CN113612429A

CN113612429A - Motor controller

Info

Publication number: CN113612429A
Application number: CN202010878876.1A
Authority: CN
Inventors: 张骏飞; 姜佳佳; 朱佳鑫; 曹金浩; 张跃斌; 朱小强; 杨攀; 吉拉姆·卢克
Original assignee: Baoding R&D Branch of Honeycomb Transmission System Jiangsu Co Ltd; Honeycomb Drive System Jiangsu Co Ltd
Current assignee: Baoding R&D Branch of Honeycomb Transmission System Jiangsu Co Ltd; Honeycomb Drive System Jiangsu Co Ltd
Priority date: 2020-08-27
Filing date: 2020-08-27
Publication date: 2021-11-05

Abstract

The application discloses machine controller, machine controller includes: a lower cap base having an open mounting cavity; the IGBT module is detachably arranged in the mounting cavity and is in sealing fit with the inner wall of the mounting cavity, and the IGBT module is electrically connected with the AC output module; the control board is arranged in the installation cavity and is spaced from the IGBT module, and the control board is connected with a signal plug-in; the drive plate is installed in the installation cavity, and the control panel and the IGBT module are electrically connected with the drive plate. The motor controller of this application embodiment, IGBT module, control panel and drive plate are integrated in the installation cavity of lower cover base, have improved motor controller's integrated level greatly, make motor controller's overall structure less, and the simple installation is convenient for install motor controller and motor and reduction gear in the rear axle floor below of vehicle jointly, reinforcing suitability.

Description

Motor controller

Technical Field

The application relates to the technical field of control equipment manufacturing, in particular to a motor controller.

Background

In the correlation technique, the controller is mostly split type structure with motor, reduction gear, and part producer is also carrying out the development of trinity product. Compared with the three-in-one scheme, the existing split scheme has the advantages of large overall weight, low material utilization rate and low efficiency. Wherein, each part of current motor controller is the components of a whole that can function independently design, and through the three-phase line, it links to each other to change the pencil and realizes the connection of self inner structure and be connected with outer structure soon, the inconvenient while leakproofness of installation dismantlement of water pipe is relatively poor, the not hard up condition easily appears, and the overall structure of current split type controller is great, only can arrange the trunk in, occupy the trunk space, lead to the trunk unevenness, simultaneously because spatial structure's restriction, can only rationally be applicable to the less electricelectric motor car of space restriction, and need arrange the front deck and use as the front drive electric bridge, and can't satisfy rear axle direction of height's requirement, can not rationally install in rear axle floor below, there is the space of improvement.

Disclosure of Invention

The present application is directed to solving at least one of the problems in the prior art. Therefore, an object of the present application is to provide a motor controller, which reduces the overall space occupied by the structure and can be flexibly arranged under the floor of the rear axle of the vehicle by designing the controller structure design scheme of the three-in-one rear drive bridge for the hybrid electric vehicle.

According to the motor controller of the embodiment of the application, include: a lower cap base having an open mounting cavity; the IGBT module is detachably arranged in the mounting cavity and is in sealing fit with the inner wall of the mounting cavity, and the IGBT module is electrically connected with the AC output module; the control board is arranged in the installation cavity and is spaced from the IGBT module, and the control board is connected with a signal plug-in; the drive plate is installed in the installation cavity, and the control panel and the IGBT module are electrically connected with the drive plate.

According to the motor controller of this application embodiment, IGBT module, control panel and drive plate are integrated in the installation cavity of lower cover base, have improved motor controller's integrated level greatly, make motor controller's overall structure reduce, and the simple installation has bigger cost advantage and flexibility ratio, is convenient for install motor controller and motor and reduction gear in the rear axle floor below of vehicle jointly, reinforcing suitability.

According to the motor controller of some embodiments of the present application, the IGBT module is electrically connected to the driving board by wave soldering, and the control board is electrically connected to the driving board by a pulse modulation harness.

A motor controller according to some embodiments of the present application, further comprising: the direct current support capacitor and the direct current filter assembly are arranged in the installation cavity at intervals, the direct current filter assembly is connected with a power supply connector, the direct current filter assembly is electrically connected with the direct current support capacitor, and the direct current support capacitor is electrically connected with the IGBT module.

According to the motor controller of some embodiments of the present application, the dc filter assembly includes: the base is provided with an input copper bar connected with the power connector; the magnetic ring is connected with the base through heat conduction fixing glue; the safety capacitor is connected with the base through heat conduction fixing glue and electrically connected through resistance welding, and the safety capacitor is electrically connected with the direct current support capacitor; the base is provided with a following groove, and the magnetic ring and the safety capacitor are both arranged in the following groove.

According to the motor controller of some embodiments of this application, the IGBT module with the inner wall of installation cavity passes through threaded connection spare detachably and links to each other, just the IGBT module with be equipped with the IGBT sealing washer between the inner wall of installation cavity.

A motor controller according to some embodiments of the present application, further comprising: the shielding plate, the shielding plate with lower cover base detachably links to each other, just the shielding plate is located the control panel with between the IGBT module.

According to the motor controller of some embodiments of the present application, a heat conduction pad is disposed between the shielding plate and the control plate, and a heat conduction gap filler is disposed between the shielding plate and the inner wall of the lower cover base.

A motor controller according to some embodiments of the present application, further comprising: the upper cover is detachably mounted on the lower cover base and used for sealing the opening of the mounting cavity, and the upper cover and the shielding plate are spaced by the upper cover reinforcing ribs.

A motor controller according to some embodiments of the present application, further comprising: the water tap comprises a bent water tap and a quick-insertion water tap, wherein the bent water tap and the quick-insertion water tap are detachably mounted on the lower cover base, sealing parts are arranged at the matching positions of the bent water tap and the quick-insertion water tap and the lower cover base, and a water path communicated with the bent water tap and the quick-insertion water tap is arranged in the mounting cavity.

A motor controller according to some embodiments of the present application, further comprising: the direct current Hall sensor is electrically connected with the control board through a current detection wire harness; and the alternating current Hall sensor is fixedly connected with the AC output module through a bolt, and is electrically connected with the control panel through an AC Hall wire harness. Additional aspects and advantages of the present application will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the present application.

Drawings

The above and/or additional aspects and advantages of the present application will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1 is an exploded view of a motor controller according to an embodiment of the present application;

FIG. 2 is an exploded view of a motor controller (with top cover) according to an embodiment of the present application;

fig. 3 is a cross-sectional view of a motor controller according to an embodiment of the present application.

Reference numerals:

the motor controller (100) is provided with a motor,

the device comprises a lower cover base 1, a direct-current supporting capacitor 2, a cylindrical pin 3, a water bending nozzle 4, a voltage detection wiring harness 5, a driving board 6, an AC output busbar 7, an alternating-current Hall sensor 8, a vent valve 9, an AC output module 10, an AC Hall wiring harness 11, a rotary-change wiring harness 12, an IGBT module 13, a pulse modulation wiring harness 14, a quick-plugging water nozzle 15, a current detection wiring harness 16, a direct-current Hall sensor 17, a base 18, a magnetic ring 19, an ampere rule capacitor 20, an upper cover 21, a shielding plate 22, a heat conducting pad 23, a control plate 24, a DC plug connector 25, a temperature detection wiring harness 26, an IGBT sealing ring 27, a high-voltage warning label 28, a wire fixing clamp 29, a controller nameplate 30 and a signal plug 31.

Detailed Description

Reference will now be made in detail to embodiments of the present application, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are exemplary only for the purpose of explaining the present application and are not to be construed as limiting the present application.

Unless otherwise specified, the front-rear direction in the present application is the longitudinal direction of the vehicle, i.e., the X direction; the left and right directions are the transverse direction of the vehicle, namely the Y direction; the up-down direction is the vertical direction of the vehicle, i.e., the Z direction.

In the description of the present application, it is to be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," and the like are used in the orientations and positional relationships indicated in the drawings for convenience in describing the present application and for simplicity in description, and are not intended to indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and are therefore not to be considered limiting of the present application.

The motor controller 100 according to the embodiment of the present application is described below with reference to fig. 1 to 3, and the motor controller 100 has a small overall structure, occupies a small installation space, can be reasonably installed under the rear axle floor, and has a good applicability.

As shown in fig. 1, a motor controller 100 according to an embodiment of the present application includes: lower cover base 1, IGBT module 13, control panel 24 and drive plate 6.

Lower cover base 1 has open installation cavity, lower cover base 1 is as motor controller 100's envelope carrier, as shown in fig. 1, the upper end of installation cavity is opened, IGBT module 13, control panel 24 and drive plate 6 are integrated to be installed in lower cover base 1's installation cavity, motor controller 100's in this application main component all locates lower cover base 1 promptly, thus, each component need not occupy installation space alone, do benefit to and reduce motor controller 100 holistic structural dimension, and install each component in the installation cavity, can avoid the component to receive the outer interference of lower cover base 1, improve motor controller 100's job stabilization nature.

It should be noted that the lower cover base 1 is provided with the vent valve 9, the mechanical connection between the vent valve 9 and the lower cover base 1 is realized through a plastic buckle, the sealing between the vent valve 9 and the lower cover base 1 is realized through an o-shaped ring axial sealing mode, and the vent valve 9 realizes the gas exchange and the pressure difference balance inside and outside the box body through a waterproof vent film.

Meanwhile, the lower cover base 1 is provided with the cylindrical pin 3, and the cylindrical pin 3 and the lower cover base 1 are pressed on the lower cover base 1 in an interference fit manner, so that the relative position of the lower cover base 1 and other parts is fixed.

The IGBT module 13 is detachably mounted in the mounting cavity, for example, the IGBT module 13 and the lower cover base 1 may be mechanically connected by bolts, so that the IGBT module 13 can be flexibly detached from the mounting cavity. And the IGBT module 13 is in sealing fit with the inner wall of the installation cavity, it should be noted that a water channel for radiating each element is arranged in the installation cavity, meanwhile, the IGBT module 13 and the lower cover base 1 are sealed through an IGBT sealing ring 27, the installation cavity is provided with an IGBT sealing groove, the IGBT sealing ring 27 is installed in the IGBT sealing groove, and when the IGBT module 13 compresses the IGBT sealing ring 27 through the bolt pretightening force, the IGBT module 13 is fixed on the lower cover base to seal the water channel.

The IGBT module 13 is used for controlling the on-off of current, the IGBT module 13 is electrically connected with the AC output module 10, wherein, the AC output module 10 is electrically connected with the motor input copper bar of the motor, so that the IGBT module 13 can output the driving current to the motor through the AC output module 10, start to operate with the driving motor, wherein, be equipped with AC output busbar 7 between AC output module 10 and the IGBT module 13, so that AC output module 10 realizes the electricity connection with the IGBT module 13 through AC output busbar 7, realize fixedly and the heavy current switches on through the form that the bolt crimping is fixed between AC output busbar 7 and AC output module 10, and realize fixedly and the heavy current switches on through the form that the bolt crimping is fixed between AC output busbar 7 and the IGBT module 13.

Wherein, realize sealedly through the sealing washer between AC output module 10 and the lower cover base 1, and AC output module 10 realizes the fixed of motor three-phase copper terminal through the form of conductive copper post tapping, it has improved electric drive system's integrated level to have replaced motor wire holder structure, longer transmission pencil has been reduced and has been born the risk of external disturbance, original three-phase line mounting process's loaded down with trivial details nature has been simplified, electric drive system's integrated level has been improved, when making to reduce the wire holder reduce cost, the temperature rise of copper bar has been reduced, system's efficiency has been improved.

The control board 24 is installed in the installation cavity, the control board 24 is spaced apart from the IGBT module 13, and the control board 24 is connected to the signal plug-in 31, that is, the control board 24 can receive an external control signal through the signal plug-in 31. And the control panel 24 is connected with a voltage detection wire harness 5 for detecting voltage, and wire harness welding fixation and signal conduction are realized between the voltage detection wire harness 5 and the control panel 24 in a mode of selective wave soldering after a plug-in unit is passed through a hole. The control board 24 is in signal connection with the resolver harness 12 through a signal plug-in, and the resolver harness 12 is in signal connection with the motor resolver connector through the signal plug-in.

The wiring harness 12 is formed by injection molding of the wiring harness and a plastic part, and a lip-shaped sealing ring is arranged on the outer ring of the plastic part. The rotary transformer wire harness 12 and the lower cover base 1 are mechanically connected through bolts. And the rotary transformer wire harness 12 forms radial labyrinth seal with the box body when being installed, the rotary transformer wire harness 12 is sealed with the lower cover base 1 through a multi-lip radial sealing ring, sealing between the cavity of the motor controller 100 and the cavity of the motor is guaranteed, the rotary transformer wire harness 12 is designed to be shielded and grounded, and the rotary transformer wire harness is communicated with the box body through an installation point. The sealing structure of the whole rotary transformation wire harness 12 is more compact, and the space occupancy rate is small.

The control board 24 and the IGBT module 13 are both electrically connected to the drive board 6, that is, the control board 24 and the IGBT module 13 can both realize transmission of electrical signals with the drive board 6, and in specific implementation, after receiving an external control signal, the control board 24 controls the drive board 6 to drive the IGBT module 13 to turn on and off according to the control signal, and converts the input direct current into an alternating current, and then outputs the alternating current to the motor to control the motor to turn on and operate.

Be equipped with temperature detection pencil 26 on the lower cover base 1, realize temperature sensor's fixed and stable signal acquisition through the fixed form of bolt crimping between temperature detection pencil 26 and the lower cover base 1, pencil welded fastening and signal conduction are realized to drive plate 6 and temperature detection pencil 26 through the form of selective wave-soldering behind the plug-in components via hole, after temperature sensor's the detection, transmit drive plate 6 through temperature detection pencil 26 on, drive plate 6 carries out signal processing through revolving to become pencil 12 with signal transmission to control panel MCU.

Wherein, in this application, it is sealed, sealed to become pencil 12 soon through AC output module 10 for motor controller 100 monomer sealing grade reaches IP67, compares with current trinity scheme, and motor controller 100's the ability of anti environmental disturbance of this application is stronger, and foreign matter such as screw drops to inside the box when can effectively preventing to close the case, has realized the function of anti dropping, preventing the foreign matter.

The motor controller 100 of the embodiment of the application, IGBT module 13, control panel 24 and drive plate 6 are integrated in the installation cavity of lower cover base 1, have improved motor controller 100's integrated level greatly, make motor controller 100's overall structure reduce, and simple installation has bigger cost advantage and flexibility ratio, is convenient for install motor controller 100 and motor and reduction gear in the rear axle floor below of vehicle jointly, reinforcing suitability.

In some embodiments, the IGBT module 13 is electrically connected to the driver board 6 by wave soldering, specifically, signal conduction between the IGBT and the driver board 6 is realized by selecting a wave soldering form after the driver board 6 and the IGBT module 13 pass through the IGBT signal pin via hole, so that the driver board 6 drives the IGBT module 13 to perform related operations, and the driver board 6 and the IGBT module 13 are mechanically connected by a plastic self-tapping screw.

The control board 24 is electrically connected with the drive board 6 through a pulse modulation wire harness 14, namely, the drive board 6 is in signal connection with the control board 24 through the pulse modulation (PWM) wire harness 14. It should be noted that the pulse modulation harness 14 and the control board 24 are in signal connection through a signal plug, and the pulse modulation harness 14 and the drive board 6 are in signal connection through a signal plug.

Wherein, the motor controller 100 of the present application further includes: a DC support capacitor 2 and a DC filter component.

Direct current support capacitor 2 and direct current filter subassembly are spaced apart and are installed in the installation cavity, and like this, more components of motor controller 100 all integrate in the installation cavity of lower cover base 1, do benefit to the integrated level that improves motor controller 100, reduce the component and set up required installation space alone.

The direct current filter assembly is connected with a power connector, wherein the power connector is used for being connected with an external power supply, so that external direct current can be input into the direct current filter assembly through the power connector. And the direct current filter component is electrically connected with the direct current support capacitor 2, and the direct current support capacitor 2 is electrically connected with the IGBT module 13. That is, after the dc power is input through the power connector, the dc power is transmitted to the IGBT module 13 through the dc filter module and the dc support capacitor 2 in sequence.

Specifically, the direct current support capacitor 2 and the IGBT module 13 are electrically connected in a copper bar compression joint mode, the direct current support capacitor 2 and the IGBT module 13 are fixed through screws, mechanical connection between the direct current support capacitor 2 and the lower cover base 1 is achieved in a bolt fixing mode, heat transfer connection is achieved between the direct current support capacitor 2 and the lower cover base 1 through a heat conduction gap filler, and therefore fixing of the relative positions of the direct current support capacitor 2, the direct current filter assembly and the IGBT module 13 can be achieved. And the direct current supports electric capacity 2 and still is connected with voltage detection pencil 5, and realizes through the fixed form of bolt crimping that the fixed and signal of pencil switches on between voltage detection pencil 5 and the electric capacity. Wherein, the other end of the voltage detection wire harness 5 realizes wire harness welding fixation in a mode of selective wave soldering after passing through a plug-in unit via hole, and transmits a voltage signal to the control board 24 for signal processing.

The mounting binding surface of the direct current support capacitor 2 is made of aluminum materials, so that the core of the direct current support capacitor 2 is directly contacted with the aluminum materials, the heat dissipation capacity of the direct current support capacitor 2 is improved through the excellent heat conduction capacity of the aluminum materials, and the heat dissipation efficiency is improved. Meanwhile, 4Y capacitors are integrated in the plastic shell of the direct current support capacitor 2, so that the filtering capacity of the direct current support capacitor 2 is higher.

In some embodiments, the dc filtering assembly comprises: base 18, magnetic ring 19 and ann rule electric capacity 20.

Wherein, the base 18 is provided with an input copper bar connected with the power connector, and the power connector and the base 18 realize the insertion fit through the input copper bar on the base 18.

It should be noted that the base 18 integrates the male end copper bar feature of the power connector, so that the size of the motor controller 100 in the height direction is shortened to facilitate the whole vehicle carrying, and meanwhile, the male end copper bar of the direct current filter assembly integrated quick-plug connector is beneficial to the structural arrangement of the motor controller 100, so that the use number of the copper bars and bolts is reduced, and the cost for purchasing the male end of the plug-in is saved.

The magnetic ring 19 is connected with the base 18 through heat-conducting fixing glue, namely, the magnetic ring 19 is mechanically connected with the base 18 through the heat-conducting fixing glue, and the magnetic ring 19 converts noise in current into heat energy through filtering action to filter the heat energy, so that the electromagnetic compatibility of the product is improved.

The safety capacitor 20 is connected with the base 18 through heat conduction fixing glue and electrically connected through resistance welding, and the safety capacitor 20 is electrically connected with the direct current support capacitor 2. That is to say, pin fixation and signal conduction are realized between the safety capacitor 20 and the base 18 through resistance welding, and the safety capacitor 20 filters noise in current through the filter characteristic of the capacitor, so that the electromagnetic compatibility of the product is improved.

The safety capacitor 20 comprises two Y capacitors at the front end and the rear end of the magnetic ring 19 respectively, an X capacitor at the rear end of the magnetic ring 19, 4Y capacitors and 1X capacitor are directly connected with the power copper bar by using a resistance welding process and are independently grounded through the copper bar, the distance between pins of the capacitors is greatly shortened, the filtering performance is improved, and meanwhile, the stable and reliable quality of welding spots is guaranteed.

The base 18 is provided with a following groove, the base 18 fixes the magnetic ring 19 and the safety capacitor 20 in a mode of combining the injection following groove with the heat conducting fixing glue in a bonding mode, the magnetic ring 19 and the capacitor can be guaranteed to filter at the most suitable topological structure position, and meanwhile, the installation is convenient and the mechanical structure is stable and reliable.

Therefore, the direct current filter assembly is installed as a sub-assembly through key parts such as the integrated base 18, the magnetic ring 19 and the safety capacitor 20, the filter module is higher in integration level and simple and convenient to install, and the cost advantage is higher.

In some embodiments, the IGBT module 13 is detachably connected to the inner wall of the mounting cavity by a threaded connection, and an IGBT sealing ring 27 is provided between the IGBT module 13 and the inner wall of the mounting cavity.

The IGBT module 13 is mechanically connected with the lower cover base 1 through bolts, the IGBT module 13 is sealed with the lower cover base 1 through an IGBT sealing ring 27, the IGBT sealing ring 27 is installed in an IGBT sealing groove of the lower cover base 1, and the sealing of a water channel in a controller cavity is realized through the pressing force of the IGBT and the lower cover base 1 of the box body.

In some embodiments, the IGBT module 13 adopts a PIN sub-structure to increase the heat exchange area between the power device and the water flow, the IGBT module 13 adopts a customized module, the height direction and the width direction are about 20% smaller than the existing modules in the market, and meanwhile, the PIN sub-structure with high heat dissipation efficiency is adopted to directly cool water, and the heat dissipation efficiency is improved by increasing the direct contact area between the power device and the water flow.

The embodiment of the application further comprises: and the shielding plate 22, wherein the shielding plate 22 is detachably connected with the lower cover base 1, and the shielding plate 22 is positioned between the control board 24 and the IGBT module 13. For example, the shielding plate 22 and the lower cover base 1 may be mechanically connected by bolting, and the shielding plate 22 and the control board 24 may be mechanically connected by bolting.

It should be noted that the shielding plate 22 is made of die-cast aluminum alloy material to make a cold-turn steel plate different from a common product, and has the same shielding effect and improved vibration resistance, and the position accuracy of each mounting surface is improved due to different manufacturing processes, and the heat conductivity coefficient of the die-cast aluminum material is higher than that of the cold-turn steel plate, so that the heat dissipation capability of the circuit of the control plate 24 is improved. Meanwhile, the weight and the cost are more obvious than those of a cold-coil steel plate.

A heat conducting pad 23 is arranged between the shielding plate 22 and the control plate 24, a heat conducting gap filler is arranged between the shielding plate 22 and the inner wall of the lower cover base 1, and the control plate 24 and the shielding plate 22 are mechanically connected in a bolt fixing mode. Realize heat transfer connection through heat conduction pad 23 between shield plate 22 and the control panel 24, with the heat on the control panel 24, on conducting to shield plate 22, reduce the thermal resistance between control panel 24 and the shield plate 22, improve the heat-sinking capability, compare with traditional insulated paper with heat conduction silicone grease, the installation is more convenient, can dismantle many times, and insulating, radiating effect is stable. Meanwhile, the heat transfer connection between the shielding plate 22 and the lower cover base 1 is realized through a heat-conducting gap filler. It should be noted that the shielding plate 22 and the wire fixing clip 29 fix the signal wire harness on the shielding plate 22 by means of fir-tree-shaped fasteners, so as to achieve smooth routing of the wire harness.

The embodiment of the application further comprises: an upper cover 21, the upper cover 21 is detachably mounted on the lower cover base 1, the upper cover 21 is used for closing the opening of the mounting cavity, and the upper cover 21 and the shielding plate 22 are separated by an upper cover reinforcing rib.

In concrete implementation, the upper cover 21 and the lower cover base 1 are mechanically connected through a bolt, and the upper cover 21 and the DC connector 25 are mechanically connected through a bolt. Realize the box through sealed glue between upper cover 21 and the lower cover base 1 and seal up in order to play the effect of protecting inside device, this sealed glue has good elasticity, and there is viscidity in the single face after the solidification, can realize dismouting many times, realizes automated production and quality management and control more easily than traditional sealing washer. Meanwhile, the cost of a single sealing ring is lower than that of the traditional sealing ring.

Wherein, the isolation of the noise source and the signal circuit is realized between the upper cover 21 and the lower cover base 1 through the upper cover reinforcing ribs and the shielding plate 22, and the electromagnetic compatibility characteristic is optimized. Meanwhile, the upper cover 21 optimizes NVH performance through modeling design and reasonable arrangement of the reinforcing ribs, and compared with a conventional controller, the first-order mode is increased by about 200 HZ-300 HZ, so that the three-in-one high-power rear axle is more suitable for the three-in-one high-power rear axle environment.

It should be noted that the DC connector 25 and the upper cover 21 are disposed in the upper and lower positions, and the open cover interlock and the high voltage interlock are changed from the logical parallel relationship to the logical series relationship unlike other products. In terms of mechanical structure, if the high-voltage interlocking plug-in unit needs to be pulled out when the cover is opened, a single cover opening interlocking structure is omitted, the cost is reduced, meanwhile, the application of the wire harness and the signal plug-in unit 31 is reduced, and the reliability of the system is improved.

The embodiment of the application further comprises: bent water injection well choke 4 and fast water injection well choke 15, bent water injection well choke 4 and the equal detachably of fast water injection well choke 15 install in lower cover base 1, and bent water injection well choke 4 and the cooperation department of fast water injection well choke 15 and lower cover base 1 all are equipped with the sealing member, are equipped with the water route with bent water injection well choke 4, the fast water injection well choke 15 intercommunication in the installation cavity.

In some embodiments, the quick-insertion water nozzle 15 and the lower cover base 1 can be mechanically connected in a bolt fixing mode, and the quick-insertion water nozzle 15 and the lower cover base 1 can be sealed in a radial sealing mode through an o-shaped ring, so that water leakage in a water channel is avoided. Meanwhile, a mistake-proofing pin is arranged between the quick-insertion water nozzle 15 and the lower cover base 1 to achieve installation mistake proofing.

Therefore, the lower cover base 1 serves as an envelope carrier of the motor controller 100 and plays roles of three-phase output port sealing, resolver harness 12 sealing, control board 24 low-voltage connector sealing, IGBT water channel sealing, water channel arrangement, internal device protection, supporting, fixing and the like. The water channel in the box body is sealed inside the box body through the IGBT sealing ring 27, the water channel outside the box body is sealed through friction stir welding, and compared with similar products, the sealing structure is simpler and has higher reliability by using bolts, cover plates and sealing rings.

The embodiment of the application further comprises: a dc hall sensor 17 and an ac hall sensor 8.

The direct current hall sensor 17 is electrically connected with the control board 24 through the current detection wiring harness 16, and meanwhile, the direct current hall sensor 17 and the base 18 are mechanically connected and conducted with current in a bolt fixing mode. The current detection wiring harness 16 is in signal connection with the direct current Hall sensor 17 through a signal plug-in, and the current detection wiring harness 16 is in signal connection with the control board 24 through the signal plug-in, so that signals detected by the direct current Hall sensor 17 are transmitted to the control board 24 through the current detection wiring harness 16.

The AC hall sensor 8 is electrically connected to the AC output module 10. The AC Hall sensor 8 and the AC output module 10 are fixed in a bolt compression joint mode, the AC Hall sensor 8 and the control board 24 are provided with an AC Hall wire harness 11, and signal connection is achieved through the AC Hall wire harness 11. And an AC current signal is collected between the AC Hall sensor 8 and the AC output module 10 through a Hall effect, after the signal is obtained, the AC Hall wire harness 11 conducts the signal with a signal plug-in of the AC Hall sensor 8, and the signal is led into the control board 24 through the AC Hall wire harness 11. The AC Hall wire harness 11 and the lower cover base 1 are fixed through a wire fixing clamp 29.

In a specific implementation, the high voltage warning label 28 may be adhered to the machined surface of the upper cover 21 by its own adhesive. Through the pictures and texts on the high-voltage warning label 28, the safety protection consciousness is improved. Meanwhile, the controller nameplate 30 can be pasted on the machining surface of the lower cover base 1 through self-back glue. The main parameters of the product can be known to the user through the characters on the nameplate.

In the description herein, reference to the description of the terms "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example," or "some examples" or the like means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the application. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

While embodiments of the present application have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the application, the scope of which is defined by the claims and their equivalents.

Claims

1. A motor controller (100) comprising:

the lower cover base (1), the lower cover base (1) is provided with an open installation cavity;

the IGBT module (13) is detachably mounted in the mounting cavity and is in sealing fit with the inner wall of the mounting cavity, and the IGBT module (13) is electrically connected with the AC output module (10);

a control board (24), the control board (24) is installed in the installation cavity and is spaced apart from the IGBT module (13), and the control board (24) is connected with a signal plug-in (31);

the driving plate (6) is installed in the installation cavity, and the control board (24) and the IGBT module (13) are electrically connected with the driving plate (6).

2. The motor controller (100) of claim 1, wherein the IGBT module (13) is electrically connected to the drive board (6) by wave soldering, and the control board (24) is electrically connected to the drive board (6) by a pulse modulated wire harness (14).

3. The motor controller (100) of claim 1, further comprising: the direct current support capacitor (2) and the direct current filter assembly are arranged in the installation cavity at intervals, the direct current filter assembly is connected with a power connector and electrically connected with the direct current support capacitor (2), and the direct current support capacitor (2) is electrically connected with the IGBT module (13).

4. The motor controller (100) of claim 3, wherein the DC filtering assembly comprises:

the base (18), the said base (18) has input copper bar linking with said power connector;

the magnetic ring (19) is connected with the base (18) through heat conduction fixing glue;

the safety capacitor (20), the safety capacitor (20) is connected with the base (18) through heat conduction fixing glue and is electrically connected with the base through resistance welding, and the safety capacitor (20) is electrically connected with the direct current support capacitor (2); wherein,

the base (18) is provided with a following groove, and the magnetic ring (19) and the safety capacitor (20) are arranged in the following groove.

5. The motor controller (100) of claim 1, wherein the IGBT module (13) is detachably connected with the inner wall of the installation cavity through a threaded connector, and an IGBT sealing ring (27) is arranged between the IGBT module (13) and the inner wall of the installation cavity.

6. The motor controller (100) of claim 1, further comprising: the shielding plate (22), the shielding plate (22) with lower cover base (1) detachably links to each other, just shielding plate (22) are located control panel (24) with between IGBT module (13).

7. The motor controller (100) of claim 6, wherein a heat conducting pad (23) is provided between the shielding plate (22) and the control board (24), and a heat conducting gap filler is provided between the shielding plate (22) and the inner wall of the lower cover base (1).

8. The motor controller (100) of claim 6, further comprising: the upper cover (21), upper cover (21) detachably install in lower cover base (1), and upper cover (21) are used for sealing the open mouth of installation cavity, and upper cover (21) with shield plate (22) are separated by the upper cover strengthening rib.

9. The motor controller (100) of claim 1, further comprising: curved water injection well choke (4) and fast water injection well choke (15) of inserting, curved water injection well choke (4) and the equal detachably of fast water injection well choke (15) install in lower cover base (1), just curved water injection well choke (4) and fast water injection well choke (15) with the cooperation department of lower cover base (1) all is equipped with the sealing member, be equipped with in the installation cavity with curved water injection well choke (4) the water route of fast water injection well choke (15) intercommunication.

10. The motor controller (100) of claim 1, further comprising:

the direct current Hall sensor (17), the said direct current Hall sensor (17) is connected electrically with the said control panel (24) through the current detection pencil (16);

the alternating current Hall sensor (8), the alternating current Hall sensor (8) with the AC output module (10) is fixedly connected through bolts, and the alternating current Hall sensor (8) is electrically connected with the control panel (24) through an AC Hall wire harness (11).