CN106655647A - Inverter integrated into motor - Google Patents
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- CN106655647A CN106655647A CN201611063645.5A CN201611063645A CN106655647A CN 106655647 A CN106655647 A CN 106655647A CN 201611063645 A CN201611063645 A CN 201611063645A CN 106655647 A CN106655647 A CN 106655647A
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- 239000003990 capacitor Substances 0.000 claims abstract description 52
- 238000001816 cooling Methods 0.000 claims abstract description 15
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 22
- 238000004378 air conditioning Methods 0.000 claims description 6
- 229910000831 Steel Inorganic materials 0.000 claims description 4
- 239000010959 steel Substances 0.000 claims description 4
- 238000001746 injection moulding Methods 0.000 claims description 3
- 230000008054 signal transmission Effects 0.000 claims description 3
- 238000013022 venting Methods 0.000 claims 2
- 239000000498 cooling water Substances 0.000 claims 1
- 238000013461 design Methods 0.000 abstract description 8
- 230000010354 integration Effects 0.000 description 11
- 230000005540 biological transmission Effects 0.000 description 6
- 238000000034 method Methods 0.000 description 5
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- 239000007924 injection Substances 0.000 description 3
- 239000002826 coolant Substances 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000009423 ventilation Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
- H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K5/00—Casings; Enclosures; Supports
- H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
- H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
- H02K5/225—Terminal boxes or connection arrangements
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K9/00—Arrangements for cooling or ventilating
- H02K9/19—Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Inverter Devices (AREA)
Abstract
本发明涉及一种集成于电机的逆变器，其特征在于：逆变器集成于电机后侧，同时在逆变器上布置减速器输出轴的轴承，以及布置于直流母线电容下方的接线座、直流母排、Y电容，接线座安装于主箱体上，空调保险固定于接线座的嵌装螺母上，空调保险一端与直流母排的负极伸出端相连，一端与空调接插件的负极线束相连；所述直流母排与直流接插件的端子电连接，同时在接线座上分别与空调保险的一端、以及空调接插件的正极线束相连；其可以很好地实现与电机、减速器进行集成，并使得整个集成装置尽可能小地占用整车空间，同时该逆变器具有结构紧凑、成本低、功率密度高、冷却设计简单可靠等特点。
The invention relates to an inverter integrated in a motor, which is characterized in that: the inverter is integrated on the rear side of the motor, and at the same time, the bearing of the output shaft of the reducer is arranged on the inverter, and the terminal block is arranged under the DC bus capacitor , DC busbar, Y capacitor, the terminal block is installed on the main box, the air conditioner insurance is fixed on the embedded nut of the terminal block, one end of the air conditioner insurance is connected to the negative pole extension end of the DC busbar, and the other end is connected to the negative pole of the air conditioner connector connected to the wiring harness; the DC busbar is electrically connected to the terminal of the DC connector, and at the same time connected to one end of the air conditioner insurance and the positive wire harness of the air conditioner connector on the terminal block; it can be well connected with the motor and the reducer. Integrate, and make the entire integrated device occupy as little space as possible in the vehicle. At the same time, the inverter has the characteristics of compact structure, low cost, high power density, and simple and reliable cooling design.
Description
技术领域technical field
本发明涉及一种集成于电机的逆变器，是一种电动汽车内与电机高度集成的逆变器结构。The invention relates to an inverter integrated in a motor, which is an inverter structure highly integrated with a motor in an electric vehicle.
背景技术Background technique
在电动汽车中，逆变器是实现电池的直流电供电与电机的交流电用电变换、实现电机的驱动运行的关键部件，属于电动汽车的核心功率部件，它必须能够持续可靠的运行。In an electric vehicle, the inverter is a key component to realize the DC power supply of the battery, the AC power conversion of the motor, and the driving operation of the motor. It belongs to the core power component of the electric vehicle, and it must be able to operate continuously and reliably.
目前，电动汽车上匹配的逆变器一般是独立安装于车架上，电机和逆变器一般通过高压线束、低压线束、水管进行交流电、控制信号、冷却液的传递，造成了成本过高、能量损耗以及空间浪费等，因而电机、逆变器以及减速器的集成化设计成为电动汽车发展的方向。专利CN102267362A描述了一种电动车驱动集成化一体结构，其中逆变器径向集成于电机的正上方，变速器通过联轴器与电机连接，可以实现结构紧凑、体积小、重量轻和效率高的要求。但由于电机和逆变器仍然采用电缆连接，因而没有实现最优的集成化设计，另外逆变器布置于电机的正上方，可能不便于进一步在上部布置DC/DC和充电机等。专利CN1819418A中描述了一种电机和逆变器轴向布置的结构，逆变器和电机共用壳体，实现了较高程度的集成；该逆变器通过电介质的冷却流体对逆变器的功率模块进行喷射冷却，可以实现良好的热交换。但这种设计需要复杂的外部冷却泵和散热器的支撑，造成动力系统结构复杂、成本升高、可靠性下降。专利CN205417150U描述了一种带冷却机构的电机、逆变器和变速器集成装置，包括电机、逆变器、变速器和下部冷却腔、上部冷却腔和中部导流通道，可以对电机、逆变器、变速器进行很好的冷却，也实现了较高程度的集成。但该集成装置的水道设计过于复杂、造成密封困难、可靠性下降；该集成装置并没有进一步解决或阐述逆变器和变速器的集成方式；该集成装置的逆变器的高、低压线束的出线方向为电机的径向方向，并没有最优地利用电机的轴向空间，造成该集成装置所需整车空间较大。At present, the matching inverters on electric vehicles are generally installed independently on the frame, and the motor and inverter generally transmit AC power, control signals, and coolant through high-voltage wire harnesses, low-voltage wire harnesses, and water pipes, resulting in high costs, Energy loss and space waste, etc., so the integrated design of motors, inverters and reducers has become the development direction of electric vehicles. Patent CN102267362A describes an electric vehicle drive integrated structure, in which the inverter is radially integrated directly above the motor, and the transmission is connected to the motor through a coupling, which can achieve compact structure, small size, light weight and high efficiency. Require. However, because the motor and inverter are still connected by cables, the optimal integrated design has not been realized. In addition, the inverter is arranged directly above the motor, which may not be convenient for further arranging DC/DC and chargers on the upper part. Patent CN1819418A describes a structure in which the motor and the inverter are axially arranged, and the inverter and the motor share a housing to achieve a high degree of integration; the inverter uses the dielectric cooling fluid to control the power of the inverter The modules are spray-cooled, allowing good heat exchange. However, this design requires the support of complex external cooling pumps and radiators, resulting in complex power system structures, increased costs, and reduced reliability. Patent CN205417150U describes a motor, inverter and transmission integrated device with cooling mechanism, including motor, inverter, transmission and lower cooling cavity, upper cooling cavity and middle guide channel, which can be used for motor, inverter, The transmission is well cooled and also achieves a high level of integration. However, the water channel design of the integrated device is too complicated, resulting in difficult sealing and reduced reliability; the integrated device does not further solve or explain the integration method of the inverter and transmission; the outgoing line of the high and low voltage wiring harness of the inverter of the integrated device The direction is the radial direction of the motor, and the axial space of the motor is not optimally utilized, resulting in a larger vehicle space required by the integrated device.
针对上述问题，需要设计一种适合电动汽车特别是纯电动轿车，同时解决逆变器和电机甚至减速器集成度不高、空间浪费严重、成本较高、结构复杂、可靠性低的紧凑化逆变器。In view of the above problems, it is necessary to design a compact inverter that is suitable for electric vehicles, especially pure electric cars, and solves the problems of low integration of inverters, motors and even reducers, serious waste of space, high cost, complex structure, and low reliability. Transformer.
发明内容Contents of the invention
本发明的目的在于提供一种集成于电机的逆变器，是一种新能源车用逆变器，其可以很好地实现与电机、减速器进行集成，并使得整个集成装置尽可能小地占用整车空间，同时该逆变器具有结构紧凑、成本低、功率密度高、冷却设计简单可靠等特点。The purpose of the present invention is to provide an inverter integrated in the motor, which is a new energy vehicle inverter, which can be well integrated with the motor and reducer, and makes the whole integrated device as small as possible Occupies the space of the whole vehicle, and at the same time, the inverter has the characteristics of compact structure, low cost, high power density, simple and reliable cooling design, etc.
基于上述目的，本发明的技术方案是这样实现的：一种集成于电机的逆变器，包括主箱体和顶盖及固定在主箱体内部的电机轴承、电机旋转变压器、IGBT模块、驱动板、电流传感器、电流传感器支架、一体化注塑交流母排、放电电阻、直流母线电容、屏蔽板、控制板，其特征在于：逆变器集成于电机后侧，同时在逆变器上布置减速器输出轴的轴承，以及布置于直流母线电容下方的接线座、直流母排、Y电容，接线座安装于主箱体上，空调保险固定于接线座的嵌装螺母上，空调保险一端与直流母排的负极伸出端相连，一端与空调接插件的负极线束相连；所述直流母排与直流接插件的端子电连接，同时在接线座上分别与空调保险的一端、以及空调接插件的正极线束相连；所述Y电容安装于接线座的矩形卡槽内，每个Y电容的一条线束的线鼻子分别与其中一个直流母排相连，每个Y电容的另外一条线束的线鼻子通过螺栓与主箱体相连，固定在主箱体外部的直流接插件、空调接插件、低压接插件和透气塞；其中直流接插件、空调接插件、低压接插件并排布置于电机的轴向，透气塞布置于逆变器主箱体的侧面，电机的径向；电机轴承通过轴承钢套固定在主箱体上；电机旋转变压器通过螺栓安装于主箱体；IGBT模块通过螺栓安装于主箱体，并布置于电机旋转变压器上方；驱动板布置于IGBT模块上方，并焊接于IGBT模块上；Based on the above purpose, the technical solution of the present invention is achieved as follows: an inverter integrated in the motor, including the main box and the top cover and the motor bearing fixed inside the main box, the motor resolver, the IGBT module, the drive Board, current sensor, current sensor bracket, integrated injection molding AC busbar, discharge resistor, DC bus capacitor, shielding plate, control board, characterized in that: the inverter is integrated on the rear side of the motor, and the deceleration device is arranged on the inverter The bearing of the output shaft of the inverter, and the terminal block, DC bus bar, and Y capacitor arranged under the DC bus capacitor. The terminal block is installed on the main box, and the air conditioner safety is fixed on the embedded nut of the terminal block. The negative extension end of the busbar is connected, and one end is connected with the negative wire harness of the air conditioner connector; The positive wire harness is connected; the Y capacitor is installed in the rectangular slot of the terminal block, and the wire lug of one wire harness of each Y capacitor is respectively connected with one of the DC busbars, and the wire lug of the other wire harness of each Y capacitor is passed through the bolt Connected with the main box, the DC connectors, air-conditioning connectors, low-voltage connectors and ventilation plugs fixed outside the main box; the DC connectors, air-conditioning connectors, and low-voltage connectors are arranged side by side in the axial direction of the motor, and the ventilation plugs Arranged on the side of the inverter main box, in the radial direction of the motor; the motor bearing is fixed on the main box through bearing steel sleeves; the motor resolver is installed on the main box through bolts; the IGBT module is installed on the main box through bolts, And arranged above the motor resolver; the drive board is arranged above the IGBT module and welded on the IGBT module;
在IGBT模块相对的两侧分别布置有直流母线电容和电流传感器，一体化注塑交流母排布置于电流传感器和IGBT模块之间，直流母线电容上方依次布置屏蔽板和控制板；接线座布置于直流母线电容下方，并安装于主箱体的局部凹槽内，Y电容卡接于接线座；直流接插件、空调接插件和低压接插件出线方向均为电机轴向。On the opposite sides of the IGBT module, there are DC bus capacitors and current sensors. The integrated injection-molded AC busbar is arranged between the current sensor and the IGBT module. A shielding plate and a control board are arranged above the DC bus capacitor in sequence; the terminal block is arranged on the DC Below the busbar capacitor, it is installed in the local groove of the main box, and the Y capacitor is clamped to the terminal block; the outlet direction of the DC connector, the air conditioner connector and the low-voltage connector are all in the axial direction of the motor.
所述的主箱体内部布置有IGBT模块的冷却水道，冷却水道的进水管安装于主箱体的侧面，冷却水道的出水孔位于主箱体端面，与电机水道直接相连；IGBT模块内部集成水道，主箱体内侧有两个水孔与IGBT模块的水口相连。The cooling channel of the IGBT module is arranged inside the main box. The water inlet pipe of the cooling channel is installed on the side of the main box. , There are two water holes inside the main box connected to the water port of the IGBT module.
所述电流传感器采用三联电流传感器，通过电流传感器支架安装于主箱体的内部、IGBT模块的三相交流端子侧；电机交流端子通过定制的线鼻子穿过电流传感器的开口与一体化注塑交流母排相连。The current sensor adopts a triple current sensor, which is installed inside the main box and on the three-phase AC terminal side of the IGBT module through the current sensor bracket; the AC terminal of the motor passes through the opening of the current sensor through a customized wire lug and is connected to the integrated injection-molded AC bus. Connected in rows.
所述的一体化注塑交流母排另一侧与IGBT模块相连；一体化注塑母排的绝缘骨架还设有固定线束的卡槽结构。The other side of the integrated injection-molded AC busbar is connected to the IGBT module; the insulating frame of the integrated injection-molded busbar is also provided with a slot structure for fixing the wiring harness.
所述放电电阻通过支架固定于主箱体，支架还设计有固定电机温度传感器线束、放电电阻线束和电流传感器线束的绑扎带开孔；电流传感器线束和电机温度传感器线束通过8针接插件与控制板相连，放电电阻线束通过线鼻子与直流母线电容直流端子相连。The discharge resistor is fixed to the main box through a bracket, and the bracket is also designed with a binding hole for fixing the motor temperature sensor harness, the discharge resistor harness and the current sensor harness; The board is connected, and the discharge resistor harness is connected to the DC terminal of the DC bus capacitor through the lug.
所述控制板固定于屏蔽板上，屏蔽板与直流母线电容通过螺栓固定于主箱体；控制板与驱动板通过排线进行信号传递。The control board is fixed on the shielding board, and the shielding board and the DC bus capacitor are fixed to the main box by bolts; the control board and the driving board are transmitted through cables.
所述Y电容卡接于接线座内部或采用电容单体灌装于接线座内部。The Y capacitor is clamped inside the terminal block or filled inside the terminal block with a single capacitor.
所述直流接插件和空调接插件带有高压互锁线束，高压互锁线束串联后与控制板上的2针接插件相连。The DC connector and the air conditioner connector are equipped with a high-voltage interlock harness, which is connected in series with the 2-pin connector on the control board.
所述的空调保险安装于接线座上，其一端与负极直流母排相连，另一端与空调接插件的负极线束相连；空调接插件的正极线束与正极直流母排相连。The air conditioner fuse is installed on the terminal block, one end of which is connected to the negative DC bus bar, and the other end is connected to the negative wire harness of the air conditioner connector; the positive wire harness of the air conditioner connector is connected to the positive DC bus bar.
所述低压接插件通过线束分别与控制板上的12针和16针接插件相连；所述电机旋变线束通过8针接插件与控制板相连；所述主箱体外侧安装两个透气塞，用于保证逆变器和电机内外气压平衡。The low-voltage connectors are respectively connected to the 12-pin and 16-pin connectors on the control board through the wire harness; the motor resolver wire harness is connected to the control board through the 8-pin connector; two vent plugs are installed outside the main box, It is used to ensure the air pressure balance inside and outside the inverter and motor.
本发明的积极效果是通过主箱体集成电机轴承、电机旋转变压器、以及集成减速器输出轴轴承等部件，实现与电机、减速器的高度集成；同时为了最大限度地实现集成装置紧凑化，逆变器的直流接插件、空调接插件以及低压接插件均采用电机轴向出线、逆变器水管采用轴向进水；另外逆变器的IGBT模块及驱动板、电流传感器、直流母线电容及控制板采用并排布置方式，接线座、直流母排和Y电容等布置于直流母线电容下方，不占用集成装置的径向空间；逆变器内部集成直通水道，仅通过一个出水口与电机进水口相连，降低系统水阻，提高了IGBT模块冷却效果以及水道密封可靠性。据此实现了逆变器与电机、减速器的高度集成，同时使得逆变器具有结构紧凑、成本低、功率密度高、冷却设计简单可靠等特点。The positive effect of the present invention is to achieve high integration with the motor and the reducer through the main box integrating the motor bearing, the motor resolver, and the output shaft bearing of the reducer; DC connectors, air conditioner connectors, and low-voltage connectors of the inverter all adopt the axial outlet of the motor, and the water pipe of the inverter adopts axial water inlet; in addition, the IGBT module and drive board, current sensor, DC bus capacitor and control of the inverter The boards are arranged side by side, and the terminal blocks, DC busbars and Y capacitors are arranged under the DC bus capacitors, which do not occupy the radial space of the integrated device; the inverter integrates a straight-through water channel, which is only connected to the motor water inlet through a water outlet , reduce the water resistance of the system, improve the cooling effect of the IGBT module and the reliability of the water channel seal. According to this, the high integration of the inverter, the motor and the reducer is realized, and the inverter has the characteristics of compact structure, low cost, high power density, simple and reliable cooling design, etc.
附图说明Description of drawings
图1是本发明实施例的逆变器与电机、减速器集成示意图。Fig. 1 is a schematic diagram of the integration of an inverter, a motor, and a reducer according to an embodiment of the present invention.
图2是本发明实施例的剖视示意图。Fig. 2 is a schematic cross-sectional view of an embodiment of the present invention.
图3是本发明实施例的背面示意图。Fig. 3 is a schematic view of the back of the embodiment of the present invention.
图4是本发明实施例的取下顶盖的正面示意图。Fig. 4 is a schematic front view of the embodiment of the present invention with the top cover removed.
图5是本发明实施例的取下直流母线电容的接线座布置示意图。Fig. 5 is a schematic diagram of the layout of the terminal block for removing the DC bus capacitor according to the embodiment of the present invention.
具体实施方式detailed description
为了使本发明所要解决的技术问题、技术方案及有益效果更加清楚明白，以下结合附图及实施例，对本发明做进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention.
如图1-图5所示，该实施例公开了一种与电机集成的逆变器100，该逆变器100集成于电机200的后侧，同时该逆变器100还布置了减速器300输出轴的轴承孔26，实现了逆变器100、电机200和减速器300形成一个紧凑的集成装置，以便作为一个动力总成模块在整车上灵活布置。同时，为了最大限度地实现集成装置的紧凑度，该逆变器100的直流接插件16、空调接插件22、低压接插件23以及逆变器进水管24的朝向均为电机200的轴向方向，进一步节省了整车空间，该空间可以方便DC/DC、充电机等总成的布置，也可以作为行李舱给用户提供更佳的舒适性体验。As shown in Figures 1-5, this embodiment discloses an inverter 100 integrated with the motor, the inverter 100 is integrated on the rear side of the motor 200, and the inverter 100 is also equipped with a speed reducer 300 The bearing hole 26 of the output shaft realizes that the inverter 100, the motor 200 and the reducer 300 form a compact integrated device, so as to be flexibly arranged on the whole vehicle as a powertrain module. At the same time, in order to maximize the compactness of the integrated device, the DC connector 16 of the inverter 100, the air conditioner connector 22, the low-voltage connector 23 and the inverter water inlet pipe 24 are all oriented in the axial direction of the motor 200 , which further saves the space of the vehicle, which can facilitate the arrangement of DC/DC, charger and other assemblies, and can also be used as a luggage compartment to provide users with a better comfort experience.
该实施例所述逆变器100主要包括主箱体1和顶盖2，所述逆变器的各功能型构件分别以特定的位置关系安装在所述主箱体1和顶盖2的内部或者外部。同时所述主箱体1还集成了用于安装电机轴承3的轴承钢套17，该轴承钢套17与铝合金压铸的主箱体1采用一体化铸造的方式，用以提高轴承连接处壳体的强度；同时主箱体上还安装了用于检测电机200转子位置的旋转变压器4，这种集成方式实现了所述逆变器100和电机200的高度耦合，极大地减小了集成装置的轴向尺寸。The inverter 100 in this embodiment mainly includes a main box body 1 and a top cover 2, and each functional component of the inverter is installed inside the main box body 1 and the top cover 2 in a specific positional relationship. or external. At the same time, the main box 1 is also integrated with a bearing steel sleeve 17 for installing the motor bearing 3. The bearing steel sleeve 17 and the main box 1 of aluminum alloy die-casting adopt an integrated casting method to improve the bearing connection. The strength of the body; at the same time, the resolver 4 for detecting the rotor position of the motor 200 is also installed on the main box. This integration method realizes the high coupling between the inverter 100 and the motor 200, greatly reducing the integrated device. axial dimension.
同时，一种集成于电机的逆变器100和电机200的集成还体现在冷却回路一体化和直接的电连接。冷却液在通过所述逆变器100主箱体1的进水口24在对所述逆变器的IGBT模块5冷却后，通过所述主箱体1上的出水口25直接对电机200进行冷却，从而降低了集成装置系统水阻，提高了冷却效果和水道密封的可靠性；另外，电机200的交流端子通过定制的线鼻子10直接与所述逆变器100的一体化注塑交流母排9相连，降低了电连接回路由于电阻过大产生的热损耗，提升了系统性能。At the same time, the integration of the inverter 100 integrated into the motor and the motor 200 is also reflected in the integration of the cooling circuit and direct electrical connection. After cooling the IGBT module 5 of the inverter through the water inlet 24 of the main box 1 of the inverter 100, the coolant directly cools the motor 200 through the water outlet 25 on the main box 1 , thereby reducing the water resistance of the integrated device system, improving the cooling effect and the reliability of the waterway seal; in addition, the AC terminal of the motor 200 is directly connected to the integrated injection-molded AC busbar 9 of the inverter 100 through the customized wire lug 10 The connection reduces the heat loss caused by the excessive resistance of the electrical connection circuit and improves the system performance.
具体而言，在所述主箱体1内部固定有IGBT模块5、驱动板6、电流传感器7、电流传感器支架8、一体化注塑交流母排9、放电电阻30、放电电阻支架31、直流母线电容11、屏蔽板12、控制板13。Specifically, an IGBT module 5, a drive board 6, a current sensor 7, a current sensor bracket 8, an integrated injection molded AC busbar 9, a discharge resistor 30, a discharge resistor bracket 31, and a DC bus are fixed inside the main box 1. Capacitor 11, shielding plate 12, control board 13.
在主箱体1内部，直流母线电容11下方还布置了接线座14、直流母排15、Y电容21；所述主箱体1的外侧安装有直流接插件16、空调接插件22、低压接插件23和透气塞28。Inside the main box 1, a terminal block 14, a DC bus bar 15, and a Y capacitor 21 are arranged below the DC bus capacitor 11; a DC connector 16, an air conditioner connector 22, and a low-voltage connector are installed on the outside of the main box 1. Insert 23 and breathable plug 28.
在主箱体1内部：IGBT模块5通过螺栓安装于的主箱体1上，并布置于旋转变压器4的上方。IGBT模块5内部集成水道，仅留出两个圆形水孔19与主箱体1的水道相连。相应地，所述主箱体1内部设计与水孔19同轴的水道18和水道垂直的水道41，所述同轴的水道18和垂直的水道41封闭于主箱体1内，可通过钻孔成型，降低了加工成本；钻孔的道具入口通过碗形塞27密封，与同轴的水道18垂直的电机200的轴向分别为逆变器100的进水管24和出水口25，该设计降低了水道水阻、提高了所述IGBT模块5的散热效果，同时提高了密封可靠性。Inside the main box 1 : the IGBT module 5 is installed on the main box 1 by bolts, and is arranged above the resolver 4 . The IGBT module 5 integrates water channels inside, and only two circular water holes 19 are left to connect with the water channels of the main box 1 . Correspondingly, the inside of the main box body 1 is designed with the water channel 18 coaxial with the water hole 19 and the water channel 41 perpendicular to the water channel. The coaxial water channel 18 and the vertical water channel 41 are enclosed in the main box body 1 and can be drilled The holes are formed to reduce the processing cost; the drilled tool entrance is sealed by a bowl-shaped plug 27, and the axial direction of the motor 200 perpendicular to the coaxial water channel 18 is the water inlet pipe 24 and the water outlet 25 of the inverter 100 respectively. The water resistance of the water channel is reduced, the heat dissipation effect of the IGBT module 5 is improved, and the sealing reliability is improved at the same time.
所述IGBT模块5的上方布置有驱动板6，所述驱动板6通过螺栓和焊接针脚固定于IGBT模块5上。A driving board 6 is arranged above the IGBT module 5 , and the driving board 6 is fixed on the IGBT module 5 by bolts and welding pins.
所述IGBT模块5相对的两侧分别布置有直流母线电容11和电流传感器7。所述直流母线电容11为薄膜电容。为了实现所述逆变器100和减速器300的集成，所述直流母线电容11在IGBT模块5和轴承孔26中间处局部变窄，所述直流母线电容11的顶部分别伸出三对直流端子与IGBT模块5电连接、伸出一对直流端子与直流母排15电连接。The two opposite sides of the IGBT module 5 are respectively arranged with a DC bus capacitor 11 and a current sensor 7 . The DC bus capacitor 11 is a film capacitor. In order to realize the integration of the inverter 100 and the speed reducer 300, the DC bus capacitor 11 is partially narrowed in the middle of the IGBT module 5 and the bearing hole 26, and the top of the DC bus capacitor 11 protrudes three pairs of DC terminals respectively. It is electrically connected with the IGBT module 5 , and a pair of DC terminals are extended to be electrically connected with the DC busbar 15 .
所述电流传感器7为一个三联的电流传感器，该结构形式可以更好地满足逆变器内部紧凑化布置。为了满足交流母排连接的要求，所述电流传感器7的安装面垂直于主箱体1的底面，该结构形式通过固定电流传感器7的电流传感器支架8实现。The current sensor 7 is a triple current sensor, and this structural form can better meet the compact arrangement inside the inverter. In order to meet the requirements of the AC busbar connection, the installation surface of the current sensor 7 is perpendicular to the bottom surface of the main box 1 , and this structure is realized by the current sensor bracket 8 that fixes the current sensor 7 .
为了保证所述逆变器100装配方便，该逆变器使用了一体化注塑交流母排9。把U、V、W母排和绝缘支架一体化注塑，主要可以实现交流母排作为单件直接安装于所述主箱体1，提高连接可靠性，同时所述一体化注塑交流母排9内部设计了一体化注塑的嵌装螺母，便于所述电机交流端子10直接与一体化注塑交流母排9进行螺栓固定。所述一体化注塑交流母排9的另一侧母排底面与IGBT模块5通过螺栓连接，实现IGBT模块5与电机交流端子10间的交流电传输。另外，所述一体化注塑交流母排9设计卡槽结构29，用以固定电流传感器线束34。In order to ensure that the inverter 100 is easy to assemble, the inverter uses an integrated injection-molded AC busbar 9 . The integrated injection molding of U, V, W busbars and insulating brackets can mainly realize that the AC busbars are directly installed in the main box 1 as a single piece, which improves the connection reliability. At the same time, the integrated injection molded AC busbars 9 An integrated injection-molded embedded nut is designed to facilitate bolt fixing of the AC terminal 10 of the motor directly to the integrated injection-molded AC busbar 9 . The bottom surface of the integrated injection molded AC busbar 9 on the other side is connected to the IGBT module 5 by bolts to realize the AC power transmission between the IGBT module 5 and the AC terminal 10 of the motor. In addition, the integrated injection-molded AC busbar 9 is designed with a slot structure 29 for fixing the current sensor wire harness 34 .
为了实现所述逆变器100停机时直流母线电容11的电荷释放，所述逆变器100采用独立的放电电阻30，可以保证停机时直流母线电容11的电压在规定时间内降到规定数值，该功能是通过放电电阻30的线束33与直流母线电容11上的直流端子进行电连接实现。所述放电电阻30通过支架31安装于主箱体1，该支架还设计了使用绑扎带固定电流传感器线束34、电机温度传感器线束32以及放电电阻线束33的卡槽。In order to release the charge of the DC bus capacitor 11 when the inverter 100 is shut down, the inverter 100 uses an independent discharge resistor 30, which can ensure that the voltage of the DC bus capacitor 11 drops to a prescribed value within a prescribed time when the inverter 100 is shut down. This function is realized by electrically connecting the wire harness 33 of the discharge resistor 30 to the DC terminal on the DC bus capacitor 11 . The discharge resistor 30 is installed on the main box body 1 through a bracket 31 , and the bracket is also designed with binding slots for fixing the current sensor harness 34 , the motor temperature sensor harness 32 and the discharge resistor harness 33 .
所述控制板13通过螺栓固定于屏蔽板12的压铆螺柱上，所述屏蔽板12与直流母线电容11通过螺栓同时固定于所述主箱体1。所述控制板13与驱动板6之间通过排线36进行信号传输，同时所述控制板13还布置了与电联传感器线束34和电机温度传感器线束32连接的8针接插件35、与旋转变压器4的信号线束连接的8针接插件40、与高压互锁线束连接的2针接插件37、与低压接插件23的信号线束连接的12针接插件38和16针接插件39。The control board 13 is fixed on the riveted studs of the shielding plate 12 by bolts, and the shielding plate 12 and the DC bus capacitor 11 are fixed on the main box 1 by bolts at the same time. Signal transmission is carried out between the control board 13 and the drive board 6 through a cable 36, and the control board 13 is also arranged with an 8-pin connector 35 connected to the electric sensor harness 34 and the motor temperature sensor harness 32, and the rotary The 8-pin connector 40 connected to the signal harness of the transformer 4, the 2-pin connector 37 connected to the high-voltage interlock harness, the 12-pin connector 38 and the 16-pin connector 39 connected to the signal harness of the low-voltage connector 23 .
为了最大限度地利用电机200的轴向空间，所述逆变器100的接线座14布置于直流母线电容11的下方。所述接线座14设计矩形卡槽结构用以安装所述Y电容21，所述的Y电容21也可以将薄膜电容的单体灌装于所述接线座14的矩形卡槽内。In order to maximize the use of the axial space of the motor 200 , the terminal block 14 of the inverter 100 is arranged below the DC bus capacitor 11 . The terminal block 14 is designed with a rectangular slot structure for installing the Y capacitor 21 , and the Y capacitor 21 can also fill a single film capacitor in the rectangular slot of the terminal block 14 .
所述逆变器100的主箱体1外侧、接线座14的接线座下方并排布置了直流接插件16、空调接插件22、低压接插件23。所述直流接插件16在逆变器100内部与直流母排15通过螺栓连接，所述直流母排15上侧与直流母线电容11的直流端子相连，实现所述逆变器100的直流输入。On the outside of the main box 1 of the inverter 100 and below the terminal block 14, a DC connector 16, an air conditioner connector 22, and a low voltage connector 23 are arranged side by side. The DC connector 16 is connected to the DC busbar 15 by bolts inside the inverter 100 , and the upper side of the DC busbar 15 is connected to the DC terminal of the DC bus capacitor 11 to realize the DC input of the inverter 100 .
所述空调接插件22可以为空调压缩机提供直流电，其供电回路上使用了空调保险20。主要电连接关系为：所述直流母排15的正极母排151与空调接插件22的正极线束221通过线鼻子相连，所述直流母排15的负极母排152与空调保险20的一端相连，所述空调保险20的另一端与空调接插件22的负极线束222通过线鼻子相连。当空调接插件22的对配接插件安装到位时，可以实现空调压缩机的直流供电。The air conditioner connector 22 can provide direct current for the air conditioner compressor, and the air conditioner fuse 20 is used on the power supply circuit. The main electrical connection relationship is: the positive busbar 151 of the DC busbar 15 is connected to the positive wiring harness 221 of the air conditioner connector 22 through a wire lug, the negative busbar 152 of the DC busbar 15 is connected to one end of the air conditioner insurance 20, The other end of the air conditioner fuse 20 is connected to the negative wire harness 222 of the air conditioner connector 22 through a wire lug. When the mating connector of the air conditioner connector 22 is installed in place, the DC power supply of the air conditioner compressor can be realized.
所述低压接插件23通过低压线束42与控制板13上的12针接插件38和16针接插件39相连，实现所述控制板13与整车控制器进行信号传输。The low-voltage connector 23 is connected to the 12-pin connector 38 and the 16-pin connector 39 on the control board 13 through the low-voltage wire harness 42 to realize signal transmission between the control board 13 and the vehicle controller.
为了满足高压安全的要求，所述直流接插件16和空调接插件22分别带有高压互锁线束，可以实现所述直流接插件16和空调接插件22的对配端子插接不良时整车控制器给逆变器下电，防止人员触电。主要实现方式为：两组高压互锁线束在接线座14内串联后形成两根信号线束41，该信号线束41通过2针接插件与控制板13相连，进而通过低压线束42和低压接插件23将高压互锁信号提供给整车控制器。In order to meet the requirements of high-voltage safety, the DC connector 16 and the air-conditioning connector 22 are equipped with high-voltage interlocking harnesses respectively, which can realize the control of the whole vehicle when the mating terminals of the DC connector 16 and the air-conditioning connector 22 are not well connected. Power off the inverter to prevent personnel from electric shock. The main implementation method is: two sets of high-voltage interlocking wire harnesses are connected in series in the terminal block 14 to form two signal wire harnesses 41, the signal wire harness 41 is connected to the control board 13 through a 2-pin connector, and then through the low-voltage wire harness 42 and the low-voltage connector 23 Provide the high voltage interlock signal to the vehicle controller.
所述逆变器100和电机200在工作时温度较高、内部气压较大，为了保证逆变器100和电机200内外气压平衡，在主箱体1的外侧安装了两个透气塞28。The temperature of the inverter 100 and the motor 200 is relatively high during operation, and the internal air pressure is high. In order to ensure the balance of the internal and external air pressure of the inverter 100 and the motor 200, two vent plugs 28 are installed on the outside of the main box 1 .
以上所述仅为本发明的较佳实施例而已，并非限定本发明的保护范围。凡在本发明的精神和原则之内所做的任何修改、等同替换、改进等，均包含在本发明的保护范围内。The above descriptions are only preferred embodiments of the present invention, and do not limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present invention are included in the protection scope of the present invention.
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