CN115250597A - Coupling rectifying device for motor controller - Google Patents

Abstract

The invention relates to a coupling rectifying device for a motor controller, which comprises a coupling bracket, a wiring copper bar, a rectifying core, a rectifying ring, a first rectifying block, a second rectifying block and a rectifying device, wherein the first rectifying block is connected with the rectifying ring; the coupling support comprises a core mounting groove and a rectifying frame distributed on one side of the core mounting groove, and the rectifying core is arranged in the core mounting groove; the copper bar that works a telephone switchboard on the rectifier bracket passes first mounting groove, second mounting groove, third mounting groove and fourth mounting groove in proper order, and the winding wiring copper bar in first mounting groove is installed to the rectifier ring, and first rectifier block is installed and is encircleed the wiring copper bar in the second mounting groove, and the winding wiring copper bar in fourth mounting groove is installed to the second rectifier block, and rectifier device installs the connection wiring copper bar in the third mounting groove. Compared with the prior art, the invention can realize multilayer purification of the current entering the motor controller from the battery end of the whole vehicle, has excellent anti-interference performance and can match the noise performance test requirements of six channels of the whole vehicle.

Description

A coupling rectifier device for motor controller

technical field

The invention relates to the field of electric vehicle controllers, in particular to a coupling rectifier device for motor controllers.

Background technique

In recent years, the domestic and overseas markets have continuously increased the performance demand of new energy electric vehicles and paid more and more attention to the driving experience. In this context, new energy electric vehicles are developing rapidly in the direction of high power, high density, high integration, multi-function and intelligence. At the same time, the power of high-voltage devices on vehicles is increasing, and low-voltage electronic equipment and There are more and more sensors, and the electromagnetic environment of the vehicle is becoming more and more complex. As one of the three electric vehicles of new energy vehicles, the internal power module of the controller generates transient current and voltage during the high-frequency switching process, which injects a certain amount of noise pollution into the DC high-voltage system of the vehicle. The current will also have an impact on other electronic devices such as vehicle sensors, which not only affect the performance, but also reduce the safety and reliability of the vehicle during operation. Traditional motor controllers generally use a rectification scheme within two channels to meet the noise test requirements of early new energy vehicles on-load, but this design scheme has become stretched in current and future high-performance, highly integrated vehicles. It is difficult to meet the higher-level noise testing requirements of the entire vehicle. Therefore, it is urgent to design a more effective coupling rectifier to meet the higher-level performance requirements of the vehicle.

SUMMARY OF THE INVENTION

The purpose of the present invention is to provide a coupling rectifier device for a motor controller in order to overcome the above-mentioned defects of the prior art.

The object of the present invention can be realized through the following technical solutions:

A coupling rectifier device for a motor controller, comprising a coupling bracket, a wiring copper bar, a rectifier core, a rectifier ring, a first rectifier block, a second rectifier block and a rectifier device;

The coupling bracket includes a core installation slot, and a rectifier frame distributed on one side of the core installation slot, the rectifier core is arranged in the core installation slot, and the side of the rectifier core facing the rectifier frame is provided with a turntable. Connected to the copper bar, the opposite side is provided with the output copper bar;

The rectifier frame includes a first installation slot, a second installation slot, a third installation slot and a fourth installation slot arranged in sequence, and the wiring copper bar passes through the first installation slot, the second installation slot, and the third installation slot in sequence. slot and fourth installation slot, the rectifier ring is installed in the first installation slot and surrounds the wiring copper bar, the first rectifier block is installed in the second installation slot and surrounds the wiring copper bar, and the second rectifier block is installed in the first installation slot. The four installation slots are surrounded by copper wiring bars, the rectifier device is installed in the third installation slot and connected to the wiring copper bars, one end of the wiring copper bars passes through the first installation slot as a connection terminal, and the other end passes through the fourth installation slot Connect the transfer copper bar.

Further, the core installation slot is a box structure with an open top, the output copper bars and the transfer copper bars are both "several" type metal sheets, and the grooves are embedded in the side walls of the core installation slot. superior.

Further, the rectifier core includes a plurality of non-polar cores, and the plurality of non-polar cores are fixed in the core installation groove by epoxy potting.

Further, the cross section of the non-polar core is oval, and the number is at least three.

Further, the first rectifier block includes a first upper rectifier unit and a first lower rectifier unit, the first upper rectifier unit is in a "mountain" shape, and the wiring copper bar divides the second installation slot into three empty spaces. cavity, the first lower rectifier unit is located at the bottom of the second installation slot and under the wiring copper bar, and the three protrusions of the first upper rectifier unit are inserted into the three cavities and are close to the first lower rectifier at the bottom unit.

Further, the second rectifier block includes a second upper rectifier unit and a second lower rectifier unit, the second upper rectifier unit is in a "mountain" shape, and the wiring copper bar divides the fourth installation slot into three empty spaces. cavity, the second lower rectifier unit is located at the bottom of the fourth installation slot and under the wiring copper bar, the three protruding parts of the second upper rectifier unit are inserted into the three cavities and close to the second lower rectifier at the bottom unit.

Further, the bottoms of the side walls of the second installation slot and the fourth installation slot are provided with side suction openings, and the first lower rectifier unit and the second lower rectification unit are installed to the second installation slot and the fourth installation slot through the side suction openings. Inside.

Further, the third installation slot is divided into a plurality of installation cavities by the wiring copper bar and the rib plate, and upwardly protruding calipers are arranged on the wiring copper bar, and the rectifier device is correspondingly installed in each installation cavity and connected with the wiring. The calipers on the copper bar are connected.

Further, the rectifier ring is a magnetic ring formed by winding a nano metal film material.

Further, the first rectifier block and the second rectifier block are both manganese-zinc and nickel-zinc composite modules.

Compared with the prior art, the present invention has the following beneficial effects:

1. The present invention highly integrates the rectifier core, the rectifier ring, the first rectifier block, the second rectifier block and the rectifier device. Integrating multi-channel rectifier devices, this structure can realize the multi-layer purification of the current entering the motor controller from the battery end of the vehicle to become more pure, with excellent anti-interference performance, which can match the noise performance test requirements of the vehicle's six channels .

2. The coupling rectifier device of the present invention adopts a left and right integrated structure. Half of the coupling bracket is a core installation slot, and the rectifier core is installed in the core installation slot to connect the "ji" type metal sheets on both sides as the connecting copper bar, and the other half The coupling bracket is longitudinally divided into a plurality of installation slots, and each rectifier block and rectifier device are directly arranged in the installation slot to complete the connection or surround with the wiring copper bar, thereby significantly reducing the occupied space of the device and making the The structure is compact and the assembly is convenient; at the same time, the present invention is convenient for users to reasonably configure differential mode devices, common mode devices and anti-interference modules according to different electromagnetic environments of different vehicles, and has better adaptability and expansibility.

3. The rectifier block in the present invention adopts the lower rectifier unit and the upper rectifier unit in the "mountain"-shaped structure, so as to realize the independent winding of the wiring copper bars and improve the effect of filtering noise.

4. The bottom surface of the capacitive coupling bracket is a flat structure, which can be closely attached to the heat dissipation surface of the motor controller base plate, so that the heat generated by the coupling rectifier device during the filtering process can be effectively exported, and it has good heat dissipation performance, which can make the whole device The performance is more efficient and stable operation.

Description of drawings

FIG. 1 is a schematic structural diagram of the present invention.

FIG. 2 is a schematic structural diagram of a coupling bracket.

FIG. 3 is a schematic structural diagram of a rectifier core.

FIG. 4 is a schematic diagram of the structure of the wiring copper bar.

FIG. 5 is a schematic structural diagram of a rectifier block.

Reference numerals: 1. Coupling bracket, 11, rectifier frame, 111, first installation slot, 112, second installation slot, 113, third installation slot, 114, fourth installation slot, 12, core installation slot, 13 , side extraction port, 2, wiring copper bar, 21, caliper, 3, rectifier core, 31, non-polar core, 4, rectifier ring, 5, first rectifier block, 51, first upper rectifier unit, 52, The first lower rectifier unit, 6, the second rectifier block, 61, the second upper rectifier unit, 62, the second lower rectifier unit, 7, the rectifier device, 8, the transfer copper bar, 9, the output copper bar.

Detailed ways

The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is implemented on the premise of the technical solution of the present invention, and provides a detailed implementation manner and a specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

As shown in FIG. 1 and FIG. 2 , this embodiment provides a coupling rectifier device for a motor controller, including a coupling bracket 1 , a wiring copper bar 2 , a rectifier core 3 , a rectifier ring 4 , a first rectifier block 5 , and a second rectifier block 5 . Rectifier block 6 and rectifier device 7 .

The coupling bracket 1 is a left-right structure, the left coupling bracket 1 is provided with a core mounting slot 12 , and the right side is a rectifier frame 11 . The commutating core 3 is arranged in the core mounting slot 12 , the side of the commutating core 3 facing the commutating frame 11 is provided with an adapter copper bar 8 , and the opposite side is provided with an output copper bar 9 , as shown in FIG. 3 . Specifically, the rectifier core 3 includes a plurality of non-polar cores 31 with elliptical cross-sections, and the plurality of non-polar cores 31 are fixed in the core installation groove 12 by epoxy potting. The number of non-polar cores 31 is generally at least three, and five are preferred in this embodiment. The core installation slot 12 is a box structure with an open top. The output copper bar 9 and the transfer copper bar 8 are both "ji" type metal sheets.

The fairing frame 11 includes a first installation slot 111 , a second installation slot 112 , a third installation slot 113 and a fourth installation slot 114 which are arranged in sequence. The wiring copper bar 2 is two conductive plates arranged side by side, as shown in FIG. One end of the connection copper bar 2 passes through the first installation slot 111 as a connection terminal, and the other end passes through the fourth installation slot 114 to connect to the transfer copper bar 8 . The rectifier ring 4 is installed in the first installation slot 111 to surround the wiring copper bar 2; the first rectifier block 5 is installed in the second installation slot 112 to surround the wiring copper bar 2; the second rectifier block 6 is installed in the fourth installation slot 114 to surround the wiring copper bar 2 The wiring copper bar 2; the rectifying device 7 is installed in the third installation slot 113 to connect the wiring copper bar 2.

As shown in FIG. 2 and FIG. 5 , the first rectifier block 5 includes a first upper rectifier unit 51 and a first lower rectifier unit 52 . A side suction port 13 is provided at the bottom of the side wall of the second installation slot 112 , and the first lower rectifier unit 52 is installed to the bottom of the second installation slot 112 through the side suction port 13 and is located under the wiring copper bar 2 . The first upper rectifier unit 51 is in the shape of a "mountain", and the wiring copper bar 2 divides the second installation slot 112 into three cavities. The three protruding parts of the first upper rectifying unit 51 are inserted into the three cavities and then close to the first lower rectifying unit 52 at the bottom to form a horizontal "sun" shape. As a result, the first rectifier block 5 forms a circle around the conductive plates in the second installation slot 112 respectively, and plays the role of filtering and denoising. Similarly, the second rectifier block 6 includes a second upper rectifier unit 61 and a second lower rectifier unit 62 . A side suction port 13 is provided at the bottom of the side wall of the fourth installation slot 114 , and the second lower rectifier unit 62 is installed to the bottom of the fourth installation slot 114 through the side suction port 13 and is located under the wiring copper bar 2 . The first upper rectifier unit 51 is in the shape of a "mountain", and the fourth installation slot 114 is divided into three cavities by the wiring copper bar 2 . The three protruding parts of the second upper rectifying unit 61 are inserted into the three cavities and then close to the second lower rectifying unit 62 at the bottom to form a horizontal "sun" shape. As a result, the second rectifier block 6 surrounds the conductive plates in the fourth installation slot 114 respectively, which also plays the role of filtering and denoising.

The third installation groove 113 is divided into a plurality of installation cavities by the copper wiring bar 2 and the rib. A caliper 21 protruding upward is provided on the wiring copper bar 2 , as shown in FIG. 4 . After each rectifier device 7 is installed in each installation cavity correspondingly, it can be directly connected to the caliper 21 on the wiring copper bar 2 to complete the assembly.

In this embodiment, the rectifier ring 4 is a magnetic ring made of a nano metal film material, which can be used to suppress high-frequency noise in the circuit; the first rectifier block 5 is made of Ni-Zn mixed metal powder fired, and is used to suppress the circuit The intermediate frequency noise in the circuit; the second rectifier block 6 is fired from Mn-Zn mixed metal powder, which can be used to suppress the low frequency noise in the circuit.

The specific assembly process of this embodiment is as follows:

First, fill the rectifier core 3 in the left rectangular sunken box structure of the coupling bracket 1, and pour it into the left area of the coupling bracket 1 from the potting surface; 8 and the transfer end of the wiring copper bar 2 are electrically connected by bolts.

Next, install the first rectifier block 5 , the rectifier device 7 and the second rectifier block 6 into the second installation groove 112 , the third installation groove 113 and the fourth installation groove 114 on the right side of the coupling bracket 1 , respectively. The terminals of each rectifier device 7 are connected in series between the two lead plates of the copper wiring bar 2 through the caliper 21 . First insert the first lower rectifier unit 52 and the second lower rectifier unit 62 into the side extraction holes below the corresponding installation slots, and then insert the first upper rectifier unit 51 into the second installation slot 112, and then insert the second upper rectifier unit 51 into the second installation slot 112. The rectifying unit 61 is inserted into the third installation groove 113 .

So far, the installation process of the coupling rectifier device for a novel motor controller of the present embodiment is completed. Subsequently, the input end of the wiring copper bar 2 is connected to the power supply system of the whole vehicle, and the output copper bar 9 is connected to the power module, so that the superior purification performance of the present invention can be realized.

The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make many modifications and changes according to the concept of the present invention without creative efforts. Therefore, all technical solutions that can be obtained by those skilled in the art through logical analysis, reasoning or limited experiments on the basis of the prior art according to the concept of the present invention shall fall within the protection scope determined by the claims.

Claims (10)

1. A coupling rectifying device for a motor controller is characterized by comprising a coupling support (1), a wiring copper bar (2), a rectifying core (3), a rectifying ring (4), a first rectifying block (5), a second rectifying block (6) and a rectifying device (7);

the coupling support (1) comprises a core mounting groove (12) and a rectifying frame (11) distributed on one side of the core mounting groove (12), the rectifying core (3) is arranged in the core mounting groove (12), one side, facing the rectifying frame (11), of the rectifying core (3) is provided with a switching copper bar (8), and the opposite side is provided with an output copper bar (9);

including first mounting groove (111), second mounting groove (112), third mounting groove (113) and fourth mounting groove (114) that set gradually on rectifier frame (11), wiring copper bar (2) pass first mounting groove (111), second mounting groove (112), third mounting groove (113) and fourth mounting groove (114) in proper order, install in first mounting groove (111) inner ring wiring copper bar (2) rectifier ring (4), install in second mounting groove (112) inner ring wiring copper bar (2) first rectifier block (5), second rectifier block (6) are installed in fourth mounting groove (114) inner ring wiring copper bar (2), rectifier device (7) are installed and are connected wiring copper bar (2) in third mounting groove (113), the one end of wiring copper bar (2) passes first mounting groove (111) as the wiring end, and the other end passes fourth mounting groove (114) connection copper bar switching (8).

2. The coupling rectifying device for the motor controller according to claim 1, wherein the core mounting groove (12) is a box structure with an open top end, the output copper bar (9) and the switching copper bar (8) are both n-shaped metal sheets, and the grooves of the n-shaped metal sheets are embedded in the side wall of the core mounting groove (12).

3. The coupling rectifying device for the motor controller according to claim 1, wherein the rectifying core (3) comprises a plurality of non-polar cores (31), and the plurality of non-polar cores (31) are fixed in the core mounting groove (12) by epoxy potting.

4. A coupling rectifying device for a motor controller according to claim 3, characterized in that said non-polar core (31) has an elliptical cross section, and the number is at least three.

5. The coupling rectifying device for the motor controller according to claim 1, wherein the first rectifying block (5) comprises a first upper rectifying unit (51) and a first lower rectifying unit (52), the first upper rectifying unit (51) is "mountain" shaped, the wiring copper bar (2) divides the second mounting groove (112) into three cavities, the first lower rectifying unit (52) is located at the bottom of the second mounting groove (112) and under the wiring copper bar (2), and three protrusions of the first upper rectifying unit (51) are inserted into the three cavities and then closely attached to the first lower rectifying unit (52) at the bottom.

6. The coupling rectifying device for the motor controller according to claim 5, wherein the second rectifying block (6) comprises a second upper rectifying unit (61) and a second lower rectifying unit (62), the second upper rectifying unit (61) is "mountain" -shaped, the wiring copper bar (2) divides the fourth mounting groove (114) into three cavities, the second lower rectifying unit (62) is located at the bottom of the fourth mounting groove (114) and under the wiring copper bar (2), and three protrusions of the second upper rectifying unit (61) are inserted into the three cavities and then closely attached to the second lower rectifying unit (62) at the bottom.

7. The coupling rectifying device for the motor controller according to claim 6, wherein side drawing openings (13) are formed at bottom portions of side walls of the second mounting groove (112) and the fourth mounting groove (114), and the first lower rectifying unit (52) and the second lower rectifying unit (62) are mounted in the second mounting groove (112) and the fourth mounting groove (114) through the side drawing openings (13).

8. The coupling rectifying device for the motor controller as claimed in claim 1, wherein the third mounting groove (113) is divided into a plurality of mounting cavities by the wiring copper bar (2) and the rib plate, the wiring copper bar (2) is provided with a pair of calipers (21) protruding upwards, and the rectifying devices (7) are correspondingly mounted in the respective mounting cavities and connected with the calipers (21) on the wiring copper bar (2).

9. The coupling rectifying device for the motor controller as claimed in claim 1, wherein the rectifying ring (4) is a magnetic ring formed by winding a nano metal film material.

10. The coupled rectifying device for the motor controller according to claim 1, wherein the first rectifying block (5) and the second rectifying block (6) are manganese zinc and nickel zinc composite modules.

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