CN114070167A - High-power electric machine controller is with high integrated electric device - Google Patents
High-power electric machine controller is with high integrated electric device Download PDFInfo
- Publication number
- CN114070167A CN114070167A CN202010747846.7A CN202010747846A CN114070167A CN 114070167 A CN114070167 A CN 114070167A CN 202010747846 A CN202010747846 A CN 202010747846A CN 114070167 A CN114070167 A CN 114070167A
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- Prior art keywords
- phase
- power module
- support
- magnetic ring
- motor controller
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- 239000003990 capacitor Substances 0.000 claims abstract description 30
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 21
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 20
- 239000010409 thin film Substances 0.000 claims description 19
- 229910052802 copper Inorganic materials 0.000 claims description 18
- 239000010949 copper Substances 0.000 claims description 18
- 238000009413 insulation Methods 0.000 claims description 15
- 230000017525 heat dissipation Effects 0.000 claims description 12
- 239000010408 film Substances 0.000 claims description 8
- 239000003292 glue Substances 0.000 claims description 4
- 230000010354 integration Effects 0.000 abstract description 4
- 238000003466 welding Methods 0.000 description 5
- 230000005855 radiation Effects 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000011900 installation process Methods 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 239000000741 silica gel Substances 0.000 description 2
- 229910002027 silica gel Inorganic materials 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000110 cooling liquid Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P25/00—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details
- H02P25/16—Arrangements or methods for the control of AC motors characterised by the kind of AC motor or by structural details characterised by the circuit arrangement or by the kind of wiring
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
- H05K7/20927—Liquid coolant without phase change
Landscapes
- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Power Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Inverter Devices (AREA)
Abstract
The invention relates to a highly integrated electric device for a high-power motor controller, which comprises a bus pole plate, a film capacitor, a power module assembly, a control panel, a three-phase output pole plate, a drive plate and a three-phase plastic-coated bracket, wherein the power module assembly comprises a power module and a radiator; film capacitor and drive plate set up respectively in the relative both sides of power module subassembly, film capacitor's input pass the magnetic ring subassembly with the bus-bar polar plate is connected, the drive plate is fixed on the support is moulded to the three-phase package and be connected with the control panel, support fixed connection is moulded to radiator and three-phase package, the input of support and power module's output electrical connection is moulded to the three-phase package, the output electrical connection of support is moulded with the three-phase package after current sensor is passed to the input of three-phase output polar plate. Compared with the prior art, the invention has the advantages of high integration level, modular structure, compact structure and small volume.
Description
Technical Field
The invention relates to the field of motor controllers, in particular to a highly integrated electric device for a high-power motor controller.
Background
The traditional motor controller for the new energy automobile generally comprises devices such as a bus pole plate, a magnetic ring support, a thin film capacitor, a current sensor, an IGBT (insulated gate bipolar transistor), a drive plate, a shielding plate and a control plate, wherein the bus pole plate, the magnetic ring support, the thin film capacitor and the IGBT are independently assembled inside a controller box body, the arrangement area in the box body is increased, the integration level is low, and the length and the width of the box body are large, and parts are inconvenient to assemble. Because the traditional heat dissipation water channel is arranged on the bottom surface of the box body, the complexity of the structure and the processing technology of the box body is increased, and the manufacturing cost of the box body is increased.
Disclosure of Invention
The present invention is directed to overcoming the above-mentioned drawbacks of the prior art and providing a highly integrated electric device for a high power motor controller.
The purpose of the invention can be realized by the following technical scheme:
a high-integration electric device for a high-power motor controller comprises a bus pole plate, a film capacitor, a power module assembly, a control board, a three-phase output pole plate, a drive board and a three-phase plastic-coated bracket, wherein the power module assembly comprises a power module and a radiator; film capacitor and drive plate set up respectively in the relative both sides of power module subassembly, film capacitor's input pass the magnetic ring subassembly with the bus-bar polar plate is connected, the drive plate is fixed on the support is moulded to the three-phase package and be connected with the control panel, support fixed connection is moulded to radiator and three-phase package, the input of support and power module's output electrical connection is moulded to the three-phase package, the output electrical connection of support is moulded with the three-phase package after current sensor is passed to the input of three-phase output polar plate.
Preferably, the bus polar plate comprises front insulating paper, a positive copper bar, middle-layer insulating paper, a negative copper bar and back insulating paper which are sequentially stacked.
Preferably, the upper edges and the lower edges of the front insulating paper, the middle insulating paper and the back insulating paper exceed a certain height of the positive copper bar, and the exceeding parts are pressed together by glue water.
Preferably, the radiator comprises a plurality of positioning cavities arranged in a double-layer manner, and the power module is installed in the positioning cavities.
Preferably, a water inlet and a water outlet are respectively arranged at two ends of the radiator, a heat dissipation water channel is distributed between the two layers of positioning cavities, and the water inlet, the heat dissipation water channel and the water outlet are communicated with each other.
Preferably, the magnetic ring assembly comprises a magnetic ring support and a magnetic ring, a kidney-shaped groove is formed in the magnetic ring support, a terminal outlet hole is formed in the kidney-shaped groove, and the magnetic ring is fixedly sealed in the kidney-shaped groove.
Preferably, the magnetic ring support is provided with a threaded hole, the input end of the thin film capacitor penetrates through the terminal outlet hole and is electrically connected with the output end of the bus pole plate, and the input end of the thin film capacitor and the output end of the bus pole plate are fixed on the magnetic ring support through the threaded hole.
Preferably, the three-phase plastic-coated support is provided with a plurality of struts and threaded holes, and the three-phase plastic-coated support is provided with through rectangular holes and rectangular gaps; the rectangular holes are multiple and respectively correspond to the positions of the power modules, and the rectangular notches correspond to the positions of the current sensors.
Preferably, the control board is disposed on an upper side of the heat sink through a pillar.
Preferably, a plurality of side surfaces of the radiator are provided with upright posts.
Compared with the prior art, the invention has the following advantages:
1. the components of the device are connected into a whole, the structure is compact, the integration level is high, and the device can be directly assembled in the controller box or taken out from the controller box.
2. The radiator integrates a water inlet, a water outlet, a radiating water channel and a positioning cavity, and the integration level is high; the modular design is adopted, the number of the positioning cavities can be designed according to the number of the power modules, and the structural adaptability is strong; a plurality of sides of the radiator are provided with upright columns, and threaded holes are formed in the upright columns, so that the upright columns can be used as supports for fixing other components.
3. The positive insulation paper, the positive copper bar, the middle layer insulation paper, the negative copper bar and the back insulation paper of the bus polar plate are sequentially arranged in a laminated manner, so that the electrical insulation between the positive copper bar and the negative copper bar is realized; the upper edges and the lower edges of the three pieces of insulation paper are hot-pressed together by glue, so that the connection between the insulation paper and the anode copper bar and the cathode copper bar is realized, and the insulation mode has the advantages of simple processing technology, low cost, and small mass and volume.
4. The three-phase plastic-coated support is used for coating three copper bars inside the support, and a protruding support column and a threaded hole are formed in the front of the support, so that the three-phase plastic-coated support has the functions of circulating large current and fixing a driving plate.
Drawings
FIG. 1 is a schematic structural view of the present invention;
FIG. 2 is a schematic structural view of a bus plate of the present invention;
FIG. 3 is a schematic structural view of a magnetic ring support in the present invention;
FIG. 4 is a schematic structural diagram of a thin film capacitor according to the present invention;
fig. 5 is a schematic structural diagram of a three-phase plastic-coated bracket in the invention.
The figure is marked with: the device comprises a bus pole plate 1, a magnetic ring support 2, a magnetic ring 3, a film capacitor 4, a power module 5, a radiator 6, a control board 7, a current sensor 8, a three-phase output pole plate 9, a driving board 10 and a three-phase plastic-coated support 11, wherein the bus pole plate is a bus pole plate; 1-1 is a positive copper bar, 1-2 is a negative copper bar, 1-3 is front insulating paper, 1-4 is middle insulating paper, and 1-5 is back insulating paper; 2-1 is a terminal outlet, and 2-2 is a kidney-shaped groove; 4-1 is the input end of the thin film capacitor, and 4-2 is the output end of the thin film capacitor; 9-1 is the input end of the three-phase plastic-coated bracket, and 9-2 is the output end of the three-phase plastic-coated bracket.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments. The present embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation manner and a specific operation process are given, but the scope of the present invention is not limited to the following embodiments.
As shown in fig. 1, the present application provides a highly integrated electrical device for a high power motor controller, which includes a bus plate 1, a thin film capacitor 4, a power module assembly, a control board 7, a three-phase output plate 9, a drive board 10, a three-phase plastic-coated bracket 11, a magnetic ring assembly, and a current sensor 8, wherein the power module assembly includes a power module 5 and a heat sink 6.
The thin film capacitor 4 and the driving plate 10 are respectively arranged on two opposite sides of the power module assembly, and the input end 4-1 of the thin film capacitor penetrates through the magnetic ring assembly to be connected with the bus pole plate 1. The driving plate 10 is fixed on the three-phase plastic-coated bracket 11 and is connected with the control plate 7. The radiator 6 is fixedly connected with the three-phase plastic-coated support 11, and the input end 9-1 of the three-phase plastic-coated support is electrically connected with the output end of the power module 5. The input end of the three-phase output polar plate 9 penetrates through the current sensor 8 and then is electrically connected with the output end 9-2 of the three-phase plastic-coated support, and the output end of the three-phase output polar plate 9 is electrically connected with other equipment to output three-phase alternating current. The control board 7 is disposed on the upper side of the radiator 6 by a pillar.
The radiator 6 comprises a plurality of positioning cavities which are arranged in a double-layer mode, and the power module 5 is installed in each positioning cavity. The left end and the right end of the bottom surface of the radiator 6 are respectively provided with a water inlet and a water outlet, a heat radiation water channel is distributed between the two layers of positioning cavities, the water inlet, the heat radiation water channel and the water outlet are communicated, and the other positions of the heat radiation water channel except the water inlet and the water outlet are completely sealed. The radiator 6 is provided with pillars on a plurality of sides. In this embodiment, the heat sink 6 has three positioning cavities, each having a rectangular cross section and penetrating in the front and rear direction, and 1 positioning cavity is provided on the first layer and located below the heat dissipation water channel, and 2 positioning cavities are provided on the second layer and located above the heat dissipation water channel. The number of the power modules 5 is 3, the power modules are respectively arranged in the 3 positioning cavities, and the heat dissipation surfaces of the power modules 5 are ensured to be tightly attached to one side of the heat dissipation water channel of the heat radiator 6. The number of positioning cavities can be flexibly changed according to the number of power modules 5. When the power module 5 is in operation, most of the heat is transferred to the heat sink 6 through the heat dissipation surface. The cooling liquid enters the heat dissipation water channel from the water inlet, takes away the heat on the radiator 6 and flows out from the water outlet. The top surface distribution of radiator 6 has 8 stands, and the stand is higher than peripheral plane 0.5mm, respectively has a screw hole in every stand, is control panel 7 on the stand, passes through the screw connection between control panel 7 and the stand. The front of the radiator 6 is provided with 4 threaded holes which are connected with the three-phase plastic-coated bracket 11 through screws.
As shown in fig. 2, the bus plate 1 is an L-shaped bent structure, and includes front-side insulation paper 1-3, a positive copper bar 1-1, middle-layer insulation paper 1-4, a negative copper bar 1-2, and back-side insulation paper 1-5, which are stacked in sequence. The upper edges and the lower edges of the front insulating paper 1-3, the middle insulating paper 1-4 and the back insulating paper 1-5 exceed a certain height of the positive copper bar 1-1, in the embodiment, the upper edges and the lower edges exceed 5mm, and the exceeding parts are pressed together by glue water, so that the insulating paper is connected with the positive copper bar 1-1 and the negative copper bar 1-2.
As shown in fig. 3, the magnetic ring assembly comprises a magnetic ring support 2 and a magnetic ring 3, a kidney-shaped groove 2-2 is formed on the magnetic ring support 2, a terminal outlet 2-1 is formed in the kidney-shaped groove 2-2, and the magnetic ring 3 is fixedly sealed in the kidney-shaped groove 2-2 through silica gel. The magnetic ring support 2 is provided with a threaded hole. Two-phase high-voltage current is input from the input end of the bus pole plate 1, the input end 4-1 of the film capacitor penetrates through the terminal outlet hole 2-1 and then is electrically connected with the output end of the bus pole plate 1, and the two are fixed on the magnetic ring support 2 through the threaded hole.
As shown in fig. 4, the input terminal 4-1 of the thin film capacitor is in a longer positive and negative bus bar structure. The output end 4-2 of the thin film capacitor is in a short three-pair positive and negative busbar structure, and each pair of positive and negative busbars are electrically connected with the input end of a power module 5 through laser welding.
As shown in fig. 5, the three-phase plastic-coated bracket 11 is provided with a plurality of pillars and threaded holes, and the three-phase plastic-coated bracket 11 is provided with through rectangular holes and rectangular gaps. The rectangular hole is equipped with 3, corresponds the position at power module 5 place respectively, prevents to interfere with power module 5's output and signal contact pin. The rectangular notch corresponds to the position of the current sensor 8 at the lower right corner, and interference with the current sensor 8 is prevented. The output end of the power module 5 is electrically connected with the input end 9-1 of the three-phase plastic-coated support through laser welding, and the signal pin of the power module 5 is electrically connected with the driving plate 10 through wave soldering.
The film capacitor 4, the power module 5 and the three-phase plastic-coated support 11 are electrically connected through laser welding, and space is saved.
The installation process of the device is as follows:
1. mounting the power module 5 on the heat sink 6: in the installation process, the power module 5 is placed right in front of the positioning cavity, so that the radiating surface of the power module 5 is opposite to one side of a radiating water channel of the radiator 6, and force is applied in a direction perpendicular to the cross section of the power module 5 to enable the power module to slide backwards along the upper cavity until only the wiring terminal of the power module 5 is exposed out of the cavity; after the installation is finished, the power module 5 is ensured to be clamped in the positioning cavity without looseness, and the heat dissipation surface of the power module 5 is tightly attached to the inner surface of the positioning cavity.
2. The magnetic ring 3 is placed in the kidney-shaped groove 2-2 of the magnetic ring support 2 and is solidified through silica gel.
3. And (3) penetrating the magnetic ring support 2 provided with the magnetic ring 3 through the input end 4-1 of the thin film capacitor, laminating the output end of the bus pole plate 1 and the input end 4-1 of the thin film capacitor, and fixing the two on the magnetic ring support 2 through bolts.
4. The output end 4-2 of the thin film capacitor and the input end of the power module 5 are placed in a laminated mode, the two end faces of the thin film capacitor and the input end are aligned, and then the thin film capacitor and the power module are welded into a whole through laser welding.
5. The current sensor 8 is fixed to the front right lower corner of the heat sink 6 by screws.
6. The output end of the power module 5 and the input end 9-1 of the three-phase plastic-coated support are placed in a laminated mode, the end faces of the two sides are aligned, then the three-phase plastic-coated support 11 is fixed in front of the radiator 6 through screws, and the output end of the power module 5 and the input end of the three-phase plastic-coated support 11 are welded into a whole through laser welding.
7. The input end of a three-phase output polar plate 9 passes through the current sensor 8 and is fixed at the output end 9-2 of the three-phase plastic-coated support through a screw.
8. The driving plate 10 is fixed in front of the three-phase plastic-coated bracket 11 through bolts, and signal pins of the power module 5 are welded at corresponding positions on the driving plate 10 through wave soldering.
9. The control board 7 is fixed to the upper side of the heat sink 6, and the electrical connection between the control board 7 and the drive board 10 is made by a wire harness.
Claims (10)
1. A high-integration electric device for a high-power motor controller comprises a bus pole plate (1), a thin-film capacitor (4), a power module assembly, a control panel (7), a three-phase output pole plate (9), a drive plate (10) and a three-phase plastic-coated bracket (11), wherein the power module assembly comprises a power module (5) and a radiator (6); its characterized in that, film capacitor (4) and drive plate (10) set up respectively in the relative both sides of power module subassembly, film capacitor's input (4-1) pass the magnetic ring subassembly with bus-bar polar plate (1) is connected, drive plate (10) are fixed on support (11) is moulded to the three-phase package and be connected with control panel (7), support (11) fixed connection is moulded with the three-phase package to radiator (6), the input of support is moulded to the three-phase package (9-1) and the output electrical connection of power module (5), the input of three-phase output polar plate (9) passes behind current sensor (8) and moulds output (9-2) electrical connection of support with the three-phase package.
2. The highly integrated electrical device for the high-power motor controller according to claim 1, wherein the bus bar plate (1) comprises front insulation paper (1-3), a positive copper bar (1-1), middle insulation paper (1-4), a negative copper bar (1-2) and back insulation paper (1-5) which are sequentially stacked.
3. The highly integrated electrical device for the high power motor controller according to claim 2, wherein the upper and lower edges of the front insulation paper (1-3), the middle insulation paper (1-4), and the back insulation paper (1-5) all exceed a certain height of the positive copper bar (1-1), and the exceeding portions are hot pressed together by glue water.
4. The highly integrated electrical device for the high-power motor controller according to claim 1, wherein the heat sink (6) comprises a plurality of positioning cavities arranged in a double layer, and the power module (5) is installed in the positioning cavities.
5. The highly integrated electrical device for the high power motor controller according to claim 4, wherein the two ends of the heat sink (6) are respectively provided with a water inlet and a water outlet, and a heat dissipation water channel is distributed between the two layers of positioning cavities, and the water inlet, the heat dissipation water channel and the water outlet are communicated with each other.
6. The highly integrated electrical device for the high power motor controller according to claim 1, wherein the magnetic ring assembly comprises a magnetic ring support (2) and a magnetic ring (3), the magnetic ring support (2) is provided with a kidney-shaped groove (2-2), the kidney-shaped groove (2-2) is provided with a terminal outlet (2-1), and the magnetic ring (3) is sealed in the kidney-shaped groove (2-2).
7. The highly integrated electrical device for the high power motor controller in claim 6, wherein the magnetic ring support (2) is provided with a threaded hole, the input terminal (4-1) of the thin film capacitor is electrically connected to the output terminal of the bus bar plate (1) after passing through the terminal exit hole (2-1), and the two are fixed on the magnetic ring support (2) through the threaded hole.
8. The highly integrated electric device for the high-power motor controller according to claim 1, wherein the three-phase plastic-coated bracket (11) is provided with a plurality of pillars and threaded holes, and the three-phase plastic-coated bracket (11) is provided with through rectangular holes and rectangular notches; the rectangular holes are multiple and respectively correspond to the positions of the power modules (5), and the rectangular notches correspond to the positions of the current sensors (8).
9. The highly integrated electric device for high power motor controller according to claim 1, wherein the control board (7) is disposed on the upper side of the heat sink (6) by a pillar.
10. The highly integrated electric device for high power motor controller according to claim 1, wherein the heat sink (6) is provided with pillars at a plurality of sides.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010747846.7A CN114070167A (en) | 2020-07-30 | 2020-07-30 | High-power electric machine controller is with high integrated electric device |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010747846.7A CN114070167A (en) | 2020-07-30 | 2020-07-30 | High-power electric machine controller is with high integrated electric device |
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| Publication Number | Publication Date |
|---|---|
| CN114070167A true CN114070167A (en) | 2022-02-18 |
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|---|---|---|---|
| CN202010747846.7A Pending CN114070167A (en) | 2020-07-30 | 2020-07-30 | High-power electric machine controller is with high integrated electric device |
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| CN (1) | CN114070167A (en) |
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2020
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