CN213213362U

CN213213362U - High-power motor controller for electric bus

Info

Publication number: CN213213362U
Application number: CN202021538843.4U
Authority: CN
Inventors: 陈登峰; 陈雷; 孙臣玉; 温小伟; 梅友忠
Original assignee: Shanghai Auto Edrive Co Ltd; Shanghai Auto Edrive Engineering Technology Research Center; Shanghai Edrive Co Ltd
Current assignee: Shanghai Auto Edrive Co Ltd; Shanghai Auto Edrive Engineering Technology Research Center; Shanghai Edrive Co Ltd
Priority date: 2020-07-30
Filing date: 2020-07-30
Publication date: 2021-05-14
Anticipated expiration: 2030-07-30

Abstract

The utility model relates to a high power motor controller for electric bus, including current sensor, three-phase output subassembly, module support, three-phase filtering subassembly, drive plate, film capacitor, control panel, the IGBT module is fixed on three-phase support and module support and cooperates with the basin of box bottom surface, the output of IGBT module is connected with the input of three-phase output copper bar respectively, the input of three-phase switching copper bar passes current sensor and is connected with the output of three-phase output copper bar; the input end of the thin film capacitor is sleeved with the two-phase filtering assembly and is electrically connected with the input end of the high-voltage input wire harness; the control panel is arranged above the thin film capacitor and fixed on the thin film capacitor. Compared with the prior art, the utility model has the advantages that the whole structure is compact, the parallelly connected use of IGBT module, radiating effect are excellent, and output doubles, reduces the whole volume of machine controller, has improved machine controller's reliability, makes things convenient for automatic assembly.

Description

High-power motor controller for electric bus

Technical Field

The utility model relates to a machine controller especially relates to an electronic high power machine controller for big bus.

Background

With the continuous development of electric automobiles, the traditional fuel oil private car is gradually replaced by the electric automobile, the traditional private car needs a set of relatively low-power motor controller and driving motor because of light weight and no overlarge load capacity, and the traditional motor controller is mostly matched with the market of passenger cars and has the defect that the power is low and the high-power driving motor is difficult to drive. For the electric bus, if the electric bus is to be driven by electricity, considering that the size and the weight of the electric bus are large and the load has strict requirements, if the electric bus needs to be driven, several low-power motor controllers and driving motors of the same type are required to be driven simultaneously to meet the use requirements, the requirement on the installation space of the electric bus is very strict, and the electric bus is difficult to have enough space to install several sets of motor controllers and driving motors under normal conditions. Therefore, it is necessary to design a high-power controller for electric bus.

SUMMERY OF THE UTILITY MODEL

The utility model aims at providing a high power motor controller for electric bus in order to overcome the defects of the prior art.

The purpose of the utility model can be realized through the following technical scheme:

a high-power motor controller for an electric bus comprises a box body, wherein a water inlet pipe and a water outlet pipe are arranged on the box body, a current sensor, a three-phase output assembly, a module support, a three-phase filtering assembly, a driving plate, a thin film capacitor and a control plate are arranged in the box body, the three-phase output assembly comprises a three-phase support and a three-phase output copper bar encapsulated in the three-phase support, the three-phase filtering assembly comprises a filtering support, a filter and a three-phase switching copper bar, the filter is encapsulated in the filtering support, and the three-phase switching copper bar penetrates through the filtering support;

the IGBT module is fixed on the three-phase support and the module support and is matched with the water tank on the bottom surface of the box body, the output end of the IGBT module is respectively and electrically connected with the input end of the three-phase output copper bar, and the input end of the three-phase switching copper bar passes through the current sensor and is electrically connected with the output end of the three-phase output copper bar; the driving board is arranged above the IGBT module and is electrically connected with a signal pin of the IGBT module; the thin film capacitor is arranged above the drive board, the output end of the thin film capacitor is electrically connected with the input end of the IGBT module, and the input end of the thin film capacitor is sleeved with the two-phase filter assembly and is electrically connected with the input end of the high-voltage input wire harness; the control panel is arranged above the thin film capacitor and fixed on the thin film capacitor.

Preferably, the bottom surface of the box body is provided with a first water tank and a second water tank which are arranged side by side, and IGBT modules are respectively arranged in the first water tank and the second water tank.

Preferably, the bottom surface of the IGBT module is provided with a heat dissipation water channel which is arranged in a labyrinth manner.

Preferably, the first water tank and the second water tank are respectively provided with a plurality of water tanks, a first water tank inlet and a first water tank outlet which are positioned at two ends of a diagonal line are arranged in the first water tank, and a second water tank inlet and a second water tank outlet which are positioned at two ends of the diagonal line are arranged in the second water tank.

Preferably, the side of box is equipped with first water inlet channel, first water outlet channel, second water inlet channel, second water outlet channel, the import of first water outlet channel and the export intercommunication of second water inlet channel, first basin entry and the export intercommunication of first water inlet channel, first basin export and first water outlet channel entry intercommunication, second basin entry and second water inlet channel export intercommunication, second basin export and second water outlet channel entry intercommunication.

Preferably, the number of the IGBT modules is even, and the IGBT modules are arranged in parallel in two rows.

Preferably, the input end of the three-phase output copper bar is welded into two bifurcated structures by laser.

Preferably, the upper surface of the thin film capacitor is provided with a plurality of pillars, and the output ends of the pillars are arranged in two rows symmetrically.

Preferably, the three-phase support is provided with three L-shaped grooves which are horizontally stacked, and the three-phase output copper bar is encapsulated in the L-shaped grooves to form a three-phase output assembly.

Preferably, the same side of the box body is provided with a high-voltage input wire harness and an interface board.

Compared with the prior art, the utility model has the advantages of it is following:

1. this high power machine controller for electronic big bus structure arranges, is equipped with a plurality of IGBT modules of even number to divide two rows of parallel arrangement, can let machine controller's output promote one time, the power that has greatly promoted the controller satisfies driving motor's in the big bus power demand.

2. The three-phase switching copper bar of the motor controller penetrates through the central rectangular hole of the filtering support, the filter is sleeved on the periphery of the three-phase switching copper bar, and the two-phase filtering component is also sleeved on the input end copper bar of the film capacitor, so that the EMC performance of the input end of the motor controller is improved, the EMC problem of the input end of the driving motor is improved, and the anti-interference and anti-radiation capabilities of the whole controller are improved.

3. The bottom surface of the IGBT module is provided with a labyrinth type heat dissipation water channel, the water channels of the plurality of IGBT modules are respectively sunk into the first water tank and the second water tank, because the inlet of the first water tank is communicated with the outlet of the first water inlet channel, the outlet of the first water tank is communicated with the inlet of the first water outlet channel, the inlet of the second water tank is communicated with the outlet of the second water inlet channel, the outlet of the second water tank is communicated with the inlet of the second water outlet channel, the bottom heat dissipation water channel of the IGBT module in the first water tank is communicated with the inlet of the first water tank and the outlet of the first water tank, the bottom heat dissipation water channel of the IGBT module in the second water tank is communicated with the inlet of the second water tank and the outlet of the second water tank, so a serial type heat dissipation water channel is formed, cooling and heat dissipation of.

4. Three-phase output assembly has integrateed three-phase support and three-phase output copper bar simultaneously, and the three-phase support has three to be L shape recess, and the embedment of three-phase output copper bar is fixed as a whole with four parts, has both satisfied the insulation and has kept apart, has satisfied the three-phase water conservancy diversion again, with the three-phase input of the leading-in motor of alternating current of the output of IGBT module, and the anti-vibration ability is stronger moreover, and the reliability is higher.

5. The input of three-phase output copper bar becomes two forked structures through laser welding, can guarantee like this that the output of two IGBT modules can be connected to the input of same three-phase output copper bar, can guarantee like this the punctuality of IGBT module output end electric current, has solved and has adopted disconnect-type copper bar independent connection IGBT module to carry out parallelly connected current inequality.

6. There are many spinal branchs posts film capacitor upper surface, can play the effect of fixed control board, reduced installation space, be favorable to integrating the design, the output of film capacitor lower surface is two rows of symmetrical arrangement, two rows of outputs can be simultaneously with the input electrical connection of a plurality of IGBT modules like this, ensure that film capacitor can satisfy the rectification demand of a plurality of IGBT module normal work.

Drawings

Fig. 1 is an exploded view of the motor controller of the present invention;

fig. 2 is a schematic structure of a three-phase support of the motor controller of the present invention;

fig. 3 is a schematic diagram of a three-phase output copper bar structure of the motor controller of the present invention;

fig. 4 is a schematic structural diagram of a three-phase filtering assembly of the motor controller of the present invention;

fig. 5 is a schematic structural view of a filtering support of the motor controller of the present invention;

fig. 6 is a schematic view of the bottom structure of the box body of the motor controller of the present invention;

fig. 7 is a schematic side view of the case of the motor controller of the present invention;

fig. 8 is a schematic view of the bottom structure of the IGBT module of the motor controller of the present invention;

fig. 9 is a schematic diagram of a thin film capacitor structure of the motor controller of the present invention;

the figure is marked with: 1. the device comprises a box body, 2, a water outlet pipe, 3, a water inlet pipe, 4, an IGBT module, 5, a driving board, 6, a three-phase output assembly, 7, a film capacitor, 8, a control board, 9, a box cover, 10, a two-phase filtering assembly, 11, a current sensor, 12, a three-phase filtering assembly, 13, a module support, 14, a high-voltage input wiring harness, 15, an interface board, 1-1, a first water tank, 1-2, a first water tank inlet, 1-3, a first water tank outlet, 1-4, a second water tank inlet, 1-5, a second water tank, 1-6, a second water tank outlet, 1-7, a first water inlet channel, 1-8, a first water outlet channel, 1-9, a second water inlet channel, 1-10, a second water outlet channel, 6-1, a three-phase support, 6-2, a three-phase output copper bar, 12-1, 12-2 parts of a filtering support, 12-3 parts of a filter and 12-3 parts of a three-phase switching copper bar.

Detailed Description

The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. The embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation manner and a specific operation process are given, but the scope of the present invention is not limited to the following embodiments.

Examples

As shown in figure 1, the application provides a high-power motor controller for an electric bus, which comprises a box body 1, wherein a water inlet pipe 3 and a water outlet pipe 2 are arranged on the box body 1. The box body 1 is internally provided with a current sensor 11, a three-phase output assembly 6, a module support 13, a three-phase filtering assembly 12, a driving plate 5, a film capacitor 7 and a control plate 8. The three-phase output assembly 6 comprises a three-phase support 6-1 and a three-phase output copper bar 6-2 encapsulated in the three-phase support 6-1. The three-phase filtering component 12 comprises a filtering support 12-1, a filter 12-2 and a three-phase switching copper bar 12-3, wherein the filter 12-2 is encapsulated in the filtering support 12-1, and the three-phase switching copper bar 12-3 penetrates through the center of the filtering support 12-1.

The current sensor 11, the three-phase output assembly 6 and the module support 13 are fixed on the bottom surface of the box body 1. The IGBT module 4 is fixed on the three-phase support 6-1 and the module support 13 and is matched with the water tank on the bottom surface of the box body 1, the output end of the IGBT module 4 is respectively and electrically connected with the input end of the three-phase output copper bar 6-2, and the input end of the three-phase switching copper bar 12-3 penetrates through the central hole of the current sensor 11 and is electrically connected with the output end of the three-phase output copper bar 6-2. The driving plate 5 is arranged right above the IGBT module 4, and the driving plate 5 is fixed on a small support column on the bottom surface of the box body 1 and is electrically connected with a signal pin of the IGBT module 4. The thin film capacitor 7 is arranged right above the driving board 5 and fixed on a support column on the bottom surface of the box body 1, and the output end of the thin film capacitor is electrically connected with the input end of the IGBT module 4. The two-phase filter assembly 10 is also fixed on the support column on the bottom surface of the box body 1 and is sleeved on the input end of the thin film capacitor 7. The high-voltage input wire harness 14 and the interface board 15 are fixed on the same side surface of the box body 1, and the input end of the high-voltage input wire harness 14 is electrically connected with the input end of the thin-film capacitor 7. The control board 8 is arranged above the thin film capacitor 7 and fixed on the thin film capacitor 7. The water inlet pipe 3 and the water outlet pipe 2 are fixed on a water channel water inlet and a water channel water outlet on the side surface of the box body 1, and the box cover 9 is fixed above the box body 1.

Two or even a plurality of IGBT modules 4 are connected in parallel, so that the output power of the motor controller can be doubled, the size of too many motor controllers is not increased, the requirement of high power of the electric bus can be met, and the requirement of assembly space on the bus can be met. In this embodiment, the number of the IGBT modules 4 is six, two rows of IGBT modules are arranged in parallel, and the two IGBT modules 4 are arranged in parallel symmetrically and respectively, so that the output power of the motor controller can be doubled, and the power of the controller is greatly increased to meet the power requirement of the driving motor in the bus.

As shown in fig. 2, the three-phase support 6-1 is provided with three L-shaped grooves which are horizontally stacked, the three-phase output copper bar 6-2 is inserted into the L-shaped grooves and encapsulated by epoxy resin, and the four parts are combined into an integral assembly, so that the vibration reliability is improved.

As shown in FIG. 3, the input end of the three-phase output copper bar 6-2 is welded into two bifurcate structures by laser. Therefore, the three-phase output copper bar 6-2 can be simultaneously connected with the output ends of the two IGBT modules 4, and the problem of current unevenness caused by the fact that the IGBT modules 4 are independently connected through the separated copper bars to be connected in parallel is solved.

As shown in fig. 4 and 5, the center of the filter support 12-1 is provided with three rectangular through holes, an oval groove is formed around the rectangular through holes, the filter 12-2 is encapsulated in the oval groove through epoxy resin, and the three-phase switching copper bar 12-3 is inserted into the three rectangular through holes.

As shown in fig. 6 and 7, a first water tank 1-1 and a second water tank 1-5 are symmetrically arranged side by side on the bottom surface of the box body 1, and IGBT modules 4 are respectively arranged in the first water tank 1-1 and the second water tank 1-5. The first water tank 1-1 and the second water tank 1-5 are respectively provided with three water tanks, and the cross sections of the water tanks are square. The first water tank 1-1 is provided with a first water tank inlet 1-2 and a first water tank outlet 1-3 which are positioned at two ends of a diagonal line, and the second water tank 1-5 is provided with a second water tank inlet 1-4 and a second water tank outlet 1-6 which are positioned at two ends of the diagonal line.

The side surface of the box body 1 is provided with a first water inlet channel 1-7, a first water outlet channel 1-8, a second water inlet channel 1-9 and a second water outlet channel 1-10, the inlet of the first water outlet channel 1-8 is communicated with the outlet of the second water inlet channel 1-9, the inlet 1-2 of the first water tank is communicated with the outlet of the first water inlet channel 1-7, the outlet 1-3 of the first water tank is communicated with the inlet of the first water outlet channel 1-8, the inlet 1-4 of the second water tank is communicated with the outlet of the second water inlet channel 1-9, and the outlet 1-6 of the second water tank is communicated with the inlet of the second water outlet channel 1-10.

As shown in fig. 8, the bottom surface of the IGBT module 4 is provided with a heat radiation water channel arranged in a labyrinth manner.

Water channels of the six IGBT modules 4 are respectively sunk into the first water tank 1-1 and the second water tank 1-5, heat dissipation water channels at the bottoms of the IGBT modules 4 in the first water tank 1-1 are communicated with the first water tank inlet 1-2 and the first water tank outlet 1-3, and heat dissipation water channels at the bottoms of the IGBT modules 4 in the second water tank 1-5 are communicated with the second water tank inlet 1-4 and the second water tank outlet 1-6, so that a serial connection type heat dissipation water channel is formed, cooling and heat dissipation of the six IGBT modules 4 can be simultaneously met, and heat dissipation performance of the motor controller is improved.

As shown in fig. 9, the upper surface of the thin film capacitor 7 is provided with 8 pillars, and the output ends thereof are arranged in two rows symmetrically.

The specific assembly process of the motor controller for the electric bus is as follows:

firstly, pressing a water inlet pipe 3 and a water outlet pipe 2 onto a box body 1 by a press machine, then fixing a module support 13 and a three-phase output assembly 6 on the bottom surface of the box body 1, then respectively placing an IGBT module 4 into a first water tank 1-1 and a second water tank 1-5, and respectively fixing the output end of the IGBT module 4 and a three-phase output copper bar 6-2 on the three-phase support 6-1 by bolts; sleeving the current sensor 11 on the input end of the three-phase switching copper bar 12-3 of the three-phase filtering component 12, and then fixing the current sensor 11 and the three-phase filtering component 12 on the bottom surface of the box body; then, the input end of a three-phase switching copper bar 12-3 and a three-phase output copper bar 6-2 are fixed on a three-phase support 6-1 together, a driving plate 5 is fixed on a small support column on the bottom surface of a box body 1, and a signal pin of an IGBT module 4 is welded and fixed with the driving plate 5 through soldering tin; then fixing the thin film capacitor 7 on a support column of the box body 1, and fixing the output end of the thin film capacitor 7 and the input end of the IGBT module 4 on the module support 13 respectively; then sleeving the two-phase filtering component 10 on the input end of the thin film capacitor 7 and fixing the two-phase filtering component on a bottom surface support column of the box body 1; fixing a high-voltage input wire harness 14 on the side surface of the box body 1, and fixing an output end terminal of the high-voltage input wire harness 14 and an input end copper bar of the thin-film capacitor 7 on the two-phase filtering component 10 together; then the interface board 15 is fixed on the side wall of the box body, and then the control board 8 is fixed on the support column on the upper surface of the thin film capacitor 7; and finally, fixing the box cover 9 on the box body 1 to complete the assembly of the whole motor controller.

In the working process of the motor controller, cooling liquid firstly enters the first water inlet channels 1-7 from the water inlet pipe 3, then enters the first water tank 1-1 from the first water tank inlet 1-2 at the same time, after the cooling liquid circulates for a circle in the labyrinth type heat dissipation water channel at the bottom of the three IGBT modules 4, flows into the first water outlet channel 1-8 from the first water tank outlet 1-3, flows through the oval groove on the side wall of the box body 1, enters the second water inlet channel 1-9, then enters a second water tank 1-5 from a second water tank inlet 1-4, after cooling liquid circulates for a circle in a labyrinth type heat dissipation water channel at the bottom of the three IGBT modules 4, and finally, the water flows into the second water outlet channels 1-10 from the second water tank outlets 1-6 and flows out of the water outlet pipe 2, so that the serial connection type heat dissipation and cooling of the six IGBT modules 4 are completed, and the stable performance output of the motor controller is ensured.

Claims

1. A high-power motor controller for an electric bus comprises a box body (1), wherein a water inlet pipe (3) and a water outlet pipe (2) are arranged on the box body (1), and the high-power motor controller is characterized in that a current sensor (11), a three-phase output assembly (6), a module support (13), a three-phase filtering assembly (12), a driving plate (5), a film capacitor (7) and a control plate (8) are arranged in the box body (1), the three-phase output assembly (6) comprises a three-phase support (6-1) and a three-phase output copper bar (6-2) encapsulated in the three-phase support (6-1), the three-phase filtering assembly (12) comprises a filtering support (12-1), a filter (12-2) and a three-phase switching copper bar (12-3), the filter (12-2) is encapsulated in the filtering support (12-1, the three-phase switching copper bar (12-3) penetrates through the filtering support (12-1);

the IGBT module (4) is fixed on the three-phase support (6-1) and the module support (13) and is matched with the water tank on the bottom surface of the box body (1), the output end of the IGBT module (4) is respectively and electrically connected with the input end of the three-phase output copper bar (6-2), and the input end of the three-phase switching copper bar (12-3) penetrates through the current sensor (11) and is electrically connected with the output end of the three-phase output copper bar (6-2); the driving plate (5) is arranged above the IGBT module (4) and is electrically connected with a signal pin of the IGBT module (4); the thin film capacitor (7) is arranged above the driving plate (5), the output end of the thin film capacitor is electrically connected with the input end of the IGBT module (4), and the input end of the thin film capacitor is sleeved with the two-phase filter assembly (10) and is electrically connected with the input end of the high-voltage input wire harness (14); the control panel (8) is arranged above the thin film capacitor (7) and fixed on the thin film capacitor (7).

2. The high-power motor controller for the electric bus according to claim 1, wherein the bottom surface of the box body (1) is provided with a first water tank (1-1) and a second water tank (1-5) which are arranged side by side, and the first water tank (1-1) and the second water tank (1-5) are respectively provided with an IGBT module (4).

3. The high-power motor controller for the electric bus according to claim 2, wherein the bottom surface of the IGBT module (4) is provided with a heat dissipation water channel arranged in a labyrinth manner.

4. The high-power motor controller for the electric bus according to claim 2, wherein the first water tank (1-1) and the second water tank (1-5) are respectively provided in plurality, the first water tank (1-1) is provided with a first water tank inlet (1-2) and a first water tank outlet (1-3) at two ends of a diagonal line, and the second water tank (1-5) is provided with a second water tank inlet (1-4) and a second water tank outlet (1-6) at two ends of a diagonal line.

5. The high power motor controller for electric bus according to claim 4, the side surface of the box body (1) is provided with a first water inlet channel (1-7), a first water outlet channel (1-8), a second water inlet channel (1-9) and a second water outlet channel (1-10), the inlet of the first water outlet channel (1-8) is communicated with the outlet of the second water inlet channel (1-9), the first water tank inlet (1-2) is communicated with the outlet of the first water inlet channel (1-7), the first water tank outlet (1-3) is communicated with the inlet of the first water outlet channel (1-8), the inlet (1-4) of the second water tank is communicated with the outlet of the second water inlet channel (1-9), and the outlet (1-6) of the second water tank is communicated with the inlet of the second water outlet channel (1-10).

6. High-power motor controller for electric buses according to claim 1, characterised in that the IGBT modules (4) are provided in an even number and arranged in parallel in two rows.

7. The high-power motor controller for the electric bus according to claim 1, wherein the input ends of the three-phase output copper bars (6-2) are welded into two branched structures by laser.

8. The high-power motor controller for electric buses according to claim 1, characterized in that the upper surface of the thin-film capacitor (7) is provided with a plurality of pillars, and the output ends of the pillars are arranged in two rows symmetrically.

9. The high-power motor controller for the electric bus according to claim 1, wherein the three-phase support (6-1) is provided with three L-shaped grooves which are horizontally stacked, and the three-phase output copper bar (6-2) is encapsulated in the L-shaped grooves to form a three-phase output assembly (6).

10. The high power motor controller for electric bus according to claim 1, characterized in that the same side of the box (1) is provided with the high voltage input harness (14) and the interface board (15).