CN214102121U - Double-motor air-cooled silicon carbide controller for electric automobile - Google Patents

Abstract

The utility model relates to a bi-motor forced air cooling carborundum controller for electric automobile, including box subassembly, the anti-interference subassembly of electromagnetism, two power module subassemblies, high frequency current filtering subassembly and air-cooled radiator subassembly. The top surface of the bottom of the box body is provided with two heat dissipation surfaces; the two power module assemblies are arranged at the bottom of the box body side by side; the high-frequency current filtering component is arranged on one side of the two power module components; the electromagnetic anti-interference component is arranged above the two power module components; the air-cooled radiator assembly is arranged on the bottom surface of the bottom of the box body and is positioned below the radiating fins. Compared with the prior art, the utility model discloses have higher chip junction temperature, faster switching rate is not high relatively to the heat dissipation demand, can satisfy the demand of whole car performance under the abominable operating mode, does to improve the operating efficiency of actuating system at city operating mode, improves whole car efficiency, increases the continuation of the journey mileage.

Description

Double-motor air-cooled silicon carbide controller for electric automobile

Technical Field

The utility model relates to a machine controller especially relates to a bi-motor forced air cooling carborundum controller for electric automobile.

Background

With the gradual depletion of global ore energy and the increasing of environmental problems, the sale prohibition time limit of fuel vehicles has been clearly announced by multiple countries in the world. The new energy electric automobile is generally accepted and accepted by various national organizations and people due to the advantages of rich energy, green and low emission and the like.

At present, a main stream pure electric vehicle driving system in the market mainly adopts a single motor and is provided with a liquid cooling silicon-based chip controller. Under severe working conditions, the power requirement of a vehicle is high, the temperature rise of a controller chip is high, the traditional silicon-based module is required to be supplemented with a liquid cooling scheme for heat dissipation, the performance of a motor controller reaches the limit, and the power is difficult to be continuously improved to improve the performance of the whole vehicle; under urban working conditions, the required power of the vehicle is relatively low, the single-motor driving system mostly operates in a low-efficiency area, and the liquid cooling system is also in a over-heat-dissipation working condition, so that the energy utilization rate of the whole vehicle is not improved.

SUMMERY OF THE UTILITY MODEL

The utility model aims at providing a two motor forced air cooling carborundum controllers for electric automobile in order to overcome the defect that above-mentioned prior art exists, improved the inside integrated level of controller, have integrated level height, simple structure, space compactness, assemble convenient, electromagnetic compatibility is good, advantages such as stable performance.

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

the utility model provides a bi-motor forced air cooling carborundum controller for electric automobile, includes box subassembly, the anti-interference subassembly of electromagnetism, two power module subassemblies, high frequency current filter subassembly and forced air cooling radiator subassembly, its characterized in that:

the box body assembly comprises a box body and a box cover, a high-voltage direct-current plug-in, a first high-voltage alternating-current plug-in, a second high-voltage alternating-current plug-in and a waterproof connector are arranged on the side wall of the box body, and two heat dissipation surfaces are arranged on the top surface of the bottom of the box body;

the two power module assemblies are arranged at the bottom of the box body side by side, each power module assembly comprises a current sensor, a three-phase switching copper bar, a silicon carbide power module and a fixed support, the current sensors are fixed on the silicon carbide power modules, the three-phase switching copper bar is fixed on the current sensors, one end of each power module assembly is connected with the current sensor, the other end of each power module assembly penetrates through the current sensors to be electrically connected with a first high-voltage alternating-current plug-in unit or a second high-voltage alternating-current plug-in unit, and the silicon carbide power modules are attached to the heat dissipation surface at the bottom of the box body through the fixed supports;

the high-frequency current filtering assembly is arranged on one side of the two power module assemblies and is electrically connected with the high-voltage direct current plug-in;

the electromagnetic anti-interference component is arranged above the two power module components;

the air-cooled radiator assembly is arranged below the bottom surface of the bottom of the box body, and a power supply wire harness of the air-cooled radiator assembly penetrates through the waterproof connector to be connected with the electromagnetic anti-interference assembly.

Furthermore, the bottom surface of the bottom of the box body is provided with radiating fins.

Furthermore, the radiating fins are wavy, and the adjacent radiating fins are distributed in a wave shape in a crossed manner.

Further, the high-frequency current filter assembly comprises an X filter capacitor, a support filled with a magnetic filter body and a switching copper bar, the output end of the X filter capacitor is divided into a first output channel on the left side and a second output channel on the right side, the two output channels are connected with two power module assemblies respectively, and the input end of the X filter capacitor penetrates through the support filled with the magnetic filter body and is electrically connected with the high-voltage direct-current plug-in unit through the switching copper bar.

Furthermore, the back of the support is provided with a waist-shaped encapsulation groove, the bottom of the support is provided with a square boss, the top of the support is provided with a circular protection ring, and one side of the waist-shaped encapsulation groove is provided with an arc-shaped encapsulation opening.

Furthermore, the electromagnetic anti-interference component comprises a shielding plate and two PCBA control plates, and a low-voltage plug-in is integrated on each PCBA control plate.

Furthermore, the shielding plate is of a rectangular structure, and a square notch is formed in the end where the short edge is located.

Furthermore, a waist-shaped hole is formed in the middle of the shielding plate, and a wiring harness for connecting the power module assembly and the electromagnetic anti-interference assembly penetrates through the waist-shaped hole.

Furthermore, the air-cooled radiator assembly comprises a radiating support, a radiating fan and a protective cover, and a power supply wire harness of the radiating fan penetrates through the waterproof joint and is electrically connected with the two PCBA control boards respectively.

Further, still including the fixing support who supports carborundum power module output, be equipped with the mounting hole on the bottom of box, fixing support's bottom is equipped with the erection column, makes fixing support location install in the bottom half through the cooperation of mounting hole and erection column.

Compared with the prior art, the utility model discloses following beneficial effect has:

1. the utility model discloses a bi-motor forced air cooling carborundum controller adopts the carborundum module, has better temperature resistance, faster switching frequency, bigger output, reduces the controller to the demand of heat dispersion, realizes the air-cooled heat dissipation cooperation that the energy consumption is lower. And simultaneously, the utility model discloses integrated as an organic whole with two machine controller, realize the bi-motor simultaneous control to new energy automobile, also can be according to vehicle operating mode rational distribution motor power output, guarantee that the motor is in high efficiency operation district, improve the utilization ratio of the energy, under the unchangeable condition of whole car battery capacity, improved the duration of vehicle to a certain extent.

2. The traditional low-voltage plug-in of the motor controller is connected with the control panel through the adapter plate and the wiring harness. The utility model discloses in through the optimization of structure, with electromagnetic interference resisting component, two power module subassemblies, high frequency current filtering subassembly and forced air cooling radiator subassembly integrated as an organic whole, reduced the use of keysets and connecting wire harness, reduced the installation degree of difficulty and the manufacturing cost of controller.

3. Among the anti-interference subassembly of electromagnetism, make the rectangle with X filter capacitor, X filter capacitor's output terminal divide into the first output channel in left side and the second output channel in right side, respectively with two power module subassembly electrical connection, realized uniting two into one two power module subassembly's X filter capacitor, cancelled the switching polar plate of connecting two power module subassemblies respectively simultaneously, reduced the quantity of controller internals, improved the inside integrated level of controller, be fit for the volume production assembly.

4. A power supply wire harness of the cooling fan penetrates through the waterproof connector to be electrically connected with the two PCBA control panels respectively, so that the running working condition of the vehicle and the heating condition of the chip can be accurately monitored, the controller can dynamically adjust the power of the air-cooled radiator assembly, efficient dynamic heat dissipation is timely realized on the power module assembly, and the excessive heat dissipation energy loss of the radiator assembly is reduced.

Drawings

Fig. 1 is a schematic diagram of the structure explosion of the present invention.

Fig. 2 is a schematic structural view of the outer side of the box body.

Fig. 3 is a schematic structural view of the inside of the box.

Fig. 4 is a schematic structural view of the box cover.

Fig. 5 is a schematic structural diagram of a power module assembly.

Fig. 6 is a schematic structural diagram of the high-frequency current filtering assembly.

Fig. 7 is a schematic structural view of the support.

Fig. 8 is a schematic structural diagram of an electromagnetic interference rejection assembly.

Fig. 9 is a schematic structural view of the shielding plate.

Fig. 10 is a schematic structural view of an air-cooled heat sink assembly.

Reference numerals:

the box assembly is shown as 1, the box is shown as 11, the mounting hole is shown as 11a, the radiating fin is shown as 11b, the high-voltage direct-current plug-in is shown as 12, the first high-voltage alternating-current plug-in is shown as 13, the second high-voltage alternating-current plug-in is shown as 14, the waterproof joint is shown as 15, and the radiating surface is shown as 16;

2 is a box cover;

3 is an electromagnetic anti-interference component, 31 is a first PCBA control plate, 32 is a second PCBA control plate, 33 is a shielding plate, 33a is a waist-shaped hole, and 34 is a low-voltage plug-in;

4 is a first power module component, 41 is a current sensor, 42 is a three-phase switching copper bar, 43 is a silicon carbide power module, 44 is a fixed support, 44a is a mounting column, and 5 is a second power module component;

6, a high-frequency current filter assembly, 61, an X filter capacitor, 62, a support, 62a, a waist-shaped encapsulation groove, 62b, a square boss, 62c, a circular protection ring, 63, a switching copper bar, 64, a Y filter capacitor and 65, wherein the X filter capacitor, the support, the waist-shaped encapsulation groove, the square boss and the circular protection ring are arranged in sequence;

7 is an air-cooled radiator component, 71 is a radiating bracket, 72 is a radiating fan, and 73 is a protective cover.

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.

As shown in fig. 1, the present embodiment provides a dual-motor air-cooled silicon carbide controller for an electric vehicle, which includes a box assembly 1, an electromagnetic anti-interference assembly 3, two power module assemblies (a first power module assembly 4 and a second power module assembly 5), a high-frequency current filtering assembly 6, and an air-cooled heat sink assembly 7.

The case assembly 1 includes a case 11 and a case cover 2. As shown in fig. 2 and 3, the cabinet 11 has a high voltage dc card 12, a first high voltage ac card 13, a second high voltage ac card 14, and a watertight connector 15 mounted on a sidewall thereof. The top surface of the bottom of the box body 11 is provided with two radiating surfaces 16, the bottom surface of the bottom of the box body 11 is provided with radiating fins 11b, and the radiating fins 11b are specifically 48 longitudinally distributed and have the height of 28 mm. The radiating fins 11b are wavy, and the waveforms of the adjacent radiating fins 11b are distributed in a staggered and orderly crossed manner. The outer contour of the box body 11 is in a convex shape. As shown in fig. 4, the center of the outer surface of the whole case cover 2 is provided with bat-shaped convex patterns, the upper surface of the case cover 2 is an arc-shaped surface, and the two ends of the arc-shaped surface are provided with ribs with symmetrically-changed lengths, so that the strength and NVH (noise, vibration and harshness) performance of the case cover structure are effectively improved.

The first power module assembly 4 and the second power module assembly 5 are arranged side by side at the bottom of the box body 11. As shown in fig. 2 and 5, each power module assembly includes a current sensor 41, a three-phase patch copper bar 42, a silicon carbide power module 43, and a fixed support 44. The current sensor 41 is fixed on the silicon carbide power module 43, the three-phase switching copper bar 42 is fixed on the current sensor 41, one end of the three-phase switching copper bar is connected with the output end of the silicon carbide power module 43, and the other end of the three-phase switching copper bar penetrates through the current sensor 41 and is electrically connected with the first high-voltage alternating current plug-in 13. The three-phase switching copper bar 42 of the first power module assembly 4 is connected with the high-voltage alternating-current plug-in 13, and the three-phase switching copper bar 42 of the second power module assembly 5 is connected with the second high-voltage alternating-current plug-in 14. The silicon carbide power module 43 is attached to the heat radiation surface 16 at the bottom of the case 11. The fixed support 44 is used for supporting the output end of the silicon carbide power module 43, the bottom of the box body 11 is provided with a mounting hole 11a, the bottom of the fixed support 44 is provided with a mounting column 44a, and the fixed support 44 is positioned and mounted at the bottom of the box body 11 through the matching of the mounting hole 11a and the mounting column 44 a.

The high frequency current filter assembly 6, as shown in fig. 6, is mounted at the bottom of the case 11 and is located at one side of the two power module assemblies 4, 5. The high-frequency current filtering assembly 6 comprises an X filtering capacitor 61, a support 62 in which a magnetic filter is embedded, and a switching copper bar 63. The output end of the X filter capacitor 61 is divided into a left first output channel and a right second output channel, which are respectively connected to the two power module assemblies. The input end of the X filter capacitor 61 passes through a support 62 filled with a magnetic filter body and is connected with the high-voltage direct-current plug-in 12 through a switching copper bar 63. The X filter capacitor 61 is a rectangular parallelepiped structure, and its output end is specifically a copper bar arranged in a staggered manner at high and low positions on one side of the capacitor.

As shown in fig. 7, the back of the holder 62 is provided with a kidney-shaped potting groove 62a, the bottom is provided with a square boss 62b, and the top is provided with a circular protection ring 62 c. An arc-shaped pouring opening is formed in one side of the waist-shaped pouring groove 62a, so that pouring of pouring sealant is facilitated. The circular guard ring 62c is used to avoid bumping the microswitch during installation.

As shown in fig. 8, the electromagnetic interference preventing unit 3 is mounted above the two power module units 4 and 5. The electromagnetic interference rejection assembly 3 includes a shield 33 and two PCBA control boards (a first PCBA control board 31 and a second PCBA control board 32) on which a low voltage plug 34 is integrated. Four strip holes are formed in the PCBA, so that when the low-voltage plug-in unit 34 is fixed to the box body 11, the PCBA and the shielding plate 33 move relatively, and over-constraint on the PCBA is avoided. Six cylindrical bosses for fixing the shield plate 33 are provided inside the case 11. The shielding plate 33 is provided with a slotted hole 33a in the middle, and a wiring harness connecting the power module assembly and the electromagnetic interference resisting assembly 3 passes through the slotted hole 33 a. As shown in fig. 9, the X-shaped stamped stiffener is disposed on the left and right sides of the kidney-shaped hole 33a, which effectively improves the structural strength and vibration resistance of the shielding plate 33. The shielding plate 33 is rectangular, and two square notches are formed in the width direction, so that the PCBA control board can be conveniently installed and plugged.

The air-cooled radiator assembly 7 is mounted on the bottom surface of the bottom of the box body 11 below the radiating fins 11 b. As shown in fig. 10, the air-cooled heat sink assembly 7 includes a heat dissipating bracket 71, a heat dissipating fan 72, and a shield 73. The power supply wiring harness of the heat radiation fan 72 penetrates through the waterproof connector 15 to be electrically connected with the two PCBA control boards respectively. The outer side of the bottom of the box body 11 is provided with 6 bosses for connecting with mounting feet of the heat dissipation bracket 71. The air-cooled radiator assembly 7 generally comprises 2-6 radiator fans 72, preferably 4, and the diameter of the radiator fan 72 is preferably 88 mm. The protective cover 73 is composed of 6 steel rings with different sizes and 2V-shaped steel bars, and is of a net structure integrally. Rectangular openings are respectively arranged on two sides of the heat dissipation support 71, so that hot air can flow conveniently.

The specific assembly process of this embodiment is as follows:

firstly, assembling the box body assembly 1, dispensing and curing the periphery of the joint of the box body 11 and the box cover 2, and then installing the high-voltage direct current plug-in 12, the first high-voltage alternating current plug-in 13 and the second high-voltage alternating current plug-in 14 on the side wall of the box body.

Secondly, assembling the first power module assembly 4, installing a fixed support 44 at a mounting hole 11a in the box body 11, then coating heat-conducting silicone grease on the bottom of the silicon carbide power module 43 to be fixed on the rectangular heat dissipation surface 16 at the bottom of the inner side of the box body 11, then penetrating the three-phase switching copper bar 42 through the current sensor 41 to be fixed on the silicon carbide power module 43, and finally connecting the output end of the three-phase switching copper bar 42 with the high-voltage alternating-current plug-in on the side wall of the box body 11 through a bolt. Then, the second power module assembly 5 is assembled in the same manner.

Next, the high-frequency current filter assembly 6 is assembled. Firstly, the Y capacitor 64 is encapsulated in rectangular grooves at the left side and the right side of the support 62, the magnetic filter body is encapsulated in a runway-shaped annular groove at the back of the support 62, then the direct current transfer polar plate 63 and the grounding copper bar 65 are fixed on the support 62 through bolts, and then the input end of the X filter capacitor 61 penetrates through the support 62 and is electrically connected with the transfer polar plate 63. Finally, the assembled high-frequency current filter assembly 6 is fixed to the bottom of the case assembly 1 by bolts, and the X filter capacitor 61 is locked with the input end of the silicon carbide power module 43 by bolts.

Then, the electromagnetic interference rejection assembly 3 is assembled. The wire harness connecting the shield plate 33 and the first and second silicon carbide power modules 4 and 5 is passed through the waist-shaped hole 33a of the shield plate 33, the shield plate 33 is fixed to 6 raised cylinders in the case 11, the interface board of the first PCBA control board 31 is fixed to the side wall of the case 11, and the first PCBA control board 31 and the shield plate 33 are fixed by bolts. Similarly, the second PCBA control board 32 is installed.

Then, the air-cooled radiator module 7 is assembled. The heat radiation fan 72, the heat radiation support 71 and the protective cover 73 are assembled into an integral air-cooled radiator assembly 7 through bolts, the air-cooled radiator assembly 7 is fixed on 6 bosses at the bottom of the outer side of the box body 11, and finally a power line of the air-cooled radiator assembly 7 penetrates through the waterproof connector 15 and is electrically connected with the first PCBA control board 31 and the second PCBA control board 32 respectively.

Finally, the case cover 2 is fitted right above the case assembly 1. Therefore, after the double-motor air-cooled silicon carbide controller for the electric automobile is assembled, the high-voltage direct-current plug-in 12 is connected with a whole automobile direct-current high-voltage circuit, the first high-voltage alternating-current plug-in 13 and the second high-voltage alternating-current plug-in 14 are electrically connected with the input ends of the double motors, and the whole automobile control circuit is electrically connected with the low-voltage plug-ins 34 at the two ends of the side wall of the box body 11, so that the function of the pre-designed controller can be realized.

The foregoing has described in detail preferred embodiments of the present invention. It should be understood that numerous modifications and variations can be devised by those skilled in the art in light of the teachings of the present invention without undue experimentation. Therefore, the technical solutions that can be obtained by a person skilled in the art through logic analysis, reasoning or limited experiments based on the prior art according to the concepts of the present invention should be within the scope of protection defined by the claims.

Claims (10)

1. The utility model provides a bi-motor forced air cooling carborundum controller for electric automobile, includes box subassembly (1), anti-interference subassembly of electromagnetism (3), two power module subassemblies (4, 5), high frequency current filter subassembly (6) and air-cooled radiator subassembly (7), its characterized in that:

the box body assembly (1) comprises a box body (11) and a box cover (2), a high-voltage direct-current plug-in (12), a first high-voltage alternating-current plug-in (13), a second high-voltage alternating-current plug-in (14) and a waterproof connector (15) are arranged on the side wall of the box body (11), and two heat dissipation surfaces (16) are arranged on the top surface of the bottom of the box body (11);

the two power module assemblies (4, 5) are arranged at the bottom of the box body (11) side by side, each power module assembly comprises a current sensor (41), a three-phase switching copper bar (42), a silicon carbide power module (43) and a fixed support (44), the current sensor (41) is fixed on the silicon carbide power module (43), the three-phase switching copper bar (42) is fixed on the current sensor (41), one end of the three-phase switching copper bar is connected with the current sensor (41), the other end of the three-phase switching copper bar penetrates through the current sensor (41) to be electrically connected with a first high-voltage alternating current plug-in unit (13) or a second high-voltage alternating current plug-in unit (14), and the silicon carbide power module (43) is attached to a heat dissipation surface (16) at the bottom of the box body (11) through the fixed support (44);

the high-frequency current filtering assembly (6) is arranged on one side of the two power module assemblies (4, 5) and is electrically connected with the high-voltage direct current plug-in (12);

the electromagnetic anti-interference component (3) is arranged above the two power module components (4, 5);

the air-cooled radiator assembly (7) is installed below the bottom surface of the bottom of the box body (11), and a power supply wire harness of the air-cooled radiator assembly (7) penetrates through the waterproof connector (15) to be connected with the electromagnetic anti-interference assembly (3).

2. The dual-motor air-cooled silicon carbide controller for the electric automobile according to claim 1, wherein the bottom surface of the bottom of the box body (11) is provided with heat radiating fins (11 b).

3. The double-motor air-cooled silicon carbide controller for the electric automobile as claimed in claim 2, wherein the heat dissipation fins (11b) are wave-shaped, and the adjacent heat dissipation fins (11b) are wave-shaped and distributed in a crossed manner.

4. The double-motor air-cooled silicon carbide controller for the electric automobile according to claim 1, wherein the high-frequency current filter assembly (6) comprises an X filter capacitor (61), a support (62) filled with a magnetic filter body and a switching copper bar (63), an output end of the X filter capacitor (61) is divided into a left first output channel and a right second output channel which are respectively connected with the two power module assemblies (4, 5), and an input end of the X filter capacitor (61) penetrates through the support (62) filled with the magnetic filter body and is electrically connected with the high-voltage direct current plug-in unit (12) through the switching copper bar (63).

5. The dual-motor air-cooled silicon carbide controller for the electric automobile according to claim 4, wherein a waist-shaped pouring groove (62a) is formed in the back of the support (62), a square boss (62b) is formed in the bottom of the support, a circular protection ring (62c) is formed in the top of the support, and an arc-shaped pouring opening is formed in one side of the waist-shaped pouring groove (62 a).

6. The dual-motor air-cooled silicon carbide controller for the electric automobile according to claim 1, wherein the electromagnetic interference resisting component (3) comprises a shielding plate (33) and two PCBA control plates (31, 32), and a low-voltage plug-in (34) is integrated on each PCBA control plate.

7. The dual-motor air-cooled silicon carbide controller for the electric automobile as claimed in claim 6, wherein the shielding plate (33) is rectangular, and a square notch is formed at the end of the short side.

8. The double-motor air-cooled silicon carbide controller for the electric automobile according to claim 6, wherein a waist-shaped hole (33a) is formed in the middle of the shielding plate (33), and a wire harness for connecting the power module assemblies (4, 5) and the electromagnetic interference resisting assembly (3) penetrates through the waist-shaped hole (33 a).

9. The dual-motor air-cooled silicon carbide controller for the electric automobile according to claim 1, wherein the air-cooled radiator assembly (7) comprises a radiating bracket (71), a radiating fan (72) and a protective cover (73), and a power supply wire harness of the radiating fan (72) passes through the waterproof connector (15) to be electrically connected with the two PCBA control boards (31, 32) respectively.

10. The dual-motor air-cooled silicon carbide controller for the electric automobile according to claim 1, further comprising a fixed support (44) supporting the output end of the silicon carbide power module (43), wherein a mounting hole (11a) is formed in the bottom of the box body (11), a mounting column (44a) is formed in the bottom of the fixed support (44), and the fixed support (44) is positioned and mounted at the bottom of the box body (11) through cooperation of the mounting hole (11a) and the mounting column (44 a).

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