CN115665984A

CN115665984A - Electric vehicle controller and electric vehicle

Info

Publication number: CN115665984A
Application number: CN202211424203.4A
Authority: CN
Inventors: 陈夏新
Original assignee: Taizhou Lingxi Electronics Co ltd
Current assignee: Taizhou Lingxi Electronics Co ltd
Priority date: 2022-11-15
Filing date: 2022-11-15
Publication date: 2023-01-31

Abstract

The application belongs to the electric vehicle controller field, provides an electric vehicle controller, includes: a circuit board; the power tubes are welded on the circuit board and are configured into upper bridge arm power tubes and lower bridge arm power tubes of a first phase, a second phase and a third phase; the bridge arm power tube comprises at least 3 lower bridge arm thermal relays thermally connected with the back surface of a metal back plate of the lower bridge arm power tube, and at least 1 upper bridge arm thermal relay thermally connected with the back surface of the metal back plate of the upper bridge arm power tube; the upper bridge arm power tubes and the lower bridge arm power tubes of the first phase and the second phase are positioned on a first side of the circuit board and are arranged into four rows in the arrangement direction of three pins of a single power tube, and the upper bridge arm power tubes and the lower bridge arm power tubes of the third phase are arranged into two rows on a second side opposite to the first side. The application also provides an electric vehicle. The method and the device can achieve the purpose of enabling the internal structure layout of the electric vehicle controller to be reasonable, and can be suitable for high-power electric vehicle controllers.

Description

Electric vehicle controller and electric vehicle

Technical Field

The application belongs to the technical field of electric vehicle controllers, and particularly relates to an electric vehicle controller and an electric vehicle.

Background

In the prior art, a three-phase motor is generally used for driving an electric vehicle to move, and an electric vehicle controller is used for controlling the three-phase motor to control the movement of the electric vehicle. In the electric vehicle controller, the output power of the electric vehicle controller is determined based on the number and specifications of the power tubes included therein, and the output power of the electric vehicle controller determines the control performance of the electric vehicle.

Along with the higher and higher requirements of consumers on the performance of the electric vehicle, the power requirement of the electric vehicle controller is higher and higher, the number of the power tubes is more and more, the number of the power tubes not only determines the power of the electric vehicle controller, but also influences the internal structure and the volume of the electric vehicle controller.

If the reasonable structural layout design is not carried out on the power tube, the problems of complex internal structure, overlarge volume and the like of the electric vehicle controller are inevitably caused. Therefore, how to design the reasonable structural layout of the power tube makes the internal structural layout of the electric vehicle controller more reasonable and the volume controlled, which is one of the problems to be solved urgently in the application of the high-power electric vehicle controller.

Disclosure of Invention

The embodiment of the application provides an electric vehicle controller, and aims to solve the technical problems that how to reasonably design the structural layout of a large number of power tubes in a high-power electric vehicle controller, so that the internal structural layout of the electric vehicle controller is reasonable, and the volume of the electric vehicle controller is controlled.

The embodiment of the present application is implemented as follows, an electric vehicle controller includes:

a circuit board;

a plurality of power tubes welded on the circuit board and configured into an upper bridge arm power tube and a lower bridge arm power tube of a first phase, a second phase and a third phase; and

the bridge arm power tube comprises at least 3 lower bridge arm thermal relays thermally connected with the back surface of the metal back plate of the lower bridge arm power tube, and at least 1 upper bridge arm thermal relay thermally connected with the back surface of the metal back plate of the upper bridge arm power tube;

the upper bridge arm power tubes and the lower bridge arm power tubes of the first phase and the second phase are positioned on a first side of the circuit board and are arranged in four rows in the arrangement direction of three pins of a single power tube, and the upper bridge arm power tubes and the lower bridge arm power tubes of the third phase are arranged in two rows on a second side opposite to the first side.

Furthermore, the upper bridge arm power tube and the lower bridge arm power tube of the third phase are arranged in the same direction and/or perpendicular to the arrangement direction of the three pins of the single power tube.

Furthermore, the upper bridge arm power tube and the lower bridge arm power tube of the third phase are arranged in a straight line with the upper bridge arm power tube and the lower bridge arm power tube of the first phase or the second phase.

Still further, the electric vehicle controller further includes a terminal electrically connected to the thermal relay;

the terminals include a positive terminal and a three-phase output terminal.

Further, in the present invention,

the positive terminal is arranged between the upper bridge arm power tube and the lower bridge arm power tube of the first phase or the third phase;

any one phase output terminal in the three-phase output terminals is arranged between the upper bridge arm power tube and the lower bridge arm power tube of the second phase;

the other two-phase output terminals in the three-phase output terminals are arranged on the second side;

the three-phase output terminals are arranged in a row along the arrangement direction of the three pins of the single power tube.

Furthermore, the electric vehicle controller further comprises a front thermal relay thermally connected with the front sides of the metal back plates of the upper bridge arm power tubes and the lower bridge arm power tubes of the first phase, the second phase and the third phase.

Further, the terminal is integrally formed with the heat relay body.

The present application further provides an electric vehicle, which includes:

a three-phase motor; and

according to any one of the electric vehicle controllers, a three-phase line interface of the three-phase motor is electrically connected with a three-phase output of the controller.

In the application, the upper bridge arm power tubes and the lower bridge arm power tubes of the first phase and the second phase are distributed on the first side of the circuit board, the upper bridge arm power tubes and the lower bridge arm power tubes of the two phases are further arranged in four rows in the arrangement direction of three pins of a single power tube, the upper bridge arm power tubes and the lower bridge arm power tubes of the third phase are arranged in two rows on the second side of the circuit board, the power tubes are more regularly and compactly distributed in the electric vehicle controller, the arrangement is more reasonable, the electric design of the electric vehicle controller and the arrangement of other components are facilitated, the internal structural layout of the electric vehicle controller is more reasonable, the size can be controlled, the electric vehicle controller is suitable for a high-power electric vehicle controller, and meanwhile, through the combination of at least one upper bridge arm heat relay and at least three lower bridge arm heat relays, the heat of the three phases can be effectively radiated, the normal work of the power tubes is ensured, and the normal operation of the electric vehicle controller is further ensured.

Drawings

Fig. 1 is a schematic perspective view of an electric vehicle controller according to an embodiment of the present application;

fig. 2 is a three-dimensional disassembled schematic view of an electric vehicle controller provided in the embodiment of the present application;

fig. 3 is a schematic structural diagram of a partial structure of an electric vehicle controller according to an embodiment of the present disclosure;

fig. 4 is a schematic structural diagram of a partial structure of an electric vehicle controller according to another embodiment of the present application;

fig. 5 is a schematic structural diagram of a partial structure of an electric vehicle controller according to still another embodiment of the present disclosure;

FIG. 6 is a schematic perspective view of a portion of the electric vehicle controller shown in FIG. 3;

FIG. 7 is a perspective view of a thermal relay in the electric vehicle controller shown in FIG. 3;

FIG. 8 is a disassembled perspective view of the thermal relay shown in FIG. 7;

FIG. 9 is a schematic perspective view of a circuit board of the electric vehicle controller shown in FIG. 3;

fig. 10 is a schematic perspective view of a power tube according to an embodiment of the present application;

fig. 11 is a schematic perspective view illustrating a vertical installation of a power tube according to an embodiment of the present disclosure;

fig. 12 is a schematic perspective view illustrating an oblique installation of a power tube according to an embodiment of the present application;

fig. 13 is a schematic view illustrating an assembly of a front thermal relay and a power tube according to an embodiment of the present application;

fig. 14 is another schematic assembly diagram of a front thermal relay and a power tube according to an embodiment of the present disclosure;

fig. 15 is a schematic structural diagram of an electric vehicle according to an embodiment of the present application.

Detailed Description

In order to make the objects, technical solutions and advantages of the present application more clearly understood, the present application is further described in detail below with reference to the accompanying drawings and embodiments. Examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are exemplary only for the purpose of explaining the present application and are not to be construed as limiting the present application. Furthermore, it should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application.

In the description of the present application, it is to be understood that the orientation or positional relationship indicated in the description of the direction and positional relationship is based on the orientation or positional relationship shown in the drawings, and is only for convenience of description and simplification of the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present application.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", may explicitly or implicitly include one or more of the described features. In the description of the present application, "a plurality" means two or more unless specifically limited otherwise.

The following disclosure provides many different embodiments, or examples, for implementing different features of the application. In order to simplify the disclosure of the present application, specific example components and arrangements are described below. Of course, they are merely examples and are not intended to limit the present application. Moreover, the present application may repeat reference numerals and/or letters in the various examples, which have been repeated for purposes of simplicity and clarity and do not in themselves dictate a relationship between the various embodiments and/or arrangements discussed. In addition, examples of various specific processes and materials are provided herein, but one of ordinary skill in the art may recognize applications of other processes and/or use of other materials.

In the application, the upper bridge arm power tubes and the lower bridge arm power tubes of the first phase and the second phase are distributed on the first side of the circuit board and are arranged in four rows in the arrangement direction of three pins of a single power tube, the upper bridge arm power tubes and the lower bridge arm power tubes of the third phase are arranged in two rows on the second side of the circuit board, the arrangement of the power tubes in the electric vehicle controller is more regular and compact, the distribution is more reasonable, and the internal structural distribution of the electric vehicle controller is more reasonable so as to control the volume of the electric vehicle controller.

Example one

Referring to fig. 1 to 8, an electric vehicle controller 100 of the present application includes:

a circuit board 10;

a plurality of power tubes 20 soldered to a circuit board 10, and an upper arm power tube 202 and a lower arm power tube 201 arranged in a first phase, a second phase, and a third phase; and

at least 1 upper bridge arm thermal relay 301 thermally connected to the back of the metal back plate of the upper bridge arm power tube 202, and at least 3 lower bridge arm thermal relays 302 thermally connected to the back of the metal back plate 21 of the lower bridge arm power tube 201;

the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase are located on the first side 11 of the circuit board 10, and are arranged in four rows in the arrangement direction of the three pins of the single power tube 20, and the upper arm power tubes 202 and the lower arm power tubes 201 of the third phase are arranged in two rows on the second side 12 opposite to the first side 11.

In the electric vehicle controller 100 of the present application, the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase are disposed on the first side 11 of the circuit board 10, and further the upper arm power tubes 202 and the lower arm power tubes 201 of the two phases are arranged in four rows in the arrangement direction of three pins of a single power tube 20, and the upper arm power tubes 202 and the lower arm power tubes 201 of the third phase are arranged in two rows on the second side 12 of the circuit board 10, the arrangement of the power tubes 20 in the electric vehicle controller 100 is more regular and compact, the layout is more reasonable, which facilitates the electrical design of the electric vehicle controller 100 and the arrangement of other components, so that the internal configuration layout of the electric vehicle controller 100 is more reasonable to control the volume, and the electric vehicle controller 100 can be applied to a high-power electric vehicle controller 100.

Meanwhile, through the combination of at least 1 upper arm thermal relay 301 and at least 3 lower arm thermal relays 302, the three-phase upper arm power tube 202 and lower arm power tube 201 can be effectively radiated, so that the normal operation of the power tube 20 is ensured, and the normal operation of the electric vehicle controller 100 is further ensured.

In the embodiment of the present application, the electric vehicle controller 100 may be a three-phase motor controller, which is applied to the electric vehicle 1000 to provide three-phase output, so as to realize accurate control of the motor of the electric vehicle 1000 and the electric vehicle 1000. The controller of the three-phase motor 200 is a controller commonly used in the field of the electric vehicle 1000, and the functions and advantages thereof are not described herein.

Referring to fig. 3 and 10, in the embodiment of the present invention, the power transistor 20 may be a direct-insert visible metal-packaged power transistor 20, which is formed by packaging three pins 22 and a metal back plate 21 together by a plastic package, where the three pins 22 are a gate, a drain and a source, respectively, and are arranged in a row on the plastic package, the metal back plate 21 is electrically connected to the drain, and the power transistor 20 is soldered to the circuit board 10 through the three pins 22 to be fixed on the circuit board 10.

The arrangement direction of the three pins 22 of the power tube 20 determines the relative position relationship between the power tube 20 and the circuit board 10, the arrangement direction of the three pins 22 on the power tube 20 is fixed, and the three pins 22 are welded on the circuit board 10 and can be in a transverse direction, a longitudinal direction or an inclined direction, so that the power tubes 20 in a row can be in a transverse direction, a longitudinal direction or an inclined direction on the circuit board 10 and are arranged in an extending manner in different directions.

With reference to fig. 3 to fig. 6, the circuit board 10 is further provided with a signal control module 13 and circuit components of the electric vehicle controller 100, the signal control module 13 is, for example, a control chip and a signal pin, the position of the signal control module 13 on the circuit board 10 needs to be separated from the position of the power tube 20 on the circuit board 10 to avoid mutual interference, and the arrangement of the power tube 20 on the circuit board 10 has a direct influence on the layout of other components on the circuit board 10.

In the embodiment of the present application, the upper arm thermal relay 301 is thermally connected to the back surface of the metal back plate 21 of the upper arm power tube 202, that is, the upper arm thermal relay 301 can absorb heat transferred from the upper arm power tube 202, and the lower arm thermal relay 302 is thermally connected to the back surface of the metal back plate 21 of the lower arm power tube 201, that is, the lower arm thermal relay 302 can absorb heat transferred from the lower arm power tube 201.

On the basis that the power tubes 20 are configured as the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase, the second phase and the third phase, at least one upper arm thermal relay 301 and at least three lower arm thermal relays 302 are configured to pertinently, quickly and effectively conduct heat and dissipate heat to the three-phase upper arm power tubes 202 and the three-phase lower arm power tubes 201, so as to ensure the operation safety of the electric vehicle controller 100 and improve the working reliability of the electric vehicle controller 100.

Upper arm thermal relay 301 and lower arm thermal relay 302 are collectively referred to as thermal relay 30, and in the present embodiment, are specifically defined by the specific functions of thermal relay 30, that is, thermal relay 30 thermally connected to upper arm power tube 202 is defined as upper arm thermal relay 301, and thermal relay 30 thermally connected to lower arm power tube 201 is defined as lower arm thermal relay 302.

Where some of the following does not relate to a specific function, the thermal relay 30 will be described as an example for a brief description.

Further, the upper arm thermal relay 301 is in conductive thermal connection with the metal back plate 21 of the upper arm power tube 202, and the lower arm thermal relay 302 is in conductive thermal connection with the metal back plate 21 of the lower arm power tube 201, where the conductive thermal connection can be understood as that the thermal relay 30 is in direct contact with the metal back plate 21 of the power tube 20, and the two can conduct electricity and conduct heat, and can also be understood as that the thermal relay 30 is in indirect contact with the metal back plate 21 of the power tube 20 through other elements, so as to implement indirect conduction and heat conduction.

In the embodiment of the present application, the electrically and thermally conductive connection means that the thermal relay 30 directly contacts the metal back plate 21 of the power tube 20 to conduct electricity and heat, and the purpose of electrically and thermally conductive connection can be achieved by contacting any part of the thermal relay 30 and the metal back plate 21, for example, contacting the parts of the thermal relay 30, such as the front surface, the back surface and/or the side surface of the metal back plate 21. The back surface of the metal back plate 21 of the power transistor 20 is the lower surface of the metal back plate 21 shown in fig. 10, and the upper surface is the front surface of the metal back plate 21.

It can be understood that the back surface of the metal back plate 21 has a larger area than the front surface, and has a larger contact area with the thermal relay 30, so that the thermal relay 30 is in contact with the back surface of the metal back plate 21 of the power tube 20, and can conduct electricity and heat to the power tube 20 in a larger area, thereby ensuring stability of electrical connection and efficient heat conduction and dissipation effects.

In order to ensure the electrical and thermal conductivity of the thermal relay 30, the thermal relay 30 in the embodiment of the present application is made of metal, which includes but is not limited to copper and/or aluminum and/or copper-aluminum composite, so that the structural strength of the thermal relay 30 can be improved, and the excellent electrical and thermal conductivity and heat dissipation effects can be achieved.

In a preferred embodiment, the row of upper bridge arm power tubes 202 of the first phase and the row of upper bridge arm power tubes 202 of the second phase are arranged side by side, or the row of lower bridge arm power tubes 201 of the first phase and the row of lower bridge arm power tubes 201 of the second phase are arranged side by side, on the basis that the metal back plates 21 of the two rows of power tubes 20 are not in contact, the interval between the two rows of power tubes 20 can be set to be smaller, so that the area occupied by the power tubes 20 on the circuit board 10 can be controlled, and further, the arrangement of other components is facilitated.

In addition, when the row of upper arm power tubes 202 of the first phase and the row of upper arm power tubes 202 of the second phase are arranged side by side, based on the electrical characteristics of the upper arm power tubes 202, the row of upper arm power tubes 202 of the first phase and the row of upper arm power tubes 20 of the second phase can be electrically connected to one upper arm thermal relay 301 in common, and the one upper arm thermal relay 301 is shared for conducting electricity and heat conduction, so that the upper arm thermal relay 301 does not need to be arranged correspondingly for the row of upper arm power tubes 202 of the first phase and the row of upper arm power tubes 202 of the second phase respectively, which not only facilitates assembly and disassembly, but also can save material cost, further control the cost of the electric vehicle controller 100, and improve production efficiency.

Furthermore, in the embodiment of the present application, three rows of the upper arm power tubes 202 of the first phase, the second phase, and the third phase may be electrically connected to one upper arm thermal relay 301 in common, and one upper arm thermal relay 301 is used for conducting and dissipating heat, so that at least one upper arm thermal relay 301 in the embodiment of the present application is provided.

It should be noted that, when the upper arm power tubes 202 of two phases share one upper arm thermal relay 301, and the upper arm power tube 202 of the other phase is spaced apart from the upper arm power tubes 202 of the two phases by a certain distance and needs to separately arrange the upper arm thermal relay 301 of the other phase, the upper arm thermal relay 301 of the one phase may be electrically and thermally connected to the upper arm thermal relay 301 of the previous phase by a connecting member with an electrically and thermally conductive function, so that the two upper arm thermal relays 301 of the two phases form the integrated upper arm thermal relay 301, that is, the two thermal relays 30 that are fixedly connected together may still be understood as one thermal relay 30.

Of course, in other embodiments, one upper arm thermal relay 301 may be respectively disposed corresponding to three rows of upper arm power tubes 202 of the first phase, the second phase, and the third phase, so that each upper arm power tube 202 of each phase has a corresponding conductive heat dissipation path.

In addition, in the embodiment of the present application, the number of rows of the lower arm power tubes 201 is the same as the number of the lower arm thermal relays 302, and if three rows of the first phase, the second phase, and the third phase of the lower arm power tubes 201 are provided, three lower arm thermal relays 302 are provided, and are respectively in corresponding thermal connection with the first phase, the second phase, and the third phase of the lower arm power tubes 201, so that effective heat dissipation of each phase of the lower arm power tubes 201 can be ensured.

In a preferred embodiment, the thermal relay 30 is made of aluminum.

Aluminum has a not very different conductive and heat conductive properties compared to copper, but is less expensive, can control the production cost of the electric vehicle controller 100, and is lighter in weight to control the mass of the electric vehicle controller 100.

In the embodiment of the present application, the power tube 20 may be mounted on the circuit board 10 in a horizontal, vertical or inclined mounting manner, specifically:

as shown in fig. 3 to 6, the metal back plate 21 of the power tube 20 horizontally mounted is parallel to the circuit board 10, and at this time, the portion of the thermal relay 30 contacting the metal back plate 21 of the power tube 20 is also parallel to the circuit board 10;

as shown in fig. 11, the metal back plate 21 of the power transistor 20 mounted vertically is perpendicular to the circuit board 10, and the portion of the thermal relay 30 contacting the metal back plate 21 may also be perpendicular to the circuit board 10;

as shown in fig. 12, the metal back plate 21 mounted obliquely as the power transistor 20 is inclined with respect to the circuit board 10, and at this time, the portion of the thermal relay 30 in contact with the metal back plate 21 is also inclined with respect to the circuit board 10.

That is, when the power tube 20 is mounted on the circuit board 10 in different mounting manners, the portion of the thermal relay 30 contacting the metal back plate 21 of the power tube 20 is always in the same direction as the power tube 20, so as to ensure that the two can be closely attached and contacted, thereby ensuring the heat conduction effect.

As a preferred example of the present application, the power tube 20 is mounted on the circuit board 10 in a horizontal mounting manner, and in this mounting manner, the power tube 20 occupies less space in the vertical direction in the electric vehicle controller 100, and is more convenient for the arrangement of the thermal relay 30.

In the embodiment of the present application, the first phase, the second phase and the third phase may be phases a, B and C, the first side 11 and the second side 12 of the circuit board 10 may be understood as a right side and a left side of the circuit board 10 in the length direction, as shown in fig. 3 to 6, the first side 11 is the right side of the circuit board 10, the second side 12 is the left side of the circuit board 10, and the arrangement direction of the three pins of the single power tube 20 is the length direction of the circuit board 10 and is the transverse direction shown in fig. 3 to 6.

Alternatively, the side of the circuit board where the upper arm power transistor 202 and the lower arm power transistor 201 of two phases are provided is understood as the first side 11, whereas the side of the circuit board where the upper arm power transistor 202 and the lower arm power transistor 201 of one phase are provided is understood as the second side 12.

Based on the above orientation, the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase are located on the first side 11 of the circuit board 10, and the four rows in the arrangement direction of the three pins 22 of the single power tube 20 can be understood as that the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase are located on the right side of the circuit board 10 and are arranged in four rows in the transverse direction of the circuit board 10, and the upper arm power tubes 202 and the lower arm power tubes 201 of the third phase are arranged in two rows on the second side 12 opposite to the first side 11, and that the upper arm power tubes 202 and the lower arm power tubes 201 of the third phase are arranged in two rows on the left side of the circuit board 10.

In the embodiment of the present application, the first phase, the second phase, and the third phase may correspond to any one of three phases a, B, and C, that is, the first phase may be any one of three phases a, B, and C, the second phase may be any one of three phases a, B, and C, and the third phase may be any one of three phases a, B, and C, as long as three-phase output can be satisfied, the number of the power tubes 20 is at least 6, and at least 6 power tubes 20 are configured as at least 3 upper arm power tubes 202 and at least 3 lower arm power tubes 201 of the three phases a, B, and C, which meet basic requirements of three-phase output of the electric vehicle controller 100.

The type, number, combination, and arrangement of the power tubes 20 are not specifically limited, and the type, number, combination, and arrangement of the power tubes 20 shown in the embodiment of the present application are only examples, and should not be construed as a limitation to the present application, and on the basis that the electric vehicle controller 100 is ensured to be capable of normally providing three-phase output, the above items of the power tubes 20 may be specifically selected according to the specific power requirement of the electric vehicle controller 100.

Illustratively, when there are 6 power transistors 20, the 6 power transistors 20 include three upper bridge arm power transistors 202 and three lower bridge arm power transistors 201, which are:

the three-phase inverter comprises an A-phase upper bridge arm power tube 2021, a B-phase upper bridge arm power tube 2022, a C-phase upper bridge arm power tube 2023, an A-phase lower bridge arm power tube 2011, a B-phase lower bridge arm power tube 2012 and a C-phase lower bridge arm power tube 2013.

The a-phase upper bridge arm power tube 2021, the B-phase upper bridge arm power tube 2022 and the C-phase upper bridge arm power tube 2023 are electrically connected to a positive electrode of a power supply and provide positive input of the power supply, and the a-phase lower bridge arm power tube 2011, the B-phase lower bridge arm power tube 2012 and the C-phase lower bridge arm power tube 2013 are electrically connected to the circuit board 10 and provide three-phase output of the electric vehicle controller 100.

In the above case, the single power tube 20 disposed on the circuit board 10 may be regarded as "one row", that is, the a-phase upper arm power tube 2021, the B-phase upper arm power tube 2022, the C-phase upper arm power tube 2023, the a-phase lower arm power tube 2011, the B-phase lower arm power tube 2012, and the C-phase lower arm power tube 2013 disposed on the circuit board 10 may be regarded as "one row", and in this case, the total 4 power tubes 20 of the first phase and the second phase in the a, B, and C phases are arranged in four rows in the arrangement direction of the pins 22 of the single power tube 20, that is, the 4 power tubes 20 are respectively arranged in one row.

Referring to fig. 3 to 6, in the embodiment shown in fig. 3, 8 power tubes 20 are arranged in one row, 6 rows of the upper arm power tubes 202 and the lower arm power tubes 201 of the three phases a, B, and C are total, and the total number of the power tubes 20 is 6 × 8=48, so that the electric vehicle controller 100 can provide a large output power.

Generally, with the layout of the power tubes 20 according to the embodiment of the present application, one row of power tubes 20 is at least 6, and the upper arm power tubes 202 and the lower arm power tubes 201 of the three phases a, B, and C are arranged in 6 rows, that is, the total number of the power tubes 20 is at least 6 × 6=36, so as to meet the power requirement of the high-power electric vehicle controller 100.

In the embodiment of the present application, the arrangement that the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase are located on the first side 11 of the circuit board 10, and are arranged in four rows in the arrangement direction of the three pins 22 of a single power tube 20, and the upper arm power tubes 202 and the lower arm power tubes 201 of the third phase are arranged in two rows on the second side 12 opposite to the first side 11 may be:

1. the phase A upper bridge arm power tube 2021, the phase A lower bridge arm power tube 2011, the phase B upper bridge arm power tube 2022 and the phase B lower bridge arm power tube 2012 are arranged on the first side 11, and the phase C upper bridge arm power tube 2023 and the phase C lower bridge arm power tube 2013 are arranged on the second side 12;

2. the phase A upper bridge arm power tube 2021, the phase C lower bridge arm power tube 2013, the phase C upper bridge arm power tube 2023 and the phase A lower bridge arm power tube 2011 are arranged on the first side 11, and the phase B upper bridge arm power tube 2022 and the phase B lower bridge arm power tube 2012 are arranged on the second side 12;

3. the phase B upper bridge arm power tube 2022, the phase C lower bridge arm power tube 2013, the phase C upper bridge arm power tube 2023 and the phase B lower bridge arm power tube 2012 are arranged on the first side 11, and the phase A upper bridge arm power tube 2021 and the phase A lower bridge arm power tube 2011 are arranged on the second side 12.

For example, referring to fig. 3 to fig. 6, assuming that the first phase, the second phase and the third phase are phase a, phase B and phase C, respectively, the arrangement direction of the three pins of the single power tube 20 is horizontal, the number of the power tubes 20 in a row is 8, the first side 11 is the right side of the circuit board 10, and the second side 12 is the left side of the circuit board 10, then:

the upper arm power tube 202 and the lower arm power tube 201 of the first phase are an a-phase upper arm power tube 2021 and an a-phase lower arm power tube 2011, the upper arm power tube 202 and the lower arm power tube 201 of the second phase are a B-phase lower arm power tube 2012 and a B-phase upper arm power tube 2022, the upper arm power tube 202 and the lower arm power tube 201 of the third phase are a C-phase lower arm power tube 2013 and a C-phase upper arm power tube 2023, and the three-phase upper arm power tube 202 and the three-phase lower arm power tube 201 are arranged as follows:

the circuit board 10 includes 8 a-phase upper arm power tubes 2021 arranged in a row on the right side thereof, 8B-phase upper arm power tubes 2022 arranged in a row, 8 a-phase lower arm power tubes 2011 arranged in a row, 8B-phase lower arm power tubes 2012 arranged in a row, and 8C-phase upper arm power tubes 2023 arranged in a row on the left side thereof, and 8C-phase lower arm power tubes 2013 arranged in a row.

The phase a upper bridge arm power tube 2021, the phase B upper bridge arm power tube 2022, the phase a lower bridge arm power tube 2011 and the phase B lower bridge arm power tube 2012 can be randomly distributed and arranged in four rows on the right side of the circuit board 10, for example, from top to bottom, the phase a upper power tube, the phase B upper power tube, the phase a lower power tube, the phase C upper bridge arm power tube 2023 and the phase C lower bridge arm power tube 2013 can be respectively arranged in a horizontal row, a vertical row or an oblique row on the left side of the circuit board 10, and other components on the circuit board 10 can be inserted into the space between any two adjacent rows of power tubes 20 or arranged on an empty area of the circuit board 10 where no power tube 20 is arranged, so as to improve the space utilization rate of the circuit board 10.

In a preferred embodiment, the upper arm power tube 202 and the lower arm power tube 201 of the same phase are disposed adjacent to each other, that is, the a-phase upper arm power tube 2021 and the a-phase lower arm power tube 2011 are adjacent to each other, the B-phase upper arm power tube 2022 and the B-phase lower arm power tube 2012 are adjacent to each other, and the C-phase upper arm power tube 2023 and the C-phase lower arm power tube 2013 are adjacent to each other, so that the power tubes 20 are conveniently mounted, and the electrical design of the electric vehicle controller 100 is also facilitated.

The above description of the structural layout of the upper arm power tube 202 and the lower arm power tube 201 of the three phases a, B, and C is only an example, and in other embodiments, the upper arm power tube 202 and the lower arm power tube 201 of the three phases a, B, and C may also have other structural layouts, and no specific limitation is made herein.

Referring to fig. 3 and 9, because two rows of power tubes 20 are disposed in the middle of the circuit board 10, in order to achieve effective conductive thermal connection between the back surface of the metal back plate 21 of the power tube 20 and the thermal relay 30, in the embodiment of the present invention, a through slot 14 is disposed at a corresponding position of the circuit board 10, the power tube 20 of the embodiment shown in fig. 3 is located in the upper half of the circuit board 10, and when a part of the power tube 20 is located in the opposite middle of the circuit board 10 (the part of the power tube 20 shown in fig. 3 is a lower bridge arm power tube 201), the metal back plate 21 of the part of the power tube 20 and the thermal relay 30 disposed below the circuit board 10 achieve conductive thermal connection through the through slot 14.

In some embodiments (not shown), when the power transistor 20 is located under the circuit board 10, the through-slot 14 is not required; in still other embodiments (not shown), when the front surface of the metal back plate of the power tube 20 is also provided with the thermal relay 30, the through-slots 14 can also be used to achieve an electrically conductive thermal connection between the metal back plate of the power tube 20 and the thermal relay 30 of the front surface. .

Except for the power tube 20 arranged in the middle of the circuit board 10, the embodiment of the present application further includes the power tube 20 arranged at the edge of the circuit board 10, at this time, the metal back plate 21 of the power tube 20 is close to the edge of the circuit board 10, and the thermal relay 30 is correspondingly arranged at the edge of the circuit board 10, so that the thermal relay 30 is correspondingly contacted with the back surface of the metal back plate 21 of the power tube 20 at the edge of the circuit board 10 to realize conductive thermal connection, and the edge of the circuit board 10 can also play a reference role for the arrangement of the power tube 20, so that the arrangement of the power tube 20 is more regular.

That is, in the embodiment of the present invention, if the power tube 20 is disposed at the internal position of the circuit board 10, the through groove 14 is formed in the circuit board 10, so that the thermal relay 30 can be inserted into the through groove 14 to be in corresponding contact with the back surface of the metal back plate 21 of the power tube 20, thereby implementing the conductive thermal connection, or the power tube 20 can be inserted into the through groove 14, so that the front surface of the metal back plate 21 is in corresponding contact with the thermal relay 30 at the front surface, thereby implementing the conductive thermal connection, and if the power tube 20 is disposed at the edge position of the circuit board 10, the thermal relay 30 is disposed at the edge of the circuit board 10 to be in corresponding contact with the back surface of the metal back plate 21 of the power tube 20, thereby implementing the conductive thermal connection.

Referring to fig. 1 to fig. 3, the electric vehicle controller 100 of the embodiment of the present application further includes a housing 40, the circuit board 10, the power tube 20 and the heat relay 30 are all disposed in the housing 40, and the heat relay 30 is electrically and thermally connected to the metal back plate 21 of the power tube 20, that is, the heat relay 30 can simultaneously achieve electrical and thermal conduction to the power tube 20, so as to ensure normal operation of the power tube 20.

On the other hand, the thermal relay 30 is thermally connected to the housing 40 in an insulating manner, so that a heat dissipation path from the power tube 20 to the thermal relay 30 to the housing 40 is established, and the heat generated by the power tube 20 is conducted to the housing 40 for effective heat dissipation on the premise of ensuring the electrical safety of the electric vehicle controller 100.

By insulating thermal connection it is understood that the thermal relay 30 is first insulated and non-conductive from the housing 40, and that the electrical current from the power tube 20 is prevented from passing to the housing 40 and causing short circuits or other hazards, and that the insulation between the thermal relay 30 and/or the housing 40 may be provided by applying an insulating coating or by spacing an insulating object between the two. Meanwhile, the housing 40 also has a certain heat conduction capability, so that the heat dissipation of the electric vehicle controller 100 can be realized on the premise that the heat relay 30 is in insulation contact with the electric vehicle controller 100 to ensure the electrical safety of the electric vehicle controller 100.

In addition, when an insulating material is selected to be interposed between the heat relay member 30 and the housing 40 to achieve an insulating connection therebetween, the insulating material also has a certain heat conduction capability.

Referring to fig. 1 and fig. 2, a housing 40 of the embodiment of the present application includes an upper housing 41 and a lower housing 42 detachably disposed in cooperation with each other.

The detachable setting between the upper casing 41 and the lower casing 42 can be realized through screw fastening, fastening fixation or rivet anchoring and other modes, the upper casing 41 and the lower casing 42 are combined to form an inner space, and the internal components of the electric vehicle controller 100, such as the circuit board 10, the power tube 20 and the thermal relay 30, are all arranged in the inner space, so that the components can be prevented from being influenced by external direct impact and water vapor impurities, and the normal use and the service life of the internal components are ensured.

Moreover, the upper casing 41 and the lower casing 42 can be made of metal or plastic, which has high enough hardness and strength and better ductility, so that the overall strength of the casing 40 can be improved, and the designed shape can be easily manufactured.

It is worth noting that at least a portion of the structure of at least one of the upper and

lower shells

41, 42 is made of metal, including but not limited to copper and/or aluminum and/or copper aluminum composite.

Referring to fig. 3, 7 and 8, in the embodiment of the present invention, the heat relay body 30 includes a heat absorbing portion 31 and an extending portion 32 extending from the heat absorbing portion 31, the heat absorbing portion 31 is electrically and thermally connected to the metal back plate 21 of the power tube 20, a heat absorbing surface 311 electrically and thermally connected to the back surface of the metal back plate 21 of the power tube 20 is disposed on the heat relay body 30, and a heat transferring surface thermally connected to the housing 40 in an insulating manner is further disposed on the heat relay body 30.

The design of the heat absorbing portion 31 and the extension portion 32 enables the heat relay 30 to have a certain heat storage and dissipation space, improves the heat storage capacity of the heat relay 30, can more effectively conduct away the heat of the power tube 20, realizes quick and effective heat dissipation of the electric vehicle controller 100, reduces the heat dissipation burden of the electric vehicle controller 100, and further ensures normal operation of the electric vehicle controller, and the heat absorbing surface 311 and the heat transfer surface respectively form good surface contact with the power tube 20 and the housing 40, thereby ensuring the heat conduction effect and the current transmission effect of the heat absorbing portion 31 on the power tube 20.

In the embodiment of the present application, the top surface of the heat absorbing portion 31 is electrically and thermally connected to the back surface of the metal back plate 21 of the power tube 20, that is, the heat absorbing surface 311 is the top surface of the heat absorbing portion 31, and the bottom surface of the thermal relay 30 is thermally connected to the housing 40 in an insulating manner, that is, the heat transfer surface is the bottom surface of the thermal relay 30.

Specifically, on the basis of the electric conduction of the heat absorption portion 31, the heat absorption surface 311 absorbs the heat generated by the power tube 20 from the back surface of the metal back plate 21 and conducts the heat to the heat absorption portion 31, the heat absorption portion 31 conducts the heat to the extension portion 32 and distributes the heat to the heat absorption portion 31 and the extension portion 32, and then the heat is conducted to the housing 40 through the heat transfer surface in a large area, so that a heat conduction path between the power tube 20 (metal back plate 21) -the heat absorption surface 311-the heat absorption portion 31 and the extension portion 32-the heat transfer surface-the housing 40 is formed, thereby realizing the rapid heat conduction and dissipation of the power tube 20 and ensuring the normal operation of the power tube 20 and the electric vehicle controller 100.

In the embodiment of the present application, the back surface of the metal back plate 21 of the power tube 20 may be substantially rectangular, that is, the contact surface between the back surface of the metal back plate 21 and the heat absorbing portion 31 is substantially rectangular, and the shape of the heat absorbing surface 311 may be adapted to the shape of the back surface of the metal back plate 21 and the two are arranged in a coplanar manner, so that the heat absorbing surface 311 completely covers the back surface of the metal back plate 21, thereby increasing the thermal contact area between the two, forming a good electrical and thermal connection between the two, and increasing the thermal conduction effect.

Of course, in other embodiments, the back surface of the metal back plate 21 and the heat absorbing surface 311 are not limited to the horizontal plane, and may be specifically disposed in a specific embodiment.

It should be noted that, in the embodiment of the present application, a row of power tubes 20 shares one heat relay 30 and also shares one heat absorbing surface 311, where the heat absorbing surface 311 is the upper surface of the whole heat relay 30 and is electrically and thermally connected to the back surface of the metal back plate 21 of the power tube 20 arranged in a row, so as to reduce the manufacturing process of the heat relay 30 and the structural complexity of the electric vehicle controller 100 on the basis of ensuring effective electrical and thermal conduction.

With continued reference to fig. 3, 7 and 8, the heat absorbing portion 31 has a mounting hole 312 fixed to the metal back plate 21 of the power tube 20.

Furthermore, in order to improve the contact stability between the metal back plate 21 of the power tube 20 and the heat absorbing surface 311 and avoid the problem that the heat conduction and the heat conduction are possibly affected by the separation of the two, in the embodiment of the present application, the heat absorbing surface 311 is provided with the mounting hole 312 for thermally connecting with the back surface of the metal back plate 21 of the power tube 20, the mounting hole 312 corresponds to the through hole on the metal back plate 21 of the power tube 20, and the mounting hole 312 may be a screw hole or a through hole.

Therefore, fasteners such as screws, bolts or rivets can penetrate through the through holes and the mounting holes 312 on the metal back plate 21 and then be screwed or compressed downwards to compress and attach the metal back plate 21 and the heat absorbing surface 311, so that the metal back plate 21 and the heat absorbing surface 311 are thermally connected, the stability between the metal back plate 21 and the heat absorbing surface 311 can be improved, and the reliability of the electric vehicle controller 100 is improved.

In other embodiments, the heat absorbing surface 311 may be further electrically and thermally connected to the metal back plate 21 of the power tube 20 by pressing, welding or gluing (such as conductive glue), and on the basis of ensuring effective electrical and thermal connection between the heat absorbing surface 311 and the metal back plate 21, the connection manner between the two may be reasonably selected, which is not limited herein.

Example two

Referring to fig. 3 to fig. 6, further, the upper arm power transistor 202 and the lower arm power transistor 201 of the third phase are arranged in the same direction and/or perpendicular to the arrangement direction of the three pins of the single power transistor 20.

That is to say, the upper arm power tubes 202 and the lower arm power tubes 201 which are two rows in total for the third phase are parallel, perpendicular or both to the upper arm power tubes 202 and the lower arm power tubes 201 which are four rows in total for the first phase and the second phase, wherein the upper arm power tubes 202 and the lower arm power tubes 201 which are two rows in total for the third phase are parallel and perpendicular to the upper arm power tubes 202 and the lower arm power tubes 201 which are four rows in total for the first phase and the second phase can be understood as follows:

one row of upper bridge arm power tubes 202 or one row of lower bridge arm power tubes 201 of the third phase are parallel to the four rows of upper bridge arm power tubes 202 and the lower bridge arm power tubes 201 relative to the first phase and the second phase, and the other row of lower bridge arm power tubes 201 or the other row of upper bridge arm power tubes 202 of the third phase are perpendicular to the four rows of upper bridge arm power tubes 202 and the lower bridge arm power tubes 201 relative to the first phase and the second phase, so that different structural layouts are formed and different arrangement requirements are met.

By way of example:

example 1: as shown in fig. 3, the arrangement direction of three pins of a single power tube 20 is horizontal, the arrangement directions of the upper arm power tube 202 and the lower arm power tube 201, which are two rows in total, of the third phase and the three pins of the single power tube 20 are the same, that is, the three pins are arranged and distributed along the length direction of the circuit board 10, and other circuit components on the circuit board 10 can be arranged in the interval between the upper arm power tube 202 and the lower arm power tube 201, which are two rows in total, of the third phase and can also be arranged at the vacant position on the left side of the circuit board 10, so that the space utilization rate of the circuit board 10 is improved, and the structural distribution on the circuit board 10 is more regular and compact;

example 2: as shown in fig. 4, the arrangement direction of three pins of a single power tube 20 is horizontal, the arrangement directions of the three pins of a single power tube 20 and the three pins of a third three-phase two-row upper bridge arm power tube 202 and the three pins of a third three-phase three-row lower bridge arm power tube 201 are the same and perpendicular to the arrangement direction of the three pins of the single power tube 20, wherein the arrangement direction of one row of upper bridge arm power tubes 202 (or the lower bridge arm power tubes 201) is vertical, that is, arranged and distributed along the width direction of the circuit board 10, the arrangement direction of the other row of lower bridge arm power tubes 201 (or the upper bridge arm power tubes 202) is horizontal, that is, arranged and distributed along the length direction of the circuit board 10, and other circuit components on the circuit board 10 can be arranged in a space surrounded by the upper bridge arm power tubes 202 and the lower bridge arm power tubes 201 of the third three-phase two-row;

example 3: as shown in fig. 5, the arrangement direction of the three pins of the single power tube 20 is longitudinal, the upper arm power tube 202 and the lower arm power tube 201, which are two rows in total, of the third phase are perpendicular to the arrangement direction of the three pins of the single power tube 20, that is, are arranged and distributed along the width direction of the circuit board 10, and the arrangement manner of other circuit components on the circuit board 10 may refer to the arrangement manner described above, which is not described herein again.

In the present application, the above example 1 is one preferred embodiment.

By adopting the layout manner of example 1, that is, the upper arm power tube 202 of the third phase is aligned with the upper arm power tube 202 of the first phase or the second phase, and the lower arm power tube 201 of the third phase is aligned with the lower arm power tube 201 located below the upper arm power tube 202 of the first phase or the second phase, in this way, the arrangement of the power tubes 20 is more regular, a larger and more regular area can be left on the circuit board 10, which is convenient for the centralized arrangement of other components of the electric vehicle controller 100, and is beneficial to promoting the compactness and integration of the electric vehicle controller 100.

It should be noted that no matter how the upper arm power tubes 202 and the lower arm power tubes 201 in two rows of the third phase are arranged, the upper arm power tubes 202 and the lower arm power tubes 201 in four rows of the first phase and the second phase are always arranged close to each other to control the volume of the electric vehicle controller 100.

Furthermore, in a preferred mode, a row of upper bridge arm power tubes 202 or a row of lower bridge arm power tubes 201 in the third phase may be disposed near the edge of the circuit board 10, and the thermal relay 30 is correspondingly disposed at the edge of the circuit board 10 to contact the row of upper bridge arm power tubes 202 or the row of lower bridge arm power tubes 201, so that the formation of the through groove 14 on the circuit board 10 may be reduced, the processing flow may be reduced, and the difficulty of the process may be controlled.

Certainly, the upper arm power tubes 202 and the lower arm power tubes 201 in two rows of the third phase may be randomly arranged on the circuit board 10 to meet actual design requirements, and no specific limitation is made herein.

EXAMPLE III

Referring to fig. 2, fig. 3 and fig. 6, further, the upper arm power transistor 202 and the lower arm power transistor 201 of the third phase are linearly arranged with the upper arm power transistor 202 and the lower arm power transistor 201 of the first phase or the second phase.

That is, the arrangement directions of the upper arm power tubes 202 and the lower arm power tubes 201 in two rows of the third phase are the same as the arrangement direction of the three pins of the single power tube 20, are both horizontal, and are aligned with the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase to form a linear arrangement, that is, the upper arm power tubes 202 and the lower arm power tubes 201 in two rows of the third phase are arranged and distributed along the length direction of the circuit board 10 to form two horizontal rows.

Specifically, the upper arm power tube 202 of the third phase and the upper arm power tube 202 of the first phase or the second phase are arranged in a straight line, the lower arm power tube 201 of the third phase and the lower arm power tube 201 of the first phase or the second phase are arranged in a straight line, and other circuit components on the circuit board 10 are arranged along the interval between the upper arm power tube 202 and the lower arm power tube 201 of the two rows of the third phase, and can also be arranged at the vacant position on the left side of the circuit board 10, so that the space utilization rate of the circuit board 10 is improved, and the structural distribution on the circuit board 10 is more regular and compact.

Further, of the upper arm power tubes 202 and the lower arm power tubes 201 in the four rows of the first phase and the second phase, the upper arm power tubes 202 and the lower arm power tubes 201 in the first row and the second row in the longitudinal direction of the first side 11 of the circuit board 10 are respectively aligned with the upper arm power tubes 202 and the lower arm power tubes 201 in the two rows of the third phase.

So, the vacant space department in circuit board 10 lower left corner can be located to other circuit components on circuit board 10, locates the latter half of circuit board 10 second side 12 promptly for the components and parts on the whole circuit board 10 distribute comparatively even rule, and inner structure is comparatively compact and integrates, can control electric vehicle controller 100's volume, also is convenient for do electrical design.

For example, taking fig. 3 and fig. 6 as an example, taking the right side (the first side 11) of the circuit board 10 as two rows of the upper arm power tubes 202 and the lower arm power tubes 201 of the two rows a and B, and the left side (the second side 12) as two rows of the upper arm power tubes 202 and the lower arm power tubes 201 of the two rows C as an example, if the four rows of the upper arm power tubes 202 and the lower arm power tubes 201 of the two rows a and B are respectively:

the upper bridge arm power tubes 202 and the lower bridge arm power tubes 201 which are arranged in two rows including a horizontal row A of lower bridge arm power tubes 2011, a horizontal row A of upper bridge arm power tubes 2021, a horizontal row B of upper bridge arm power tubes 2022 and a horizontal row B of lower bridge arm power tubes 2012 and C are respectively a horizontal row C of upper bridge arm power tubes 2023 and a horizontal row C of lower bridge arm power tubes 2013, so that the horizontal row C of upper bridge arm power tubes 2023 and the horizontal row A of lower bridge arm power tubes 2011 are aligned to form a straight line arrangement, and the horizontal row C of lower bridge arm power tubes 2013 and the horizontal row A of upper bridge arm power tubes 2021 are aligned to form a straight line arrangement.

In the embodiment of the present application, six rows of upper arm power tubes 202 and lower arm power tubes 201, including three rows of upper arm power tubes 202 and three rows of lower arm power tubes 201, of three phases a, B, and C in total, may be defined as "four + two" rows of power tubes 20 if defined from the arrangement of the power tubes 20 on the single-side circuit board 10, and may be defined as six rows of power tubes 20 if defined from the number of rows of the power tubes 20.

Example four

Referring to fig. 3 to 8, further, the electric vehicle controller 100 further includes a terminal 50 electrically connected to the heat relay 30, and the terminal 50 includes a positive terminal 501 and a three-phase output terminal 502.

In the embodiment of the present application, the terminal 50 provides a positive power input and/or a three-phase motor output of the electric vehicle controller 100, specifically:

1. the terminal 50 is electrically connected with the positive input of the power supply to provide the positive input of the power supply, namely when the terminal 50 is the positive terminal 501, the terminal is arranged on the upper bridge arm thermal relay 301, current is transmitted from one end of the upper bridge arm thermal relay 301 to the other end through the positive terminal 501, then is transmitted to the metal back plate 21 of the power tube 20, and is input to the circuit board 10 through the three pins 22 of the power tube 20, so that the power supply of the electric vehicle controller 100 is realized;

2. when the terminal 50 is used as a three-phase output of the electric vehicle controller 100, that is, when the terminal 50 is a three-phase output terminal 502, the terminal is disposed on the lower arm thermal relay 302, and the pin 22 of the power tube 20 is welded to the circuit board 10, so that the power tube 20 can transmit a control signal from the circuit board 10 to the other end of the circuit board from the end in contact with the lower arm thermal relay 302 through the metal back plate 21, and finally output the control signal to the three-phase motor 200 through the three-phase output terminal 502 to realize control of the three-phase motor;

3. when the terminal 50 provides the positive input of the power supply and the three-phase output of the motor of the electric vehicle controller 100, that is, when the terminal 50 is the positive terminal 501 and the three-phase output terminal 502, the positive terminal 501 is disposed on the upper bridge arm thermal relay 301, and the three-phase output terminal 502 is disposed on the lower bridge arm thermal relay 302, the two functions can be simultaneously realized, so that the positive input of the power supply and the three-phase output of the motor are both realized.

Specifically, the terminal 50 may be in the form of a terminal, a wiring hole, a wiring slot, a wiring protrusion or a wiring block, so as to meet different structural requirements and adapt to different structural designs. In the embodiment of the present application, the terminal 50 is a hollow column, that is, the structural shape of the terminal is the above-mentioned terminal, so that a wire can be conveniently inserted into the hollow column through a screw to be electrically connected with the thermal relay 30 for conducting, the connection relationship is relatively stable, and stable transmission of current is ensured.

In this embodiment, three phase output terminals 502 are provided, and specifically, three phase output terminals 5021, two phase output terminals 5022 and two phase output terminals 5023 are provided on the three lower bridge arm thermal relays 302 and electrically connected to the three phase interface of the motor of the electric vehicle 1000, respectively, so as to provide three phase outputs of the electric vehicle controller 100 to control the operation of the electric vehicle 1000.

In one embodiment, the phase a output terminal 5021, the phase B output terminal 5022, and the phase C output terminal 5023 may be arranged in parallel at intervals on the same side of the electric vehicle controller 100, which is not only regular and beautiful, but also facilitates electrical connection with the three-phase motor 200 when the wires are outgoing on the same side.

More specifically, the terminal 50 of the present embodiment is integrally formed or connected to the heat sink portion 31 and/or the extension portion 32, so that the terminal 50 can be disposed at any reasonable position of the electric vehicle controller 100 according to different arrangements of the heat sink portion 31 or the extension portion 32.

Of course, in other embodiments, the phase a output terminal 5021, the phase B output terminal 5022, and the phase C output terminal 5023 may be disposed at other positions and may be disposed at any reasonable position of the electric vehicle controller 100 according to actual requirements, which is not limited herein.

Referring to fig. 3-6, in the embodiment of the present application, the terminal 50 further includes a negative terminal 503.

The negative terminal 503 is not provided on the thermal relay 30, but is provided on a separate metal structure, which is electrically connected to the negative terminal of the power supply through the negative terminal 503, and is also electrically connected to the negative copper foil of the circuit board 10 to provide the negative input of the motor controller.

In an embodiment of the present application, three rows of upper arm power transistors 202 are disposed at a position relatively in the middle of the circuit board 10, and three rows of lower arm power transistors 201 are disposed at positions on the upper and lower edges of the circuit board 10.

In this way, the positive terminal 501 provided on the upper arm thermal relay 301 is closest to the three-phase output terminals 502 provided on the three lower arm thermal relays 302, so that the outgoing lines of the electric vehicle controller 100 are more concentrated.

In another embodiment of the present application, three rows of lower bridge arm power tubes 201 are disposed at the relatively middle position of the circuit board 10, and three rows of upper bridge arm power tubes 202 are disposed at the upper and lower edge positions of the circuit board 10.

Thus, the positive terminal 501 of the upper bridge arm thermal relay 301 and the three-phase output terminals 502 of the three lower bridge arm thermal relays 302 are distributed near the upper and lower sides of the electric vehicle controller 100, the electric vehicle controller 100 can output wires at the upper and lower sides, and the outgoing direction makes the outgoing wires more regular, so that the three-phase electric motor 200 of the electric vehicle 1000 can be electrically connected through wires.

EXAMPLE five

Referring to fig. 2, fig. 3 and fig. 6, further, a positive terminal 501 is disposed between the upper arm power transistor 202 and the lower arm power transistor 201 of the first phase or the third phase, any one phase output terminal 50 of the three-phase output terminals 502 is disposed between the upper arm power transistor 202 and the lower arm power transistor 201 of the second phase, the remaining two phases output terminals 50 of the three-phase output terminals 502 are disposed on the second side 12, and the three-phase output terminals 502 are arranged in a row along the arrangement direction of the three pins of the single power transistor 20.

Specifically, in the embodiment of the present invention, the upper arm power tube 202 and the lower arm power tube 201 of the first phase are disposed on the upper right side of the circuit board 10, the upper arm power tube 202 and the lower arm power tube 201 of the second phase are disposed on the lower right side of the circuit board 10, and the upper arm power tube 202 and the lower arm power tube 201 of the third phase are disposed on the upper left side of the circuit board 10.

Based on the above layout, the positive terminal 501 is provided between the upper arm power transistor 202 and the lower arm power transistor 201 of the first phase or the third phase, that is, the positive terminal 501 is provided in the upper half of the circuit board 10. Any one phase output terminal 50 of the three-phase output terminals 502 is arranged between the upper arm power tube 202 and the lower arm power tube 201 of the second phase, that is, any one phase output terminal 50 of the three-phase output terminals 502 is arranged at the lower half part of the circuit board 10, and the other two-phase output terminals 50 are arranged at the left side of the circuit board 10 and are arranged in a row with the output terminal 50 between the upper arm power tube 202 and the lower arm power tube 201 of the second phase, that is, the other two-phase output terminals 50 are also arranged at the lower half part of the circuit board 10, so that the three-phase output terminals are arranged in a row at the lower half part of the circuit board 10. Thus, the arrangement of the three-phase output terminals 502 is regular, which is convenient for electrical design, and the electric vehicle controller 100 can be led out from the upper and lower sides, which is convenient for connecting with the three-phase motor 200.

Exemplarily, if the first phase, the second phase and the third phase are a, B and C phases, respectively, the three-phase output terminals 502 are an a-phase output terminal 5021, a B-phase output terminal 5022 and a C-phase output terminal 5023, respectively, the first side 11 is the right side of the circuit board 10, the second side 12 is the left side of the circuit board 10, and the arrangement direction of the three pins 22 of the single power tube 20 is the transverse direction, then:

the positive terminal 501 is arranged between the upper arm power tube 202 and the lower arm power tube 201 of the a phase, any one of the a-phase output terminal 5021, the B-phase output terminal 5022 and the C-phase output terminal 5023 is arranged between the upper arm power tube 202 and the lower arm power tube 201 of the B phase, the remaining two-phase output terminals 50 are arranged on the left side of the circuit board 10, and the a-phase output terminal 5021, the B-phase output terminal 5022 and the C-phase output terminal 5023 are arranged in a row in the transverse direction.

Any one of the phase a output terminal 5021, the phase B output terminal 5022, and the phase C output terminal 5023 is disposed between the phase B upper bridge arm power tube 202 and the phase B lower bridge arm power tube 201, and the remaining two phase output terminals 50 disposed on the left side of the circuit board 10 may specifically be:

1. the phase a output terminal 5021 is arranged between the phase B upper bridge arm power tube 202 and the phase B lower bridge arm power tube 201, and the phase B output terminal 5022 and the phase C output terminal 5023 are arranged on the left side of the circuit board 10;

2. a phase B output terminal 5022 is arranged between the phase B upper bridge arm power tube 202 and the phase B lower bridge arm power tube 201, and a phase a output terminal 5021 and a phase C output terminal 5023 are arranged on the left side of the circuit board 10;

3. the C-phase output terminal 5023 is provided between the B-phase upper arm power tube 202 and the B-phase lower arm power tube 201, and the a-phase output terminal 5021 and the B-phase output terminal 5022 are provided on the left side of the circuit board 10.

In a preferred embodiment of the present application, a C-phase output terminal 5023 is provided between the upper arm power transistor 202 and the lower arm power transistor 201 of the B-phase, and a B-phase output terminal 5022 is provided between an a-phase output terminal 5021 and the C-phase output terminal 5023.

EXAMPLE six

Further, the terminal 50 is integrally formed with the heat relay body 30.

Specifically, the heat relay body 30 and the terminal 50 are integrally formed into a whole, so that the heat relay body and the terminal can be used as standard parts of the electric vehicle controller 100 to be manufactured and sold before leaving factory, and are directly installed in a matched manner with the power tube 20, and after the terminal 50 and the heat dissipation structure are respectively produced as in the prior art, the terminal and the heat dissipation structure are not required to be respectively assembled and connected with the power tube 20, so that the assembly process of the electric vehicle controller 100 is simplified, the material cost and the labor cost are saved, the production efficiency of the electric vehicle controller 100 is improved, and the production cost is controlled.

In one embodiment, the thermal relay body 30 and the terminal 50 are integrally formed by a die casting process.

The die-casting aluminum process can make the aluminum material into a structure with a certain bending angle, the heat relay body 30 and the wiring terminal 50 can be set into an integral structure, so that the manufacturing, assembling process and cost are saved, meanwhile, the heat relay body 30 is made into the structure with the certain bending angle, and a specific heat dissipation path and an electric connection path are further formed, the extension length of the heat relay body 30 can be increased in a limited space, so that the heat dissipation area is increased, different connection modes and different structural designs can be adapted, the wiring terminal 50 is arranged at any place of the heat relay body 30, the wiring terminal can extend to any possible place along with the heat relay body 30, the space of the electric vehicle controller 100 is fully utilized, and the structural layout of the electric vehicle controller 100 is more reasonable and reliable.

The terminal 50 in the embodiment of the present application is integrally formed on the heat absorbing portion 31 and/or the extending portion 32, specifically:

1. the terminal 50 is integrally formed on the heat absorption part 31, and the heat absorption part 31 can directly realize the electrical connection between the terminal 50 and the power tube 20 while realizing the heat absorption and the heat conduction of the power tube 20;

2. the terminal 50 is integrally formed on the extension portion 32, and the terminal 50 can be located at any feasible position in the electric vehicle controller 100 along with the extension portion 32, so as to meet the design requirements of the internal structure of the electric vehicle controller 100 and make the wire connection of the electric vehicle controller 100 more flexible;

3. the terminal 50 is integrally formed on the heat absorbing portion 31 and the extending portion 32, and at this time, the terminal 50 is located at a connection position of the heat absorbing portion 31 and the extending portion 32 to meet a special connection requirement.

In a preferred embodiment, the terminal 50 is integrally formed with the extension 32.

That is, the positive input terminal may be integrally formed with extension portion 32 of upper arm thermal relay 301, phase a terminal 50 may be integrally formed with extension portion 32 of phase a lower arm thermal relay 302, phase B terminal 50 may be integrally formed with extension portion 32 of phase B lower arm thermal relay 302, and phase C terminal 50 may be integrally formed with extension portion 32 of phase C lower arm thermal relay 302.

EXAMPLE seven

Further, referring to fig. 13 and 14, the electric vehicle controller further includes a front thermal relay 303 thermally connected to the front surfaces of the metal back plates 21 of the upper arm power transistor 202 and the lower arm power transistor 201 of the first phase, the second phase and the third phase.

That is, the front thermal relay 303 is a thermal relay thermally connected to the front surface of the metal back plate 21 of each power tube 20, and the front thermal relay 303 may cover the front surface of the metal back plate 21 of each power tube 20, that is, the front thermal relay 303 may be disposed on the front surfaces of the metal back plates 21 of the upper arm power tube 202 and the lower arm power tube 201 of the first phase, the metal back plates 21 of the upper arm power tube 202 and the lower arm power tube 201 of the second phase, and the metal back plates 21 of the upper arm power tube 202 and the lower arm power tube 201 of the third phase, so as to further improve the heat dissipation effect on the power tubes 20.

When the front thermal relay 303 is disposed on the front surface of the metal back plate 21 of the power tube 20, the single front thermal relay 303 may correspond to the single power tube 20 one by one, and when the single front thermal relay 303 and/or the power tube 20 is damaged or fails, replacement and maintenance of each front thermal relay 303 and/or the power tube 20 are facilitated, or a plurality of front thermal relays 303 in a row may be directly covered and fixed on the power tube 20 in a row, which is more convenient for assembly and disassembly, and reduces assembly time.

Example eight

Referring to fig. 13, an electric vehicle 1000 of the present application includes:

a three-phase motor 200; and

according to the electric vehicle controller 100 of any one of the above, the three-phase interface of the three-phase motor 200 is electrically connected to the three-phase output of the controller.

The electric vehicle 1000 of the application is applied with the electric vehicle controller 100, in the electric vehicle controller 100, the upper arm power tubes 202 and the lower arm power tubes 201 of the first phase and the second phase are arranged on the first side 11 of the circuit board 10, and further the upper arm power tubes 202 and the lower arm power tubes 201 of the two phases are arranged in four rows in the arrangement direction of the three pins 22 of the single power tube 20, while the upper arm power tubes 202 and the lower arm power tubes 201 of the third phase are arranged in two rows on the second side 12 of the circuit board 10, the arrangement of the power tubes 20 in the electric vehicle controller 100 is more regular and compact, the layout is more reasonable, the electric design of the electric vehicle controller 100 and the arrangement of other components are facilitated, further, the internal structural arrangement of the electric vehicle controller 100 is more reasonable to control the volume, and the electric vehicle controller can be applied to the high-power electric vehicle controller 100.

The three-phase line interface of the three-phase motor 200 may include an a-phase line interface, a B-phase line interface, and a C-phase line interface, and the three-phase output end of the electric vehicle controller 100 includes an a-phase output end, a B-phase output end, and a C-phase output end, that is, the a-phase output terminal 5021, the B-phase output terminal 5022, and the C-phase output terminal 5023 in the foregoing, and the three are electrically connected with the three-phase line interface of the three-phase motor 200 in a one-to-one correspondence manner, so as to control the three-phase motor 200.

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

The present invention is not intended to be limited to the particular embodiments shown and described, but is to be accorded the widest scope consistent with the principles and novel features herein disclosed.

Claims

1. An electric vehicle controller, comprising:

a circuit board;

the power tubes are welded on the circuit board and are configured into upper bridge arm power tubes and lower bridge arm power tubes of a first phase, a second phase and a third phase; and

2. The electric vehicle controller according to claim 1, characterized in that the upper bridge arm power tube and the lower bridge arm power tube of the third phase are arranged in the same direction and/or perpendicular to the arrangement direction of three pins of a single power tube.

3. The electric vehicle controller according to claim 2, wherein the upper arm power transistor and the lower arm power transistor of the third phase are arranged in a straight line with the upper arm power transistor and the lower arm power transistor of the first phase or the second phase.

4. The electric vehicle controller of claim 3, further comprising a terminal electrically connected to the thermal relay;

the terminals include a positive terminal and a three-phase output terminal.

5. The electric vehicle controller according to claim 4,

6. The electric vehicle controller of claim 4, wherein the terminal is integrally formed with the thermal relay body.

7. The electric vehicle controller according to claim 1, further comprising a front side thermal relay thermally connected to front sides of metal back plates of the upper leg power tubes and the lower leg power tubes of the first phase, the second phase and the third phase.

8. An electric vehicle, comprising:

a three-phase motor; and

the electric vehicle controller according to any one of claims 1 to 7, wherein a three-phase wire interface of the three-phase motor is electrically connected to a three-phase output of the controller.