CN216162569U - Power module assembly and motor controller - Google Patents

Abstract

The utility model discloses a power module assembly and a motor controller, wherein the power module assembly comprises power modules corresponding to each phase of alternating current, each power module comprises an output copper bar and upper bridge IGBT single tubes and lower bridge IGBT single tubes which are in one-to-one correspondence, collectors of the upper bridge IGBT single tubes are electrically connected with external direct current positive electrodes, emitters of the lower bridge IGBT single tubes are electrically connected with external direct current negative electrodes, the emitters of the upper bridge IGBT single tubes and collectors of the lower bridge IGBT single tubes are respectively electrically connected with the output copper bar, and ceramic copper-clad plates for heat conduction are respectively arranged at the bottoms of the upper bridge IGBT single tubes and the lower bridge IGBT single tubes. According to the utility model, each phase of alternating current can be output only by a single power module assembly, the volume of equipment is reduced, the IGBT single tubes in each power module are connected in parallel to output high-power and high-density current, and in addition, the IGBT single tubes are conducted by the ceramic copper-clad plate, so that heat conduction silicone grease is omitted, and the thermal resistance of the power module is reduced.

Description

Power module assembly and motor controller

Technical Field

The utility model relates to the technical field of power semiconductor devices, in particular to a power module assembly and a motor controller.

Background

The new energy motor controller is one of the core components of the new energy automobile, is the key for realizing various working modes of the new energy automobile, and directly influences the performance of the whole automobile.

An Insulated Gate Bipolar Transistor (IGBT) is a composite fully-controlled voltage-driven power semiconductor device consisting of a Bipolar Junction Transistor (BJT) and an insulated Gate field effect transistor (MOS), has the advantages of both high input impedance of the MOSFET and low conduction voltage drop of a GTR, and in a motor controller, an IGBT power module component is the most core device of the motor controller, and the cost of the IGBT power module component accounts for about 40% of the cost of a motor controller assembly. At present, most of IGBT power module assemblies are monopolized by foreign companies, and power module assemblies produced by different manufacturers have poor compatibility due to different module forms and interface sizes.

Chinese patent CN110254247A discloses a half-bridge power module assembly, which adopts at least two power IGBT single tubes fixed in the supporting structure, and will through output copper bar, anodal copper bar and negative copper bar at least two power IGBT single tubes are parallelly connected, in order to realize the function of traditional power module high power, high current density output, and be different from traditional power module, its compatibility is better, but this patent adopts three independent power module assembly just can constitute a complete machine controller, single power module assembly only supports single-phase current, the complexity of machine controller has been increased.

SUMMERY OF THE UTILITY MODEL

The technical problem to be solved by the utility model is as follows: aiming at the technical problems in the prior art, the utility model provides a power module assembly and a motor controller, which are compact in structure and have good heat dissipation performance.

In order to solve the technical problems, the technical scheme provided by the utility model is as follows:

the utility model provides a power module subassembly, includes three and each looks one-to-one power module of alternating current, power module is including being used for outputting corresponding looks output copper bar and at least a pair of upper bridge IGBT single tube and at least a pair of lower bridge IGBT single tube, upper bridge IGBT single tube and lower bridge IGBT single tube one-to-one, the collecting electrode of upper bridge IGBT single tube and outside direct current's anodal electricity are connected, lower bridge IGBT single tube's projecting pole and outside direct current's negative pole electricity are connected, upper bridge IGBT single tube's projecting pole and lower bridge IGBT single tube's collecting electrode are connected with output copper bar electricity respectively, and each pair of upper bridge IGBT single tube, each pair of lower bridge IGBT single tube bottom is equipped with the ceramic copper-clad plate that is used for heat conduction respectively.

Furthermore, the pin side of the upper bridge IGBT single tubes is provided with collector terminals for connecting collectors, each pair of upper bridge IGBT single tubes is provided with an upper bridge collector copper bar on the other side relative to the pin side, the collector terminals of the upper bridge IGBT single tubes are electrically connected with the corresponding upper bridge collector copper bars through corresponding ceramic copper-clad plates, and the upper bridge collector copper bars are connected with the positive pole of external direct current.

Furthermore, the pin side of the lower bridge IGBT single tube is provided with a collector terminal for connecting a collector, each pair of lower bridge IGBT single tubes is provided with a lower bridge collector copper bar relative to the other side of the pin side, the collector terminals of the lower bridge IGBT single tubes are electrically connected with the corresponding lower bridge collector copper bars through corresponding ceramic copper-clad plates, and the lower bridge collector copper bars are electrically connected with the output copper bars.

The lower bridge IGBT single tube is characterized by further comprising a negative copper bar used for connecting a negative electrode of external direct current, an emitter pin used for connecting an emitter is arranged on the pin side of the lower bridge IGBT single tube, and the emitter pin of the lower bridge IGBT single tube is connected with the negative electrode of the external direct current through the negative copper bar.

Furthermore, the ceramic copper-clad plate is fixedly arranged on the radiator respectively.

Further, the inside cavity that is equipped with of radiator, be equipped with the heat dissipation tooth in the cavity, the radiator bottom be equipped with water inlet port and the play water port of cavity intercommunication, the cover is equipped with the sealing washer on water inlet port and the play water port respectively.

The utility model further provides a motor controller, which comprises a driving plate, a power module assembly and a control plate, wherein the driving plate, the power module assembly and the control plate are sequentially arranged in the box body from top to bottom, the power module assembly is any one of the power module assemblies, each upper bridge IGBT single tube, each lower bridge IGBT single tube, each upper bridge collector copper bar and each lower bridge collector copper bar in the driving plate and the power module assembly are electrically connected, and the control plate is electrically connected with the driving plate.

Further, still include direct current input interface and interchange output assembly, direct current input interface and interchange output assembly set up respectively on the radiator in the power module subassembly, interchange output assembly and every output copper bar electricity are connected, direct current input interface and upper bridge collector copper bar and negative pole copper bar electricity are connected.

Furthermore, a current sensor is arranged on the alternating current output assembly, and the current sensor is electrically connected with the driving plate.

Furthermore, the device also comprises a low-voltage direct-current input interface, wherein the low-voltage direct-current input interface is arranged on the box body and is electrically connected with the control panel.

Compared with the prior art, the utility model has the advantages that:

1. the utility model arranges three power modules corresponding to each phase of the alternating current one by one, so that each phase of the alternating current can be output by a single power module assembly, the volume of the equipment is reduced, in each power module, the collector of the upper bridge IGBT single tube is electrically connected with the anode of the external direct current, the emitter of the lower bridge IGBT single tube is electrically connected with the cathode of the external direct current, the emitter of the upper bridge IGBT single tube and the collector of the lower bridge IGBT single tube are respectively and electrically connected with the output copper bar, thereby connecting each pair of upper bridge IGBT single tubes in parallel and each pair of lower bridge IGBT single tubes in parallel, high power and high density current can be output with good compatibility, and further, in each power module, the bottoms of each pair of upper bridge IGBT single tubes and each pair of lower bridge IGBT single tubes are respectively provided with a ceramic copper-clad plate for heat conduction, so that the coating of heat-conducting silicone grease is omitted, and the thermal resistance of the power module is reduced;

2. according to the utility model, the collector of the upper bridge IGBT single tube substrate is electrically connected with the corresponding upper bridge collector copper bar through the corresponding ceramic copper-clad plate, the collector of the lower bridge IGBT single tube substrate is electrically connected with the corresponding lower bridge collector copper bar through the corresponding ceramic copper-clad plate, the electric conduction characteristics of the copper bars and the ceramic copper-clad plate are utilized, and current is directly connected to the collector of the IGBT single tube substrate through the collector copper bars and the ceramic copper-clad plate, so that the heat loss is reduced, the heat dissipation performance is improved, and the stray inductance is reduced;

3. in the motor controller provided by the embodiment of the utility model, the control board, the power module assembly and the drive board are arranged in a layered manner, the structure is compact, and the space utilization rate is improved.

Drawings

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

Fig. 2 is an external structural view of a motor controller according to an embodiment of the present invention.

Fig. 3 is an internal structural view of a motor controller according to an embodiment of the present invention.

Illustration of the drawings: 10-direct current input interface, 20-cover plate, 30-box body, 40-low voltage direct current input interface, 50-drive plate, 60-power module component, 61-negative copper bar, 62-output copper bar, 63-upper bridge collector copper bar, 64-IGBT unit, 641-upper bridge IGBT single tube, 642-lower bridge IGBT single tube, 65-ceramic copper clad plate, 66-port, 661-water inlet port, 662-water outlet port, 67-sealing ring, 68-radiator, 69-lower bridge collector copper bar, 70-current sensor, 80-alternating current output component, 90-water pipe joint, 100-control plate, 110-capacitance unit.

Detailed Description

The utility model is further described below with reference to the drawings and specific preferred embodiments of the description, without thereby limiting the scope of protection of the utility model.

As shown in fig. 1, the power module assembly proposed by the present invention includes three power modules corresponding to each phase of alternating current one by one, the three power modules in fig. 1 are sequentially arranged along the length direction of the power module assembly, and respectively correspond to U/V/W phases of alternating current, each of the power modules includes an output copper bar 62 and an IGBT unit 64 for outputting the corresponding phase, the IGBT unit 64 includes at least one pair of upper bridge IGBT single tubes 641 and at least one pair of lower bridge IGBT 642, the upper bridge IGBT 641 and the lower bridge IGBT single tubes 642 correspond one by one, a collector of the upper bridge IGBT single tubes 641 is electrically connected to an anode of external direct current, an emitter of the lower bridge IGBT single tubes 642 is electrically connected to a cathode of the external direct current, an emitter of the upper bridge IGBT single tubes 641 and a collector of the lower bridge IGBT single tubes 642 are electrically connected to the output copper bar 62, through the above-mentioned structure, the power module assembly can directly output each phase of alternating current, the size of equipment is reduced, at least one pair of upper bridge IGBT single tubes 641 is connected in parallel to form an upper bridge arm, at least one pair of lower bridge IGBT single tubes 642 is connected in parallel to form a lower bridge arm, output of high-power and high-density current is achieved by connecting a plurality of IGBT single tubes in parallel, and the power module assembly is high in expandability, good in compatibility and relatively low in cost.

As shown in fig. 1, in this embodiment, a ceramic Copper clad plate 65 is disposed at the bottom of each pair of upper-bridge IGBT single tubes 641, a ceramic Copper clad plate 65 is also disposed at the bottom of each pair of lower-bridge IGBT single tubes 642, and a Copper clad ceramic (DBC) substrate is abbreviated as a ceramic Copper clad plate, and is composed of a top metal layer, a middle ceramic layer, and a bottom metal layer, and has the characteristics of ceramic, such as high thermal conductivity, high electrical insulation, high mechanical strength, and low expansion.

For the upper bridge IGBT monotube 641 and the lower bridge IGBT monotube 642, the lead sides thereof are originally provided with a gate lead for connecting a gate, a collector lead for connecting a collector, and an emitter lead for connecting an emitter, in this embodiment, the collector leads on the lead sides of the upper bridge IGBT monotube 641 and the lower bridge IGBT monotube 642 are cut off by a preset length, the remaining part of the collector leads after the cutting off of the preset length is a collector terminal, an upper bridge collector copper bar 63 and a lower bridge collector copper bar 69 are separately designed, in the power module, each pair of upper bridge IGBT monotube 641 corresponds to one upper bridge collector copper bar 63, each pair of lower bridge IGBT monotube 642 corresponds to one lower bridge collector copper bar 69, the upper bridge collector copper bar 63 and the lower bridge collector copper bar 69 are respectively arranged on the other side of the corresponding upper bridge IGBT monotube 641 and the corresponding lower bridge IGBT monotube 642 relative to the lead sides, and the collector terminal of each pair of the upper bridge IGBT monotube 641 and the corresponding upper bridge collector copper bar 63 are welded The formula is electrically connected with the metal layer of the corresponding ceramic copper-clad plate 65, the collector terminal of each pair of lower bridge IGBT single tubes 642 and the corresponding lower bridge collector copper bar 69 are also electrically connected with the metal layer of the corresponding ceramic copper-clad plate 65 in a welding mode, so that the stray inductance of the whole loop is smaller, the heat loss is lower, the current output capacity of the upper bridge IGBT single tube 641 and the lower bridge IGBT single tube 642 is stronger, in the power module, the upper bridge collector copper bar 63 is electrically connected with the anode of external direct current, and the emitter pin of each pair of upper bridge IGBT single tubes 641 and the lower bridge collector copper bar 69 are electrically connected with the output copper bar 62 in a welding mode.

Through the structure, for the upper bridge IGBT single tube 641, the current transmitted to the collector electrode is input through the corresponding upper bridge collector copper bar 63 and the ceramic copper-clad plate 65 instead of being input from the collector electrode pin, and for the lower bridge IGBT single tube 642, the current transmitted to the collector electrode is input through the corresponding lower bridge collector copper bar 69 and the ceramic copper-clad plate 65 instead of being input from the collector electrode pin, so that the stray inductance of the whole loop is smaller, the heat loss is lower, the current output capacity of the IGBT is stronger, because the copper has good conductivity, the copper clad on the surface of the ceramic copper clad laminate 65 increases the current-intercepting area of the collector, the heat-radiating performance is better, and the ceramic layer in the ceramic copper clad laminate 65 has good heat conductivity, compared with the method that current is directly input to the collector of the IGBT single-tube substrate from the collector pin, the method has the advantages of lower heat loss, better heat dissipation performance and relatively lower stray inductance of the power module.

As shown in fig. 1, in this embodiment, the power module assembly further includes a negative copper bar 61 for connecting to an external dc negative electrode, and in each power module, the emitter pins of each pair of lower bridge IGBT single tubes 642 are electrically connected to the negative copper bar 61 by welding, so as to ensure stable connection and avoid the situation of open circuit or poor contact of the emitter pins when connecting to the external dc negative electrode.

With the above-described connection structure, the current loop of each power module in the power module assembly is: the positive current sequentially passes through the upper bridge collector copper bar 63 and the corresponding ceramic copper-clad substrate 65 to be sent to the corresponding collector of the upper bridge IGBT single tube 641, then is sent to the output copper bar 62 through the emitter pin of the upper bridge IGBT single tube 641, and outputs the current corresponding to the phase, and meanwhile, the output copper bar 62 is sent to the corresponding collector of the lower bridge IGBT single tube 642 through the corresponding lower bridge collector copper bar 69 and the corresponding ceramic copper-clad substrate 65, then is sent to the negative copper bar 61 through the emitter pin of the lower bridge IGBT single tube 642, and finally is communicated to the negative electrode.

As shown in fig. 1, in this embodiment, the power module assembly further includes a heat sink 68, the ceramic copper clad laminates 65 are respectively fixed on the heat sink 68 by welding, and the heat sink 68 can rapidly cool each power module by the heat conduction performance of the ceramic copper clad laminates 65.

In this embodiment, the inside cavity that is equipped with of radiator 68, be equipped with the heat dissipation tooth in the cavity, as shown in fig. 1, in this embodiment, radiator 68 bottom be equipped with two with the port 66 of cavity intercommunication is intake port 661 and outlet port 662 respectively, and intake port 661 and outlet port 662 are connected with radiator 68 through the mode of cementing, threaded connection or crimping, and intake port 661 and outlet port 662 form the rivers passageway with the cavity intercommunication of radiator 68 respectively, improve the radiating efficiency through water-cooled mode, it is equipped with sealing washer 67 to overlap respectively on intake port 661 and the outlet port 662, sealed water course when can connecting the water pipe.

As shown in fig. 2 and fig. 3, the present invention further provides a motor controller, which includes a driving board 50, a power module assembly 60, and a control board 100, which are sequentially arranged in a box 30 from top to bottom, where the power module assembly 60 is any one of the power module assemblies, an emitter pin and a gate pin of each upper bridge IGBT single tube 641 in the driving board 50 and the power module assembly, an emitter pin and a gate pin of each lower bridge IGBT single tube 642, an upper bridge collector copper bar 63, and a lower bridge collector copper bar 69 are electrically connected by welding, the control board 100 and the driving board 50 are electrically connected by a flat cable, the control board 100 transmits a low voltage signal to the driving board 50, and the low voltage signal controls the upper bridge IGBT single tube 641 and the lower bridge IGBT single tube 642 to be turned on and off after the driving board 50 is amplified.

Through the structure, the driving plate 50, the power module assembly 60 and the control board 100 are arranged in a layered mode, the structure is compact, and the space utilization rate inside the box body 30 is improved.

As shown in fig. 2, in the present embodiment, a cover plate 20 is disposed on the top of the box body 30, so that the cover plate 20 can be opened according to actual needs to perform maintenance on the equipment inside the box body 30.

As shown in fig. 2 and fig. 3, the motor controller in this embodiment further includes a dc input interface 10 and an ac output assembly 80, where the ac output assembly 80 is an integral body formed by three copper bars (U \ V \ W three phases) and an injection molding piece through plastic-coating, the dc input interface 10 and the ac output assembly 80 are respectively fixed to the heat sink 68 in the power module assembly 60 by screws, the three copper bars of the three phases of the AC output assembly 80U \ V \ W are electrically connected with the output copper bar 62 of the corresponding power module in a welding way, thereby outputting U-phase, V-phase and W-phase alternating currents for driving the motor, the direct current input interface 10 is electrically connected with the upper bridge collector copper bar 63 and the negative electrode copper bar 61, thereby inputting a direct current positive electrode to the upper bridge collector copper bar 63 and inputting a direct current negative electrode to the negative electrode copper bar 61.

In this embodiment, direct current input interface 10 adopts the plug connector, furthermore, the motor controller in this embodiment further includes capacitance unit 110, capacitance unit 110 sets up on radiator 68, the plug connector passes through capacitance unit 110 and is connected with upper bridge collecting electrode copper bar 63 and negative pole copper bar 61 electricity, capacitance unit 110 adopts direct current to support the condenser in this embodiment, direct current supports the condenser and passes through the fix with screw and set up on radiator 68, the plug connector passes through direct current and supports condenser and upper bridge collecting electrode copper bar 63 and negative pole copper bar 61 electricity and connect, the plug connector, upper bridge collecting electrode copper bar 63 and negative pole copper bar 61 respectively with direct current support condenser through the welding mode electricity and connect. The DC support capacitor can smoothly filter the output voltage of the plug-in unit and prevent voltage overshoot and transient overvoltage from affecting the upper bridge IGBT single tube 641

As shown in fig. 3, in the motor controller of this embodiment, a current sensor 70 is disposed on the ac output assembly 80, the current sensor 70 is fixedly disposed on the ac output assembly 80 through a screw for collecting a current output by the ac output assembly 80, and the current sensor 70 is electrically connected to the driving board 50 through a welding manner, so that collected current data is fed back to the driving board 50, and the driving board 50 is convenient to perform subsequent adjustment according to the current data.

As shown in fig. 2 and fig. 3, the motor controller in this embodiment further includes a low-voltage dc input interface 40, where the low-voltage dc input interface 40 is disposed on the box body 30, and the low-voltage dc input interface 40 is electrically connected to the control board 100. In this embodiment, the low-voltage dc input interface 40 also adopts a plug connector, which is fixedly disposed on the box 30 by screws and electrically connected to the control board 100 by a wire harness.

As shown in fig. 3, in the motor controller of this embodiment, the bottom of box 30 is equipped with water pipe connector 90, water pipe connector 90 sets up in the bottom of box 30 through the fix with screw, water pipe connector 90 respectively with inlet port 661, outlet port 662 one-to-one, the tip of inlet port 661, outlet port 662 is inserted respectively and is located the hole that corresponds water pipe connector 90, inlet port 661's sealing washer 67 sets up in the space between inlet port 661 outer wall and the hole that corresponds water pipe connector 90, outlet port 662's sealing washer 67 sets up in the space between outlet port 662 outer wall and the hole that corresponds water pipe connector 90 for inlet port, outlet port 662 respectively with the water pipe connector 90 installation of correspondence firm and increased the leakproofness.

The foregoing is considered as illustrative of the preferred embodiments of the utility model and is not to be construed as limiting the utility model in any way. Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical spirit of the present invention should fall within the protection scope of the technical scheme of the present invention, unless the technical spirit of the present invention departs from the content of the technical scheme of the present invention.

Claims (10)

1. The power module assembly is characterized by comprising three power modules which correspond to each phase of alternating current one by one, wherein each power module comprises an output copper bar (62) used for outputting the corresponding phase, at least one pair of upper bridge IGBT single tubes (641) and at least one pair of lower bridge IGBT single tubes (642), the upper bridge IGBT single tubes (641) correspond to the lower bridge IGBT single tubes (642) one by one, the collector electrodes of the upper bridge IGBT single tubes (641) are electrically connected with the positive electrodes of external direct current, the emitter electrodes of the lower bridge IGBT single tubes (642) are electrically connected with the negative electrodes of the external direct current, the emitter electrodes of the upper bridge IGBT single tubes (641) and the collector electrodes of the lower bridge IGBT single tubes (642) are respectively electrically connected with the output copper bar (62), and the bottoms of each pair of the upper bridge IGBT single tubes (641) and each pair of the lower bridge IGBT single tubes (642) are respectively provided with a ceramic copper-clad plate (65) used for heat conduction.

2. The power module assembly according to claim 1, wherein the pin side of the upper bridge single-tube IGBT (641) is provided with a collector terminal for connecting a collector, the other side of each pair of upper bridge single-tube IGBT (641) opposite to the pin side is provided with an upper bridge collector copper bar (63), the collector terminal of each upper bridge single-tube IGBT (641) is electrically connected with the corresponding upper bridge collector copper bar (63) through a corresponding ceramic copper-clad plate (65), and the upper bridge collector copper bar (63) is connected with the positive pole of external direct current.

3. The power module assembly according to claim 1, wherein the pin side of the lower bridge single IGBT tubes (642) is provided with a collector terminal for connecting a collector, the other side of each pair of lower bridge single IGBT tubes (642) opposite to the pin side is provided with a lower bridge collector copper bar (69), the collector terminals of the lower bridge single IGBT tubes (642) are electrically connected with the corresponding lower bridge collector copper bar (69) through a corresponding ceramic copper clad laminate (65), and the lower bridge collector copper bar (69) is electrically connected with the output copper bar (62).

4. The power module assembly according to claim 1, further comprising a negative copper bar (61) for connecting a negative electrode of external direct current, wherein an emitter pin for connecting an emitter is arranged on a pin side of the lower bridge IGBT single tube (642), and the emitter pin of the lower bridge IGBT single tube (642) is connected with the negative electrode of the external direct current through the negative copper bar (61).

5. The power module assembly according to claim 1, further comprising a heat sink (68), wherein the ceramic copper clad laminates (65) are respectively fixedly arranged on the heat sink (68).

6. The power module assembly as claimed in claim 5, wherein a cavity is formed inside the heat sink (68), heat dissipation teeth are arranged in the cavity, a water inlet port (661) and a water outlet port (662) which are communicated with the cavity are formed in the bottom of the heat sink (68), and sealing rings (67) are respectively sleeved on the water inlet port (661) and the water outlet port (662).

7. A motor controller is characterized by comprising a driving plate (50), a power module assembly (60) and a control plate (100), wherein the driving plate (50), the power module assembly (60) and the control plate (100) are sequentially arranged in a box body (30) from top to bottom, the power module assembly (60) is the power module assembly according to any one of claims 1 to 6, the driving plate (50) is electrically connected with each upper bridge IGBT single tube (641), each lower bridge IGBT single tube (642), each upper bridge collector copper bar (63) and each lower bridge collector copper bar (69) in the power module assembly, and the control plate (100) is electrically connected with the driving plate (50).

8. The motor controller according to claim 7, further comprising a dc input interface (10) and an ac output assembly (80), wherein the dc input interface (10) and the ac output assembly (80) are respectively disposed on the heat sink (68) in the power module assembly, the ac output assembly (80) is electrically connected to each output copper bar (62), and the dc input interface (10) is electrically connected to the upper bridge collector copper bar (63) and the negative electrode copper bar (61).

9. The motor controller according to claim 8, wherein the ac output assembly (80) is provided with a current sensor (70), and the current sensor (70) is electrically connected with the driving plate (50).

10. The motor controller according to claim 7, further comprising a low voltage DC input interface (40), wherein the low voltage DC input interface (40) is disposed on the box (30), and the low voltage DC input interface (40) is electrically connected with the control board (100).

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