CN212970329U - Electric vehicle and power module, motor controller and power assembly thereof - Google Patents

Abstract

The utility model relates to an electric vehicle and power module, machine controller, power assembly thereof, this power module includes control panel, radiator, drive plate and power tube subassembly, and control panel, radiator and drive plate are in the range upon range of in proper order and are arranged, and control panel and drive plate electrical connection, power tube subassembly weld in the drive plate, and control panel, drive plate and power tube subassembly respectively with radiator heat conduction contact; according to the power module, the power tube assembly is in heat conduction contact with the radiator, the control board and the drive board are respectively arranged on two sides of the radiator, the control board and the drive board are respectively in heat conduction contact with the radiator, the radiator can radiate the control board and the drive board simultaneously, and the radiator can radiate the whole power module well.

Description

Electric vehicle and power module, motor controller and power assembly thereof

Technical Field

The utility model relates to a new energy automobile field, in particular to electric motor car and power module, machine controller, power assembly thereof.

Background

The existing electric vehicle is provided with an alternating current motor controller for converting a direct current power supply output by a storage battery into a three-phase alternating current power supply and driving a motor to rotate.

The power unit in the motor controller receives the direct current output by the storage battery and inverts the direct current into alternating current to output to the motor, so that each power module corresponds to one phase of the three-phase motor and is used for outputting U, V, W one-phase power supply in the three-phase power supply to the motor. Each power module is provided with two terminals for receiving a direct current power supply, is respectively used for receiving a positive power supply and a negative power supply, and is provided with a current output terminal for outputting a current signal to one phase of the motor. In addition, controllable switching devices such as power tubes and capacitors are required to be arranged between the two dc power supply terminals and the current output terminal, the power tubes can be thyristors or IGBTs and the like, and are used for controlling dc power, and the power tubes can generate waste heat during operation, so that the power tubes generally need to be subjected to heat dissipation treatment.

However, the conventional motor controller mainly focuses on heat dissipation of power components, and has a poor heat dissipation effect on a PCB board, such as a driving board and a control board, for mounting various components.

SUMMERY OF THE UTILITY MODEL

A first object of the utility model is to provide a power module layout scheme, when guaranteeing to power component heat dissipation, improves the radiating effect to its PCB board that has.

A second object of the utility model is to provide a machine controller, power assembly and electric motor car based on above-mentioned power module.

In order to achieve the above object, the utility model provides a following technical scheme:

the utility model provides a power module, includes control panel, radiator, drive plate and power tube subassembly, the control panel the radiator and the drive plate stacks gradually and arranges, the control panel with drive plate electrical connection, the power tube subassembly weld in the drive plate, just the control panel the drive plate and the power tube subassembly respectively with radiator heat conduction contact.

Preferably, the power tube assembly includes a plurality of power tubes, and each of the power tubes is fixed to a side surface of the heat sink facing the driving board by a fixing structure.

Preferably, the heat sink is provided with an avoiding via hole penetrating through the heat sink in the thickness direction, and the pin header on one of the drive board and the control board penetrates through the avoiding via hole to be in plug-in fit with the pin header on the other of the drive board and the control board.

Preferably, the avoiding through hole divides the inner cavity of the radiator into at least two parallel flow channels, and the flow channels at least pass through the position on the radiator for arranging the power tube assembly.

Preferably, heat conduction layers are respectively arranged between the control board and the heat sink and between the driving board and the heat sink.

A motor controller comprising:

a controller case;

the power module of any preceding claim, disposed within the controller housing.

Preferably, the water inlet and outlet of the radiator of the power module are respectively in sealing butt joint with the water inlet and outlet on the controller box body.

Preferably, a heat conducting glue layer is filled between the driving plate of the power module and the inner wall of the controller box body.

A power assembly comprises a motor, a gearbox and a motor controller, wherein the motor controller is connected with the motor, and the motor is connected with the gearbox.

Preferably, the gearbox and the motor form an L-shaped structure, and the motor controller is disposed in a gap between the gearbox and the motor.

Preferably, a water inlet and a water outlet on a controller box of the motor controller are connected into a cooling circulation system of the power assembly.

An electric vehicle comprising a powertrain as claimed in any preceding claim.

It can be seen from the above technical solutions that the present invention discloses a power module, which comprises a control board, a heat sink, a driving board and a power tube assembly, wherein the control board, the heat sink and the driving board are sequentially stacked, i.e. the control board and the driving board are respectively disposed at two sides of the heat sink, the control board is electrically connected with the driving board, the electrical connection between the control board and the driving board can be realized by bypassing the heat sink or by directly passing through the heat sink, the power tube assembly is welded to the driving board, and the control board, the driving board and the power tube assembly are respectively in heat-conducting contact with the heat sink, the refrigeration surface of the heat sink can be in direct contact with the heating surface of the control board, the driving board or the power tube assembly, or a heat-conducting plate or heat-conducting, the heat conducting plate comprises but is not limited to a ceramic heat conducting plate and a copper plate, the heat conducting material coating comprises but is not limited to heat conducting silicone grease, and it should be noted that the driving plate also comprises other elements besides the power tube assembly, such as a copper bar, a capacitor assembly, a pin header and the like; according to the power module, the power tube assembly is in heat conduction contact with the radiator, the control board and the drive board are respectively arranged on two sides of the radiator, the control board and the drive board are respectively in heat conduction contact with the radiator, the radiator can radiate the control board and the drive board simultaneously, and the radiator can radiate the whole power module well.

The utility model also provides a motor controller, power assembly and electric motor car, because above-mentioned power module has all been adopted to this motor controller, power assembly and electric motor car, this power module helps improving the operating stability of motor controller, power assembly and electric motor car because its good radiating effect.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.

Fig. 1 is a schematic structural diagram of a power module according to an embodiment of the present invention;

fig. 2 is an exploded view of a power module according to an embodiment of the present invention;

fig. 3 is a cross-sectional view of a power module according to an embodiment of the present invention;

fig. 4 is a schematic structural diagram of a driving plate according to an embodiment of the present invention;

fig. 5 is a schematic structural diagram of a heat sink equipped with a power tube assembly according to an embodiment of the present invention;

FIG. 6 is an exploded view of FIG. 5;

fig. 7 is a schematic structural diagram of a heat sink equipped with a power tube assembly according to another embodiment of the present invention;

fig. 8 is a schematic view of an internal structure of the heat sink provided by the present invention;

fig. 9 is a schematic structural view of an upper cover plate of a heat sink according to the present invention;

fig. 10 is a bottom view of the upper cover plate of the heat sink provided by the present invention;

fig. 11 is a schematic structural view of a lower cover plate of a heat sink according to the present invention;

fig. 12 is an exploded view of a motor controller according to an embodiment of the present invention;

fig. 13 is a top view of an internal structure of a motor controller according to an embodiment of the present invention;

fig. 14 is a cross-sectional view of an internal structure of a motor controller according to an embodiment of the present invention;

fig. 15 is a schematic structural diagram of a power assembly provided in an embodiment of the present invention.

Wherein:

100 is a power module; 110 is a control panel; 120 is a radiator; 121 is an upper cover plate; 122 is a lower cover plate; 123 is the water outlet of the radiator; 124 is the water inlet of the radiator; 125 is a first screw hole column; 126 is a second screw hole column; 127 is a ceramic heat-conducting plate; 128 is a fixing hole; 129 is a diamond-shaped tooth; 1210 is a first via; 1211 is a second via hole; 130 is a driving plate; 131 is a three-phase alternating current copper bar; 132 is a membrane capacitor; 133 is a direct current output copper bar; 134 is a driving pin header; 135 is a power tube; 136 is a filter capacitor; 140 is a U-shaped spring plate; 150 is an AC wire holder; 200 is a motor controller; 210 is a big cover; 211 is a small cover; 220 is a box body; 230 is a water nozzle; 240 is a signal terminal; 250 are direct current positive and negative terminals; 260 is a DC wire holder; 270 are fasteners.

Detailed Description

One of the cores of the utility model is to provide a power module layout scheme to when guaranteeing to the power component heat dissipation, improve the radiating effect to its PCB board that has.

The utility model discloses an another core provides a machine controller, power assembly and electric motor car based on above-mentioned power module.

The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.

Referring to fig. 1-3, fig. 1 is a schematic structural diagram of a power module according to an embodiment of the present invention, fig. 2 is an exploded view of the power module according to an embodiment of the present invention, and fig. 3 is a cross-sectional view of the power module according to an embodiment of the present invention.

The embodiment of the utility model provides an in disclose a power module 100 for the power assembly of electric motor car, this power module 100 includes control panel 110, radiator 120, drive plate 130 and power tube subassembly.

The control board 110, the heat sink 120 and the driving board 130 are sequentially stacked, that is, the control board 110 and the driving board 130 are respectively disposed on two sides of the heat sink 120, the control board 110 is electrically connected to the driving board 130, the electrical connection between the control board 110 and the driving board 130 can be realized by bypassing the heat sink 120 or by directly passing through the heat sink 120, the power tube assembly is welded to the driving board 130, it should be noted that, in addition to the power tube assembly, other components are welded to the driving board 130, for example, the driving board 130 is further provided with elements such as a three-phase ac copper bar 131, a capacitor assembly (a film capacitor 132, a filter capacitor 136), a dc output copper bar 133, and a driving pin 134, as; the control board 110, the driving board 130 and the power tube assembly are respectively in heat-conducting contact with the heat sink 120, the cooling surface of the heat sink 120 may be in direct contact with the heating surfaces of the control board 110, the driving board 130 or the power tube assembly, or a heat-conducting plate or a heat-conducting material coating may be disposed between the cooling surface of the heat sink 120 and the heating surfaces of the control board 110, the driving board 130 or the power tube assembly, the heat-conducting plate includes, but is not limited to, a ceramic heat-conducting plate 127 and a copper plate, and the heat.

In conclusion, compared with the prior art, the embodiment of the present invention provides a power module 100 not only with power tube assembly and heat conduction contact of heat sink 120, still through setting up control board 110 and drive board 130 respectively in heat sink 120 both sides and make control board 110 and drive board 130 respectively with heat conduction contact of heat sink 120, realize that heat sink 120 dispels the heat to control board 110 and drive board 130 simultaneously, realize that heat sink 120 dispels the holistic good heat of power module 100.

As shown in fig. 3, a gap X1 is formed between the control board 110 and the heat sink 120, a gap X2 is formed between the driving board 130 and the heat sink 120, and a heat conducting layer is disposed in the gap X1 and the gap X2, specifically, the heat conducting layer is a heat conducting adhesive layer or any other heat conducting material layer capable of filling the gap X1 and the gap X2, such a structure can increase the heat dissipation effect of the heat sink 120 on the control board 110 and the driving board 130, and on the other hand, the power module 100 can form a more stable whole.

In the prior art, the vertical parallel structure is adopted for the power tube assembly, which leads to more concentrated heat generation of the power module 100 and is not beneficial to heat dissipation, therefore, in the embodiment of the utility model, the power tube module adopts the flat-type design, as shown in fig. 5 and fig. 6, the power tube assembly includes a plurality of power tubes 135, the power tubes 135 may be conventional power devices or switching devices such as IGBTs, each power tube 135 is flatly fixed on a side surface of the heat sink 120 facing the driving board 130 by a fixing structure, each power tube 135 may directly contact with the heat sink 120, or a heat conducting structure may be disposed on the heat sink 120, the heat conducting structure comprises a ceramic heat conducting plate 127, or a heat conducting plate made of other materials, or heat conducting silicone grease, or a structure combining the heat conducting plate and the heat conducting silicone grease, the power tube 135 is then placed on the thermally conductive structure to increase the efficiency of heat transfer between the two.

Through the tiled design of the power tube module and the arrangement of the radiator 120, the control board 110 and the drive board 130 are respectively arranged on the layout structures on the two sides, so that the height of the whole power assembly can be reduced, the height of the power assembly can be further reduced, the arrangement of the power assembly on the whole vehicle is facilitated, and the application range of the power assembly is enlarged.

In the embodiment provided in fig. 5 and 6, in order to achieve the close contact between the heat sink 120 and the power tube 135, the fixing structure is a U-shaped elastic sheet 140, and the power tube 135 is clamped on the heat sink 120 by the U-shaped elastic sheet 140.

Certainly, other modes can also be adopted to realize the close contact between the power tube 135 and the heat sink 120, as shown in fig. 7, in this embodiment, the power tube 135 is closely attached to the surface of the heat sink 120 through an adhesive layer, and in other embodiments, the two modes can also be combined for use, that is, the power tube 135 is firstly adhered to the heat sink 120 through the adhesive layer, and then is clamped through the U-shaped elastic sheet 140, so as to realize the double fixation of the power board.

Preferably, the heat sink 120 is provided with an avoiding via hole penetrating through the thickness direction of the heat sink, and the pin header on one of the driving board 130 and the control board 110 passes through the avoiding via hole to be in plug-in fit with the pin header on the other one of the driving board 130 and the control board 110, so that the structure not only avoids the driving pin header 134 to facilitate the connection between the driving board 130 and the control board 110, but also limits the position of the heat sink 120 by using the connection structure between the driving board 130 and the control board 110 to facilitate the subsequent assembly.

Specifically, as shown in fig. 8, the heat sink 120 is composed of an upper cover plate 121 and a lower cover plate 122, the upper cover plate 121 and the lower cover plate 122 are hermetically fitted to enclose a cavity through which cooling liquid flows, a first through hole 1210 is disposed on the upper cover plate 121, a second through hole 1211 is disposed on the lower cover plate 122, and an annular boss is disposed around an opening at one end of the first through hole 1210 in the cavity, and the annular boss is hermetically fitted to the lower cover plate 122 and encloses the second through hole 1211 on the lower cover plate 122 to form the above-mentioned avoiding through hole.

As shown in fig. 9 and 11, the upper cover plate 121 is provided with a first screw hole column 125 for connecting with the control plate 110, the lower cover plate 122 is provided with a second screw hole column 126 for connecting with the driving plate 130, the lower cover plate 122 is provided with second screw hole columns 126 at four corners and at the center, respectively, in order to avoid the second screw hole column 126 at the center, the second through hole 1211 on the lower cover plate 122 is formed by three holes, and the second screw hole column 126 is provided between two adjacent three holes.

Further, in order to improve the heat dissipation efficiency of the heat sink 120, the inner wall of the heat sink 120 is further provided with a structure such as a heat dissipation fin, a heat dissipation tooth, a heat dissipation boss, etc. to increase the contact area between the heat sink 120 and the cooling water, so as to increase the heat exchange efficiency.

As shown in fig. 8 and 10, a plurality of diamond-shaped teeth 129 extending toward the lower cover plate 122 are disposed on the inner wall of the upper cover plate 121 of the heat sink 120 in an array arrangement to increase the contact area between the upper cover plate 121 and the cooling water, so as to improve the heat dissipation effect on the power tubes 135 disposed on the upper cover plate 121 of the heat sink 120.

As shown in fig. 5 to 9, a water inlet 124 and a water outlet 123 which are communicated with the cavity are disposed at two ends of the upper cover plate 121 in the length direction, and the heat sink 120 can be connected to a cooling circulation system of the power assembly through the water inlet 124 and the water outlet 123, so as to dissipate heat of the power tube 135.

Further optimizing the above technical solution, the avoiding via hole divides the inner cavity of the heat sink 120 into at least two parallel flow channels, each flow channel is connected in parallel between the water inlet 124 and the water outlet 123 of the heat sink 120, and the flow channel passes through at least the position on the heat sink 120 for arranging the power tube assembly.

Based on the power module 100, the embodiment of the present invention further provides a motor controller 200, please refer to fig. 12, in which the motor controller 200 includes a controller box and the power module 100 as described in the above embodiment, and the power module 100 is disposed in the controller box.

Specifically, as shown in fig. 12, the controller box includes a box cover and a box 220, and the box cover and the box 220 enclose a space for accommodating the power module 100, where the box cover includes a large cover 210 and a small cover 211, the large cover 210 is provided with a wiring hole, and the small cover 211 is openably disposed on the large cover 210 to close and open the wiring hole, and when in application, the small cover 211 can be removed to perform a dc wiring harness wiring operation; besides the power module 100, the case 220 further contains an ac connection base 150 and a dc connection base 260, the ac connection base 150 is connected to the three-phase ac copper bar 131 on the power module 100, terminals of the ac connection base 150 extend from an opening of the case 220 to the outside of the controller case, the outer wall of the case 220 is provided with a signal terminal 240 and dc positive and negative terminals 250, and the dc positive and negative terminals 250 are connected to the dc connection base 260.

A control box water inlet used for being in sealed butt joint with the water inlet of the radiator 120 and a control box water outlet used for being in sealed butt joint with the water outlet of the radiator 120 are arranged in the box body 220, a water nozzle 230 is connected to one end, outside the box body 220, of the control box water inlet in a pressing mode, and one end, outside the box body 220, of the control box water outlet is in sealed plug-in connection with the water inlet of the motor.

As shown in fig. 12 and 13, third screw holes are respectively formed in the case 220 at positions corresponding to two ends of the heat sink 120, fixing holes 128 penetrating through the thickness direction of the heat sink 120 are formed at two ends of the heat sink 120, the fixing holes 128 are formed in the two ends of the heat sink 120, and the fastening members 270 pass through the fixing holes 128 and are matched with the third screw holes to fix the heat sink 120 in the case 220.

Further optimizing the above technical solution, as shown in fig. 14, a gap X3 is formed between the drive board 130 of the power module 100 and the inner wall of the controller box, and a heat conductive adhesive layer is filled in the gap X3, so that the heat conductive adhesive layers are disposed on both sides of the drive board 130, which can realize more effective heat dissipation of the drive board 130, and is helpful for reducing the overall temperature of the power module 100.

Based on above-mentioned power module 100 and machine controller 200, the embodiment of the utility model provides a still provide a power assembly, as shown in fig. 15, this power assembly includes motor, gearbox and machine controller 200 as described in above-mentioned embodiment, machine controller 200 is connected with the motor, and the motor links to each other with the gearbox, because this power assembly has adopted machine controller 200 as described above, therefore the beneficial effect of power assembly please refer to above-mentioned embodiment.

Further optimizing the technical scheme, as shown in fig. 15, the gearbox and the motor form an L-shaped structure, the motor controller 200 is arranged in a gap between the gearbox and the motor, the arrangement structure is compact in size and low in overall height, and the problem that the power assembly is applicable to small vehicles and vehicle types with insufficient height space is solved.

Preferably, a water inlet and a water outlet on the control box of the motor controller 200 are connected to a cooling circulation system of the motor, so that the cooling liquid enters from a water nozzle 230 of the motor controller 200, passes through the radiator 120 in the power module 100, and then flows out to the motor to dissipate heat of the motor.

Based on above-mentioned power assembly, the embodiment of the utility model provides an electric motor car is still provided, and this electric motor car adopts the power assembly in the above-mentioned embodiment, therefore the beneficial effect of this electric motor car please refer to above-mentioned embodiment.

The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims (12)

1. The power module is characterized by comprising a control board, a radiator, a drive board and a power pipe assembly, wherein the control board, the radiator and the drive board are sequentially arranged in a stacked mode, the control board is electrically connected with the drive board, the power pipe assembly is welded on the drive board, and the control board, the drive board and the power pipe assembly are respectively in heat conduction contact with the radiator.

2. The power module as claimed in claim 1, wherein the power tube assembly comprises a plurality of power tubes, each of the power tubes being mounted by a fixing structure to be laid flat on a side surface of the heat sink facing the driving board.

3. The power module according to claim 1 or 2, wherein the heat sink is provided with an avoiding via hole penetrating through the heat sink in the thickness direction, and a pin header on one of the driving board and the control board passes through the avoiding via hole to be in plug-in fit with a pin header on the other of the driving board and the control board.

4. The power module of claim 3, wherein the bypass via divides the interior cavity of the heat sink into at least two parallel flow paths that pass at least through a location on the heat sink where the power tube assembly is located.

5. The power module as claimed in any one of claims 1, 2 and 4, wherein a heat conducting layer is respectively disposed between the control board and the heat sink and between the driving board and the heat sink.

6. A motor controller, comprising:

a controller case;

the power module of any of claims 1-5 disposed within the controller housing.

7. The machine controller of claim 6, wherein the water inlet and outlet ports of the heat sink of the power module are sealingly interfaced with the water inlet and outlet ports on the controller housing, respectively.

8. The motor controller according to claim 6 or 7, wherein a heat conductive adhesive layer is filled between the driving plate of the power module and the inner wall of the controller box.

9. A powertrain comprising an electric machine, a gearbox and a machine controller according to any of claims 6-8, the machine controller being connected to the electric machine, the electric machine being connected to the gearbox.

10. A powertrain according to claim 9, wherein the gearbox and the electric machine form an L-shaped structure, and the electric machine controller is disposed in a gap between the gearbox and the electric machine.

11. A drive train according to claim 9 or claim 10, wherein the water inlet and outlet ports on the controller housing of the motor controller are connected to a cooling circulation system of the drive train.

12. An electric vehicle comprising a powertrain according to any of claims 9-11.

Images