WO2017092192A1

WO2017092192A1 - Electric motor controller

Info

Publication number: WO2017092192A1
Application number: PCT/CN2016/075900
Authority: WO
Inventors: 黄风太; 彭魏文
Original assignee: 中山大洋电机股份有限公司
Priority date: 2015-11-30
Filing date: 2016-03-08
Publication date: 2017-06-08
Also published as: CN205212748U

Abstract

An electric motor controller, comprising a controller box body (1), a DC-DC module (2), a capacitance module (3), a driving circuit board (4), a control circuit board (5) and at least two independent power modules (6), wherein a heat-dissipation wall (11) is provided in the middle of the controller box body (1), and the heat-dissipation wall (11) divides a cavity in the middle of the controller box body (1) into an upper cavity (100) located at an upper portion and a lower cavity (101) located at a lower portion, wherein a protrusion (110) is provided inside the upper cavity (100) and on a top face of the heat-dissipation wall (11); the capacitance module (3) is mounted on one side of the protrusion (110) and the top face of the heat-dissipation wall (11); the plurality of power modules (6) are mounted on the other side of the protrusion (110) and the top face of the heat-dissipation wall (11) side by side; the driving circuit board (4) and the control circuit board (5) are both mounted inside the upper cavity (100), and the control circuit board (5) controls the driving circuit board (4) driving the running and operation of the power modules (6); the DC-DC module (2) is mounted inside the lower cavity (101) and on a bottom face of the heat-dissipation wall (11); and a cooling water channel is provided on the heat-dissipation wall (11) and the heat-dissipation wall is provided with a water inlet (111) and a water outlet (112) which are in communication with the cooling water channel, and heat dissipation is performed on the DC-DC module (2), the capacitance module (3) and the power modules (6) uniformly by means of the cooling water channel. The present invention is simple and compact in structure.

Description

Motor controller

Technical field:

The utility model relates to a motor controller, belonging to the technical field of electric vehicles.

Background technique:

In the existing electric vehicles, a DC-DC module, a plurality of power modules, and a plurality of motors are generally integrated, and the DC-DC module is used to increase a low-voltage power supply to some components in the electric vehicle, and a plurality of power modules are used for driving Multiple motors, the existing technical solution is to integrate multiple power modules into different controller cabinets, but because of the limited space in electric vehicles, if multiple power modules are integrated in different controller cabinets This will inevitably occupy a large amount of space inside the electric vehicle, making it larger in size and smaller in power density. In addition, the number of components increases, which is inconvenient for heat dissipation and management.

Summary of the invention:

The purpose of the utility model is to provide a motor controller which is simple and compact in structure.

The object of the present invention is achieved by the following technical solutions.

A motor controller includes a controller box, a DC-DC module, a capacitor module, a driving circuit board, a control circuit board, and at least two independent power modules, and a heat dissipation wall is disposed in the middle of the controller box, and the heat dissipation wall is disposed The cavity in the middle of the controller box is divided into an upper cavity at the upper portion and a lower cavity at the lower portion, and a protrusion is arranged on the top surface of the upper cavity and the heat dissipation wall, and the capacitor module is mounted on the convex side and the heat dissipation wall. On the top surface, a plurality of power modules are installed side by side on the other side of the protrusion and on the top surface of the heat dissipation wall, and the driving circuit board and the control circuit board are installed in the upper cavity, and the control circuit board controls the driving circuit board to drive the power module. In operation, the DC-DC module is installed in the lower cavity and on the bottom surface of the heat dissipation wall. A cooling water channel is opened on the heat dissipation wall and a water inlet and a water outlet connected to the cooling water channel are provided, and the DC-DC module is passed through the cooling water channel. The capacitor module and the power module perform unified heat dissipation.

The above-mentioned convex side is provided with a groove on the top surface of the heat dissipation wall, and at least two side-by-side water tanks are arranged on the other side of the convex wall and the top surface of the heat dissipation wall, and the capacitor module is installed in the groove and convex Tightly attached together, a power module is installed on each sink, and the needle bed is extended downward from the bottom surface of the power module, and the needle bed extends into the sink.

The water flow passage extending along the longitudinal direction thereof is opened in the middle of the protrusion, and the water inlet, the plurality of water tanks, the water flow passage and the water outlet are sequentially connected.

The DC busbar is mounted on the top surface of the protrusion, and the capacitor module and the plurality of power modules are electrically connected through the DC busbar, and the external DC power source is input to each power module through the DC busbar.

Two high-voltage DC input terminals are mounted on one side of the controller box outside the upper cavity, and the high-voltage DC input terminal is electrically connected with the DC busbar, and a through hole is opened in the heat dissipation wall. The upper cavity and the lower cavity are in communication, and the high voltage direct current input terminal and the DC-DC module are electrically connected together by a wire, and the wire passes through the middle of the through hole.

The number of the above power modules is two, and one driving circuit board is installed on the top surface of each power module, and the control circuit board is installed above the driving circuit board and inside the upper cavity, and the control circuit board and the driving circuit are controlled. The boards are electrically connected together by a board-to-board connector.

The above is installed on the top surface of each driving circuit board with three current sensors, and a copper column is arranged in the middle of each current sensor, and the copper column passes through the middle of the current sensor, on the side of the upper cavity and on the side of the controller box. There are six AC output terminals installed, and one AC output terminal is electrically connected to one copper post.

The low voltage signal connector is soldered and mounted on the control circuit board, and the low voltage signal connector protrudes outward from the controller cabinet.

The fuse is installed in the controller box, and the fuse and the DC-DC module are all connected with the control circuit board.

The low-voltage output terminal is mounted on one of the side surfaces of the controller case outside the lower cavity, and the low-voltage output terminal is electrically connected to the DC-DC module.

The cover plate is respectively mounted on the top and the bottom of the controller case, and the two cover plates respectively seal the opening at the top of the cavity and the opening at the bottom of the lower cavity.

Compared with the prior art, the utility model has the following effects:

1) By integrating the DC-DC module, capacitor module, drive circuit board, control circuit board and at least two independent power modules in the same controller cabinet, and redesigning the structure of the controller cabinet and rationally arranging each The layout of the components makes the entire motor controller structure more compact and is reducing Its volume increases its power density, and it also reduces the number of parts and components, facilitating production management;

2) The capacitor module is installed inside the groove and is closely attached to the protrusion. A power module is installed on each sink, and the needle bed is extended from the bottom surface of the power module, and the needle bed is inserted into the sink. A water flow channel extending along the length thereof is opened in the middle of the protrusion, and the water inlet, the plurality of water tanks, the water flow channel and the water outlet are sequentially connected, and the cooling structure of the motor controller is simple and ingenious, and the DC-DC module can be passed through the cooling water channel. The capacitor module and the power module perform unified heat dissipation, and the heat dissipation efficiency is high and the effect is ideal;

3) In the prior art, there is a lack of consideration for heat dissipation of the DC busbar, but since the high voltage DC power source flows from the DC busbar, the heat generation of the DC busbar is actually relatively large, and the DC in the present invention The busbar is mounted on the top surface of the protrusion, and the protrusion is in direct contact with the DC busbar so that the protrusion can take away the heat of the DC busbar portion. Further, the cooling water flows through the water flow channel disposed in the middle of the protrusion. Take more heat to achieve the purpose of rapid heat dissipation of the DC busbar;

4) a through hole is formed in the heat dissipation wall, and the through hole communicates the upper cavity and the lower cavity, and the high voltage DC input terminal and the DC-DC module are electrically connected together through the wire, and the wire passes through the middle of the through hole. The structure is simple, the connection is convenient and reliable;

5) The control circuit board and the driving circuit board are electrically connected together through the board-to-board connector, and the structure is simple, the connection is convenient and reliable, and the technical solution of using the wire harness connection control circuit board and the driving circuit board is used, and the board is used. The board connector connection can save space and cost;

6) Three current sensors are installed on the top surface of each driving circuit board, and a copper column is arranged in the middle of each current sensor, and the copper column passes through the middle of the current sensor, outside the upper cavity and on the side of the controller box There are 6 AC output terminals installed on the top, and one AC output terminal is electrically connected with one copper post. Compared with the existing technical solution of using AC copper to output AC power, the technical solution is simpler, more compact and more connected. Convenient and reliable;

7) A cover plate is respectively installed at the top and the bottom of the controller box, and the two cover plates respectively seal the opening at the top of the upper cavity and the opening at the bottom of the lower cavity, and the structure is simple, thereby increasing the sealing property of the controller box. Effectively ensure that the components inside the controller cabinet are not contaminated, to ensure the stability of their work and to extend their Life expectancy.

BRIEF DESCRIPTION OF THE DRAWINGS:

Figure 1 is a perspective view of one angle of the motor controller in the embodiment;

Figure 2 is a perspective view of another angle of the motor controller in the embodiment;

Figure 3 is a first exploded view of the motor controller in the embodiment;

Figure 4 is a second exploded view of the motor controller in the embodiment;

Figure 5 is a third exploded view of the motor controller in the embodiment;

Figure 6 is a plan view of the motor controller in the embodiment;

Figure 7 is a cross-sectional view taken along line A-A of Figure 6;

Figure 8 is a cross-sectional view taken along line B-B of Figure 6;

Figure 9 is a perspective view of the controller case in the embodiment;

Figure 10 is a cross-sectional view showing the structure of a controller case in the embodiment.

detailed description:

The present invention will be further described in detail below through the specific embodiments and the accompanying drawings.

Embodiment 1 As shown in FIG. 1 to FIG. 10, this embodiment is a motor controller including a controller box 1, a DC-DC module 2, a capacitor module 3, a driving circuit board 4, a control circuit board 5, and Two independent power modules 6 are disposed in the middle of the controller box 1 with a heat dissipation wall 11 which divides the cavity in the middle of the controller box 1 into an upper cavity 100 at the upper portion and a lower cavity 101 at the lower portion. In the upper cavity 100, a top surface of the heat dissipation wall 11 is provided with a protrusion 110. On the side of the protrusion 110, a top surface of the heat dissipation wall 11 is provided with a groove 113, on the other side of the protrusion 110, a heat dissipation wall The top surface of the 11 is provided with two side by side water tanks 114. The capacitor module 3 is mounted inside the recess 113 and is closely attached to the protrusion 110. One power module 6 is mounted on each of the water tanks 114, and the power module is installed. The needle bed 61 is extended downwardly on the bottom surface of the needle 6. The needle bed 61 extends into the water tank 114. The heat generated by the power module 6 is transmitted to the needle bed 61, and the cooling water flowing from the water tank 114 carries the needle bed 61. The heat on the heat thus achieves heat dissipation to the power module 6. The driving circuit board 4 and the control circuit board 5 are both mounted in the upper cavity 100, wherein one driving circuit board 4 is mounted on the top surface of each power module 6, and the upper surface of the upper circuit 100 is mounted on the driving circuit board 4. The control circuit board 5 is mounted, and the control circuit board 5 and the driving circuit board 4 are electrically connected together through a board-to-board connector (not shown), and the control circuit board 5 controls the driving circuit board 4 to drive the power module. 6 running work. The DC-DC module 2 is mounted on the bottom surface of the lower cavity 101 and on the bottom surface of the heat dissipation wall 11. The cooling water wall 11 is provided with a cooling water channel and is provided with a water inlet 111 and a water outlet 112 communicating with the cooling water channel. Preferably, at the water inlet At the 111 and the water outlet 112, a nozzle 84 is mounted on the controller casing 1, and the DC-DC module 2, the capacitor module 3, and the power module 6 are uniformly radiated through the cooling water passage.

A water flow channel 1100 extending along a length thereof is opened in the middle of the protrusion 110. The water inlet 111, the two water tanks 114, the water flow channel 1100 and the water outlet 112 are sequentially connected. The cooling water channel includes the two water tanks 114 and the water flow. The channel 1100 heats the power module 6 through the water tank 114, and dissipates the capacitor module 3 and the DC busbar 7 mounted on the top surface of the bump 110 through the water flow channel 1100.

A DC busbar 7 is mounted on the top surface of the protrusion 110, and the capacitor module 3 and the plurality of power modules 6 are electrically connected together through the DC busbar 7, and an external DC power source is input to each power module 6 through the DC busbar 7. . Two high-voltage DC input terminals 81 are mounted on one of the sides of the controller housing 1 outside the upper cavity 100. The high-voltage DC input terminal 81 is electrically connected to the DC busbar 7 and is opened on the heat dissipation wall 11. a hole 115, the through hole 115 communicates the upper cavity 100 and the lower cavity 101, and the high voltage DC input terminal 81 and the DC-DC module 2 are electrically connected together by a wire, and the wire passes through the through hole 115. The wire can be made of high voltage DC harness. In addition to the wires, the high-voltage DC input terminal 81 and the DC-DC module 2 may be connected by other conductive connectors as long as the electrical connection between the two can be achieved.

Three current sensors 91 are mounted on the top surface of each of the driving circuit boards 4, and a copper post 92 is disposed in the middle of each current sensor 91. The copper post 92 passes through the middle of the current sensor 91, and is controlled outside the upper cavity 100. Six AC output terminals 82 are mounted on the side of the cabinet 1 , and one AC output terminal 82 is electrically connected to one copper post 92 , and the AC output terminal 82 , the copper post 92 and the power module 6 are locked by using screws. tight.

A low voltage signal connector 51 is mounted on the control circuit board 5, and the low voltage signal connector 51 extends outward from the controller housing 1. All signals on the control circuit board 5 can pass through the low voltage signal connector 51. The externally input control signal is outputted or received through the low voltage signal connector 51.

A fuse 12 is mounted in the controller housing 1. Preferably, the fuse 12 is mounted on the heat dissipation wall 11, and the fuse 12 and the DC-DC module 2 are connected to the control circuit board 5 to enable the control circuit board. 5 The state of the fuse 12 can be detected at any time. When the fuse 12 is activated, the control circuit board 5 can stop the operation of the motor controller at any time to ensure the safety of the motor controller.

A low voltage output terminal 83 is mounted on one of the sides of the controller housing 1 outside the lower cavity 101. The low voltage output terminal 83 is electrically connected to the DC-DC module 2, and the DC-DC module 2 is externally passed through the low voltage output terminal 83. Output 12V or 24V low-voltage DC to provide a stable and reliable power supply for other components in the car.

The low voltage output terminal 83, the water nozzle 84 and the high voltage DC input terminal 81 are located on the same outer side A of the controller housing 1, and the low voltage signal connector 51 is located on the outer side B of the controller housing 1, the outer side A and The outer side surface B is opposed to each other, the alternating current output terminal 82 is located on the outer side surface C of the controller casing 1, and the outer side surface C is located between the outer side surface A and the outer side surface B.

A cover plate 10 is mounted on the top and bottom of the controller housing 1, respectively, and the two cover plates 10 respectively seal the opening at the top of the cavity 100 and the opening at the bottom of the lower cavity 101.

The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited thereto, and any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principles of the present invention. Equivalent replacement means are included in the scope of protection of the present invention.

Claims

A motor controller comprising a controller cabinet (1), a DC-DC module (2), a capacitor module (3), a drive circuit board (4), a control circuit board (5), and at least two independent power modules (6), characterized in that: a heat dissipation wall (11) is disposed in the middle of the controller box (1), and the heat dissipation wall (11) divides the cavity in the middle of the controller box (1) into an upper cavity located at the upper portion ( 100) and a lower cavity (101) located in the lower portion, a protrusion (110) is disposed on the top surface of the upper cavity (100), the heat dissipation wall (11), and the capacitor module (3) is mounted on the protrusion (110) On one side and the top surface of the heat dissipation wall (11), a plurality of power modules (6) are mounted side by side on the other side of the protrusion (110), on the top surface of the heat dissipation wall (11), and drive the circuit board (4) and The control circuit board (5) is installed inside the upper cavity (100), the control circuit board (5) controls the driving circuit board (4) to drive the power module (6) to operate, and the DC-DC module (2) is installed in the lower cavity ( 101) Inside, on the bottom surface of the heat dissipation wall (11), a cooling water channel is opened on the heat dissipation wall (11) and a water inlet (111) and a water outlet (112) connected to the cooling water channel are provided, and the DC channel is passed through the cooling water channel. DC module (2), capacitor module (3) and power mode Block (6) performs unified heat dissipation.
A motor controller according to claim 1, characterized in that: on the side of the protrusion (110), the top surface of the heat dissipation wall (11) is provided with a groove (113), and the protrusion (110) is further On one side, the top surface of the heat dissipation wall (11) is provided with at least two side by side water tanks (114), and the capacitor module (3) is mounted inside the groove (113) and is closely attached to the protrusion (110). A power module (6) is mounted on each of the water tanks (114), and a needle bed (61) is extended downward from the bottom surface of the power module (6), and the needle bed (61) projects into the water tank (114).
A motor controller according to claim 2, wherein a water flow passage (1100) extending along a length thereof, a water inlet (111), and a plurality of water tanks (114) are opened in the middle of the protrusion (110). The water flow channel (1100) and the water outlet (112) are sequentially connected.
A motor controller according to claim 1 or 2 or 3, characterized in that a DC busbar (7) is mounted on the top surface of the projection (110), and the capacitor module is passed through the DC busbar (7). (3) And a plurality of power modules (6) are electrically connected together, and an external DC power source is input to each power module (6) through the DC busbar (7).
A motor controller according to claim 4, wherein two high voltage DC input terminals (81) are mounted on one of the sides of the upper casing (100) and the controller casing (1). The high-voltage DC input terminal (81) is electrically connected to the DC busbar (7), and a through hole (115) is opened in the heat dissipation wall (11), and the upper cavity (100) and the lower cavity are provided through the through hole (115) ( 101) Connected, the high voltage DC input terminal (81) and the DC-DC module (2) are electrically connected together by wires, and the wires pass through the middle of the through holes (115).
A motor controller according to claim 1 or 2 or 3, wherein the number of the power modules (6) is two, and one of the top surfaces of each power module (6) is mounted. a block driving circuit board (4), the control circuit board (5) is mounted above the driving circuit board (4) and inside the upper cavity (100), and the control circuit board (5) and the driving circuit board (4) are passed between The board-to-board connectors are electrically connected together.
A motor controller according to claim 6, wherein three current sensors (91) are mounted on the top surface of each of the driving circuit boards (4), and are disposed in the middle of each current sensor (91). There is a copper column (92), the copper column (92) passes through the middle of the current sensor (91), and six AC output terminals (82) are mounted on the side of the upper casing (100) and on the side of the controller box (1). One AC output terminal (82) is electrically connected to one copper post (92).
A motor controller according to claim 6, wherein a low voltage signal connector (51) and a low voltage signal connector (51) are mounted on the control circuit board (5) from the controller housing (1). ) Stretch out.
A motor controller according to claim 8, characterized in that a fuse (12), a fuse (12) and a DC-DC module (2) are mounted and controlled in the controller housing (1). The circuit board (5) establishes a communication connection.
A motor controller according to claim 1 or 2 or 3, characterized in that a low-voltage output terminal (83) is mounted on one of the sides of the lower casing (101) and the controller casing (1). The low voltage output terminal (83) is electrically connected to the DC-DC module (2).
A motor controller according to claim 1 or 2 or 3, characterized in that A cover plate (10) is mounted on the top and bottom of the controller housing (1), respectively, and the two cover plates (10) respectively seal the opening at the top of the upper cavity (100) and the opening at the bottom of the lower cavity (101).