CN223125091U

CN223125091U - Flat motor controller and new energy vehicles

Info

Publication number: CN223125091U
Application number: CN202420814806.3U
Authority: CN
Inventors: 康博
Original assignee: Global Intelligent Power Technology Shanghai Co ltd
Current assignee: Global Intelligent Power Technology Shanghai Co ltd
Priority date: 2024-04-18
Filing date: 2024-04-18
Publication date: 2025-07-18
Anticipated expiration: 2034-04-18

Abstract

The utility model discloses a flat motor controller and a new energy vehicle, which relates to the technical field of new energy vehicles, including a box body, having a first accommodating chamber and a second accommodating chamber arranged in back-to-back relation; a three-phase output module is electrically connected to an IGBT power module through a copper busbar, the IGBT power module is electrically connected to a film capacitor through a copper busbar, the film capacitor is electrically connected to a boost relay through a copper busbar, and the three-phase output module, the IGBT power module, the film capacitor and the boost relay are distributed in the first accommodating chamber; an OBC+DC‑DC module is arranged in the second accommodating chamber; a cover plate, including a first cover plate and a second cover plate, is respectively arranged in the first accommodating chamber and the second accommodating chamber. The above components are reasonably arranged in the accommodating chamber, aiming to design a flat motor controller under the premise of ensuring the function of the motor controller, and replace the wire with a copper busbar, thereby solving the disadvantage of the traditional motor controller being too large in size.

Description

Flat motor controller and new energy automobile

Technical Field

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

Background

The utility model provides a new energy automobile motor controller, as one of the core components of electric automobile driving system, mainly be responsible for carrying out accurate control and management to driving motor's operation, motor controller to new energy automobile can include a plurality of independent modules such as on-vehicle charging system (OBC), direct current converter (DC-DC), battery Management System (BMS), traditional motor controller uses a PCB board to integrate above-mentioned each functional module, refill into a casing and form a motor controller, or directly place in the front and back incasement of car, there is heavy generating line and high pencil cost, lead to the space utilization to motor controller casing low, motor controller's volume is big, it is difficult to arrange in the vehicle, lead to the space utilization to the car low in front and back case, finally influence the mechanical strength and the security of whole car.

Disclosure of utility model

The utility model aims to solve the defect of overlarge volume of the motor controller on the premise of ensuring the function of the motor controller.

In order to solve the above problems, the present utility model proposes a flat type motor controller comprising:

The box body is provided with a first accommodating cavity and a second accommodating cavity which are arranged in a back way;

the three-phase output module is electrically connected with the IGBT power module through the copper bars, the IGBT power module is electrically connected with the thin film capacitor through the copper bars, the thin film capacitor is electrically connected with the boost relay through the copper bars, and the three-phase output module, the copper bars, the IGBT power module, the thin film capacitor and the boost relay are distributed in the first accommodating cavity;

The OBC+DC-DC module is arranged in the second accommodating cavity;

the cover plate comprises a first cover plate and a second cover plate, and the first accommodating cavity and the second accommodating cavity are respectively covered and arranged.

In an embodiment, the first accommodating cavity is provided with a plurality of accommodating areas, and each accommodating area is respectively matched with the three-phase output module, the copper bar, the IGBT power module, the film capacitor and the boost relay in size.

In an embodiment, the first accommodating cavity includes a plurality of accommodating areas, and each accommodating area is respectively adapted to the three-phase output module, the copper bar, the IGBT power module, the thin film capacitor and the boost relay.

In an embodiment, the cavity wall of the first accommodating cavity is provided with a recess facing the second accommodating cavity, the outer wall of the recess is at least partially abutted with the outer cavity wall of the second accommodating cavity, and the recess is used for forming accommodating areas with relatively higher heights in the first accommodating cavity.

In an embodiment, the box body is formed with at least one boss in the first accommodating cavity, and the concave portion and the boss are matched to form an accommodating area matched with the three-phase output module, the IGBT power module, the film capacitor and the boost relay in size.

In an embodiment, a first plugging area is arranged on the side wall of the box body, and a plurality of plugging ports are arranged on the first plugging area.

In an embodiment, the first accommodating cavity is provided with an interaction area communicated with the second accommodating cavity, and the first plugging area is communicated with the interaction area and is electrically connected with the OBC+DC-DC module through the interaction area.

In an embodiment, the motor controller further comprises a direct-current high-voltage plug connector, a second plug region is arranged on the side wall of the box body, and the second plug region is communicated with the boost relay and the film capacitor and is used for plugging the direct-current high-voltage plug connector.

In an embodiment, the dc high voltage connector is a 3P dc high voltage connector, and the 3P dc high voltage connector is provided with a quick-charging function.

In an embodiment, the three-phase output module, the IGBT power module, the thin film capacitor, the boost relay, and the obc+dc-DC module are fixed to the case by fixing members.

The utility model also discloses a new energy automobile, which comprises the flat motor controller.

The beneficial effects are that:

1. The motor controller in the embodiment divides the box into a first accommodating cavity and a second accommodating cavity through an innovatively designed box structure, all three-phase output modules, copper bars, IGBT power modules, film capacitors and boosting relays are arranged in the first accommodating cavity in a flat plate mode, and the OBC+DC-DC modules integrate functions of an on-board charging system (OBC) and a direct current converter (DC-DC) and are also paved in the second accommodating cavity. Through at the first holding chamber design holding district, match the size of each part, realize flattening design, strengthened the intensity of this motor controller structure, and be convenient for whole car installation more, also reduced the occupation volume to carriage space.

2. According to the embodiment, the copper bar is used for replacing the lead, the copper bar has higher mechanical strength and stability compared with a fine lead, the larger cross section area and thickness of the copper bar can provide better structural support, loosening or fracture risk caused by vibration, impact or mechanical stress is reduced, and the structural strength and durability of the motor controller are enhanced. In contrast, conventional wires may require more space to accommodate and route. By using copper bars, the internal space can be effectively utilized and the overall structure of the motor controller can be optimized.

3. The side wall of the box body is provided with a first plugging area and a second plugging area, so that effective communication and power transmission among all modules are ensured. In the whole structure, the height of the motor controller is reduced, the plugging area is arranged at the side edge, the volume of the motor controller is reduced, the utilization rate of the transverse space is improved, and the reasonable arrangement in the new energy automobile is facilitated.

Drawings

In order to more clearly illustrate the embodiments of the present utility model or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are only some embodiments of the present utility model, and other drawings may be obtained according to the structures shown in these drawings without inventive effort for a person skilled in the art.

FIG. 1 is an exploded view of a flat motor controller according to the present utility model;

FIG. 2 is a self-contained schematic view of a flat motor controller according to the present utility model;

fig. 3 is another view of the overall schematic of the flat motor controller according to the present utility model.

Reference numerals illustrate:

the achievement of the objects, functional features and advantages of the present utility model will be further described with reference to the accompanying drawings, in conjunction with the embodiments.

Detailed Description

The following description of the embodiments of the present utility model will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the utility model. All other embodiments, which can be made by those skilled in the art based on the embodiments of the utility model without making any inventive effort, are intended to be within the scope of the utility model.

It should be noted that all directional indicators (such as up, down, left, right, front, and rear are used in the embodiments of the present utility model) are merely for explaining the relative positional relationship, movement conditions, and the like between the components in a certain specific posture (as shown in the drawings), and if the specific posture is changed, the directional indicators are changed accordingly.

Furthermore, the description of "first," "second," etc. in this disclosure is for descriptive purposes only and is not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In addition, the technical solutions of the embodiments may be combined with each other, but it is necessary to base that the technical solutions can be realized by those skilled in the art, and when the technical solutions are contradictory or cannot be realized, the combination of the technical solutions should be considered to be absent and not within the scope of protection claimed in the present utility model.

The utility model provides a new energy automobile motor controller, as one of the core parts of electric automobile driving system, mainly be responsible for carrying out accurate control and management to driving motor's operation, motor controller to new energy automobile can include a plurality of independent modules such as on-vehicle charging system (OBC), direct current converter (DC-DC), battery Management System (BMS), traditional motor controller uses a PCB board to integrate above-mentioned each functional module, form a motor controller in the reloading a casing, there are heavy generating line and high pencil cost, lead to the space utilization to motor controller casing low, motor controller's volume is big, be difficult to arrange in the vehicle, finally influence the mechanical strength and the security of whole car.

In order to solve the above problems, the present utility model proposes a flat type motor controller 1 including a case 100, a three-phase output module 10, a plurality of copper bars 20, an IGBT power module 30, a thin film capacitor 40, a boost relay 50, an obc+dc-DC module 70, and a cover plate 200.

The case 100 has a first receiving chamber 110 and a second receiving chamber 120 disposed opposite to each other. The three-phase output module 10, the copper bar 20, the IGBT power module 30, the thin film capacitor 40 and the boost relay 50 are distributed in the first accommodating cavity 110, the three-phase output module 10 is electrically connected with the IGBT power module 30 through the copper bar 20, the upper copper bar 20 of the three-phase output module is fixedly contacted with output terminals of the power module to form electrical connection for supplying power to a motor, the IGBT power module 30 is electrically connected with the thin film capacitor 40, the upper copper bar of the input terminal of the IGBT power module is fixedly contacted with output terminals of the thin film capacitor 40 to form electrical connection, and the thin film capacitor 40 is electrically connected with the boost relay 50 through the copper bar 20. The OBC module and the DC-DC module are arranged in the second receiving chamber 120. The cover plate 200 includes a first cover plate 210 and a second cover plate 220, which are respectively disposed in the first receiving chamber 110 and the second receiving chamber 120.

In this embodiment, the copper bar 20 and the terminal copper bar are used to replace the conductive wires, the copper bar 20 has higher mechanical strength and stability compared with the fine conductive wires, the larger cross-sectional area and thickness of the copper bar 20 can provide better structural support, the loosening or breaking risk caused by vibration, impact or mechanical stress is reduced, and the structural strength and durability of the motor controller 1 are enhanced. In contrast, conventional wires may require more space to accommodate and route. The use of the copper bars 20 makes it possible to effectively utilize the internal space and optimize the overall structure of the motor controller 1.

The case 100 is made of a material with high heat dissipation capability, and may be aluminum or copper, and it should be noted that aluminum has poor corrosion resistance and needs additional coating or treatment for protection. Likewise, the material of the cover plate 200 may be identical to that of the case 100, and have a strong heat dissipation capability.

The case 100 is divided into a first accommodating chamber 110 and a second accommodating chamber 120, and the three-phase output module 10, the copper bar 20, the IGBT power module 30, the thin film capacitor 40, and the boost relay 50 are arranged in the first accommodating chamber 110 in a flat manner. The OBC module and the DC-DC module are integrated into an obc+dc-DC module 70, and the obc+dc-DC module 70 is a flat square body and is disposed in the second accommodating cavity 120, so that space is saved, the number of external connecting wires and interfaces can be reduced, space occupation is reduced, the whole motor controller 1 is in a flat shape, and the overall thickness and volume of the motor controller are effectively reduced. Therefore, the whole motor controller 1 in this embodiment is flat, is convenient for whole car installation, and installs behind new energy automobile, can save space for the vehicle, provide more installation space for other subassemblies, improve whole car design flexibility and overall arrangement effect.

In addition, the three-phase output module 10, the copper bar 20, the IGBT power module 30, the film capacitor 40 and the boost relay 50 in this embodiment have a reasonable connection mode, and are reasonably arranged according to the functions thereof, and the components (the three-phase output module 10, the film capacitor 40 and the boost relay 50) needing to be externally connected with the plug-in connector are arranged at the edge of the box 100, so that the external plug-in connector is convenient, the components needing to be externally connected with the plug-in connector are not arranged at the middle of the first accommodating cavity 110, and the components needing to be externally connected with external equipment can be directly arranged at the edge of the box, thereby avoiding the complex wiring of the internal wiring harness. In this way, components that do not require an external connector can be more centrally placed in the middle of the first receiving cavity, thereby optimizing the internal layout. The layout mode reduces the number and the length of the internal wiring harnesses, so that the connection of the internal parts is simpler, the number of the parts in the motor controller is reduced, and the whole size is reduced.

In this embodiment, the obc+dc-DC module 70 is separately placed in the second accommodating cavity 120, because the occupied volume is larger, and the obc+dc-DC module is separately placed in the second accommodating cavity 120, so that the space of the first accommodating cavity 110 can be released, and other functional modules and components can be more flexibly placed in the first accommodating cavity 110, thereby helping to improve the flexibility of the overall layout and the space utilization.

Therefore, the embodiment increases the space utilization rate of the box 100 through the flattened form and reasonable component arrangement and ring-by-ring arrangement, so that the internal structure of the motor controller 1 is simple and compact, and the performance of the motor controller 1 and the structural stability of the whole vehicle assembly after arrangement are ensured.

In this embodiment, a plurality of accommodating areas 111 are disposed in the first accommodating cavity 110, and dimensions (length, width, and height) of each accommodating area 111 are respectively adapted to dimensions (length, width, and height) of the three-phase output module 10, the IGBT power module 30, the thin film capacitor 40, and the boost relay 50, so that the above components are perfectly disposed in the accommodating areas 111, and space utilization is improved.

It should be noted that, in this embodiment, the first accommodating cavity 110 is finely divided according to the volume differences of the three-phase output module 10, the copper bar 20, the IGBT power module 30, the thin film capacitor 40 and the boost relay 50, and each component is designed with a reasonable installation space to help to realize a compact layout. The size of the first accommodating chamber 110 is larger than that of the second accommodating chamber 120, and the height of the first accommodating chamber 110 at a position where the first accommodating chamber 110 is backed up against the second accommodating chamber 120 is relatively low, and in order to save space, a control board 60 with a low thickness may be disposed at this position, and other areas may be provided with a three-phase output module 10, a copper bar 20, an IGBT power module 30, a thin film capacitor 40, and a boost relay 50. Therefore, each accommodating area 111 can correspond to a corresponding component, so that the internal arrangement is more reasonable, the wiring is clearer, and the space utilization rate is improved.

It should be noted that if other relatively high components are provided at a position where the first accommodating chamber 110 is backed up against the second accommodating chamber 120, the thickness of the entire motor controller 1 is increased and the space utilization in other areas is also lowered.

In this embodiment, the cavity wall of the first accommodating cavity 110 is provided with a recess 112 facing the second accommodating cavity 120, the outer wall 1121 of the recess is at least partially abutted against the outer cavity wall 121 of the second accommodating cavity, and the recess 112 is used for forming a relatively higher accommodating area 111 of the plurality of accommodating areas 111 in the first accommodating cavity 110.

It will be appreciated that since the first receiving cavity 110 is larger than the second receiving cavity 120, and since the three-phase output module 10, the IGBT power module 30, the thin film capacitor 40, and the boost relay 50 have different heights, a relatively high receiving area 111 is required for the components having the higher heights to match. Therefore, the recess 112 is provided in this embodiment, the recess 112 faces the second accommodating area 111, and when adapting to a higher component, the space of the first accommodating cavity 110 and the second accommodating cavity 120, which are not overlapped, is reasonably utilized, so as to improve the vertical space utilization. The height of the cavity wall of the first accommodating cavity 110 of the box body 100 is prevented from extending outwards due to overhigh one part, so that the whole size is enlarged, and the volume of the body is increased.

In the above embodiment, the recess is designed to control the thickness of the whole motor controller 1 to be slightly different from the thickness of the obc+dc-DC module 70, and the thickness of the whole motor controller is that of the obc+dc-DC module 70, the thickness of the inner layer of the case 100 and the thickness of the control board 60 arranged in the middle, and the whole motor controller 1 is a flat motor controller after being assembled.

In this embodiment, the case 100 forms at least one boss in the first accommodating cavity 110, and the recess 112 cooperates with the boss to form an accommodating area 111 that is adapted to the dimensions of the three-phase output module 10, the IGBT power module 30, the thin film capacitor 40, and the boost relay 50.

The design of the boss forms a receiving area 111 adapted to the size of the respective functional modules and components having different heights. This means that each module and element can find a suitable space in the corresponding accommodation area 111, ensuring that their installation and wiring is more compact and efficient, improving the vertical space utilization of the whole motor controller 1. And the existence of the boss can form certain space isolation between the functional module and the element, which is helpful to reduce mutual interference and interference between the modules and improve the electromagnetic compatibility and stability of the whole motor controller 1.

In this embodiment, a first plugging area 130 is disposed on a side wall of the case 100, and a plurality of plugging ports are disposed on the first plugging area 130. The multiple plug interfaces of the first plug area 130 are used for plugging power plug connectors and the like, such as a plug slow charge plug connector 131 and a DC+ plug connector 132.

For placing the plugging area at the top or bottom, the thickness of the box 100 is increased, the subsequent whole vehicle installation is difficult to arrange, and in this embodiment, the lateral space can be better utilized by arranging the plugging area on the side wall, so that the whole motor controller 1 is more compact in the vertical direction. This helps to solve the problem of large volume and improves space utilization efficiency.

In this embodiment, the first accommodating cavity 110 is provided with an interaction area 150 that communicates with the second accommodating cavity 120, and the first plugging area 130 communicates with the interaction area 150 and is electrically connected to the obc+dc-DC module 70 through the interaction area 150.

It will be appreciated that by the arrangement of the interaction zone 150, an electrical connection may be made between the first patch zone 130 and the obc+dc-DC module 70. This connectivity allows wires, cables or other electrical connectors to more conveniently pass from the first patch region 130 through the interaction region 150, from within the cavity directly to connect with the obc+dc-DC module 70. In this way, the wiring of the electrical connection is simpler, the layout of the whole motor controller 1 is more compact, the crossing and winding of the connecting circuit are reduced, and the space utilization efficiency is optimized.

Thus, the presence of the interaction area 150 may increase the possibility of dividing the case 100 into two chambers, an upper chamber and a lower chamber, and the establishment of the interaction area not only provides a channel for electrical connection, but also forms a mechanism for sharing space between the first accommodating chamber 110 and the second accommodating chamber 120. The design can more flexibly utilize the space between the two accommodating cavities, and the layout positions of all the components can be adjusted according to the needs, so that different design requirements can be better met.

In this embodiment, the slow charging plug 131 is installed in the first plugging area 130, and the zero line and the live line of the slow charging plug are fixed on the obc+dc-DC module 70 by bolts, and when the slow charging plug works, the interface provides 220V alternating current, and the battery pack is charged by the obc+dc-DC module 70. The dc+ plug 132 is installed in the first plug area 130, and the copper bar 20 thereof is connected with the obc+dc-DC module 70 to provide 12V voltage for the low voltage electric equipment of the whole vehicle.

In this embodiment, the motor controller 1 further includes a dc high-voltage connector, a second plugging area 140 is disposed on a side wall of the case 100, and the second plugging area 140 is in communication with the boost relay 50 and the thin film capacitor 40, and is used for plugging the dc high-voltage connector. One end of the boost relay 50 is electrically connected to the dc high voltage connector 141 through the copper bar 20, and the other end is electrically connected to the thin film capacitor 40, and at the same time, the thin film capacitor 40 is electrically connected to the dc high voltage connector 141 through the copper bar 20.

It should be noted that after the three-phase output module 10, the copper bar 20, the IGBT power module 30, the thin film capacitor 40, and the boost relay 50 are connected to each other, the boost relay 50 and the thin film capacitor 40 are further connected to the dc high voltage plug, and the second plug area 140 for the dc high voltage plug is disposed on the side wall of the box 100, so that the boost relay 50 and the thin film capacitor 40 need to be disposed at the edge of the first accommodating cavity 110 and disposed in the second plug area 140. The dc high voltage connector can be plugged in the second plugging area 140 of the side wall, thereby saving space inside the box 100. In this way, more space can be left for other functional modules or elements, optimizing the overall layout of the motor controller 1.

It will be appreciated that the first mating region 130 is used to make electrical connection to the devices within the second receiving chamber 120 and the second mating region 140 is used to make electrical connection to the devices within the first receiving chamber 110. The plugging areas are divided according to the positions of the functional modules, so that wiring in each plugging area is more orderly and concise, the complexity and confusion of wiring are reduced, and the risk of faults is reduced.

In this embodiment, the dc high voltage plug is a 3P dc high voltage plug 141, and the 3P dc high voltage plug 141 is provided with a quick-charging function.

It should be noted that the conventional dc high voltage connector is an element for connecting to a high voltage dc power supply, and has various functions including power input and output, signal transmission, electric protection, noise reduction and shielding, air sealing, water and dust prevention, and the like. In the present embodiment, on the basis of these functions, the quick charging function is also integrated in the dc high voltage plug 141, and the quick charging function can be realized while the plug is connected to the motor controller 1 or other devices. In this way, the user does not need extra charging equipment or cables, and can conveniently and rapidly charge by only using the 3P direct current high-voltage plug connector 141 supporting rapid charging, so that the charging experience and convenience of the user are improved, the components used by the motor controller 1 are reduced, and the volume is reduced.

In this embodiment, the three-phase output module 10, the IGBT power module 30, the thin film capacitor 40, the boost relay 50, and the obc+dc-DC module 70 are fixed to the case 100 by fixing members.

It should be noted that, the fixing member may be a bolt, and the IGBT power module 30, the three-phase output module 10, the control board 60, the boost relay 50, the film capacitor 40, and the obc+dc-DC module 70 are all fixed on the box 100 by using bolts, so that the structural strength of the motor controller 1 is increased, and excessive damage caused by the vibration structure is avoided.

The utility model also discloses a new energy automobile, which comprises a motor controller, wherein the specific structure of the motor controller refers to the embodiment, and as the motor controller adopts all the technical schemes of all the embodiments, the new energy automobile at least has all the beneficial effects brought by the technical schemes of the embodiments, and the detailed description is omitted.

The foregoing description is only of the preferred embodiments of the present utility model and is not intended to limit the scope of the utility model, and all equivalent structural changes made by the description of the present utility model and the accompanying drawings or direct/indirect application in other related technical fields are included in the scope of the utility model.

Claims

1. A flat motor controller, the motor controller comprising:

The OBC+DC-DC module is arranged in the second accommodating cavity;

The cover plate comprises a first cover plate and a second cover plate, and the first cover plate and the second cover plate are respectively covered in the first accommodating cavity and the second accommodating cavity;

The first accommodation cavity is provided with a plurality of accommodation areas, and each accommodation area is respectively matched with the three-phase output module, the IGBT power module, the film capacitor and the boost relay in size.

2. The flat type motor controller according to claim 1, wherein a cavity wall of the first accommodation cavity is provided with a recess toward the second accommodation cavity, an outer wall of the recess being at least partially abutted with an outer cavity wall of the second accommodation cavity, the recess being for forming a relatively higher-height accommodation area among the plurality of accommodation areas in the first accommodation cavity.

3. The flat type motor controller as claimed in claim 2, wherein the case is formed with at least one boss in the first accommodation chamber, and the recess is formed with the boss to be matched with an accommodation area of the three-phase output module, the copper bar, the IGBT power module, the film capacitor and the boost relay in size.

4. The flat type motor controller according to claim 1, wherein a first plugging area is provided on a side wall of the case, and a plurality of plugging ports are provided on the first plugging area.

5. The flat type motor controller as claimed in claim 4, wherein said first receiving chamber is provided with an interaction area communicating with said second receiving chamber, said first plugging area communicating with said interaction area, and electrically connected with said obc+dc-DC module through said interaction area.

6. The flat motor controller as claimed in claim 1, further comprising a dc high voltage plug, wherein a second plug area is provided on a side wall of the case, and the second plug area is in communication with the boost relay and the thin film capacitor for plugging the dc high voltage plug.

7. The flat type motor controller according to claim 6, wherein the dc high voltage plug is a 3P dc high voltage plug, and the 3P dc high voltage plug is provided with a quick charge function.

8. The flat type motor controller according to any one of claims 1 to 7, wherein the three-phase output module, the IGBT power module, the thin film capacitor, the boost relay, and the obc+dc-DC module are fixed to the case by a fixing member.

9. A new energy vehicle, characterized in that the new energy vehicle comprises a flat motor controller according to any one of claims 1 to 8.