CN117578683A - All-in-one electric drive power supply system and design method thereof - Google Patents

All-in-one electric drive power supply system and design method thereof Download PDF

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Publication number
CN117578683A
CN117578683A CN202311460162.9A CN202311460162A CN117578683A CN 117578683 A CN117578683 A CN 117578683A CN 202311460162 A CN202311460162 A CN 202311460162A CN 117578683 A CN117578683 A CN 117578683A
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CN
China
Prior art keywords
circuit
direct current
vehicle
module
capacitor
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Application number
CN202311460162.9A
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Chinese (zh)
Inventor
王明强
林霖
徐玮
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United Automotive Electronic Systems Co Ltd
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United Automotive Electronic Systems Co Ltd
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Priority to CN202311460162.9A priority Critical patent/CN117578683A/en
Publication of CN117578683A publication Critical patent/CN117578683A/en
Pending legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/02—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from ac mains by converters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0048—Circuits or arrangements for reducing losses
    • H02M1/0054—Transistor switching losses
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/32—Means for protecting converters other than automatic disconnection
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M3/00—Conversion of dc power input into dc power output
    • H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
    • H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
    • H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
    • H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
    • H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M3/3353—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only having at least two simultaneously operating switches on the input side, e.g. "double forward" or "double (switched) flyback" converter
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/42—Conversion of dc power input into ac power output without possibility of reversal
    • H02M7/44—Conversion of dc power input into ac power output without possibility of reversal by static converters
    • H02M7/48—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/53—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/537—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
    • H02M7/5387—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration
    • H02M7/53871—Conversion of dc power input into ac power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration with automatic control of output voltage or current
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P27/00—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
    • H02P27/04—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage
    • H02P27/06—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)

Abstract

The invention provides an all-in-one electric drive power system and a design method thereof. The vehicle-mounted charger module comprises a power factor correction unit and a direct current conversion unit, wherein a part of bridge arms of the power factor correction unit are multiplexed to serve as primary side circuits of the direct current conversion unit, the primary side circuits of the direct current conversion unit can be simplified or completely canceled, a direct current output end of the vehicle-mounted charger module is connected with an input capacitor of the motor control module, the input capacitor of the multiplexing motor control module serves as an output capacitor of the vehicle-mounted charger module, the output capacitor of the vehicle-mounted charger module can be simplified or completely canceled, integration of power circuit topology levels is realized, the power circuit topology structure of the all-in-one electric drive power supply system is simplified, the integration level of the all-in-one electric drive power supply system is improved, the cost is reduced, the volume is reduced, and the working efficiency of the vehicle-mounted charger module is also improved.

Description

All-in-one electric drive power supply system and design method thereof
Technical Field
The invention relates to the technical field of electric drive integration, in particular to an all-in-one electric drive power supply system and a design method thereof.
Background
Currently, the multiple-in-one electric drive power supply carried by a vehicle gradually enters the market to become a technical trend, and the multiple-in-one electric drive power supply is mainly beneficial to the cost reduction advantage and the structure miniaturization advantage brought by the deep integration of the multiple-in-one product. The following description will be given by taking the mainstream six-in-one (vehicle-mounted charging and power distribution unit and three-in-one bridge) integration as an example: the vehicle-mounted charging and distribution unit integrates three functional devices of a vehicle-mounted charger (OBC), a vehicle-mounted power converter (DCDC) and a distribution box (PDU), the related cost of a high-voltage bus wire harness and a connector can be saved after the integration, the mechanical cost of a shell, a vehicle bracket and the like can be saved by sharing a shell and a water channel, and the design cost of a set of main control chip, auxiliary power supply, a communication loop and the like is saved after the design of a PCB; the system saves part of components and materials, reduces the cost, saves the occupied space of the system, utilizes the integrated integration to more fully utilize scattered space, realizes smaller volume and is beneficial to vehicle arrangement.
However, the existing electric drive power supply all-in-one product integration mainly uses mechanical integration, only partial products have weak current control integration, almost no products relate to deep power topology integration, the mechanical integration almost reaches the limit, and the weak current control integration only can reduce circuit boards, so that the electric drive power supply all-in-one product integration has little contribution to cost reduction, synergy and structural miniaturization design. Meanwhile, a plurality of large-size and large-size power switching tubes are needed to form a bridge power loop in the complex electric drive power supply systems such as the vehicle-mounted charger and the motor controller, and the whole size of the corresponding electric drive power supply system is still larger. This makes it impossible to further increase the integration of the integrated power supply system, which limits the related applications.
Therefore, a technical solution of the all-in-one electric drive power supply based on power topology integration is needed to further improve the integration level of the all-in-one electric drive power supply system.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, the present invention aims to provide an all-in-one electric drive power supply technical scheme, which integrates and integrates a plurality of power circuit topologies based on the local multiplexing principle of the power circuit topologies connected with each other, so as to omit part of the power circuit topologies, simplify the power circuit topology structure of the all-in-one electric drive power supply system, and further improve the integration level of the all-in-one electric drive power supply system.
In order to achieve the above object and other related objects, the present invention provides the following technical solutions.
The all-in-one electric drive power supply system comprises a vehicle-mounted charger module, a motor control module and a motor, wherein an alternating current input end of the vehicle-mounted charger module is used for being connected with an alternating current power supply, a direct current output end of the vehicle-mounted charger module is used for being connected with a power battery, an input end of the motor control module is used for being connected with the power battery, and an output end of the motor control module is connected with the motor; the vehicle-mounted charger module comprises a power factor correction unit and a direct current conversion unit, wherein a primary side circuit of the direct current conversion unit multiplexes the power factor correction unit to simplify the primary side circuit of the direct current conversion unit; and the direct current output end of the vehicle-mounted charger module is connected with the input capacitor of the motor control module so as to multiplex the input capacitor into the output capacitor of the vehicle-mounted charger module.
Optionally, the control circuit of the vehicle-mounted charger module and the control circuit of the motor control module are integrated and arranged on a circuit board.
Optionally, the all-in-one electric drive power system further comprises a battery management module, a whole vehicle control module and a thermal management module, wherein the battery management module, the whole vehicle control module and a control circuit of the thermal management module are integrally arranged on the circuit board.
Optionally, the all-in-one electric drive power system further comprises a direct current conversion module, and a control circuit of the direct current conversion module is integrally arranged on the circuit board.
Optionally, the power factor correction unit and the direct current conversion unit are integrated into a single-stage conversion correction unit, the single-stage conversion correction unit comprises a three-phase bridge rectifier circuit, a clamping capacitor, a transformer circuit and a secondary side circuit, the input end of the three-phase bridge rectifier circuit is connected with the alternating current power supply, the output end of the three-phase bridge rectifier circuit is connected with the clamping capacitor, the three-phase bridge rectifier circuit is further connected with the primary side of the transformer circuit, a part of the three-phase bridge rectifier circuit is multiplexed into the primary side circuit, and the secondary side of the transformer circuit is connected with the secondary side circuit.
Optionally, the primary side circuit is a full-bridge structure, and two bridge arms of the three-phase bridge rectifier circuit are multiplexed into the primary side circuit.
Optionally, the primary side circuit is of a half-bridge structure, and one bridge arm of the three-phase bridge rectifier circuit is multiplexed into one bridge arm of the primary side circuit.
Optionally, the transformer circuit is in an LLC structure, a CLC structure or a CLLC structure, and the secondary circuit is in a full-bridge structure, a half-bridge structure or a push-pull structure.
Optionally, the motor control module includes three-phase bridge type inverter circuit, input capacitance includes direct current support electric capacity and filter capacitance, three-phase bridge type inverter circuit's output termination the motor, three-phase bridge type inverter circuit's input positive pole connects direct current support electric capacity's first pole, three-phase bridge type inverter circuit's input negative pole connects direct current support electric capacity's second pole, filter capacitance with direct current support electric capacity connects in parallel, filter capacitance's first pole with power battery's positive pole and direct current support electric capacity's first pole are connected respectively, filter capacitance's second pole with power battery's negative pole and direct current support electric capacity's second pole are connected respectively, secondary circuit's output positive pole with direct current support electric capacity's first pole is connected, secondary circuit's output negative pole with direct current support electric capacity's second pole is connected.
The design method of the all-in-one electric drive power supply system is applied to the design of the all-in-one electric drive power supply system, and comprises the following steps:
multiplexing the power factor correction unit as a primary side circuit of the direct current conversion unit, and integrating the power factor correction unit and the direct current conversion unit into a single-stage topological structure so as to cancel the primary side circuit of the direct current conversion unit;
multiplexing the input capacitor as an output capacitor of the vehicle-mounted charger module, and connecting an output end of a secondary circuit in the direct-current conversion unit with the input capacitor of the motor control module to simplify the output capacitor of the direct-current conversion unit;
and the multiplexing circuit board integrates the control circuit of the vehicle-mounted charger module, the control circuit of the motor control module, the battery management module, the whole vehicle control module and the control circuit of the thermal management module on the circuit board.
As described above, the all-in-one electric drive power system and the design method thereof have at least the following beneficial effects:
the method comprises the steps that an all-in-one electric drive power supply system is designed by combining a vehicle-mounted charger module, a motor control module and a motor, wherein the vehicle-mounted charger module comprises a power factor correction unit and a direct current conversion unit, a primary circuit of the direct current conversion unit multiplexes the power factor correction unit to simplify a primary circuit of the direct current conversion unit, and a direct current output end of the vehicle-mounted charger module is connected with an input capacitor of the motor control module to multiplex the input capacitor into an output capacitor of the vehicle-mounted charger module; based on the circuit topology multiplexing between the cascaded power factor correction unit and the direct current conversion unit, the primary circuit of the direct current conversion unit can be simplified, the output capacitance of the vehicle-mounted charger module can be simplified based on the filter capacitance multiplexing between the vehicle-mounted charger module and the motor control module which are connected with each other, the integration of the power circuit topology level is realized, the power circuit topology structure of the all-in-one electric drive power supply system is simplified, the integration level of the all-in-one electric drive power supply system is improved, the production cost of the all-in-one electric drive power supply system is reduced, the size and the volume of the all-in-one electric drive power supply system are reduced, and the working efficiency of the vehicle-mounted charger module is improved.
Drawings
Fig. 1 is a schematic diagram of a power topology circuit of an all-in-one electric drive power system in the prior art.
Fig. 2 is a schematic diagram of a power topology circuit of an all-in-one electric driving power system according to an embodiment of the invention.
Fig. 3 is a schematic diagram of a power topology circuit of another multiple-in-one electric driving power system in the prior art.
Fig. 4 is a schematic diagram of a power topology circuit of an all-in-one electric driving power system according to a second embodiment of the invention.
Detailed Description
Other advantages and effects of the present invention will become apparent to those skilled in the art from the following disclosure, which describes the embodiments of the present invention with reference to specific examples. The invention may be practiced or carried out in other embodiments that depart from the specific details, and the details of the present description may be modified or varied from the spirit and scope of the present invention.
Please refer to fig. 1 to 4. It should be noted that, the illustrations provided in the present embodiment merely illustrate the basic concept of the present invention by way of illustration, and only the components related to the present invention are shown in the drawings and are not drawn according to the number, shape and size of the components in actual implementation, and the form, number and proportion of the components in actual implementation may be arbitrarily changed, and the layout of the components may be more complex. The structures, proportions, sizes, etc. shown in the drawings attached hereto are for illustration purposes only and are not intended to limit the scope of the invention, which is defined by the claims, but rather by the claims.
As mentioned in the foregoing background art, the inventor researches and discovers that, with popularization and application of electric vehicles, due to the advantage of cost reduction and advantage of miniaturization of structure caused by deep integration of multiple-in-one products, multiple-in-one of electric driving power sources on vehicles gradually cut into the market, and various manufacturers integrate a Motor EM (E-Motor), a Gearbox gecarbox, an Inverter, an on-board charger OBC (or Bi-directional on-board charger Bi-OBC), a direct current converter DCDC, a high voltage power distribution unit HV PDU, a battery management system BMS/BCU, a vehicle controller VCU and other functional modules.
Specifically, the mature all-in-one electric drive power supply system is an eight-in-one integrated product of BYD or a seven-in-one product of Hyundai, and the two products are stacked and integrated in physical space mainly by virtue of all product modules which are formed, so that part of shell supports can be saved, part of product modules are integrated by weak current control units, circuit boards can be saved, part of circuit components can be shared, components and materials are saved, besides the cost is reduced, the occupied space of the system can be saved, scattered space can be more fully utilized by recycling integrated integration, smaller volume is realized, and the vehicle space layout setting is facilitated.
However, the existing electric drive power supply all-in-one product integration mainly uses mechanical integration, only partial products have weak current control integration, almost no products relate to deep power topology integration, the mechanical integration almost reaches the limit, and the weak current control integration only can reduce circuit boards, so that the electric drive power supply all-in-one product integration has little contribution to cost reduction, synergy and structural miniaturization design. Meanwhile, a plurality of large-size and large-size power switching tubes are needed to form a bridge power loop in the complex electric drive power supply systems such as the vehicle-mounted charger and the motor controller, and the whole size of the corresponding electric drive power supply system is still larger. This makes it impossible to further increase the integration of the integrated power supply system, which limits the related applications.
Based on the above, the invention provides an all-in-one electric drive technical scheme: the method comprises the steps that an all-in-one electric drive power supply system is designed by combining a vehicle-mounted charger module, a motor control module and a motor, single-stage topology integration is carried out on a power factor correction unit and a direct current conversion unit in the vehicle-mounted charger module, the multiplexing power factor correction unit is used as a primary circuit of the direct current conversion unit, capacitance integration multiplexing is carried out on the vehicle-mounted charger module and the motor control module by simplifying the primary circuit of the direct current conversion unit, an input capacitance of the multiplexing motor control module is used as an output capacitance of the vehicle-mounted charger module, the output capacitance of the vehicle-mounted charger module is simplified, integration of a power circuit topology level is realized, the power circuit topology structure of the all-in-one electric drive power supply system is simplified, the integration level of the all-in-one electric drive power supply system is improved, and the working efficiency of the vehicle-mounted charger module is improved; the control circuit of the vehicle-mounted charger module, the control circuit of the motor control module and the control circuits of other functional modules are integrated on one circuit board, so that the number of the required circuit boards is reduced.
Example 1
Fig. 1 is a schematic diagram of a power topology circuit structure of an existing all-in-one electric drive power system, which comprises a vehicle-mounted charger module 1, a motor control module 2 and a motor 3, wherein an alternating current input end of the vehicle-mounted charger module 1 is used for being connected with an alternating current power supply AC, a direct current output end of the vehicle-mounted charger module 1 is used for being connected with a power battery 4, an input end of the motor control module 2 is used for being connected with the power battery 4, and an output end of the motor control module 2 is connected with the motor 3; in a charging mode, the vehicle-mounted charger module 1 receives alternating current provided by an alternating current power supply AC and converts the alternating current into direct current, and the direct current is used for charging and storing energy for the power battery 4; in the drive mode, the motor control module 2 receives the direct current stored in the power battery 4 and converts the direct current into alternating current, and rotationally drives the motor 3 by using the alternating current.
Specifically, as shown in fig. 1, the vehicle-mounted charger module 1 includes a power factor correction unit and a dc conversion unit, the power factor correction unit includes power switching tubes T1 to T6 and inductors L1 to L2, the power switching tubes T1 to T6 form a three-phase bridge rectifier circuit, the dc conversion unit includes power switching tubes Q1 to Q8, capacitors Cr1 to Cr2, an inductor Lr and a transformer TX, the capacitors Cr1 to Cr2, the inductor Lr and the transformer TX form a CLC transformer circuit, the power switching tubes Q1 to Q4 form a primary circuit of a full-bridge structure, the power switching tubes Q5 to Q8 form a secondary circuit of the full-bridge structure, and the dc conversion unit is a full-bridge dc converter. The power factor correction unit receives alternating current provided by an alternating current power supply AC and converts the alternating current into direct current, meanwhile, the power factor correction is regulated and controlled, and the direct current conversion unit receives the direct current output by the power factor correction unit and performs direct current conversion on the direct current to obtain direct current with other specifications and sizes.
In detail, as shown in fig. 1, the vehicle-mounted charger module 1 further includes switches K1 to K3, a resistor R1, a Fuse and a clamping capacitor C1, the switches K1 to K3 form a switching unit, the switching unit is used for switching control of bridge arm input of the three-phase bridge rectifier circuit, the resistor R1 and the Fuse form a protection unit for limiting current and preventing current surge, and the clamping capacitor C1 is used for clamping output of output voltage of the three-phase bridge rectifier circuit to smooth output of direct current voltage and reduce voltage fluctuation and ripple.
In detail, as shown in fig. 1, the vehicle-mounted charger module 1 further includes an AC filter and a dc filter 1, the AC filter is disposed at an AC input end of the vehicle-mounted charger module 1 to perform filtering processing on an AC input by an AC power source AC, and the dc filter 1 is disposed at an output end of the dc conversion unit to perform filtering processing on a dc output by the dc conversion unit.
It should be noted that, the foregoing description is that the power topology circuit in the strong current aspect in the vehicle-mounted battery module 1, as shown in fig. 3, the vehicle-mounted battery module 1 further includes a control circuit in the weak current aspect, the control circuit further includes a main control circuit 1 and other functional circuits 1, the main control circuit 1 is at least connected with the switches K1 to K3, the power switching tubes T1 to T6 and the control ends of the power switching tubes Q1 to Q8 respectively, so as to realize switch control, and further adjust the working parameters of the vehicle-mounted battery module 1, the main control circuit 1 may be a multi-use integrated circuit of the main control circuit of the vehicle-mounted battery module 1 and the main control circuit of other electric drive power systems, and the other functional circuits 1 include various weak current control circuits such as SBC safety chips, aux auxiliary power supplies, COM communication circuits, sensors, driving circuits, isolation circuits and protection circuits.
Specifically, as shown in fig. 1, the motor control module 2 includes a three-phase bridge inverter circuit and an input capacitor, the three-phase bridge inverter circuit includes power switching transistors S1 to S6, the input capacitor further includes a dc supporting capacitor C2 and a dc filter 2, the dc filter 2 is connected with the power battery 4, the dc supporting capacitor C2 and the dc filter 2 are connected in parallel, the dc supporting capacitor C2 and the dc filter 2 perform filtering processing on a dc voltage output by the power battery 4, the filtered dc voltage is transmitted to an input end of the three-phase bridge inverter circuit, the three-phase bridge inverter circuit performs inversion processing on the dc voltage to obtain and output ac power to the motor 3, and further the motor 3 is rotationally driven by the ac power.
Similarly, as shown in fig. 1, the motor control module 2 also includes a control circuit, the control circuit further includes a main control circuit 2 and other functional circuits 2, the main control circuit 2 is at least connected with the control ends of the power switch tubes S1 to S6 respectively to realize switch control, so as to adjust the inversion working parameters of the motor control module 2, and the other functional circuits 2 include SBC safety chips, aux auxiliary power supply, COM communication circuits, sensors, driving circuits, isolation circuits, protection circuits and other weak current control circuits.
In more detail, in the all-in-one electric drive power system as shown in fig. 1, a direct current output end of the vehicle-mounted charger module 1 is directly connected with the power battery 4, a circuit topology of the vehicle-mounted charger module 1 and a circuit topology of the motor control module 2 are mutually independent, the direct current output end of the vehicle-mounted charger module 1 is provided with a direct current filter 1, and an input end of the motor control module 2 is provided with a direct current filter 2; in the vehicle-mounted charger module 1, a power factor correction unit and a direct current conversion unit are mutually independent, and the output of three bridge arms of a three-phase bridge rectifier circuit in the power factor correction unit is connected with two bridge arms of a primary side circuit in the direct current conversion unit, so that the number of the bridge arms is more; meanwhile, the control circuit of the vehicle-mounted charger module 1 and the control circuit of the motor control module 2 are mutually independent and occupy one circuit board respectively. The circuit topology of the all-in-one electric drive power supply system is relatively bulky.
The ac filter, the dc filter 1 and the dc filter 2 are all capacitance-based filter circuits, and details thereof can be found in the prior art, and are not described herein.
Based on this, in the embodiment of the present invention, the integrated integration of circuit topology levels is performed on the all-in-one electric drive power system shown in fig. 1, and an all-in-one electric drive power system is provided, as shown in fig. 2, which includes a vehicle-mounted charger module 1, a motor control module 2, a power battery 4 and a motor 3, wherein an AC input end of the vehicle-mounted charger module 1 is used for connecting an AC power supply AC, a dc output end of the vehicle-mounted charger module 1 is connected with the power battery 4, an input end of the motor control module 2 is connected with the power battery 4, and an output end of the motor control module 2 is connected with the motor 3; the vehicle-mounted charger module 1 comprises a power factor correction unit and a direct current conversion unit, wherein a primary circuit of the direct current conversion unit multiplexes the power factor correction unit to simplify the primary circuit of the direct current conversion unit; the direct current output end of the vehicle-mounted charger module 1 is connected with the input capacitor of the motor control module 2 so as to multiplex the input capacitor of the motor control module 2 into the output capacitor of the vehicle-mounted charger module 1.
In detail, as shown in fig. 2, in the vehicle-mounted charger module 1, for the dc conversion unit with a full-bridge structure as the primary circuit, the power factor correction unit and the dc conversion unit are integrated into a single-stage conversion correction unit by multiplexing the bridge arm formed by the power switch tube in the power factor correction unit as the bridge arm of the primary circuit at the cascade connection of the power factor correction unit and the dc conversion unit, so as to reduce the components of the power circuit and improve the conversion efficiency of the vehicle-mounted charger module 1.
In more detail, as shown in fig. 2, the single-stage conversion correction unit includes a three-phase bridge rectifier circuit, a clamping capacitor C1, a transformer circuit and a secondary side circuit, the three-phase bridge rectifier circuit includes power switching tubes T1 to T6, an input end of the three-phase bridge rectifier circuit is connected to an AC power supply AC, an output end of the three-phase bridge rectifier circuit is connected to the clamping capacitor C1, the three-phase bridge rectifier circuit is further connected to a primary side of the transformer circuit, the transformer circuit includes capacitors Cr1 to Cr2, an inductor Lr and a transformer TX, a primary side coil of the transformer TX is connected to a midpoint of two bridge arms in the three-phase bridge rectifier circuit through the serially connected inductor Lr and the capacitor Cr1, that is, a primary side of the transformer circuit is connected to a midpoint of two bridge arms in the three-phase bridge rectifier circuit, a secondary side of the transformer circuit is connected to a secondary side circuit, the secondary side circuit includes power switching tubes Q5 to Q8, and the secondary side coil of the transformer TX is connected to a midpoint of two bridge arms in the secondary side circuit through the serially connected capacitor Cr 2.
The direct current conversion unit is a direct current converter with a full-bridge CLC structure, the primary side circuit and the secondary side circuit are respectively with a full-bridge structure, the transformer circuit is a CLC transformer structure, two bridge arms of the three-phase bridge rectifier circuit are multiplexed into the primary side circuit of the direct current conversion unit, and the primary side circuit of the direct current conversion unit is completely canceled.
In detail, as shown in fig. 2, the motor control module 2 includes a three-phase bridge inverter circuit and an input capacitor, the three-phase bridge inverter circuit includes power switch tubes S1 to S6, the power switch tubes S1 to S6 form three bridge arms, the input capacitor further includes a dc supporting capacitor C2 and a filter capacitor, the output end of the three-phase bridge inverter circuit is connected to the motor 3, the positive electrode of the input end of the three-phase bridge inverter circuit is connected to the first electrode of the dc supporting capacitor C2, the negative electrode of the input end of the three-phase bridge inverter circuit is connected to the second electrode of the dc supporting capacitor C2, the filter capacitor is connected in parallel with the dc supporting capacitor C2, the first electrode of the filter capacitor is connected to the positive electrode of the power battery 4 and the first electrode of the dc supporting capacitor C2, the second electrode of the filter capacitor is connected to the negative electrode of the power battery 4 and the second electrode of the dc supporting capacitor C2, the positive electrode of the output end of the secondary circuit is connected to the first electrode of the dc supporting capacitor C2, and the negative electrode of the secondary circuit is connected to the second electrode of the dc supporting capacitor C2.
The filter capacitor and the dc filter 2 are in the same circuit topology structure, and are both filter circuits based on capacitors, and are replaced by filter capacitors only for convenience of description, and details can be found in the prior art, and are not described herein again; the output end of the secondary side circuit is directly connected with the direct current supporting capacitor C2, so that the direct current voltage output by the secondary side circuit is transmitted to the power battery 4 after passing through the direct current supporting capacitor C2 and the filter capacitor, at the moment, the input capacitor of the motor control module 2 is multiplexed into the output capacitor of the vehicle-mounted charger module 1, the direct current supporting capacitor C2 (which is generally tens of times of the output capacitor of the vehicle-mounted charger module 1) and the filter capacitor are larger, the capacitance value of the output capacitor of the vehicle-mounted charger module 1 can be effectively reduced, even the capacitance value of the output capacitor of the vehicle-mounted charger module 1 is completely cancelled, and the power topology circuit structure is further simplified.
In detail, as shown in fig. 2, the control circuit of the vehicle-mounted charger module 1 and the control circuit of the motor control module 2 are integrated and arranged on a circuit board, so that one circuit board can be reduced, weak current control integration is realized, and the volume and the cost are reduced.
It can be understood that the all-in-one electric drive power system can integrate other functional modules, such as a battery management module, a whole vehicle control module, a thermal management module, an additional direct current conversion module (or a TAB three-port magnetic integrated circuit) and the like, and at this time, the battery management module, the whole vehicle control module, a control circuit of the thermal management module and a control circuit of the direct current conversion module are also integrated and arranged on a circuit board, so that weak current control integration is further improved, and a larger number of circuit boards are saved.
Meanwhile, the motor 3 is not limited to the three-phase motor shown in fig. 1-2, but may be other multi-phase motors such as a four-phase motor and a six-phase motor, and the details of the motor are referred to in the prior art and are not described herein.
In more detail, the operation mode of the all-in-one electric drive power system shown in fig. 2 is as follows:
1) In the charging mode, the trend of the electric energy in the power topology circuit is as follows: the alternating current power supply AC (alternating current) provided by the alternating current pile is conducted, the alternating current filter-single-stage conversion correction unit is conducted, the direct current supporting capacitor C2 is conducted, the filtering capacitor is conducted, and the power battery 4 is conducted, wherein the large capacitor of the direct current supporting capacitor C2 can effectively reduce ripple current of the vehicle-mounted charger module 1, and the primary circuit of the direct current conversion unit is simplified, so that the efficiency of the vehicle-mounted charger module 1 is improved compared with that of the all-in-one electric drive power supply system shown in FIG. 3;
2) In the driving mode, the trend of electric energy in the power topology circuit is as follows: power battery 4++filtering capacitance++direct current support capacitance C2++three-phase bridge inverter circuit- & gt motor 3.
The primary circuit of the direct-current conversion unit and the output capacitor of the vehicle-mounted charger module 1 are canceled, so that integration of power circuit topology levels is realized, the power circuit topology structure of the all-in-one electric drive power supply system is simplified, the integration level of the all-in-one electric drive power supply system is improved, the cost and the volume are reduced, and the working efficiency of the vehicle-mounted charger module 1 is improved; meanwhile, the control circuit of the vehicle-mounted charger module 1 and the control circuit of the motor control module 2 are integrated on one circuit board, so that weak current control integration is realized, the number of the required circuit boards is reduced, the cost is further reduced, and the size is further reduced.
It should be noted that the foregoing is directed to integrating and integrating power topology levels of the dc conversion unit of the full-bridge CLC structure, but is not limited to this, and the power topology integration of the dc conversion unit of other structures can be further extended, so long as the primary side circuit of the dc conversion unit is guaranteed to be of a full-bridge structure, two bridge arms of the three-phase bridge rectifier circuit are directly multiplexed as the primary side circuit of the dc conversion unit during integration, for example, the dc conversion unit of the full-bridge LC structure, the dc conversion unit of the full-bridge LLC structure, or the dc conversion unit of the full-bridge CLC structure, or the primary side circuit is of a full-bridge structure, the secondary side circuit is of a half-bridge structure, or the dc conversion unit of the push-pull structure, and the corresponding transformer circuit may be of a CLLC structure, an LLC structure, a CLC structure, or a CLLC structure, which will not be described herein.
Meanwhile, the embodiment of the invention also provides a design method of the all-in-one electric drive power system, which is applied to the design of the all-in-one electric drive power system and comprises the following steps:
s1, multiplexing a power factor correction unit as a primary side circuit of a direct current conversion unit, and integrating the power factor correction unit and the direct current conversion unit into a single-stage topological structure so as to cancel the primary side circuit of the direct current conversion unit;
s2, multiplexing the input capacitor as an output capacitor of the vehicle-mounted charger module, and connecting the output end of the secondary side circuit in the direct-current conversion unit with the input capacitor of the motor control module to simplify the output capacitor of the direct-current conversion unit;
s3, multiplexing the circuit board, and integrating the control circuit of the vehicle-mounted charger module, the control circuit of the motor control module, the battery management module, the whole vehicle control module, the thermal management module and the control circuit of the additional direct current conversion module on the circuit board.
The detailed process of steps S1 to S3 can be referred to the above description of the all-in-one electric drive power system, and will not be repeated here.
In addition, the embodiment of the invention also provides a vehicle which comprises the all-in-one electric drive power supply system, and is based on the power topological integration of the vehicle-mounted charger module 1 and the motor control module 2 and the weak current control integration of the corresponding control circuit, so that the integration level of the all-in-one electric drive power supply system is improved, the cost is effectively reduced, the size and the vertical height are reduced, the structural optimization layout of the vehicle is facilitated, and the vehicle is particularly suitable for a rear-drive electric vehicle with limited space in a trunk.
In an alternative embodiment of the present invention, the technical effects are compared and verified, and the following results are obtained: compared with the all-in-one electric drive power system shown in fig. 1, the all-in-one electric drive power system shown in fig. 2 reduces the primary circuit and the output capacitance of the direct current conversion unit in the vehicle-mounted charger module 1, simultaneously reduces one path of control board, reduces the volume by about 5%, reduces the cost by about 40RMB, and improves the working efficiency of the vehicle-mounted charger module 1 by about 1%.
Example two
In the first embodiment of the invention, the internal power topology integration is performed on the vehicle-mounted charger module 1 with the primary side circuit of the direct-current conversion unit being in a half-bridge structure, so that the primary side circuit of the direct-current conversion unit can be completely canceled, the power topology structure of the vehicle-mounted charger module 1 is effectively simplified and optimized, and the power topology structure can be expanded to the direct-current conversion unit with the primary side circuit being in the half-bridge structure.
Based on this, the embodiment of the invention provides an all-in-one electric drive power system as shown in fig. 4 for power topology integration and weak current control integration of the all-in-one electric drive power system as shown in fig. 3.
In detail, as shown in fig. 3, the all-in-one electric drive power system comprises a vehicle-mounted charger module 1, a motor control module 2 and a motor 3, wherein an alternating current input end of the vehicle-mounted charger module 1 is used for being connected with an alternating current power supply AC, a direct current output end of the vehicle-mounted charger module 1 is used for being connected with a power battery 4, an input end of the motor control module 2 is used for being connected with the power battery 4, and an output end of the motor control module 2 is connected with the motor 3; the vehicle-mounted charger module 1 comprises a power factor correction unit and a direct current conversion unit, wherein a primary circuit of the direct current conversion unit is of a half-bridge structure, one bridge arm is composed of power switching tubes Q1-Q2, the other bridge arm is composed of capacitors C01-C02, a transformer circuit of the direct current conversion unit is of a CLC structure, a secondary circuit of the direct current conversion unit is of a full-bridge structure, and power switching tubes Q5-Q8 are composed of two bridge arms. Other structures of the all-in-one electric drive power system are similar to those of fig. 1, and details can be found in the related description of the first embodiment of the present invention, which is not repeated here.
In detail, as shown in fig. 4, in the embodiment of the present invention, in the vehicle-mounted charger module 1, power topology integration is performed at the cascade connection position of the power factor correction unit and the dc conversion unit, and one bridge arm of the three-phase bridge rectifier circuit in the power factor correction unit is multiplexed into one bridge arm formed by the power switch tube in the primary side circuit of the dc conversion unit, so that the bridge arm formed by the power switch tube in the primary side circuit is omitted, and only the bridge arm formed by the capacitors C01 to C02 in the primary side circuit is reserved. Other circuit topologies are similar to those of the embodiments of the present invention and will not be described in detail herein.
The power topology structure of the all-in-one electric drive power supply system is simplified, the power topology structure of the vehicle-mounted charger module 1 is effectively simplified and optimized, the structural design that the direct current output end of the vehicle-mounted charger module 1 is connected with the input capacitor of the motor control module 2 is combined, the input capacitor of the motor control module 2 is effectively reused as the output capacitor of the vehicle-mounted charger module 1, the integration of the power circuit topology level is realized, the power circuit topology structure of the all-in-one electric drive power supply system is simplified, the integration level of the all-in-one electric drive power supply system is improved, the cost is reduced, the volume is reduced, and the working efficiency of the vehicle-mounted charger module 1 is also improved; meanwhile, based on the structural design that the control circuit of the vehicle-mounted charger module 1 and the control circuit of the motor control module 2 are integrally arranged on one circuit board, weak current control integration is realized, the number of the required circuit boards is reduced, the cost is further reduced, and the size is further reduced.
Similarly, the integration of the power topology levels is performed on the dc conversion units of the primary half-bridge and secondary full-bridge CLC structures, but the integration is not limited thereto, and the integration of the power topology of the dc conversion units of other structures can be further extended, so long as the primary circuit of the dc conversion unit is ensured to be of a half-bridge structure, one bridge arm of the three-phase bridge rectifier circuit is directly multiplexed as one bridge arm of the primary circuit of the dc conversion unit during the integration, for example, the primary circuit is of a half-bridge structure, the secondary circuit is of a half-bridge structure or a direct-current conversion unit of a push-pull structure, and the corresponding transformer circuit can be of an LC structure, an LLC structure, a CLC structure or a CLLC structure, which will not be described herein.
In summary, in the all-in-one electric drive power supply system and the design method thereof provided by the invention, the all-in-one electric drive power supply system is designed by combining the vehicle-mounted charger module, the motor control module and the motor, the vehicle-mounted charger module comprises the power factor correction unit and the direct current conversion unit, a part of bridge arms of the power factor correction unit are used as primary circuits of the direct current conversion unit, the primary circuits of the direct current conversion unit can be simplified or completely cancelled, the direct current output end of the vehicle-mounted charger module is connected with the input capacitor of the motor control module, the input capacitor of the multiplexing motor control module is used as the output capacitor of the vehicle-mounted charger module, the output capacitor of the vehicle-mounted charger module can be simplified or completely cancelled, the integration of the power circuit topology level is realized, the power circuit topology structure of the all-in-one electric drive power supply system is simplified, the integration level of the all-in-one electric drive power supply system is improved, the cost is reduced, the volume is reduced, and the work efficiency of the vehicle-mounted charger module is also improved. Meanwhile, the control circuit based on the vehicle-mounted charger module, the control circuit of the motor control module and the control circuit of other functional modules are integrated on the same circuit board, so that weak current control integration is realized, the number of required circuit boards is reduced, the cost is further reduced, and the size is reduced.
The above embodiments are merely illustrative of the principles of the present invention and its effectiveness, and are not intended to limit the invention. Modifications and variations may be made to the above-described embodiments by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is intended that all equivalent modifications and variations of the invention be covered by the claims, which are within the ordinary skill of the art, be within the spirit and scope of the present disclosure.

Claims (10)

1. The all-in-one electric drive power supply system is characterized by comprising a vehicle-mounted charger module, a motor control module and a motor, wherein an alternating current input end of the vehicle-mounted charger module is used for being connected with an alternating current power supply, a direct current output end of the vehicle-mounted charger module is used for being connected with a power battery, an input end of the motor control module is used for being connected with the power battery, and an output end of the motor control module is connected with the motor; the vehicle-mounted charger module comprises a power factor correction unit and a direct current conversion unit, wherein a primary side circuit of the direct current conversion unit multiplexes the power factor correction unit to simplify the primary side circuit of the direct current conversion unit; and the direct current output end of the vehicle-mounted charger module is connected with the input capacitor of the motor control module so as to multiplex the input capacitor into the output capacitor of the vehicle-mounted charger module.
2. The all-in-one electric drive power system of claim 1, wherein the control circuit of the vehicle-mounted charger module is integrated with the control circuit of the motor control module on a circuit board.
3. The all-in-one electric drive power system of claim 2, further comprising a battery management module, a vehicle control module, and a thermal management module, wherein control circuits of the battery management module, the vehicle control module, and the thermal management module are integrally disposed on the circuit board.
4. The all-in-one electric drive power supply system of claim 2, further comprising a direct current conversion module, wherein a control circuit of the direct current conversion module is integrally disposed on the circuit board.
5. The all-in-one electric drive power supply system according to claim 1, wherein the power factor correction unit and the direct current conversion unit are integrated into a single-stage conversion correction unit, the single-stage conversion correction unit comprises a three-phase bridge rectifier circuit, a clamping capacitor, a transformer circuit and a secondary side circuit, the input end of the three-phase bridge rectifier circuit is connected with the alternating current power supply, the output end of the three-phase bridge rectifier circuit is connected with the clamping capacitor, the three-phase bridge rectifier circuit is further connected with the primary side of the transformer circuit, part of the three-phase bridge rectifier circuit is multiplexed into the primary side circuit, and the secondary side of the transformer circuit is connected with the secondary side circuit.
6. The all-in-one electric drive power system of claim 5, wherein the primary side circuit is a full bridge structure, and two bridge arms of the three-phase bridge rectifier circuit are multiplexed into the primary side circuit.
7. The all-in-one electrically driven power system of claim 5, wherein the primary side circuit is a half-bridge structure and one leg of the three-phase bridge rectifier circuit is multiplexed to one leg of the primary side circuit.
8. The all-in-one electric drive power supply system according to claim 6 or 7, wherein the transformer circuit is of an LLC structure, a CLC structure or a CLLC structure, and the secondary circuit is of a full bridge structure, a half bridge structure or a push-pull structure.
9. The all-in-one electric drive power system of claim 8, wherein the motor control module comprises a three-phase bridge inverter circuit, the input capacitor comprises a direct current support capacitor and a filter capacitor, the output end of the three-phase bridge inverter circuit is connected with the motor, the positive electrode of the input end of the three-phase bridge inverter circuit is connected with the first electrode of the direct current support capacitor, the negative electrode of the input end of the three-phase bridge inverter circuit is connected with the second electrode of the direct current support capacitor, the filter capacitor is connected with the direct current support capacitor in parallel, the first electrode of the filter capacitor is respectively connected with the positive electrode of the power battery and the first electrode of the direct current support capacitor, the second electrode of the filter capacitor is respectively connected with the negative electrode of the power battery and the second electrode of the direct current support capacitor, the positive electrode of the output end of the secondary side circuit is connected with the first electrode of the direct current support capacitor, and the negative electrode of the output end of the secondary side circuit is connected with the second electrode of the direct current support capacitor.
10. A design method of an all-in-one electric drive power supply system, applied to the design of the all-in-one electric drive power supply system as claimed in any one of claims 1 to 9, comprising:
multiplexing the power factor correction unit as a primary side circuit of the direct current conversion unit, and integrating the power factor correction unit and the direct current conversion unit into a single-stage topological structure so as to cancel the primary side circuit of the direct current conversion unit;
multiplexing the input capacitor as an output capacitor of the vehicle-mounted charger module, and connecting an output end of a secondary circuit in the direct-current conversion unit with the input capacitor of the motor control module to simplify the output capacitor of the direct-current conversion unit;
and the multiplexing circuit board integrates the control circuit of the vehicle-mounted charger module, the control circuit of the motor control module, the battery management module, the whole vehicle control module and the control circuit of the thermal management module on the circuit board.
CN202311460162.9A 2023-11-04 2023-11-04 All-in-one electric drive power supply system and design method thereof Pending CN117578683A (en)

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CN202311460162.9A CN117578683A (en) 2023-11-04 2023-11-04 All-in-one electric drive power supply system and design method thereof

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