Power module, electric motor controller, electric drive assembly and vehicle

Abstract

The present disclosure relates to a power module, an electric motor controller, an electric drive assembly and a vehicle. The power module comprises a phase terminal, wherein the phase terminal is provided with a current sampling section, and the extension direction of the phase terminal intersects with the extension direction of the current sampling section. By means of structural optimization, the power module is beneficial for improving the measurement precision of the current at the phase terminal.

Description

Power modules, motor controllers, electric drive assemblies, and vehicles

[0001] Cross-references to related applications

[0002] This application claims priority to Chinese Patent Application No. 202521096005.9, filed on May 29, 2025, entitled "Power Module, Motor Controller, Electric Drive Assembly and Vehicle"; Chinese Patent Application No. 202520522561.1, filed on March 21, 2025, entitled "Power Module, Motor Controller, Electric Drive Assembly and Vehicle"; Chinese Patent Application No. 202510351665.5, filed on March 21, 2025, entitled "Power Module, Motor Controller, Electric Drive Assembly and Vehicle"; and Chinese Patent Application No. 202510716044.2, filed on May 29, 2025, entitled "Power Module, Motor Controller, Electric Drive Assembly and Vehicle", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to the field of vehicle technology, and in particular to a power module, a motor controller, an electric drive assembly, and a vehicle. Background Technology

[0004] The motor controller is one of the important components in new energy vehicles. A motor controller includes: a set of control devices that convert direct current (DC) to alternating current (AC) to drive the motor, and / or a set of control devices that convert AC power to DC power to control a generator motor.

[0005] In conventional motor controllers, the power module integrates a current sensor to detect the magnitude of the phase current output by the power module. Some solutions employ a differential sensor, where two detection positions are arranged along the width of the phase terminals of the power module. This generates a differential signal characterizing the current magnitude based on the magnetic field produced by the current transmitted within the phase terminals. However, this arrangement is susceptible to crosstalk from magnetic fields generated by other phase terminals, thus requiring improved measurement accuracy. Summary of the Invention

[0006] The purpose of this application is to provide a power module, a motor controller, an electric drive assembly, and a vehicle, wherein the power module, through structural optimization, facilitates improved accuracy in measuring phase terminal current.

[0007] To address the aforementioned technical problems, this application provides a power module including a phase terminal, wherein a current sampling segment is provided on the phase terminal, and the extension direction of the phase terminal intersects with the extension direction of the current sampling segment.

[0008] In one feasible approach, the current sampling segment is used to set up a differential sensing element.

[0009] In one feasible solution, the projection of the differential sensing element onto a first plane is located on both sides of the current sampling segment, where the first plane is the plane containing the current sampling segment.

[0010] In one possible implementation, the phase terminal includes a first terminal segment and a second terminal segment, which are connected via the current sampling segment.

[0011] In one feasible solution, the phase terminal includes a first through port and a second through port, and the current sampling segment is located between the first through port and the second through port.

[0012] In one feasible solution, along the width direction of the phase terminal, the projection of the first through-hole in a plane perpendicular to the width direction does not overlap with the projection of the second through-hole in a plane perpendicular to the width direction.

[0013] In one feasible solution, along the width direction of the phase terminal, the projection of the first through-hole in a plane perpendicular to the width direction at least partially overlaps with the projection of the second through-hole in a plane perpendicular to the width direction.

[0014] In one feasible solution, at least one of the first through-hole and the second through-hole is a hole structure, or at least one of the first through-hole and the second through-hole is a groove structure.

[0015] In one possible implementation, the current sampling segment is formed between at least a portion of the edge of the first through-hole and at least a portion of the edge of the second through-hole.

[0016] In one feasible embodiment, the extension direction of the current sampling segment is perpendicular to the extension direction of the phase terminal.

[0017] In one feasible solution, both the first through-hole and the second through-hole are rectangular, and the first through-hole and the second through-hole are spaced apart in the extension direction of the phase terminal.

[0018] In one feasible embodiment, the extension direction of the first terminal segment is parallel to the extension direction of the second terminal segment.

[0019] In one feasible embodiment, the differential sensing element includes two magnetic sensing elements, which are disposed on both sides of the current sampling segment.

[0020] In one feasible embodiment, the arrangement direction of the two magnetic sensing elements is consistent with the extension direction of the phase terminal.

[0021] In one feasible solution, the power module includes at least two phase terminals, each of which is spaced apart along a first direction, the first direction being consistent with the width direction of the phase terminals.

[0022] This application embodiment also provides a power module, including a phase terminal, wherein the phase terminal is provided with a hollow structure, and the edge of the hollow structure forms a current sampling segment.

[0023] In one feasible solution, the hollow structure is used to set a differential sensing element, the projection of the differential sensing element onto the second plane is located on both sides of the current sampling segment, and the second plane is perpendicular to the width direction of the phase terminal.

[0024] In one feasible solution, the hollow structure is a symmetrical structure, with its axis of symmetry perpendicular to the extension direction of the phase terminal and parallel to the plane where the current sampling segment is located.

[0025] In one feasible solution, the hollow structure is a symmetrical structure, and its axis of symmetry is parallel to the extension direction of the phase terminal.

[0026] In one feasible solution, the hollow structure is rectangular.

[0027] This application also provides a motor controller, including the power module described in any of the above embodiments.

[0028] This application also provides an electric drive assembly, including the power module described above.

[0029] This application also provides a vehicle including the electric drive assembly described above.

[0030] The power module provided in this embodiment can be used as a component of a motor controller and applied to an electric drive assembly. It can be used in scenarios requiring both motor drive and power generation, such as in range-extended vehicles. In this embodiment, a current sampling segment is provided on each phase terminal, and the extension direction of the phase terminal intersects with the extension direction of the current sampling segment. Because the extension direction of the current sampling segment intersects with the extension direction of the phase terminal, the direction of the current in the current sampling segment is changed. The current detection element that cooperates with the current sampling segment can rotate at a certain angle, which can avoid crosstalk problems between different phase terminals and provides conditions for improving the accuracy of current measurement.

[0031] This application also provides a power module, including a phase terminal, the phase terminal having a hollow structure, the phase terminal including a sampling segment, the sampling segment being arranged adjacent to the hollow structure;

[0032] The phase terminal is equipped with a current sensor, which includes a differential sensing element, and the differential sensing element includes at least two magnetic sensing elements. The differential sensing element is configured to generate a differential signal based on the magnetic field generated by the sampling segment.

[0033] In one feasible embodiment, the differential sensing element comprises two magnetic sensing elements.

[0034] In one feasible solution, the hollow structure includes a first through-hole and a second through-hole, the phase terminal includes a terminal segment located between the first through-hole and the second through-hole, and the sampling segment includes the terminal segment; the current sensor and the phase terminal have an electrical gap in the thickness direction of the phase terminal.

[0035] In one feasible solution, at least one of the magnetic sensing elements is arranged near the first through-hole, and at least one of the magnetic sensing elements is arranged near the second through-hole.

[0036] In one feasible solution, the first through-hole is a groove structure that penetrates one side of the phase terminal in its width direction; the second through-hole is a groove structure that penetrates the other side of the phase terminal in its width direction.

[0037] In one feasible solution, the opening direction of the first through-hole is opposite to the opening direction of the second through-hole.

[0038] In one feasible solution, the first through-hole and the second through-hole are staggered along the length of the phase terminal.

[0039] In one feasible embodiment, at least two of the magnetic sensing elements are arranged symmetrically relative to a first centerline of the terminal segment, the extension direction of the first centerline being consistent with the extension direction of the terminal segment.

[0040] In one feasible embodiment, the extension direction of the terminal segment is consistent with the width direction of the phase terminal.

[0041] In one feasible solution, the arrangement direction of the two magnetic sensing elements is consistent with the length direction of the phase terminal.

[0042] In one possible embodiment, the hollow structure includes a through-hole extending through the phase terminal in the thickness direction, at least a portion of the current sensor is located within the through-hole, and there is an electrical clearance between the current sensor and the peripheral wall forming the through-hole.

[0043] In one feasible embodiment, at least two of the magnetic sensing elements are located on either side of the central surface of the phase terminal, the central surface being perpendicular to the thickness direction of the phase terminal.

[0044] In one feasible embodiment, at least two of the magnetic sensing elements are arranged in the thickness direction of the phase terminal.

[0045] In one feasible embodiment, at least two of the magnetic sensing elements are arranged symmetrically relative to the center plane of the phase terminal.

[0046] In one feasible solution, along the width direction of the phase terminal, the phase terminal includes a first segment terminal and a second segment terminal located on both sides of the through hole, the sampling segment includes the first segment terminal and the second segment terminal, the first segment terminal and the second segment terminal are symmetrically arranged with respect to the second center line of the through hole, and the extension direction of the second center line is consistent with the length direction of the phase terminal.

[0047] In one possible implementation, the power module further includes a circuit board, and the current sensor is electrically connected to the circuit board.

[0048] In one feasible solution, the power module includes at least one of a drive control module and a power generation control module. Both the drive control module and the power generation control module include a plurality of phase terminals, each of which is equipped with a current sensor. The plurality of phase terminals are arranged at intervals along the width direction of the phase terminals.

[0049] In one feasible solution, the power module includes a drive control module and a power generation control module. The drive control module includes multiple sub-power modules, and the power generation control module includes multiple sub-power modules. In the drive control module and the power generation control module, at least one of the multiple sub-power modules shares the same substrate.

[0050] This application also provides a motor controller, including the power module described in any of the above embodiments.

[0051] This application also provides an electric drive assembly, including the power module described above.

[0052] This application also provides a vehicle including the electric drive assembly described above.

[0053] The power module provided in this embodiment can be used as a component of a motor controller and applied to an electric drive assembly. It can be used in scenarios requiring both motor drive and power generation, such as in range-extended vehicles. In this embodiment, a hollow structure is provided on the phase terminals. The differential sensing element of the current sensor corresponds to the position of the hollow structure. The differential sensing element is configured to generate a differential signal based on the magnetic field generated by the phase terminals to detect the current in the phase terminals. Thus, the current sensor in the power module used to detect the current transmitted in the phase terminals eliminates the need for a magnetic core. The absence of a magnetic core around the phase terminals reduces the distance between adjacent phase terminals, thereby reducing the overall envelope size and weight of the power module. This improves the integration of the power module and helps reduce the size and weight of the motor controller, facilitating vehicle layout. Furthermore, eliminating the magnetic core in the power module reduces costs. Attached Figure Description

[0054] Figure 1 is a structural diagram of the power module provided in this application;

[0055] Figure 2 is a partial structural diagram of the phase terminals in Figure 1;

[0056] Figure 3 is a side view of the power module shown in Figure 1;

[0057] Figure 4 is a structural diagram of the phase terminal and differential sensing element in the second embodiment provided in this application;

[0058] Figure 5 is a structural diagram of the phase terminal and differential sensing element in the third embodiment provided in this application;

[0059] Figure 6 is a structural diagram of the phase terminal and differential sensing element in the fourth embodiment provided in this application;

[0060] Figure 7 is a structural diagram of the phase terminal and differential sensing element in the fifth embodiment provided in this application;

[0061] Figure 8 is a structural diagram of the phase terminal and differential sensing element in the sixth embodiment provided in this application;

[0062] Figure 9 is a structural diagram of another power module provided in this application;

[0063] Figure 10 is a partial structural diagram of the phase terminals in Figure 9;

[0064] Figure 11 is a side view of the power module shown in Figure 9;

[0065] Figure 12 is a structural diagram of another power module provided in this application.

[0066] Explanation of reference numerals in the attached drawings: Power module 100, frame 101, drive control module 102, first sub-power module 1021, power generation control module 103, second sub-power module 1031; Phase terminal 110, hollow structure 111, first through-hole 1111, second through-hole 1112, through hole 1113, terminal segment 112, first terminal segment 1131, second terminal segment 1132, current sampling segment 114, first terminal segment 1151, second terminal segment 1152; Current sensor 120, differential sensing element 121, magnetic sensor element 1211; Circuit board 130; First center line C1, first axis of symmetry C21, second axis of symmetry C22. Specific Implementation

[0067] New energy vehicles use electric drive systems to propel themselves. Taking range-extended electric vehicles as an example, one of their core components is the range extender. Its main function is to activate the range extender when the battery charge drops to a certain level. The engine then drives a generator to produce electricity, part of which powers the drive motor and the other part charges the battery. Once the battery is fully charged, the range extender stops working, and the drive motor continues to operate powered by the battery.

[0068] Range-extended electric vehicles have many advantages, including:

[0069] In daily urban commuting, range-extended electric vehicles can run on pure electric power with zero emissions, reducing exhaust pollution and meeting environmental protection requirements. At the same time, electric drive is more energy-efficient than gasoline drive, reducing energy consumption and operating costs.

[0070] Range-extended electric vehicles are equipped with an engine as a range extender. When the battery is low, the engine drives a generator to produce electricity, providing continuous power to the vehicle. This avoids the range anxiety problem caused by the limited range of pure electric vehicles, making long-distance travel more convenient.

[0071] In addition, range-extended vehicles also have the following advantages in terms of driving experience:

[0072] Pure electric drive: The range-extended electric vehicle (REEV) is essentially a pure electric drive system. The vehicle's power is entirely provided by the drive motor; the engine does not directly drive the vehicle but instead acts as a generator, starting when the battery is low to convert fuel into electricity to power the drive motor or charge the battery. This pure electric drive method makes the vehicle's power source singular and pure, consistent with the drive system of pure electric vehicles, fundamentally ensuring a comfortable driving experience.

[0073] Rapid power response: The characteristics of the drive motor determine that it can output maximum torque instantly. In vehicles with a range-extended topology, when the driver presses the accelerator pedal, the drive motor can respond immediately, quickly outputting strong power to achieve rapid start and acceleration. This instantaneous power response is far superior to that of traditional gasoline vehicles, allowing the driver to feel a more direct and rapid push-back sensation. Whether it's the frequent start-stop in urban traffic or overtaking maneuvers on the highway, it can easily handle the situation, bringing a smooth driving experience.

[0074] No power interruption: During the operation of a range-extended vehicle, since it is always driven by the electric motor, there is no power interruption issue as seen in traditional gasoline vehicles when shifting gears. Whether driving at low or high speeds, power output remains continuous and smooth. Even when the battery is low and the engine starts generating electricity, the system uses precise control strategies to ensure that the power output of the electric motor is not affected, preventing any jerking or power interruption. This provides the driver with a consistently stable driving experience, enhancing driving comfort and safety.

[0075] The electric drive assembly of a range-extended electric vehicle (REEV) includes components such as a generator motor, a drive motor, a drive control module, and a power generation control module. In conventional REEVs, the drive control module and the power generation control module are two independent components, each with its own power module (e.g., using diodes, IGBTs, SiC semiconductors for AC-DC conversion), current sensors, temperature sensors, and motor rotor position sensors. This results in higher weight, size, and cost, necessitating optimization.

[0076] For ease of understanding and description, the terms used in the following text are explained below.

[0077] A power module may consist of only a drive control module, or only a power generation control module, or both.

[0078] Both the drive control module and the power generation control module include sub-power modules. Taking a three-phase full-bridge as an example, both the drive control module and the power generation control module include three half-bridges, each half-bridge consisting of an upper half-bridge and a lower half-bridge.

[0079] The upper and lower half-bridges each include a first chip and a second chip connected in reverse parallel to it. The first chip can be an IGBT (Insulated Gate Bipolar Transistor), and the second chip can be a fast recovery diode. The first chip can be made of SiC material.

[0080] A sub-power module refers to a half-bridge, which includes an upper half-bridge and a lower half-bridge. Here, the sub-power module includes the first sub-power module of the drive control module and the second sub-power module of the power generation control module.

[0081] In a power module, current sensors are configured on the phase terminals of the sub-power modules to detect current. In conventional solutions, the current sensors are equipped with magnetic cores. The magnetic cores prevent the detection signal from being affected by magnetic fields generated by other phase terminals. The magnetic cores are typically U-shaped or C-shaped and fitted around the outer periphery of the phase terminals. This arrangement prevents the distance between adjacent phase terminals from being reduced, thus affecting the miniaturization of the power module. To address the above problems, this application provides a power module comprising:

[0082] Phase terminals, the phase terminals have a hollow structure;

[0083] The phase terminal is equipped with a current sensor, which includes a differential sensing element. The differential sensing element includes two magnetic sensing elements. The differential sensing elements are configured to generate a differential signal based on the magnetic field generated by the phase terminal. The position of the magnetic sensing elements corresponds to the position of the hollow structure.

[0084] By adopting the above technical solution, the current sensor used to detect the current in the phase terminal in the power module eliminates the need for a magnetic core, and there is no magnetic core sleeved on the outer periphery of the phase terminal. This reduces the spacing between two adjacent phase terminals, thereby reducing the overall envelope size of the power module. This helps to reduce the size and weight of the motor controller and provides convenience for the overall vehicle layout.

[0085] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0086] For ease of understanding and description, this paper constructs three directions: the first direction x, the second direction y, and the third direction z. These three directions are based on the phase terminals of the power module. The first direction x is the width direction of the phase terminal, the second direction y is the length direction of the phase terminal, and the third direction z is the thickness direction of the phase terminal.

[0087] Please refer to Figures 1 to 3. Figure 1 is a structural diagram of a power module provided in this application, Figure 2 is a partial structural diagram of the phase terminals in Figure 1, and Figure 3 is a side view of the power module shown in Figure 1.

[0088] In one embodiment provided in this application, the power module 100 includes a phase terminal 110, on which a current sampling segment 114 is provided. The extension direction of the phase terminal 110 is a second direction y, which can be understood as the length direction of the phase terminal 110. The extension direction of the phase terminal 110 intersects with the extension direction of the current sampling segment 114.

[0089] When current is transmitted through phase terminal 110, current sampling section 114 will generate a magnetic field. By detecting the relevant signal of the magnetic field generated by current sampling section 114 through current detection element, current measurement can be realized.

[0090] By adopting the above scheme, since the extension direction of the current sampling section 114 intersects with the extension direction of the phase terminal 110, the direction of the current in the current sampling section 114 is changed. The current detection element that cooperates with the current sampling section 114 can rotate at a certain angle, which can alleviate or solve the crosstalk problem between different phase terminals 110, and provide conditions for improving the accuracy of current measurement.

[0091] In one embodiment, the current sampling segment 114 is used to set the differential sensing element 121. Thus, current detection is achieved through the differential sensing element 121. The differential sensing element 121 can generate a differential signal based on the magnetic field generated by the current sampling segment 114. Through the differential principle, interference caused by other magnetic fields in the measurement environment can be weakened or eliminated, which is beneficial to improving detection accuracy.

[0092] When current is transmitted through phase terminal 110, current sampling section 114 will generate a magnetic field. Differential sensing element 121 can collect detection signals of at least two positions in the magnetic field that reflect the strength or flux of the magnetic field. Differential signal is output through differential calculation, and the differential signal can characterize the magnitude of the current.

[0093] In one embodiment, the projection of the differential sensing element 121 onto a first plane is located on both sides of the current sampling segment 114, where the first plane is the plane containing the current sampling segment 114. The plane containing the current sampling segment 114 can be understood as the plane constructed by the first direction x and the second direction y, or a plane perpendicular to the third direction z. This configuration ensures that the differential sensing element 121 can generate a differential signal based on the magnetic field generated by the current sampling segment 114, thereby guaranteeing the validity and reliability of the measurement.

[0094] In some embodiments, the differential sensing element 121 includes two magnetic sensing elements 1211, which are disposed on both sides of the current sampling section 114. Thus, a differential signal can be generated based on the two magnetic sensing elements 1211. The differential sensing element 121 has a simple structure, which helps to save material costs.

[0095] Two magnetic sensing elements 1211 are disposed on both sides of the current sampling segment 114, meaning that the two magnetic sensing elements 1211 are located on both sides of the longitudinal centerline of the current sampling segment 114, wherein the longitudinal centerline of the current sampling segment 114 is consistent with the extension direction of the current sampling segment 114. In the example shown in Figure 2, the longitudinal centerline of the current sampling segment 114 is the first centerline C1.

[0096] The two magnetic sensing elements 1211 of the differential sensing element 121 can be integrated on a single chip to form a current sensor 120. As shown in Figure 3, the current sensor 120 and the phase terminal 110 have an electrical gap in the third direction z, that is, the current sensor 120 and the phase terminal 110 have a distance between them in the third direction z.

[0097] Within the projection plane perpendicular to the third direction z, i.e., within the first plane constructed by the first direction x and the second direction y, the projections of the two magnetic sensing elements 1211 are located on both sides of the current sampling segment 114.

[0098] In one embodiment, the phase terminal 110 includes a first terminal segment 1151 and a second terminal segment 1152, which are connected by a current sampling segment 114. Thus, the phase terminal 110 has better structural performance. The aforementioned structural arrangement of the phase terminal 110 allows current to flow from the first terminal segment 1151 through the current sampling segment 114 into the second terminal segment 1152, thereby changing the direction of the current.

[0099] In one embodiment, the phase terminal 110 includes a first through-hole 1111 and a second through-hole 1112, and a current sampling segment 114 is located between the first through-hole 1111 and the second through-hole 1112. Both the first through-hole 1111 and the second through-hole 1112 penetrate the phase terminal 110 in a third direction z. The through-hole design facilitates the intersection of the extension direction of the current sampling segment 114 with the extension direction of the phase terminal 110, and the through-hole is easy to manufacture.

[0100] At least one of the first through-hole 1111 and the second through-hole 1112 is a hole structure, or at least one of the first through-hole 1111 and the second through-hole 1112 is a groove structure.

[0101] The first through-hole 1111 can be a hole structure, that is, the first through-hole 1111 is closed in the circumferential direction and does not penetrate the side of the phase terminal 110. The first through-hole 1111 can also be a groove structure, that is, the first through-hole 1111 is not closed in the circumferential direction and penetrates the side of the phase terminal 110.

[0102] The second through-hole 1112 can be a hole structure, that is, the second through-hole 1112 is closed in the circumferential direction and does not penetrate the side of the phase terminal 110. The second through-hole 1112 can also be a groove structure, that is, the second through-hole 1112 is not closed in the circumferential direction and penetrates the side of the phase terminal 110.

[0103] In some embodiments, the first through-hole 1111 and the second through-hole 1112 may both be groove structures or both be hole structures. In other embodiments, one of the first through-hole 1111 and the second through-hole 1112 may be a groove structure and the other may be a hole structure.

[0104] In the examples shown in Figures 1 and 2, both the first through-hole 1111 and the second through-hole 1112 are groove structures. The first through-hole 1111 penetrates one side of the phase terminal 110, and the second through-hole 1112 penetrates the other side of the phase terminal 110.

[0105] As shown in Figure 4, Figure 4 illustrates the structure of the phase terminal 110 and the differential sensing element 121 in the second embodiment. The first through-hole 1111 and the second through-hole 1112 of the phase terminal 110 are both hole structures.

[0106] As shown in Figure 5, Figure 5 illustrates the structure of the phase terminal 110 and the differential sensing element 121 in the third embodiment. The first through-hole 1111 of the phase terminal 110 is a hole structure, and the second through-hole 1112 is a slot structure.

[0107] In the examples shown in Figures 1 and 2, as well as Figures 4 and 5, both the first through-hole 1111 and the second through-hole 1112 are rectangular, and are spaced apart in the extending direction of the phase terminal 110. Thus, the current sampling segment 114 located between the first through-hole 1111 and the second through-hole 1112 is also approximately rectangular in shape, which facilitates arranging the two magnetic sensing elements 1211 of the differential sensing element 121 at positions with substantially the same magnetic field strength, thereby improving measurement accuracy.

[0108] In other embodiments, the first through opening 1111 and the second through opening 1112 can also be other shapes, such as regular shapes like ellipse, circle, square, triangle, etc., or they can be irregular shapes. The shapes of the first through opening 1111 and the second through opening 1112 can be the same or different.

[0109] In one embodiment, along the width direction of the phase terminal 110, i.e., along the first direction x, the projections of the first through-hole 1111 and the second through-hole 1112 in a plane perpendicular to the width direction (first direction x) do not overlap. In other words, the first through-hole 1111 and the second through-hole 1112 are completely staggered in the extension direction of the phase terminal 110 (i.e., the second direction y). Examples are shown in Figures 1, 2, 4, and 5. The plane perpendicular to the width direction can be understood as the plane constructed by the second direction y and the third direction z.

[0110] In another embodiment, the projection along the width direction of the phase terminal 110, i.e. along the first direction x, the projection of the first through-hole 1111 in a plane perpendicular to the width direction and the projection of the second through-hole 1112 in a plane perpendicular to the width direction at least partially overlap.

[0111] Figure 6 shows a structural diagram of the phase terminal 110 and the differential sensing element 121 in the fourth embodiment. Both the first through-hole 1111 and the second through-hole 1112 are triangular in shape and are slot structures. The positions of the first through-hole 1111 and the second through-hole 1112 correspond in the extending direction of the phase terminal 110. Along the first direction x, the projection of the first through-hole 1111 in a plane perpendicular to the first direction x and the projection of the second through-hole 1112 in a plane perpendicular to the first direction x overlap.

[0112] As shown in Figure 7, Figure 7 illustrates the structure of the phase terminal 110 and the differential sensing element 121 in the fifth embodiment. Both the first through-hole 1111 and the second through-hole 1112 are hole structures. The first through-hole 1111 is approximately rectangular, and the second through-hole 1112 is approximately elliptical. Along the first direction x, the projections of the first through-hole 1111 and the second through-hole 1112 in the same plane partially overlap.

[0113] In one embodiment, a current sampling segment 114 is formed between at least a portion of the edge of the first through-port 1111 and at least a portion of the edge of the second through-port 1112.

[0114] In one embodiment, the extension direction of the current sampling segment 114 is perpendicular to the extension direction of the phase terminal 110. Examples are shown in Figures 1, 2, 4, and 5. Thus, based on the magnetic field direction generated by the current sampling segment 114 along the extension direction of the phase terminal 110, after arranging the differential sensing element 121, the two magnetic sensing elements 1211 are located on both sides of the current sampling segment 114. The magnetic field strength at the locations of the two magnetic sensing elements 1211 is essentially the same, which is more conducive to mitigating crosstalk between different phase terminals 110, thereby improving measurement accuracy.

[0115] In one embodiment, the arrangement direction of the two magnetic sensing elements 1211 of the differential sensing element 121 is consistent with the extension direction of the phase terminal 110. In other words, the two magnetic sensing elements 1211 of the differential sensing element 121 are arranged along the second direction y, as shown in the examples in Figures 1, 2, 4, and 5. It can be understood that the connection direction of the two magnetic sensing elements 1211 is consistent with the extension direction of the phase terminal 110.

[0116] The power module 100 includes at least two phase terminals 110, which are spaced apart along a first direction x (i.e., the width direction of the phase terminals 110). In the example shown in FIG1, the power module 100 is provided with three phase terminals 110, which are spaced apart along the first direction x.

[0117] As shown above, after arranging the two magnetic sensing elements 1211 along the second direction y, for the differential sensing element 121 corresponding to one phase terminal 110, the distance between the two magnetic sensing elements 1211 and the adjacent phase terminal 110 is consistent. In this way, the magnetic field information of the magnetic field generated by the adjacent phase terminal 110 at the location of the two magnetic sensing elements 1211 is approximately consistent. The differential sensing element 121 can minimize the interference of the magnetic field generated by the adjacent phase terminal 110 on the detection through differential calculation, that is, it can minimize interphase crosstalk and improve the detection accuracy of the differential sensing element 121.

[0118] In other embodiments, the arrangement direction of the two magnetic sensing elements 1211 of the differential sensing element 121 can also be at a certain angle to the extension direction of the phase terminal 110, as shown in Figures 6 and 7.

[0119] In the examples shown in Figures 1, 2, and 4 to 7, the current sampling segment 114 of the phase terminal 110 is located between two through-holes. In other embodiments, the phase terminal 110 may not have a through-hole structure. As shown in Figure 8, Figure 8 illustrates the structure of the phase terminal 110 and the differential sensing element 121 in the sixth embodiment. In the embodiment shown in Figure 8, the phase terminal 110 includes a first terminal segment 1151 and a second terminal segment 1152. The extension direction of the first terminal segment 1151 is parallel to the extension direction of the second terminal segment 1152. The first terminal segment 1151 is connected to the second terminal segment 1152 through the current sampling segment 114. This configuration simplifies the processing steps of the phase terminal 110 and eliminates the need for through-hole processing.

[0120] The extension direction of phase terminal 110 refers to the overall length direction of phase terminal 110. In the example shown in Figure 8, the extension direction of phase terminal 110 is the second direction y.

[0121] Referring to Figures 1 to 3, in this embodiment, the power module 100 includes a frame 101, and related structures of the drive control module or power generation control module (e.g., liner, heat sink, etc.) can be integrated on the frame 101. The power module 100 includes a phase terminal 110, which extends outward from the frame 101 in the second direction y.

[0122] Phase terminal 110 has a hollow structure 111. Phase terminal 110 includes a current sampling section 114, which is arranged adjacent to the hollow structure 111. Phase terminal 110 is equipped with a current sensor 120, which includes a differential sensing element 121. The differential sensing element 121 includes at least two magnetic sensing elements 1211. The differential sensing element 121 is configured to generate a differential signal based on the magnetic field generated by the current sampling section 114 of phase terminal 110.

[0123] When current is transmitted through phase terminal 110, a magnetic field is generated. The magnetic sensing element 1211 can collect the detection signal that reflects the strength or flux of the magnetic field. The detection signals of at least two magnetic sensing elements 1211 can be used to output a differential signal through differential calculation. This differential signal can characterize the magnitude of the current.

[0124] By adopting the above solution, the current sensor 120 in the power module 100, which detects the current transmitted in the phase terminal 110, eliminates the need for a magnetic core. Since there is no magnetic core surrounding the phase terminal 110, the distance between adjacent phase terminals 110 can be reduced, thereby reducing the overall envelope size and weight of the power module 100. This improves the integration of the power module 100, helps reduce the size and weight of the motor controller, and facilitates vehicle layout. Furthermore, eliminating the magnetic core in the power module 100 reduces costs.

[0125] In addition, this embodiment uses a differential sensing element 121 to detect the current of the phase terminal 110. The differential principle can reduce or eliminate interference caused by other magnetic fields in the measurement environment, which is beneficial to improving the detection accuracy.

[0126] In this embodiment, the current sensor 120 does not require a magnetic core, which avoids the problem of limited detection range caused by the limitations of the physical properties of the magnetic core. This embodiment can measure larger currents or a wider range of currents.

[0127] The differential sensing element 121 of the current sensor 120 may include two magnetic sensing elements 1211. Based on the detection signals of the two magnetic sensing elements 1211, a differential signal characterizing the magnitude of the current is obtained through differential calculation.

[0128] The differential sensing element 121 of the current sensor 120 may also include three or more magnetic sensing elements 1211. These magnetic sensing elements 1211 may be divided into at least two magnetic sensing element groups, each group including two magnetic sensing elements 1211. At least two differential detection signals can be obtained based on the current sampling segment 114 of the phase terminal 110. After processing these differential detection signals (e.g., averaging), a differential signal characterizing the current magnitude is obtained.

[0129] The following description uses the differential sensing element 121, which has two magnetic sensing elements 1211, as an example.

[0130] In one embodiment, as shown in Figures 1 to 3, the hollow structure 111 of the phase terminal 110 includes a first through-hole 1111 and a second through-hole 1112. The phase terminal 110 includes a terminal segment 112 located between the first through-hole 1111 and the second through-hole 1112. The current sampling segment 114 includes the terminal segment 112. The current sensor 120 and the phase terminal 110 have an electrical gap in the third direction z (i.e., the thickness direction of the phase terminal 110).

[0131] With the above settings, the current sensor 120 and the phase terminal 110 can be arranged in the third direction z. The differential sensing element 121 can generate a differential signal based on the magnetic field generated by the terminal segment 112, which is convenient for arrangement and helps to reduce the space occupied by the power module 100.

[0132] In the differential sensing element 121, one magnetic sensing element 1211 is arranged near the first through-port 1111, and the other magnetic sensing element 1211 is arranged near the second through-port 1112. In this way, the terminal segment 112 serves as the current sampling segment 114 of the differential sensing element 121, which ensures that the differential sensing element 121 can generate a differential signal based on the magnetic field generated by the terminal segment 112.

[0133] The arrangement of the magnetic sensing element 1211 near the through-hole means that, in the projection plane perpendicular to the third direction z, the projection of one magnetic sensing element 1211 can be partially or entirely located within the first through-hole 1111, and the projection of another magnetic sensing element 1211 can be partially or entirely located within the second through-hole 1111; or, in the projection plane perpendicular to the third direction z, the distance between the projection of one magnetic sensing element 1211 and the first through-hole 1111 is less than the distance between the projection of another magnetic sensing element 1211 and the first through-hole 1111, and the distance between the projection of one magnetic sensing element 1211 and the second through-hole 1112 is greater than the distance between the projection of another magnetic sensing element 1211 and the second through-hole 1112.

[0134] In some embodiments, both the first through-hole 1111 and the second through-hole 1112 are groove structures, with the first through-hole 1111 penetrating one side of the phase terminal 110 in its width direction and the second through-hole 1112 penetrating the other side of the phase terminal 110 in its width direction. In other embodiments, the first through-hole 1111 and the second through-hole 1112 may also penetrate the same side of the phase terminal 110 in its width direction.

[0135] In some implementations, the opening direction of the first through-hole 1111 can be opposite to the opening direction of the second through-hole 1112. In other implementations, the opening direction of the first through-hole 1111 can be at a certain angle to the opening direction of the second through-hole 1112.

[0136] In some implementations, the first through-hole 1111 and the second through-hole 1112 are completely offset along the length of the phase terminal 110, as shown in Figures 1, 2, 4, and 5. This helps to reduce the heat generation of the phase terminal 110 in the area where the hollow structure 111 is located. In other implementations, the first through-hole 1111 and the second through-hole 1112 can be positioned correspondingly along the width of the phase terminal 110, as shown in Figure 6.

[0137] As shown in Figure 2, the phase terminal 110 in the area where the hollow structure 111 is located is roughly S-shaped or serpentine.

[0138] As shown in Figure 3, the differential sensing element 121 of the current sensor 120 and the phase terminal 110 have an electrical clearance in the third direction z (i.e., the thickness direction of the phase terminal 110) to ensure the safety and reliability of the power module 100 during operation. The specific value of the electrical clearance can be set according to the actual application requirements and is not limited here.

[0139] In other embodiments, the first through-hole 1111 and the second through-hole 1112 can be hole structures, or the first through-hole 1111 can be a groove structure and the second through-hole 1112 can be a hole structure, or the first through-hole 1111 can be a hole structure and the second through-hole 1112 can be a groove structure.

[0140] The magnetic sensing element 1211 can be a Hall sensing element, and the differential signal generated by the differential sensing element 121 is a voltage signal.

[0141] In some embodiments, two magnetic sensing elements 1211 are arranged symmetrically relative to the first center line C1 of the terminal segment 112, and the extension direction of the first center line C1 of the terminal segment 112 is consistent with the extension direction of the terminal segment 112. In this way, the magnetic field positions of the two magnetic sensing elements 1211 are symmetrical, and the same magnetic field parameter (e.g., magnetic flux) component can be detected, which is beneficial to improving the accuracy of detection.

[0142] Here, the same magnetic field parameter component refers to the component of the magnetic field parameter in the same direction. For example, by setting the magnetic sensing element 1211, the magnetic sensing element 1211 can measure the component in the thickness direction of the phase terminal 110.

[0143] In other embodiments, the two magnetic sensing elements 1211 may also be arranged asymmetrically relative to the first center line C1 of the terminal segment 112.

[0144] The two magnetic sensing elements 1211 can also be arranged in other forms, as long as they are located within the magnetic field generated by the phase terminal 110 and can output differential signals.

[0145] In some embodiments, the extension direction of terminal segment 112 is consistent with the width direction of phase terminal 110. In other words, the extension direction of terminal segment 112 is a first direction x. As shown in FIG2, the first direction x is the left-right direction, the opening of the first through-hole 1111 faces to the right, and the opening of the second through-hole 1112 faces to the left. In this way, the hollow structure 111 on the phase terminal 110 can be controlled within a relatively small area, which is beneficial to ensuring the structural reliability of the phase terminal 110 and can reduce the heat generation of the phase terminal 110 in the area where the hollow structure 111 is located.

[0146] In some embodiments, the arrangement direction of the two magnetic sensing elements 1211 is consistent with the length direction of the phase terminal 110. This can be understood as the direction of the connection between the two magnetic sensing elements 1211 being consistent with the length direction of the phase terminal 110. In other words, the two magnetic sensing elements 1211 are arranged in the second direction y.

[0147] The power module 100 is generally provided with multiple phase terminals 110, which are arranged at intervals along the first direction x (i.e. the width direction of the phase terminals 110).

[0148] After arranging the two magnetic sensing elements 1211 in the second direction y, for the current sensor 120 of one phase terminal 110, the distance between the two magnetic sensing elements 1211 and the adjacent phase terminal 110 is consistent. In this way, the detection signals of the magnetic fields generated by the adjacent phase terminal 110 sensed by the two magnetic sensing elements 1211 are approximately consistent. By differential calculation, the interference of the magnetic field generated by the adjacent phase terminal 110 on the detection of the current sensor 120 can be eliminated as much as possible, thereby improving the detection accuracy of the current sensor 120.

[0149] In other embodiments, the arrangement direction of the two magnetic sensing elements 1211 may also be at a certain angle to the length direction of the phase terminal 110, that is, the connection direction of the two magnetic sensing elements 1211 is inclined relative to the length direction of the phase terminal 110.

[0150] Without conflict, the examples of the above-described hollow structure 111, terminal segment 112, and arrangement of the two magnetic sensing elements 1211 can be combined arbitrarily.

[0151] In the examples shown in Figures 1 to 3, the extension direction of the terminal segment 112 is the first direction x, and the two magnetic sensing elements 1211 are arranged symmetrically with respect to the first center line C1 of the terminal segment 112.

[0152] The first through-hole 1111 and the second through-hole 1112 of the hollow structure 111 can be rectangular as shown in the figure, which is convenient for processing. In other examples, the first through-hole 1111 and the second through-hole 1112 can also be other shapes, such as rectangles with rounded corners or approximately elliptical shapes.

[0153] The first through-hole 1111 and the second through-hole 1112 of the hollow structure 111 can be centrally symmetrical. In this way, the heat generated in the area where the phase terminal 110 is located during operation can be distributed as evenly as possible, avoiding affecting the working performance.

[0154] Taking a three-phase AC motor as an example, the drive control module or the power generation control module in the power module 100 includes three sub-power modules. The phase terminals 110 of each sub-power module are located at the same end of the power module 100 in the second direction y, and the three phase terminals 110 are arranged at intervals along the first direction x. As shown in Figure 1, the current sensor 120 used in this embodiment omits the magnetic core, and the outer peripheral space of the phase terminals 110 is not occupied by the magnetic core. Compared with the current sensor 120 with a magnetic core, the distance between two adjacent phase terminals 110 can be reduced, which helps to reduce the size of the power module 100 in the first direction x and is beneficial to improving the integration of the power module 100.

[0155] As shown in Figure 3, the power module 100 also includes a circuit board 130, and the current sensor 120 is electrically connected to the circuit board (PCB). The circuit board 130 and the frame 101 of the power module 100 can be arranged in the third direction z, which can reduce the space occupied by the power module 100. In application, after receiving the differential signal output by the current sensor 120, the circuit board 130 can control the operation of the motor according to the differential signal.

[0156] The current sensors 120 configured on each phase terminal 110 of the power module 100 can be electrically connected to the same circuit board 130 to facilitate assembly and save manufacturing costs.

[0157] The circuit board 130 can be connected to the half-bridge circuit in the sub-power module via signal terminals for controlling and detecting the operating status of the half-bridge circuit.

[0158] The terminals of the current sensor 120 can be electrically connected to the circuit board 130 by soldering. This provides high reliability.

[0159] In addition to the power module 100 shown in Figures 1 to 3, the form of the hollow structure 111 of the phase terminal 110 and the arrangement of the phase terminal 110 and the current sensor 120 can also be other ways.

[0160] Please refer to Figures 9 to 11. Figure 9 is a structural diagram of another power module provided in this application, Figure 10 is a partial structural diagram of the phase terminals in Figure 9, and Figure 11 is a side view of the power module shown in Figure 9. To clearly illustrate the arrangement of the two magnetic sensing elements 1211 of the current sensor 120, the structure of the current sensor 120 is shown in Figure 11. It should be understood that, from the perspective of Figure 11, the structure of the current sensor 120 located within the through hole 1113 (described below) is not visible. The location of the through hole 1113 is indicated by a dashed line in Figure 11.

[0161] In the embodiments shown in Figures 9 to 11, the power module 100 includes a frame 101, and related structures of the drive control module or power generation control module (such as liner plates, heat sinks, etc.) can be integrated on the frame 101.

[0162] The power module 100 includes a phase terminal 110, on which a hollow structure 111 is provided. The edge of the hollow structure 111 forms a current sampling section 114. This arrangement allows the current sensing element to be installed inside the hollow structure 111, resulting in high integration and reduced space occupation. In addition, the current sensing element is located beside the current sampling section 114, in a position where the magnetic field generated by the current sampling section 114 is relatively strong, which helps to improve measurement accuracy.

[0163] In one embodiment, the hollow structure 111 is in the form of a through hole 1113, which penetrates the phase terminal 110 in the thickness direction (i.e., the third direction z). Along the first direction x, at least a portion of the phase terminal 110 on both sides of the through hole 1113 can form a current sampling segment 114.

[0164] In one embodiment, the hollow structure 111 is used to house the differential sensing element 121. The projection of the differential sensing element 121 onto the second plane is located on both sides of the current sampling section 114. The second plane is perpendicular to the width direction of the phase terminal 110, that is, the second plane is perpendicular to the first direction x. This arrangement ensures that the differential sensing element 121 can generate a differential signal based on the magnetic field generated by the current sampling section 114, thereby guaranteeing the validity and reliability of the measurement.

[0165] The differential sensing element 121 can be installed within the hollow structure 111. In the embodiment where the hollow structure 111 is a through hole 1113, the differential sensing element 121 is installed within the through hole 1113. The differential sensing element 121 is configured to generate a differential signal based on the magnetic field generated by the current sampling segment 114.

[0166] As configured above, the differential sensing element 121 is installed in the through hole 1113. The differential sensing element 121 is located at a position where the magnetic field generated by the current sampling section 114 is relatively strong. If the differential sensing element 121 and the phase terminal 110 are offset in the third direction z due to factors such as vibration or assembly error, the differential sensing element 121 can still effectively detect the current sampling section 114 and reduce the detection error caused by vibration, which helps to ensure the reliability of the detection results.

[0167] In one embodiment, the hollow structure 111 is a symmetrical structure, with its axis of symmetry perpendicular to the extension direction of the phase terminal 110 and parallel to the plane where the current sampling segment 114 is located. Specifically, the hollow structure 111 has a first axis of symmetry C21, which is parallel to a first direction x (i.e., the width direction of the phase terminal 110).

[0168] In one embodiment, the hollow structure 111 is a symmetrical structure, and its axis of symmetry is parallel to the extension direction of the phase terminal 110. Specifically, the hollow structure 111 has a second axis of symmetry C22, which is parallel to a second direction y.

[0169] In some embodiments, the hollow structure 111 may have only a first axis of symmetry C21.

[0170] In some embodiments, the hollow structure 111 may have only a second axis of symmetry C22.

[0171] In some embodiments, the hollow structure 111 may have both a first axis of symmetry C21 and a second axis of symmetry C22, as shown in the example in Figure 10.

[0172] In one embodiment, the hollow structure 111 can be rectangular.

[0173] In one embodiment, the power module 100 includes a phase terminal 110 and a current sensor 120. The hollow structure 111 includes a through hole 1113 extending through the phase terminal 110 in the third direction z (i.e., the thickness direction of the phase terminal 110). At least a portion of the current sensor 120 is located within the through hole 1113. There is an electrical clearance between the current sensor 120 and the peripheral wall of the through hole 1113 to ensure the safety and reliability of the power module 100 during operation.

[0174] In the application, two magnetic sensing elements 1211 are located on both sides of the center plane S1 of the phase terminal 110, which is perpendicular to the thickness direction (third direction z) of the phase terminal 110, as shown in Figure 5. In this way, it can be ensured that the two magnetic sensing elements 1211 can generate differential signals based on the magnetic field generated by the phase terminal 110.

[0175] In some embodiments, the two magnetic sensing elements 1211 are arranged in the thickness direction of the phase terminal 110. This facilitates the insertion of the current sensor 120 into the through hole 1113 along the third direction z, minimizing the size of the through hole 1113 and ensuring the structural performance of the phase terminal 110. In other embodiments, the arrangement direction of the two magnetic sensing elements 1211 may also be at a certain angle to the thickness direction of the phase terminal 110.

[0176] Similarly, the magnetic sensing element 1211 can be a Hall sensing element, and the differential signal generated by the differential sensing element 121 is a voltage signal.

[0177] Since the current sensor 120 is inserted into the through hole 1113, both magnetic sensing elements 1211 of the differential sensing element 121 are located at positions where the magnetic field strength generated by the phase terminal 110 is relatively large. This makes them insensitive to assembly errors and vibrations, ensuring the effectiveness and reliability of the detection. In other words, even if the current sensor 120 shifts relative to the phase terminal 110 in the third z-direction due to assembly errors or external vibrations to the power module 100 during application, the two magnetic sensing elements 1211 can still effectively detect the shift.

[0178] In practical applications, the current sensor 120 can be a pre-coated chip. This ensures electrical insulation between the current sensor 120 and the phase terminal 110 after the current sensor 120 is directly inserted into the through hole 1113, thus ensuring safety and reliability.

[0179] In some embodiments, the two magnetic sensing elements 1211 of the differential sensing element 121 are arranged symmetrically with respect to the center plane S1 of the phase terminal 110. In this way, the magnetic field positions of the two magnetic sensing elements 1211 are symmetrical, and the same magnetic field parameter (e.g., magnetic flux) components can be detected, which is beneficial to improving the accuracy of detection.

[0180] Here, the same magnetic field parameter component refers to the component of the magnetic field parameter in the same direction. For example, by setting the magnetic sensing element 1211, the magnetic sensing element 1211 can measure the component in the width direction of the phase terminal 110.

[0181] In some embodiments, the two magnetic sensing elements 1211 are positioned correspondingly in the third direction z. Thus, for a current sensor 120 with one phase terminal 110, the distances between the two magnetic sensing elements 1211 and the adjacent phase terminals 110 are consistent. This means that the detection signals of the magnetic fields generated by the adjacent phase terminals 110 sensed by the two magnetic sensing elements 1211 are approximately identical. Differential calculations can minimize the interference of the magnetic fields generated by the adjacent phase terminals 110 on the current sensor 120's detection, thereby improving the detection accuracy of the current sensor 120.

[0182] In other embodiments, the two magnetic sensing elements 1211 may not be arranged symmetrically with respect to the center of the through hole 1113. For example, in the third direction z, the two magnetic sensing elements 1211 are respectively disposed on both sides of the center of the through hole 1113. The distance between one magnetic sensing element 1211 and the center surface S1 of the phase terminal 110 may be greater than or less than the distance between the other magnetic sensing element 1211 and the center surface S1 of the phase terminal 110.

[0183] In other embodiments, the two magnetic sensing elements 1211 may be staggered in the width direction of the phase terminal 110, or arranged in other ways, as long as they are located within the magnetic field generated by the phase terminal 110 and can output differential signals.

[0184] Along the width direction of the phase terminal 110, the phase terminal 110 includes a first terminal 1131 and a second terminal 1132 located on both sides of the through hole 1113. The first terminal 1131 and the second terminal 1132 are the current sampling segments 114 of the differential sensing element 121.

[0185] In some embodiments, the first terminal 1131 and the second terminal 1132 are symmetrically arranged relative to the second axis of symmetry C22 of the through hole 1113. The extension direction of the second axis of symmetry C22 is consistent with the length direction of the phase terminal 110, that is, the second axis of symmetry C22 extends along the second direction y. With this arrangement, the heat generation of the first terminal 1131 and the second terminal 1132 is approximately the same, which helps to ensure the operational reliability of the phase terminal 110.

[0186] In other embodiments, the first terminal 1131 and the second terminal 1132 may not be arranged symmetrically relative to the second axis of symmetry C222.

[0187] In the illustrated example, the through hole 1113 is rectangular. In other implementation examples, the through hole 1113 can also be racetrack-shaped or elliptical, etc.

[0188] Taking a three-phase AC motor as an example, the drive control module or the power generation control module in the power module 100 includes three sub-power modules. The phase terminals 110 of each sub-power module are located at the same end of the power module 100 in the second direction y, and the three phase terminals 110 are arranged at intervals along the first direction x. As shown in Figure 9, the current sensor 120 used in this embodiment omits the magnetic core, and the outer peripheral space of the phase terminals 110 is not occupied by the magnetic core. Compared with the current sensor 120 with a magnetic core, the distance between two adjacent phase terminals 110 can be reduced, which helps to reduce the size of the power module 100 in the first direction x and is beneficial to improving the integration of the power module 100.

[0189] As shown in Figure 11, the power module 100 also includes a circuit board 130, to which the current sensor 120 is electrically connected. The circuit board 130 and the frame 101 of the power module 100 can be arranged in the third direction z, which can reduce the space occupied by the power module 100. The terminals of the current sensor 120 can extend through holes 1113 in the third direction z and be electrically connected to the circuit board 130 by soldering, which has high reliability.

[0190] In the power module 100 shown in Figures 1 to 3, the structure of each phase terminal 110 and the arrangement of the matching current sensor 120 with the phase terminal 110 are the same; in the power module shown in Figures 9 to 11, the structure of each phase terminal 110 and the arrangement of the matching current sensor 120 with the phase terminal 110 are the same.

[0191] In other embodiments, among the multiple phase terminals 110 in the power module 100, some phase terminals 110 may have a structure similar to that shown in Figures 1 to 3, or some phase terminals 110 may have a structure similar to any example in Figures 4 to 8. The arrangement of the current sensor 120 and the phase terminals 110 may also be consistent with that shown in Figures 1 to 3 or similar to any example in Figures 4 to 8. Furthermore, some phase terminals 110 may have a structure similar to that shown in Figures 9 to 11, and the arrangement of the current sensor 120 and the phase terminals 110 may also be similar to that shown in Figures 9 to 11.

[0192] Please refer to Figure 12, which is a structural diagram of another power module provided in this application.

[0193] As shown in Figure 12, in this embodiment, the power module 100 includes both a drive control module 102 and a power generation control module 103. The drive control module 102 includes multiple first sub-power modules 1021, and the power generation control module 103 includes multiple second sub-power modules 1031. Each first sub-power module 1021 has a phase terminal 110, and each second sub-power module 1031 has a phase terminal 110. Each phase terminal 110 is equipped with a current sensor 120.

[0194] The current sensor 120 is not shown in Figure 12. In applications, the phase terminal 110 and its configured current sensor 120 in the power module 100 shown in Figure 12 can adopt a similar scheme to the embodiments shown in Figures 1 to 8 above, and the phase terminal 110 and its configured current sensor 120 can also adopt a similar scheme to the embodiments shown in Figures 9 to 11 above. Further details will not be repeated here.

[0195] In some embodiments, the drive control module 102 and the power generation control module 103 are arranged along a first direction x to reduce the space occupied by the power module 100.

[0196] In some embodiments, each first sub-power module 1021 of the drive control module 102 has an independent backing plate, and multiple first sub-power modules 1021 are arranged along a first direction x. Taking a three-phase motor connected to the drive control module 102 as an example, the drive control module 102 includes three first sub-power modules 1021, and the phase terminals 110 of the three first sub-power modules 1021 are used to connect one-to-one with the three-phase AC terminals of the drive motor.

[0197] The multiple second sub-power modules 1031 of the power generation control module 103 share the same substrate. Taking the generator motor connected to the power generation control module 103 as an example as a three-phase motor, the power generation control module 103 includes three second sub-power modules 1031. The three second sub-power modules 1031 use the same substrate, and the phase terminals 110 of the three second sub-power modules 1031 are used to connect one-to-one with the three-phase AC terminals of the generator motor.

[0198] With the above settings, since the multiple second sub-power modules 1031 of the power generation control module 103 share the same substrate, the number of substrates of the power module 100 is reduced, which can realize the miniaturization of the substrate of the power generation control module 103 and effectively reduce the occupied size of the power generation side functional area in the first direction x. Combined with the aforementioned structural settings of the phase terminal 110 and the layout of the current sensor 120, the occupied size of the power module 100 in the first direction x can be greatly reduced. Thus, the reduction in the occupied volume and weight of the entire electronic control unit can be utilized, and the overall vehicle layout can be more flexible.

[0199] In other embodiments, each first sub-power module 1021 of the drive control module 102 in the power module 100 may share the same liner, and each second sub-power module 1031 of the power generation control module 103 may have an independent liner.

[0200] In other embodiments, each first sub-power module 1021 of the drive control module 102 in the power module 100 may share the same substrate, and multiple second sub-power modules 1031 of the power generation control module 103 may share the same substrate.

[0201] In some embodiments, the drive control module 102 and the power generation control module 103 can be integrated on a single frame 101 to further reduce the space occupied by the power module 100 and improve the integration of the power module 100.

[0202] This application also provides a motor controller, which includes the power module 100 described in the foregoing embodiments. The motor controller may further include a capacitor module, which can be used in conjunction with the power module 100 to balance the DC bus voltage.

[0203] This application also provides an electric drive assembly, which includes the motor controller described in the foregoing embodiments. The electric drive assembly further includes a generator motor and a drive motor. The drive control module 102 of the power module 100 is connected to the drive motor, and the generator control module 103 is connected to the generator motor. This electric drive assembly has similar technical effects to the aforementioned power module 100, and will not be repeated here.

[0204] This application also provides a vehicle that includes the aforementioned electric drive assembly. In practical applications, this vehicle can be a range-extended vehicle, with independent motor drive requirements and independent power generation requirements. This vehicle, employing the aforementioned electric drive assembly, achieves similar technical effects, which will not be repeated here. In other applications, the vehicle can also be other types of vehicles, not limited to range-extended vehicles.

[0205] In practical applications, the aforementioned power module 100, motor controller, and electric drive assembly can also be applied to other occasions with motor drive and power generation requirements, not limited to vehicles.

[0206] The ordinal numbers used in this article, such as first and second, are used to distinguish different parts with the same name and do not indicate a specific order or primary / secondary relationship.

[0207] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are only for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

Claims

1. A power module, comprising a phase terminal, wherein a current sampling segment is provided on the phase terminal, and the extension direction of the phase terminal intersects the extension direction of the current sampling segment.

2. The power module of claim 1, wherein, The current sampling section is used to set up differential sensing elements.

3. The power module of claim 2, wherein, The projection of the differential sensing element on the first plane is located on both sides of the current sampling segment, and the first plane is the plane where the current sampling segment is located.

4. The power module of any one of claims 1-3, wherein, The phase terminal includes a first terminal segment and a second terminal segment, which are connected through the current sampling segment.

5. The power module of any one of claims 1-4, wherein, The phase terminal includes a first through port and a second through port, and the current sampling segment is located between the first through port and the second through port.

6. The power module of claim 5, wherein, Along the width direction of the phase terminal, the projection of the first through-hole in a plane perpendicular to the width direction does not overlap with the projection of the second through-hole in a plane perpendicular to the width direction.

7. The power module of claim 5 or 6, wherein, Along the width direction of the phase terminal, the projection of the first through-hole in a plane perpendicular to the width direction at least partially overlaps with the projection of the second through-hole in a plane perpendicular to the width direction.

8. The power module according to any one of claims 5-7, wherein, At least one of the first through-hole and the second through-hole is a hole structure, or at least one of the first through-hole and the second through-hole is a groove structure.

9. The power module according to any one of claims 5-8, wherein, The current sampling segment is formed between at least a portion of the edge of the first through-hole and at least a portion of the edge of the second through-hole.

10. The power module according to any one of claims 1-6 and 8-9, wherein, The extension direction of the current sampling segment is perpendicular to the extension direction of the phase terminal.

11. The power module according to any one of claims 5-9, wherein, Both the first through-hole and the second through-hole are rectangular, and the first through-hole and the second through-hole are spaced apart in the extension direction of the phase terminal.

12. The power module according to claim 4, wherein, The extension direction of the first terminal segment is parallel to the extension direction of the second terminal segment.

13. The power module according to claim 2 or 3, wherein, The differential sensing element includes two magnetic sensing elements, which are disposed on both sides of the current sampling segment.

14. The power module according to claim 13, wherein, The arrangement direction of the two magnetic sensing elements is consistent with the extension direction of the phase terminal.

15. The power module according to any one of claims 1-14, wherein, The power module includes at least two phase terminals, each of which is spaced apart along a first direction, the first direction being consistent with the width direction of the phase terminals.

16. A power module, wherein, It includes a phase terminal, on which a hollow structure is provided, and the edge of the hollow structure forms a current sampling segment.

17. The power module according to claim 16, wherein, The hollow structure is used to set differential sensing elements, the projection of which is located on both sides of the current sampling segment on the second plane, and the second plane is perpendicular to the width direction of the phase terminal.

18. The power module according to claim 16 or 17, wherein, The hollow structure is a symmetrical structure, with its axis of symmetry perpendicular to the extension direction of the phase terminal and parallel to the plane where the current sampling segment is located.

19. The power module according to any one of claims 16-18, wherein, The hollow structure is a symmetrical structure, and its axis of symmetry is parallel to the extension direction of the phase terminal.

20. The power module according to any one of claims 16-19, wherein, The hollow structure is rectangular.

21. A motor controller comprising the power module as described in any one of claims 1-20.

22. An electric drive assembly, comprising the motor controller as claimed in claim 21.

23. A vehicle comprising the electric drive assembly as claimed in claim 22.

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