WO2021022575A1

WO2021022575A1 - New-type electric motor controller, electric motor controller manufacturing method, and electric vehicle

Info

Publication number: WO2021022575A1
Application number: PCT/CN2019/100289
Authority: WO
Inventors: 刘贵生; 吴庆国; 刘志钢; 吕学文; 吕佳明; 许嘉慧
Original assignee: 北斗航天汽车（北京）有限公司
Priority date: 2019-08-02
Filing date: 2019-08-13
Publication date: 2021-02-11
Also published as: CN110417309A

Abstract

Disclosed is a new-type electric motor controller, comprising a shell (1). A capacitor body (2), a cooling water pipe column, an IGBT connection column (10) and a capacitor direct-current output terminal (7) are installed at the bottom of the shell (1); a direct-current quick-connection plug (8) is arranged on the shell (1); each capacitor body (2), each cooling water pipe column and each IGBT connection column (10) are fixed to an inner wall of the shell (1) by means of a heat-conducting insulating packaging filling rubber block to form a whole; the capacitor direct-current output terminal (7) and one end of the direct-current quick-connection plug (8) connected with same are both arranged in the heat-conducting insulating packaging filling rubber block; an upper end opening of the cooling water pipe column extends out of the heat-conducting insulating packaging filling rubber block, and a lower end pipe opening of the cooling water pipe column is connected to the shell (1) in a sealed manner; an upper end of the capacitor direct-current output terminal (7) extends out of the heat-conducting insulating packaging filling rubber block; and an upper end of the IGBT connection column (10) extends out of the heat-conducting insulating packaging filling rubber block. Further disclosed are a manufacturing method for the electric motor controller, and an electric vehicle comprising the electric motor controller. According to the invention, by means of the design of the electric motor controller, the technical problems of a poor cooling effect, overheating during use and easily damaging the capacitor body inside the controller existing in the prior art are thus solved.

Description

Novel motor controller, motor controller manufacturing method and electric vehicle

Technical field

The invention relates to the technical field of motor controllers, in particular to a new type of motor controller, a method for manufacturing the motor controller, and an electric vehicle.

Background technique

The motor controller inevitably generates heat during its operation. Therefore, it is necessary to conduct heat to the outside in a timely and rapid manner through the heat dissipation structure; otherwise, it will affect the function of the controller's related electronic components, and even the controller's related electronic components will be burned, and eventually the motor will not work, so the controller's heat dissipation performance The quality is directly related to the service life of the controller.

Limited by material cost and material characteristics, the current temperature resistance of the capacitor body can only reach 105°C, and the temperature resistance of other parts inside the motor controller can reach 125°C. The capacitor body has become the shortest increase in the upper limit of the motor controller power. Therefore, providing a good cooling environment for the capacitor body is the current research direction.

Patent CN201920401988.0 discloses a motor controller housing assembly. Although a number of heat dissipation fins are arranged on the outer surface of the housing, it is still unable to directly contact the capacitor body, resulting in poor heat dissipation efficiency.

Therefore, in view of the above-mentioned problems, the present invention urgently needs to provide a new type of motor controller, a method of manufacturing the motor controller, and an electric vehicle.

Summary of the invention

The purpose of the present invention is to provide a new type of motor controller, a method for manufacturing the motor controller, and an electric vehicle, through the design of the new type of motor controller to solve the problem of poor cooling effect of the internal capacitor body of the controller in the prior art, and overheated use. Fragile technical issues.

The invention provides a new type of motor controller, which includes a shell. A plurality of capacitor bodies arranged side by side and spaced apart are installed at the bottom of the shell. A plurality of cooling water pipe columns, a plurality of IGBT connection columns and a capacitor DC output are arranged in the shell. Terminal, the shell is provided with a DC quick-connect plug directly connected to the DC output terminal of the capacitor; the inner wall of the shell and each of the capacitor body, each cooling water pipe column and each IGBT connecting column are fixed to One piece, and the height of the thermally conductive insulating package filling rubber block is higher than the height of each capacitor body. The capacitor DC output terminal and one end of the DC quick connect plug connected to the capacitor DC output terminal are all placed in the thermally conductive insulating package filling rubber block; cooling water pipe column The upper port extends out of the thermally conductive and insulating packaging filling rubber block to communicate with the cooling water channel on the IGBT module, the lower end of the cooling water pipe string is sealed to the shell, and the upper end of the capacitor DC output terminal extends from the thermally conductive insulating packaging filling rubber block and the IGBT module Connected, the upper end of the IGBT connecting column extends out of the thermally conductive insulating packaging filling rubber block.

Preferably, a driving circuit board is stacked at intervals above the IGBT module, and a control circuit board is stacked at intervals above the driving circuit board; the driving circuit board is provided with IGBT output terminals, and conductive copper pillars are inserted into the IGBT output terminals. The bottom of the IGBT module goes deep into the IGBT module, and the top of the conductive copper pillar is connected with the AC quick connect plug on the shell.

Preferably, the end of the DC quick-connect plug connected to the capacitor DC output terminal is covered with a ferrite common mode inductor, and the ferrite common mode inductor is packaged in a thermally conductive and insulating package filling rubber block.

Preferably, the cooling water pipe string includes a water inlet pipe section and a water outlet pipe section. The upper ends of the water inlet pipe section and the water outlet pipe section both extend from the thermally conductive insulating packaging filling rubber block to respectively connect with the IGBT water inlet and the IGBT water outlet of the cooling water channel on the IGBT module. Connected, the bottom of the water inlet pipe section communicates with the water inlet on the shell, and the bottom of the water outlet pipe section communicates with the water outlet on the shell; the upper ports of the water inlet pipe section and the water outlet pipe section are sleeved with rubber sealing rings.

Preferably, a temperature sensor is encapsulated on the capacitor body.

Preferably, the top of the IGBT connecting column is provided with a through hole extending to the inside of the IGBT connecting column, the IGBT module is provided with a connecting hole corresponding to each through hole in the circumferential direction, and a connecting rod connected with the IGBT connecting column is inserted in the connecting hole. .

Preferably, a dedicated connector for direct connection with an external connector is inserted on the control circuit board.

Preferably, the shell is integrally cast; the material of the shell is aluminum alloy.

The present invention also includes a method for manufacturing a motor controller for manufacturing the novel motor controller as described in any one of the above, including the following steps: preparing a shell, and the inner bottom of the manufactured shell has a plurality of cooling water pipes Pillars and multiple IGBT connection pillars;

Install multiple capacitor bodies on the bottom of the shell so that the capacitor bodies are placed in the gap between the inner wall of the shell, each cooling water pipe column and each IGBT connection column, and the ferrite common mode inductor is sleeved in the DC deep into the shell On the quick-connect plug, connect the capacitor DC output terminal directly with the DC quick-connect plug on the housing, and use a thermally conductive insulating packaging filler to connect the capacitor body, cooling water pipe column, IGBT connection column, DC quick-connect plug, and capacitor DC output terminal The common mode inductor with ferrite is packaged at the bottom of the shell;

Outside the casing, the IGBT module and the driving circuit board are installed as a whole, and then the IGBT module and the driving circuit board are connected and fixed together with the IGBT connecting column through the connecting rod, so that the IGBT module and the driving circuit board are fixed above the capacitor body.

Insert the conductive copper column from the IGBT input terminal on the drive circuit board and insert it down into the IGBT module, and connect the AC quick connect plug on the shell to the conductive copper column;

Place the control circuit board on the top of each connecting rod and detachably connect with the connecting rod through bolts.

The present invention also includes an electric vehicle, including the novel motor controller as described in any one of the above.

Compared with the prior art, the novel motor controller, the method for manufacturing the motor controller, and the electric vehicle provided by the present invention have the following improvements:

1. In the present invention, a plurality of capacitor bodies arranged side by side and spaced apart are installed on the bottom of the shell. A plurality of cooling water pipe columns, a plurality of IGBT connection columns and a capacitor DC output terminal are arranged in the shell. The output terminal is directly connected to the DC quick-connect plug; the inner wall of the housing and each of the capacitor body, each cooling water pipe column and each IGBT connection column are fixed in one body by a thermally conductive and insulating packaging filler block, and the thermally conductive insulating packaging filler block The height is higher than the height of each capacitor body, the capacitor DC output terminal and one end of the DC quick connect plug connected to the capacitor DC output terminal are all placed in the thermally conductive insulating packaging filling block; the upper port of the cooling water pipe column extends out of the thermally conductive insulating packaging filling The rubber block is connected with the cooling water channel on the IGBT module, the lower end of the cooling water pipe string is sealed and connected with the shell, the upper end of the capacitor DC output terminal extends out of the thermally conductive insulating package and the filling rubber block is connected to the IGBT module, and the upper end of the IGBT connecting column extends out of thermally insulating The design of the packaging and filling rubber block, the bottom of the shell is arranged with a cooling water channel around the capacitor body to realize the real water cooling of the capacitor body, improve the high temperature resistance of the capacitor body, and increase the power limit of the motor controller. Provides strong hardware support; the capacitor body is directly glued and encapsulated on the bottom of the shell, which improves the space utilization inside the shell and maximizes the application of the shell space; the DC quick connect plug is directly connected to the capacitor DC output terminal, and It is placed in the thermally conductive and insulating packaging filling rubber block to improve the heat dissipation efficiency of the DC quick-connect plug and the capacitor DC output terminal, ensure the normal operation of the motor controller, and extend the use time of the motor controller; the design of the IGBT connection column is convenient for the IGBT module The installation and fixation of the IGBT module ensure the stability of the IGBT module. The structure design is simple, and there is no need to add multiple welding brackets. It is convenient to install and disassemble; the thermally conductive and insulating packaging filler block can include the capacitor body as a whole, increase the heat dissipation contact area, improve the heat dissipation efficiency, and conduct heat insulation The packaging and filling rubber block has certain elasticity, and at the same time increases the shock absorption and impact resistance of the capacitor body.

2. In the present invention, a driving circuit board is stacked at intervals above the IGBT module, and a control circuit board is stacked at intervals above the driving circuit board; the driving circuit board is provided with IGBT output terminals, and conductive copper pillars are inserted into the IGBT output terminals to conduct electricity. The bottom of the copper pillar goes deep into the IGBT module, and the top of the conductive copper pillar is connected to the AC quick-connect plug on the shell. It is stacked and arranged. The structure is simple and easy to install and disassemble. The IGBT output terminal is directly connected to the IGBT through the conductive copper pillar. The AC quick-connect plug connection does not need to increase the wiring harness inside the shell, avoiding the messy and excessive heat dissipation of the wiring harness of the shell, and the structure design is simple and convenient for processing.

3. According to the present invention, the end of the DC quick-connect plug connected to the capacitor DC output terminal is covered with a ferrite common mode inductor, and the ferrite common mode inductor is packaged in a thermally conductive insulating packaging filling rubber block. The ferrite common mode inductor It is placed in the thermally conductive and insulating packaging filling plastic block, which effectively reduces the heat of the ferrite common mode inductance and ensures the effective operation of the motor controller. The ferrite common mode inductance is designed in a ring shape and is fixed after being put on the DC quick connect plug. In the thermally conductive and insulating packaging filled plastic block, it is easy to install and save space.

4. The capacitor body in the present invention is encapsulated with a temperature sensor; a temperature sensor is arranged inside the capacitor, and a capacitor over-temperature protection mechanism is set up to monitor the temperature inside the capacitor body in real time to prevent the temperature of the capacitor body from exceeding the upper limit value, resulting in the capacitor body Damage to the capacitor body; improve the service life of the capacitor body.

Description of the drawings

In order to explain the specific embodiments of the present invention or the technical solutions in the prior art more clearly, the following will briefly introduce the drawings that need to be used in the specific embodiments or the description of the prior art. Obviously, the appendix in the following description The drawings are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative work.

Figure 1 is a schematic structural diagram (top view) of the motor controller in the present invention;

Figure 2 is a cross-sectional view of Figure 1 A-A;

Figure 3 is a B-B sectional view of Figure 1;

Figure 4 is a C-C cross-sectional view of Figure 1;

Figure 5 is a schematic structural diagram (stereoscopic view) of the motor controller of the present invention;

Fig. 6 is a schematic structural diagram (a perspective view) of the connecting rod in the present invention;

7 is a block diagram of the circuit connection relationship of the motor controller in the present invention;

Fig. 8 is a method for preparing the motor controller in the present invention.

Description of reference signs:

1. Shell; 2. Capacitor body; 3. IGBT module; 4. Drive circuit board; 5. Control circuit board; 6. Cooling water pipe column; 7. Capacitor DC output terminal; 8. DC quick connect plug; 9. Iron Oxygen common mode inductance; 61, water inlet pipe section; 62, water outlet pipe section; 101, water inlet; 102, water outlet; 10, IGBT connecting column; 11, connecting rod; 13, special connector; 41, IGBT output Terminal; 42, conductive copper column; 16, AC quick connect plug.

detailed description

The technical solutions of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.

In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. The indicated orientation or positional relationship is based on the orientation or positional relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the pointed device or element must have a specific orientation or a specific orientation. The structure and operation cannot therefore be understood as a limitation of the present invention. In addition, the terms "first", "second", and "third" are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance.

In the description of the present invention, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense, unless otherwise clearly specified and limited. For example, they can be fixed or detachable. Connected or integrally connected; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication between two components. For those of ordinary skill in the art, the specific meaning of the above-mentioned terms in the present invention can be understood in specific situations.

As shown in Figure 1, Figure 2, Figure 3, Figure 4, and Figure 5, a new type of motor controller in this embodiment includes a housing 1. A plurality of capacitors arranged side by side and spaced apart are installed on the bottom of the housing 1. The main body 2, a plurality of cooling water pipe columns, a plurality of IGBT connection columns 10 and a capacitor DC output terminal 7 are arranged in the case 1, and a DC quick connect plug 8 directly connected to the capacitor DC output terminal 7 is provided on the case 1; The inner wall of the body 1 and each of the capacitor bodies 2, each cooling water pipe column, and each IGBT connection column 10 are fixed in one body by a thermally conductive insulating packaging filling rubber block, and the height of the thermally conductive insulating packaging filling rubber block is higher than that of each capacitor body 2 Height, the capacitor DC output terminal 7 and one end of the DC quick-connect plug 8 connected to the capacitor DC output terminal 7 are all placed in the thermally conductive insulating packaging filling block; the upper port of the cooling water pipe column extends from the thermally conductive insulating packaging filling block and the IGBT The cooling water channel on the module 3 is connected, the lower end of the cooling water pipe column is sealed and connected with the shell 1, the upper end of the capacitor DC output terminal 7 extends out of the thermally conductive insulating packaging filling block to connect to the IGBT module 3, and the upper end of the IGBT connecting column 10 extends out of heat conduction Insulating packaging filled with plastic block.

In the present invention, a plurality of capacitor bodies 2 arranged side by side and spaced apart are installed at the bottom of the housing 1. A plurality of cooling water pipe columns, a plurality of IGBT connection columns 10 and a capacitor DC output terminal 7 are arranged in the housing 1. A DC quick-connect plug 8 directly connected to the capacitor DC output terminal 7 is provided; the inner wall of the housing 1 and each of the capacitor body 2, each cooling water pipe column, and each IGBT connection column 10 are fixed to The height of the integrated and thermally conductive insulating package filling rubber block is higher than the height of each capacitor body 2. The capacitor DC output terminal 7 and one end of the DC quick-connect plug 8 connected to the capacitor DC output terminal 7 are all placed in the thermally conductive insulating package filling rubber block ; The upper port of the cooling water pipe string extends out of the thermally insulating packaging filling rubber block to communicate with the cooling water channel on the IGBT module 3, the lower end of the cooling water pipe string is sealed and connected to the housing 1, and the upper end of the capacitor DC output terminal 7 extends out of the heat conduction insulation The package filling plastic block is connected to the IGBT module 3, and the upper end of the IGBT connecting post 10 extends out of the thermally conductive and insulating packaging filling plastic block. The bottom of the housing 1 is provided with a cooling water channel around the capacitor body to achieve real water to the capacitor body 2. Cooling improves the high temperature resistance level of the capacitor body, and provides strong hardware support for increasing the power limit of the motor controller; the capacitor body 2 is directly glued and encapsulated at the bottom of the shell 1 to increase the utilization space inside the shell 1 , So that the space of the shell 1 can be maximized; the DC quick connect plug 8 is directly connected to the capacitor DC output terminal 7 and placed in the thermally conductive insulating packaging filling rubber block, which improves the DC quick connect plug 8 and the capacitor DC output terminal 7 The heat dissipation efficiency of the motor controller ensures the normal operation of the motor controller and prolongs the use time of the motor controller; the design of the IGBT connecting column 10 facilitates the installation and fixation of the IGBT module 3, and ensures the stability of the IGBT module 3. The structure design is simple, and there is no need to add more The IGBT module 3 in the present invention uses Fuji M653 IGBT module; the thermally conductive and insulating packaging filler block can include the capacitor body as a whole to increase the heat dissipation contact area and improve the heat dissipation efficiency. The thermally conductive insulating packaging filler block Has a certain degree of flexibility, while increasing the shock absorption and impact resistance of the capacitor body.

The IGBT water inlet and the IGBT water outlet of the cooling water channel of the IGBT module of the present invention are both prior art, which are not shown in the figure, and will not be repeated here.

As shown in Figures 2, 3, and 4, in this embodiment, a drive circuit board 4 is stacked on top of the IGBT module 3 at intervals, and a control circuit board 5 is stacked on top of the drive circuit board 4; the drive circuit board 4 is provided with IGBT output terminal 41, a conductive copper pillar 42 is inserted into the IGBT output terminal 41, the bottom of the conductive copper pillar 42 penetrates into the IGBT module 3, and the top of the conductive copper pillar 42 is connected to the AC quick connect plug 16 on the housing 1.

In the present invention, a driving circuit board 4 is stacked at intervals above the IGBT module 3, and a control circuit board 5 is stacked at intervals above the driving circuit board 4; an IGBT output terminal 41 is provided on the driving circuit board 4, and the IGBT output terminal 41 is inserted with Conductive copper pillar 42. The bottom of the conductive copper pillar 42 penetrates into the IGBT module 3, and the top of the conductive copper pillar 42 is connected to the AC quick-connect plug 16 on the housing 1. The design is stacked, and the structure design is simple, which is convenient for installation and disassembly. , The IGBT output terminal 41 is directly connected to the AC quick-connect plug 16 through the conductive copper column 42, no need to increase the wiring harness inside the housing 1, avoiding the messy and excessive heat dissipation of the wiring harness of the housing 1. The structure design is simple and convenient Processing.

As shown in Figure 4, the end of the DC quick connect plug 8 connected to the capacitor DC output terminal 7 in this embodiment is covered with a ferrite common mode inductor 9, and the ferrite common mode inductor 9 is encapsulated in a thermally conductive and insulating packaging filling plastic block .

In the present invention, the end of the DC quick-connect plug 8 connected with the capacitor DC output terminal 7 is covered with a ferrite common mode inductor 9, and the ferrite common mode inductor 9 is packaged in a thermally conductive insulating package filling rubber block. The mode inductance 9 is placed in the thermally conductive and insulating packaging filling rubber block, which effectively reduces the heat of the ferrite common mode inductance 9 and ensures the effective operation of the motor controller. The ferrite common mode inductance is designed in a ring shape, and it is sleeved in the DC quick connect After the plug 8 is fixed in the thermally conductive and insulating packaging filling rubber block, it is easy to install and save space.

As shown in Figure 2, the cooling water pipe string in this embodiment includes a water inlet pipe section 61 and a water outlet pipe section 62. The upper ends of the water inlet pipe section 61 and the water outlet pipe section 62 extend from the thermally conductive and insulating packaging filling rubber block respectively to the IGBT module 3. The IGBT water inlet of the upper cooling water channel communicates with the IGBT water outlet, the bottom of the water inlet pipe section 61 communicates with the water inlet 101 on the housing 1, and the bottom of the water outlet pipe section 62 communicates with the water outlet 102 on the housing 1; The upper ports of the pipe section 61 and the water outlet pipe section 62 are both sleeved with rubber sealing rings; the rubber sealing rings are of the prior art, not shown in the figure, and will not be repeated here.

In the present invention, the cooling water pipe string 6 includes a water inlet pipe section 61 and a water outlet pipe section 62. The upper ends of the water inlet pipe section 61 and the water outlet pipe section 62 extend from the thermally conductive insulating packaging filling rubber block to respectively connect with the IGBT water inlet and the IGBT outlet of the IGBT module. The water inlet is connected, the bottom of the water inlet pipe section 61 is communicated with the water inlet on the housing 1, and the bottom of the water outlet pipe section 62 is connected with the water outlet on the housing 1. The cooling water channel is obtained through CAE analysis and optimization design. Inside the IGBT module Equipped with a cooling water channel, the IGBT module is also provided with a cold water inlet and a cold water outlet connected to the cooling water channel. The cold water inlet is connected with the water inlet pipe section 61, and the cold water outlet is connected with the water outlet pipe section 62. The structure design is simple, easy to process, and low water resistance. , The pressure difference is low, and the heat exchange efficiency to the capacitor body 2 is high; through the design of the rubber sealing ring, the tightness of the connection between the inlet pipe section 61 and the outlet pipe section 62 and the IGBT water inlet and IGBT water outlet respectively is ensured to avoid water seepage It will affect the normal operation of the motor controller.

The capacitor body 2 in the present invention is encapsulated with a temperature sensor; a temperature sensor is arranged inside the capacitor, and a capacitor over-temperature protection mechanism is set to monitor the temperature inside the capacitor body 2 in real time. The critical temperature of the capacitor body 2 can be reached during use, so that The motor controller runs at the maximum power, and at the same time, it prevents the temperature of the capacitor body 2 from exceeding the upper limit, causing damage to the capacitor body in the capacitor body 2; to increase the service life of the capacitor body 2, and the temperature sensor is not shown in the figure, which is a well-known technology , I won’t mention it here.

As shown in Figures 3 and 6, in this embodiment, the top of the IGBT connecting column 10 is provided with a through hole 1001 extending inside the IGBT connecting column 10, and the IGBT module 3 is provided with a connecting hole corresponding to each through hole 1001 in the circumferential direction. , The connecting hole is fitted with a connecting rod 11 connected to the IGBT connecting column 10; the connecting rod 11 includes a first connecting section 111 and a second connecting section 112 arranged at the upper end of the first connecting rod section 111, the first connecting rod section 111 Coaxially arranged with the second connecting section 112, the outer diameter of the first connecting section 111 is smaller than the outer diameter of the second connecting section 112, the top of the second connecting section 112 is provided with a threaded hole 113, and the outer wall of the first connecting section 111 is provided with an outer Thread, the cross section of the second connecting section 112 is polygonal.

In the present invention, a plurality of IGBT connecting pillars 10 are arranged in the housing 1, the upper end of the IGBT connecting pillar 10 protrudes from the top of the thermally conductive insulating packaging filling rubber block, and the top of the IGBT connecting pillar 10 is provided with a wear extending inside the IGBT connecting pillar 10 Hole 1001, IGBT module 3 is provided with a connecting hole corresponding to each through hole 1001 in the circumferential direction. The connecting hole is designed with connecting rod 11 connected with IGBT connecting column 10, which is convenient for installation and fixing of IGBT module 3 and convenient for disassembly. And maintenance, the installation structure is simple, and the manufacturing cost is reduced. The connecting rod 11 includes a first connecting section 111 and a second connecting section 112 arranged at the upper end of the first connecting rod section 111. The first connecting rod section 111 and the second connecting section 112 are the same The outer diameter of the first connecting section 111 is smaller than the outer diameter of the second connecting section 112, the top of the second connecting section 112 is provided with a threaded hole 113, the outer wall of the first connecting section 111 is provided with an external thread, and the second connecting section 112 The cross section of the connecting rod 11 is designed in a polygonal setting. The lower end of the connecting rod 11 is convenient to connect with the IGBT connecting column 10, the top of the connecting rod 11 is convenient to connect with the control circuit board 5, and the detachable connector 12 passes through the control circuit board 5 and the threaded hole 113 Screw connection.

As shown in FIG. 2, FIG. 3, FIG. 4, and FIG. 5, the control circuit board 5 in this embodiment is plugged with a dedicated connector 13 for directly connecting with the external connector 19.

The present invention facilitates the direct connection between the external plug 19 and the control circuit board 5 through the design of the control circuit board 5 with a special plug 13 for direct connection with the external plug 19, without the need to introduce a wiring harness, and is easy to process And assembly, saving the wiring harness inside the motor controller, thereby reducing the heat inside the controller, and the structure design is simple.

The casing 1 of the present invention is formed by integral casting; the material of the casing 1 is aluminum alloy; the weight is light and the structure is compact.

As shown in Figs. 2 and 4, the top end of the capacitor output terminal 7 of this embodiment extends from the thermally conductive and insulating packaging filling rubber block to overlap with the drive circuit board 4, and is fastened together by bolts.

In the present invention, the top of the capacitor DC output terminal 7 extends from the thermally insulating packaging filling rubber block to overlap with the drive circuit board 4, and the design of bolt fastening is integrated to realize the connection between the capacitor DC output terminal 7 and the drive circuit board 4. , The structure design is simple and the installation is convenient.

In the present invention, a vent hole is provided on the side wall of the housing 1 to facilitate the dissipation of heat inside the housing; the vent hole is a prior art, well-known in the art, and is not marked in the figure.

As shown in FIG. 5, the outer wall of the housing 1 in this embodiment is provided with a sheet metal fixing frame installation hole, and a sheet metal fixing frame 18 is installed on the sheet metal fixing frame installation hole.

According to the present invention, the outer wall of the housing 1 is provided with a sheet metal fixing frame mounting hole, and the sheet metal fixing frame mounting hole is equipped with a design for installing the sheet metal fixing frame 18, so that the relay can be installed on the sheet metal fixing frame 18, which can save the shell. The space inside the body 1 prevents too many internal components of the housing 1 from causing excessive temperature rise and affecting the normal operation of the motor controller.

As shown in FIG. 2 and FIG. 4, the capacitor DC output terminal 7 that penetrates from the thermally conductive insulating package filling rubber block in this embodiment is arranged in a bent configuration.

According to the present invention, the capacitor DC output terminal 7 which penetrates from the thermally conductive insulating packaging filling rubber block is arranged in a bent design, which facilitates the connection of the capacitor DC output terminal 7 and the driving circuit board 4.

The outer wall of the casing 1 of the present invention is provided with an AC quick-connect plug installation hole, and an AC quick-connect plug 16 is installed in the AC quick-connect plug installation hole.

As shown in Fig. 7, in this embodiment, a plurality of smoke sensors are arranged circumferentially in the housing 1. The smoke sensors are electrically connected to the central controller, and the switch of the motor controller is electrically connected to the central controller to monitor whether there is smoke in the housing in time. The fire source was found to ensure the safe and normal driving of the car.

The smoke sensor is a miniature smoke sensor produced by Zhengzhou Weisheng Electronic Technology Co., Ltd. The present invention aims to protect the overall electrical connection of the above-mentioned electrical device. The above-mentioned electrical device only completes the signal transmission process, and does not apply software to the signal itself. Processing.

As shown in FIG. 8, the present invention also provides a method for manufacturing a motor controller for manufacturing the novel motor controller described in any one of the above, including the following steps:

S1) Prepare the housing 1. The inner bottom of the housing 1 is provided with multiple cooling water pipe columns and multiple IGBT connection columns 10; the design purpose of the multiple cooling water pipe columns is to directly cool the capacitor body 2 in the capacitor body 2. The cooling water channel is set in the circumferential direction to realize the real water cooling of the capacitor body 2. After the optimization design of CAE, the cooling effect is good, and the normal operation of the capacitor body 2 is ensured. When the temperature in the motor controller exceeds 105 ℃, the water is on the capacitor body. 2 cooling, the temperature of the capacitor body 2 will not exceed 105°, within its normal working range, so as to ensure the normal operation of the motor controller; the design of multiple IGBT connection posts 10 is to achieve the installation and fixation of the IGBT module , To ensure that the IGBT module is firmly inside the housing 1 to ensure the normal operation of the motor controller.

S2) Mount a plurality of capacitor bodies on the bottom of the casing 1, so that the capacitor bodies are placed in the gap between the inner wall of the casing 1, the cooling water pipe columns and the IGBT connection columns 10, and the ferrite common mode inductor 9 is sleeved Directly connect the capacitor DC output terminal 7 to the DC quick-connect plug 8 on the housing 1 on the DC quick-connect plug 8 deep into the housing 1, and use the thermally conductive and insulating packaging filler to connect the capacitor body, cooling water pipe column, IGBT The connecting post 10, the DC quick-connect plug 8, the capacitor DC output terminal 7 and the ferrite common-mode inductor 9 are encapsulated on the bottom of the case 1; the capacitor body is encapsulated on the bottom of the case by a thermally conductive and insulating encapsulating filler to improve the inside of the case 1 The use of space maximizes the space of the housing 1 and improves the heat dissipation effect of the capacitor body 1. The DC quick connect plug 8 is directly connected to the capacitor DC output terminal 7 and placed in the thermally conductive insulating packaging filling block , The heat dissipation efficiency of the DC quick connect plug 8 and the capacitor DC output terminal 7 is improved. At the same time, the oxygen common mode inductor 9 is also placed in the thermally conductive and insulating packaging filling block, which improves the heat dissipation efficiency and ensures the normal operation of the motor controller.

S3) Outside the housing 1, install the IGBT module 3 and the drive circuit board 4 into one body, and then connect the IGBT module 3 and the drive circuit board 4 together through the connecting rod 11 to the IGBT connecting post 10, so that the IGBT module 3 and the drive The circuit board 4 is fixed above the capacitor body 2; outside the housing 1, the IGBT module 3 and the driving circuit board 4 are installed as a whole, which is convenient for assembly, and can be entrusted to third-party production, which saves manufacturing costs, improves work efficiency, and shortens the cost of the car. Time to market.

S4) Insert the conductive copper pillar 42 from the IGBT input terminal on the drive circuit board 4 and insert it down into the IGBT module 3, and connect the AC quick connect plug 16 on the housing 1 with the conductive copper pillar 42; the structure design is simple, It is convenient to install and disassemble. The IGBT output terminal 41 is directly connected to the AC quick connect plug 16 through the conductive copper column 42. There is no need to increase the wiring harness inside the housing 1 to avoid the mess of the wiring harness of the housing 1 and excessive heat dissipation. The design is simple and easy to process.

S5) Place the control circuit board 5 on the top of each connecting rod 11 and detachably connect to the connecting rod 11 by bolts; it is convenient to install and disassemble, the structure design is simple, the installation efficiency is improved, and the maintenance is also convenient.

The thermally conductive insulating packaging filling glue of the present invention is selected from the insulating and thermally conductive glue produced by Dongguan Yimei Polymer Products Co., Ltd.

Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand: It is still possible to modify the technical solutions described in the foregoing embodiments, or equivalently replace some or all of the technical features; these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the technical solutions of the embodiments of the present invention range.

Claims

A new type of motor controller, which is characterized in that it comprises a housing (1), a plurality of capacitor bodies (2) arranged side by side at intervals are installed at the bottom of the housing (1), and a plurality of capacitor bodies (2) are arranged in the housing (1). Cooling water pipe column, multiple IGBT connection columns (10) and capacitor DC output terminal (7). The shell (1) is provided with a DC quick connect plug (8) directly connected to the capacitor DC output terminal (7); (1) The inner wall and each of the capacitor body (2), each cooling water pipe column and each IGBT connection column (10) are fixed in one body by a thermally conductive insulating packaging filling block, and the height of the thermally conductive insulating packaging filling block is higher than The height of each capacitor body (2), the capacitor DC output terminal (7) and one end of the DC quick connect plug (8) connected to the capacitor DC output terminal (7) are all placed in the thermally conductive insulating packaging filling rubber block; on the cooling water pipe column The port extends out of the thermally conductive insulating packaging filling rubber block to communicate with the cooling water channel on the IGBT module (3), the lower end of the cooling water pipe string is sealed and connected to the housing (1), and the upper end of the capacitor DC output terminal (7) extends out of the heat conduction The insulating packaging filling plastic block is connected with the IGBT module (3), and the upper end of the IGBT connecting column (10) extends out of the thermally conductive insulating packaging filling plastic block.
The new motor controller according to claim 1, characterized in that: the drive circuit board (4) is stacked at intervals above the IGBT module (3), and the control circuit board (5) is stacked at intervals above the drive circuit board (4). ); The drive circuit board (4) is provided with an IGBT output terminal (41), a conductive copper column (42) is inserted into the IGBT output terminal (41), and the bottom of the conductive copper column (42) penetrates into the IGBT module (3) Inside, the top of the conductive copper column (42) is connected with the AC quick connect plug (16) on the shell (1).
The new motor controller according to claim 2, characterized in that: the end of the DC quick connect plug (8) connected to the capacitor DC output terminal (7) is covered with a ferrite common mode inductor (9), the ferrite common The mold inductor (9) is packaged in a thermally conductive and insulating package filling rubber block.
The new motor controller according to claim 3, characterized in that: the cooling water pipe string includes a water inlet pipe section (61) and a water outlet pipe section (62), and the upper ends of the water inlet pipe section (61) and the water outlet pipe section (62) are both Extending from the thermally conductive and insulating packaging filling rubber block is respectively connected with the IGBT water inlet and IGBT water outlet of the cooling water channel on the IGBT module (3), and the bottom of the water inlet pipe section (61) is connected with the water inlet (101) on the housing (1) ) Is connected, the bottom of the outlet pipe section (62) is communicated with the outlet (102) on the housing (1); the upper ports of the inlet pipe section (61) and the outlet pipe section (62) are both sleeved with rubber seals .
The novel motor controller according to claim 4, characterized in that: a temperature sensor is encapsulated on the capacitor body (2).
The new motor controller according to claim 5, characterized in that: the top of the IGBT connecting column (10) is provided with a through hole (1001) extending inside the IGBT connecting column (10), and the IGBT module (3) is circumferentially provided with Each penetration hole (1001) has a one-to-one corresponding connection hole, and a connection rod (11) connected with the IGBT connection column (10) is penetrated in the connection hole.
The new motor controller according to claim 6, characterized in that: a special connector (13) for direct connection with an external connector is inserted on the control circuit board (5).
The new motor controller according to claim 7, characterized in that: the shell (1) is integrally cast; the material of the shell (1) is aluminum alloy.
A method for manufacturing a motor controller for manufacturing the novel motor controller according to any one of claims 1-8, characterized in that:

Including the following steps:

Prepare the shell (1), and the inner bottom of the shell (1) is provided with a plurality of cooling water pipe columns and a plurality of IGBT connection columns (10);

Install a plurality of capacitor bodies on the bottom of the shell (1) so that the capacitor bodies are placed in the gap between the inner wall of the shell (1), the cooling water pipe columns, and the IGBT connection columns (10), and the ferrite is in a common mode The inductor (9) is sleeved on the DC quick connect plug (8) deep into the shell (1), and then the capacitor DC output terminal (7) is directly connected to the DC quick connect plug (8) on the shell (1) , The capacitor body, cooling water pipe column, IGBT connection column (10), DC quick connect plug (8), capacitor DC output terminal (7) and ferrite common mode inductor (9) are encapsulated in the shell with thermally conductive insulating packaging filler Body (1) bottom;

Outside the shell, install the IGBT module (3) and the drive circuit board (4) as a whole, and then connect the IGBT module (3) and the drive circuit board (4) to the IGBT connection column (10) through the connecting rod (11) Fixing so that the IGBT module (3) and the driving circuit board (4) are fixed above the capacitor body (2).

Insert the conductive copper pillar (42) from the IGBT input terminal on the drive circuit board (4) and insert it down into the IGBT module (3), and connect the AC quick connect plug (16) on the housing (1) with the conductive copper Column (42) connection;

The control circuit board (5) is placed on the top of each connecting rod (11), and is detachably connected with the connecting rod (11) through bolts.
An electric vehicle, characterized by comprising the new motor controller according to any one of claims 1-8.