CN115515404A - High power density motor controller structure assembly - Google Patents

Abstract

The invention discloses a high power density motor controller structural assembly, comprising a controller housing, a cooling assembly is fixed inside the controller housing, the cooling assembly has two cooling surfaces and the two cooling surfaces are connected to the The two ends of the controller housing face each other, and the two cooling surfaces of the cooling assembly are attached with three groups of corresponding low-power modules, and the corresponding groups of small-power modules are electrically connected to each other. In the present invention, by arranging the cooling assembly between the two ends of the controller housing, a plurality of low-power modules are attached to the two cooling surfaces of the cooling assembly, so that the cooling area of the cooling assembly is doubled, so that multiple The structure of parallel connection of small power modules reduces the cost, greatly reduces the area occupied by the bottom of the controller housing by adopting the scheme of parallel connection of small power modules, reduces the cost, and can also reduce the volume of the controller.

Description

A High Power Density Motor Controller Structural Assembly

technical field

The invention relates to the technical field of motor control modules, in particular to a structural assembly of a high power density motor controller.

Background technique

As a key component of electric vehicles, motor controllers play an important role in vehicle design; with the gradual increase in the demand for miniaturization and light weight of vehicle components, the lightweight and miniaturization of motor controllers is becoming increasingly urgent.

Existing motor controllers generally install and fix interfaces on the controller casing, and install power modules, capacitors, control modules, low-voltage connectors and other components on the casing; for controllers with high heat dissipation requirements, generally A cooling water circuit needs to be installed, so the existing motor controllers are generally large in size; for large-capacity motor controllers, sometimes in order to save costs, two smaller power modules are used in parallel to replace the larger power module.

Problems existing in the existing motor controllers: the controller is large in size, the structural layout of components is not compact enough, and the space utilization rate in the controller is low; The size and cost of the power converter also increase accordingly, and the scheme of using smaller power modules in parallel to replace larger power modules increases the number of power modules, although the cost is reduced, but because the small power The cooling water road arranged on the surface increases the bottom area of the motor controller and further increases the volume of the motor controller.

Contents of the invention

The main purpose of the present invention is to provide a high power density motor controller structure assembly, which solves the problems of unreasonable internal layout and low space utilization of the motor controller mentioned in the background art, resulting in a large volume.

To achieve the above object, the present invention provides the following technical solutions:

A structural assembly of a high power density motor controller, including a controller housing, a cooling assembly is fixed inside the controller housing, the cooling assembly has two cooling surfaces and the two cooling surfaces are connected to the controller The two ends of the housing are facing each other, and the two cooling surfaces of the cooling assembly are respectively attached with three groups of corresponding small power modules, and the corresponding small power modules of each group are electrically connected;

The controller housing is also provided with a capacitor assembly, a control module, an input terminal, and a low-voltage plug-in. The capacitor assembly is electrically connected to three groups of the small power modules, and the input terminal is electrically connected to the capacitor assembly. The low-voltage plug-in is electrically connected to the control module.

Preferably, the capacitor assembly is provided with a joint, and the low power module is electrically connected to the capacitor assembly through the joint.

Preferably, the controller housing is provided with a wire socket, the input terminal is mounted on the wire socket, an interface is provided on the capacitor assembly, and the input terminal is electrically connected to the interface of the capacitor assembly, so The terminal of the input terminal away from the interface of the capacitor component passes through the controller housing.

Preferably, the side wall of the controller housing is open and fixes the low-voltage plug-in.

Preferably, the controller housing includes a housing frame connected end to end, and an upper cover and a lower cover connected to the upper and lower end surfaces of the housing frame, and the cooling surface of the cooling assembly is parallel to the upper cover or the lower cover.

Preferably, the small power modules corresponding to each group are connected through conductive copper bars.

Preferably, the cooling surface of the cooling assembly is bonded to the small power module through an insulating heat conducting member.

Preferably, the cooling assembly includes a cooling water channel and a water inlet and a water outlet connected to both ends of the cooling water channel.

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

1. The present invention arranges the cooling assembly between the two ends of the controller housing, and attaches multiple low-power modules to the two cooling surfaces of the cooling assembly, so that the cooling area of the cooling assembly can be doubled, so that it can be used The structure of parallel connection of multiple small power modules reduces the cost, greatly reduces the area occupied by the bottom of the controller housing by using the small power module parallel connection scheme, reduces the cost, and can also reduce the volume of the controller;

2. The present invention reduces the wiring by connecting the capacitor component and the small power module through the joint, and connects the capacitor component and the input terminal through the interface, so that the assembly of the motor controller is faster, the structure is more compact, and the connection stability is also more excellent. ; At the same time, each component is matched with the structure of the controller shell through profiling design, which further improves the space utilization rate inside the controller and reduces the volume of the motor controller.

Description of drawings

Fig. 1 is a schematic diagram of an explosion structure of an embodiment of the present invention;

Fig. 2 is a schematic cross-sectional view of the front view structure of the embodiment of the present invention.

In the figure: 1. Shell frame; 2. Lower cover; 3. Upper cover; 4. Capacitor component; 5. First power module; 6. Second power module; 7. Cooling component; 8. Conductive copper bar; 9 1. The first control module; 10. The second control module; 11. The low-voltage plug-in; 12. The input terminal; 13. The terminal block; 14. The motor;

701, water inlet; 702, water outlet.

detailed description

The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.

Referring to Fig. 1 and Fig. 2, the embodiment of the present invention discloses a high power density motor controller structural assembly, including a controller housing, a cooling assembly 7 is fixed inside the controller housing, the cooling assembly 7 has two cooling surfaces and The two cooling surfaces are opposite to the two ends of the controller housing, and the two cooling surfaces of the cooling assembly 7 are attached with three groups of corresponding low-power modules, and each group of corresponding low-power modules is electrically connected.

Specifically, referring to FIG. 1, the controller housing includes a housing frame 1 connected end to end and an upper cover 3 and a lower cover 2 connected to the upper and lower end surfaces of the housing frame. The upper cover and the lower cover 2 are arranged in parallel, and the cooling assembly 7 It is located between the upper cover 3 and the lower cover 2 in the controller housing, and its cooling surface is parallel to the upper cover 3 (that is, also parallel to the lower cover 2). In the prior art, the cooling water circuit is often installed on one end surface of the controller housing, so that when cooling the power assembly, the power assembly can only be installed on one side of the cooling water circuit, but in the present invention, the cooling assembly 7 If it is installed in the middle of the controller housing, the two cooling surfaces of the cooling assembly 7 can cool the power assembly. Therefore, the present invention adopts three groups of corresponding small power modules, and each group of small power modules is connected in parallel. Three holes are drilled on the lower cover 2 of the device housing, and three groups of parallel small power modules are connected with the three phases of the motor 14 through cables. In this embodiment, six small power modules are provided, which are three first power modules 5 arranged on the front of the cooling assembly 7 and three second power modules 6 arranged on the back of the cooling assembly 7, each first Each of the power modules 5 is connected with a second power module 6 . Of course, more small power modules in each group can be provided as required, as long as the small power modules in each group are connected in parallel.

Exemplarily, the first power module 5 and the second power module 6 of this embodiment are connected through a conductive copper bar 8, and the conductive copper bar 8 is correspondingly connected with the three-phase cable of the motor.

Specifically, referring to FIG. 2 , the cooling assembly 7 includes a cooling water channel and a water inlet 701 and a water outlet 702 connected to both ends of the cooling water channel. 702 is fixed to the opening, and the cooling material is transferred through the water inlet 701 and the water outlet 702, so as to absorb heat and cool down the small power components. Exemplarily, the substance used for cooling in the cooling assembly 7 may be cooling water, or cooling oil, etc., as long as it can perform heat exchange to cool down the low-power components.

Preferably, in order to improve the heat transfer efficiency between the cooling assembly 7 and the low-power module, the cooling surface of the cooling assembly 7 of the present invention and the small-power module are closely bonded through insulating and heat-conducting parts, and the low-power The heat of the modules is quickly transferred to the cooling surface of the cooling assembly 7 . Exemplarily, materials such as heat-conducting silicone grease, heat-conducting silicone sheet, and heat-conducting adhesive of the insulating heat-conducting member.

The controller housing is also provided with a capacitor assembly 4, a control module, an input terminal 12, and a low-voltage plug-in 13. The capacitor assembly 4 is electrically connected to three groups of small power modules. The input terminal 12 is electrically connected to the capacitor assembly 4, and the low-voltage plug-in 13 is electrically connected. Connected to the control module.

Further, the capacitive component 4 is provided with connectors, and the low power module is electrically connected to the capacitive component 4 by inserting the connectors. By reserving joints on the capacitor assembly 4 in advance, the assembly of the small power module and the capacitor assembly is quicker.

Further, a terminal block 13 is provided inside the controller casing, and two through holes are provided on the side of the controller casing. The input terminal 12 is installed on the terminal block 13, and the positive and negative plugs of the input terminal 12 pass through the through holes and are located on the On the outside of the controller housing, an interface is provided on the capacitor assembly 4 , and the input terminal 12 is electrically connected to the interface of the capacitor assembly 4 . The present invention makes the connection between the input terminal 12 and the capacitor component 4 more stable by fixing the connecting part of the input terminal 12 and the capacitor component 4 on the wire base 13 .

Further, the side wall of the controller housing of the present invention is open and fixes the low-voltage plug-in 13 . The control module in this embodiment includes a first control module 9 and a second control module 10 , and the low-voltage plug-in 13 is electrically connected to the first control module 9 and the second control module 10 respectively. Exemplarily, the low-voltage plug-in 13 may be a pin structure.

Capacitor component 4 is connected to high-voltage direct current through input terminal 12, and converts high-voltage direct-current signal into alternating-current signal through small power module to control motor 14 to work, and low-voltage plug-in 13 is connected to low-voltage direct current to supply power for low-voltage control components such as control module.

During motor 14 operation, direct current enters controller by motor controller input end of the present invention, direct current is transformed into three-phase alternating current by controller, and the three-phase cable connection of controller output end and motor 14, realizes motor controller to motor 14 control.

In the present invention, the shape of the controller housing and the shapes of the internal components are profiled, so that the layout of the controller housing and the structures of the internal components is more compact. For example, with reference to the structure of this embodiment, the two opposite corners of the controller housing are chamfered, one chamfered position is provided with a capacitor component 4, and the capacitor component 4 is also subjected to corresponding chamfering, and the other chamfered position is set to be chamfered accordingly. The corner treated first control module 9 is provided with a low-voltage plug-in 13 on its side, and the second control module 10 is vertically arranged between the low-voltage plug-in 13 and the cooling assembly, thereby reducing the bottom area of the controller, thereby reducing the size of the motor controller.

In summary, the motor controller structural assembly of the present invention has the following advantages:

1. Some components of the present invention are adapted to the controller shell structure through profiling design, so that the internal space utilization rate of the motor controller is high, and the volume of the controller is reduced;

2. Compared with the large-capacity motor controller, two small-power modules are used in parallel to replace the high-power module to reduce costs; and by installing small-power modules on both cooling surfaces of the cooling assembly, the utilization rate of the cooling water surface area is increased. Reduce the area of cooling components and the bottom area of the controller;

3. Reasonable use of the vertical space inside the motor controller makes the components of the motor controller compact in structure, and the space utilization rate in the controller is high, further reducing the volume of the controller.

It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply that there is a relationship between these entities or operations. There is no such actual relationship or order between them. Furthermore, the term "comprises", "comprises" or any other variation thereof is intended to cover a non-exclusive inclusion such that a process, method, article or apparatus comprising a set of elements includes not only those elements, but also includes elements not expressly listed. other elements of or also include elements inherent in such a process, method, article, or device.

Although the embodiments of the present invention have been shown and described, those skilled in the art can understand that various changes, modifications and substitutions can be made to these embodiments without departing from the principle and spirit of the present invention. and modifications, the scope of the invention is defined by the appended claims and their equivalents.

Claims (8)

1. A high power density motor controller structural assembly, characterized in that it comprises a controller housing, a cooling assembly is fixed inside the controller housing, the cooling assembly has two cooling surfaces and two cooling The surface is opposite to the two end surfaces of the controller housing, and the two cooling surfaces of the cooling assembly are respectively attached with three groups of corresponding small power modules, and the corresponding small power modules of each group are electrically connected; The controller housing is also provided with a capacitor assembly, a control module, an input terminal, and a low-voltage plug-in. The capacitor assembly is electrically connected to three groups of the small power modules, and the input terminal is electrically connected to the capacitor assembly. The low-voltage plug-in is electrically connected to the control module. 2 . The structural assembly of the motor controller according to claim 1 , wherein a connector is provided on the capacitor component, and the low power module is electrically connected to the capacitor component through the connector. 3 . 3. The structural assembly of the motor controller according to claim 1, wherein a wire socket is arranged inside the controller housing, the input terminal is mounted on the wire socket, and an interface is arranged on the capacitor assembly , the input terminal is electrically connected to the interface of the capacitor component, and the terminal of the input terminal away from the interface of the capacitor component passes through the controller casing. 4 . The structural assembly of the motor controller according to claim 1 , wherein the side wall of the controller housing is open and fixes the low-voltage plug-in. 5 . 5. The motor controller structural assembly according to claim 1, wherein the controller housing comprises a housing frame connected end to end and an upper cover and a lower cover connected to the upper and lower end surfaces of the housing frame, The cooling surface of the cooling assembly is parallel to the upper cover or the lower cover. 6 . The motor controller structural assembly according to claim 1 , wherein the small power modules corresponding to each group are connected by conductive copper bars. 7 . 7 . The motor controller structural assembly according to claim 1 , wherein the cooling surface of the cooling assembly is bonded to the small power module through an insulating and heat conducting member. 8 . 8 . The structural assembly of the motor controller according to claim 1 , wherein the cooling assembly comprises a cooling water channel and a water inlet and a water outlet connected to two ends of the cooling water channel.

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