CN219227462U - Motor drive controller and new energy automobile thereof - Google Patents

Abstract

The utility model discloses a motor drive controller and a new energy automobile thereof, comprising: each set of power modules comprises a power semiconductor element, a driving circuit board and a control circuit board, and each set of power modules is configured into one or more of a direct current-direct current conversion module for boosting or reducing direct current and an alternating current-alternating current conversion module for regulating voltage and frequency by alternating current; the integrated liquid cooling radiator comprises a bus capacitor, the bus capacitor comprises a capacitor core, a liquid cooling radiator and a laminated busbar, two sets of power modules are arranged on two sides of the bus capacitor, the bus capacitor is provided with a runner for cooling the power semiconductor element, and the laminated busbar is provided with an input port and an output port which are connected with the two sets of power modules. The utility model can meet the power conversion applied in different occasions, reduce the number of bridging copper bars and the cost of the copper bars while reducing stray capacitance parameters, and improve the power density.

Description

Motor drive controller and new energy automobile thereof

Technical Field

The utility model relates to the field of new energy automobiles, in particular to a motor drive controller and a new energy automobile thereof.

Background

New energy automobiles and industrial drives, for example: electric vehicles, hydrogen fuel cell vehicles, mining machinery, or combustion engines, etc., have different requirements for corresponding controllers due to different application requirements. In the application of hydrogen fuel cell automobiles, the direct-current voltage generated by the reaction of the hydrogen fuel cell stack needs to be boosted or reduced to be converted into direct-current of the required voltage, and then the direct-current is converted into alternating current to drive an air compressor to work; in electric automobile applications, it is necessary to convert the direct current output from the battery into two sets of alternating current to drive the dual motor or dual winding motor to work; in industrial driving applications, it is necessary to convert the voltage of the power grid into a direct current of a desired voltage, and then convert the direct current into an alternating current to drive the motor to work.

At present, for the condition of the application, two different platforms and different types of controllers are needed for voltage and current conversion, which is not beneficial to reducing the production and maintenance cost, and meanwhile, in order to ensure that the bus capacitor works at a proper temperature, an indirect heat dissipation mode is often adopted, and the volume of the bus capacitor needs to be increased, which is not beneficial to improving the power density of the controllers and the reliability of the bus capacitor.

Disclosure of Invention

In order to solve the above technical problems, one of the purposes of the present utility model is to provide a motor driving controller, which can solve the problems that two different platforms and different types of controllers are needed for voltage and current conversion, which is not beneficial to reducing production and maintenance costs, and meanwhile, in order to ensure that a bus capacitor works at a proper temperature, an indirect heat dissipation mode is often adopted, and the volume of the bus capacitor needs to be increased, which is not beneficial to improving the power density of the controller and the reliability of the bus capacitor.

In order to solve the technical problems, the second object of the present utility model is to provide a new energy automobile, which can solve the problems that two different platforms and different types of controllers are needed for voltage and current conversion, which is not beneficial to reducing production and maintenance costs, and meanwhile, in order to ensure that the bus capacitor works at a proper temperature, an indirect heat dissipation mode is often adopted, and the volume of the bus capacitor needs to be increased, which is not beneficial to improving the power density of the controllers and the reliability of the bus capacitor.

One of the purposes of the utility model is realized by adopting the following technical scheme:

a motor drive controller comprising:

each power module comprises a power semiconductor element, a driving circuit board and a control circuit board, and is configured into one or more of a direct current-direct current conversion module for boosting or reducing direct current, an alternating current-alternating current conversion module for regulating voltage and frequency of alternating current, a direct current-alternating current conversion module for converting the direct current into alternating current or an alternating current-direct current conversion module for controllably rectifying the alternating current into direct current;

the integrated liquid cooling radiator comprises a bus capacitor, the bus capacitor comprises a capacitor core, a liquid cooling radiator and a laminated busbar, two sets of power modules are arranged on two sides of the bus capacitor, the bus capacitor is provided with a runner for cooling the power semiconductor element, and the laminated busbar is provided with an input port and an output port which are connected with the two sets of power modules.

Further, the motor drive controller further includes: and the connector is used for connecting the two sets of power modules and the integrated liquid cooling radiator and comprises a direct current connector or an alternating current connector.

Further, the two sides of the integrated liquid cooling radiator are respectively provided with a sealed shell, and the two sets of power modules are respectively arranged in the two sealed shells.

Further, the power semiconductor element is arranged at two sides of the liquid cooling radiator, the driving circuit board is connected with the power semiconductor element, and the power semiconductor element is connected with the bus capacitor.

Further, the power semiconductor element comprises one or more of a direct liquid cooling three-phase module, a direct liquid cooling half-bridge module, an indirect liquid cooling three-phase module or an indirect liquid cooling half-bridge module.

Further, the connection mode of the power semiconductor element and the bus capacitor is one or more of bolt connection, laser welding or resistance welding.

Further, the liquid cooling radiator comprises one or more radiators, and the material of the liquid cooling radiator is one or more of metal or plastic.

Further, the motor driving controller comprises a set of control circuit board and two sets of driving circuit boards, wherein the set of control circuit board is connected with the two sets of driving circuit boards through two sets of connectors, and the control circuit board is installed on any one of the two sets of power modules.

Further, the motor drive controller comprises a set of drive control circuit board and a set of drive circuit board, and the set of drive control circuit board is connected with the set of drive circuit board on the other side through a set of connector.

The second purpose of the utility model is realized by adopting the following technical scheme:

a new energy vehicle comprising a motor drive controller as claimed in any one of the preceding claims.

Compared with the prior art, the utility model has the beneficial effects that:

according to the technical scheme, the motor driving controller can be flexibly configured according to different requirements, can meet the application requirements of different occasions such as hydrogen fuel automobiles, electric automobiles and industrial driving, can realize power conversion of direct current-direct current, direct current-alternating current, alternating current-alternating current and the like, and different schemes belong to the same platform, can finish production through the same assembly production line, reduce production cost, improve manufacturability and maintainability, and meanwhile, the laminated busbar in the integrated liquid cooling radiator is provided with input and output ports which can be directly connected with two sets of power modules, so that the stray parameters of capacitance are reduced, the number of bridging copper bars and the copper bar cost are reduced, and the power density is improved.

According to the technical scheme, the bus capacitor in the integrated liquid cooling radiator enhances the heat dissipation of the capacitor by cooling four sides of the capacitor, effectively reduces the volume of the capacitor and improves the reliability of the capacitor and the power density of the controller.

In the technical scheme of the utility model, one set of driving control circuit board and one set of driving circuit board can be adopted, and the material cost and the manufacturing cost are saved by adopting fewer elements.

In the technical scheme of the utility model, the whole assembly can adopt a part assembly scheme, the liquid cooling radiator, the power semiconductor element, the circuit board and the like are pre-assembled, and the liquid cooling radiator, the power semiconductor element, the circuit board and the like can be directly arranged in the controller shell after the test is completed, so that the shell does not need to be reversed, and the assembly materials and the production and manufacturing cost are reduced.

Drawings

The accompanying drawings, which are included to provide a further understanding of the utility model and are incorporated in and constitute a part of this disclosure, illustrate embodiments of the utility model and together with the description serve to explain the utility model. In the drawings:

fig. 1 is a schematic structural diagram of a motor driving controller according to an embodiment of the present disclosure, in which one set of control circuit boards and two sets of driving circuit boards are used;

fig. 2 is a schematic structural diagram of a motor driving controller employing a set of driving control circuit boards and a set of driving circuit boards according to an embodiment of the present disclosure

Fig. 3 is a schematic diagram of a motor driving controller configured as dc-dc conversion modules according to an embodiment of the disclosure

Fig. 4 is a schematic diagram of a first type of connection of the motor driving controller configured as dc-dc, dc-ac conversion modules in the embodiment of the disclosure

Fig. 5 is a schematic diagram of a second type of connection of the motor driving controller configured as dc-dc, dc-ac conversion modules in the embodiment of the disclosure

Fig. 6 is a schematic diagram of a first type of connection of motor drive controllers configured as dc-ac power modules in an embodiment of the disclosure

Fig. 7 is a second type of wiring schematic diagram of the motor driving controller configured as dc-ac power modules in the embodiment of the disclosure

FIG. 8 is a schematic diagram of the motor driving controller respectively configured as AC-DC, DC-AC modules in the embodiment of the disclosure

Reference numerals: 1 a shell, 2 a liquid cooling radiator, 3 a control circuit board, 4 a drive circuit board, 5 a power semiconductor element, 6 a power semiconductor element, 7 a drive circuit board, 8 a bus capacitor, 9 a drive control circuit board, 10 a laminated bus bar, 11 a bus capacitor core, 12 a direct current bus bar, 13 a direct current bus bar, 14 a direct current bus bar, 16 a direct current bus bar, 17 a direct current bus bar, 19 a direct current bus bar, 20 an alternating current bus bar, 21 a direct current bus bar, 22 an alternating current copper bar, 23 an alternating current copper bar, 24 an alternating current copper bar, 25 an alternating current copper bar, 28 a direct current connector, 29 a direct current connector and 30 an alternating current connector.

Detailed Description

The present utility model will be further described with reference to the accompanying drawings and detailed description, wherein it is to be understood that, on the premise of no conflict, the following embodiments or technical features may be arbitrarily combined to form new embodiments.

The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to give a thorough understanding of embodiments of the disclosure. One skilled in the relevant art will recognize, however, that the disclosed aspects may be practiced without one or more of the specific details, or with other methods, components, materials, devices, or the like. In these instances, well-known structures, methods, devices, implementations, materials, or operations are not shown or described in detail.

Example 1

In order to solve the problems that two controllers with different platforms and different types are needed for voltage and current transformation, which is not beneficial to reducing production and maintenance cost, and meanwhile, in order to ensure that a bus capacitor works at a proper temperature, an indirect heat dissipation mode is often adopted, the volume of the bus capacitor is needed to be increased, the power density of the controllers and the reliability of the bus capacitor are not beneficial to being improved, the utility model provides a motor driving controller, which comprises the following components: each power module comprises a power semiconductor element, a driving circuit board and a control circuit board, and is configured into one or more of a direct current-direct current conversion module for boosting or reducing direct current, an alternating current-alternating current conversion module for regulating voltage and frequency of alternating current, a direct current-alternating current conversion module for converting the direct current into alternating current or an alternating current-direct current conversion module for controllably rectifying the alternating current into direct current; the integrated liquid cooling radiator comprises a bus capacitor, the bus capacitor comprises a capacitor core, a liquid cooling radiator and a laminated busbar, two sets of power modules are arranged on two sides of the bus capacitor, the bus capacitor is provided with a runner for cooling the power semiconductor element, and the laminated busbar is provided with an input port and an output port which are connected with the two sets of power modules.

Specifically, the motor drive controller includes integrated liquid cooling radiator, two sets of power module and adapter's connector, and two sets of power module can make motor drive controller can realize following function through the connected mode of series connection or parallelly connected: the DC-DC conversion controller for boosting or reducing the DC, the DC-AC conversion controller for converting the DC into AC and the AC-AC conversion controller for regulating the voltage and the frequency of the AC are used for meeting the application requirements of various working conditions. Each set of power module comprises a power semiconductor element, a driving circuit board and a control circuit board, wherein the power semiconductor elements are arranged on two sides of the liquid cooling radiator, the driving circuit board is connected with the power semiconductor elements, and the power semiconductor elements are connected with the bus capacitor. The power semiconductor element supports a variety of designs including one or more of a direct liquid cooled three-phase module, a direct liquid cooled half-bridge module, an indirect liquid cooled three-phase module, or an indirect liquid cooled half-bridge module. The bus capacitor of the integrated liquid cooling radiator can be composed of a capacitor core, a liquid cooling radiator and a laminated bus bar, the material of the liquid cooling radiator can be metal or plastic, the liquid cooling radiator can be formed by combining one or more radiators, the forming mode of the liquid cooling radiator comprises one or more of machining, injection molding, die casting, 3D printing and the like, the laminated bus bar in the bus capacitor of the integrated liquid cooling radiator can effectively reduce stray inductance of a bus bar, meanwhile, the laminated bus bar is provided with an input port and an output port, is used as a single component to realize connection with each functional element, can realize direct connection with an upper power module and a lower power module, can also realize connection with a direct current copper bar, and can realize bolting, laser welding, resistance welding and the like according to the connection modes of different power semiconductor elements. The bus capacitor of the integrated liquid cooling radiator is provided with a runner for cooling the bus capacitor and the power semiconductor element, the cooling runner is provided with an inlet and an outlet, and sealing connection is realized through the cooling runner of the sealing ring shell. Further, the two sides of the integrated liquid cooling radiator are respectively provided with a sealed shell, and the two sets of power modules are respectively arranged in the two sealed shells.

In some embodiments, the motor driving controller is configured with a set of control circuit board and two sets of driving circuit boards, one set of control circuit board is connected with the two sets of driving circuit boards through the two sets of connectors at the same time, so that communication between the two sets of power modules is realized, the two sets of power modules are all designed with mounting positions of the control circuit boards, and the control circuit can be selectively arranged above one power module according to actual application requirements.

In some embodiments, the motor drive controller is configured with a set of drive control circuit boards, one set of drive control circuit boards connected with one set of drive circuit boards on the other side through one set of connectors, and still achieve communication with two sets of power modules.

In some embodiments, for hydrogen fuel cell automotive applications, the two power modules of the motor drive controller may be configured as two dc-dc conversion modules that boost or buck dc power, converting the dc power that is up-converted by the fuel cell into the high voltage dc power that is required by the energy storage cell.

In some embodiments, for hydrogen fuel cell automotive applications, the two power modules of the motor drive controller may be configured as a dc-dc conversion module that steps up or down dc power and a dc-ac conversion module that converts dc power to ac power. The direct current-direct current conversion module is used for boosting or reducing the voltage of the fuel cell into high-voltage direct current required by components such as the battery, the air compressor and the like, and the direct current-alternating current conversion module is used for converting the direct current into alternating current required by the driving motor.

In some embodiments, for electric vehicle applications, the two power modules of the motor drive controller may be configured as one dc-dc conversion module for boosting dc power and one dc-ac conversion module for converting dc power into ac power, wherein the dc-dc conversion module boosts the battery voltage to a desired high voltage, and the dc-ac conversion module is used for converting dc power into ac power required for driving the motor. Meanwhile, the battery charging device is provided with a reverse battery charging function, so that the battery is charged by the motor.

In some embodiments, for industrial drive applications, the two power modules of the motor drive controller may be configured as an ac-dc module that controllably rectifies ac power to dc power and a dc-ac module that converts dc power to ac power. The alternating current-direct current module can convert the voltage of the power grid into high-voltage power required by the motor, and the direct current-alternating current conversion module is used for converting direct current into alternating current required by driving the motor, and can realize feedback of braking energy of the motor to the power grid.

In some embodiments, the motor driving controller is assembled, the two sets of power modules can be installed on two sides of a bus capacitor of the integrated liquid cooling radiator in advance on a production line in a preassembled mode, and are connected with the bus capacitor in advance, meanwhile, the power semiconductor element and the wiring terminal are connected with each other in advance through a copper bar, so that a part assembly is completed, the part assembly can be directly installed in a shell of the motor driving controller, the fixing of the part assembly and the sealing of a cooling flow passage are realized through bolts, the motor driving controller is provided with a direct current connector or an alternating current connector according to different application scenes, and after the part assembly is installed in the shell, the connection is realized through different copper bars and connectors.

Specifically, referring to fig. 1 and 2, the motor driving controller mainly comprises a bus capacitor 8 of the integrated liquid cooling radiator, two sets of power semiconductor elements 5 and 6, driving circuit boards 4 and 7, a control circuit board 3 or a driving control circuit board 9, and a housing 1.

The bus capacitor 8 of the integrated liquid cooling radiator mainly comprises a bus capacitor core 11, a liquid cooling radiator 2 and a laminated bus bar 10, wherein the laminated bus bar 10 and the power semiconductor elements 5 and 6 can be directly connected, an inlet, an outlet, a sealing groove and mounting pins which are mounted and sealed with the shell 1 are arranged on the liquid cooling radiator 2, the power semiconductor elements 5 and 6 are mounted on two sides of the liquid cooling radiator, and the power semiconductor elements and the bus capacitor share a liquid cooling heat dissipation flow channel.

In some embodiments, referring to fig. 1, the power semiconductor device 5 and the driving circuit board 4 form a first set of power modules, and the power semiconductor device 6 and the driving circuit board 7 form a second set of power modules. The control circuit board 3 is connected with the driving circuit board 4 and the driving circuit board 7 through a wire harness, so that signal communication between two sets of power modules is realized, and the two sets of power modules can be assembled with a bus capacitor 8 part of the integrated liquid cooling radiator in a preassembled mode and then assembled into the shell 1 together.

In some embodiments, referring to fig. 2, the power semiconductor element 5 and the driving control circuit board 9 form a first set of power modules, the power semiconductor element 6 and the driving circuit board 7 form a second set of power modules, and the driving control circuit board 9 is connected to the driving circuit board 7 through a set of connectors, so that communication between the two sets of power modules can still be achieved.

Example two

For hydrogen fuel cell automotive applications, the power module in the controller is configured as two dc-dc conversion modules or one dc-dc conversion module and one dc-ac conversion module. Referring to fig. 3, the input end is connected to the dc input ends of two sets of dc-dc conversion modules by a dc connector 28 through two sets of dc bus bars 12 and 13, and the output is output after being boosted or reduced by the dc-dc conversion modules, and the output of the dc-dc conversion module is connected to the bus capacitor through the laminated bus bar 10 and is connected to a dc connector 29 through two sets of dc bus bars 14, so as to complete dc-dc conversion. The application shown in fig. 4 differs from that of fig. 3 in that: the direct current-direct current conversion module is connected to the output direct current connector through the direct current busbar 16 on one side of the busbar after being output, so that the direct current-direct current conversion function is completed, meanwhile, the direct current-direct current conversion module is connected with the direct current-alternating current conversion module through the direct current busbar 17, and the direct current-direct current conversion module is led out to the alternating current connector 30 through the alternating current busbar after being converted into alternating current, so that the direct current-alternating current conversion function is completed.

Example III

For electric vehicle applications, one of the power modules in the controller is configured as a dc-dc conversion module and the other is configured as a dc-ac conversion module. Referring to fig. 5, two power semiconductor device modules are connected in series, wherein one of the power semiconductor device modules is configured as a dc-dc conversion module, and the other power semiconductor device module is configured as a dc-ac conversion module; the input end is a direct current connector 28, is connected to the input end of the direct current-direct current conversion module through the direct current busbar 19, is connected with the input end of the direct current-alternating current conversion module through the laminated busbar after being output by the module and passing through the busbar capacitor, and is output to the alternating current connector 30 through the alternating current busbar 20 after being output by the module, so that the direct current-alternating current conversion function is completed.

Example IV

For a new energy automobile adopting a double motor or a double-winding motor, the power module in the controller is configured into two direct current-alternating current conversion modules for converting direct current into alternating current. Referring to fig. 6, both sets of power modules are configured as dc-ac conversion modules, and such a configuration can directly drive a dual motor or a dual winding motor. The input end is connected with the DC input end of a bus capacitor 8 of the integrated liquid cooling radiator through a DC bus 21 by a DC connector 28, two output ends are arranged in a laminated bus in the bus capacitor and are respectively connected with two sets of DC-AC power modules, and the AC output ends of the two sets of power modules are respectively connected with two sets of AC connectors 30 by estimated AC copper bars 22 and 23. For high power motor applications, as shown in fig. 7, the difference from fig. 6 is that the ac power output from the two sets of dc-ac power modules is collected into one set of ac connectors through ac copper bars 24, 25.

Example five

For industrial motor applications, the power module in the controller is configured as an ac-dc conversion module that converts ac to dc and a dc-ac conversion module that converts dc to ac. One set of power modules is an alternating current-direct current conversion module, the other set of power modules is a direct current-alternating current conversion module, and the two sets of power modules are assembled to form an alternating current-alternating current power conversion controller. Referring to fig. 8, the ac power of the power grid is input to the controller through the ac connector 30, and is connected to the ac-dc power module through the ac copper bar 27, the dc output end of the first power module is directly connected to the bus capacitor 8 of the integrated liquid cooling radiator, the other output end of the bus capacitor is connected to the second power module, the second power module realizes dc-ac power conversion, and the ac output of the second power module is connected to the ac connector 30 through the ac copper bar 27. Meanwhile, the feedback of the braking energy of the motor to the power grid can be realized.

According to the embodiment, the bus capacitor of the integrated liquid cooling radiator can be used as an independent component, the two power modules are respectively arranged on two sides of the bus capacitor and are in cooling flow passage with the bus capacitor public liquid cooling radiator, and the two power modules can be flexibly configured to meet the application requirements of different occasions such as hydrogen fuel automobiles, electric automobiles and industrial driving. Therefore, the motor driving controller has the characteristics of high power density, low manufacturing cost and high compatibility and expansibility.

On the basis of any embodiment of the disclosure, the disclosure also provides a new energy automobile, which comprises the motor driving controller in any embodiment.

The above embodiments are only preferred embodiments of the present utility model, and the scope of the present utility model is not limited thereto, but any insubstantial changes and substitutions made by those skilled in the art on the basis of the present utility model are intended to be within the scope of the present utility model as claimed.

Claims (10)

1. A motor drive controller, comprising:

each power module comprises a power semiconductor element, a driving circuit board and a control circuit board, and is configured into one or more of a direct current-direct current conversion module for boosting or reducing direct current, an alternating current-alternating current conversion module for regulating voltage and frequency of alternating current, a direct current-alternating current conversion module for converting the direct current into alternating current or an alternating current-direct current conversion module for controllably rectifying the alternating current into direct current;

the integrated liquid cooling radiator comprises a bus capacitor, the bus capacitor comprises a capacitor core, a liquid cooling radiator and a laminated busbar, two sets of power modules are arranged on two sides of the bus capacitor, the bus capacitor is provided with a runner for cooling the power semiconductor element, and the laminated busbar is provided with an input port and an output port which are connected with the two sets of power modules.

2. The motor drive controller according to claim 1, further comprising: and the connector is used for connecting the two sets of power modules and the integrated liquid cooling radiator and comprises a direct current connector or an alternating current connector.

3. The motor drive controller according to claim 1, wherein: the integrated liquid cooling radiator is characterized in that two sides of the integrated liquid cooling radiator are respectively provided with a sealed shell, and the two sets of power modules are respectively arranged in the two sealed shells.

4. The motor drive controller according to claim 1, wherein the power semiconductor elements are provided on both sides of the liquid-cooled radiator, the drive circuit board is connected to the power semiconductor elements, and the power semiconductor elements are connected to the bus capacitor.

5. The motor drive controller of claim 4, wherein the power semiconductor element comprises one or more of a direct liquid cooled three-phase module, a direct liquid cooled half-bridge module, an indirect liquid cooled three-phase module, or an indirect liquid cooled half-bridge module.

6. The motor drive controller of claim 4, wherein the power semiconductor element is connected to the bus capacitor by one or more of bolting, laser welding, or resistance welding.

7. The motor drive controller of claim 4 wherein the liquid cooled heat sink comprises one or more heat sinks, the liquid cooled heat sink being one or more of metallic or plastic.

8. The motor drive controller of claim 1, wherein the motor drive controller comprises a set of control circuit boards, two sets of drive circuit boards, the set of control circuit boards being connected to the two sets of drive circuit boards by two sets of connectors, the control circuit boards being mounted on either of the two sets of power modules.

9. The motor drive controller according to claim 1, wherein the motor drive controller includes a set of drive control circuit boards, a set of drive circuit boards, the set of drive control circuit boards being connected to the set of drive circuit boards on the other side by a set of connectors.

10. A new energy vehicle comprising a motor drive controller according to any one of claims 1 to 9.

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