CN118478806B - Controller device for vehicle and new energy commercial vehicle - Google Patents

Abstract

The present invention belongs to the technical field of new energy commercial vehicles, and discloses a vehicle controller device and a new energy commercial vehicle, the device includes a shell and a controller body, the controller body includes a four-in-one distribution box and a single motor driver; the four-in-one distribution box and the single motor driver are integrated to form a five-in-one controller; the functional units of the five-in-one controller include: a main drive functional unit, a PDU functional unit, a DC-DC functional unit, an oil pump functional unit, and an air pump functional unit; and/or, the accommodating space inside the shell is divided into an upper cavity, a lower cavity, and a heat dissipation area, the upper cavity and the lower cavity are arranged at corresponding intervals up and down, the controller body is arranged in the upper cavity and the lower cavity, the heat dissipation area is located between the upper cavity and the lower cavity, and the heat dissipation area is provided with a series liquid cooling heat dissipation channel. This solution achieves high integration by integrating the four-in-one distribution box and the single motor driver and using a wiring harness connector, and the controller is small in size.

Description

Vehicle controller device and new energy commercial vehicle

Technical Field

The present invention belongs to the technical field of new energy commercial vehicles, and specifically relates to a vehicle controller device, and a new energy commercial vehicle having the vehicle controller device, and more particularly to a five-in-one controller for a new energy commercial vehicle, and a new energy commercial vehicle having the five-in-one controller for a new energy commercial vehicle.

Background Art

New energy commercial vehicles refer to commercial vehicles that use new energy technologies. The power systems of these vehicles use electricity, solar energy, hydrogen fuel, etc. Electric commercial vehicles mainly use batteries as a power source to drive electric motors to provide power, including electric trucks, electric buses, electric passenger cars, etc. New energy commercial vehicles have been used in public transportation and logistics transportation in more and more cities. China's new energy commercial vehicle market has entered a new normal of steady development. From the perspective of vehicle manufacturer costs and technology development routes, the call for lightweight and low-cost vehicles is growing. Commercial vehicles have higher requirements for the technical level of parts and components and vehicle quality standards. Core component suppliers need to cooperate with vehicle manufacturers to reduce the weight of the vehicle and accelerate the "cost reduction" of technology to improve the cost performance of the vehicle and help the steady development of new energy commercial vehicles. The control of the power system of new energy commercial vehicles generally adopts the form of "four-in-one distribution box + single motor driver", and the four-in-one distribution box + single motor driver each occupies a relatively large space and has a high assembly cost. At least there are problems such as low integration, high development cost, large size, unclear functional division, and few covered models.

The above contents are only used to assist in understanding the technical solution of the present invention and do not constitute an admission that the above contents are prior art.

Summary of the invention

The purpose of the present invention is to provide a vehicle controller device and a new energy commercial vehicle to solve the problem that the control of the power system of the new energy commercial vehicle adopts the form of "four-in-one distribution box + single motor driver", which at least has low integration, high development cost, large size, unclear functional division, and few covered vehicle models. By integrating the four-in-one distribution box and the single motor driver and using a wiring harness connector, a high degree of integration of the multi-functional area is achieved, connectors and long-distance leads are reduced, the controller is small in size, which is conducive to improving the integration and reducing the development cost.

The present invention provides a controller device for a vehicle, comprising: a shell and a controller body, the controller body being adapted to the shell; the controller body comprising: a four-in-one distribution box and a single motor driver; wherein the four-in-one distribution box and the single motor driver are integrated to form a five-in-one controller for the vehicle; the functional units of the five-in-one controller for the vehicle comprise: a main drive functional unit, a PDU functional unit, a DC-DC functional unit, an oil pump functional unit and an air pump functional unit; and/or, the accommodating space inside the shell is divided into an upper cavity, a lower cavity and a heat dissipation area; wherein the upper cavity and the lower cavity are arranged at corresponding intervals above and below, and the controller body is arranged in the upper cavity and the lower cavity; the heat dissipation area is located between the upper cavity and the lower cavity, and the heat dissipation area is provided with a series liquid-cooled heat dissipation channel for dissipating heat from the heating elements in the controller body.

In some embodiments, the functional modules in the PDU functional unit include: an air conditioning module, a heating module, a defrost module and a reserved functional module; the reserved functional module is used to expand the functional modules in the PDU functional unit; the high-voltage positive electrode of the high-voltage battery of the vehicle is connected to the high-voltage main circuit; the high-voltage negative electrode of the high-voltage battery of the vehicle is connected to the high-voltage negative circuit; wherein, in the branch corresponding to each module in the air conditioning module, the heating module, the defrost module, and the reserved functional module, a first fuse and a first relay are provided; the high-voltage main circuit is connected to the branch corresponding to each module after passing through the first fuse and the first relay in the branch corresponding to each module. The positive pole of the corresponding interface; the negative pole of the interface corresponding to each module is connected to the high-voltage negative circuit; and/or, in the branch corresponding to the DC-DC functional unit, a second fuse and a DC-DC power conversion module are provided; the high-voltage main circuit is connected to the battery interface corresponding to the battery of the vehicle after passing through the second fuse and the DC-DC power conversion module; the ground end of the DC-DC power conversion module is connected to the high-voltage negative circuit; and/or, in the branch corresponding to the auxiliary drive functional unit where the oil pump functional unit and the air pump functional unit are located, an auxiliary drive pre-charging circuit and an auxiliary drive main circuit are provided, and an auxiliary drive pre-charging relay, Auxiliary drive pre-charging resistor and a third fuse, a second relay and a fourth fuse are arranged in the auxiliary drive main circuit; the high-voltage main circuit is connected to the positive pole of the oil pump interface corresponding to the oil pump functional unit after passing through the auxiliary drive pre-charging relay, the auxiliary drive pre-charging resistor and the third fuse; the negative pole of the oil pump interface is connected to the high-voltage negative circuit; the high-voltage main circuit is also connected to the positive pole of the air pump interface corresponding to the air pump functional unit after passing through the second relay and the fourth fuse; the negative pole of the air pump interface is connected to the high-voltage negative circuit; the branch where the auxiliary drive pre-charging relay and the auxiliary drive pre-charging resistor are located is connected in parallel with the branch where the second relay is located; and/or, in the A main drive pre-charging circuit and a main drive main circuit are arranged in the branch corresponding to the main drive functional unit, the main drive pre-charging circuit is connected in parallel with the main drive main circuit, a main drive pre-charging relay and a main drive pre-charging resistor are arranged in the main drive pre-charging circuit, and a fifth fuse and a third relay are arranged in the main drive main circuit; the high-voltage main circuit is connected to the positive pole of the input end of the IGBT inverter module corresponding to the main drive functional unit through the main drive pre-charging relay and the main drive pre-charging resistor; the high-voltage main circuit is also connected to the positive pole of the input end of the IGBT inverter module through the fifth fuse and the third relay, and the negative pole of the input end of the IGBT inverter module is connected to the high-voltage negative circuit.

In some embodiments, the main drive functional unit includes: a main control module, a PDU power distribution module and an inverter functional module; the main control module, the PDU power distribution module and the inverter functional module are integrated in the upper cavity; the oil pump functional unit, the air pump functional unit, and the DC-DC power conversion module in the DC-DC functional unit are integrated in the lower cavity.

In some embodiments, a sheet metal part is arranged in the shell; the PDU power distribution module includes: a PDU fuse and a PDU relay; wherein the main control module, the PDU fuse, and the PDU relay except the air-conditioning relay are all installed on the sheet metal part; the current input end of the PDU relay is connected to the PDU relay copper bus, and the PDU relay copper bus is connected to the positive pole of the first DC bus copper bus of the main drive functional unit through a wire.

In some embodiments, the inverter function module includes: an IGBT inverter module; the setting form of the IGBT inverter module includes: a single power module and a dual power module; the upper cavity is divided into a top layer and a bottom layer, and the single power module and the dual power module are both arranged in the bottom layer of the upper cavity, for selecting the single power module and the dual power module according to the vehicle model.

In some embodiments, a debugging interface of the five-in-one controller, a VCU signal interface, a water outlet, a water inlet, a negative electrode interface of the battery, a positive electrode interface of the battery, and a ground wire interface are provided on the first side outside the shell; wherein the debugging interface and the VCU signal interface are connected to the main control module, the water outlet and the water inlet are connected to the series heat dissipation channel, the negative electrode interface of the battery and the positive electrode interface of the battery are connected to the DC-DC power conversion module, and the ground wire interface is grounded and shares a common ground with the motor corresponding to the main drive functional unit.

In some embodiments, a flow channel cover plate is provided to match the series heat dissipation flow channel; the oil pump functional unit and the air pump functional unit form an auxiliary drive functional unit; the auxiliary drive functional unit includes: an auxiliary drive main control module and an auxiliary drive drive module; wherein the auxiliary drive main control module, the auxiliary drive drive module, and the DC-DC power supply conversion module are all installed on the shell and the flow channel cover plate.

In some embodiments, a PDU interface, an auxiliary drive interface, and a high-voltage input and three-phase input interface of the five-in-one controller are provided on the second side outside the shell; the PDU interface is provided corresponding to the PDU functional unit; the PDU interface includes: an air-conditioning interface, a heating interface, a defrost interface and a reserved function interface; the connectors of the air-conditioning interface, the heating interface, the defrost interface and the reserved function interface all use wiring harness connectors; the auxiliary drive interface includes: an oil pump interface and an air pump interface; the connectors of the oil pump interface and the air pump interface all use wiring harness connectors; the high-voltage input and three-phase input interfaces include: a high-voltage input interface, a high-voltage output interface, and a UVW three-phase output interface, and all are connected to the power line of the vehicle through a hole connector.

In some embodiments, the controller body also includes a junction box; the junction box is provided with a positive and negative interface, a high-voltage input interface, a high-voltage output interface, and a UVW three-phase output interface; the positive and negative interface, the high-voltage input interface, the high-voltage output interface, and the UVW three-phase output interface all use cable glands.

In some embodiments, the shell has a controller cover; adapted to the PDU fuse in the PDU power distribution module, a PDU fuse top cover is also provided; the PDU fuse top cover is provided on the controller cover and is located above the PDU fuse.

Matching the above device, the present invention further provides a new energy commercial vehicle, including: the vehicle controller device described above.

Therefore, the solution of the present invention integrates the four-in-one distribution box and the single motor driver (i.e., the main motor driver), the auxiliary drive motor, the low-voltage battery and the PDU function of the vehicle, and uses a wiring harness connector instead of a high-cost quick-connect connector; thereby, by integrating the four-in-one distribution box and the single motor driver and using a wiring harness connector, a high degree of integration of the multi-functional area is achieved, connectors and long-distance leads are reduced, and the controller is smaller in size, which is conducive to improving integration and reducing development costs. At the same time, the interior of the controller shell of the five-in-one controller is divided into upper and lower cavities, and a series heat dissipation channel is arranged between the upper and lower cavities, and the upper cavity is divided into a top layer and a bottom layer to isolate the weak current part from the strong current part; by dividing the interior of the controller shell into upper and lower cavities and setting a series heat dissipation channel between the upper and lower cavities, and isolating the strong and weak electricity by layering the upper cavity, it is not only compact in structure, but also improves the heat dissipation effect and the safety of strong and weak electricity operation; in addition, the internal functional divisions of the controller are clear, the internal functional divisions are obvious, and the layout of each functional module is flexible; by adopting the single-double module compatible design of the IGBT inverter module, the current sharing effect is good, and the single and double modules and the corresponding electrical components can be flexibly switched according to the vehicle model, which can reduce the mold opening cost of a single module, and has high power density and covers a wide range of vehicle models.

Other features and advantages of the present invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the present invention.

The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a schematic structural diagram of an embodiment of a vehicle controller device of the present invention;

Figure 2 is an integrated functional block diagram of a five-in-one controller;

FIG3 is a structural block diagram of a vehicle including a four-in-one distribution box and a single motor driver in a related solution;

Figure 4 is a block diagram of the whole vehicle structure of the five-in-one controller for commercial vehicles;

Figure 5 is a schematic diagram of the electrical principle of a five-in-one controller for commercial vehicles;

Figure 6 is an exploded view of a five-in-one controller for commercial vehicles;

FIG7 is a cross-sectional view of the upper and lower cavities of the five-in-one controller for commercial vehicles;

FIG8 is a schematic diagram of the layout and installation of single and double power modules on the top layer in the upper cavity of a five-in-one controller for commercial vehicles (a);

FIG9 is a schematic diagram of the layout and installation of the dual power modules at the bottom layer in the upper cavity of the five-in-one controller for commercial vehicles (b);

FIG10 is a schematic diagram of the layout and installation of a single power module at the bottom layer in the upper cavity of a five-in-one controller for commercial vehicles (c);

FIG11 is a schematic diagram of the side layout installation of a five-in-one controller for commercial vehicles;

FIG12 is a schematic diagram of the lower cavity layout and installation of a five-in-one controller for commercial vehicles;

FIG13 is a schematic diagram of the layout of the power distribution input and output ports of the five-in-one controller for commercial vehicles;

FIG. 14 is an isometric view of the appearance of the five-in-one controller for commercial vehicles.

In conjunction with the accompanying drawings, the reference numerals in the embodiments of the present invention are as follows:

1-controller housing; 2-main control module; 3-PDU fuse; 4-filter board; 5-PDU relay; 6-PDU relay copper busbar; 7-main fuse; 8-main drive relay; 9-sheet metal; 10-bus capacitor; 11-IGBT inverter module; 12-current sensor; 13-W phase copper busbar; 14-V phase copper busbar; 15-U phase copper busbar; 16-negative DC busbar copper busbar; 17-positive first DC busbar copper busbar; 18-copper busbar support column; 19-main drive pre-charging resistor; 20-positive second DC busbar copper busbar; 21-positive third DC busbar copper busbar; 22-debugging interface; 23-VCU signal interface; 24-water outlet; 25-waterproof breathable valve; 26-water inlet; 27-low-voltage battery negative electrode interface; 28-ground wire interface; 29-low-voltage battery positive electrode interface; 30-auxiliary drive main control module; 31-auxiliary drive module; 32-DC-DC power conversion module; 33-DC-DC output connection copper bus; 34-discharge resistor; 35-flow channel cover; 36-PDU interface, 37-auxiliary drive interface, 38-high voltage input and three-phase output interface, 39-junction box cover, 40-PDU fuse top cover; 41-controller cover; 42-main drive board.

DETAILED DESCRIPTION

In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the specific embodiments of the present invention and the corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

Considering that the control of the power system of new energy commercial vehicles generally adopts the form of "four-in-one distribution box + single motor driver", the four-in-one distribution box + single motor driver each occupies a relatively large space and has a high assembly cost. Some schemes disclose an all-in-one controller for new energy commercial vehicles, including a controller shell, an upper bottom surface and a lower bottom surface are arranged in parallel inside the controller shell, a battery/motor high-voltage interface module is arranged on the front side of the outside of the controller shell, a high-voltage and low-current output interface, a low-voltage communication interface and a 24V voltage interface are arranged on the right side of the outside of the controller shell, and a large-current and high-voltage interface is arranged on the rear side of the outside of the controller shell. A microcontroller unit (MCU) functional area, a power distribution unit (PDU) functional area and a filter module are arranged on the upper bottom surface, the MCU functional area is electrically connected to the battery/motor high-voltage interface module through the filter module, the MCU functional area is electrically connected to the PDU functional area, and the PDU functional area is electrically connected to the high-voltage and low-current output interface and the large-current and high-voltage interface respectively, the MCU functional area is arranged on the front side of the upper bottom surface, the PDU functional area is arranged on the rear of the upper bottom surface, and the filter module is arranged on the right side of the MCU functional area.

Some other solutions provide a high-voltage integrated unit for a powertrain and a powertrain, wherein the high-voltage integrated unit includes a housing, a motor control unit, a DC power converter and an on-board charging system, wherein the motor control unit, the DC power converter and the on-board charging system are integrated in the same housing, and the housing has a cooling water channel, which is configured to dissipate heat for the motor control unit, the DC power converter and the on-board charging system. By applying the above technical solution, a high degree of integration can be achieved, pipe connections can be reduced, and heat dissipation efficiency can be improved.

Some other schemes provide a control assembly for new energy vehicles, which includes a box body, a heat dissipation water channel is arranged in the box body, and the heat dissipation water channel divides the internal space of the box body into an upper cavity and a lower cavity. Two HPD drive modules, two DCAC (i.e., direct current to alternating current) drive modules, a main contactor, three high-voltage distribution contactors, a high-voltage distribution fuse, a control board, a DC busbar, a composite busbar and an AC busbar are arranged in the upper cavity, and a drive board is arranged on each hybrid pack drive (HPD) drive module, and an on-board current sensor is arranged on the drive board, a magnetic ring and a Y capacitor board are arranged on the DC busbar, and two capacitors are arranged in the lower cavity. The internal structure layout of the present invention is compact and reasonable, small in size, diverse in functions, and can be flexibly cut and matched, has good electromagnetic compatibility, and is easy to arrange, install, maintain and use as a whole vehicle.

However, the controller in the above scheme may be a single insulated gate bipolar transistor (IGBT), the inverter module is designed with low power, and there are few compatible vehicle models, or it may be a dual IGBT inverter module with dual motor input design, and the wiring harness is twice that of a single motor input, which is more expensive, and the functional divisions are not obvious. The space occupied by each is relatively large, and the assembly cost is high.

Therefore, the scheme of the present invention proposes a vehicle controller device, specifically a five-in-one controller for a new energy commercial vehicle, which integrates a four-in-one distribution box with a single motor driver to improve integration and reduce development costs, and the internal space of the controller housing is divided into upper and lower cavities, a series heat dissipation channel is arranged between the upper and lower cavities, and the upper cavity is divided into a top layer and a bottom layer to isolate the weak current part and the strong current part, so that the electromagnetic compatibility effect is good, and the use of magnetic rings is reduced compared with other controllers; and a wiring harness connector is used instead of a high-cost quick-plug connector to achieve a high degree of integration of the multi-functional area, reduce connectors and long-distance leads, and the controller is small in size, which is conducive to improving integration and reducing development costs, with clear functional divisions, and reducing cumbersome wiring and copper busbar connections; the scheme is a single-motor input design, adopts a dual IGBT inverter module parallel design, has a good current sharing effect, high power density, is compatible with a single IGBT inverter module, can flexibly switch between single and double modules according to the vehicle model, and covers a wide range of vehicle models; by integrating the four-in-one distribution box and the single motor driver and using a wiring harness connector, connectors and long-distance leads are reduced, which is conducive to improving integration and reducing development costs.

According to an embodiment of the present invention, a controller device for a vehicle is provided. See FIG1 for a schematic diagram of the structure of an embodiment of the device of the present invention. The controller device of the vehicle may include: a housing and a controller body, the controller body is adapted to be arranged with the housing, the housing is such as the controller housing 1; the controller body includes: a four-in-one distribution box and a single motor driver, the four-in-one distribution box is used to distribute the high voltage electricity provided by the high-voltage battery of the vehicle to the main motor controller, the module of the PDU functional area, the auxiliary drive module and the battery. The function of the four-in-one distribution box includes distributing the high voltage in the power battery pack to the main motor controller, the PDU functional area (air conditioning, PTC, defrosting), the auxiliary drive module (oil pump module, air pump module), the low-voltage battery, and the main motor driver inverts and outputs to the main drive motor. FIG3 is a block diagram of the whole vehicle structure of the four-in-one distribution box and the single motor driver in the related scheme. As shown in Figure 3, in the relevant scheme, new energy commercial vehicles use a four-in-one distribution box to distribute the high voltage in the power battery pack to the main motor controller, PDU functional area (air conditioning, PTC, defrosting, etc.), auxiliary drive module (oil pump module, air pump module), low-voltage battery, and the main motor driver inverter outputs to the main drive motor. Among them, PTC (Positive Temperature Coefficient) represents a positive temperature coefficient, which is a PTC thermistor.

Among them, in the scheme of the present invention, the four-in-one distribution box and the single motor driver are integrated to form a five-in-one controller of the vehicle; the functional units of the five-in-one controller of the vehicle include: a main drive functional unit, a PDU functional unit, a DC-DC (i.e., direct current to direct current) functional unit, an oil pump functional unit and an air pump functional unit.

Figure 2 is an integrated functional block diagram of a five-in-one controller. As shown in Figure 2, the five-in-one controller for new energy commercial vehicles provided by the solution of the present invention is mainly divided into the following areas: main drive function area, PDU function area, DC-DC function area, oil pump function area, and air pump function area. The main integrated functions are: main drive function, PDU function, DC-DC function, oil pump function, and air pump function.

Figure 4 is a block diagram of the whole vehicle structure of the five-in-one controller for commercial vehicles. As shown in Figure 4, the five-in-one controller formed by integrating the four-in-one distribution box and the single motor driver in the solution of the present invention, that is, integrating the main motor driver into the four-in-one distribution box, can directly control the main drive motor and the auxiliary drive motor, and can also distribute power to the PDU functional area and the low-voltage battery, reducing the high-voltage connectors from the four-in-one distribution box to the main motor driver power harness and the four-in-one distribution box in the related solutions, integrating the motor controller and the four-in-one distribution box, reducing the use of the four-in-one distribution box, freeing up space on the vehicle, and the volume of the integrated five-in-one controller is 25% less than that of the original motor controller plus the four-in-one distribution box, and the total development cost can be reduced by 13%.

And/or, in the scheme of the present invention, the shell is made of ADC12 material by high-pressure casting, and the accommodating space inside the shell is divided into an upper cavity, a lower cavity and a heat dissipation area; wherein the upper cavity and the lower cavity are arranged at corresponding intervals above and below, and the controller body is arranged in the upper cavity and the lower cavity; the heat dissipation area is located between the upper cavity and the lower cavity, and the heat dissipation area is provided with a series liquid-cooled heat dissipation channel for dissipating the heat of the heating elements in the controller body.

Figure 7 is a cross-sectional view of the upper and lower cavities of the five-in-one controller for commercial vehicles. As shown in Figure 7, the controller housing 1 is made of ADC12 material by high-pressure casting. The controller housing 1 is divided into an upper cavity A and a lower cavity B. There is a series liquid cooling heat dissipation channel between the two cavities, which can dissipate heat for the heating elements of the upper and lower cavities at the same time. While meeting the heat dissipation requirements, the flow channel length is reduced. This design can reduce the overall volume of the controller. ADC12 material, such as Al-Si-Cu alloy, is a die-cast aluminum alloy suitable for manufacturing housings, cylinders, brackets, etc.

The five-in-one controller for new energy commercial vehicles proposed in the solution of the present invention is preferably a five-in-one controller for new energy electric buses. The four-in-one distribution box is integrated with the single motor driver to improve integration and reduce development costs. Specifically, the four-in-one high-voltage distribution box on the commercial vehicle in the relevant solution is integrated into the main motor driver. After the five-in-one controller is formed, the volume is reduced by 25%, which solves the problems of the single function of the motor controller structure of the new energy electric bus in the relevant solution, the large area occupied by each functional module, the low integration and the high cost, and can release vehicle space and reduce development costs; the internal space of the controller shell is divided into upper and lower cavities, and a series heat dissipation flow channel is arranged between the upper and lower cavities. The upper cavity is divided into a top layer and a bottom layer to isolate the weak current part and the strong current part, which solves the problem of long-distance lead wires between the single motor controller and the four-in-one distribution box, reduces the introduction of external interference, and reduces energy loss on the line; and uses a wiring harness connector instead of a high-cost quick-plug connector to reduce development costs.

In some embodiments, the functional modules in the PDU functional unit include: an air conditioning module, a heating module, a defrost module and a reserved functional module; the reserved functional module is used to expand the functional modules in the PDU functional unit; the high-voltage positive electrode of the vehicle's high-voltage battery is connected to the high-voltage main circuit; the high-voltage negative electrode of the vehicle's high-voltage battery is connected to the high-voltage negative circuit.

Wherein, in the branch corresponding to each module in the air-conditioning module, the heating module, the defrost module, and the reserved function module, a first fuse and a first relay are provided; the high-voltage main circuit is connected to the positive pole of the interface corresponding to each module after passing through the first fuse and the first relay in the branch corresponding to each module; the negative pole of the interface corresponding to each module is connected to the high-voltage negative circuit; wherein, the first fuse is fuse F3, fuse F8, fuse F7 in Figure 5, and the first relay is relay K3, relay K8, relay K7 in Figure 5.

And/or, in the branch corresponding to the DC-DC functional unit, a second fuse and a DC-DC power conversion module 32 are provided; the high-voltage main circuit is connected to the battery interface corresponding to the battery of the vehicle after passing through the second fuse and the DC-DC power conversion module 32; the ground end of the DC-DC power conversion module 32 is connected to the high-voltage negative circuit; wherein the second fuse is fuse F4 in Figure 5.

And/or, in the branch corresponding to the auxiliary drive functional unit where the oil pump functional unit and the air pump functional unit are located, an auxiliary drive pre-charging circuit and an auxiliary drive main circuit are provided, an auxiliary drive pre-charging relay, an auxiliary drive pre-charging resistor and a third fuse are provided in the auxiliary drive pre-charging circuit, and a second relay and a fourth fuse are provided in the auxiliary drive main circuit; the high-voltage main circuit is connected to the positive electrode of the oil pump interface corresponding to the oil pump functional unit after passing through the auxiliary drive pre-charging relay, the auxiliary drive pre-charging resistor and the third fuse; the negative electrode of the oil pump interface is connected to the high-voltage negative circuit; The high-voltage main circuit is also connected to the positive pole of the air pump interface corresponding to the air pump functional unit after passing through the second relay and the fourth fuse; the negative pole of the air pump interface is connected to the high-voltage negative circuit; the branch where the auxiliary drive pre-charging relay and the auxiliary drive pre-charging resistor are located is connected in parallel with the branch where the second relay is located; wherein, the auxiliary drive pre-charging relay is the relay K5 in Figure 5, the auxiliary drive pre-charging resistor is the resistor R2 in Figure 5, the second relay is the relay K6 in Figure 5, the third fuse is the fuse F5 in Figure 5, and the fourth fuse is the fuse F6 in Figure 5.

And/or, a main drive pre-charging circuit and a main drive main circuit are provided in the branch corresponding to the main drive functional unit, the main drive pre-charging circuit is connected in parallel with the main drive main circuit, a main drive pre-charging relay and a main drive pre-charging resistor are provided in the main drive pre-charging circuit, and a fifth fuse and a third relay are provided in the main drive main circuit; the high-voltage main circuit is connected to the positive pole of the input end of the IGBT inverter module 11 corresponding to the main drive functional unit through the main drive pre-charging relay and the main drive pre-charging resistor; the high-voltage main circuit is also connected to the positive pole of the input end of the IGBT inverter module 11 through the fifth fuse and the third relay, and the negative pole of the input end of the IGBT inverter module 11 is connected to the high-voltage negative circuit. Among them, the main drive pre-charging relay is the relay K1 in Figure 5, the main drive pre-charging resistor is the resistor R1 in Figure 5, the fifth fuse is the fuse F1 in Figure 5, and the third relay is the relay K2 in Figure 5.

Figure 5 is a schematic diagram of the electrical principle of the five-in-one controller for commercial vehicles. As shown in Figure 5, the positive electrode of the high-voltage battery of the five-in-one controller for commercial vehicles is connected to the high-voltage positive circuit; the negative electrode of the high-voltage battery of the five-in-one controller for commercial vehicles is connected to the high-voltage negative circuit. The high-voltage positive circuit is connected to the positive electrode of the air-conditioning interface through the fuse F3 and the relay K3, and the negative electrode of the air-conditioning interface is connected to the high-voltage negative circuit. The high-voltage positive circuit is connected to the positive electrode of the heating interface through the fuse F8 and the relay K8, and the negative electrode of the heating interface is connected to the high-voltage negative circuit. The high-voltage positive circuit is connected to the positive electrode of the defrost interface through the fuse F7 and the relay K7, and the negative electrode of the defrost interface is connected to the high-voltage negative circuit. The high-voltage positive circuit is connected to the charging end of the low-voltage battery through the fuse F4 and the DC-DC power conversion module 32, and the high-voltage negative electrode of the DC-DC power conversion module 32 is connected to the high-voltage negative circuit. The high-voltage positive circuit is connected to the anode of the diode D through the relay K5; the cathode of the diode D is connected to the positive electrode of the oil pump interface through the resistor R2 and the fuse F5; the negative electrode of the oil pump interface is connected to the high-voltage negative circuit. The high-voltage positive circuit is connected to the positive electrode of the air pump interface through the relay K6 and the fuse F6, and the negative electrode of the air pump interface is connected to the high-voltage negative circuit. The branch where the relay K5, the diode D and the resistor R2 are located is connected in parallel with the branch where the relay K6 is located. The high-voltage positive circuit is connected to the positive electrode of the input end of the IGBT inverter module 11 through the relay K1 and the resistor R1, and the negative electrode of the input end of the IGBT inverter module 11 is connected to the high-voltage negative circuit. The capacitor C and the resistor R3 are connected in parallel between the positive and negative electrodes of the input end of the IGBT inverter module 11. The high-voltage positive circuit is also connected to the positive electrode of the input end of the IGBT inverter module 11 through the fuse F1 and the relay K2. The branch where the relay K1 and the resistor R1 are located is connected in parallel with the branch where the fuse F1 and the relay K2 are located.

In the solution of the present invention, the motor controller and the four-in-one distribution box are integrated, reducing the use of the four-in-one distribution box. The main body size is 606mm*442mm*225mm, and the volume of the five-in-one controller is reduced by 25% compared with the single motor controller plus the four-in-one distribution box in the related solution. The connectors and leads between the two controllers (i.e., the single motor controller and the four-in-one distribution box) in the related solution are reduced, thereby reducing the material cost, development cost and occupied area of the five-in-one controller.

In some embodiments, the main drive functional unit includes: a main control module 2, a PDU power distribution module and an inverter functional module, wherein the main control module 2 integrates the PDU control and voltage sampling functions; the main control module 2, the PDU power distribution module and the inverter functional module are integrated in the upper cavity; the oil pump functional unit, the air pump functional unit, and the DC-DC power conversion module 32 in the DC-DC functional unit are integrated in the lower cavity.

Figure 6 is an exploded view of a five-in-one controller for commercial vehicles. As shown in Figure 6, the five-in-one controller for commercial vehicles includes: a controller housing 1, a main control module 2, a PDU fuse 3, a filter board 4, a PDU relay 5, a PDU relay copper bar 6, a main fuse 7, a main drive relay 8, a sheet metal part 9, a bus capacitor 10, an IGBT inverter module 11, a current sensor 12, a W-phase copper bar 13, a V-phase copper bar 14, a U-phase copper bar 15, a negative pole of a DC bus copper bar 16, a positive pole of a first DC bus copper bar 17, a copper bar support column 18, a main drive pre-charging resistor 19, a positive pole of a second DC bus copper bar 20, a positive pole of a third DC bus copper bar 21, a debugging interface 22, and a vehicle controller for electric vehicles. Unit, VCU) signal interface 23, water outlet 24, waterproof breathable valve 25, water inlet 26, low-voltage battery negative electrode interface 27, ground wire interface 28, low-voltage battery positive electrode interface 29, auxiliary drive main control module 30, auxiliary drive drive module 31, DC-DC power conversion module 32, DC-DC output connection copper bus 33, discharge resistor 34, flow channel cover 35, PDU interface 36, auxiliary drive interface 37, high-voltage input and three-phase output interface 38, junction box cover 39, PDU fuse top cover 40, controller upper cover 41, main drive drive board 42.

In the scheme of the present invention, in the controller housing, layout and control assembly design of the five-in-one controller, the internal space of the housing of the entire controller is divided into two upper and lower cavities. The upper cavity is mainly provided with a main control module 2, a PDU fuse 3, a filter board 4, a PDU relay 5, a main fuse 7, a main drive relay 8, a sheet metal part 9, a bus capacitor 10, an IGBT inverter module 11, a current sensor 12, a main drive pre-charging resistor 19, and a main drive drive board 42. The lower cavity is mainly provided with an auxiliary drive main control module 30, an auxiliary drive drive module 31, a DC-DC power conversion module 32, a DC-DC output connection copper bus 33, a discharge resistor 34, and a flow channel cover 35, so that the space can be fully utilized. Between the upper and lower cavities of the shell internal space of the entire controller is a series heat dissipation channel, which is located between the upper and lower cavities and covers the dual power module and the DC-DC power conversion module 32, so that the power density of the five-in-one controller is high, and the high integration of the multi-functional area is achieved. In addition, the layout of each functional module is flexible, and the functional division is clear, which reduces the cumbersome wiring and copper busbar connection, and has less electromagnetic interference. It also reduces the cost of the five-in-one controller and is easy to assemble and produce; and, in the related scheme, the five-in-one controller uses a quick-connect connector for connection, while in the scheme of the present invention, the shell structure of the entire controller uses a wiring harness connector instead of a high-cost quick-connect connector, specifically, the shell interface uses a wiring harness connector instead of a high-cost quick-connect connector, which further reduces the overall development cost. From a structural point of view, the control assembly structure design, layout and plug-in method in the scheme of the present invention are improved to avoid the use of a large number of quick-connect connectors; the cost of using a large number of quick-connect connectors is twice the cost of using wiring harness connectors in the scheme of the present invention, and they are prone to aging and detachment after long-term use.

In some embodiments, a sheet metal part 9 is provided in the shell; the PDU power distribution module includes: a PDU fuse 3 and a PDU relay 5; wherein the main control module 2, the PDU fuse 3, and the PDU relay 5 except the air-conditioning relay are all installed on the sheet metal part 9; the current input end of the PDU relay 5 is connected to the PDU relay copper bus 6, and the PDU relay copper bus 6 is connected to the positive pole 17 of the first DC bus copper bus of the main drive functional unit through a wire.

Figure 8 is a schematic diagram of the layout and installation of the single and double power modules on the top layer in the upper cavity of the commercial vehicle five-in-one controller (a), and Figure 9 is a schematic diagram of the layout and installation of the double power modules on the bottom layer in the upper cavity of the commercial vehicle five-in-one controller (b). As shown in Figures 8 and 9, the main control module 2, PDU fuse 3, and PDU relay 5 are fixed to the sheet metal 9 by screws except the air-conditioning relay, and the air-conditioning relay is fixed to the controller housing 1 by screws; the main control module 2 includes a power module, a communication module, a minimum system, a main drive control module, a PDU relay control module, a sampling circuit, a protection circuit, and a fault processing circuit, with a high degree of integration, reducing the original wiring harness connection with the PDU control sampling board, and at the same time achieving the purpose of strong and weak isolation. From left to right, the PDU relay 5 is the air conditioning, main drive pre-charging, heating, defrosting, oil pump, and air pump relays. Functional relays and fuses can be added or reduced according to customer needs. All PDU relay 5 current input ends are mechanically connected through PDU relay copper bus 6 screws, which reduces the use of wiring harnesses and reduces costs. The PDU relay copper bus 6 is connected to the positive pole 17 of the first DC bus copper bus through a wire. The positive pole 17 of the first DC bus copper bus is used for positive conduction. The main control module 2 controls and samples the voltage of the PDU relay 5 through a wire. The lower right corner of the sheet metal 9 is the PDU fuse 3, which is from left to right. The air conditioning, heating, defrosting, DC-DC, oil pump, and air pump fuses are respectively connected. The output end of the PDU relay 5 is electrically connected to the PDU fuse 3 through a wire. The PDU fuse 3 is used to protect the circuit electrical parts and prevent overload and short-circuit current from burning components, such as relays and air conditioning loads. When the loop current exceeds the rated value of the fuse for a period of time, the heat generated by itself melts the fuse, thereby disconnecting the circuit. The filter board 4 is a Y capacitor, which filters the high voltage DC input of the battery to meet the EMC requirements. The current passes through the positive pole 17 of the first DC bus copper bar to the main fuse 7, and then to the main drive relay 8. The main fuse 7 and the main drive relay 8 are connected through the positive pole 20 of the second DC bus copper bar. The output of the main drive relay 8 enters the bus capacitor 10 for storage. The bus capacitor 10 can smooth the bus voltage and weaken the peak voltage of the bus, so that the bus voltage is relatively smooth when the IGBT inverter module 11 is switched; the current is output from the bus capacitor 10 to the IGBT inverter module 11, and then output as U, V, and W three-phase alternating current. Two IGBT inverter modules 11 are used in each phase to increase the power of the controller. The three-phase alternating current is output to the motor through the U-phase copper bar 15, the V-phase copper bar 14, and the W-phase copper bar 13 respectively; the negative pole 16 of the DC bus copper bar, the positive pole 17 of the first DC bus copper bar, the U-phase copper bar 15, the V-phase copper bar 14, and the W-phase copper bar 13 are all fixed to the copper bar support column 18 by screws, and the copper bar support column 18 is fixed to the controller housing 1 by screws. The current sensor 12 is fixed on the V-phase copper bar 14 and the W-phase copper bar 13 by screws to sample the current, and is electrically connected to the main control module 2 by a wire, and the sampling signal is transmitted to the main control module 2 for processing. The main drive functional area is mainly composed of the main control module 2, the main fuse 7, the main drive relay 8, the bus capacitor 10, the IGBT inverter module 11, and the current sensor 12. When the vehicle stops running, the discharge resistor 34 discharges the bus capacitor 10, the main drive pre-charge resistor 19 is located below the main fuse 7, and is fixed to the controller housing 1 by screws. The input end of the main drive pre-charge resistor 19 is connected to the output end of the main drive pre-charge relay by a wire, and the output end of the main drive pre-charge resistor 19 is electrically connected to the positive pole of the bus capacitor 10 by a wire to form a pre-charge circuit to prevent the charging current from being too large at the moment of direct power-on. Excessive instantaneous current may cause damage to the main drive relay 8 and the bus capacitor 10. Among them, a pre-charge circuit is formed to prevent the charging current from being too large at the moment of direct power-on, and damage to the main drive relay 8 and the bus capacitor 10.

In some embodiments, the inverter function module includes: an IGBT inverter module 11; of course, the inverter function module also includes a bus capacitor 10 and a main drive drive board 42; the setting form of the IGBT inverter module 11 includes: a single power module and a dual power module; the upper cavity is divided into a top layer and a bottom layer, and the single power module and the dual power module are both arranged in the bottom layer of the upper cavity, which is used to select the single power module and the dual power module according to the vehicle model. The solution of the present invention is a top layer of the upper cavity, a bottom layer of the upper cavity, and a lower cavity design; and the solution of the present invention is a compatible design of a single IGBT inverter module and a dual IGBT inverter module, which is not only suitable for low-power vehicles, but also for high-power vehicles, such as minibuses, medium buses, large buses and heavy trucks, with a wide coverage area, a large performance gap between the two, and the installation and replacement of single and dual inverter modules can reduce mold opening costs.

FIG10 is a schematic diagram (c) of the layout and installation of a single power module at the bottom layer in the upper cavity of a five-in-one controller for commercial vehicles. As shown in FIG9 and FIG10, the five-in-one controller for commercial vehicles is compatible with single and dual power modules. FIG9 is a dual IGBT inverter module 11, which can use dual 450A, dual 600A and other modules. Its output current and power density are larger to adapt to heavy-duty models, such as buses and heavy trucks. FIG10 is a single IGBT inverter module 11, which can use single 450A and single 600A modules, and other electrical components can also be replaced with low-current models to further reduce costs. It is suitable for minibuses, medium buses and other models. The rated power range of the two schemes can be from 90kW to 200kW, which is suitable for different models and reduces the mold opening cost of the controller. The upper cavity of the five-in-one controller for commercial vehicles is also compatible with a single power module to adapt to low-power models, reducing the mold opening cost of the controller, and other electrical components can also be replaced with low-current models to further reduce costs.

In the scheme of the present invention, the dual-module high-power integrated scheme and compatible scheme are designed. The upper cavity of the five-in-one controller is used as the main control module 2, the PDU power distribution module, and the inverter function module integration area. The main control module 2 integrates the PDU control and voltage sampling functions, reducing the line connection between the main control module and the PDU power distribution board in the relevant scheme; the lower cavity of the five-in-one controller is used as the oil and gas pump integration module and the DC-DC power conversion module 32 integration area. The design of the five-in-one controller is adapted to the installation and replacement of single power modules and dual power modules, which can reduce the mold opening cost and meet different power requirements. It is suitable for minibuses, buses, heavy trucks and other models, and can cover 10.5m-14m new energy buses. Among them, the inverter function module includes the bus capacitor 10, the IGBT inverter module 11, and the main drive drive board 42 in Figure 2. The auxiliary drive module only includes the oil and gas pump integration module, which is divided into an auxiliary drive main control module 30 and an auxiliary drive drive module 31. The solution of the present invention, through the compatible design of the single and double IGBT inverter modules 11, the rated power range of the two solutions can be from 90kW to 200kW, which is suitable for different vehicle models and reduces the mold opening cost of the five-in-one controller.

In some embodiments, a debugging interface 22, a VCU signal interface 23, a water outlet 24, a water inlet 26, a negative electrode interface of a battery, a positive electrode interface of a battery and a ground wire interface 28 of the five-in-one controller are provided on the first side outside the shell, the negative electrode interface of the battery is such as the negative electrode interface 27 of the low-voltage battery, and the positive electrode interface of the battery is such as the positive electrode interface 29 of the low-voltage battery; wherein the debugging interface 22 and the VCU signal interface 23 are connected to the main control module 2, the water outlet 24 and the water inlet 26 are connected to the series heat dissipation channel, the negative electrode interface of the battery and the positive electrode interface of the battery are connected to the DC-DC power conversion module 32, and the ground wire interface 28 is grounded and shares a common ground with the motor corresponding to the main drive functional unit.

Figure 11 is a schematic diagram of the side layout installation of the five-in-one controller for commercial vehicles. As shown in Figure 11, the weak current interface and water nozzle of the five-in-one controller for commercial vehicles are distributed on the right side of the controller. It is more convenient to disassemble and assemble them on the same side. The debugging interface 22 and the VCU signal interface 23 are both external interfaces of the main control module 2. The debugging interface 22 is its communication interface, which is convenient for flashing program debugging; the VCU signal interface 23 is connected to the VCU externally. The water outlet 24 and the water inlet 26 are connected to the flow channel between the upper and lower cavities. The low-voltage battery negative electrode interface 27 and the low-voltage battery positive electrode interface 29 are connected to the vehicle's low-voltage battery to charge it, and are connected to the DC-DC power conversion module 32 internally through the DC-DC output connection copper bus 33. The ground wire interface 28 is grounded and shared with the motor.

In some embodiments, a flow channel cover plate 35 is provided to match the series heat dissipation flow channel; the oil pump functional unit and the air pump functional unit form an auxiliary drive functional unit; the auxiliary drive functional unit includes: an auxiliary drive main control module 30 and an auxiliary drive drive module 31; wherein the auxiliary drive main control module 30, the auxiliary drive drive module 31, and the DC-DC power supply conversion module 32 are all installed on the shell and the flow channel cover plate 35.

Figure 12 is a schematic diagram of the lower cavity layout installation of the five-in-one controller for commercial vehicles. As shown in Figure 12, the auxiliary drive main control module 30, auxiliary drive drive module 31, and DC-DC power conversion module 32 of the five-in-one controller for commercial vehicles are all fixed to the controller housing 1 and the flow channel cover 35 by screws. Its main heating modules are all placed on the flow channel cover 35 to achieve the purpose of heat dissipation. Double-sided heat dissipation also improves the utilization rate of the flow channel and meets the heat dissipation requirements. The DC-DC power conversion module 32 can convert high-voltage DC into low-voltage DC and output it through the DC-DC output connection copper bus 33 to supply power to the integrated main control module 2 and the low-voltage battery. Its signal interface is electrically connected to the main control module 2 through a copper wire. Among them, the upper side of the double-sided heat dissipation is the bottom surface of the upper cavity and the top surface of the lower cavity, and the heat dissipation flow channel is between the upper and lower cavities.

In some embodiments, the PDU interface 36, auxiliary drive interface 37, and high-voltage input and three-phase input interface 38 of the five-in-one controller are provided on the second side outside the shell; the PDU interface 36 is provided corresponding to the PDU functional unit; the PDU interface 36 includes: air conditioning interface, heating interface, defrost interface and reserved function interface; the connectors of the air conditioning interface, the heating interface, the defrost interface and the reserved function interface all use wiring harness connectors; the auxiliary drive interface 37 includes: oil pump interface and air pump interface; the connectors of the oil pump interface and the air pump interface all use wiring harness connectors; the high-voltage input and three-phase input interface 38 includes: high-voltage input interface, high-voltage output interface, UVW three-phase output interface, and all are connected to the power line of the vehicle through a hole connector. Among them, the reserved function interface can expand three-way reserved function, so that the design of the present invention can have six-way PDU function interfaces, and the function interfaces can be increased or decreased according to customer needs. In addition, the controller body also includes a junction box; the junction box is provided with positive and negative interfaces, a high-voltage input interface, a high-voltage output interface, and a UVW three-phase output interface; the positive and negative interfaces, the high-voltage input interface, the high-voltage output interface, and the UVW three-phase output interface all use cable glands. The controller of the present invention is designed with a junction box, and the positive and negative interfaces and the three-phase interfaces all use cable glands, which are lower in cost than quick-plug connectors.

Figure 13 is a schematic diagram of the layout of the power distribution input and output ports of the five-in-one controller for commercial vehicles. As shown in Figure 13, the schematic diagram of the layout of the power distribution input and output ports of the five-in-one controller for commercial vehicles, the PDU interface 36 includes an air conditioning interface, a heating interface, a defrosting interface and a reserved function interface, which is electrically connected to the PDU fuse 3 and the negative pole 16 of the DC bus copper bar through a wire inside the five-in-one controller of the commercial vehicle. The reserved function interface can be configured with different function drivers according to the different functions designed by the integrated main control module, realizing the high compatibility and derivability of the driver; the auxiliary drive interface 37 includes an oil pump interface and an air pump interface, which are electrically connected to the U, V, and W three-phase output interfaces of the auxiliary drive module 31 inside the controller through a wire; the high-voltage input and three-phase output interfaces 38 are both connected to the power line of the vehicle using a through-hole connector, from left to right: high-voltage input, high-voltage output, UVW three-phase output interface (i.e., U, V, W three-phase output interface), and the through-hole connector is lower in cost, less prone to damage, and more corrosion-resistant than the high-voltage plug-in interface. There is no reserved function interface in the relevant solution and a quick-plug interface is used. The reserved function interface means that in addition to functions such as air conditioning, heating, and defrosting, the main control module also reserves more PDU branch control functions; for example: the reserved function interface can add functions such as PTC and Thermal Management System (TMS). Each function is a PDU branch. As shown in Figure 8, the relays and fuses of the corresponding branch can be added to the upper position of the sheet metal 9 and connected to the reserved interface to form a PDU branch, so it can be configured according to customer needs. In addition, when the customer does not need functions such as defrosting and PTC, the relays, fuses and wiring harnesses of the branch can be directly not installed in the controller.

In some embodiments, the shell has a controller cover 41; adapted to the PDU fuse 3 in the PDU power distribution module, a PDU fuse top cover 40 is also provided; the PDU fuse top cover 40 is provided on the controller cover 41 and is located above the PDU fuse 3.

FIG14 is an isometric view of the appearance of the five-in-one controller for commercial vehicles. As shown in FIG14 , after the junction box cover 39 of the five-in-one controller for commercial vehicles is removed, it is convenient for high-voltage power line wiring. The PDU fuse top cover 40 is fixed on the controller upper cover 41 and is located above the PDU fuse 3. When the PDU fuse is damaged, the PDU fuse top cover 40 can be removed to replace the PDU fuse.

The solution of the present invention provides a highly integrated, low-cost five-in-one controller for new energy commercial vehicles, preferably a five-in-one controller for new energy electric buses, which integrates the single motor controller and the four-in-one distribution box in the relevant solution into an integrated design, and integrates the four-in-one high-voltage distribution box on the commercial vehicle in the relevant solution into the main motor driver to form a five-in-one controller. The volume of the five-in-one controller can be reduced by 25%, and the cost of the five-in-one controller can be reduced by 13%. There are no long-distance leads, which reduces the introduction of external interference and reduces energy loss on the line; and the five-in-one controller adopts a double-layer structure design, which can ensure the high integration of functional areas and the high power density of the five-in-one controller, and has good compatibility. The reserved function interface can be used to freely configure the PDU function according to the use requirements, and the corresponding power module can be switched according to the bus model (such as switching single and double power modules). The five-in-one controller is a dual-power module design and can also be adapted to a single power module.

By adopting the technical solution of the present invention, the four-in-one distribution box and the single motor driver (i.e., the main motor driver), the auxiliary drive motor, the low-voltage battery and the PDU function of the vehicle are integrated, and a wiring harness connector is used instead of a high-cost quick-connect connector; thus, by integrating the four-in-one distribution box and the single motor driver and using a wiring harness connector, a high degree of integration of the multi-functional area is achieved, connectors and long-distance leads are reduced, the controller is small in size, which is conducive to improving integration and reducing development costs. At the same time, the interior of the controller shell of the five-in-one controller is divided into upper and lower cavities, and a series heat dissipation channel is arranged between the upper and lower cavities. The upper cavity is divided into a top layer and a bottom layer to isolate the weak current part and the strong current part. It is not only compact in structure, but also improves the heat dissipation effect and the safety of strong and weak current operation. In addition, the internal functional divisions of the controller are clear, the internal functional divisions are obvious, and the layout of each functional module is flexible. By adopting the single-module and double-module compatible design of IGBT inverter modules, the current sharing effect is good, and the single and double modules and corresponding electrical components can be flexibly switched according to the vehicle model, which can reduce the mold opening cost of a single module, with high power density and wide coverage of vehicle models.

According to an embodiment of the present invention, a new energy commercial vehicle corresponding to a controller device of the vehicle is also provided. The new energy commercial vehicle may include: the controller device of the vehicle described above.

Since the processing and functions implemented by the new energy commercial vehicle of this embodiment basically correspond to the embodiments, principles and examples of the device, for the details not described in this embodiment, please refer to the relevant descriptions in the aforementioned embodiments, and no further details will be given here.

In summary, it is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

The above description is only an embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included in the scope of the claims of the present invention.

Claims (10)

1. A vehicle controller device, characterized in that it is applied to new energy commercial vehicles, comprising: a housing and a controller body, wherein the controller body is adapted to be arranged with the housing; the controller body comprises: a four-in-one distribution box and a single motor driver; wherein, The four-in-one distribution box and the single motor driver are integrated to form a five-in-one controller of the vehicle; the functional units of the five-in-one controller of the vehicle include: a main drive functional unit, a PDU functional unit, a DC-DC functional unit, an oil pump functional unit and an air pump functional unit; the main drive functional unit includes: a main control module (2), a PDU power distribution module and an inverter functional module; the inverter functional module includes: an IGBT inverter module (11); the configuration form of the IGBT inverter module (11) includes: a single power module and a dual power module; The functional modules in the PDU functional unit include: an air conditioning module, a heating module, a defrosting module and a reserved functional module; the reserved functional module is used to expand the functional modules in the PDU functional unit; A sheet metal part (9) is arranged in the housing; the PDU power distribution module comprises: a PDU fuse (3) and a PDU relay (5); wherein the main control module (2), the PDU fuse (3), and the PDU relay (5) except the air conditioning relay are all mounted on the sheet metal part (9); The accommodating space inside the shell is divided into an upper cavity, a lower cavity and a heat dissipation area; wherein the upper cavity and the lower cavity are arranged at corresponding intervals up and down, and the controller body is arranged in the upper cavity and the lower cavity; the heat dissipation area is located between the upper cavity and the lower cavity, and the heat dissipation area is provided with a series liquid cooling heat dissipation channel for dissipating heat from the heating element in the controller body; the controller shell of the five-in-one controller is divided into upper and lower cavities, and a series heat dissipation channel is arranged between the upper and lower cavities, and the upper cavity is divided into a top layer and a bottom layer to isolate the weak current part and the strong current part; by dividing the inside of the controller shell into upper and lower cavities and arranging a series heat dissipation channel between the upper and lower cavities, and isolating the strong and weak electricity by layering the upper cavity, the structure is compact, and the heat dissipation effect and the safety of the strong and weak electricity operation are improved; the DC-DC functional unit, the oil pump functional unit, and the air pump functional unit are all arranged in the lower cavity; The upper cavity is divided into a top layer and a bottom layer. The single power module and the dual power module are both arranged in the bottom layer of the upper cavity, and are used to select the single power module and the dual power module according to the vehicle model. The IGBT inverter module is designed to be compatible with single and dual modules, which has a good current sharing effect. The single and dual modules and corresponding electrical components can be flexibly switched according to the vehicle model, thereby reducing the cost of single module mold opening. The PDU functional unit and the sheet metal component (9) are both arranged in the top layer of the upper cavity. 2. The vehicle controller device according to claim 1, characterized in that the high-voltage positive electrode of the high-voltage battery of the vehicle is connected to the high-voltage main circuit; the high-voltage negative electrode of the high-voltage battery of the vehicle is connected to the high-voltage negative circuit; in, In the branch corresponding to each module in the air conditioning module, the heating module, the defrosting module, and the reserved function module, a first fuse and a first relay are provided; the high-voltage main circuit is connected to the positive electrode of the interface corresponding to each module after passing through the first fuse and the first relay in the branch corresponding to each module; the negative electrode of the interface corresponding to each module is connected to the high-voltage negative circuit; and/or, In the branch corresponding to the DC-DC functional unit, a second fuse and a DC-DC power conversion module (32) are provided; the high-voltage main circuit is connected to a battery interface corresponding to the battery of the vehicle after passing through the second fuse and the DC-DC power conversion module (32); the ground terminal of the DC-DC power conversion module (32) is connected to the high-voltage negative circuit; and/or, In the branch corresponding to the auxiliary drive functional unit where the oil pump functional unit and the air pump functional unit are located, an auxiliary drive pre-charging circuit and an auxiliary drive main circuit are provided, an auxiliary drive pre-charging relay, an auxiliary drive pre-charging resistor and a third fuse are provided in the auxiliary drive pre-charging circuit, and a second relay and a fourth fuse are provided in the auxiliary drive main circuit; the high-voltage main circuit is connected to the positive electrode of the oil pump interface corresponding to the oil pump functional unit after passing through the auxiliary drive pre-charging relay, the auxiliary drive pre-charging resistor and the third fuse; the negative electrode of the oil pump interface is connected to the high-voltage negative circuit; the high-voltage main circuit is also connected to the positive electrode of the air pump interface corresponding to the air pump functional unit after passing through the second relay and the fourth fuse; the negative electrode of the air pump interface is connected to the high-voltage negative circuit; the branch where the auxiliary drive pre-charging relay and the auxiliary drive pre-charging resistor are located is connected in parallel with the branch where the second relay is located; and/or, A main drive pre-charging circuit and a main drive main circuit are provided in the branch corresponding to the main drive functional unit, the main drive pre-charging circuit is connected in parallel with the main drive main circuit, a main drive pre-charging relay and a main drive pre-charging resistor are provided in the main drive pre-charging circuit, and a fifth fuse and a third relay are provided in the main drive main circuit; the high-voltage main circuit is connected to the positive electrode of the input end of the IGBT inverter module (11) corresponding to the main drive functional unit through the main drive pre-charging relay and the main drive pre-charging resistor; the high-voltage main circuit is also connected to the positive electrode of the input end of the IGBT inverter module (11) through the fifth fuse and the third relay, and the negative electrode of the input end of the IGBT inverter module (11) is connected to the high-voltage negative circuit. 3. The vehicle controller device according to claim 1 or 2, characterized in that the main control module (2), the PDU power distribution module and the inverter function module are integrated in the upper cavity; The oil pump function unit, the air pump function unit, and a DC-DC power conversion module (32) in the DC-DC function unit are integrated in the lower cavity. 4. The vehicle controller device according to claim 3 is characterized in that the current input end of the PDU relay (5) is connected to the PDU relay copper bus (6), and the PDU relay copper bus (6) is connected to the positive pole (17) of the first DC bus copper bus of the main drive functional unit through a wire. 5. The vehicle controller device according to claim 3, characterized in that a debugging interface (22), a VCU signal interface (23), a water outlet (24), a water inlet (26), a negative electrode interface of a battery, a positive electrode interface of a battery and a ground wire interface (28) of the five-in-one controller are provided on a first side portion outside the housing; wherein, The debugging interface (22) and the VCU signal interface (23) are connected to the main control module (2), the water outlet (24) and the water inlet (26) are connected to the series heat dissipation channel, the negative electrode interface of the battery and the positive electrode interface of the battery are connected to the DC-DC power conversion module (32), and the ground wire interface (28) is grounded and shares a common ground with the motor corresponding to the main drive functional unit. 6. The vehicle controller device according to claim 3, characterized in that a flow channel cover plate (35) is provided to match the serial heat dissipation flow channel; the oil pump function unit and the air pump function unit form an auxiliary drive function unit; the auxiliary drive function unit comprises: an auxiliary drive main control module (30), an auxiliary drive drive module (31); wherein, The auxiliary drive main control module (30), the auxiliary drive driving module (31), and the DC-DC power conversion module (32) are all mounted on the housing and the flow channel cover plate (35). 7. The vehicle controller device according to claim 3, characterized in that a PDU interface (36), an auxiliary drive interface (37), and a high-voltage input and three-phase input interface (38) of the five-in-one controller are provided on a second side portion outside the housing; The PDU interface (36) is arranged corresponding to the PDU functional unit; the PDU interface (36) comprises: an air conditioning interface, a heating interface, a defrosting interface and a reserved function interface; the connectors of the air conditioning interface, the heating interface, the defrosting interface and the reserved function interface all adopt wiring harness connectors; The auxiliary drive interface (37) comprises: an oil pump interface and an air pump interface; the connecting pieces of the oil pump interface and the air pump interface are both wire harness connectors; The high-voltage input and three-phase input interface (38) comprises: a high-voltage input interface, a high-voltage output interface, and a UVW three-phase output interface, and all are connected to the power line of the vehicle through a hole connector. 8. The vehicle controller device according to claim 7 is characterized in that the controller body also includes a junction box; the junction box is provided with a positive and negative interface, a high-voltage input interface, a high-voltage output interface, and a UVW three-phase output interface; the positive and negative interface, the high-voltage input interface, the high-voltage output interface, and the UVW three-phase output interface all use cable glands. 9. The vehicle controller device according to claim 3 is characterized in that the housing has a controller cover (41); adapted to the PDU fuse (3) in the PDU power distribution module, a PDU fuse top cover (40) is also provided; the PDU fuse top cover (40) is provided on the controller cover (41) and is located above the PDU fuse (3). 10. A new energy commercial vehicle, characterized by comprising: a vehicle controller device as claimed in any one of claims 1 to 9.