CN103607159A - Electric vehicle motor controller and controller assembly modularization unit structure mode - Google Patents
Electric vehicle motor controller and controller assembly modularization unit structure mode Download PDFInfo
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- CN103607159A CN103607159A CN201310631406.5A CN201310631406A CN103607159A CN 103607159 A CN103607159 A CN 103607159A CN 201310631406 A CN201310631406 A CN 201310631406A CN 103607159 A CN103607159 A CN 103607159A
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Abstract
Provided are an electric vehicle alternating-current motor controller and a modularization unit structure and layout mode of a controller assembly. A power semiconductor module, a driving control board unit thereof, an aluminum electrolytic capacitor integration module, an output terminal component module 3 with a built-in current sensor, and a component unit 4 formed by a contactor 4a, a power fuse protector 4b and a diverter 4c are included and are arranged on an inner bottom plate of a radiating aluminum outer shell 5 in sequence. A plastic inner cover 6 seals the power semiconductor module, the driving control board unit 1 thereof, the capacitor integration module 2 and the output terminal component module 3 with the built-in current sensor in a sealed space, and the motor controller is formed. An outer cover 7 again seals input binding posts 2c and 2d of the motor controller, output binding posts 3f, 3g and 3h and the component unit 4 formed by the contactor 4a, the power fuse protector 4b and the diverter 4c in a sealed outer shell formed with the radiating aluminum outer shell 5, and the motor controller assembly is formed.
Description
Technical field:
The present invention relates to the modular unit topology layout mode of small-sized electric vehicle AC motor control and control assembly, specifically: power semiconductor modular and driving control board unit 1 thereof; Aluminium electrolytic capacitor integration module 2; Inside establish the lead-out terminal construction part module 3 of current sensor; Contactor 4a, power fuse 4b, shunt 4c constant power measuring and protecting assembly unit 4; heat radiation sealing shell with radiation aluminium shell 5, plastic cement inner cap 6, enclosing cover 7 form, forms the topology layout mode of AC motor control or control assembly for small-sized electric vehicle.
Background technology:
Electric motor car not combustion of fossil fuels produces power, has environmental protection, pollutes little feature, has become the developing direction of future automobile.At present small-sized pure electric automobile, electric golf cart, electric space vehicle and industrial class motor vehicle are comparatively fast popularized as electri forklift etc.
Electric vehicles electromagnetic motor roughly can be divided into direct current machine and alternating current machine, and alternating current machine comprises AC induction motor (induction machine) and ac synchronous motor.Automobile-used ac synchronous motor is generally permagnetic synchronous motor or switched reluctance machines.When permagnetic synchronous motor is operated in square wave commutation pattern, be often called again brshless DC motor.
AC motor control and control assembly, for converting the DC power supply of storage battery output to three-phase alternating-current supply and controlling the torque and rotational speed of motor, are the core technology parts of electric automobile.
Fig. 1 is electric machine controller assembly electrical block diagram of the present invention.
On market, small-sized electric vehicle is general adopt in, low-voltage driving system, the company of automobile-used low-voltage alternating-current electric machine controller product: as U.S. curtis, Britain sevcon, Italian zapi, Italian sme, U.S. danaher, Britain pg etc., comprise that China specializes in the company that motor vehicle electric machine controller research and development are produced, these enterprises in the accumulation of motor vehicle field for many years, have ripe product.
Conventionally low voltage motor controller is composed in parallel the device for power switching unit that makes direct current be converted to alternating current by MOS EFT single tube; By aluminium electrolytic capacitor Shunt Capacitor Unit, for MOS EFT switching device unit provides voltage regulation filtering and absorbing high-frequency noise purposes.
Because loop of power circuit consists of discrete component parallel connection, all press equal flow problem more outstanding; Complex structure causes main circuit pulse current to make to exist stronger electromagnetic field radiation to disturb in whole circuit structure space; Major loop aluminium electrolytic capacitor ESR value is larger, and the heat producing during loaded work piece does not have heat dissipation design, causes controller internal temperature rise very high, and component reliability reduces; Smd controller One's name is legion particularly, worker is made time and effort consuming.
Adopt the electric machine controller product of components and parts integration mode in parallel not for electric automobile, to apply specially, the market orientation of a lot of products is only alternating current controlled fork truck field, so controller is used in high speed electric vehicle, aspect vibration reliability, there is more serious defect.
In addition electric machine controller is installed needs specific level and smooth metal covering, smear heat-conducting silicone grease and ensure with the accurate laminating of controller base plate the dissipation of heat that maximum heat conduction and power produce, in general environment for use, need external radiator, this brings a lot of inconvenience to installing and using of electric machine controller.
While having again the measuring and protecting device composition control device assemblies such as electric machine controller and contactor, power fuse, shunt; each several part structural compatibility is bad; need other housing to do exterior protection and use, exist electric machine controller assembly to be difficult for realizing miniaturization etc. problem.
People are for the miniaturization of electric machine controller and electric machine controller assembly product, and assembly working summary, solves product heat dissipation problem and improve the demands such as reliability strong.Low-voltage and high-current power MOSFET module product emerges at present, as the FM of Mitsubishi Electric Co. series power MOSFET module product group, power MOSFET module and common columned electrolytic capacitor have been realized miniaturization simple connection by " rectangular block shape has the aluminium electrolytic capacitor power modules of radiating surface " technology (Chinese Patent Application No.: 201310009423.5, hereinafter referred to as patent documentation 1).
Summary of the invention:
The present invention discloses the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly, comprising: power semiconductor modular and driving control board unit 1 thereof; The capacitor integration module 2 that has "+", "-" utmost point input and output terminal; Inside establish U phase 3f, the V phase 3g of current sensor 3d, 3e, the construction part module 3 of W phase 3h lead-out terminal; The assembly unit 4 that contactor 4a, the power fuse 4b being connected with capacitor integration module 2 "+" utmost point input terminal 2c forms with the shunt 4c constant power measuring and protecting device being connected with capacitor integration module 2 "-" utmost point input terminal 2d, above unit is installed on radiation aluminium shell 5 inner bottom platings successively, and plastic cement inner cap 6 is by power semiconductor modular and drive control board unit 1; The capacitor integration module 2 that has "+", "-" utmost point input and output terminal; Inside establish U phase 3f, the V phase 3g of current sensor 3d, 3e, the construction part module 3 of W phase 3h lead-out terminal, be enclosed in a confined space, form electric machine controller; For making power semiconductor modular and driving 1 assembly of control board unit convenient, its corresponding radiation aluminium shell 5 sidewall locations are left a blank, by the plastic cement inner cap 6 flank position 6g position of leaving a blank, sealed; The assembly unit 4 that enclosing cover 7 forms input wires terminal 2c, 2d, output wiring terminal 3f, 3g, 3h and the contactor 4a of electric machine controller, power fuse 4b, shunt 4c is enclosed in the sealing shell forming with radiation aluminium shell 5 again, forms electric machine controller assembly; Convenient for assembly unit 4 assembly workings that contactor 4a, power fuse 4b, shunt 4c constant power measuring and protecting device are formed, its corresponding radiation aluminium shell 5 sidewall locations are left a blank, by the enclosing cover 7 design flanks position of leaving a blank, sealed; There is control signal wiring connector 1i port on electric machine controller assembly shell surface, the U phase 5h being connected with motor, V phase 5i, W phase 5j outlet cable aperture, B+ utmost point 5l, B-utmost point 5k lambda line cable aperture that battery connects.(the first invention)
According to above invention:
Power semiconductor modular 1l can be for the IGBT of six or seven cellular constructions or MOSFET, also can be the three phase inverter bridge that three group of two elemental semiconductor forms, direct current input P utmost point 1a, N utmost point 1b and exchanges export U phase 1c, V phase 1d, W phase 1e terminal divides in both sides, power semiconductor modular 1l drive plate 1f and electric machine controller assembly control board (ECU) 1g, 1h are installed on the top of module 1l or three groups of parallel module 1l, form the space structure of square rectangular characteristic, form the core-power semiconductor modular of AC motor control and drive control board unit 1 part;
At power semiconductor modular and driving control board unit 1 direct current thereof, input P utmost point 1a, N utmost point 1b side, using "+" utmost point conductive bus bar 2f, "-" utmost point conductive bus bar 2g as supporting construction skeleton, and the parallel distribution of aluminium electrolytic capacitor 2e i.e. " lodging " is arranged 2f, 2g both sides at busbar.Busbar is arranged to 2f, 2g again, aluminium electrolytic capacitor 2e is potted in housing 2h with heat-conducting medium, be formed with " the rectangular block shape aluminium electrolytic capacitor module of radiating surface " unit 2 and (refer to patent documentation 1, lower same), be used to power semiconductor modular 1l burning voltage and filtering High-frequency Interference.
The present invention adopts the capacitor integration module 2 of power semiconductor modular 1l and rectangular block shape, and the structure of electric machine controller and packaging technology are simplified, and is conducive to the miniaturization of electric machine controller and control assembly.
At power semiconductor modular and driving control board unit 1 thereof, exchange U phase 1c, V phase 1d, W phase 1e outlet side, two current sensor 3d, 3e are received into and are supported in " the square shape box " of fixing use into U phase 3f, V phase 3g, W phase 3h lead-out terminal, the construction part module 3 of " square shape box " is at power semiconductor and drive control board unit 1 one sides to have terminal hole 3j, makes the measuring-signal line terminals of current sensor 3d, 3e can be by with power semiconductor modular and drive control ECU plate 1g, the 1h of control board unit 1 to be connected.Lead-out terminal construction part module 3 fixedly mounts by the mounting screw hole 3k on module housing 3i and radiation aluminium shell 5 base plates, forms the installation fixation problem that " inside establishing U phase 3f, V phase 3g, the W phase 3h lead-out terminal construction part module 3 of current sensor 3d, 3e " solved U phase 3f, V phase 3g, W phase 3h lead-out terminal and current sensor 3d, 3e simultaneously.
The miniaturization of installing for realizing contactor 4a, fuse 4b and shunt 4c constant power measuring and protecting device; by contactor 4a and fuse 4b, shunt 4c, vertical to be side by side installed to a base plate 4k upper, the terminal base 4e, the 4d that on base plate 4k, are designed with fuse 4b, shunt 4c support and are connected and fixed with the battery B+ utmost point, B-polar conductor.With conducting copper, each device terminal is connected; comprise the copper bar that connects aluminium electrolytic capacitor integration module 2 "+" gate terminal 2c, "-" gate terminal 2d; become with electric machine controller of the present invention and control assembly structural compatibility better, the power measurement of essentially rectangular side's shape space structure protection assembly unit 4.
Briefly say; the assembly unit 4 of contactor 4a, power fuse 4b and shunt 4c belongs to the combination of power measurement protection device; group is controlled protection fuse with comprising; also can remove shunt 4c etc. combining form, all belong to electric machine controller and form in addition the category of the power measurement protection device unit 4 of electric machine controller assembly.
According to the category of above power measurement protection device unit 4; above device can be assembled on same base plate 4k; get in the position that also the larger D.C. contactor 4a of body in assembly directly can be fixedly installed to radiation aluminium shell 5 interior correspondences; the less power measurement protection device combination of power fuse 4b, shunt 4c body is assembled to fixed support 4l and base plate 4k is upper, then is installed on the position of radiation aluminium shell 5 interior correspondences and forms complete assembly unit.So separately assemble contactor 4a and can reduce base plate 4k and the hard-wired requirement of strength of radiation aluminium shell 5, improve the reliability of whole power measurement protection assembly unit 4 under vibratory impulse condition.(the 3rd invention)
That supplements says, the radiation aluminium shell 5 bottoms radiating fin 5g that can distribute also can corresponding concrete assembled condition make level and smooth metal covering and install with the accurate laminating in motor vehicle installation site, guarantee heat conduction and power dissipation of heat; Can also make and force cooling structure heat sink design, provided with fan dispels the heat; More can adopt the water cooling design that efficiency is higher, by the position at the corresponding power semiconductor modular 1l in radiation aluminium shell 5 bottoms and capacitor integration module 2, installing cooling water pipeline mode additional dispels the heat, now the distribute thermolysis of radiating fin 5g of radiation aluminium shell 5 outer surfaces reduces greatly, from reducing costs angle, can remove.
The present invention's's " motor vehicle electric machine controller and control assembly modular unit frame mode " heat dissipation design comprises above various ways, does not get rid of with upper type and the present invention and is used in combination.
That supplements says, the vertical installation arranged side by side of contactor 4a, power fuse 4b and shunt 4c, wherein power fuse 4b and shunt 4c are fixed on mounting bracket 4l, above constituent components is assembled on base plate 4k, by the upper fixing hole 4m of base plate 4k, be fixed on the interior correspondence position of radiation aluminium shell 5, above modular construction is installed complicated.
Also power measurement can be protected near assembly unit 4, radiation aluminium shell 5 lateral location on cable line-entering hole 5l, 5k top are left a blank, and facilitate the fixedly assembling of power measurement protection assembly unit 4, and the position of leaving a blank is sealed by enclosing cover design flank.(the 4th invention)
Conventionally electric machine controller is responsible for assembling by the accurate manufacturer of specialty.Motor vehicle manufacturer is contactor 4a, fuse 4b and shunt 4c constant power measuring and protecting device and electric machine controller assembling all-in-one-piece electric machine controller assembly, or adheres to two different housings separately and form electric machine controller assemblies.For realizing the electric machine controller assembly of one, and assembly stage and control assembly application assembling stage at electric machine controller all have suitable protection, the present invention designs plastic cement inner cap 6, and enclosing cover 7 forms with heat-dissipating casing body 5 requirement of shelter that " dual " confined space meets electric machine controller and two stages of electric machine controller assembly.
First in radiation aluminium shell 5, there is insulating course 5n radiation aluminium shell 5 inside to be separated to 4 two different locational spaces of assembly unit of electric machine controller and contactor 4a, power fuse 4b, shunt 4c, by power semiconductor modular and drive control board unit 1; Capacitor integration module 2; The lead-out terminal construction part module 3 of inside establishing current sensor is put into the locational space of electric machine controller, and plastic cement inner cap 6 is sealed forms electric machine controller.Lead-out terminal module U phase 3f, V phase 3g, W phase 3h lead- out terminal hole 6a, 6b, 6c and capacitor module "+" utmost point 2c, "-" utmost point 2d input terminal hole 6d, 6e are arranged at plastic cement inner cap 6 tops, plastic cement inner cap flank 6f has control signal wiring connector 1i port 6g, after electric machine controller specialty manufacturer is airtight by inner cap 6, completes electric machine controller manufacture.Enclosing cover 7 has plastic cement inner cap 6 tops in the space of U phase 3f, V phase 3g, W phase 3h lead-out terminal and "+" utmost point 2c, "-" utmost point 2d input terminal together with the another one locational space sealing of the power measurement protection assembly unit 4 of the interior corresponding contactor 4a of radiation aluminium shell 5, power fuse 4b, shunt 4c, makes the inner formation electric machine controller of radiation aluminium shell 5 assembly.Motor vehicle manufacturer connects the cable of U phase 3f, V phase 3g, W phase 3h lead-out terminal and battery B+ utmost point splicing ear 4e, battery B-utmost point splicing ear 4d, completes the application assembling of electric machine controller assembly after enclosing cover 7 is airtight.
Plastic cement inner cap 6 adapts to the feature in electric machine controller assembly and electric machine controller assembly application two stages of assembling, met the requirement of shelter during electric machine controller and control assembly middle transition, and taken into account electric machine controller internal power semiconductor module and driven control board unit 1 assembly working efficiency.(the 5th invention)
That supplements says, if motor vehicle manufacturer protects one group of the another one-tenth of assembly unit 4 by power measurement, be divided into two different housings with electric machine controller, now enclosing cover 7 is by electric machine controller top U phase 3f, V phase 3g, the cavity of the cavity of W phase 3h lead-out terminal and capacitor module "+" utmost point 2c "-" utmost point 2d input terminal seals again, form a surface of shell and have control signal wire connector port 1i, the U phase 5h being connected with motor, V phase 5i, W phase 5j outlet cable aperture, the B+ utmost point 5l being connected with battery, the electric machine controller of B-utmost point 5k lambda line cable aperture, now motor controller structure still belongs to the category of the present invention's " motor vehicle electric machine controller and control assembly modular unit frame mode ".
The present invention program's enforcement, can subdue electric machine controller internal components quantity, has realized the miniaturization of electric machine controller assembly; ; Employing to capacitor integration module 2, reduces internal temperature rise and has improved component reliability; Simplify controller product structure, realize and assemble subduing of man-hour, reduce costs.
Accompanying drawing explanation:
Fig. 1: be electric machine controller assembly circuit structure diagram of the present invention;
Fig. 2 (a): be to observe power semiconductor modular and drive control board unit 1 assembly structure figure, Fig. 2 (b) from direct current input P utmost point 1a, N utmost point 1b side: be to observe power semiconductor modular and drive control board unit 1 assembly structure figure from interchange output U phase 1c, V phase 1d, W phase 1e side;
Fig. 3: be to have "+" utmost point 2c "-" utmost point 2d input, capacitor integration module 2 assembly structure figures of "+" utmost point 2a "-" utmost point 2b lead-out terminal;
Fig. 4: lead-out terminal construction part module 3 assembly structure figures of establishing current sensor 3d, 3e in being;
Fig. 5 (a): be to observe the assembly structure figure of contactor 4a, power fuse 4b, shunt 4c power measurement protection assembly unit 4, Fig. 5 (b) from capacitor module 2 sides: be to observe the assembly structure figure of contactor 4a, power fuse 4b, shunt 4c power measurement protection assembly unit 4 from electric machine controller assembly lateral direction;
Fig. 6: be protection radiation aluminium shell 5 structure charts;
Fig. 7: be protection inner cap 6, enclosing cover 7 structure charts;
Fig. 8 (a): be modularized motor control assembly structure chart; Fig. 8 (b): be modularized motor control assembly installation diagram.Digitized representation in figure:
1, power semiconductor modular and driving control board unit thereof,
Wherein 1a, power semiconductor modular P utmost point input;
1b, power semiconductor modular N utmost point input;
1c, power semiconductor modular exchange U phase output terminal;
1d, power semiconductor modular exchange V phase output terminal;
1e, power semiconductor modular exchange W phase output terminal;
1f, power semiconductor modular drive plate;
1g, motor controller controls plate ECU1;
1h, motor controller controls plate ECU2;
1i, electric machine controller signal port connector;
1j, power semiconductor modular radiating copper base plate;
1k, power semiconductor modular mounting screw hole;
1l, power semiconductor modular.
2, aluminium electrolytic capacitor integration module,
Wherein, 2a, with semiconductor module 1l P utmost point splicing ear;
2b, with semiconductor module 1l N utmost point splicing ear;
2c, capacitor integration module "+" utmost point input terminal;
2d, capacitor integration module "-" utmost point input terminal;
2e, monomer aluminium electrolytic capacitor;
2f, capacitor module "+" utmost point busbar copper coin;
2g, capacitor module "-" utmost point busbar copper coin;
2h, capacitor integration module shell;
2i, capacitor integration module mounting screw hole.
3, in, establish the lead-out terminal construction part module of current sensor,
Wherein 3a, terminal is connected with semiconductor module U;
3b, terminal is connected with semiconductor module V;
3c, terminal is connected with semiconductor module W;
3d, semiconductor U phase output current transducer;
3e, semiconductor W phase output current transducer;
3f, the motor U terminal that is connected;
3g, the motor V terminal that is connected;
3h, the motor W terminal that is connected;
3i, lead-out terminal construction part module shell;
3k, lead-out terminal construction part module mounting screw hole.
4, contactor, fuse, shunt power measurement protection assembly unit,
Wherein, 4a, contactor;
4b, fuse;
4c, shunt;
4d, battery B-utmost point input splicing ear;
4e, battery B+ utmost point input splicing ear;
4f, contactor are connected copper bar with capacitor module 2 "+" gate terminal;
4g, contactor are connected copper bar with fuse;
4h, fuse are connected copper bar with battery B+ utmost point input splicing ear;
4i, shunt are connected copper bar with capacitor module 2 "-" gate terminal;
4j, shunt are connected copper bar with battery B-utmost point input splicing ear;
4k, assembly unit mounting base;
4l, fuse, shunt mounting bracket;
4m, contactor, fuse, shunt power measurement protection assembly unit screw mounting hole.
5, aluminium heat-dissipating casing,
Wherein, 5a, power semiconductor modular 1l screw fixed hole;
5b, capacitor integration module 2 screw fixed holes;
5c, lead-out terminal construction part module 3 screw fixed holes;
5d, contactor, fuse, diverter assembly unit 4 screw fixed holes;
5e, plastic cement inner cap 6 screw mounting holes;
5f, enclosing cover 7 screw mounting holes;
5g, radiating fin;
5h, output U phase cable outlet hole;
5i, output V phase cable outlet hole;
5j, output W phase cable outlet hole;
5k, battery input B+ cable line-entering hole;
5l, battery input B-cable line-entering hole;
5m, electric machine controller assembly bolt mounting holes;
5n, aluminium heat-dissipating casing inner space insulating course.
6, plastic cement inner cap,
Wherein, 6a, in cover lead-out terminal module U phase 3f terminal hole;
6b, in cover lead-out terminal module V phase 3g terminal hole;
6c, in cover lead-out terminal module W phase 3h terminal hole;
6d, inner cap container integration module input "+" utmost point 2c terminal hole that powers on;
6e, inner cap container integration module input "-" utmost point 2d terminal hole that powers on;
6f, inner cap flank;
6g, control signal connector 1i terminal hole;
6h, inner cap mounting screw hole;
6i, electric machine controller assembly enclosing cover;
7, enclosing cover, wherein 7a is enclosing cover mounting screw hole.
Specific embodiment:
Below with reference to accompanying drawing, the preferred embodiments of the present invention are described.
The circuit structure diagram that Fig. 1 means " motor vehicle electric machine controller and control assembly modular unit frame mode " of the present invention, this electric machine controller assembly is used for motor vehicle and controls and be equipped on its vehicle as the alternating current machine of the vehicles such as electric golf cart, electric space vehicle or medium and small pure electric passenger vehicle drives.
In this figure, 1 is power semiconductor modular and drives ，Gai unit, control board unit to have power semiconductor circuit 1l and semiconductor driver element 1f, Electric Machine Control ECU unit 1g, tri-parts of 1h; Also comprise semiconductor inlet highway terminal 1a, 1b, lead-out terminal 1c, 1d, 1e; Wherein power semiconductor circuit is threephase switch change-over circuit module 1l, and this unit is the core of electric machine controller and control assembly.
In Fig. 1,2 is capacitor integration modules, capacitor integration module 2 is comprised of many aluminium electrolytic capacitor 2e that are connected in parallel in the present invention, capacitor integration module 2 also comprise between power semiconductor modular 1l side terminal 2a, 2b and input side terminal 2c, 2d and "+" utmost point two ends between the conductive bus bar 2f of shunt capacitor and "-" utmost point two ends for the conductive bus bar 2g of shunt capacitor.
In Fig. 1,3 is lead-out terminal construction part modules, comprise U phase 3f, V phase 3g, W phase 3h splicing ear that 3c that 3b, 1e that the 3a, the 1d that are connected with power semiconductor modular 1l lead-out terminal 1c connect connect is connected with motor, and the current sensor 3d of U phase 3f output, the current sensor 3e of W phase 3h output.
In Fig. 1,4 is contactor 4a, fuse protector 4b and shunt 4c power measurement protection assembly unit, and contactor 4a and power fuse 4b are connected on battery " B+ " utmost point incoming line, and shunt 4c is connected on battery " B-" utmost point incoming line.
Power measurement protection assembly unit is except having contactor 4a, fuse protector 4b and shunt 4c also comprises battery B+ splicing ear 4e; Battery B-splicing ear 4d; Also have contactor 4a to be connected conducting copper 4f with capacitor integration module "+" utmost point 2c; Contactor 4a is connected conducting copper 4g with fuse 4b; Fuse 4c is connected conducting copper 4h with battery B+ splicing ear 4e; Shunt 4c is connected conducting copper 4i with capacitor integration module "-" utmost point 2d; Between shunt 4c and battery B-splicing ear 4d, be connected conducting copper 4j.
Power semiconductor modular and driving control board unit 1 thereof, capacitor integration module 2, lead-out terminal construction part module 3 three parts form the full functional circuit of electric machine controllers; Electric machine controller again with contactor 4a, power fuse 4b, shunt 4c constant power measuring and protecting assembly unit 4, form all functions circuit of electric machine controller assembly.
Below with reference to Fig. 2～Fig. 8, each modular unit structure and the assembly structure of electric machine controller of the present invention and control assembly are elaborated.
Fig. 2 (a) is to be direct current input P utmost point 1a, N utmost point 1b unilateral observation power semiconductor modular and the mounting structure figure that drives control board unit 1 from capacitor module 2 one sides, and Fig. 2 (a) exchanges the mounting structure figure of output U phase 1c, V phase 1d, W phase 1e unilateral observation semiconductor module and driving control board unit 1 from lead-out terminal construction part module 3.
In figure, power semiconductor modular 1l adopts IGBT or the MOSFET module of six cellular constructions, direct current input P utmost point 1a, N utmost point 1b and exchanges export U phase 1c, V phase 1d, W phase 1e terminal divides in both sides, power model drive plate 1f and motor controller controls plate (ECU) 1g, 1h is installed on to the top of power semiconductor modular 1l.
In figure, 1f is power semiconductor modular 1l drive plate, can, according to the amplitude shape of different Drive Protecting Circuit mode conversion substrate 1f, not affect direct current input side capacitor module 2, be limited with the installation site that exchanges outlet side lead-out terminal construction part module 3.
In figure, 1g, 1h are that electric machine controller and control assembly are controlled ECU unit, can be according to the function control circuit increase and decrease substrate 1g of different motor types, the amplitude shape of 1h.Wherein the substrate 1h 35 core connector 1i that have been welded, can realize airtight connection with controller outside by plastic cement inner cap 6 flank 6f control signal connector stomidium 6g.
In figure, 1j is the radiating copper base plate of power semiconductor modular, after power semiconductor modular 1l installs, radiating copper base plate 1j contacts installation with radiation aluminium shell 5 bottom surfaces, and the heat that power semiconductor modular 1l produces distributes by the radiating fin 5g on radiation aluminium shell 5 surfaces.
In figure, 1k is the bolt installation fixing hole of power semiconductor modular, with the corresponding erection of radiation aluminium shell 5 inner bolt installing hole 5a.
Fig. 3 is the stereochemical structure installation diagram of aluminium electrolytic capacitor module, in figure, branched monomer aluminium electrolytic capacitor 2e lodging is in conductive copper bus-bar 2f, 2g plane, conductive copper bus-bar 2f, 2g fold and connect the P utmost point input 1a of power semiconductor modular 1l and terminal 2a, the 2b of N utmost point input 1b in power semiconductor modular 1l mono-side symmetry, opposite side divides two planes that fold in isoplanar, and the conductive stud that is welded is respectively as input "+" utmost point 2c "-" utmost point 2d splicing ear.Shell 2h is put in above aluminium electrolytic capacitor 2e assembling in parallel, as a whole with heat-conducting medium embedding, the interior correspondence position plane contact of bottom embedding media plane and radiation aluminium shell 5, by the bolt fixing hole 2i on capacitor module shell 2h and the radiation aluminium shell corresponding erection of 5 internal-flange bolt installing hole 5b (internal structure is asked for an interview patent documentation 1 in detail).
Fig. 4 is " U phase 3f, V phase 3g, the W phase 3h lead-out terminal construction part module of inside establishing current sensor 3d, 3e " internal structure installation diagram, in figure, with power semiconductor modular 1l output U phase 1c splicing ear 3a, extend and fold plane on running through respectively after current sensor 3d, 3e and be welded conductive stud as the output U terminal 3f terminal 3h that is connected with output W that is connected with the conducting copper of W phase 1e splicing ear 3c; The conducting copper of power semiconductor modular 1l output V phase 1d splicing ear 3b extends upper folding and folds plane again and be welded conductive stud as the output V terminal 3g that is connected.The position, hole of three upper planes of conductive stud counterpart member module housing 3i, fixes with casting glue embedding after fixing, by assembling above constituent components, and integrant lead-out terminal construction part module 3.
Construction part module shell 3i is at power semiconductor modular and drive control board unit 1 one sides to have two current sensor 3d, 3e signal terminal hole 3j, for passing through the signal terminal of current sensor 3d, 3e.
The bolt fixing hole 3k of construction part module 3 and the corresponding erection of radiation aluminium shell 5 internal-flange bolt installing hole 5c.
Fig. 5 (a) is that contactor 4a, fuse protector 4b and shunt 4c power measurement protect assembly unit 4 in the structural perspective of capacitor module 2 unilateral observations, and Fig. 5 (b) is the structural perspective that contactor 4a, fuse protector 4b and shunt 4c power measurement protection assembly unit 4 are observed in electric machine controller assembly outside.
The vertical installation arranged side by side of contactor 4a, power fuse 4b and shunt 4c in figure, wherein power fuse 4b and shunt 4c are fixed on mounting bracket 4l above, and fixed support 4l dividing plate is done electrical isolation to power fuse 4b, shunt 4c and battery B+ utmost point splicing ear 4e, B-utmost point splicing ear 4d respectively.Shunt 4c is connected conducting copper 4j and is connected conducting copper 4h with battery B+ splicing ear 4e with power fuse 4a respectively through fixed support 4l dividing plate bending connection with battery B-utmost point splicing ear 4d.Power fuse 4b and contactor 4a are connected conducting copper 4g, at the power fuse 4a fixed support 4l dividing plate back side, by power fuse 4a hold-down screw conduction, connect.By conducting copper 4g, power fuse 4b and contactor 4a realize and being connected in series on battery B+ incoming line.Contactor 4a and capacitor module "+" gate terminal 2c be connected conducting copper 4f and shunt 4c extends in the past to capacitor module "+" utmost point 2c, "-" utmost point 2d terminal direction respectively with the conducting copper 4i that is connected of capacitor module "-" gate terminal 2d.
All constituent components are assembled into base plate 4k above above, the power measurement protection assembly unit 4 being integrally formed.
Power measurement protection assembly unit 4 is by base plate 4k screwing installing hole 4m and the corresponding erection of the interior 5d bolt mounting holes of radiation aluminium shell 5.
Fig. 6 is that radiation aluminium shell 5 inputs from direct current the structure chart that a skew back, direction is observed.
In figure, 5a is the bolt mounting holes of corresponding power semiconductor modular 1l installing hole 1k; 5b is the bolt mounting holes of corresponding capacitor module 2 mounting screw hole 2i; 5c is the bolt mounting holes of corresponding lead-out terminal construction part module 3 mounting screw hole 3k; 5d is the bolt mounting holes of the assembly unit 4 base plate 4k mounting screw hole 4m of corresponding contactor 4a, fuse protector 4b and shunt 4c.
Above lead-out terminal module 3 bolt mounting holes 5c positions, on radiation aluminium shell 5, having corresponding U phase, V phase, W phase cable outlet hole 5h, 5i, 5j, there are the corresponding plastic inner cap of screw mounting hole 5e 6 screw mounting hole 6h at radiation aluminium shell 5 edges, bottom, cable outlet hole.The installation site of the corresponding capacitor module 2 of the capacitor module 2 screw mounting hole 5b power measurement corresponding with power measurement protection assembly unit 4 screw mounting hole 5d protected between assembly unit 4 installation sites radiation aluminium shell 5 inner compartment layer 5n, and there are the corresponding screw mounting hole 5e of plastic cement inner cap 6 screw mounting hole 6h at insulating course 5n edge.
At the battery B-utmost point splicing ear 4d of radiation aluminium shell 5 internal power measuring and protecting assembly units 4, have cable line-entering hole 5l, 5k on the radiation aluminium shell 5 of battery B+ utmost point splicing ear 4e correspondence position.
The radiation aluminium shell 5 outer surfaces radiating fin 5g that extensively distributes.
Fig. 7 is the structure chart of plastic cement inner cap 6 and enclosing cover 7.
Wherein 6a, 6b, 6c are respectively the terminal holes of corresponding lead-out terminal module lead-out terminal 3f, 3g, 3h, 6d, 6e are corresponding capacitor module 2 input "+" gate terminal 2c, the terminal hole of "-" gate terminal 2d has projection to cut off and prevents creepage between electrode terminal, short circuit between each terminal hole.
There is flank 6f the corresponding radiation aluminium shell 5 of plastic cement inner cap 6 position of leaving a blank, by the radiation aluminium shell 5 position sealing of leaving a blank.On flank 6f, there is control signal connector 1i plug terminal hole 6g.
Plastic cement inner cap 6 has the edge that overlaps with enclosing cover 7 on radiation aluminium shell 5 positions, edge, and enclosing cover 7 mounting screws are by installing hole 7a and run through the corresponding erection of bolt mounting holes 5f of plastic cement inner cap 6 edges and radiation aluminium shell 5.
Fig. 8 (a) is modular unit electric machine controller assembly structure chart.
In figure, lead-out terminal module 3, power semiconductor modular and driving control board unit 1, aluminium electrolytic capacitor integration module 2, power measurement protection assembly unit 4 are arranged in order and pack on the inner corresponding position of radiation aluminium shell 5.Plastic cement inner cap 6 is at lead-out terminal module 3, power semiconductor modular and drive control board unit 1, aluminium electrolytic capacitor integration module 2 top positions; can be sealed installation; enclosing cover 7, above lead-out terminal module 3, power semiconductor modular and driving control board unit 1, aluminium electrolytic capacitor integration module 2, the corresponding radiation aluminium enclosure location of power measurement protection assembly unit 4, can form electric machine controller assemblies by 5 sealings of radiation aluminium shell.
Fig. 8 (b) is modular unit electric machine controller general assembly figure.
Plastic cement inner cap 6 is by lead-out terminal module 3, power semiconductor modular and drive control board unit 1,2 sealings of aluminium electrolytic capacitor integration module to form electric machine controller; Power measurement protection assembly unit 4 packs the position of radiation aluminium shell 5 interior correspondences into, and enclosing cover 7 seals formation electric machine controller assembly again by electric machine controller and power measurement protection assembly unit 4.
Claims (13)
1. a modular unit structure and layout mode for motor vehicle AC motor control and control assembly, comprising: power semiconductor modular and driving control board unit thereof; The capacitor integration module that has "+", "-" utmost point input and output terminal; Inside establish U phase, the V phase of current sensor, the construction part module of W phase output terminals; The assembly unit that the contactor being connected with capacitor integration module "+" utmost point input terminal, power fuse and the shunt constant power measuring and protecting device being connected with capacitor integration module "-" utmost point input terminal form, above unit is installed on radiation aluminium shell inner bottom plating successively, and plastic cement inner cap is by power semiconductor modular and drive control board unit; The capacitor integration module that has "+", "-" utmost point input and output terminal; Inside establish U phase, the V phase of current sensor, the construction part module of W phase output terminals, be enclosed in a confined space, form electric machine controller; For making power semiconductor modular and driving the assembly of control board unit convenient, left a blank in its corresponding radiation aluminium side wall of outer shell position, by the position of leaving a blank, plastic cement inner cover side alar part position, sealed; The assembly unit that enclosing cover forms input wires terminal, output wiring terminal and the contactor of electric machine controller, power fuse, shunt is enclosed in the sealing shell forming with radiation aluminium shell again, forms electric machine controller assembly; Convenient for the assembly unit assembly working that contactor, power fuse and shunt constant power measuring and protecting device form, left a blank in its corresponding radiation aluminium side wall of outer shell position, by the enclosing cover design flank position of leaving a blank, sealed; There is control signal wire connector port on electric machine controller assembly shell surface, the U phase being connected with motor, V phase, W phase outlet cable aperture, the B+ utmost point, B-utmost point lambda line cable aperture that battery connects.
2. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, in wherein said, establish U phase, the V phase of current sensor, the construction part module feature of W phase output terminals is: current sensor is designed to one rectangular block shape with U phase, V phase, W phase output terminals, by the mounting screw hole in module housing and radiation aluminium shell bottom plate, fixedly mounts.
3. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, in wherein said, establish U phase, the V phase of current sensor, the construction part module feature of W phase output terminals is: construction part module is at power semiconductor and drive control board unit one side to have terminal hole, make the measuring-signal line terminals of current sensor can be by with power semiconductor modular and drive the control ECU plate of control board unit to be connected.
4. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, the feature of the assembly unit that wherein said contactor, power fuse and shunt constant power measuring and protecting device form is: can, by contactor, fuse and shunt vertical being installed on a base plate arranged side by side, be designed with fuse, shunt support on base plate; Also the larger D.C. contactor of body in assembly directly can be fixedly installed to position corresponding in radiation aluminium shell gets on; the power measurement protection device combination that power fuse, shunt body is less is assembled on fixed support and base plate, then is installed on position corresponding in radiation aluminium shell and forms complete assemblies unit.
5. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, wherein said contactor, the feature of the assembly unit that power fuse and shunt constant power measuring and protecting device form is: contactor, the assembly unit of power fuse and shunt belongs to the combination of power measurement protection device, group is controlled protection fuse with comprising, also can remove shunt etc. combining form, all belong to electric machine controller and form in addition the category of the power measurement protection device unit of electric machine controller assembly.
6. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, wherein said contactor, power fuse with the feature of the assembly unit that shunt constant power measuring and protecting device forms is: if motor vehicle manufacturer protects assembly unit separately to become one group power measurement, be divided into two different housings with electric machine controller, now enclosing cover seals the cavity of electric machine controller top lead-out terminal and the cavity of input terminal again, form a surface of shell and have control signal wire connector port, the U phase being connected with motor, V phase, W phase outlet cable aperture, the B+ utmost point being connected with battery, the electric machine controller of B-utmost point lambda line cable aperture, now motor controller structure still belongs to the invention category of " motor vehicle electric machine controller and control assembly modular unit frame mode ".
7. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1; the feature of the assembly unit that wherein said contactor, power fuse and shunt constant power measuring and protecting device form is: the vertical installation arranged side by side of contactor, power fuse and shunt; wherein power fuse and shunt are fixed on mounting bracket, and fixed support dividing plate is done electrical isolation to power fuse, shunt and battery B+ utmost point splicing ear, B-utmost point splicing ear respectively.
8. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, wherein said " for making power semiconductor modular and driving the assembly of control board unit convenient, left a blank in its corresponding radiation aluminium side wall of outer shell position, by plastic cement inner cover side alar part position, the position of leaving a blank is sealed " feature be: the corresponding power semiconductor modular of radiation aluminium shell and to drive the sidewall of control board cell mesh can be to leave a blank in both sides, also can be monolateral leaving a blank, the plastic cement inner cap that seals its position of leaving a blank can be that bilateral flank or monolateral flank are corresponding.
9. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, wherein said " is contactor, the assembly unit assembly working that power fuse and shunt constant power measuring and protecting device form is convenient, left a blank in its corresponding radiation aluminium side wall of outer shell position, by enclosing cover design flank, the position of leaving a blank is sealed " feature be: contactor, power fuse, the assembly unit that shunt forms, its three corresponding radiation aluminium side wall of outer shell, can at radiation aluminium side wall of outer shell, be applicable to position leave a blank rule or the irregular shape of leaving a blank according to concrete assembly working, also can be according to contactor, power fuse, the concrete size cases of the assembly unit that shunt forms, the design of not leaving a blank in radiation aluminium side wall of outer shell position.
10. the modular unit structure and layout mode of a kind of motor vehicle AC motor control and control assembly according to claim 1, the feature of wherein said " radiation aluminium shell " is: in radiation aluminium shell, have insulating course radiation aluminium enclosure to be divided into the power measurement protection assembly cell position space of electric machine controller locational space and contactor, power fuse, shunt.
The 11. modular unit structure and layout modes of a kind of motor vehicle AC motor control and control assembly according to claim 1, the feature of wherein said " plastic cement inner cap " is: in plastic cement, cover the lead-out terminal hole of corresponding lead-out terminal module and the terminal hole of corresponding capacitor module input terminal respectively, have projection to cut off and prevent creepage between electrode terminal, short circuit between each terminal hole.
The 12. modular unit structure and layout modes of a kind of motor vehicle AC motor control and control assembly according to claim 1, the feature of wherein said " plastic cement inner cap " is: radiation aluminium shell and the airtight formation electric machine controller of plastic cement inner cap enclosure space, enclosing cover has plastic cement inner cap top again the part of lead-out terminal and input terminal to cover sealing, forms electric machine controller assembly enclosure space with radiation aluminium shell.
The 13. modular unit structure and layout modes of a kind of motor vehicle AC motor control and control assembly according to claim 1, the feature of wherein said " AC motor control and control assembly surface of shell " is: housing is by radiation aluminium shell, plastic cement inner cap flank and enclosing cover three is partially enclosed forms, there is control signal wire connector port, the U phase being connected with motor, V phase, W phase outlet cable aperture, the B+ utmost point, B-utmost point lambda line cable aperture that battery connects.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201310631406.5A CN103607159A (en) | 2013-12-02 | 2013-12-02 | Electric vehicle motor controller and controller assembly modularization unit structure mode |
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| CN201310631406.5A CN103607159A (en) | 2013-12-02 | 2013-12-02 | Electric vehicle motor controller and controller assembly modularization unit structure mode |
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| CN103825528A (en) * | 2014-03-13 | 2014-05-28 | 杭州明果教育咨询有限公司 | Integrally-packaged motor controller for low-speed electric cars |
| CN103986309A (en) * | 2014-05-23 | 2014-08-13 | 台达电子企业管理（上海）有限公司 | DC capacitor module and its laminated busbar structure |
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| CN105207540A (en) * | 2015-09-29 | 2015-12-30 | 东风商用车有限公司 | Internal arrangement structure of electric vehicle switched reluctance motor controller |
| CN105406791A (en) * | 2014-09-10 | 2016-03-16 | 周旺龙 | Electric vehicle motor controller and structure mode of controller assembly |
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| CN107508504A (en) * | 2016-09-30 | 2017-12-22 | 宁波精控电子科技有限公司 | Control circuit and signal transfer control method and the motor with control circuit |
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| CN105406791A (en) * | 2014-09-10 | 2016-03-16 | 周旺龙 | Electric vehicle motor controller and structure mode of controller assembly |
| CN105048911A (en) * | 2015-07-10 | 2015-11-11 | 沈阳航空航天大学 | Large power high efficiency PMSM (Permanent Magnet Synchronous Motor) servo controller for manned electric airplane |
| CN105207540A (en) * | 2015-09-29 | 2015-12-30 | 东风商用车有限公司 | Internal arrangement structure of electric vehicle switched reluctance motor controller |
| TWI701990B (en) * | 2016-02-29 | 2020-08-11 | 日商Ｓｍｃ股份有限公司 | Controller assembly |
| CN106061145A (en) * | 2016-06-14 | 2016-10-26 | 珠海英搏尔电气股份有限公司 | Electrical component assembly for electric vehicle |
| CN106061145B (en) * | 2016-06-14 | 2017-11-10 | 珠海英搏尔电气股份有限公司 | Electric car electric component assembly |
| CN107508504A (en) * | 2016-09-30 | 2017-12-22 | 宁波精控电子科技有限公司 | Control circuit and signal transfer control method and the motor with control circuit |
| CN107508504B (en) * | 2016-09-30 | 2024-04-16 | 宁波精控电子科技有限公司 | Control circuit, signal transmission control method and motor with control circuit |
| CN110247520A (en) * | 2018-03-09 | 2019-09-17 | 上海电驱动股份有限公司 | A kind of integrated electric machine control system |
| CN110247520B (en) * | 2018-03-09 | 2024-05-10 | 上海电驱动股份有限公司 | Integrated motor control system |
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Application publication date: 20140226 |