the other hand, this application also discloses a motor drive system, which includes the aforementioned motor controller and the wiring structure of the motor controller. The motor drive system further includes: a motor body, including a rotor assembly and a stator assembly, wherein the stator assembly is disposed around the central axis of the motor body on the outer periphery of the rotor assembly, the number of phases of the stator assembly is equal to the number of terminals, and the stator assembly is electrically connected to the terminals 200 of the motor controller; wherein the motor controller is disposed at one end of the motor body on the central axis.

[0055] This application improves the integration of the motor controller's wiring structure by integrating the sealing assembly 300 and the choke ring 400 into the same housing 10, thereby meeting the miniaturization requirements of the motor controller and motor drive system. Furthermore, because the motor controller of this application has a small thickness W, it can be positioned at one end of the central axis of the motor body. Compared to the prior art where the motor controller is positioned on the radial side of the motor body, the motor drive system of this application has a smaller height, reducing the space occupied by the motor drive system in the engine compartment. This improves the adaptability of the motor drive system while increasing the space in the passenger compartment, providing more seating space and improving vehicle passenger comfort.

[0056] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. All equivalent variations and modifications made in accordance with the shape, structure, features and spirit described in the claims of this application shall be included within the scope of the claims of this application.

Claims

1. A wiring structure for a motor controller, wherein, The outgoing wiring structure of the motor controller includes: a housing (10), the housing (10) including at least one mounting pipe (110) penetrating the housing (10); At least one terminal (200) is disposed within the mounting tube (110); A sealing assembly (300) for sealing the gap between the housing (10) and the housing (51) of the motor controller, and the gap between the terminal (200) and the mounting tube (110); At least one choke ring (400) is disposed within the housing (100) and surrounds the outer periphery of the mounting tube (110).

2. The outgoing wiring structure of the motor controller as described in claim 1, wherein, The sealing assembly (300) includes at least one first sealing ring (310) and at least one second sealing ring (320). The first sealing ring (310) surrounds the mounting tube (110) and is sandwiched between the housing (10) and the outer shell (51). The second sealing ring (320) is sleeved on the outer periphery of the terminal (200) and sandwiched between the terminal (200) and the inner wall of the mounting tube (110).

3. The outgoing wiring structure of the motor controller as described in claim 2, wherein, The circumferential surface of the terminal (200) is provided with a second limiting groove (230), and the second sealing ring (320) is partially embedded in the second limiting groove (230).

4. The outgoing wiring structure of the motor controller as described in claim 2, wherein, Each of the mounting tubes (110) is surrounded by the first sealing ring (310), wherein one of the first sealing rings (310) surrounds at least one of the mounting tubes (110).

5. The wiring structure of the motor controller as described in claim 1 or 2, wherein, Each of the mounting tubes (110) is surrounded by a choke ring (400), wherein one of the choke rings (400) surrounds at least one of the mounting tubes (110).

6. The wiring structure of the motor controller as described in claim 1, wherein, The housing has an internal accommodating cavity (101). The housing (10) also includes a partition (130) disposed in the accommodating cavity (101). The partition (130) cooperates with the mounting tube (110) to divide the space of the accommodating cavity other than the mounting tube (110) into an annular groove (1011) and a hollow groove (1012). The choke ring (400) is embedded in the annular groove (1011).

7. The outgoing wiring structure of the motor controller as described in claim 6, wherein, The housing (10) has an opening (10021) on one side surface that communicates with the accommodating cavity (101); the choke ring (400) is embedded in the annular groove (1011) through the opening (10021).

8. The wiring structure of the motor controller as described in claim 1, wherein, The housing (10) is an integral structure.

9. The wiring structure of the motor controller as described in any one of claims 1-8, wherein, The shell (10) is made of engineering plastics.

10. The wiring structure of the motor controller as described in claim 1, wherein, The choke ring (400) includes an iron core (410) and an insulating layer (420), wherein the insulating layer (420) covers the iron core (410); The insulating layer (420) is an adhesive material, and the choke ring (400) is bonded to the housing (10) through the insulating layer (420).

11. A motor controller, comprising the outgoing wiring structure of the motor controller according to any one of claims 1-10, wherein, The motor controller also includes: The housing (51) has an internal mounting chamber, and the surface of the housing (51) has a wire passage hole (5121) communicating with the mounting chamber; the wiring structure of the motor controller is installed inside the housing (51), and the terminal (200) is exposed from the wire passage hole (5121); An inverter (52) is installed inside the housing (51). The inverter (52) has a number of electrical connectors (521) corresponding to the number of terminals (200). The electrical connectors (521) are fixedly connected to the terminals (200) one by one.

12. A motor drive system, comprising the output wiring structure of the motor controller according to any one of claims 1-10, wherein, The motor drive system also includes: The motor body includes a rotor assembly and a stator assembly. The stator assembly is disposed around the central axis of the motor body on the outer periphery of the rotor assembly, and the stator assembly is electrically connected to the terminal (200).

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