Motor controller, electric drive apparatus, electric drive system and electric device

Abstract

The present application relates to the technical field of electric drive, and provides a motor controller, an electric drive apparatus, an electric drive system, and an electric device. The motor controller comprises two power modules, a bus capacitor, and a direct current connector, wherein the two power modules are arranged side by side in a first direction, and each power module is provided with first input terminals and second input terminals having opposite polarities; the bus capacitor is located between the two power modules and is provided with first output terminals and second output terminals; the direct current connector is located between the two power modules and is stacked with the bus capacitor in a second direction; the direct current connector comprises a first electrode member and a second electrode member which are separated and stacked in the second direction; the first electrode member is electrically connected to the first output terminals and the first input terminals of the two power modules; and the second electrode member is electrically connected to the second output terminals and the second input terminals of the two power modules. The motor controller provided in embodiments of the present application reduces stray inductance and improves the performance of the electric drive apparatus.

Description

Motor controllers, electric drive units, electric drive systems and electric equipment

[0001] This application claims priority to Chinese Patent Application No. 202423323385.3, filed on December 31, 2024, entitled "Motor Controller, Electric Drive Device, Electric Drive System and Electric Equipment", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application belongs to the field of electric drive technology, and more specifically, relates to a motor controller, electric drive device, electric drive system and electric equipment. Background Technology

[0003] With increasing environmental pollution, new energy vehicles are gaining popularity. The electric drive system, as the power unit of new energy vehicles, converts the electrical energy provided by the battery into mechanical energy to propel the vehicle.

[0004] In the development of new energy technologies, how to improve the performance of electric drive devices is a technical problem that urgently needs to be solved. Summary of the Invention

[0005] The purpose of this application is to provide a motor controller, an electric drive device, an electric drive system, and an electric equipment to solve the technical problem of poor performance of electric drive devices in related technologies.

[0006] To achieve the above objectives, the technical solution adopted in this application embodiment is as follows: a motor controller is provided, comprising: two power modules arranged side by side along a first direction, each power module having a first input terminal and a second input terminal with opposite polarities; a bus capacitor located between the two power modules, the bus capacitor having a first output terminal and a second output terminal with opposite polarities; and a DC connector located between the two power modules and stacked with the bus capacitor along a second direction, the second direction being perpendicular to the first direction, the DC connector including a first electrode and a second electrode with opposite polarities, the first electrode and the second electrode being separated and stacked along the second direction, the first electrode being electrically connected to the first output terminal and the first input terminal of the two power modules, and the second electrode being electrically connected to the second output terminal and the second input terminal of the two power modules.

[0007] The motor controller provided in this application includes two power modules, a bus capacitor, and a DC connector. By arranging the two power modules side by side and placing the bus capacitor between them, space is saved. Each power module can be directly electrically connected to its corresponding motor via the AC connector, eliminating the need for bending the AC connector or setting up complex wiring harnesses, thus reducing component costs. Simultaneously, the current transmission path between the motor controller and the motor is effectively shortened, thereby effectively reducing stray inductance generated during current transmission. Furthermore, the DC connector, located between the two power modules and stacked with the bus capacitor, allows each power module to be electrically connected to the bus capacitor. This results in a more compact component arrangement in the motor controller, saving space. The DC connector includes a stacked first electrode and a second electrode, which has the advantage of low stray inductance. Therefore, the motor controller provided in this application reduces stray inductance, which is beneficial for improving the performance of the electric drive device.

[0008] In some embodiments, the second electrode is located between the first electrode and the bus capacitor, and the second electrode has a first through hole, through which the first electrode is connected to the first output terminal.

[0009] By adopting the above technical solution, the first electrode is connected to the first output terminal through the first through hole on the second electrode, saving the space occupied by the DC connector, and the first electrode can be stacked with the second electrode in areas other than the first through hole to reduce stray inductance.

[0010] In some embodiments, the DC connector further includes an insulating member, at least a portion of which is disposed between the first electrode and the second electrode; the insulating member has a second through hole, which corresponds to and communicates with the first through hole, and the first electrode is connected to the first output terminal through the first through hole and the second through hole.

[0011] By adopting the above technical solution, the insulating component can insulate and separate the first electrode component from the second electrode component. The insulating component is provided with a second through hole so that the first electrode component can be connected to the bus capacitor through the second through hole and the first through hole.

[0012] In some embodiments, the insulating element covers at least a portion of the first electrode element.

[0013] By adopting the above technical solution, the insulating component can insulate the first electrode component from other components in the motor controller, effectively reducing the risk of short circuit in the motor controller and thus effectively improving the working reliability of the motor controller.

[0014] In some embodiments, there are multiple first output terminals and multiple second output terminals. The multiple first output terminals and multiple second output terminals are alternately and separately arranged along a third direction. The third direction is perpendicular to the second direction and intersects the first direction. The second electrode is provided with multiple first through holes arranged along the third direction. Each first through hole exposes a first output terminal.

[0015] By adopting the above technical solution, the structure of the motor controller is more compact and saves space; the stacked area of ​​the first electrode and the second electrode is larger and the stray inductance is smaller.

[0016] In some embodiments, the first input terminal and the second input terminal are located on the side of the power module near the DC connector, and the first input terminal and the second input terminal are spaced apart in a first direction; along the second direction, the first input terminal is located on the side of the second input terminal near the DC connector; the first electrode is connected to the first input terminals of the two power modules on both sides of the first direction, and the second electrode is connected to the second input terminals of the two power modules on both sides of the first direction.

[0017] By adopting the above technical solution, it is convenient to use DC connectors to make electrical connections with power modules, reducing the size and space occupied by DC connectors; DC connectors can be adapted to the first input terminal and the second input terminal on the power module without bending the first electrode and the second electrode; the manufacturing tolerance of DC connectors is small and the reliability of motor controller is high.

[0018] In some embodiments, the first electrode has extensions on both sides along the first direction, the extensions extending to the outer side of the second electrode along the first direction, and the first electrode is connected to the first input terminal through the extensions.

[0019] By adopting the above technical solution, the first electrode can be connected to the first input terminals of the two power modules through its extensions on both sides. The DC connector occupies less space, the motor controller has a compact structure, and the middle part of the first electrode overlaps with the second electrode, which reduces stray inductance.

[0020] In some embodiments, the motor controller further includes a housing, within which two power modules, a DC connector, and a bus capacitor are disposed. The bus capacitor includes a core encapsulated within the housing.

[0021] By adopting the above technical solution, the core of the bus capacitor is arranged between the two power modules in a potting manner. The height of the power module is higher than the height of the core, which makes full use of the space below the power module. Moreover, the potting has a good cooling effect and can further reduce the volume of the capacitor.

[0022] In some embodiments, the bus capacitor further includes a first busbar, a second busbar, and an insulating support disposed on the core. Both the first busbar and the second busbar are electrically connected to the core. The first busbar is provided with a first output terminal, and the second busbar is provided with a second output terminal. The first output terminal and the second output terminal are disposed separately on the insulating support.

[0023] By adopting the above technical solution, the core is arranged in the housing by potting, and the first output terminal and the second output terminal are set on the insulating bracket and can be exposed outside the potting compound, which facilitates the connection of DC connectors.

[0024] In some embodiments, along the second direction, the orthogonal projection of the second electrode toward the first electrode falls entirely inside the first electrode.

[0025] By adopting the above technical solution, the stacked area between the first electrode and the second electrode is large, which effectively reduces the stray inductance of the DC connector.

[0026] In some embodiments, the first electrode is laser-welded to the bus capacitor; and / or, the second electrode is laser-welded to the bus capacitor.

[0027] By adopting the above technical solution, the contact resistance is reduced and the manufacturing process is simplified.

[0028] In some embodiments, the first electrode and the second electrode have the same thickness.

[0029] By adopting the above technical solutions, the installation process was simplified and the manufacturing yield was improved.

[0030] In some embodiments, the first electrode is laser-welded to the first input terminal; and / or, the second electrode is laser-welded to the second input terminal.

[0031] By adopting the above technical solution, the installation process is simplified and the contact resistance is reduced.

[0032] In some embodiments, the two opposite sides of the first electrode along the second direction are planar; and / or, the two opposite sides of the second electrode along the second direction are planar.

[0033] By adopting the above technical solution, both the first electrode and the second electrode are flat sheets that do not require bending, which reduces manufacturing tolerance and improves manufacturing yield.

[0034] In some embodiments, the distance between the first electrode and the second electrode along the second direction ranges from 0.2 mm to 1.5 mm.

[0035] By adopting the above technical solution, the first electrode and the second electrode can be conveniently connected to the power module respectively, and the two can maintain a gap and insulation between them; the first electrode and the second electrode are stacked on each other with a small gap, resulting in a small stray inductance.

[0036] In some embodiments, the motor controller further includes a housing, in which two power modules, a DC connector, and a bus capacitor are all housed; the motor controller also includes two AC connectors, which are connected to the two power modules one-to-one, with one end of each AC connector extending into the external environment of the housing and used for direct electrical connection to the motor.

[0037] By adopting the above technical solution, the motor controller directly connects to the motor through the housing with the AC connector, without the need for wiring harnesses, adapters, or other components to connect the AC connector to the motor. This effectively reduces the number of parts in the electric drive device, shortens the current transmission path between the motor controller and the motor, effectively reduces stray inductance generated during current transmission, and effectively improves the performance of the electric drive device using the above motor controller.

[0038] In some embodiments, along a first direction, two AC connectors are located on opposite sides of the two power modules.

[0039] By adopting the above technical solution, two AC connectors are respectively set on opposite sides of the housing, which can easily connect the AC connectors directly to the motor, saving wiring harness costs and further shortening the current transmission path between the motor controller and the motor, thereby further reducing stray inductance generated during current transmission.

[0040] This application also provides an electric drive device, including a motor controller, a first motor and a second motor as described in any of the above embodiments, a power module electrically connected to the first motor and another power module electrically connected to the second motor.

[0041] The electric drive device provided in this application embodiment has at least the following beneficial effects: the electric drive device provided in this application embodiment effectively improves the performance of the electric drive device by adopting the motor controller of any of the above embodiments.

[0042] This application also provides an electric drive system, including a battery and an electric drive device of any of the above embodiments, wherein the battery is electrically connected to the electric drive device.

[0043] The electric drive system provided in this application embodiment has at least the following beneficial effects: the electric drive system provided in this application embodiment effectively improves the performance of the electric drive system by adopting the electric drive device of any of the above embodiments.

[0044] This application also provides an electric device, including the above-described electric drive system.

[0045] The electric device provided in this application embodiment has at least the following beneficial effects: the electric device provided in this application embodiment effectively improves the performance of the electric device by adopting the electric drive system of any of the above embodiments. Attached Figure Description

[0046] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0047] Figure 1 is a structural schematic diagram of the vehicle provided in an embodiment of this application;

[0048] Figure 2 is a schematic diagram of the exploded structure of the battery provided in an embodiment of this application;

[0049] Figure 3 is a schematic diagram of the structure of the electric drive device provided in an embodiment of this application;

[0050] Figure 4 is a perspective view of the motor controller provided in an embodiment of this application;

[0051] Figure 5 is a three-dimensional schematic diagram of the motor controller shown in Figure 4 from another angle;

[0052] Figure 6 is a three-dimensional exploded view of the motor controller provided in the application embodiment after the AC power connector has been removed;

[0053] Figure 7 is a partial enlarged view of part A in Figure 6;

[0054] Figure 8 is a perspective view of the DC connector provided in an embodiment of this application;

[0055] Figure 9 is a side view of the DC connector shown in Figure 8;

[0056] Figure 10 is a three-dimensional exploded view of the DC connector shown in Figure 8;

[0057] Figure 11 is a schematic diagram of the structure of the housing and bus capacitor in the motor controller shown in Figure 4;

[0058] Figure 12 is a schematic diagram of the structure of the housing, bus capacitor, power module and second electrode component in the motor controller shown in Figure 4;

[0059] Figure 13 is a three-dimensional schematic diagram of the housing, bus capacitor, power module and DC connection of the motor controller shown in Figure 4.

[0060] In the figures, the following labels are used: 1. Electric drive system; 10. Electric drive device; 11. Motor controller; 111. Housing; 1111. Receiving cavity; 1112. 112. Outlet hole; 112. Busbar capacitor; 1121. First output terminal; 1122. Second output terminal; 1123. First busbar; 1124. Second busbar; 1125. Insulating bracket; 113. Power module; 1131. First input terminal; 1132. Second input terminal; 114. DC connector; 1141. First electrode; 11411. Extension; 11412. First solder joint; 1142. Second electrode; 11421. First through hole; 11422. Second solder joint; 1143. Insulating component; 11431. Second through hole; 115. AC connector; 12. First motor; 13. Second motor; 20. Battery; 21. Battery box; 211. First part; 212. Second part; 22. Battery cell; 2. Vehicle body. Embodiments of the present invention

[0061] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0062] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0063] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0064] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0065] An electric drive device is a device used to convert electrical energy into mechanical energy. An electric drive device typically includes a motor and a motor controller. The motor controller converts direct current into alternating current and transmits the alternating current to the motor to drive it. The motor controller can also be used to control the motor's operation, such as controlling its speed.

[0066] Currently, an increasing number of new energy vehicles are using dual-motor drives. In related technologies, dual-motor controllers typically use two power modules to drive two motors respectively. These two power modules are positioned adjacent to each other and located on one side of a bus capacitor. The output copper busbars of the bus capacitor can be directly connected to the power modules. However, the output copper busbars of the two power modules are too close together to be directly connected to the motors. Instead, the output copper busbars need to be bent or connected to the motors via complex high-voltage wiring harnesses, resulting in significant stray inductance during current transmission. Furthermore, the positive and negative output copper busbars of the bus capacitor are separated and independent, leading to more stray inductance and affecting the output performance of the power modules. Therefore, the performance of the electric drive device needs improvement.

[0067] To improve the performance of electric drive devices, the motor controller provided in this application saves space by arranging two power modules side-by-side and placing the bus capacitor between them. This allows each power module to be directly connected to its corresponding motor via an AC connector, eliminating the need for bent output copper busbars or complex high-voltage wiring harnesses, thus reducing component costs. It also effectively shortens the current transmission path between the motor controller and the motor, thereby reducing stray inductance generated during current transmission. Simultaneously, a DC connector is positioned between the two power modules and stacked with the bus capacitor, allowing each power module to be electrically connected to the bus capacitor. This results in a more compact component arrangement within the motor controller, saving space. The DC connector includes a first electrode and a second electrode, which are stacked to cancel out stray inductance, resulting in lower stray inductance and improved output performance of the power modules. Therefore, the motor controller provided in this application reduces stray inductance, which is beneficial for improving the performance of the electric drive device.

[0068] The technical solutions described in this application are applicable to electric drive devices and electric equipment using electric drive devices. Electric equipment can be, but is not limited to, vehicles, ships, spacecraft, and electric toys, etc. Vehicles can be gasoline-powered vehicles, natural gas-powered vehicles, or new energy vehicles; new energy vehicles can be pure electric vehicles, hybrid electric vehicles, or range-extended electric vehicles, etc. Spacecraft include airplanes, rockets, space shuttles, and spacecraft, etc. Electric toys include stationary or mobile electric toys, such as electric car toys, electric ship toys, and electric airplane toys, etc.

[0069] For ease of explanation, the following embodiments use a vehicle as an example of an electric device according to an embodiment of this application.

[0070] Please refer to Figure 1, which is a structural schematic diagram of the vehicle provided in this embodiment. The vehicle includes a body 2, a battery 20, and an electric drive unit 10. The body 2 is the main supporting component of the vehicle, and has an engine compartment and a passenger compartment. The engine compartment is used to house the electric drive unit 10, and the passenger compartment provides operating and seating space for the driver and passengers. When the vehicle is a front-wheel drive vehicle, the engine compartment is located at the front of the body 2, i.e., the engine compartment is the front engine compartment; when the vehicle is a rear-wheel drive vehicle, the engine compartment is located at the rear of the body 2, i.e., the engine compartment is the rear engine compartment; when the vehicle is a four-wheel drive vehicle, the engine compartment is divided into a front engine compartment and a rear engine compartment, with the front engine compartment located at the front of the body 2 and the rear engine compartment located at the rear of the body 2. There can be two electric drive units 10, with the two electric drive units 10 located in the front engine compartment and the rear engine compartment, respectively. The battery 20 and the electric drive unit 10 together constitute the electric drive system 1 of the vehicle. The battery 20 can be located at the bottom, front, or rear of the vehicle. The battery 20 can supply power to the electric drive unit 10 to drive the electric drive unit 10. The electric drive unit 10 is used to convert the electrical energy provided by the battery 20 into mechanical energy and output the mechanical energy to the wheels of the vehicle to drive the vehicle.

[0071] Please refer to Figure 2, which is an exploded view of the battery 20 provided in an embodiment of this application. The battery 20 includes a battery case 21 and a battery cell 22, with the battery cell 22 housed within the battery case 21. The battery case 21 provides a space for the battery cell 22 and can have various structures. In some embodiments, the battery case 21 may include a first portion 211 and a second portion 212, which overlap each other, jointly defining a space for accommodating the battery cell 22. The second portion 212 may be a hollow structure with one open end, and the first portion 211 may be a plate-like structure, covering the open side of the second portion 212 so that the first portion 211 and the second portion 212 jointly define the space. Alternatively, the first portion 211 and the second portion 212 may both be hollow structures with one open side, with the open side of the first portion 211 covering the open side of the second portion 212 so that the first portion 211 and the second portion 212 jointly define the space. Of course, the battery box 21 formed by the first part 211 and the second part 212 can be of various shapes, such as cylinder, cuboid, etc., and no specific limitation is made here.

[0072] In some embodiments, the battery box 21 may be part of the vehicle's chassis structure. For example, a portion of the battery box 21 may be at least a portion of the vehicle's floor, or a portion of the battery box 21 may be at least a portion of the vehicle's crossbeams and longitudinal beams.

[0073] Of course, in some embodiments, the battery 20 may not include the battery box 21, but rather multiple battery cells 22 are electrically connected and assembled into the vehicle after being formed into a whole by necessary fixing structures.

[0074] In battery 20, there can be multiple battery cells 22, which can be connected in series, parallel, or in a mixed manner. A mixed connection means that multiple battery cells 22 are connected in both series and parallel configurations. Multiple battery cells 22 can be directly connected in series, parallel, or in a mixed manner, and then the entire assembly of the multiple battery cells 22 is housed within battery box 21. Alternatively, battery 20 can also consist of multiple battery cells 22 first connected in series, parallel, or in a mixed manner to form a battery module, and then multiple battery modules connected in series, parallel, or in a mixed manner to form a whole, which is then housed within battery box 21. Battery 20 may also include other functional components; for example, it may include a busbar for electrical connection between the multiple battery cells 22.

[0075] Each battery cell 22 can be a secondary battery cell or a primary battery cell. A secondary battery cell refers to a battery cell 22 that can be recharged to activate its active materials and continue to be used after being discharged. A primary battery cell refers to a battery cell 22 that cannot be recharged to activate its active materials and continue to be used after its electrical energy is depleted. The battery cell 22 can also be a lithium-ion battery cell, a sodium-ion battery cell, a sodium-lithium-ion battery cell, a lithium metal battery cell, a sodium metal battery cell, a lithium-sulfur battery cell, a magnesium-ion battery cell, a nickel-metal hydride battery cell, a nickel-cadmium battery cell, a lead-acid battery cell, etc., but is not limited thereto. The battery cell 22 can be a cylindrical battery cell, a prismatic battery cell, a pouch battery cell, or a battery cell of other shapes. Prismatic battery cells include prismatic battery cells, blade-shaped battery cells, and multi-prismatic battery cells, such as hexagonal prismatic battery cells, etc. This application does not have any particular limitations.

[0076] Please refer to Figure 3, which is a schematic diagram of the structure of the electric drive device 10 provided in an embodiment of this application. The electric drive device 10 includes a motor controller 11, a first motor 12, and a second motor 13. The first motor 12 and the second motor 13 are respectively used to convert the electrical energy provided by the battery 20 into mechanical energy. The first motor 12 and the second motor 13 can be, but are not limited to, axial flux motors, radial flux motors, servo motors, brushed motors, brushless motors, etc. During the operation of the electric drive device 10, the rotational speed of the first motor 12 and the rotational speed of the second motor 13 can be the same, or the rotational speeds of the first motor 12 and the second motor 13 can be different.

[0077] In some embodiments, the shafts of the first motor 12 and the second motor 13 are parallel, and the first motor 12 may be coaxially arranged with the second motor 13, that is, the central axis of the first motor 12 and the central axis of the second motor 13 coincide. The "central axis" of the motor refers to the axial center line of the motor's shaft (or "rotor shaft"). As an example, the shaft of the first motor 12 is connected to one of the left front wheel and the right front wheel of the vehicle, and the shaft of the second motor 13 is connected to the other of the left front wheel and the right front wheel of the vehicle; or, the shaft of the first motor 12 is connected to one of the left rear wheel and the right rear wheel of the vehicle, and the shaft of the second motor 13 is connected to the other of the left rear wheel and the right rear wheel of the vehicle.

[0078] Of course, in other embodiments, the first motor 12 may also be coaxial with the second motor 13, that is, the central axis of the second motor 13 may be spaced apart from the central axis of the first motor 12 in any direction perpendicular to the central axis of the first motor 12.

[0079] The motor controller 11 is used to convert the DC current output by the battery 20 into AC current and send the AC current to the first motor 12 and the second motor 13. The motor controller 11 can also be used to control the operation of the first motor 12 and the second motor 13. For example, the motor controller 11 is used to control the start, stop, speed, torque, etc. of the first motor 12 and the second motor 13. In other words, the first motor 12, the second motor 13, and the battery 20 are electrically connected to the motor controller 11. The DC current output by the battery 20 can be transmitted to the motor controller 11 through the current transmission path between the battery 20 and the motor controller 11. After the motor controller 11 converts the DC current into AC current, the AC current can be transmitted to the first motor 12 and the second motor 13 through the current transmission paths between the motor controller 11 and the first motor 12 and between the motor controller 11 and the second motor 13 to drive the first motor 12 and the second motor 13 to operate. At the same time, the control signal of the motor controller 11 can be transmitted to the first motor 12 through the current transmission path between the motor controller 11 and the first motor 12, and can be transmitted to the second motor 13 through the current transmission path between the motor controller 11 and the second motor 13. The operating status signal of the first motor 12 can be transmitted to the motor controller 11 through the current transmission path between the motor controller 11 and the first motor 12, and the operating status signal of the second motor 13 can be transmitted to the motor controller 11 through the current transmission path between the motor controller 11 and the second motor 13, so that the motor controller 11 can control the operation of the first motor 12 and the second motor 13.

[0080] The electric drive unit 10 may further include a transmission mechanism for transmitting the mechanical energy to the vehicle wheels by changing the speed and torque of the first motor 12 and the second motor 13. For example, the transmission mechanism transmits the mechanical energy to the vehicle wheels by decreasing the speed of the first motor 12 and the speed of the second motor 13 while increasing the torque of the first motor 12 and the second motor 13. Alternatively, the transmission mechanism transmits the mechanical energy to the vehicle wheels by increasing the speed of the first motor 12 and the speed of the second motor 13 while decreasing the torque of the first motor 12 and the second motor 13. The transmission mechanism may be, but is not limited to, a gear transmission mechanism, a worm gear transmission mechanism, a planetary gear transmission mechanism, a continuously variable transmission mechanism, etc.

[0081] To illustrate the technical solutions provided in this application, the following detailed description is provided in conjunction with specific drawings and embodiments.

[0082] Firstly, referring to Figures 4 to 7, this application provides a motor controller 11, including a bus capacitor 112, two power modules 113, and a DC connector 114. The two power modules 113 are arranged side-by-side along a first direction X, and each power module 113 has a first input terminal 1131 and a second input terminal 1132 with opposite polarities. The bus capacitor 112 is located between the two power modules 113, and the bus capacitor 112 has a first output terminal 1121 and a second output terminal 1122 with opposite polarities. The DC connector 114 is located between the two power modules. Blocks 113 are stacked together with bus capacitor 112 along the second direction Z, which is perpendicular to the first direction X. The DC connector 114 includes a first electrode 1141 and a second electrode 1142 with opposite polarities. The first electrode 1141 and the second electrode 1142 are separated and stacked along the second direction Z. The first electrode 1141 is electrically connected to the first output terminal 1121 and the first input terminal 1131 of the two power modules 113. The second electrode 1142 is electrically connected to the second output terminal 1122 and the second input terminal 1132 of the two power modules 113.

[0083] The bus capacitor 112 is used to smooth the bus voltage, reduce voltage fluctuations and noise, and improve the stability and reliability of the motor controller 11. In this embodiment, the bus capacitor 112 smooths and filters the DC current carrying high-frequency impurities, and then transmits the DC current to the power module 113 through the DC connector 114. The bus capacitor 112 is provided with a first output terminal 1121 and a second output terminal 1122, one of which is a positive output terminal and the other is a negative output terminal.

[0084] For example, the first output terminal 1121 and the second output terminal 1122 are square, which helps to increase the contact area between the bus capacitor 112 and the DC connector 114; the first output terminal 1121 and the second output terminal 1122 can also be circular or other shapes.

[0085] For example, the first output terminal 1121 is the positive connection point, and the second output terminal 1122 is the negative connection point. The first electrode 1141 is fixedly connected to and electrically connected to the first output terminal 1121, and the second electrode 1142 is fixedly connected to and electrically connected to the second output terminal 1122. Thus, the bus capacitor 112 is electrically connected to the first electrode 1141 through the first output terminal 1121, and electrically connected to the second electrode 1142 through the second output terminal 1122.

[0086] Power module 113 is used to convert the DC current output by battery 20 into AC current. Power module 113 can be, but is not limited to, silicon carbide power module 113, insulated gate bipolar transistor (IGBT) power module 113, etc. Two power modules 113 are arranged side by side in the receiving cavity 1111 along a first direction X. The first direction X can be the length direction or the width direction of motor controller 11, or it can be a direction inclined relative to the length direction of motor controller 11. Each power module 113 is provided with a first input terminal 1131 and a second input terminal 1132 with opposite polarities, that is, one of the first input terminal 1131 and the second input terminal 1132 is a positive input terminal and the other is a negative input terminal.

[0087] In some embodiments, the motor controller 11 may further include a control module, which includes a main control unit and a drive unit. The main control unit is the core control device of the motor controller 11, used to control the operation of the motor, such as controlling the motor's start / stop, speed, and torque. The drive unit is electrically connected between the main control unit and the power module 113, and is used to convert the logic signals output by the main control unit into the voltage and current signals required to drive the power module 113. The main control unit and the drive unit can be integrated into a single unit, or they can be set as two independent electronic modules.

[0088] In some embodiments, the motor controller 11 may further include an AC connector 115, which is a component for electrically connecting the power module 113 and the motor. The AC connector 115 may be, but is not limited to, a copper busbar, wire, etc.

[0089] In this embodiment, since the two power modules 113 are arranged side by side and the bus capacitor 112 is located between the two power modules 113, the distance between the two power modules 113 is relatively large. This allows the two power modules 113 to be directly electrically connected to the two motors distributed on both sides through the corresponding AC connectors 115. The two power modules 113 do not need to be connected to the motors through bent AC copper busbars or complex high-voltage harnesses, which reduces component costs, saves space, and reduces stray inductance generated during current transmission.

[0090] A DC connector 114 is used to electrically connect the power module 113 and the bus capacitor 112 to provide DC current to the power module 113. In this embodiment, the DC connector 114 is located between the two power modules 113 along a first direction X, so that the DC connector 114 can connect to both power modules 113 simultaneously; the DC connector 114 and the bus capacitor 112 are stacked along a second direction Z, and the second direction Z and the first direction X can be perpendicular or substantially perpendicular to each other. The second direction Z can be the height direction of the motor controller 11. In this embodiment, the DC connector 114 is located above the bus capacitor 112. In another embodiment, the DC connector 114 can also be located below the bus capacitor 112.

[0091] The DC connector 114 includes a first electrode 1141 and a second electrode 1142. The polarities of the first electrode 1141 and the second electrode 1142 are opposite, meaning that one of the first electrode 1141 and the second electrode 1142 is a positive electrode, and the other is a negative electrode. As an example, the first electrode 1141 is the positive electrode, and the second electrode 1142 is the negative electrode.

[0092] The first electrode 1141 and the second electrode 1142 are separated, that is, the first electrode 1141 and the second electrode 1142 do not contact each other, so that the first electrode 1141 and the second electrode 1142 are insulated from each other.

[0093] The first electrode 1141 and the second electrode 1142 are stacked, meaning that at least a portion of the first electrode 1141 and at least a portion of the second electrode 1142 are stacked. In some embodiments, both the first electrode 1141 and the second electrode 1142 have a sheet-like structure, and the DC connector 114 can be a stacked busbar. In some related technologies, the positive and negative connecting copper busbars between the power module 113 and the bus capacitor 112 are independent and do not overlap, resulting in high stray inductance. In this embodiment, the first electrode 1141 and the second electrode 1142 are stacked, which reduces stray inductance.

[0094] The first electrode 1141 is electrically connected to the first output terminal 1121 and the first input terminal 1131 of the two power modules 113, and the second electrode 1142 is electrically connected to the second output terminal 1122 and the second input terminal 1132 of the two power modules 113. In this way, the DC connector 114 can electrically connect the bus capacitor 112 to each power module 113 respectively, so that the bus capacitor 112 can supply DC power to each power module 113.

[0095] It is understood that the first electrode 1141, the first output terminal 1121, and the first input terminal 1131 have the same polarity, and the second electrode 1142, the second output terminal 1122, and the second input terminal 1132 have the same polarity. For example, the first electrode 1141, the first output terminal 1121, and the first input terminal 1131 are all positive, and the second electrode 1142, the second output terminal 1122, and the second input terminal 1132 are all negative.

[0096] The working principle of the motor controller 11 is as follows: After the battery introduces DC power into the motor controller, the bus capacitor 112 smooths and filters the DC current containing high-frequency impurities, and then transmits the DC power to the two power modules 113 through the DC power connector 114, so that the power modules 113 can operate smoothly; the power modules 113 convert DC power into three-phase AC power, which is controlled by the circuit board and output through the AC power connector 115 to drive the motor to rotate and provide power to the new energy vehicle.

[0097] The DC current output from the bus capacitor 112 enters the DC connector 114 through the first output terminal 1121 and the second output terminal 1122. Then, a portion of the DC current is input into one power module 113 through the DC connector 114, and another portion of the DC current is input into another power module 113 through the DC connector 114.

[0098] The motor controller 11 provided in this embodiment includes two power modules 113, a bus capacitor 112, and a DC connector 114. By arranging the two power modules 113 side by side and placing the bus capacitor 112 between the two power modules 113, space can be saved. Furthermore, each power module 113 can be directly electrically connected to its corresponding motor via an AC connector 115, eliminating the need to bend the AC connector 115 or install complex wiring harnesses, thus reducing component costs. Simultaneously, the current transmission path between the motor controller 11 and the motor is effectively shortened, thereby effectively reducing... The stray inductance generated during current transmission is reduced. Simultaneously, the DC connector 114 is disposed between the two power modules 113 and stacked with the bus capacitor 112. The DC connector 114 can electrically connect the two power modules 113 to the bus capacitor 112 respectively. The components in the motor controller 11 are arranged more compactly, saving space. The first electrode 1141 and the second electrode 1142 in the DC connector 114 are stacked, which can cancel out stray inductance. The DC connector 114 has the advantage of low stray inductance, which is beneficial to improving the output performance of the power modules 113. Therefore, the motor controller 11 provided in this embodiment reduces stray inductance, which is beneficial to improving the performance of the electric drive device 10.

[0099] Please refer to Figures 7 to 10. In some embodiments, the second electrode 1142 is located between the first electrode 1141 and the bus capacitor 112. The second electrode 1142 is provided with a first through hole 11421. The first electrode 1141 is connected to the first output terminal 1121 through the first through hole 11421.

[0100] The DC connector 114 and the bus capacitor 112 are stacked along the second direction Z, that is, the first electrode 1141, the second electrode 1142, and the bus capacitor 112 are stacked sequentially along the second direction Z. The second electrode 1142 can be directly connected to the bus capacitor 112. The second electrode 1142 is provided with a first through hole 11421. The first through hole 11421 can be square, circular, elliptical, etc., and there can be one or more first through holes. The first through hole 11421 is arranged opposite to the first output terminal 1121 to expose the first output terminal 1121. The first through hole 11421 is used for connecting the first electrode 1141 and the bus capacitor 112.

[0101] By adopting the above technical solution, the first electrode 1141, the second electrode 1142 and the bus capacitor 112 are stacked in sequence. The second electrode 1142 is directly connected to the second output terminal 1122 on the bus capacitor 112. The first electrode 1141 is connected to the first output terminal 1121 through the first through hole 11421 on the second electrode 1142. This saves the space occupied by the DC connector 114. In addition, the first electrode 1141 and the second electrode 1142 can be stacked in the area other than the first through hole 11421 to reduce stray inductance.

[0102] In some embodiments, the first output terminal 1121 and the second output terminal 1122 are both located in the middle of one side of the bus capacitor 112. The first electrode 1141 is connected to the first output terminal 1121 through the first through hole 11421, and the second electrode 1142 is attached to the bus capacitor 112 and directly connected to the second output terminal 1122.

[0103] In other embodiments, the first output terminal 1121 may also extend to the outside of the second electrode 1142 to facilitate connection to the first electrode 1141.

[0104] In some embodiments, the DC connector 114 further includes an insulating member 1143, at least a portion of which is disposed between the first electrode member 1141 and the second electrode member 1142; the insulating member 1143 is provided with a second through hole 11431, which corresponds to and communicates with the first through hole 11421, and the first electrode member 1141 is connected to the first output terminal 1121 through the first through hole 11421 and the second through hole 11431.

[0105] Insulating component 1143 is a component used to insulate and separate the first electrode component 1141 and the second electrode component 1142. Insulating component 1143 can be insulating plastic, insulating paper, etc.

[0106] At least a portion of the insulating member 1143 is located between the first electrode member 1141 and the second electrode member 1142. The insulating member 1143 is provided with a second through hole 11431 that corresponds to and communicates with the first through hole 11421, so that the first electrode member 1141 can be connected to the first output terminal 1121 on the bus capacitor 112 through the second through hole 11431 and the first through hole 11421.

[0107] By adopting the above technical solution, the insulating component 1143 can insulate and separate the first electrode component 1141 and the second electrode component 1142. The insulating component 1143 is provided with a second through hole 11431 so that the first electrode component 1141 can be connected to the bus capacitor 112 through the second through hole 11431 and the first through hole 11421.

[0108] In some embodiments, the insulating member 1143 covers at least a portion of the first electrode member 1141.

[0109] In some embodiments, the insulating member 1143 can be integrally molded using an injection molding process. As an example, the insulating member 1143 can be injection molded onto the first electrode member 1141, or the insulating member 1143 can be injection molded onto the first electrode member 1141 and the second electrode member 1142, separating the first electrode member 1141 from the second electrode member 1142. Alternatively, the insulating member 1143 can be separately injection molded first, and then assembled together with the first electrode member 1141 and the second electrode member 1142.

[0110] The portion of the first electrode 1141 used to connect the bus capacitor 112 and the portion used to connect the power module 113 are exposed outside the insulating member 1143, while the remaining portion of the first electrode 1141 can be covered inside the insulating member 1143.

[0111] By adopting the above technical solution, the insulating component 1143 can insulate the first electrode component 1141 from the second electrode component and other components in the motor controller 11, effectively reducing the risk of short circuit in the motor controller 11 and thus effectively improving the working reliability of the motor controller 11.

[0112] In some embodiments, there are multiple first output terminals 1121 and multiple second output terminals 1122. The multiple first output terminals 1121 and multiple second output terminals 1122 are alternately and separately arranged along a third direction Y. The third direction Y is perpendicular to the second direction Z and intersects the first direction X. The second electrode 1142 is provided with multiple first through holes 11421 arranged along the third direction Y. Each first through hole 11421 exposes a first output terminal 1121.

[0113] For example, the third direction Y intersects the first direction X perpendicularly, and the third direction Y is, for example, the width direction of the motor controller 11; it can be understood that the third direction Y may also intersect the first direction X at an angle.

[0114] For example, the first electrode 1141 includes a plurality of first connecting portions, which are connected one-to-one with a plurality of first output terminals 1121. The first connecting portion is the area on the first electrode 1141 exposed by the first through hole 11421 and the second through hole. The second electrode 1142 includes a plurality of second connecting portions, which are connected one-to-one with a plurality of second output terminals 1122. The plurality of second connecting portions are separated by the first through hole 11421.

[0115] Optionally, the first electrode 1141 is provided with a plurality of third through holes (not shown in the figure). The third through holes separate the plurality of first connecting portions on the first electrode 1141 from each other, and the third through holes allow the insertion of an insulating structure, further reducing the risk of short circuit.

[0116] As shown in Figure 11, the bus capacitor 112 has three first output terminals 1121 and four second output terminals 1122 alternately arranged along the third direction Y. As shown in Figure 10, the second electrode 1142 has three first through holes 11421, each exposing one first output terminal 1121. It can be understood that the number of first output terminals 1121 and second output terminals 1122 can also be other, for example, there can be three second output terminals 1122.

[0117] Referring to Figures 10 to 13, during assembly, first fix the second electrode 1142 onto the bus capacitor 112, so that the second electrode 1142 is electrically connected to multiple second output terminals 1122, and both sides of the second electrode 1142 are electrically connected to the second input terminals 1132 of the two power modules 113 respectively; then fix the first electrode 1141 onto the bus capacitor 112, so that the first electrode 1141 is electrically connected to multiple first output terminals 1121 through the first through hole 11421, and both sides of the first electrode 1141 are electrically connected to the first input terminals 1131 of the two power modules 113 respectively.

[0118] By adopting the above technical solution, the multiple first output terminals 1121 and multiple second output terminals 1122 are arranged along the third direction Y, which makes the structure of the motor controller 11 more compact and saves space; the first electrode 1141 is connected to the multiple first output terminals 1121 on the bus capacitor 112 through multiple first through holes 11421 on the second electrode 1142, the stacked area of ​​the first electrode 1141 and the second electrode 1142 is large, and the stray inductance is small; and the connection reliability between the first electrode 1141, the second electrode 1142 and the bus capacitor 112 is high.

[0119] Referring to Figures 4, 6, and 7, in some embodiments, the first input terminal 1131 and the second input terminal 1132 are disposed on the side of the power module 113 near the DC connector 114, and the first input terminal 1131 and the second input terminal 1132 are spaced apart in the first direction X; along the second direction Z, the first input terminal 1131 is located on the side of the second input terminal 1132 near the DC connector 114; the first electrode 1141 is connected to the first input terminals 1131 of the two power modules 113 on both sides of the first direction X, and the second electrode 1142 is connected to the second input terminals 1132 of the two power modules 113 on both sides of the first direction X.

[0120] One of the first input terminal 1131 and the second input terminal 1132 is a positive terminal, and the other is a negative terminal. Each power module 113 has three positive terminals and three negative terminals. As an example, the first electrode 1141 is a positive electrode and the first input terminal 1131 is a positive terminal, and the second electrode 1142 is a negative electrode and the second input terminal 1132 is a negative terminal.

[0121] As an example, the three extensions 11411 on one side of the first electrode 1141 are respectively connected to the three first input terminals 1131 in a power module 113.

[0122] In this embodiment, two power modules 113 are arranged side by side, and the first input terminal 1131 and the second input terminal 1132 are both located on the side of the power module 113 closer to the DC connector 114. The two power modules 113 can be regarded as mirror images.

[0123] By adopting the above technical solution, the bus capacitor 112 transmits DC power to the power module 113 through the DC connector 114. Since the first input terminal 1131 and the second input terminal 1132 are both located on the side of the power module 113 close to the bus capacitor 112 and the DC connector 114, it is convenient to make electrical connection between the DC connector 114 and the power module 113, thereby reducing the size and space occupied by the DC connector 114.

[0124] The first input terminal 1131 and the second input terminal 1132 are spaced apart in the first direction X, so that the first input terminal 1131 can be connected to the first electrode 1141 and the second input terminal 1132 can be connected to the second electrode 1142, and interference is less likely to occur.

[0125] Along the second direction Z, the first input terminal 1131 is located on the side of the second input terminal 1132 that is close to the DC connector 114, that is, the height of the first input terminal 1131 is higher than the height of the second input terminal 1132. Correspondingly, the height of the first electrode 1141 is higher than the height of the second electrode 1142, which enables the DC connector 114 to be adapted to the input terminal on the power module 113.

[0126] By adopting the above technical solution, the DC connector 114 can be adapted to the first input terminal 1131 and the second input terminal 1132 on the power module 113, making it convenient to connect the DC connector 114 to the power module 113 without bending the first electrode 1141 and the second electrode 1142. The manufacturing tolerance of the DC connector 114 is small and the reliability of the motor controller 11 is high.

[0127] Referring to Figures 6 to 10, in some embodiments, the first electrode 1141 is provided with extensions 11411 on both sides along the first direction X. The extensions 11411 extend to the outer side of the second electrode 1142 along the first direction X. The first electrode 1141 is connected to the first input terminal 1131 through the extensions 11411.

[0128] The extension portion 11411 is the portion of the first electrode 1141 that extends along the first direction X to the outside of the second electrode 1142. The extension portion 11411 is fixedly connected to the first input terminal 1131 and electrically connected to the first input terminal 1131. The extension portion 11411 is the output terminal portion of the first electrode 1141 used to connect to the power module 113.

[0129] For connection to the power module 113, the extension 11411 is also located on the outside of the insulator 1143. The shape of the extension 11411 may be, but is not limited to, square, trapezoidal, dovetail, etc. The extension 11411 is fixedly connected to and electrically connected to the power module 113.

[0130] In this embodiment, the first electrode 1141 is provided with three extensions 11411 on both sides along the first direction X, and the three extensions 11411 are connected to the three first input terminals 1131 of the power module 113 in a one-to-one correspondence.

[0131] Since the first electrode 1141 and the second electrode 1142 are stacked, by providing extensions 11411 on both sides of the first electrode 1141, the first electrode 1141 can be connected to the first input terminals 1131 of the two power modules 113 through the extensions 11411 on both sides. The DC connector 114 occupies less space, and the structure of the motor controller 11 is compact. At the same time, the middle part of the first electrode 1141 overlaps with the second electrode 1142, which reduces stray inductance.

[0132] In some embodiments, the motor controller 11 further includes a housing 111, in which two power modules 113, a DC connector 114, and a bus capacitor 112 are all disposed; the bus capacitor 112 includes a core, which is encapsulated within the housing 111.

[0133] The housing 111 is a component that provides an internal mounting environment for the motor controller 11. An opening may be provided on the housing 111, through which components such as the power module 113 can be assembled into the internal mounting environment of the motor controller 11. The housing 111 can be a single-piece molded component or an assembled component composed of multiple parts. The material of the housing 111 can be, but is not limited to, copper, iron, aluminum, stainless steel, aluminum alloy, etc. At least a portion of the space within the internal mounting environment of the motor controller 11 constitutes the aforementioned receiving cavity 1111, which is used to accommodate components such as the power module 113.

[0134] In some embodiments, the motor controller 11 may further include a cover that covers the opening side of the housing 111 to isolate the internal installation environment from the external environment of the housing 111. The cover may be integrally connected to the housing 111, for example, by welding the cover to the housing 111 after it is placed on top of the housing 111. Alternatively, the cover may be detachably connected to the housing 111, for example, by fasteners such as screws. The cover may be made of, but is not limited to, copper, iron, aluminum, stainless steel, or aluminum alloy.

[0135] The core is the core component of the bus capacitor 112. There can be one or more cores. The core can be fixed inside the housing 111 using potting compound. Specifically, the core can be placed inside the housing 111 first, then potting compound can be poured into the housing 111. After the potting compound solidifies, the core is fixed inside the housing 111. After fixing the core, the power module 113 is assembled inside the housing 111. The power module 113 is located on top of the bus capacitor 112, and then the DC connector 114 is assembled. It can be understood that after the core is potted inside the housing 111, the potting compound exposes the first output terminal 1121 and the second output terminal 1122.

[0136] By adopting the above technical solution, the core of the bus capacitor 112 is arranged between the two power modules 113 by potting. The height of the power module 113 is higher than the height of the core, which makes full use of the space below the power module 113. Moreover, the potting has a good cooling effect and can further reduce the volume of the capacitor.

[0137] In some embodiments, the bus capacitor 112 further includes a first busbar 1123, a second busbar 1124, and an insulating support 1125 disposed on the core. The first busbar 1123 and the second busbar 1124 are both electrically connected to the core. The first busbar 1123 is provided with a first output terminal 1121, and the second busbar 1124 is provided with a second output terminal 1122. The first output terminal 1121 and the second output terminal 1122 are disposed separately on the insulating support 1125.

[0138] For example, multiple first output terminals 1121 and second output terminals 1122 are arranged at intervals along a third direction Y on an insulating bracket 1125, and the insulating bracket 1125 may be provided with insulating ribs to separate adjacent first output terminals 1121 and second output terminals 1122.

[0139] By adopting the above technical solution, the core is arranged in the housing 111 by potting, and the first output terminal 1121 and the second output terminal 1122 are set on the insulating bracket 1125 and can be exposed outside the potting compound, which facilitates the connection of the DC connector 114.

[0140] In some embodiments, along the second direction Z, the orthogonal projection of the second electrode 1142 toward the first electrode 1141 falls entirely inside the first electrode 1141.

[0141] The first electrode 1141 can completely cover the second electrode 1142. The stacked area between the first electrode 1141 and the second electrode 1142 is large, which effectively reduces the stray inductance of the DC connector 114.

[0142] In other embodiments, the orthographic projection of the second electrode 1142 toward the first electrode 1141 may also partially fall inside the first electrode 1141.

[0143] In some embodiments, the first electrode 1141 is laser-welded to the bus capacitor 112; and / or, the second electrode 1142 is laser-welded to the bus capacitor 112.

[0144] Since the first electrode 1141 and the second electrode 1142 are both stacked on one side of the bus capacitor 112, the overlapping part of the first electrode 1141 and the bus capacitor 112 can be connected by laser welding, and the overlapping part of the second electrode 1142 and the bus capacitor 112 can also be connected by laser welding.

[0145] In some embodiments, the first electrode 1141 is connected to the first output terminal 1121 of the bus capacitor 112 by laser welding, and the second electrode 1142 is connected to the second output terminal 1122 of the bus capacitor 112 by laser welding.

[0146] Optionally, to facilitate welding, the insulating component 1143 is provided with second through holes 11431 on both sides of the welding part of the first electrode component 1141.

[0147] In some related technologies, the output copper busbar of the bus capacitor is connected to the power module by screw fastening, which results in contact resistance and a complex installation process. In the solution provided in this application embodiment, the first electrode 1141 and / or the second electrode 1142 are connected to the bus capacitor 112 by laser welding. Compared with the screw connection method, the contact area is larger, the contact resistance is reduced, and the installation process is simplified.

[0148] In some embodiments, the first electrode 1141 and the second electrode 1142 have the same thickness.

[0149] Both the first electrode 1141 and the second electrode 1142 are sheet-shaped metal conductors, such as copper sheets. In some embodiments, the thickness of both the first electrode 1141 and the second electrode 1142 is 1 mm, resulting in a high welding yield. It is understood that the thickness of the first electrode 1141 and the second electrode 1142 can also be other, for example, 0.5 mm to 2 mm.

[0150] By setting the first electrode 1141 and the second electrode 1142 to have equal thickness, the same welding parameters can be used in the processes of laser welding the first electrode 1141 to the bus capacitor 112 and laser welding the second electrode 1142 to the bus capacitor 112, which further simplifies the installation process and improves the manufacturing yield.

[0151] In some embodiments, the first electrode 1141 is laser-welded to the first input terminal 1131; and / or, the second electrode 1142 is laser-welded to the second input terminal 1132.

[0152] For example, multiple extensions 11411 on both sides of the first electrode 1141 are soldered to the first input terminals 1131 of the two power modules 113, and multiple solder joints on both sides of the second electrode 1142 are soldered to the second input terminals 1132 of the two power modules 113. Figure 12 illustrates one of the first solder joints 11412 between the second electrode 1142 and the power module 113, and Figure 13 illustrates one of the second solder joints 11422 between the first electrode 1141 and the power module 113. For example, the second solder joint 11422 is located on the extension 11411.

[0153] In the motor controller 11 provided in this application embodiment, the DC connector 114 is located between two power modules 113. The first electrode 1141 and the second electrode 1142 are respectively attached to the two power modules 113, which facilitates connection by laser welding, simplifies the installation process, and reduces contact resistance.

[0154] In some embodiments, the two opposite surfaces of the first electrode 1141 along the second direction Z are planes; and / or, the two opposite surfaces of the second electrode 1142 along the second direction Z are planes.

[0155] Optionally, the first input terminal 1131 and the first output terminal 1121 are arranged flush, and the second input terminal 1132 and the second output terminal 1122 can also be arranged flush, which is beneficial for setting the first electrode 1141 and the second electrode 1142 as a flat sheet.

[0156] Since the first electrode 1141 and the second electrode 1142 are stacked on one side of the bus capacitor 112 and can be directly connected to the bus capacitor 112 and the power module 113, the first electrode 1141 and the second electrode 1142 are both flat sheets, which do not require bending, thus reducing manufacturing tolerance and improving manufacturing yield.

[0157] Referring to Figures 7 to 9, in some embodiments, the distance between the first electrode 1141 and the second electrode 1142 along the second direction Z ranges from 0.2 mm to 1.5 mm.

[0158] The distance D between the first electrode 1141 and the second electrode 1142 in the second direction Z can be 0.2mm, 0.5mm, 0.8mm, 1.0mm, 1.2mm, 1.5mm, etc. The smaller the distance D, the more stray inductances are canceled out between the first electrode 1141 and the second electrode 1142.

[0159] This distance is equal to or close to the spacing between the first input terminal 1131 and the second input terminal 1132 on the power module 113 in the second direction Z, so as to facilitate the electrical connection of the DC connector 114 to the power module 113. When this gap is equal to the spacing between the first input terminal 1131 and the second input terminal 1132 on the power module 113 in the second direction Z, the first electrode 1141 and the second electrode 1142 do not need to be bent, which reduces the risk of affecting the yield due to the manufacturing tolerance of bending.

[0160] The distance between the first electrode 1141 and the second electrode 1142 in the second direction Z is greater than or equal to 0.2 mm, which allows the first electrode 1141 and the second electrode 1142 to be easily connected to the power module 113 respectively, and the two can maintain a gap and insulation between them; the distance between the first electrode 1141 and the second electrode 1142 in the second direction Z is less than or equal to 1.5 mm, the first electrode 1141 and the second electrode 1142 are stacked on each other with a small gap, and the stray inductance is small.

[0161] In other embodiments, the first electrode 1141 and / or the second electrode 1142 may also be partially bent to reduce the gap between them and reduce stray inductance.

[0162] In some embodiments, the motor controller 11 further includes a housing 111, in which two power modules 113, a DC connector 114, and a bus capacitor 112 are all disposed. The motor controller 11 also includes two AC connectors 115, which are connected to the two power modules 113 in a one-to-one correspondence. One end of the AC connector 115 extends into the external environment of the housing 111 and is used for direct electrical connection to the motor.

[0163] The AC connector 115 is a component used to electrically connect the power module 113 and the motor. The input terminal of the AC connector 115 is electrically connected to the AC output terminal of the power module 113, and the output terminal of the AC connector 115 is electrically connected to the AC input terminal of the motor. The AC connector 115 can be, but is not limited to, copper busbars, wires, etc.

[0164] The bottom of the housing 111 has two outlet holes 1112. One end of the AC connector 115 is located inside the housing 111 and electrically connected to the power module 113, while the other end extends from the outlet hole 1112 to the external environment of the housing 111 and is used for direct electrical connection to the motor. Direct electrical connection of the AC connector 115 to the motor means that there is no intermediate component between the AC connector 115 and the AC input terminal of the motor; instead, the AC connector 115 is in direct contact with and connected to the AC input terminal of the motor.

[0165] The motor controller 11 provided in this application embodiment directly connects the AC connector 115 to the motor through the housing 111, without the need for wiring harnesses, adapters, or other components to connect the AC connector 115 to the motor. This effectively reduces the number of components in the electric drive device 10 and shortens the current transmission path between the motor controller 11 and the motor, thereby effectively reducing stray inductance generated during current transmission and improving the performance of the electric drive device 10 using the aforementioned motor controller 11.

[0166] In some embodiments, along the first direction X, two AC connectors 115 are located on opposite sides of two power modules 113.

[0167] Two power modules 113 are arranged side by side along the first direction X, and the AC connector 115 is connected to the side of the corresponding power module 113 away from the DC connector 114.

[0168] That is, an AC connector 115, a power module 113, another power module 113, and another AC connector 115 are arranged sequentially along a first direction X, which can be the length direction of the motor controller 11. In another embodiment, the first direction X can be the width direction of the motor controller 11.

[0169] By adopting the above technical solution, the two AC connectors 115 are located on opposite sides of the two power modules 113, and the distance between the two AC connectors 115 is large, which can facilitate the direct electrical connection of the AC connectors 115 to the motor, saving wiring harness costs, further shortening the current transmission path between the motor controller 11 and the motor, thereby further reducing stray inductance generated during current transmission, and further improving the performance of the electric drive device 10 using the above-mentioned motor controller 11.

[0170] Referring to Figures 4 to 13, in some embodiments, the motor controller 11 includes a housing 111, two power modules 113, a bus capacitor 112, and a DC connector 114. The two power modules 113 are arranged side-by-side along a first direction X. The bus capacitor 112 is encapsulated within the housing 111 and located between the two power modules 113. The DC connector 114 is located between the two power modules 113 and is stacked with the bus capacitor 112 along a second direction Z, where Z is the height direction of the motor controller 11. The two power modules 113 are electrically connected to the bus capacitor 112 via the DC connector 114. The DC connector 114 includes a first electrode 1141 and a second electrode 1142 with opposite polarities, separated and stacked. Optionally, the first electrode 1141 is a positive electrode, and the second electrode 1142 is a negative electrode.

[0171] The second electrode 1142 is disposed on the side of the first electrode 1141 near the bus capacitor 112. The second electrode 1142 has a first through hole 11421, and the first electrode 1141 is connected to the bus capacitor 112 through the first through hole 11421. The bus capacitor 112 has a first output terminal 1121 and a second output terminal 1122 on the side facing the DC connector 114. The first electrode 1141 is connected to the first output terminal 1121 by laser welding, and the second electrode 1142 is connected to the second output terminal 1122 by laser welding. The first electrode 1141 has extensions 11411 on both sides along the first direction X. The first electrode 1141 is connected to the first input terminal 1131 of the power module 113 through the extensions 11411, and the second electrode 1142 is connected to the second input terminal 1132 of the power module 113 on both sides along the first direction X.

[0172] The motor controller 11 provided in this application embodiment has less stray inductance, which is beneficial to improving the performance of the electric drive device 10.

[0173] Secondly, referring to Figure 3, this application embodiment provides an electric drive device 10, including a motor controller 11 as in the first aspect, a first motor 12 and a second motor 13, a power module 113 electrically connected to the first motor 12, and another power module electrically connected to the second motor 13.

[0174] The first motor 12 and the second motor 13 are arranged sequentially along the first direction X, and the two power modules 113 can be directly electrically connected to the motors through the corresponding AC connectors 115.

[0175] The electric drive device 10 provided in this application embodiment effectively improves the performance of the electric drive device 10 by employing the motor controller 11 described in any of the above embodiments.

[0176] Thirdly, referring to Figure 1, this application provides an electric drive system 1, including a battery 20 and an electric drive device 10 as described in any of the above embodiments, wherein the battery 20 is electrically connected to the electric drive device 10.

[0177] The electric drive system 1 provided in this application embodiment effectively improves the performance of the electric drive system 1 by employing the electric drive device 10 described in any of the above embodiments.

[0178] Fourthly, referring to Figure 1, this application embodiment provides an electric device including the above-described electric drive system 1.

[0179] The electric device provided in this application embodiment effectively improves the performance of the electric device by adopting the electric drive system 1 described in any of the above embodiments.

[0180] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A motor controller, wherein, include: Two power modules are arranged side by side along a first direction, and each power module is provided with a first input terminal and a second input terminal with opposite polarities; A bus capacitor is located between the two power modules, and the bus capacitor is provided with a first output terminal and a second output terminal with opposite polarities. A DC connector is located between the two power modules and stacked with the bus capacitor along a second direction perpendicular to the first direction. The DC connector includes a first electrode and a second electrode with opposite polarities. The first electrode and the second electrode are separated and stacked along the second direction. The first electrode is electrically connected to the first output terminal and the first input terminal of the two power modules, and the second electrode is electrically connected to the second output terminal and the second input terminal of the two power modules.

2. The motor controller as described in claim 1, wherein, The second electrode is located between the first electrode and the bus capacitor. The second electrode has a first through hole, and the first electrode is connected to the first output terminal through the first through hole.

3. The motor controller as described in claim 2, wherein, The DC connector further includes an insulating component, at least a portion of which is disposed between the first electrode and the second electrode. The insulating component has a second through hole, which corresponds to and communicates with the first through hole. The first electrode component is connected to the first output terminal through the first through hole and the second through hole.

4. The motor controller as described in claim 3, wherein, The insulating element covers at least a portion of the first electrode element.

5. The motor controller as described in any one of claims 2-4, wherein, The number of first output terminals and second output terminals are both multiple, and the multiple first output terminals and multiple second output terminals are alternately and separately arranged along a third direction, the third direction being perpendicular to the second direction and intersecting the first direction; The second electrode is provided with a plurality of first through holes arranged along the third direction, and each first through hole exposes a first output terminal.

6. The motor controller as described in any one of claims 1-5, wherein, The first input terminal and the second input terminal are located on the side of the power module closer to the DC connector, and the first input terminal and the second input terminal are spaced apart in the first direction; Along the second direction, the first input terminal is located on the side of the second input terminal closer to the DC connector; The first electrode is connected to the first input terminals of the two power modules on both sides along the first direction, and the second electrode is connected to the second input terminals of the two power modules on both sides along the first direction.

7. The motor controller as described in any one of claims 1-6, wherein, The first electrode has extensions on both sides along the first direction, and the extensions extend to the outer side of the second electrode along the first direction. The first electrode is connected to the first input terminal through the extensions.

8. The motor controller as described in any one of claims 1-7, wherein, The motor controller also includes a housing, in which the two power modules, the DC connector and the bus capacitor are all disposed. The bus capacitor includes a core, which is encapsulated within the housing.

9. The motor controller as described in claim 8, wherein, The bus capacitor also includes a first busbar, a second busbar, and an insulating support disposed on the core. The first busbar and the second busbar are both electrically connected to the core. The first busbar is provided with a first output terminal, and the second busbar is provided with a second output terminal. The first output terminal and the second output terminal are disposed separately on the insulating support.

10. The motor controller as described in any one of claims 1-9, wherein, Along the second direction, the orthogonal projection of the second electrode toward the first electrode falls entirely inside the first electrode.

11. The motor controller as described in any one of claims 1-10, wherein, The first electrode is laser-welded to the bus capacitor; and / or, The second electrode is laser-welded to the bus capacitor.

12. The motor controller as claimed in claim 11, wherein, The first electrode and the second electrode have the same thickness.

13. The motor controller as described in any one of claims 1-10, wherein, The first electrode is laser-welded to the first input terminal; and / or, The second electrode is laser-welded to the second input terminal.

14. The motor controller as described in any one of claims 1-13, wherein, The first electrode has two opposing planes along the second direction; and / or, The two opposite surfaces of the second electrode along the second direction are planes.

15. The motor controller as described in any one of claims 1-14, wherein, Along the second direction, the distance between the first electrode and the second electrode ranges from 0.2 mm to 1.5 mm.

16. The motor controller as described in any one of claims 1-15, wherein, The motor controller also includes a housing, within which the two power modules, the DC connector, and the bus capacitor are all housed; The motor controller also includes two AC power connectors, which are connected to the two power modules one by one. One end of each AC power connector extends into the external environment of the housing and is used for direct electrical connection to the motor.

17. The motor controller as claimed in claim 16, wherein, Along the first direction, the two AC connectors are located on opposite sides of the two power modules.

18. An electric drive device, wherein, The electric drive device includes a motor controller, a first motor, and a second motor as described in any one of claims 1-17, one of the power modules being electrically connected to the first motor, and the other of the power modules being electrically connected to the second motor.

19. An electric drive system, wherein, The electric drive system includes a battery and an electric drive device as described in claim 18, wherein the battery is electrically connected to the electric drive device.

20. An electric device, wherein, The electric device includes the electric drive system as described in claim 19.

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