CN117835610A - Electric drive controller for vehicle - Google Patents

Abstract

The application discloses an automotive electric drive controller, which comprises an IGBT power module, a cooling support plate and a controller shell; the cooling support plate is provided with a cooling groove, and the IGBT power module is arranged on the cooling support plate and covers the cooling groove; the controller shell comprises a bottom wall and a side wall connected with the bottom wall, and the bottom of the cooling support plate, which is opposite to the IGBT power module, is arranged on the side wall; the side wall is internally provided with a cooling part for cooling at least part of the side wall, and the cooling part comprises a cooling inlet channel and a cooling outlet channel which are communicated with the cooling groove; the bottom wall is provided with a first drainage groove and a first drainage hole communicated with the first drainage groove, and the first drainage groove extends to the side wall of the connecting part cooled by the cooling part. Through the scheme, the probability of condensation in a dangerous area can be effectively reduced, and the probability of faults of the electric drive controller is reduced.

Description

Electric drive controller for vehicle

Technical Field

The application relates to the technical field of electric automobiles, in particular to an electric drive controller for a vehicle.

Background

The electric automobile is provided with an electric drive controller, and the electric drive controller has the core function of converting direct current provided by a battery pack into alternating current, and driving a motor to operate according to instructions so as to drive the whole automobile to operate. The inside power device of electricity drives the inside during operation of controller and generates heat, and the temperature is higher, heats the inside moisture of electricity drive controller cavity on the one hand, leads to humidity to increase, and on the other hand makes the temperature of electricity drive controller cavity and the temperature of spare part appear great difference in temperature to the dew is produced in the inside electricity drive controller easily, and the dew very easily leads to the high-pressure heavy current's electricity drive controller to appear the short circuit, leads to vehicle power to lose, endangers driver and passenger safety.

Disclosure of Invention

The technical problem that this application mainly solves is to provide a vehicle electricity drives controller, effectively reduces the probability that the condensation appears in dangerous region, reduces the probability that electricity drives the controller to break down.

In order to solve the technical problems, one technical scheme adopted by the application is as follows: the utility model provides an automotive electric drive controller, which comprises an IGBT power module, a cooling support plate and a controller shell; the IGBT power module is arranged on the cooling support plate and covers the cooling groove; the controller shell comprises a bottom wall and a side wall connected with the bottom wall, and the cooling support plate is arranged on the side wall back to the bottom of the IGBT power module; a cooling part for cooling at least part of the side wall is arranged in the side wall, and comprises a cooling inlet channel and a cooling outlet channel which are communicated with the cooling groove; the bottom wall is provided with a first drainage groove and a first drainage hole communicated with the first drainage groove, and the first drainage groove extends to the side wall of the connecting part cooled by the cooling part.

The cooling part further comprises a side wall cooling channel, the orthographic projection of the side wall cooling channel on the bottom wall surrounds at least part of the first drainage groove, and two ends of the side wall cooling channel are respectively communicated with the cooling inlet channel and the cooling outlet channel.

Wherein, the cooling part also comprises a heat dissipation piece.

The corner of the bottom wall is provided with a first accommodating cavity, the first drain hole is arranged in the first accommodating cavity, and one end of the first drain groove extends to be connected with the first accommodating cavity; the height of the bottom wall of one end of the first water drainage groove far away from the first accommodating cavity along the gravity direction is higher than the height of the bottom wall connected with one end of the first accommodating cavity.

The cooling support plate is provided with a cooling groove, a guide part and a second accommodating cavity are further arranged on one side of the cooling support plate, the guide part is arranged outside the cooling groove in a surrounding mode, and the guide part is communicated with the second accommodating cavity; the side wall is equipped with first water conservancy diversion passageway towards one side of cooling backup pad, first water conservancy diversion passageway both ends communicate respectively first acceping the chamber with the chamber is acceptd to the second.

The flow guiding part comprises a second water draining groove, and the height, away from one end of the second accommodating cavity, of the second water draining groove along the gravity direction is higher than the height of one end of the second accommodating cavity.

The vehicle electric drive controller further comprises a top cover, wherein the top cover, the bottom wall and the side wall are surrounded to form a containing cavity, the inner wall of the top cover comprises at least one inclined surface, and one end, away from the side wall, of the inclined surface is higher than the top surface of the side wall along the height direction.

The side wall is provided with a diversion trench and a second diversion channel, the diversion trench surrounds and is connected with the inner wall of the top cover, and two ends of the second diversion channel are respectively communicated with the diversion trench and the first drainage trench.

Wherein, the vehicle electric drive controller also comprises an alarm system; the first water drain hole is internally provided with a one-way water drain monitoring valve, and the one-way water drain monitoring valve is used for draining water in the first accommodating cavity out of the vehicle electric drive controller and triggering the alarm system.

The IGBT power module comprises a first cooling shell and a power device, wherein a first cooling cavity is formed in the first cooling shell, and the power device is positioned in the first cooling cavity; the vehicle electric drive controller further comprises a first cooling loop, wherein the first cooling loop comprises a first cooling cavity, a cooling liquid inlet pipe and a cooling liquid outlet pipe, and the cooling liquid inlet pipe and the cooling liquid outlet pipe are communicated with the first cooling cavity; the controller shell is also provided with a first cooling channel and a liquid return port, the first cooling channel is connected with the cooling liquid inlet pipe, and the liquid return port is communicated with the cooling liquid outlet pipe.

The beneficial effects of this application are: in distinction from the prior art, the present application provides a cooling section on the side wall of the controller housing, which cooling section comprises a cooling inlet channel and a cooling outlet channel, on the one hand such that the cooling medium can enter the cooling support plate from outside the controller housing through the cooling inlet channel and leave the controller housing through the cooling outlet channel. On the other hand, when the cooling medium flows through the cooling inlet channel and the cooling outlet channel, the cooling inlet channel and the cooling outlet channel are used as cooling parts, so that the temperature of part of side walls around the cooling inlet channel and the cooling outlet channel can be reduced, namely, the temperature of the side wall surfaces around the cooling parts is obviously lower than that of the surfaces of other parts or other positions of the controller shell, when the humidity inside the controller is increased due to abnormal conditions, condensation can be firstly generated on the side wall surfaces around the cooling parts, so that the humidity inside the controller is effectively reduced, the probability of the condensation at other positions is effectively reduced, and the region is not easy to cause the failure of the electric drive controller due to the condensation, so that the probability of the failure of the electric drive controller is reduced. In addition, because this application has set up first water drainage tank and first wash port in controller casing bottom, the lateral wall around the cooling part is connected to first water drainage tank for condensation on the lateral wall can flow into first water drainage tank under the action of gravity, then flows into first wash port along first water drainage tank, finally discharges the electric drive controller, thereby has reduced the water yield in the electric drive controller, has reduced humidity, has also reduced the probability that the electric drive controller breaks down.

Drawings

FIG. 1 is an exploded view of one embodiment of an automotive electric drive controller of the present application;

FIG. 2 is an exploded view of one embodiment of a controller housing of the present application;

FIG. 3 is a schematic view of the structure of an embodiment of a cooling support plate of the present application;

FIG. 4a is a front view of an embodiment of a controller housing of the present application;

FIG. 4b is a cross-sectional view of FIG. 4a taken in the direction A-A;

FIG. 4c is a cross-sectional view of FIG. 4a in the B-B direction;

FIG. 5 is a cross-sectional view of an embodiment of an IGBT power module and cooling support plate of the present application;

FIG. 6 is a schematic diagram of an embodiment of an IGBT power module of the present application;

FIG. 7 is an exploded view of one embodiment of an IGBT power module and cooling support plate of the present application;

FIG. 8 is an exploded view of another embodiment of the vehicle electric drive controller of the present application;

fig. 9 is an exploded view of another embodiment of the vehicle electric drive controller of the present application.

Detailed Description

In order to make the objects, technical solutions and effects of the present application clearer and more specific, the present application will be further described in detail below with reference to the accompanying drawings and examples. It will be apparent that the described embodiments are only some, but not all, of the embodiments of the present application. All other embodiments, which can be made by one of ordinary skill in the art without undue burden from the present disclosure, are within the scope of the present disclosure.

Referring to fig. 1 and 2, fig. 1 is an exploded view of an embodiment of an electric drive controller for a vehicle according to the present application. Fig. 2 is an exploded view of one embodiment of a controller housing of the present application.

The electro-driver controller 100 includes an IGBT power module 10, a cooling support plate 20, and a controller housing 50. The cooling support plate 20 is provided with a cooling groove 21, the IGBT power module 10 is arranged on the cooling support plate 20, and covers the cooling groove 21; the controller housing 50 comprises a bottom wall 54 and a side wall 53 connected with the bottom wall 54, and the cooling support plate 20 is arranged on the side wall 53 back to the bottom of the IGBT power module 10; a cooling portion for cooling at least part of the side wall 53 is provided in the side wall 53, the cooling portion including a cooling inlet passage 501 and a cooling outlet passage 502 communicating with the cooling tank 21; the bottom wall 54 is provided with a first water discharge groove 541 and a first water discharge hole 543 communicating with the first water discharge groove 541, and the first water discharge groove 541 extends to the side wall 53 where the connection portion is cooled by the cooling portion.

Specifically, the IGBT power module 10 is disposed on one side of the cooling support plate 20, and referring to fig. 1 and 3, fig. 3 is a schematic structural diagram of an embodiment of the cooling support plate of the present application. The side of the cooling support plate 20 facing the IGBT power module 10 is provided with a cooling groove 21 and a sealing groove 22, the sealing groove 22 is arranged outside the cooling groove 21 in a surrounding manner, a sealing strip 221 is arranged in the sealing groove 22, the IGBT power module 10 covers the cooling groove 21 to form a cooling cavity and is in sealing connection with the cooling support plate 20, a second cooling inlet 2a and a second cooling outlet (not shown) are arranged at the bottom of the cooling groove 21, and cooling medium can flow into the cooling groove 21 from the second cooling inlet 2a and flow out of the cooling groove 21 from the second cooling outlet, so that the IGBT power module 10 is cooled. The second cooling inlet 2a and the second cooling outlet are respectively arranged close to two opposite side walls of the cooling groove 21, so that cooling medium can flow through the whole second cooling cavity 2b, the cooling area is increased, and the heat dissipation effect is ensured. The cooling medium in the present application may be water, oil, etc., and is not limited in the present application.

The cooling inlet channel 501 communicates with the second cooling inlet 2a, and the cooling outlet channel 502 communicates with the second cooling outlet, so that the cooling medium can enter the cooling support plate 20 from outside the controller housing 50 through the cooling inlet channel 501 and leave the controller housing 50 through the cooling outlet channel 502. Meanwhile, since the cooling inlet channel 501 and the cooling outlet channel 502 are both disposed in the side wall 53, when the cooling medium flows through the cooling inlet channel 501 and the cooling outlet channel 502, the cooling inlet channel 501 and the cooling outlet channel 502 can serve as cooling parts to reduce the temperature of the side wall 53 around the cooling inlet channel 501 and the cooling outlet channel 502, that is, the surface temperature of the side wall 53 around the cooling part is obviously lower than that of other parts or other positions of the controller housing 50, when the humidity in the controller is increased due to abnormal conditions, condensation can be first formed on the surface of the side wall 53 around the cooling part, so that on one hand, the humidity in the controller is effectively reduced, the probability of condensation at other positions is effectively reduced, and on the other hand, the region is not easy to cause the failure of the electric drive controller 100 due to the condensation, so that the probability of failure of the electric drive controller 100 is reduced. In addition, since the first drainage groove 541 and the first drainage hole 543 are formed in the bottom of the controller housing 50, the first drainage groove 541 is connected with the side wall 53 around the cooling portion, so that the condensation on the side wall 53 can flow into the first drainage groove 541 under the action of gravity, then flow into the first drainage hole 543 along the first drainage groove 541, and finally drain the electric drive controller 100, thereby reducing the water quantity in the electric drive controller 100, reducing the humidity, and also reducing the probability of failure of the electric drive controller 100.

Alternatively, with continued reference to fig. 1 and 2, in some embodiments, a corner of the bottom wall 54 is provided with a first receiving cavity 542, a first drain hole 543 is provided in the first receiving cavity 542, and an end of the first drain groove 541 extends to connect the first receiving cavity 542; the bottom wall 54 of the first drainage groove 541 at an end remote from the first accommodation chamber 542 has a height in the gravitational direction that is higher than the height of the bottom wall 54 connected to the end of the first accommodation chamber 542. The first receiving chamber 542 serves to collect water flowing in from the first water discharge groove 541. The first drainage groove 541 may be provided in plurality, for example, the first drainage groove 541 may extend along the bottoms of the plurality of side walls 53, be provided around the bottom wall 54, and collect the condensation on the plurality of side walls 53 to be finally collected in one first receiving chamber 542. The first drainage groove 541 may have a slope, and one end close to the first accommodating chamber 542 is low, and one end far away from the first accommodating chamber 542 is high, so that the condensation collected by the first drainage groove 541 can automatically flow into the first accommodating chamber 542 under the action of gravity, and leave the controller through the first drainage hole 543.

The cooling portion may also be of other forms. Referring to the example shown in fig. 4 a-4 c, fig. 4a is a front view of an embodiment of a controller housing of the present application, fig. 4B is a cross-sectional view of fig. 4a in A-A direction, and fig. 4c is a cross-sectional view of fig. 4a in B-B direction. In this embodiment, the cooling portion further includes a side wall cooling channel 503, and an orthographic projection of the side wall cooling channel 503 on the bottom wall 54 surrounds at least a part of the first water draining groove 541, and two ends of the side wall cooling channel 503 are respectively connected to the cooling inlet channel 501 and the cooling outlet channel 502. In this embodiment, the side wall cooling channels 503 are embedded in the three side walls 53, after the cooling medium enters the channels 501 from cooling, one path of cooling medium enters the cooling tank 21, and the other path of cooling medium can enter the side wall cooling channels 503, and as the side wall cooling channels 503 can be connected with the side walls 53, the temperature of the side walls 53 where the side wall cooling channels 503 are located is reduced, so that the cooling effect of the side walls 53 is improved, the cooling degree of the side walls 53 is kept consistent, the surface of the side walls 53 is guaranteed to be exposed first, dehumidification is further improved, and the probability of exposure at other positions is reduced. The side wall cooling channels 503 may be formed by inwardly slotting the side walls 53 and providing plugs 531 at the slots to form closed side wall cooling channels 503.

In other embodiments, the cooling portion may further include a heat dissipation member, where the heat dissipation member may be made of a material with a relatively high thermal conductivity, for example, a copper sheet may be embedded in the side wall 53 or attached to a surface, so that the heat dissipation effect of the side wall 53 where the copper sheet is disposed is better than that of other parts or components of the controller housing 50, thereby reducing the temperature of the side wall 53 where the heat dissipation member is disposed, and becoming a region where condensation first occurs. Optionally, a moisture absorbing member is provided at a position where the cooling portion is provided, so that the formed condensation is absorbed by the moisture absorbing member, and the formation of condensation at other dangerous positions is avoided, thereby avoiding the malfunction of the electric drive controller 100.

Optionally, with continued reference to fig. 2 and 3, in some embodiments, a side of the cooling support plate 20 provided with the cooling groove 21 is further provided with a flow guiding portion and a second accommodating cavity 24, the flow guiding portion is used for guiding the leaked cooling medium into the second accommodating cavity 24, specifically, the flow guiding portion includes a second drainage groove 23, the second drainage groove 23 is annularly arranged outside the cooling groove 21 and the sealing groove 22, and the second drainage groove 23 is communicated with the second accommodating cavity 24; the side wall 53 is provided with a first guide channel D1 (shown by solid arrows in fig. 2) on a side facing the cooling support plate 20, and two ends of the first guide channel D1 are respectively communicated with the first accommodating cavity 542 and the second accommodating cavity 24. Specifically, the second receiving chamber 24 is provided therein with the second drain hole 25, the side wall 53 includes a stepped surface 532, and the cooling inlet passage 501 and the cooling outlet passage 502 are each formed to open on the stepped surface 532, and the cooling support plate 20 is mounted on the stepped surface 532 such that the cooling inlet passage 501, the cooling outlet passage 502 communicate with the second cooling inlet 2a, the second cooling outlet, respectively. The first diversion channel D1 includes a first sub-groove 504, a second sub-groove 505 and a third sub-groove 506, which are disposed on the step surface 532, the two ends of the first sub-groove 504 are respectively communicated with the second drain hole 25 and the second sub-groove 505, the middle part of the second sub-groove 505 is communicated with the first sub-groove 504, one end of the second sub-groove 505 is communicated with the third sub-groove 506, the third sub-groove 506 extends along the height direction, and the two ends of the third sub-groove 506 are respectively communicated with the second sub-groove 505 and the first accommodating cavity 542. The cooling medium in the cooling tank 21 flows into the second drain tank 23 beyond the seal groove 22 in the case of seal failure, flows into the second receiving chamber 24 along the second drain tank 23, flows into the first receiving chamber 542 along the first sub-tank 504, the second sub-tank 505 and the third sub-tank 506 in this order from the second drain hole 25, and is discharged out of the controller housing 50 through the first drain hole 543, that is, once the problem of seal failure occurs, the leaked cooling medium may be finally collected into the first receiving chamber 542 together with the condensate and discharged.

Alternatively, the height of the end of the second drain groove 23 away from the second receiving chamber 24 in the gravitational direction is higher than the height of the end connected to the second receiving chamber 24. The second drain groove 23 may have a slope such that the leaked cooling medium collected by the second drain groove 23 can automatically flow into the second receiving chamber 24 by gravity and finally exit the controller housing 50 from the first drain hole 543. The second receiving chamber 24 may be provided at a corner of the cooling support plate 20 corresponding to the first receiving chamber 542, so that the length of the first guide passage D1 may be shortened, thereby enabling the leaked cooling medium to be rapidly discharged. The inner wall of the second drain groove 23 may be coated with a hydrophobic coating to ensure that the cooling medium does not remain in the second drain groove 23.

Optionally, referring to fig. 2, in some embodiments, the vehicle electric drive controller 100 further includes a top cover 52, where the top cover 52, the bottom wall 54, and the side wall 53 enclose to form the accommodating cavity 51, specifically, the top cover 52 is in a quadrangular frustum shape, the inner wall of the top cover 52 forms four inclined planes, and along the height direction, one end of the inclined plane away from the side wall 53 is higher than the top surface of the side wall 53, and a hydrophobic coating may be disposed on the inclined planes. When the temperature of the external environment is lower, the temperature of the top cover 52 is lower than the temperature of structural components of other internal non-cooling circuits, and when the electric drive controller 100 operates, the temperature of the internal cavity is high, and the temperature difference between the cavity temperature and the inner surface of the top cover 52 is the second gradient condensation temperature difference temperature. When the humidity rises due to an abnormal condition, condensation occurs at the high temperature difference position on the surface of the top cover 52 due to the high humidity and the second gradient high temperature difference. The four inclined surfaces correspond to the four side walls 53, so that the condensation is converged at the junction of the lowest point of the top cover 52 and the side walls 53 along the inclined surfaces, and flows along the side walls 53 toward the bottom wall 54. Too much condensation is prevented from collecting on the top cover 52 and dripping onto the power devices or control boards in the cavity is avoided, resulting in failure of the electro-drive controller 100. In other embodiments, the inclined surface may also have an arc shape or the like.

Optionally, with continued reference to fig. 2, the side wall 53 is provided with a diversion trench 533 and a second diversion channel D2 (indicated by a dashed arrow in fig. 2), where the diversion trench 533 surrounds and is connected to the inner wall of the top cover 52, and two ends of the second diversion channel D2 are respectively connected to the diversion trench 533 and the first drainage trench 541. Specifically, the second diversion channel D2 includes a fourth sub-groove 507, a second sub-groove 505 and a third sub-groove 506 that are sequentially connected, where the fourth sub-groove 507 extends along the height direction and is located at the junction of the two side walls 53, and two ends of the fourth sub-groove 507 are respectively communicated with one ends of the diversion groove 533 and the second sub-groove 505. The condensation formed on the top cover 52 flows into the first receiving chamber 542 along the fourth sub-groove 507, the second sub-groove 505 and the third sub-groove 506 in sequence. In this embodiment, the paths of the second diversion channel D2 and the first diversion channel D1 partially overlap on the second sub-groove 505 and the third sub-groove 506, so that the condensation formed on the top cover 52 and the cooling medium leaked from the cooling support plate 20 are both along the second sub-groove 505 and the third sub-groove 506 and finally collected into the first receiving cavity 542, so that the diversion structure is more simplified. In other embodiments, the second diversion channel D2 may be disposed at other positions and may be capable of communicating the diversion trench 533 with the first accommodation cavity 542. The diversion trench 533 may also be provided with a slope, and the height of the diversion trench 533 away from the end of the fourth sub-trench 507 along the gravity direction is higher than the height of the end connected with the fourth sub-trench 507, so that the condensation can be rapidly collected to the fourth sub-trench 507. Specifically, the top of the flow guide groove 533 is kept flush, so that the flow guide groove 533 can be always attached to the bottom of the top cover 52, and the bottom surface of the flow guide groove 533 has a slope, so that the condensation can be collected to the fourth sub-groove 507 along the inclined bottom surface.

Optionally, the vehicle electric drive controller 100 further includes an alarm system (not shown); a one-way drain monitoring valve (not shown) is provided in the first drain hole 543, and is used for draining the water in the first accommodating chamber 542 out of the vehicle electric drive controller 100 and triggering an alarm system. The one-way drainage monitoring valve monitors that leakage liquid (including condensation or cooling medium) exists in the first drainage hole 543, timely discharges the leakage liquid, and simultaneously triggers an alarm to remind leakage and prompt drivers and passengers to repair and replace timely.

Alternatively, referring to fig. 1 and 5, fig. 5 is a cross-sectional view of an embodiment of the IGBT power module and cooling support plate of the present application. The IGBT power module 10 comprises a first cooling shell 11 and a power device 12, wherein a first cooling cavity 1b is formed in the first cooling shell 11, and the power device 12 is positioned in the first cooling cavity 1 b; the vehicle electric drive controller 100 further comprises a first cooling loop L1, the first cooling loop L1 comprises a first cooling cavity 1b, a cooling liquid inlet pipe 1a and a cooling liquid outlet pipe 1c, the cooling liquid inlet pipe 1a and the cooling liquid outlet pipe 1c are communicated with the first cooling cavity 1b, the controller shell 50 is further provided with a first cooling channel T1 and a liquid return port 5c, the first cooling channel T1 is communicated with the cooling liquid inlet pipe 1a, and the liquid return port 5c is communicated with the cooling liquid outlet pipe 1 c.

Insulating cooling medium such as cooling oil can be introduced into the first cooling cavity 1b, the power device 12 arranged in the first cooling cavity 1b is directly cooled, and the direct cooling mode can realize high-efficiency heat dissipation, so that the high power requirement of the whole vehicle is met. Specifically, the insulating cooling medium first enters the first cooling passage T1 through the liquid inlet 5a, then leaves the first cooling passage T1 from the liquid outlet 5b and enters the cooling circuit in the electric drive controller 100 for the vehicle, in this embodiment, the liquid outlet 5b communicates with the cooling liquid inlet pipe 1a, the insulating cooling medium enters the first cooling circuit L1 through the cooling liquid inlet pipe 1a, then leaves the first cooling circuit L1 through the cooling liquid outlet pipe 1c, and finally leaves the electric drive controller 100 for the vehicle from the liquid return port 5 c.

While the cooling inlet channel 501, the second cooling inlet 2a, the second cooling chamber 2b, the second cooling outlet 2c and the cooling outlet channel 502 constitute a second cooling circuit L2, a cooling medium may be introduced into the second cooling circuit L2, which may be the same as or different from the insulating cooling medium in the first cooling circuit L1. The first cooling loop L1 indirectly cools the IGBT power module 10, and the second cooling loop L2 directly cools the IGBT power module 10, thereby enhancing the cooling effect on the IGBT power module 10. The first cooling loop L1 and the second cooling loop L2 are mutually independent and are arranged at intervals, so that the two cooling loops can be controlled respectively without mutual influence. The cooling modes of the first cooling loop L1 and the second cooling loop L2 for the power device 12 are direct cooling and indirect cooling respectively, and the cooling efficiencies of the first cooling loop L1 and the second cooling loop L2 are different, so that at least one cooling loop can be started according to the driving power requirement of the whole vehicle so as to meet the heat dissipation requirements under different powers.

Alternatively, referring to fig. 6 and 7, fig. 6 is a schematic structural diagram of an embodiment of the IGBT power module of the present application, and fig. 7 is an exploded view of an embodiment of the IGBT power module and the cooling support plate of the present application. In an embodiment, the IGBT power module 10 further includes a driving board 13, the first cooling housing 11 includes a housing cover 111 and a housing body 112, the driving board 13 and the power device 12 are respectively disposed on two opposite sides of the housing cover 111, and the driving board 13 is electrically connected to the power device 12. Specifically, the casing body 112 and the casing cover 111 are made of injection molding materials, the cooling liquid inlet pipe 1a and the cooling liquid outlet pipe 1c are respectively connected to two sides of the casing cover 111, the casing body 112 is integrated with an input copper bar 1121 and an output copper bar 1122, which are respectively connected to two sides of the casing body 112, the input copper bar 1121 and the output copper bar 1122 extend from the inside of the casing body 112 to the outside of the casing body 112, and the input copper bar 1121 and the output copper bar 1122 are located at one end of the inner side and are electrically connected with the power device 12. The power device 12 includes a substrate 121 and an IGBT chip (not shown) and a connection terminal 122 provided on the substrate 121, one end of the connection terminal 122 is connected to the substrate 121, the other end passes through the case cover 111 and is electrically connected to the driving board 13, and the driving board 13 drives the power device 12 to operate, and thus also has a certain amount of heat generation, and since the driving board 13 is provided on a side of the case cover 111 facing away from the first cooling chamber 1b, the insulating cooling medium in the first cooling chamber 1b can indirectly cool the driving board 13 through the case cover 111 while directly cooling the power device 12.

Optionally, with continued reference to fig. 6 and 7, the first cooling housing 11 further includes a heat dissipation plate 113, the housing cover 111 and the heat dissipation plate 113 are respectively disposed on opposite sides of the housing body 112, the housing cover 111, the heat dissipation plate 113 and the housing body 112 surround to form a first cooling cavity 1b, and the first cooling cavity 1b and the second cooling cavity 2b are respectively disposed on opposite sides of the heat dissipation plate 113. Specifically, a plurality of heat dissipation terminals 1131 arranged in an array are disposed on a side of the heat dissipation plate 113 facing the cooling support plate 20, and the heat dissipation terminals 1131 extend into the second cooling groove 21, so as to increase a contact area between the heat dissipation plate 113 and the cooling medium, and improve a heat dissipation effect. The heat dissipation plate 113 may be made of copper, and has good heat conduction performance, which is more conducive to heat dissipation. The power device 12 is sinter-fastened to the side of the heat-dissipating plate 113 facing away from the cooling support plate 20.

Alternatively, referring to fig. 8, fig. 8 is an exploded view of another embodiment of the vehicle electric drive controller of the present application. The vehicle electric drive controller 100 further includes a motor adapter 40, a second cooling housing 30, and a third cooling circuit L3 (indicated by an arrow in the figure), wherein the motor adapter 40 is connected to the IGBT power module 10; the second cooling shell 30 is positioned between the motor adapter 40 and the IGBT power module 10, a third cooling cavity 3b is formed in the second cooling shell 30, and the motor adapter 40 and the IGBT power module 10 are respectively connected with the third cooling cavity 3b; the third cooling circuit L3 includes a third cooling chamber 3b, a first cooling inlet 3a and a first cooling outlet 3c provided to the second cooling housing 30, respectively, the first cooling inlet 3a and the first cooling outlet 3c communicating with the third cooling chamber 3b, respectively, and an insulating cooling medium flowing into the third cooling chamber 3b through the first cooling inlet 3a and flowing out of the third cooling chamber 3b through the first cooling outlet 3 c.

Specifically, the motor adaptor 40 is used for switching the IGBT power module 10 and the motor, one end of the motor adaptor is connected to the U/V/W three-phase terminal of the motor, and when the motor continuously works, the temperature rises, and heat is transferred to the motor adaptor 40 through the U/V/W three-phase terminal of the motor. The other end of the motor adapter 40 is connected with the IGBT power module 10, and heat is also transferred to the IGBT power module 10. Under severe conditions, the motor adapter 40 may overheat and fail. Therefore, in order to enhance the heat radiation effect of the motor adaptor 40, the second cooling housing 30 is provided between the motor adaptor 40 and the IGBT power module 10, and since the insulating cooling medium can flow into the third cooling chamber 3b of the second cooling housing 30 through the first cooling inlet 3a, the insulating cooling medium can directly cool the connection portion of the motor adaptor 40 and the IGBT power module 10 and output the circulated insulating cooling medium through the first cooling outlet 3 c. The direct cooling mode can realize high-efficiency heat dissipation and meet the high power requirement of the whole vehicle.

In some embodiments, the first cooling circuit L1 and the third cooling circuit L3 may be disposed independently, or may be disposed in parallel. In other embodiments, the first cooling circuit L1 and the third cooling circuit L3 are connected in series, and the first cooling outlet 3c is connected to the cooling liquid inlet pipe 1 a. The insulating cooling medium flows into the third cooling cavity 3b at first to cool the joint of the motor adapter 40 and the IGBT power module 10, and flows out of the third cooling cavity 3b and then enters the first cooling cavity 1b through the cooling liquid inlet pipe 1a, so that a continuous cooling loop is formed, and the joint heat dissipation of the motor adapter 40 and the IGBT power module 10 is realized.

Specifically, with continued reference to fig. 8, the igbt power module 10 further includes a power module adaptor 14 connected to the motor adaptor 40, the power module adaptor 14 is integrated with a power module input end 141 and a power module output end 142, and the power module input end 141 includes three copper bars and is connected to three output copper bars 1122; the power module output end 142 also includes three copper bars, the intervals between the three copper bars are smaller than the intervals between the three copper bars of the power module input end 141, the power module output end 142 extends to the third cooling cavity 3b, the motor adaptor 40 includes a first end 41, the first end 41 includes three copper bars arranged at intervals, and the first end 41 extends to the third cooling cavity 3b and is connected with the power module output end 142 in the third cooling cavity 3b.

Specifically, with continued reference to fig. 8, a side of the second cooling housing 30, which is close to the IGBT power module 10, is provided with three first through holes 31, three copper bars of the power module output end 142 extend to the third cooling cavity 3b through the three first through holes 31, the power module output end 142 is in sealing fit with the first through holes 31, a side of the second cooling housing 30, which is close to the motor adapter 40, is provided with a second through hole 32, a side of the motor adapter 40, which is close to the second cooling housing 30, is provided with a first cover plate 43, the first end 41 is disposed on a side of the first cover plate 43, which faces the second cooling housing 30, the first cover plate 43 covers and seals the second through hole 32, so that the first end 41 extends to the third cooling cavity 3b, a third through hole 33 and a second cover plate 34 are further disposed at the top end of the second cooling housing 30, the third through hole 33 communicates with the third cooling cavity 3b, and the second cover plate 34 covers and seals the third through hole 33.

Optionally, referring to fig. 9, fig. 9 is an exploded view of another embodiment of the vehicle electric drive controller of the present application, and the vehicle electric drive controller 100 further includes a control module 60 and a temperature sensor (not shown) for detecting a temperature of the power module, and the control module 60 controls the insulating cooling medium to be introduced into the first cooling chamber 1b in response to the temperature being greater than or equal to a preset temperature.

Specifically, the control module 60 includes a control board 61 and a control support board 62, the control support board 62 is disposed on a side of the driving board 13 facing away from the cooling support board 20, the control board 61 is fixed on a side of the control support board 62 facing away from the driving board 13 and is electrically connected with the driving board 13, a temperature sensor may be disposed on the driving board 13, when detecting that the temperature is too high, an insulating cooling medium is controlled to enter the first cooling loop L1, and meanwhile, the cooling medium enters the second cooling loop L2, so as to cool the IGBT power module 10 and the driving board 13, thereby improving the cooling effect; when a lower temperature is detected, the insulating cooling medium may be controlled not to enter the first cooling circuit L1, and the IGBT power module 10 and the drive board 13 may be cooled indirectly only by the cooling medium in the second cooling circuit L2.

In other embodiments, the cooling mode may be selected according to the actual power requirement, for example, the actual power requirement may be divided into a first section, a second section and a third section from small to large, the first section only controls the cooling medium to be introduced into the second cooling circuit L2 for indirect cooling, the second section only controls the insulating cooling medium to be introduced into the first cooling circuit L1 for direct cooling, the third section controls the insulating cooling medium to be introduced into the first cooling circuit L1 and simultaneously controls the cooling medium to be introduced into the second cooling circuit L2, so as to realize synchronous operation of direct cooling and indirect cooling, and have an optimal cooling effect. The cooling system of the third cooling circuit L3 may be controlled by whether or not the insulating cooling medium is introduced according to the temperature.

The foregoing is only the embodiments of the present application, and not the patent scope of the present application is limited by the foregoing description, but all equivalent structures or equivalent processes using the contents of the present application and the accompanying drawings, or directly or indirectly applied to other related technical fields, which are included in the patent protection scope of the present application.

Claims (10)

1. An electric drive controller for a vehicle, comprising:

an IGBT power module;

the IGBT power module is arranged on the cooling support plate and covers the cooling groove;

the controller shell comprises a bottom wall and a side wall connected with the bottom wall, and the cooling support plate is arranged on the side wall back to the bottom of the IGBT power module; a cooling part for cooling at least part of the side wall is arranged in the side wall, and comprises a cooling inlet channel and a cooling outlet channel which are communicated with the cooling groove;

the bottom wall is provided with a first drainage groove and a first drainage hole communicated with the first drainage groove, and the first drainage groove extends to the side wall of the connecting part cooled by the cooling part.

2. The vehicle electric drive controller according to claim 1, wherein,

the cooling part also comprises a side wall cooling channel, the orthographic projection of the side wall cooling channel on the bottom wall surrounds at least part of the first drainage groove, and two ends of the side wall cooling channel are respectively communicated with the cooling inlet channel and the cooling outlet channel.

3. The vehicle electric drive controller according to claim 1, wherein,

the cooling portion further includes a heat sink.

4. The vehicle electric drive controller according to claim 1, wherein,

a first accommodating cavity is formed in the corner of the bottom wall, the first drain hole is formed in the first accommodating cavity, and one end of the first drain groove extends to be connected with the first accommodating cavity; the height of the bottom wall of one end of the first water drainage groove far away from the first accommodating cavity along the gravity direction is higher than the height of the bottom wall connected with one end of the first accommodating cavity.

5. The vehicle electric drive controller according to claim 4, wherein,

the side of the cooling support plate, provided with the cooling groove, is also provided with a flow guiding part and a second accommodating cavity, the flow guiding part is arranged outside the cooling groove in a surrounding way, and the flow guiding part is communicated with the second accommodating cavity;

the side wall is equipped with first water conservancy diversion passageway towards one side of cooling backup pad, first water conservancy diversion passageway both ends communicate respectively first acceping the chamber with the chamber is acceptd to the second.

6. The vehicle electric drive controller according to claim 5, wherein,

the flow guiding part comprises a second drainage groove, and the height of one end, far away from the second accommodating cavity, of the second drainage groove along the gravity direction is higher than the height of one end, connected with the second accommodating cavity.

7. The vehicle electric drive controller according to claim 1, characterized by further comprising:

the top cap, the top cap with the diapire the lateral wall surrounds and forms the accommodation chamber, the top cap inner wall includes at least one inclined plane, along the direction of height, the inclined plane is kept away from the one end of lateral wall is higher than the top surface of lateral wall.

8. The vehicle electric drive controller according to claim 1 or 7, characterized in that,

the side wall is provided with a diversion trench and a second diversion channel, the diversion trench surrounds and is connected with the inner wall of the top cover, and two ends of the second diversion channel are respectively communicated with the diversion trench and the first drainage trench.

9. The vehicle electric drive controller of claim 1, further comprising an alarm system;

the first water drain hole is internally provided with a one-way water drain monitoring valve, and the one-way water drain monitoring valve is used for draining water in the first water drain groove out of the vehicle electric drive controller and triggering the alarm system.

10. The vehicle electric drive controller according to claim 1, wherein,

the IGBT power module comprises a first cooling shell and a power device, wherein a first cooling cavity is formed in the first cooling shell, and the power device is positioned in the first cooling cavity;

the vehicle electric drive controller further comprises a first cooling loop, wherein the first cooling loop comprises a first cooling cavity, a cooling liquid inlet pipe and a cooling liquid outlet pipe, and the cooling liquid inlet pipe and the cooling liquid outlet pipe are communicated with the first cooling cavity.