WO2016058218A1 - 一种电机控制器 - Google Patents

一种电机控制器 Download PDF

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Publication number
WO2016058218A1
WO2016058218A1 PCT/CN2014/089517 CN2014089517W WO2016058218A1 WO 2016058218 A1 WO2016058218 A1 WO 2016058218A1 CN 2014089517 W CN2014089517 W CN 2014089517W WO 2016058218 A1 WO2016058218 A1 WO 2016058218A1
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Prior art keywords
module
water channel
inverter
motor controller
circuit board
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PCT/CN2014/089517
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English (en)
French (fr)
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黄风太
罗伯特 莫尔 贝特朗
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中山大洋电机股份有限公司
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Publication of WO2016058218A1 publication Critical patent/WO2016058218A1/zh

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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating

Definitions

  • the invention relates to a motor controller and belongs to the field of electric vehicles.
  • inverter module controls the drive motor and the generator to run, but the two inverter modules need two.
  • the motor controller which will inevitably occupy the limited space inside the motor car, and the cost is relatively high, which does not meet the development trend of low-cost and small-sized motor vehicles, and this structure will inevitably be eliminated.
  • the object of the present invention is to provide a motor controller, which is integrated with two inverter modules, has a simple and compact structure, relatively low cost, and can effectively dissipate heat between the inverter module and the capacitor module, and has a heat dissipation effect.
  • the motor controller is stable and reliable.
  • a motor controller comprises a controller box, a capacitor module and two inverter modules, wherein a radiator is installed in the controller box, a cavity is opened in the middle of the radiator, and the capacitor module is installed in the cavity, two The inverter modules are respectively installed on the top and bottom of the radiator, and a cooling water channel is arranged on the radiator and a water inlet and a water outlet connected with the cooling water channel are provided, and the capacitor module and the two inverter modules are performed through the cooling water channel. Cooling.
  • the inverter module described above comprises an IGBT module, a driving circuit board and a control circuit board.
  • the driving circuit board and the control circuit board are sequentially mounted on the top surface of the IGBT module, and the needle bed is extended downward on the bottom surface of the IGBT module.
  • a heat dissipating water channel is formed between the top surface and the bottom surface of the heat sink, and the groove is connected with the cooling water channel.
  • the two inverter modules are respectively mounted on the top surface and the bottom surface of the heat sink, on the inverter module.
  • the needle bed extends into the groove on the heat sink.
  • the cooling water channel described above includes a water channel 1 and a water channel 2, and the water channel 1 and the water channel 2 are respectively located at two sides of the heat sink, and the two grooves are disposed between the water channel 1 and the water channel 2, and the two sides of the heat sink are disposed through the two grooves
  • the water channel 1 and the water channel 2 are connected in parallel, and the water channel 1 and the water channel 2 are respectively connected with the water inlet and the water outlet.
  • the annular groove is formed on the outer periphery of the groove and the heat sink, and a sealing ring is nested in the annular groove.
  • the outer edge of the IGBT module is supported on the heat sink and the sealing ring is pressed into the annular groove.
  • the IGBT module and the heat sink are fixed together by a number of screws.
  • the top inverter module and the capacitor module are electrically connected together through the laminated busbar, and the bottom inverter module and the capacitor module are electrically connected through the laminated busbar 2, and the external DC power source is passed through.
  • the laminated busbar is electrically connected to the capacitor module.
  • the top inverter module described above outputs the alternating current through the first group of alternating copper bus
  • the current circuit board of the top inverter module is provided with a plurality of current sensors, and a copper column and copper are disposed in the middle of each current sensor.
  • the column passes through the middle of the current sensor, and the IGBT module of the top inverter module is electrically connected to the first group of alternating copper bus through the copper column;
  • the inverter module at the bottom outputs the alternating current through the second group of alternating copper bus.
  • the bottom of the inverter module has a plurality of current sensors 2 on the driving circuit board, and a copper column is arranged in the middle of each current sensor 2, and the copper column is from the current sensor.
  • the middle passes through the copper column to electrically connect the IGBT module of the inverter module at the bottom with the second group of AC copper.
  • control circuit board is installed inside the controller box, and the control circuit boards of the two inverter modules are connected to the outside through the transfer circuit board.
  • the interface panel is disposed on the front surface of the heat sink, and the outlet panel is provided with a water outlet connector, a DC input terminal, a three-phase AC output terminal, a three-phase AC output terminal 2, and a low voltage signal.
  • the connector, the water outlet connector is connected to the water outlet of the cooling water channel, the DC input terminal is electrically connected with the laminated busbar, and the three-phase AC output terminal is electrically connected with the first group of AC copper wires, and the three-phase AC output is connected.
  • Terminal 2 is electrically connected to the second group of alternating copper bus bars, and the low voltage signal connector is electrically connected to the transfer circuit board.
  • the interface panel described above blocks the opening on the front side of the controller box, and a water inlet connector is arranged on the back of the controller box, and the water inlet connector is connected to the water inlet on the radiator.
  • the opening of the cavity described above is located on the back surface of the heat sink, and the connecting portion of the capacitor module and the laminated bus bar 1 and the laminated bus bar 2 is located at the opening of the cavity.
  • the invention has the following effects:
  • a heat sink is installed in the controller box, a cavity is opened in the middle of the heat sink, and the capacitor module is installed in the cavity.
  • the two inverter modules are respectively mounted on the top and bottom of the heat sink, on the heat sink.
  • the cooling water channel is provided and the water inlet and the water outlet connected with the cooling water channel are provided, and the capacitor module and the two inverter modules are radiated through the cooling water channel, the structure is simple and compact, the cost is relatively low, and the inverter can be effectively inverted
  • the module and the capacitor module dissipate heat, the heat dissipation effect is ideal, and the operation of the motor controller is stable and reliable;
  • the inverter module includes an IGBT module, a driving circuit board and a control circuit board.
  • the driving circuit board and the control circuit board are sequentially mounted on the top surface of the IGBT module, and the modularity is high, and it is convenient to be installed in the motor controller, and the entire module can be As a component with special test tooling, it can be tested and adjusted before the final assembly of the product, which can improve the batch assembly and simplify the design as a standard module, which can improve the installation efficiency of mass production;
  • the needle bed is extended downward on the bottom surface of the IGBT module, a heat dissipation channel is formed between the needle beds, and a groove is formed on the top surface and the bottom surface of the heat sink, and the groove is connected with the cooling water channel, and the two inverter modules They are respectively installed on the top surface and the bottom surface of the heat sink, and the needle bed on the inverter module protrudes into the groove on the heat sink, and the structure is simple and compact, and the heat dissipation effect is ideal;
  • Waterway 1 and Waterway 2 are respectively located on both sides of the radiator, and two grooves are arranged between the channel 1 and the channel 2, and the water channel 1 and the channel 2 on both sides of the radiator are connected in parallel through two grooves, and the channel 1 And water
  • the second channel is connected with the water inlet and the water outlet respectively.
  • An annular groove is formed on the periphery of the groove and the heat sink, and a sealing ring is nested inside the annular groove.
  • the outer edge of the IGBT module is supported on the heat sink and the sealing ring is pressed inside the annular groove to ensure sealing.
  • the installation method is simple and reliable;
  • An adapter circuit board is installed in the controller box, and the control circuit boards of the two inverter modules are connected to the outside through the adapter circuit board, and by sharing a piece of the adapter circuit board, the inside of the controller box can be saved. Space, but also can save production costs and improve market competitiveness;
  • An interface panel is arranged on the front surface of the radiator, and a water outlet connector, a DC input terminal, a three-phase AC output terminal, a three-phase AC output terminal 2 and a low voltage signal connector are arranged on the interface panel, and the layout is neat and externally connected. Convenience.
  • Figure 1 is a perspective view of the present invention
  • Figure 2 is an exploded view of the present invention
  • Figure 3 is an exploded view of the present invention without a controller housing
  • Figure 4 is another exploded view of the present invention without a controller housing
  • Figure 5 is a plan view of the present invention.
  • Figure 6 is a cross-sectional view taken along line A-A of Figure 5;
  • Figure 7 is a partial enlarged view of B-B of Figure 6;
  • Figure 8 is a perspective view of the heat sink of the present invention.
  • Figure 9 is a circuit diagram showing the connection of one of the inverter modules to the capacitor module of the present invention.
  • Embodiment 1 As shown in FIG. 1 to FIG. 9, the present invention is a motor controller including a controller box.
  • the body 1, the capacitor module 2 and the two inverter modules 3 are mounted with a heat sink 4 inside the controller box 1, a cavity 41 is opened in the middle of the heat sink 4, and the capacitor module 2 is mounted inside the cavity 41, two The inverter modules 3 are respectively mounted on the top and bottom of the radiator 4, and the cooling water channel 42 is opened on the radiator 4 and is provided with a water inlet 43 and a water outlet 44 communicating with the cooling water channel 42, and the capacitor module is passed through the cooling water channel 42. 2 and two inverter modules 3 for heat dissipation.
  • the inverter module 3 includes an IGBT module 32, a drive circuit board 33, and a control circuit board 34.
  • the drive circuit board 33 and the control circuit board 34 are sequentially mounted on the top surface of the IGBT module 32.
  • the IGBT module 32 uses a 6-in-1 IGBT module, and the capacitor module 2 is connected to the DC bus (parallel to both ends of the DC bus) to provide a ripple current to the inverter module 3.
  • the needle bed 311 is protruded downward from the bottom surface of the IGBT module 32, and a heat dissipating water channel 3110 is formed between the needle bed 311.
  • a groove 45 is formed on the top surface and the bottom surface of the heat sink 4, and the groove 45 is connected to the cooling water channel 42.
  • the two inverter modules 3 are respectively mounted on the top surface and the bottom surface of the heat sink 4.
  • the needle bed 311 on the inverter module 3 extends into the recess 45 on the heat sink 4, and the heat generated when the IGBT module 32 operates It is transmitted to the needle bed 311 of the IGBT module 32, and the cooling water flowing from the groove 45 carries away the heat on the needle bed 311 to achieve heat dissipation to the inverter module 3.
  • the cooling water channel 42 includes a water channel one 421 and a water channel two 422.
  • the water channel one 421 and the water channel two 422 are respectively located at two sides of the radiator 4, and the two grooves 45 are arranged side by side between the water channel one 421 and the water channel two 422, through two
  • the groove 45 connects the water channel 421 and the water channel 422 on both sides of the radiator 4 in parallel, and the water channel 421 and the water channel 422 communicate with the water inlet 43 and the water outlet 44, respectively. That is, two grooves 45, a water channel 421, and a water channel two 422 are formed to surround the cavity 41, and the heat sink 4 is made of a material with good heat dissipation performance, and the heat generated by the capacitor module 2 passes through the heat sink 4. After the transfer, it is carried away by the cooling water flowing through the water channel 421, the groove 45 and the water channel 422, thereby achieving heat dissipation to the capacitor module 2.
  • the water inlet 43 is adjacent to the bottom of the heat sink 4, and the water outlet 44 is adjacent to the top of the heat sink 4, and the area of the groove 45 at the bottom is smaller than the area of the groove 45 at the top.
  • the heat sink 4 is provided with through holes 480, 481, and the through holes 480, 481 are respectively connected with the water channel 421 and the water channel 422, and the sealing holes are installed in the through holes 480, 481 (Fig.
  • the sealing plug blocks part of the space inside the through holes 480, 481, and the remaining space allows the cooling water of the cooling water channel 42 to flow therein, thereby
  • the cooling water entering from the water inlet 43 near the bottom flows into the groove 45 at the top of the radiator 4 through the water channel 421, and the cooling water flowing out from the groove 45 at the bottom passes through the water channel 422 and is located at the radiator. 4
  • the water outlet 44 at the top flows out.
  • An annular groove 46 is defined in the periphery of the recess 45 and the heat sink 4, and a sealing ring 5 is nested in the annular groove 46.
  • the outer edge of the IGBT module 31 is supported on the heat sink 4 and the sealing ring 5 is pressed against Inside the annular groove 46, the sealing property is ensured, and the cooling water is prevented from flowing out from the edge of the groove 45, thereby causing damage to the electronic components in the motor controller, thereby improving the safety and reliability of the motor controller.
  • the IGBT module 31 and the heat sink 4 are mounted and fixed together by a plurality of screws (not shown).
  • the top inverter module 3 and the capacitor module 2 are electrically connected together by a laminated bus bar 61, and the bottom inverter module 3 and the capacitor module 2 are electrically connected together by a laminated busbar 62, external DC.
  • the power source is electrically connected to the capacitor module 2 through the laminated bus bar 61.
  • the inverter module 3 at the top outputs AC power through the first group of AC copper bars 71.
  • the current circuit board 33 of the top inverter module 3 is provided with three current sensors 81, and a copper is disposed between each current sensor 81. Column 9, the copper column 9 passes through the middle of the current sensor 81, and the IGBT module 32 of the top inverter module 3 is electrically connected to the first group of alternating copper bus 71 through the copper column 9;
  • the inverter module 3 at the bottom outputs AC power through the second group of AC copper bars 72.
  • the current circuit board 33 of the inverter module 3 at the bottom is provided with three current sensors 82, and a copper is disposed between each current sensor 82.
  • the control circuit board 34 is mounted and fixed on the heat sink 4 through a plurality of support columns 11, and a notch portion 340 is disposed on the inner side of the control circuit board 34 to leave a space for the first group of AC copper bars 71 and the second group of AC copper bars. 72 connection installation.
  • An adapter circuit board 10 is mounted on the side of the heat sink 4 and inside the controller cabinet 1.
  • the control circuit board 34 of the two inverter modules 3 is connected to the outside through the patch circuit board 10, and a common transmission line is shared.
  • the board 10 can save a limited space inside the controller box 1, and can also save production cost and improve market competitiveness.
  • An interface panel 47 is disposed on the front surface of the heat sink 4.
  • the water outlet connector 111, the DC input terminal 112, the three-phase AC output terminal 113, the three-phase AC output terminal 114, and the low voltage signal connector 115 are disposed on the interface panel 47.
  • the three-phase AC output terminal 113 is near the top of the interface panel 47
  • the three-phase AC output terminal two 114 is near the bottom of the interface panel 47
  • the water outlet connector 111 is connected to the water outlet 44 of the cooling water channel 42
  • the DC input terminal 112 is laminated.
  • the busbars 61 are electrically connected together, the three-phase AC output terminal 113 is electrically connected to the first group of AC copper bars 71, and the three-phase AC output terminal two 114 is electrically connected to the second group of AC copper bars 72.
  • the signal connector 115 is electrically connected to the transit circuit board 10.
  • the interface panel 47 blocks the opening on the front side of the controller casing 1.
  • a water inlet joint 116 is provided, and the water inlet joint 116 is connected to the water inlet 43 on the radiator 4.
  • the opening 410 of the cavity 41 is located on the back surface of the heat sink 4, and the connection portion of the capacitor module 2 with the laminated bus bar 61 and the laminated bus bar 62 is located at the opening 410 of the cavity 41.
  • the stacked busbars are 61 pairs of the three pairs of interfaces 21 above the capacitor module 2 and the top inverter module 3 respectively.
  • the IGBT modules 32 are electrically connected together, and the stacked bus bars 62 electrically connect the three pairs of interfaces 21 below the capacitor module 2 with the IGBT modules 32 of the bottom inverter module 3.

Abstract

一种电机控制器，包括控制器箱体（1）、电容模块（2）和两个逆变模块（3），在控制器箱体里面安装有散热器（4），在散热器中间开设有空腔（41），电容模块安装在空腔里面，两个逆变模块分别安装在散热器的顶部和底部上，在散热器上开设有冷却水道（42）并设置有与冷却水道连通的进水口（43）和出水口（44），通过冷却水道对电容模块和两个逆变模块进行散热。该电机控制器集成有两个逆变模块，结构简单、紧凑，成本相对较低，而且可以有效地对逆变模块和电容模块就行散热，散热效果理想，电机控制器的运行稳定可靠。

Description

一种电机控制器 技术领域：
本发明涉及一种电机控制器，属于电动汽车领域。
背景技术：
在传统的混合动力汽车里面，如果需要控制驱动电机和发电机则需要在电动汽车里面配备两个逆变模块，通过逆变模块控制驱动电机和发电机运转，但是两个逆变模块就需要两台电机控制器，这必然会占据电机汽车里面有限的空间，而且成本相对高昂，不符合现在电机汽车低成本、小体积的发展趋势，这种结构必然会必淘汰。
现在逐渐出现有在一台电机控制器集成有两个逆变模块的电机控制器结构，电容模块安装在电机控制器的后端，两个逆变模块层叠安装在电机控制器的前端，这种电机控制器结构占据的空间也相对较大，而且散热效果十分不理想，依靠电机控制器底面上的冷却难以对电容模块和两个逆变模块进行散热，如果散热问题不能够有效地解决，势必影响电机控制器的运行效率，如果温度过高甚至可能出现安全事故，因此有迫切的需求解决集成有两个逆变模块的电机控制器的散热问题。
发明内容：
本发明的目的是提供一种电机控制器，该电机控制器集成有两个逆变模块，结构简单、紧凑，成本相对较低，而且可以有效地对逆变模块和电容模块就行散热，散热效果理想，电机控制器的运行稳定可靠。
本发明的目的是通过下述技术方案予以实现的。
一种电机控制器，包括控制器箱体、电容模块和两个逆变模块，在控制器箱体里面安装有散热器，在散热器中间开设有空腔，电容模块安装在空腔里面，两个逆变模块分别安装在散热器的顶部和底部上，在散热器上开设有冷却水道并设置有与冷却水道连通的进水口和出水口，通过冷却水道对电容模块和两个逆变模块进行散热。
上述所述的逆变模块包括IGBT模块、驱动线路板和控制线路板，驱动线路板和控制线路板依次安装在IGBT模块的顶面上，IGBT模块的底面上往下伸出针床，针床之间形成一散热水道，在散热器的顶面和底面上都开设有凹槽，凹槽与冷却水道连通，两个逆变模块分别安装在散热器的顶面和底面上，逆变模块上的针床伸入到散热器上的凹槽里面。
上述所述的冷却水道包括水道一和水道二，水道一和水道二分别位于散热器的两侧，两个凹槽设置在水道一和水道二之间，通过两个凹槽把散热器两侧的水道一和水道二并联起来，水道一和水道二分别与进水口和出水口连通。
上述所述的在凹槽的外围、散热器上开设有环形槽，在环形槽里面嵌套安装有密封圈，IGBT模块的外侧边缘支承在散热器上并把密封圈压紧在环形槽里面，IGBT模块与散热器之间通过若干螺钉安装固定在一起。
上述所述的顶部的逆变模块与电容模块之间通过叠层母排一电连接在一起，底部的逆变模块与电容模块之间通过叠层母排二电连接在一起，外部直流电源通过叠层母排一与电容模块电连接在一起。
上述所述的顶部的逆变模块通过第一组交流铜排往外输出交流电，顶部的逆变模块的驱动线路板上设置有若干电流传感器一，在每个电流传感器一中间设置有一铜柱，铜柱从电流传感器一中间穿过，通过铜柱把顶部的逆变模块的IGBT模块与第一组交流铜排电连接在一起；
底部的逆变模块通过第二组交流铜排往外输出交流电，底部的逆变模块的驱动线路板上设置有若干电流传感器二，在每个电流传感器二中间设置有一铜柱，铜柱从电流传感器二中间穿过，通过铜柱把底部的逆变模块的IGBT模块与第二组交流铜排电连接在一起。
上述所述的在控制器箱体里面安装有转接线路板，两个逆变模块的控制线路板通过转接线路板与外部建立连接。
上述所述的在散热器的正面上设置有接口面板，在接口面板上设置有出水接头、直流输入端子、三相交流输出端子一、三相交流输出端子二和低压信号 连接器，出水接头与冷却水道的出水口接通，直流输入端子与叠层母排一电连接在一起，三相交流输出端子一与第一组交流铜排电连接在一起，三相交流输出端子二与第二组交流铜排电连接在一起，低压信号连接器与转接线路板电连接在一起。
上述所述的接口面板封堵住控制器箱体正面的开口，在控制器箱体的背面上设置有进水接头，进水接头与散热器上的进水口接通。
上述所述的空腔的开口位于散热器的背面上，电容模块与叠层母排一和叠层母排二的连接部分位于空腔的开口处。
本发明与现有技术相比，具有如下效果：
1)在控制器箱体里面安装有散热器，在散热器中间开设有空腔，电容模块安装在空腔里面，两个逆变模块分别安装在散热器的顶部和底部上，在散热器上开设有冷却水道并设置有与冷却水道连通的进水口和出水口，通过冷却水道对电容模块和两个逆变模块进行散热，结构简单、紧凑，成本相对较低，而且可以有效地对逆变模块和电容模块就行散热，散热效果理想，电机控制器的运行稳定可靠；
2)逆变模块包括IGBT模块、驱动线路板和控制线路板，驱动线路板和控制线路板依次安装在IGBT模块的顶面上，模块化程度高，方便安装到电机控制器里面，整个模块可以作为一个组件配合专用的测试工装后，在产品总装前测试、联调好，可提高批量总装，同时可作为一个标准模块简化设计，可提高批量生产的安装效率；
3)IGBT模块的底面上往下伸出针床，针床之间形成一散热水道，在散热器的顶面和底面上都开设有凹槽，凹槽与冷却水道连通，两个逆变模块分别安装在散热器的顶面和底面上，逆变模块上的针床伸入到散热器上的凹槽里面，结构简单紧凑，散热效果理想；
4)水道一和水道二分别位于散热器的两侧，两个凹槽设置在水道一和水道二之间，通过两个凹槽把散热器两侧的水道一和水道二并联起来，水道一和水 道二分别与进水口和出水口连通，设计合理、巧妙，充分利用散热器的空间，使得可以通过冷却水道对电容模块和两个逆变模块进行散热；
5)在凹槽的外围、散热器上开设有环形槽，在环形槽里面嵌套安装有密封圈，IGBT模块的外侧边缘支承在散热器上并把密封圈压紧在环形槽里面，保证密封性，避免冷却水从凹槽的边缘往外流出从而造成电机控制器里面电子元器件的损坏，提高电机控制器的安全性和可靠性，IGBT模块与散热器之间通过若干螺钉安装固定在一起，安装方式简单、牢靠；
6)在控制器箱体里面安装有转接线路板，两个逆变模块的控制线路板通过转接线路板与外部建立连接，通过共用一块转接线路板，可以节省控制器箱体里面有限的空间，同时也可以节省生产成本，提高市场竞争力；
7)在散热器的正面上设置有接口面板，在接口面板上设置有出水接头、直流输入端子、三相交流输出端子一、三相交流输出端子二和低压信号连接器，布局整洁，对外连接方便。
附图说明：
图1是本发明的立体图；
图2是本发明的分解图；
图3是本发明没有安装控制器箱体的一个分解图；
图4是本发明没有安装有控制器箱体的另一个分解图；
图5是本发明的俯视图；
图6是图5中A-A剖视图；
图7是图6中B-B局部放大图；
图8是本发明散热器的透视图；
图9是本发明其中一个逆变模块与电容模块连接的电路图。
具体实施方式：
下面通过具体实施例并结合附图对本发明作进一步详细的描述。
实施例一：如图1至图9所示，本发明是一种电机控制器，包括控制器箱 体1、电容模块2和两个逆变模块3，在控制器箱体1里面安装有散热器4，在散热器4中间开设有空腔41，电容模块2安装在空腔41里面，两个逆变模块3分别安装在散热器4的顶部和底部上，在散热器4上开设有冷却水道42并设置有与冷却水道42连通的进水口43和出水口44，通过冷却水道42对电容模块2和两个逆变模块3进行散热。所述的逆变模块3包括IGBT模块32、驱动线路板33和控制线路板34，驱动线路板33和控制线路板34依次安装在IGBT模块32的顶面上。所述的IGBT模块32采用6合1的IGBT模块，电容模块2用于与直流母线连接(并联于直流母线两端)，为逆变模块3提供纹波电流。
IGBT模块32的底面上往下伸出针床311，针床311之间形成一散热水道3110，在散热器4的顶面和底面上都开设有凹槽45，凹槽45与冷却水道42连通，两个逆变模块3分别安装在散热器4的顶面和底面上，逆变模块3上的针床311伸入到散热器4上的凹槽45里面，IGBT模块32工作时产生的热量会传递到IGBT模块32的针床311上，从凹槽45流过的冷却水会带走针床311上的热量，实现对逆变模块3的散热。冷却水道42包括水道一421和水道二422，水道一421和水道二422分别位于散热器4的两侧，两个凹槽45并排地设置在水道一421和水道二422之间，通过两个凹槽45把散热器4两侧的水道一421和水道二422并联起来，水道一421和水道二422分别与进水口43和出水口44连通。即形成了两个凹槽45、水道一421和水道二422包围空腔41分布的格局，而且散热器4采用散热性能好的材料制造而成，电容模块2工作时产生的热量经过散热器4传递之后会被从水道一421、凹槽45和水道二422流过的冷却水带走，实现对电容模块2的散热。
进水口43靠近于散热器4的底部，出水口44靠近与散热器4的顶部，底部的凹槽45的面积少于顶部的凹槽45的面积。在底部的凹槽45的两侧、散热器4上开设有通孔480、481，通孔480、481分别与水道一421和水道二422连通，在通孔480、481安装有密封塞(图中未示出)，密封塞堵住通孔480、481里面的部分空间，剩余的空间允许冷却水道42的冷却水在里面流动，从而可以 实现从靠近底部的进水口43进入的冷却水通过水道一421流入到位于散热器4顶部的凹槽45里面，和实现从底部的凹槽45流出的冷却水经过水道二422后从位于散热器4顶部的出水口44流出。
在凹槽45的外围、散热器4上开设有环形槽46，在环形槽46里面嵌套安装有密封圈5，IGBT模块31的外侧边缘支承在散热器4上并把密封圈5压紧在环形槽46里面，保证密封性，避免冷却水从凹槽45的边缘往外流出从而造成电机控制器里面电子元器件的损坏，提高电机控制器的安全性和可靠性。IGBT模块31与散热器4之间通过若干螺钉(图中未示出)安装固定在一起。
顶部的逆变模块3与电容模块2之间通过叠层母排一61电连接在一起，底部的逆变模块3与电容模块2之间通过叠层母排二62电连接在一起，外部直流电源通过叠层母排一61与电容模块2电连接在一起。
顶部的逆变模块3通过第一组交流铜排71往外输出交流电，顶部的逆变模块3的驱动线路板33上设置有3个电流传感器一81，在每个电流传感器一81中间设置有一铜柱9，铜柱9从电流传感器一81中间穿过，通过铜柱9把顶部的逆变模块3的IGBT模块32与第一组交流铜排71电连接在一起；
底部的逆变模块3通过第二组交流铜排72往外输出交流电，底部的逆变模块3的驱动线路板33上设置有3个电流传感器二82，在每个电流传感器二82中间设置有一铜柱9，铜柱9从电流传感器二82中间穿过，通过铜柱9把底部的逆变模块3的IGBT模块32与第二组交流铜排72电连接在一起。
控制线路板34通过若干支承柱11安装固定在散热器4上，并且在控制线路板34的内侧设置有缺口部340，以留有空间方便第一组交流铜排71、第二组交流铜排72的连接安装。
在散热器4的侧边、控制器箱体1里面安装有转接线路板10，两个逆变模块3的控制线路板34通过转接线路板10与外部建立连接，通过共用一块转接线路板10，可以节省控制器箱体1里面有限的空间，同时也可以节省生产成本，提高市场竞争力。
在散热器4的正面上设置有接口面板47，在接口面板47上设置有出水接头111、直流输入端子112、三相交流输出端子一113、三相交流输出端子二114和低压信号连接器115，三相交流输出端子一113靠近接口面板47的顶部，三相交流输出端子二114靠近接口面板47的底部，出水接头111与冷却水道42的出水口44接通，直流输入端子112与叠层母排一61电连接在一起，三相交流输出端子一113与第一组交流铜排71电连接在一起，三相交流输出端子二114与第二组交流铜排72电连接在一起，低压信号连接器115与转接线路板10电连接在一起。
接口面板47封堵住控制器箱体1正面的开口，在控制器箱体1的背面上设置有进水接头116，进水接头116与散热器4上的进水口43接通。空腔41的开口410位于散热器4的背面上，电容模块2与叠层母排一61和叠层母排二62的连接部分位于空腔41的开口410处。电容模块2上共有6对，12个接口21，6对接口21分为上下两列均匀排布，叠层母排一61把电容模块2上方的3对接口21分别与顶部逆变模块3的IGBT模块32电连接在一起，叠层母排二62把电容模块2下方的3对接口21与底部逆变模块3的IGBT模块32电连接在一起。
以上实施例为本发明的较佳实施方式，但本发明的实施方式不限于此，其他任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均为等效的置换方式，都包含在本发明的保护范围之内。

Claims (10)

  1. 一种电机控制器，包括控制器箱体(1)、电容模块(2)和两个逆变模块(3)，其特征在于：在控制器箱体(1)里面安装有散热器(4)，在散热器(4)中间开设有空腔(41)，电容模块(2)安装在空腔(41)里面，两个逆变模块(3)分别安装在散热器(4)的顶部和底部上，在散热器(4)上开设有冷却水道(42)并设置有与冷却水道(42)连通的进水口(43)和出水口(44)，通过冷却水道(42)对电容模块(2)和两个逆变模块(3)进行散热。
  2. 根据权利要求1所述的一种电机控制器，其特征在于：所述的逆变模块(3)包括IGBT模块(32)、驱动线路板(33)和控制线路板(34)，驱动线路板(33)和控制线路板(34)依次安装在IGBT模块(32)的顶面上，IGBT模块(32)的底面上往下伸出针床(311)，针床(311)之间形成一散热水道(3110)，在散热器(4)的顶面和底面上都开设有凹槽(45)，凹槽(45)与冷却水道(42)连通，两个逆变模块(3)分别安装在散热器(4)的顶面和底面上，逆变模块(3)上的针床(311)伸入到散热器(4)上的凹槽(45)里面。
  3. 根据权利要求2所述的一种电机控制器，其特征在于：所述的冷却水道(42)包括水道一(421)和水道二(422)，水道一(421)和水道二(422)分别位于散热器(4)的两侧，两个凹槽(45)并排地设置在水道一(421)和水道二(422)之间，通过两个凹槽(45)把散热器(4)两侧的水道一(421)和水道二(422)并联起来，水道一(421)和水道二(422)分别与进水口(43)和出水口(44)连通。
  4. 根据权利要求3所述的一种电机控制器，其特征在于：在凹槽(45)的外围、散热器(4)上开设有环形槽(46)，在环形槽(46)里面嵌套安装有密封圈(5)，IGBT模块(32)的外侧边缘支承在散热器(4)上并把密封圈(5)压紧在环形槽(46)里面，IGBT模块(32)与散热器(4)之间通过若干螺钉安装固定在一起。
  5. 根据权利要求2或3或4所述的一种电机控制器，其特征在于：顶部的 逆变模块(3)与电容模块(2)之间通过叠层母排一(61)电连接在一起，底部的逆变模块(3)与电容模块(2)之间通过叠层母排二(62)电连接在一起，外部直流电源通过叠层母排一(61)与电容模块(2)电连接在一起。
  6. 根据权利要求5所述的一种电机控制器，其特征在于：顶部的逆变模块(3)通过第一组交流铜排(71)往外输出交流电，顶部的逆变模块(3)的驱动线路板(33)上设置有若干电流传感器一(81)，在每个电流传感器一(81)中间设置有一铜柱(9)，铜柱(9)从电流传感器一(81)中间穿过，通过铜柱(9)把顶部的逆变模块(3)的IGBT模块(32)与第一组交流铜排(71)电连接在一起；
    底部的逆变模块(3)通过第二组交流铜排(72)往外输出交流电，底部的逆变模块(3)的驱动线路板(33)上设置有若干电流传感器二(82)，在每个电流传感器二(82)中间设置有一铜柱(9)，铜柱(9)从电流传感器二(82)中间穿过，通过铜柱(9)把底部的逆变模块(3)的IGBT模块(32)与第二组交流铜排(72)电连接在一起。
  7. 根据权利要求6所述的一种电机控制器，其特征在于：在控制器箱体(1)里面安装有转接线路板(10)，两个逆变模块(3)的控制线路板(34)通过转接线路板(10)与外部建立连接。
  8. 根据权利要求7所述的一种电机控制器，其特征在于：在散热器(4)的正面上设置有接口面板(47)，在接口面板(47)上设置有出水接头(111)、直流输入端子(112)、三相交流输出端子一(113)、三相交流输出端子二(114)和低压信号连接器(115)，出水接头(111)与冷却水道(42)的出水口(44)接通，直流输入端子(112)与叠层母排一(61)电连接在一起，三相交流输出端子一(113)与第一组交流铜排(71)电连接在一起，三相交流输出端子二(114)与第二组交流铜排(72)电连接在一起，低压信号连接器(115)与转接线路板(10)电连接在一起。
  9. 根据权利要求8所述的一种电机控制器，其特征在于：接口面板(47) 封堵住控制器箱体(1)正面的开口，在控制器箱体(1)的背面上设置有进水接头(116)，进水接头(116)与散热器(4)上的进水口(43)接通。
  10. 根据权利要求9所述的一种电机控制器，其特征在于：空腔(41)的开口(410)位于散热器(4)的背面上，电容模块(2)与叠层母排一(61)和叠层母排二(62)的连接部分位于空腔(41)的开口(410)处。
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