CN117062405A - Highly integrated motor controller module based on platformization and using method - Google Patents

Abstract

The application discloses a highly integrated motor controller module based on platformization and a use method thereof, which relate to the technical field of vehicle parts and components and comprise the following steps: the controller module body consists of a heat dissipation assembly, a module assembly and a control assembly; the module assembly is arranged on the upper end face of the heat dissipation assembly, and the control assembly is arranged on the upper end face of the module assembly. The beneficial effects of the application are as follows: through cooling module, module and control assembly, realize satisfying the performance requirement of output capacity 250KW under 400V platform and output capacity 240KW under the 800V platform, all submodules of this controller module body all can satisfy the platformization design, and the degree of integration promotes than traditional scheme greatly, and this controller module body can regard as a motor controller alone to use, also can install and regard as a motor, automatically controlled two unification assemblies to use in motor and the automatically controlled integrated casing, still can install and regard as motor, automatically controlled, the three unification assemblies of reduction gear use in motor, automatically controlled and the integrated casing of reduction gear.

Description

Highly integrated motor controller module based on platformization and using method

Technical Field

The application relates to the technical field of vehicle parts, in particular to a highly integrated motor controller module based on platformization and a use method thereof.

Background

The existing motor controller for the new energy electric automobile generally comprises a high-voltage filter, a bus capacitor, a power module, a driving PCBA, a control PCBA, a current sensor, a three-phase output copper bar, a controller box body, a cover plate and the like, wherein the high-voltage filter, the bus capacitor, the power module, the driving PCBA, the control PCBA, the current sensor and the three-phase output copper bar are all independently assembled in the controller box body;

the assembly difficulty and the after-sales maintenance cost are increased due to the low integration level among all the modules and the low total integration level, and meanwhile, the occupied space of all the sub-modules is large, the volume and the weight of the whole motor controller are difficult to reduce, and the development of an electric drive system to the high power density, miniaturization and light weight directions is not facilitated; and at the beginning of the design, the compatibility design of each submodule of the motor controller under different voltage platforms and different power grades is not considered, the degree of platformization and universalization is low, the upgrading iteration of products is not facilitated, and the reliability and the stability of the whole electric drive system are reduced.

Disclosure of Invention

The application aims to overcome the defects of the background technology and provide a highly integrated motor controller module based on platformization and a use method thereof.

In a first aspect, the present application provides a highly integrated motor controller module based on platformization, comprising: the controller module body consists of a heat dissipation assembly, a module assembly and a control assembly;

the module assembly is arranged on the upper end face of the heat radiating assembly, the control assembly is arranged on the upper end face of the module assembly, the module assembly is located between the heat radiating assembly and the control assembly, a power module is arranged on one side of the module assembly, and a Hall copper bar assembly is arranged on one side of the power module.

Further, the module assembly is electrically connected with the power module through copper bar lap joints, the power module is electrically connected with the control assembly through pin welding, and the Hall copper bar assembly is electrically connected with the power module through copper bar lap joints.

Further, the heat dissipation assembly comprises a heat dissipation water cooling plate, the power module and the module assembly are arranged on the upper end face of the heat dissipation water cooling plate, a through cavity is formed between the power module and the heat dissipation water cooling plate, and two ends of the cavity are respectively communicated with a water outlet and a water inlet.

Further, the module assembly comprises a filter capacitor module, wherein the filter capacitor module is positioned between the heat dissipation assembly and the control assembly and comprises a high-voltage filter, a bus capacitor and a heat dissipation aluminum substrate;

the high-voltage filter comprises a plurality of magnetic rings, a plurality of safety capacitors, a positive electrode copper bar and a negative electrode copper bar.

Further, the bus capacitor also comprises an anode copper bar, a cathode copper bar and a plurality of capacitor cores.

Further, the control assembly includes a drive control PCBA disposed on an upper end face of the module assembly and the power module, the drive control PCBA including a drive PCBA and a control PCBA.

Further, the power module includes a Si-based IGBT module and a SiC-based module.

Further, the hall copper bar assembly comprises a current sensor and a three-phase copper bar assembly.

In a second aspect, the present application further provides a method for using a highly integrated motor controller module based on platformization, including any one of the above-mentioned highly integrated motor controller modules based on platformization, further including the following steps:

the heat dissipation water cooling plate of the heat dissipation assembly is utilized to cool the power module, the heat dissipation water cooling plate is utilized to support the whole controller module body, the high-voltage filter and the bus capacitor in the filter capacitor module of the module assembly are utilized to meet the two specification configurations of the two-stage filter 500V850uf and the two-stage filter 900V300uf, the filter capacitor module integrates the high-voltage filter and the bus capacitor together, the driving PCBA of the motor controller is integrated with the control PCBA by utilizing the driving control PCBA of the control assembly.

Further, the power module is utilized to meet the requirements of two different voltage platforms of 400V and 800V, and the Hall copper bar assembly is utilized to integrate the current sensor of the motor controller with the three-phase copper bar assembly.

Compared with the prior art, the application has the following advantages: through radiator unit, module subassembly and control assembly, realize satisfying the performance requirement of output capability 250KW under the 400V platform and output capability 240KW under the 800V platform, all submodules of this controller module body all can satisfy the platform design, the degree of integration promotes than traditional scheme greatly, this controller module body can regard as a motor controller alone to use, also can install and regard as a motor, automatically controlled two unification assemblies in motor and the automatically controlled integrated housing to use, still can install and regard as motor, automatically controlled, the three unification assemblies of reduction gear use in motor, automatically controlled and the integrated housing of reduction gear, the application is nimble, the high power density of electric drive system has greatly been satisfied, miniaturization, the demand of lightweight.

Drawings

FIG. 1 is a schematic view of the overall exploded perspective of the present application;

FIG. 2 is a schematic diagram of a three-dimensional structure of a heat-dissipating water-cooling plate according to the present application;

FIG. 3 is a schematic diagram of a three-dimensional structure of a filter capacitor module according to the present application;

FIG. 4 is a schematic perspective view of a modular assembly of the present application;

FIG. 5 is a schematic perspective view of a drive control PCBA in accordance with the present application;

FIG. 6 is a schematic diagram of a power module perspective structure according to the present application;

FIG. 7 is a schematic perspective view of a Hall copper bar assembly of the present application;

fig. 8 is a schematic perspective view of the overall structure of the present application.

In the figure:

1. a heat-dissipating water-cooling plate;

2. a filter capacitor module; 21. a high-pressure filter; 22. a bus capacitor; 23. a heat-dissipating aluminum substrate;

3. driving and controlling PCBA;

4. a power module;

5. hall copper bar assembly;

6. a controller module body.

Detailed Description

Reference will now be made in detail to the present embodiments of the application, examples of which are illustrated in the accompanying drawings. While the application will be described in conjunction with the specific embodiments, it will be understood that they are not intended to limit the application to the described embodiments. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the application as defined by the appended claims. It should be noted that the method steps described herein may be implemented by any functional block or arrangement of functions, and any functional block or arrangement of functions may be implemented as a physical entity or a logical entity, or a combination of both.

The present application will be described in further detail below with reference to the drawings and detailed description for the purpose of enabling those skilled in the art to understand the application better.

Note that: the examples to be described below are only one specific example, and not as limiting the embodiments of the present application necessarily to the following specific steps, values, conditions, data, sequences, etc. Those skilled in the art can, upon reading the present specification, make and use the concepts of the application to construct further embodiments not mentioned in the specification.

The assembly difficulty and the after-sales maintenance cost are increased due to the low integration level among all the modules and the low total integration level, and meanwhile, the occupied space of all the sub-modules is large, the volume and the weight of the whole motor controller are difficult to reduce, and the development of an electric drive system to the high power density, miniaturization and light weight directions is not facilitated; and at the beginning of the design, the compatibility design of each submodule of the motor controller under different voltage platforms and different power grades is not considered, the degree of platformization and universalization is low, the upgrading iteration of products is not facilitated, and the reliability and the stability of the whole electric drive system are reduced.

In order to solve the above-mentioned problems of the motor controller module, the highly integrated motor controller module based on platformization according to the present application, referring to fig. 1 and 8, includes: a controller module body 6 composed of a heat radiation component, a module component and a control component; the module assembly sets up in the up end of radiator unit, and control assembly sets up in the up end of module assembly, and module assembly is located between radiator unit and the control assembly, and one side of module assembly is provided with power module 4, and one side of power module 4 is provided with hall copper bar subassembly 5.

In the embodiment, all core components in the motor controller, including a high-voltage filter 21, a bus capacitor 22, a power module 4, a driving PCBA, a control PCBA, a current sensor, a three-phase output copper bar and a heat dissipation water cooling plate 1 are integrated into a controller module body 6;

wherein the high-voltage filter 21 and the bus capacitor 22 are respectively integrated into a filter capacitor module 2, the driving control PCBA3 is formed by integrating the driving PCBA and the control PCBA, the Hall copper bar assembly 5 is formed by a current sensor and a three-phase output copper bar assembly, therefore, the controller module body 6 only comprises the filter capacitor module 2, the power module 4, the driving control PCBA3, the Hall copper bar assembly 5 and the heat dissipation water cooling plate 1, and simultaneously, the filter capacitor module 2 can simultaneously meet two specification configurations of 500V850uf and 900V300uf of the secondary filter, and can be downward compatible, the power module 4 can be selected based on hybrid PACK ^TM The Drive-control PCBA3 can simultaneously meet the hardware circuit design developed based on a 400V platform and the hardware circuit design developed based on an 800V platform, and the Hall copper bar assembly 5 can meet the current capacity of 360Arms of continuous current and 1200Arms of peak current.

Based on the above embodiment, in this embodiment, the module assembly is electrically connected to the power module 4 through copper bar overlap, the power module 4 is electrically connected to the control assembly through pin welding, and the hall copper bar assembly 5 is electrically connected to the power module 4 through copper bar overlap.

Referring to fig. 2, in this embodiment, the heat dissipation assembly includes a heat dissipation water cooling plate 1, the power module 4 and the module assembly are disposed on an upper end surface of the heat dissipation water cooling plate 1, a through cavity is formed between the power module 4 and the heat dissipation water cooling plate 1, and two ends of the cavity are respectively connected with a water outlet and a water inlet.

In the embodiment, the heat dissipation water cooling plate 1 plays a role of supporting four parts, namely a module assembly, a power module 4, a control assembly and a Hall copper bar assembly 5, so that the whole module is ensured to meet enough mechanical vibration strength; secondly, providing a water cooling and heat dissipation condition for the power module 4, after the power module 4 is installed on the heat dissipation water cooling plate 1, a through cavity is formed in the heat dissipation water cooling plate 1, a water inlet and a water outlet are formed in the heat dissipation water cooling plate 1, and heat generated in the operation of the power module 4 can be taken away in the process of flowing in and out of the cooling liquid from the water inlet, so that the heat dissipation performance of the whole module is ensured; the third function is to support the whole controller module body 6, which can be installed in a single shell to be used as a single electric control, can be installed in a motor and electric control integrated shell to be used as a motor and electric control two-in-one assembly, and can also be installed in a motor, electric control and speed reducer integrated shell to be used as a motor, electric control and speed reducer three-in-one assembly.

Referring to fig. 3 to 4, in the above embodiment, the module assembly includes a filter capacitor module 2, the filter capacitor module 2 is located between the heat dissipation assembly and the control assembly, and the filter capacitor module 2 includes a high voltage filter 21, a bus capacitor 22 and a heat dissipation aluminum substrate 23; the high-voltage filter 21 comprises a plurality of magnetic rings, a plurality of safety capacitors, a positive copper bar and a negative copper bar, and the bus capacitor also comprises a positive copper bar, a negative copper bar and a plurality of capacitor cores.

In this embodiment, the high-voltage filter 21 of the motor controller and the bus capacitor 22 are integrated together, wherein the high-voltage filter 21 comprises two magnetic rings, a plurality of safety capacitors, a positive copper bar and a negative copper bar, and the bus capacitor 22 comprises a positive copper bar, a negative copper bar and a plurality of capacitor cores. The two specifications of the two-stage filtering 500V850uf and the two-stage filtering 900V300uf can be simultaneously met, and the two-stage filtering two-dimensional filtering module is downward compatible, the high-voltage filter 21 and the bus capacitor 22 are integrated by the filtering capacitor module 2, so that the space utilization rate is greatly improved, the current conduction path is shortened, the EMC performance is improved by adopting a two-stage filtering scheme, and the two specifications of the two-stage filtering 500V850uf and the two-stage filtering 900V300uf can be met, so that the requirements of two different voltage platforms of 400V and 800V are completely met.

Referring to fig. 5, in the present embodiment, the control assembly includes a drive control PCBA3, the drive control PCBA3 is disposed on the upper end surfaces of the module assembly and the power module 4, and the drive control PCBA3 includes a drive PCBA and a control PCBA.

In this embodiment, the driving control PCBA3 integrates the driving PCBA and the controlling PCBA of the motor controller, which can simultaneously satisfy the hardware circuit design developed based on the 400V platform and the hardware circuit design developed based on the 800V platform.

Referring to fig. 6, in the present embodiment, the power module 4 includes a Si-based IGBT module and a SiC-based module on the basis of the above-described embodiment.

In this embodiment, the power module 4 is optionally based on hybrid pack ^TM The Si-based IGBT module and the SiC-based power module 4 of the Drive package meet the requirements of two different voltage platforms of 400V and 800V.

Referring to fig. 7, in the present embodiment, the hall copper bar assembly 5 includes a current sensor and a three-phase copper bar assembly, based on the above-described embodiment.

In this embodiment, the hall copper bar assembly 5 integrates the current sensor of the motor controller and the three-phase copper bar assembly, so as to satisfy the current capability of 360Arms of continuous current and 1200Arms of peak current.

The application also provides a using method of the highly integrated motor controller module based on the platformization, which further comprises the following steps:

the heat dissipation water cooling plate 1 of the heat dissipation assembly is utilized to dissipate heat, the power module 4 is cooled, the heat dissipation water cooling plate 1 is utilized to support the whole controller module body 6, the high-voltage filter 21 and the bus capacitor 22 in the filter capacitor module 2 of the module assembly are utilized to meet two specification configurations of the two-stage filter 500V850uf and the two-stage filter 900V300uf, the filter capacitor module 2 integrates the high-voltage filter 21 and the bus capacitor 22 together, the driving control PCBA3 of the control assembly is utilized, and the driving PCBA and the control PCBA of the motor controller are integrated together.

Based on the above embodiment, in this embodiment, the power module is used to meet the requirements of two different voltage platforms of 400V and 800V, and the hall copper bar assembly is used to integrate the current sensor of the motor controller with the three-phase copper bar assembly.

In the description of the present application, it should be noted that the azimuth or positional relationship indicated by the terms "upper", "lower", etc. are based on the azimuth or positional relationship shown in the drawings, and are merely for convenience of describing the present application and simplifying the description, and are not indicative or implying that the apparatus or element in question must have a specific azimuth, be constructed and operated in a specific azimuth, and thus should not be construed as limiting the present application. Unless specifically stated or limited otherwise, the terms "mounted," "connected," and "coupled" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art according to the specific circumstances.

It should be noted that in the present application, relational terms such as "first" and "second" and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.

The foregoing is only a specific embodiment of the application to enable those skilled in the art to understand or practice the application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the application. Thus, the present application is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims (10)

1. A highly integrated motor controller module based on platfonn, comprising: a controller module body (6) composed of a heat radiation component, a module component and a control component;

the module assembly is arranged on the upper end face of the heat radiating assembly, the control assembly is arranged on the upper end face of the module assembly, the module assembly is located between the heat radiating assembly and the control assembly, a power module (4) is arranged on one side of the module assembly, and a Hall copper bar assembly (5) is arranged on one side of the power module (4).

2. The highly integrated motor controller module based on platfonn according to claim 1, wherein the module assembly is electrically connected to the power module (4) by copper bar lap joints, the power module (4) is electrically connected to the control assembly by pin soldering, and the hall copper bar assembly (5) is electrically connected to the power module (4) by copper bar lap joints.

3. The highly integrated motor controller module based on platform as claimed in claim 1, wherein the heat dissipation assembly comprises a heat dissipation water cooling plate (1), the power module (4) and the module assembly are arranged on the upper end face of the heat dissipation water cooling plate (1), a through cavity is formed between the power module (4) and the heat dissipation water cooling plate (1), and two ends of the cavity are respectively communicated with a water outlet and a water inlet.

4. The highly integrated motor controller module based on platformization of claim 1, wherein the module assembly comprises a filter capacitor module (2), the filter capacitor module (2) being located between the heat sink assembly and the control assembly, the filter capacitor module (2) comprising a high voltage filter (21), a bus capacitor (22) and a heat sink aluminum substrate (23);

the high-voltage filter (21) comprises a plurality of magnetic rings, a plurality of safety capacitors, a positive electrode copper bar and a negative electrode copper bar.

5. The platform based highly integrated motor controller module of claim 4 wherein the bus capacitor also comprises a positive copper bar, a negative copper bar, a plurality of capacitor cores.

6. The highly integrated platform-based motor controller module of claim 1 wherein the control assembly comprises a drive control PCBA (3), the drive control PCBA (3) being disposed on an upper face of the module assembly and the power module (4), the drive control PCBA (3) comprising a drive PCBA and a control PCBA.

7. Highly integrated motor controller module based on platfonn according to claim 1, wherein the power module (4) comprises a Si-based IGBT module and a SiC-based module.

8. Highly integrated motor controller module based on platfonn according to claim 1, wherein the hall copper bar assembly (5) comprises a current sensor and a three-phase copper bar assembly.

9. A method of using a highly integrated motor controller module based on platfonn, comprising the highly integrated motor controller module based on platfonn of any one of claims 1-8, further comprising the steps of:

the heat dissipation water cooling plate (1) of the heat dissipation assembly is utilized to cool the power module (4), the heat dissipation water cooling plate (1) is utilized to support the whole controller module body (6), the high-voltage filter (21) and the bus capacitor (22) in the filter capacitor module (2) of the module assembly are utilized to meet the two specification configurations of the two-stage filter 500V850uf and the two-stage filter 900V300uf, the filter capacitor module (2) integrates the high-voltage filter (21) and the bus capacitor (22), the driving control PCBA (3) of the control assembly is utilized, and the driving PCBA and the control PCBA of the motor controller are integrated.

10. The method of using a highly integrated motor controller module based on platfonn according to claim 9, wherein the power module (4) is used to meet the requirements of two different voltage platfonns of 400V and 800V, and the hall copper bar assembly (5) is used to integrate the current sensor of the motor controller with the three-phase copper bar assembly.