CN113733893A

CN113733893A - Dual electric control controller, hybrid power system and electric vehicle

Info

Publication number: CN113733893A
Application number: CN202010462901.8A
Authority: CN
Inventors: 喻凤传; 张星春; 陈万国
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2020-05-27
Filing date: 2020-05-27
Publication date: 2021-12-03

Abstract

The present disclosure relates to a dual electronic controller, a hybrid power system, and an electric vehicle, the dual electronic controller including a first control module, a second control module, and a case (1) accommodating the first control module and the second control module, a flow channel (4) extending adjacent to the first control module and the second control module is provided in the case (1), an inlet pipe (44) and an outlet pipe (45) respectively communicating with the flow channel (4) are connected to the case (1), so that a coolant from the inlet pipe (44) flows out of the outlet pipe (45) through the flow channel (4). The controller of the driving motor and the controller of the generator are combined into a double electric control box body, cooling liquid flows into the flow channel from the inlet pipe to cool the first control module and the second control module and then flows out from the outlet pipe, the sharing of the flow channel of the first control module and the second control module is realized, the flow channel connection of each module is omitted, the space is saved, and the weight of the box body can be lightened.

Description

Dual electric control controller, hybrid power system and electric vehicle

Technical Field

The present disclosure relates to the technical field of controllers, and in particular, to a dual electric controller, a hybrid power system, and an electric vehicle.

Background

With the development of the current social technology, new energy automobiles are more and more popular, the functions of the controllers of the new energy automobiles are more and more integrated, and the volume requirement is smaller and smaller. Hybrid vehicles typically include two electric machines, one as a main drive motor and the other as a generator, both of which require control by a controller. In the related art, the driving motor controller and the generator controller are independent boxes, and a water path, a direct current bus, a bus capacitor, a control signal wire harness and the like for cooling in each box are also relatively independent, so that the whole electric control assembly is large in size and occupies a large space.

Disclosure of Invention

The first purpose of this disclosure is to provide a two electric controller, this two electric controller can solve current vehicle controller function singleness relatively, and the integrated level is not high, and generator and driving motor's controller is independent casing, and the runner of each box all is connection water routes such as independent setting and water demand pipe, and occupation space is big, problem with high costs.

A second objective of the present disclosure is to provide a hybrid system to solve the problems of relatively single function, low integration level, large occupied space and high cost of the existing vehicle controller.

The third purpose of this disclosure is to provide an electric vehicle to solve the problems of relatively single function, low integration level, large occupied space and high cost of the existing vehicle controller.

In order to achieve the above object, the present disclosure provides a dual electric controller, including a first control module, a second control module, and a box accommodating the first control module and the second control module, wherein a flow channel extending adjacent to the first control module and the second control module is provided in the box, and an inlet pipe and an outlet pipe respectively communicating with the flow channel are connected to the box, so that a cooling liquid from the inlet pipe flows out from the outlet pipe through the flow channel.

Optionally, the first control module includes a first IGBT having a first heat dissipation pin group, the second control module includes a second IGBT having a second heat dissipation pin group, and the first heat dissipation pin group and the second heat dissipation pin group are respectively located in the flow channel.

Optionally, the first control module further comprises a first driving PCB assembly for driving the first IGBT, the second control module further comprises a second driving PCB assembly for driving the second IGBT, and a controller PCB assembly electrically connected to the first driving PCB assembly and the second driving PCB assembly is disposed in the box body.

Optionally, a blocking portion is formed in the box body and divides the flow passage into a first flow passage and a second flow passage, the first heat dissipation needle set is located in the first flow passage, the second heat dissipation needle set is located in the second flow passage, and

the box body is also internally provided with a cover plate which is separated from the blocking part, and a connecting flow passage which is communicated with the first flow passage and the second flow passage is formed between the blocking part and the cover plate.

Optionally, a first sealing member sealing between the first IGBT and the box body and a second sealing member sealing between the second IGBT and the box body,

wherein the first sealing element is at least sealed between the first heat dissipation pin group and the blocking part, and the second sealing element is at least sealed between the second heat dissipation pin group and the blocking part.

Optionally, the box body comprises an upper box body and a lower box body which are detachably connected.

Optionally, the box is equipped with the signal connector for the direct current bus connector that is connected with the battery package, be used for the distribution of distribution electricity-taking get the electric connector and be used for connecting the three-phase line lid of three-phase line, wherein, the signal connector sets up go up on the box, the direct current bus connector the distribution is got the electric connector and the three-phase line lid all sets up down on the box.

Optionally, the first control module and the second control module are both located above the flow channel, and a capacitor cavity and a boost inductor cavity are located below the flow channel, so that the cooling liquid in the flow channel can dissipate heat of the capacitor assembly and the boost inductor assembly.

According to the second aspect of the present disclosure, there is also provided a hybrid system, including a driving motor, a generator, and a controller for controlling the driving motor and the generator, wherein the controller is a dual-electric controller as described above, and one of the first control module and the second control module is used for controlling the driving motor, and the other is used for controlling the generator.

According to a third aspect of the present disclosure, there is also provided an electric vehicle including the hybrid system as described above.

Through the technical scheme, the double-electric-control controller provided by the disclosure integrates the control modules of the driving motor and the generator into one box body, becomes a double-electric-control box body, realizes the flow channel sharing of two control modules by setting an integrated cooling flow channel, saves the flow channel connection between the modules, and can share parts in the box body by two control modules, thereby saving the space and the number of parts, ensuring the installation to be convenient, and having high integration level, and being convenient for realizing the diversity of the functions of the vehicle controller. Meanwhile, the weight of the box body is lightened, so that the box body is lighter.

Additional features and advantages of the disclosure will be set forth in the detailed description which follows.

Drawings

The accompanying drawings, which are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the description serve to explain the disclosure without limiting the disclosure. In the drawings:

fig. 1 is a schematic structural diagram of a dual electric controller provided in an exemplary embodiment of the present disclosure;

FIG. 2 is a schematic view of a flow channel structure and flow direction provided in an exemplary embodiment of the present disclosure;

fig. 3 is a schematic structural diagram of a capacitor cavity and a boost inductor cavity in a lower case according to an exemplary embodiment of the present disclosure;

FIG. 4 is a cross-sectional view of a dual electric controller provided in an exemplary embodiment of the present disclosure;

FIG. 5 is a partial view of the first control module position of FIG. 4.

Description of the reference numerals

1 case 101 Upper case

102 lower box body 11 baffle part

12 cover plate 13 signal connector

14 DC bus connector 15 distribution electricity-taking connector

16 three-phase wire cover 2 first IGBT

21 first heat dissipation pin group 22 first drive PCB assembly

3 second IGBT 31 second heat radiation pin group

32 second drive PCB Assembly 4 flow channel

41 first flow passage 42 second flow passage

43 connecting flow passage 44 inlet pipe

45 outlet tube 51 first seal

52 second seal 6 controller PCB assembly

8 electric capacity cavitys of 7 pin needle coupling assembling

801 capacitance assembly 9 boost inductance cavity

Isolation rib of 901 boost inductance assembly 10

Detailed Description

The following detailed description of specific embodiments of the present disclosure is provided in connection with the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the present disclosure, are given by way of illustration and explanation only, not limitation.

In the present disclosure, unless otherwise stated, the use of directional words such as "up and down" generally means that the directional words defined in the case where the dual electric controller provided in the present disclosure is normally used, correspond to the direction of the vehicle. "inner and outer" refer to the inner and outer of the respective component profiles. Furthermore, the terms "first," "second," and the like, as used in this disclosure, are intended to distinguish one element from another, and not necessarily for order or importance. When the following description refers to the accompanying drawings, like numbers in different drawings represent the same or similar elements unless otherwise indicated.

Referring to fig. 1 to 5, the present disclosure provides a dual electric controller including a first control module, a second control module, and a case 1 accommodating the first control module and the second control module. Wherein, one of the first control module and the second control module is a controller for controlling the driving motor, the other is a controller for controlling the generator, the controller shells of the driving motor and the generator are integrated into a box body 1, and the two control modules can share parts in the box body, thereby saving space and part number. Meanwhile, the weight of the box body is lightened, so that the box body is lighter.

Specifically, be provided with the runner 4 that extends adjacent to first control module and second control module in the box 1, be connected with inlet tube 44 and outlet pipe 45 with runner 4 intercommunication respectively on the box 1, so that the coolant liquid that comes from inlet tube 44 flows out from outlet pipe 45 through runner 4, cool off the heat dissipation to first control module and second control module, through setting up integration cooling runner, runner 4 sharing of the two has been realized, the runner connection between each module has been saved, high durability and convenient installation, and space saving, the integrated level is high, be convenient for realize the variety of vehicle controller function.

Referring to fig. 4, according to some embodiments, the first control module may include a first IGBT 2(Insulated Gate Bipolar Transistor) having a first heat dissipation pin group 21, and the second control module may include a second IGBT 3 having a second heat dissipation pin group 31. The first heat dissipation pin group 21 and the second heat dissipation pin group 31 are respectively located in the flow channel 4, so that the cooling liquid in the flow channel 4 directly dissipates heat of the first heat dissipation pin group 21 and the second heat dissipation pin group 31 in a contact manner, and the purpose of cooling the first IGBT 2 and the second IGBT 3 is achieved.

In the embodiment of the present disclosure, the first control module further includes a first driver PCB assembly 22(Printed Circuit Board) for driving the first IGBT 2, the second control module further includes a second driver PCB assembly 32 for driving the second IGBT 3, a controller PCB assembly 6 is disposed in the box body 1, the first driver PCB assembly 22 and the second driver PCB assembly 32 are electrically connected to the controller PCB assembly 6, and specifically, the first driver PCB assembly and the second driver PCB assembly 32 may be electrically connected to each other through the pin connecting assembly 7, thereby realizing sharing of the controller PCB assembly 6.

The controller PCB assembly 6 can be connected to a signal connector 13, a dc bus connector 14, and a distribution power connector 15, which will be described below, so that the first control module and the second control module can share these components, and the number of parts in the related art can be reduced by one time.

Referring to fig. 4, a barrier wall capable of separating the controller PCB assembly 6 from the two drive PCB assemblies may be provided within the case 1 through which the pin connection assembly 7 can pass to enable the former to be connected with the latter. In this way, the controller PCB assembly 6 can be located in separate cavities with the two drive PCB assemblies to improve Electro Magnetic Compatibility (EMC).

The present disclosure does not specifically limit the specific arrangement position and form of the flow channel 4, and only some examples will be described below with reference to the drawings.

Referring to fig. 2 and 4, a blocking portion 11 may be formed in the box body 1 to divide the flow channel 4 into a first flow channel 41 and a second flow channel 42, the first heat dissipation pin group 21 is located in the first flow channel 41, the second heat dissipation pin group 31 is located in the second flow channel 42, and the flow channel 4 is divided into two parts by the blocking portion 11, so that the coolant may be prevented from leaking between the first heat dissipation pin group 21 and the second heat dissipation pin group 31 in the flow channel 4.

Further, the case 1 is provided with a cover plate 12 spaced apart from the baffle portion 11, and a connection flow path 43 communicating the first flow path 41 and the second flow path 42 is formed between the baffle portion 11 and the cover plate 12. The cover plate 12 may be integrally formed in the case 1, or may be fixed to the case 1 by welding, for example. For example, in the example shown in fig. 4, the first flow passage 41 and the second flow passage 42 extend straight, the bottom walls thereof are flush, the cover plate 12 is located below the partition 11, and the coolant flows first downward and then upward through the connecting flow passage 43 to communicate the first flow passage 41 with the second flow passage 42. Therefore, the first flow channel 41 and the second flow channel 42 are connected into an integrated flow channel through the connecting flow channel 43, so that the coolant is prevented from leaking, the first IGBT 2 and the second IGBT 3 share one flow channel 4, and the phenomenon that the independent flow channels are connected through water pipes, the occupied space is reduced, and the material consumption is reduced.

Further, referring to fig. 4, the dual electric controller further includes a first sealing member 51 sealed between the first IGBT 2 and the case 1 and a second sealing member 52 sealed between the second IGBT 3 and the case 1, wherein the first sealing member 51 is sealed at least between the first heat dissipation pin group 21 and the barrier 11, and the second sealing member 52 is sealed between the second heat dissipation pin group 31 and the barrier 11 to prevent the coolant from leaking between the first IGBT 2 and the second IGBT 3. For example, in the embodiment shown in fig. 4, the first sealing member 51 and the second sealing member 52 may be sealing rings surrounding the first heat dissipating pin group 21 and the second heat dissipating pin group 22, respectively, and the sealing rings are disposed at the contact positions of the first heat dissipating pin group 21 and the box body 1. It should be noted that the arrangement position and number of the sealing members are not limited to the above, and the flow passage 4 can be sealed to prevent the coolant from leaking, which all belong to the protection scope of the present disclosure.

For convenience of installation and maintenance, the case 1 may include an upper case 101 and a lower case 102 detachably connected to each other, so as to be easily disassembled and assembled for maintenance. Referring to fig. 1, an upper case 101 and a lower case 102 may be integrally mounted by a plurality of threaded fasteners.

Further, the first control module, the second control module, and the flow channel 4 may be respectively formed at the boundary between the upper case 101 and the lower case 102, so as to further improve the convenience of disassembly and assembly during maintenance. In addition, the upper case 101 and the lower case 102 can be divided into independent cavities by the first control module, the second control module, and the flow passage 4, and electronic components in the upper case 101 and the lower case 102 do not interfere with each other to improve EMC.

In order to facilitate the installation of the flow channel 4, the first control module and the second control module are laterally spaced, and the flow channel 4 is configured as a straight channel, wherein the lateral spacing means that the first control module and the second control module are spaced apart in a substantially horizontal direction in the box body 1. It should be noted that the arrangement positions of the first control module and the second control module and the arrangement form of the flow channel 4 are not limited to the above cases, and the flow channel 4 can cool and dissipate heat of the first control module and the second control module, so that the first control module and the second control module share one flow channel 4, thereby saving space and cost, and all belonging to the protection scope of the present disclosure.

Referring to fig. 4, according to some embodiments, the first control module and the second control module are both located above the flow channel 4, and a capacitor cavity 8 and a boost inductor cavity 9 are located below the flow channel 4, so that when the coolant in the flow channel 4 dissipates heat for the first control module and the second control module, the coolant also dissipates heat for the capacitor assembly 801 and the boost inductor assembly 901, respectively, thereby implementing "one-core-four-use", wherein the first IGBT 2 and the second IGBT 3 may share the capacitor assembly 801 and the boost inductor assembly 901, so as to save the part cost. Therefore, the capacitor assembly 801 and the boost inductor assembly 901 are arranged in a cavity-divided mode to form independent cavities, and therefore EMC is improved. In addition, the first drive PCB assembly 22, the second drive PCB assembly 32 and the controller PCB assembly 6 are disposed above the flow channel 4, i.e. at positions different from the capacitor cavity 8 and the boost inductor cavity 9, further improving EMC.

Referring to fig. 3, in the present embodiment, a plurality of isolation ribs 10 are disposed in the case 1, and the plurality of isolation ribs 10 surround the boost inductor cavity 9 to prevent the boost inductor assembly 901 from generating interference during operation and affecting the operation of other electronic devices. Wherein, the material of keeping apart muscle 10 can select for the aluminum alloy, and the aluminum alloy has high-efficient heat conductivity, can keep good heat dissipation function, is heat energy conversion's ideal medium, and its radiating efficiency is high, light and handy and the processing of being convenient for.

Referring to fig. 1, a box body 1 is provided with a signal connector 13, the signal connector 13 penetrates through the box body 1 to be connected with a whole vehicle, the box body 1 is further provided with a direct current bus connector 14 connected with a battery pack, a power distribution and taking connector 15 used for power distribution and taking and a three-phase wire cover 16 used for connecting a three-phase wire, and two-phase electricity of the battery pack is conveyed to a control module for processing and then conveyed to the three-phase wire to be converted into three-phase electricity to be transmitted to a motor. So set up, sharing has been realized to direct current bus, bus capacitance and signal connector 13 and pencil, has saved the cost.

Referring to fig. 1, in the case that the above-mentioned housing 1 includes an upper housing 101 and a lower housing 102 which are detachable, the signal connector 13 may be disposed on the upper housing 101, and the dc bus connector 14, the distribution and power connector 15, and the three-phase wire cover 16 may be disposed on the lower housing 102, and the flow channel 4 separates the connectors, so that the high-voltage part and the low-voltage part inside the controller respectively perform their respective heat dissipation, and the heat dissipation effect is better.

In another aspect of the present disclosure, a hybrid system and an electric vehicle having the hybrid system are also provided, the hybrid system includes a driving motor, a generator, and a controller for controlling the driving motor and the generator, the controller is the dual-electric-control controller, one of the first control module and the second control module is used for controlling the driving motor, and the other is used for controlling the generator. The hybrid system and the electric vehicle have the same advantages as the dual electric controller compared with the prior art, and are not described herein again.

The preferred embodiments of the present disclosure are described in detail with reference to the accompanying drawings, however, the present disclosure is not limited to the specific details of the above embodiments, and various simple modifications may be made to the technical solution of the present disclosure within the technical idea of the present disclosure, and these simple modifications all belong to the protection scope of the present disclosure.

It should be noted that, in the foregoing embodiments, various features described in the above embodiments may be combined in any suitable manner, and in order to avoid unnecessary repetition, various combinations that are possible in the present disclosure are not described again.

In addition, any combination of various embodiments of the present disclosure may be made, and the same should be considered as the disclosure of the present disclosure, as long as it does not depart from the spirit of the present disclosure.

Claims

1. The dual-electric-control controller is characterized by comprising a first control module, a second control module and a box body (1) accommodating the first control module and the second control module, wherein a flow channel (4) extending adjacent to the first control module and the second control module is arranged in the box body (1), and an inlet pipe (44) and an outlet pipe (45) which are respectively communicated with the flow channel (4) are connected to the box body (1) so that cooling liquid from the inlet pipe (44) flows out of the outlet pipe (45) through the flow channel (4).

2. The dual-electric-control controller according to claim 1, wherein the first control module comprises a first IGBT (2) having a first heat dissipation pin group (21), and the second control module comprises a second IGBT (3) having a second heat dissipation pin group (31), and the first heat dissipation pin group (21) and the second heat dissipation pin group (31) are respectively located in the flow channel (4).

3. The dual electric control controller according to claim 2, wherein the first control module further comprises a first driving PCB assembly (22) for driving the first IGBT (2), the second control module further comprises a second driving PCB assembly (32) for driving the second IGBT (3), and a controller PCB assembly (6) electrically connected to the first driving PCB assembly (22) and the second driving PCB assembly (32) is disposed in the case (1).

4. The dual electric controller according to claim 2, wherein a barrier (11) dividing the flow channel (4) into a first flow channel (41) and a second flow channel (42) is formed in the case (1), the first heat dissipation pin group (21) is located in the first flow channel (41), the second heat dissipation pin group (31) is located in the second flow channel (42), and

the box body (1) is further provided with a cover plate (12) which is separated from the blocking part (11), and a connecting flow passage (43) which is communicated with the first flow passage (41) and the second flow passage (42) is formed between the blocking part (11) and the cover plate (12).

5. Dual electric control controller according to claim 4, further comprising a first seal (51) sealing between the first IGBT (2) and the tank (1) and a second seal (52) sealing between the second IGBT (3) and the tank (1),

wherein the first sealing element (51) seals at least between the first heat dissipating needle group (21) and the barrier (11), and the second sealing element (52) seals at least between the second heat dissipating needle group (31) and the barrier (11).

6. The dual-electric-control controller according to claim 1, wherein the case (1) comprises an upper case (101) and a lower case (102) which are detachably connected.

7. The dual-electric-control controller according to claim 6, wherein the box body (1) is provided with a signal connector (13) for a direct-current bus connector (14) connected with a battery pack, a power distribution and taking connector (15) for power distribution and taking and a three-phase wire cover (16) for connecting three phase wires, wherein the signal connector (13) is arranged on the upper box body (101), and the direct-current bus connector (14), the power distribution and taking connector (15) and the three-phase wire cover (16) are arranged on the lower box body (102).

8. The dual-electric-control controller according to claim 1, wherein the first control module and the second control module are both located above the flow channel (4), and a capacitor cavity (8) and a boost inductor cavity (9) are located below the flow channel (4), so that the cooling liquid in the flow channel (4) can dissipate heat of the capacitor assembly (801) and the boost inductor assembly (901).

9. A hybrid system comprising a drive motor, a generator, and a controller for controlling the drive motor and the generator, wherein the controller is a dual electric controller according to any one of claims 1-8, one of the first and second control modules being for controlling the drive motor and the other being for controlling the generator.

10. An electric vehicle characterized by comprising the hybrid system according to claim 9.