WO2022218249A1 - 集成式车用逆变器总成和车辆 - Google Patents

集成式车用逆变器总成和车辆 Download PDF

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Publication number
WO2022218249A1
WO2022218249A1 PCT/CN2022/086058 CN2022086058W WO2022218249A1 WO 2022218249 A1 WO2022218249 A1 WO 2022218249A1 CN 2022086058 W CN2022086058 W CN 2022086058W WO 2022218249 A1 WO2022218249 A1 WO 2022218249A1
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WIPO (PCT)
Prior art keywords
assembly
main box
integrated vehicle
bottom cover
vehicle inverter
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Application number
PCT/CN2022/086058
Other languages
English (en)
French (fr)
Inventor
侯毅鹏
李全
苍衍
胡波
刘佳男
苏瑞涛
唐佩伦
赵慧超
贺红伟
徐德才
Original Assignee
中国第一汽车股份有限公司
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Application filed by 中国第一汽车股份有限公司 filed Critical 中国第一汽车股份有限公司
Publication of WO2022218249A1 publication Critical patent/WO2022218249A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
    • 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
    • H05K7/20218—Modifications to facilitate cooling, ventilating, or heating using a liquid coolant without phase change in electronic enclosures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/72—Electric energy management in electromobility

Definitions

  • the present application relates to the technical field of new energy vehicles, for example, to an integrated vehicle inverter assembly and a vehicle.
  • the electric drive system With the continuous development of new energy vehicles, the electric drive system is gradually developing in the direction of high speed, miniaturization and high efficiency. At the same time, the transformation of automobile electrification is gradually developing towards high reliability and high quality assurance period. The reliability requirements for multiple assemblies higher. Due to the stricter vehicle boundary restrictions, under the premise of satisfying the compact structure, the layout of the internal components of the vehicle inverter assembly needs to be more rationalized to meet the requirements for electromagnetic compatibility level and functional safety.
  • the present application provides an integrated vehicle inverter assembly and a vehicle, so as to solve the problems of low electromagnetic compatibility level and low integration level of the vehicle inverter assembly under the limit of the vehicle boundary.
  • An integrated vehicle inverter assembly comprising: a main box, two ends of the main box are respectively covered with a top cover and a bottom cover, and the three form a accommodating space, and the side of the main box is covered with a top cover and a bottom cover.
  • a low-voltage connector attachment harness assembly, a high-voltage wire harness assembly, an AC busbar assembly and a filter magnetic ring are fixedly connected to the wall, and the bottom cover is provided with a water inlet pipe and a water outlet pipe;
  • the accommodating space is provided with a cooling A channel, a control substrate assembly, a shielding plate and an Image Processing Unit (IPU) assembly, two ends of the cooling channel are respectively connected to the water inlet pipe and the water outlet pipe, and the shielding plate is arranged on the Between the control substrate assembly and the IPU assembly, the control substrate assembly is fixed on the first side of the shielding plate facing the top cover, and the IPU assembly is arranged on the second side of the shielding plate.
  • IPU Image Processing Unit
  • the low-voltage connector with wire harness assembly can pass through the side wall of the main box to connect to the control board assembly, and one end of the wire nose of the high-voltage wire harness assembly Connected to the IPU assembly to transmit DC input signals, the filter magnetic ring is connected to the main box through the high-voltage wire harness assembly, and one end of the three-phase copper column of the AC busbar assembly is connected to the main box.
  • the drive board of the IPU assembly is connected to realize the transmission of three-phase AC signals, and the drive board and the control substrate assembly transmit control signals through inter-board cables.
  • the integrated vehicle inverter assembly further includes a wiring cover and a vent plug, the wiring cover and the vent plug are provided on the side wall of the main box and are connected to the side wall.
  • the wiring holes and ventilation holes on the wall are installed together.
  • the IPU assembly further includes a current sensor, a working capacitor fixed on the drive board, an independently packaged power module and a DC wiring seat assembly, the current sensor is mounted on a spare circuit board, and the The three-phase copper bar and copper column pass through the current sensor to detect the current signal;
  • the DC connection base assembly includes a copper bar, a transfer copper column, an absorption capacitor and a DC magnetic ring, and the connecting bolts pass through the DC magnetic ring to connect all the The driving board, the transfer copper column, the absorption capacitor and the copper bar are connected.
  • the main box body and the bottom cover are connected by friction stir welding.
  • the outer side wall of the main box body facing the bottom cover is provided with box body guide ribs
  • the bottom cover is provided with bottom cover guide ribs
  • the main box body and the bottom cover After snap-fit installation, a cooling channel is formed, and both the box body air guide ribs and the bottom cover air guide ribs are located in the cooling channel.
  • protruding ribs are respectively provided on the top cover and the shielding plate, and the protruding ribs are arranged in a staggered manner around the control substrate assembly.
  • heat dissipation glue is coated between the bottom of the working capacitor and the main box.
  • the integrated vehicle inverter assembly further includes a sealing ring, and the sealing ring is arranged between the wiring cover and the main box.
  • the three-phase copper bar copper column and the AC bus bar insulating frame of the AC busbar assembly are an integral structure of injection molding.
  • the present application also provides a vehicle including the integrated vehicle inverter assembly.
  • FIG. 1 is a schematic structural exploded view of an integrated vehicle inverter machine assembly provided by the present application
  • FIG. 2 is an isolation schematic diagram of a control substrate assembly in an integrated vehicle inverter machine assembly provided by the present application
  • FIG. 3 is a schematic structural diagram of an IPU assembly in an integrated vehicle inverter machine assembly provided by the present application
  • FIG. 4 is an assembly schematic diagram of a DC terminal block assembly in an integrated vehicle inverter machine assembly provided by the present application
  • Fig. 5 is a schematic diagram of the position of the water inlet pipe and the water outlet pipe arranged on the bottom cover of an integrated vehicle inverter machine assembly provided by the present application;
  • FIG. 6 is a schematic circuit diagram of a cooling channel in an integrated vehicle inverter machine assembly provided by the present application.
  • FIG. 7 is a schematic diagram of the connection between the main box and the bottom cover in an integrated vehicle inverter machine assembly provided by the present application;
  • FIG. 8 is a schematic diagram of the connection between the medium and low voltage connector attachment harness assembly and the control substrate assembly of an integrated vehicle inverter machine assembly provided by the present application.
  • connection should be understood in a broad sense, for example, it may be a fixed connection, a detachable connection, or an integrated ; It can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two elements or the interaction relationship between the two elements.
  • connection may be a fixed connection, a detachable connection, or an integrated ; It can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, and it can be the internal connection of two elements or the interaction relationship between the two elements.
  • a first feature "on” or “under” a second feature may include direct contact between the first and second features, or may include the first and second features Not directly but through additional features between them.
  • the first feature being “above”, “over” and “above” the second feature includes the first feature being directly above and obliquely above the second feature, or simply means that the first feature is level higher than the second feature.
  • the first feature is “below”, “below” and “below” the second feature includes the first feature being directly below and diagonally below the second feature, or simply means that the first feature has a lower level than the second feature.
  • the following describes an integrated vehicle inverter assembly provided by the present application with reference to FIGS. 1 to 8 .
  • the integrated inverter assembly can solve the problems of the vehicle inverter assembly under the limitation of the vehicle boundary.
  • an integrated inverter assembly includes a main box 1, and two ends of the main box 1 are respectively covered with a top cover 2 and a bottom cover 3, and the three form a accommodating space.
  • the side wall of 1 is fixedly connected with a low-voltage connector attachment harness assembly 101, a high-voltage harness assembly 102, an AC busbar assembly 103 and a filter magnetic ring 104, and the bottom cover 3 is provided with a water inlet pipe 301 and a water outlet pipe 302; As shown in FIG.
  • the accommodating space is provided with a control substrate assembly 4 , a shielding plate 5 , an IPU assembly 6 and a cooling channel 7 , and both ends of the cooling channel 7 are respectively connected to the water inlet pipe 301 and the water outlet pipe 302 , as shown in FIGS. 1 and 1 .
  • the shielding plate 5 is arranged between the control substrate assembly 4 and the IPU assembly 6, the control substrate assembly 4 is fixed on the shielding plate 5 towards the first side of the top cover 2, and the IPU assembly 6 is arranged on the shielding plate 5
  • the low-voltage connector with wire harness assembly 101 can pass through the side wall of the main box body 1 to connect to the control board assembly 4, and one end of the wire nose of the high-voltage wire harness assembly 102 is connected to the IPU.
  • the assembly 6 is connected to transmit the DC input signal, the filter magnetic ring 104 is connected to the main box 1 through the high-voltage wire harness assembly 102, and one end of the three-phase copper column of the AC busbar assembly 103 is connected to the drive board of the IPU assembly 6.
  • 601 is connected to realize the transmission of three-phase AC signals, and the drive board 601 and the control board assembly 4 transmit control signals through the inter-board cables.
  • the control substrate assembly 4 is disposed between the top cover 2 and the shielding plate 5 , and an isolation area is formed between the top cover 2 and the shielding plate 5 , which can reduce the electromagnetic interference to the control substrate assembly 4 , improve the electromagnetic compatibility level.
  • the control substrate assembly 4 is mounted on the shielding plate 3 by bolts, and the shielding plate 3 is formed by high-pressure casting, which effectively isolates the interference of the high-voltage components on the driving plate 601 to the control substrate assembly 4 .
  • the cooling channel 7 provided in the main case 1 can cool and dissipate the IPU assembly 6 inside the main case 1 .
  • the bolted connection between the high-voltage wiring harness assembly 102 and the main box 1 is detachable, and the 6 bolted connection between the wire nose and the IPU assembly realizes the detachable connection, which can realize the transmission of the DC input signal.
  • the filter magnetic ring 104 can reduce the interference of the internal high-voltage components to the DC input signal.
  • the shielding plate 5 is provided with tie holes to facilitate the wiring of the low-voltage wiring harness.
  • the low-voltage connector attachment harness assembly 102 is divided into two parts of the low-voltage wiring harness inside the main box 1, as shown in FIG.
  • the cooling channel 7 is provided in the main box 1 and the water outlet pipe 302 on the bottom cover 3 is communicated with the water inlet pipe 301, so that the overall control board can be connected to the control board.
  • the chips and capacitors in the IPU assembly 4 and 6 are fully cooled.
  • the control substrate assembly 4 is arranged between the shielding plate 5 and the top cover 2 to form isolation for the control substrate assembly 4 , reduce electromagnetic interference received by the control substrate assembly 2 , and improve the electromagnetic compatibility level.
  • the side wall and the internal accommodation space of the main box 1 are fully utilized, which greatly improves the integration degree of the vehicle inverter.
  • the vehicle inverter assembly can be better integrated with the motor and reducer in three-in-one, with a higher degree of integration.
  • the integrated vehicle inverter assembly further includes a wiring cover 8 and a vent plug 9, and the wiring cover 8 and the vent plug 9 are provided on the side wall of the main box 1 and are connected with the wiring holes on the side wall. Install with vent holes.
  • the high-voltage wiring harness assembly 102 and the IPU assembly 6 need to be connected and installed through the wiring holes reserved on the main box body 1, and the wiring cover plate 8 is covered at the wiring holes to realize the internal storage capacity of the main box body 1.
  • a sealing groove is set on the main box 1 at the wiring hole, an O-shaped sealing ring is arranged in the sealing groove, and the wiring cover 8 presses the O-shaped sealing ring And connect the wiring holes of the main box body 1 to achieve a good sealing effect, and the wiring cover 8 can be installed in a detachable connection mode to facilitate maintenance and repair.
  • at least two ventilation holes are provided on the main box 1 below the high-voltage wire harness assembly 102 , and the ventilation plugs 9 are fixedly arranged on the ventilation holes.
  • the IPU assembly 6 further includes a current sensor 603, a working capacitor 602 fixed on the drive board 601, an independently packaged power module 604, and a DC wiring block assembly 605.
  • the current sensor 603 is installed on the spare circuit board, and three The phase copper bar passes through the current sensor 603 to detect the current signal;
  • the DC terminal block assembly 605 includes the copper bar 6051, the transfer copper column 6052, the absorption capacitor 6053 and the DC magnetic ring 6054, and the connecting bolt 606 passes through the DC magnetic ring 6054 to connect the The driving board 601 , the transfer copper column 6052 , the absorption capacitor 6053 and the copper bar 6051 are connected.
  • the IPU assembly 6 may further include an injection molding structure 6055, and the injection molding structure 6055 insulates and encapsulates the driving board 601 and the transfer copper column 6052 to improve the overall structural strength and electromagnetic compatibility performance.
  • the working capacitor 602 is mounted on the driving board 601 by an adhesive or soldering process, and the independently packaged power module 604 is welded on the driving board 601, and an independent cooling channel is designed inside it. Used for chip heat dissipation, improve work efficiency.
  • the DC terminal assembly 605 is connected to the driving board 601 by bolts, and is configured to transmit a DC input signal.
  • the DC magnetic ring 6054 is set to filter the DC input signal and improve the electromagnetic compatibility performance of the inverter assembly.
  • the copper bar 6051 and the transfer copper column 6052 meet the structural strength and reliability while satisfying the structural strength and reliability. Realize the transmission of the input signal.
  • the main box 1 and the bottom cover 3 are connected by friction stir welding, as shown in FIG. 7 , this welding method can avoid the interference between the welding head and the parts.
  • the parts are 6 mm away from the welding place.
  • the water inlet pipe 301 and the water outlet pipe 302 are respectively press-fitted on the bottom cover 3 .
  • protruding ribs 201 are respectively provided on the top cover 2 and the shielding plate 5 , and the protruding ribs 201 are arranged in a staggered manner around the control substrate assembly 4 .
  • protruding ribs 201 are alternately arranged around the control substrate assembly 4 on the top cover 2 and the shielding plate 5 , and the long axis of the protruding ribs 201 is perpendicular to the plane where the shielding plate 5 or the top cover 2 is located.
  • the component 4 is spatially isolated from the high-voltage wiring harness assembly 102 and the drive board 601, which reduces the interference of high-voltage electromagnetic signals, improves the accuracy of signal transmission on the control board assembly 4, and effectively improves the electromagnetic compatibility of the inverter assembly. .
  • the inner side of the top cover 1 is designed with reinforcing ribs, and there are multiple reinforcing ribs, and the plurality of reinforcing ribs are arranged against the inner sidewall of the top cover 1 at intervals.
  • the reinforcing ribs can be used without increasing the height of the top cover 2. Under the circumstance, the structural strength of the top cover is improved, and the process difficulty is reduced.
  • heat dissipation glue is applied between the bottom of the working capacitor 602 and the main case 1 .
  • the water inlet pipe 301 and the water outlet pipe 302 are press-fitted on the bottom cover 3, and the external cooling liquid enters the cooling channel 7 from the water inlet pipe 301, and flows in the direction shown by the arrow in FIG. 6, because the cooling channel 7
  • the back is the working capacitor 602 on the IPU assembly 6. Therefore, a heat-dissipating glue, that is, heat-dissipating silica gel, is applied between the bottom of the working capacitor 602 and the main box 1.
  • the coolant flows in the cooling channel 7, it can enhance the heat transfer of the contact interface and reduce the The contact thermal resistance acts as a heat dissipation function for the working capacitor 602.
  • the cooling liquid flows into the internal channel of the independently packaged power module 604 of the IPU assembly 6 to cool the chip to meet the temperature requirements for normal operation of the chip; finally, the cooling liquid flows out from the water outlet pipe 302.
  • the whole process realizes the cooling and heat dissipation of the working capacitor 602 and the independently packaged power module 604 respectively, which improves the working efficiency of the inverter assembly.
  • the outer side wall of the main box body 1 facing the bottom cover 3 is provided with a box body guide rib 701
  • the bottom cover 3 is provided with a bottom cover guide rib 303
  • the main box body 1 and the bottom cover 3 are buckled and installed.
  • the cooling channel 7 is formed, and the box body guide ribs 701 and the bottom cover guide ribs 303 are both located in the cooling channel 7 .
  • the side wall of the cooling channel 7 and the box guide ribs 701 are arranged on the outer side wall of the main box 1 facing the bottom cover 3.
  • the box guide ribs 701 are located in the cooling channel 7, and the cooling liquid can be cleaned. Effectively divide the flow, reduce the flow resistance to the greatest extent, and improve the cooling efficiency.
  • the box body guide ribs 701 are arranged along the central axis of the cooling channel 7, and the cooling channel 7 is divided into two parts of the cooling liquid channel.
  • the hollow structure of the body rib 701 is more conducive to the heat dissipation effect of each cooling liquid channel, and can improve the heat dissipation efficiency of the entire cooling channel. As shown in FIG.
  • the bottom cover rib 303 is provided at the position corresponding to the box body rib 701 on the bottom cover 3 .
  • the bottom cover 3 and the main box 1 are buckled together to form a cooling channel 7
  • the bottom cover rib 303 and The box body rib 701 is located inside the cooling channel 7, and the two are located opposite to each other, the end faces are abutting or there is a gap, which is set to reduce the flow resistance of the cooling liquid, and at the same time, it can play the role of a reinforcing rib to improve the structural strength during welding.
  • the distance between the cooling channel 7 on the main box 1 and the welding position is reduced, and the reliability of the structure after the welding process is improved.
  • the installation surface of the bottom cover 3 is provided with a chamfered structure to effectively improve the convenience of installation.
  • the three-phase copper busbar copper column and the AC busbar insulating frame of the AC busbar assembly 103 are an integral structure of injection molding.
  • the injection molding process is simple, the insulation and sealing effects are good, and the quality is small, and the overall structural strength of the AC busbar assembly 103 can be improved, which is convenient for installation.
  • the present application further provides a vehicle including an integrated vehicle inverter assembly.
  • the vehicle with the integrated vehicle inverter assembly has high integration degree and high electromagnetic compatibility level, and the whole vehicle meets functional safety requirements and has high work efficiency.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Transportation (AREA)
  • Sustainable Energy (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Inverter Devices (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)

Abstract

一种集成式车用逆变器总成，包括：主箱体(1)，主箱体(1)的两端分别盖设有顶盖(2)和底盖(3)并且三者形成容置空间，主箱体(1)的侧壁上固定连接有低压连接器附线束总成(101)、高压线束总成(102)、交流母排总成(103)和滤波磁环(104)，底盖(3)上设有进水管(301)和出水管(302)；容置空间内设置有冷却通道(7)、控制基板总成(4)、屏蔽板(5)和图像处理单元总成(6)，冷却通道(7)的两端分别连接进水管(301)和出水管(302),驱动板(601)与控制基板总成(4)通过板间排线传递控制信号。该集成式车用逆变器总成集成度高，电磁兼容等级高。

Description

集成式车用逆变器总成和车辆
本申请要求在2021年04月13日提交中国专利局、申请号为202110395309.5的中国专利申请的优先权，该申请的全部内容通过引用结合在本申请中。
技术领域
本申请涉及新能源汽车技术领域，例如涉及一种集成式车用逆变器总成和车辆。
背景技术
随着新能源汽车的不断发展，电驱系统逐渐朝着高速化、小型化、高效化方向发展，同时汽车电气化转型逐步向高可靠性、高质保周期发展，对多个总成的可靠性要求更高。受整车边界限制更加严格，车用逆变器总成在满足结构紧凑的前提下，内部元器件布置需要更加合理化，满足对电磁兼容等级和功能安全要求。
车用逆变器总成多数应用独立功率器件，这样更容易满足逆变器总成性能要求，但是结构体积较大，无法满足整车边界限制较高的要求，同时逆变器总成在结构布置中缺少对控制基板总成的隔离防护，导致电磁兼容等级较低。
发明内容
本申请提供了一种集成式车用逆变器总成和车辆，以解决车用逆变器总成在整车边界限制下的电磁兼容等级低和集成度低的问题。
一种集成式车用逆变器总成，包括：主箱体，所述主箱体的两端分别盖设有顶盖和底盖并且三者形成容置空间，所述主箱体的侧壁上固定连接有低压连接器附线束总成、高压线束总成、交流母排总成和滤波磁环，所述底盖上设有进水管和出水管；所述容置空间内设置有冷却通道、控制基板总成、屏蔽板和图像处理单元(Image Processing Unit,IPU)总成，所述冷却通道的两端分别连接所述进水管和所述出水管，所述屏蔽板设置在所述控制基板总成和所述IPU总成之间，所述控制基板总成固定在所述屏蔽板上朝向所述顶盖的第一侧，所述IPU总成设置在所述屏蔽板的第二侧且固定连接在所述主箱体上，所述低压连接器附线束总成能够穿过所述主箱体的侧壁连接所述控制基板总成，所述高压线束总成的线鼻子一端与所述IPU总成连接以传递直流输入信号，所述滤波磁环穿过所述高压线束总成与所述主箱体连接，所述交流母排总成的三相铜排铜柱一端与所述IPU总成的驱动板连接以实现三相交流信号的传递，所述驱动 板与所述控制基板总成通过板间排线传递控制信号。
可选地，所述集成式车用逆变器总成还包括接线盖板和透气塞，所述接线盖板和所述透气塞设于所述主箱体的侧壁上且与所述侧壁上的接线孔和透气孔配合安装。
可选地，所述IPU总成还包括电流传感器、以及固定在所述驱动板上的工作电容、独立封装功率模块和直流接线座总成，所述电流传感器安装在备用电路板上，所述三相铜排铜柱穿过所述电流传感器以检测电流信号；所述直流接线座总成包括铜排、转接铜柱、吸收电容和直流磁环，连接螺栓穿过直流磁环依次将所述驱动板、所述转接铜柱、所述吸收电容和所述铜排连接。
可选地，所述主箱体与所述底盖之间通过搅拌摩擦焊连接。
可选地，所述主箱体的朝向所述底盖的外侧壁上设有箱体导流筋，所述底盖上设有底盖导流筋，所述主箱体与所述底盖扣合安装后形成冷却通道，所述箱体导流筋和所述底盖导流筋均位于所述冷却通道内。
可选地，所述顶盖和所述屏蔽板上分别设有突出筋且所述突出筋在所述控制基板总成的四周交错布置。
可选地，所述工作电容的底部与所述主箱体之间涂覆散热胶。
可选地，所述集成式车用逆变器总成还包括密封圈，所述密封圈设置在所述接线盖板和所述主箱体之间。
可选地，所述交流母排总成的所述三相铜排铜柱和交流母排绝缘架为注塑一体结构。
本申请还提供一种车辆，包括所述集成式车用逆变器总成。
附图说明
图1是本申请提供的一种集成式车用逆变器机总成的结构分解示意图；
图2是本申请提供的一种集成式车用逆变器机总成中控制基板总成的隔离示意图；
图3是本申请提供的一种集成式车用逆变器机总成中IPU总成的结构示意图；
图4是本申请提供的一种集成式车用逆变器机总成中直流接线座总成的装配示意图；
图5是本申请提供的一种集成式车用逆变器机总成中底盖上设置进水管和出水管的位置示意图；
图6是本申请提供的一种集成式车用逆变器机总成中冷却通道的回路示意图；
图7是本申请提供的一种集成式车用逆变器机总成中主箱体与底盖的连接示意图；
图8是本申请提供的一种集成式车用逆变器机总成中低压连接器附线束总成与控制基板总成的连接示意图。
图中：
1.主箱体；101.低压连接器附线束总成；102.高压线束总成；103.交流母排总成；104.滤波磁环；2.顶盖；201.突出筋；3.底盖；301.进水管；302.出水管；303.底盖导流筋；4.控制基板总成；5.屏蔽板；6.IPU总成；601.驱动板；602.工作电容；603.电流传感器；604.独立封装功率模块；605.直流接线座总成；6051.铜排；6052.转接铜柱；6053.吸收电容；6054.直流磁环；6055.注塑结构；606.螺栓；7.冷却通道；701.箱体导流筋；8.接线盖板；9.透气塞。
具体实施方式
下面结合附图和实施例对本申请进行说明。可以理解的是，此处所描述的实施例仅仅用于解释本申请，而非对本申请的限定。另外还需要说明的是，为了便于描述，附图中仅示出了与本申请相关部分的结构。
在本申请的描述中，除非另有明确的规定和限定，术语“相连”、“连接”、“固定”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或成一体；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言，可以根据情况理解上述术语在本申请中的含义。
在本申请中，除非另有明确的规定和限定，第一特征在第二特征之“上”或之“下”可以包括第一和第二特征直接接触，也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且，第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方，或仅仅表示第一特征水平高度小于第二特征。
在本实施例的描述中，术语“上”、“下”、“左”、“右”等方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述和简化操作，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和 操作，因此不能理解为对本申请的限制。此外，术语“第一”、“第二”仅仅用于在描述上加以区分，并没有特殊的含义。
下面结合图1-图8对本申请提供的一种集成式车用逆变器总成进行说明，该集成式逆变器总成可以解决在整车边界限制下的车用逆变器总成的电磁兼容等级低和集成度低的问题。
如图1所示，一种集成式逆变器总成包括主箱体1，主箱体1的两端分别盖设有顶盖2和底盖3并且三者形成容置空间，主箱体1的侧壁上固定连接有低压连接器附线束总成101、高压线束总成102、交流母排总成103和滤波磁环104，底盖3上设有进水管301和出水管302；如图6所示，容置空间内设置有控制基板总成4、屏蔽板5、IPU总成6和冷却通道7，冷却通道7的两端分别连接进水管301和出水管302，如图1和图2，屏蔽板5设置在控制基板总成4和IPU总成6之间，控制基板总成4固定在屏蔽板5上朝向顶盖2的第一侧，IPU总成6设置在屏蔽板5的第二侧且固定连接在主箱体1上，低压连接器附线束总成101能够穿过主箱体1的侧壁连接控制基板总成4，高压线束总成102的线鼻子一端与IPU总成6连接以传递直流输入信号，滤波磁环104穿过高压线束总成102与主箱体1连接，交流母排总成103的三相铜排铜柱一端与IPU总成6的驱动板601连接以实现三相交流信号的传递，驱动板601与控制基板总成4通过板间排线传递控制信号。
如图1和图2所示，控制基板总成4设置在顶盖2和屏蔽板5之间，顶盖2和屏蔽板5之间形成隔离区域，可以减少对控制基板总成4的电磁干扰，提高电磁兼容等级。本实施例中，控制基板总成4通过螺栓安装在屏蔽板3上，屏蔽板3采用高压铸造成型，有效隔离驱动板601上高压器件对控制基板总成4的干扰。主箱体1内设置的冷却通道7能够对主箱体1内部的IPU总成6进行冷却散热。高压线束总成102与主箱体1之间螺栓连接实现可拆卸，线鼻子与IPU总成6螺栓连接实现可拆卸连接，可以实现直流输入信号的传递。滤波磁环104可以减少内部高压器件对直流输入信号的干扰。需要说明的是，屏蔽板5上设有扎线孔，便于低压线束走线，低压连接器附线束总成102在主箱体1的内部分成两部分的低压线束，如图8所示，两部分低压线束均通过屏蔽板5上的扎线孔后，通过扎线带固定后，按照图8中箭头方向与控制基板总成4上的接插件连接，实现控制基板总成4与整车外部信号的传输。
可以理解，本申请的一种集成式车用逆变器总成，通过在主箱体1内设置冷却通道7并通过底盖3上的出水管302和进水管301连通，可以对控制基板总成4和IPU总成6中的芯片和电容等进行充分冷却。控制基板总成4设置在屏蔽板5和顶盖2之间可以形成对控制基板总成4的隔离，减小控制基板总成2 受到的电磁干扰，提高电磁兼容等级。上述提供的集成式车用逆变器总成中，充分利用了主箱体1的侧壁和内部容置空间，大大提高了车用逆变器的集成度，在满足整车边界要求的前提下，严格布置各个分立式功率器件，车用逆变器总成可以与电机和减速器进行更好的三合一集成，具有更高的集成度。
可选地，集成式车用逆变器总成还包括接线盖板8和透气塞9，接线盖板8和透气塞9设于主箱体1的侧壁上且与侧壁上的接线孔和透气孔配合安装。
本实施例中，高压线束总成102和IPU总成6需要通过主箱体1上预留的接线孔进行连接安装，接线盖板8盖设在接线孔处可以实现对主箱体1内部容置空间的密封，为了实现更好的密封效果，本实施例中在接线孔处的主箱体1上开设密封槽，密封槽内设置O型密封圈，接线盖板8压紧O型密封圈并连接主箱体1的接线孔，实现良好密封效果，可采用可拆卸是连接方式安装接线盖板8便于维护和检修等。如图1所示，主箱体1上位于高压线束总成102的下方设有至少两个透气孔，透气塞9固定设置在透气孔上。
可选地，IPU总成6还包括电流传感器603、以及固定在驱动板601上的工作电容602、独立封装功率模块604和直流接线座总成605，电流传感器603安装在备用电路板上，三相铜排穿过电流传感器603以检测电流信号；直流接线座总成605包括铜排6051、转接铜柱6052、吸收电容6053和直流磁环6054，连接螺栓606穿过直流磁环6054依次将驱动板601、转接铜柱6052、吸收电容6053和铜排6051连接。需要说明的是，IPU总成6还可以包括注塑结构6055，注塑结构6055将驱动板601、转接铜柱6052进行绝缘封装，提高整体结构强度和电磁兼容性能。
如图2-图4所示，本实施例中，工作电容602通过粘接或锡焊工艺安装在驱动板601上，独立封装功率模块604焊接在驱动板601上，其内部设计有独立冷却通道用于芯片散热，提高工作效率。直流接线座总成605通过螺栓连接在驱动板601上，设置为传输直流输入信号。直流接线座总成605中，直流磁环6054设置为对直流输入信号进行过滤，提高逆变器总成的电磁兼容性能，铜排6051和转接铜柱6052在满足结构强度和可靠性的同时实现输入信号的传递。
可选地，主箱体1与底盖3之间通过搅拌摩擦焊连接，如图7所示，这种焊接方式可以避免焊接头与零件发生干涉，本实施例中零件在距离焊接处6mm的范围内无任何设计，进水管301和出水管302分别压装在底盖3上。
可选地，顶盖2和屏蔽板5上分别设有突出筋201且突出筋201在控制基板总成4的四周交错布置。
如图2所示，顶盖2和屏蔽板5上在控制基板总成4的四周交错布置突出 筋201，突出筋201的长轴垂直于屏蔽板5或顶盖2所在平面，将控制基板总成4与高压线束总成102和驱动板601在空间上隔离开，降低高压电磁信号的干扰，提高控制基板总成4上信号传输的准确度，有效提高了逆变器总成的电磁兼容性能。在一些实施例中，顶盖1的内侧设计有加强筋，加强筋设有多个，且多个加强筋贴靠顶盖1的内侧壁间隔设置，加强筋能够在不增加顶盖2高度的情况下提高顶盖的结构强度，降低工艺难度。
可选地，工作电容602的底部与主箱体1之间涂覆散热胶。
结合图5和图6，进水管301和出水管302压装在底盖3上，外部冷却液从进水管301进入冷却通道7内，按照图6中箭头所示方向进行流动，由于冷却通道7背部是IPU总成6上的工作电容602，因此在工作电容602底部与主箱体1之间涂覆散热胶即散热硅胶，冷却液在冷却通道7内流动时可以增强接触界面热传递，减少接触热阻，起到对工作电容602的散热功能，冷却液流入IPU总成6的独立封装功率模块604内部通道对芯片进行冷却，满足芯片正常工作的温度要求；最后冷却液从出水管302流出车用逆变器总成，整个过程实现了对工作电容602和独立封装功率模块604的分别冷却散热，提高了逆变器总成的工作效率。
可选地，主箱体1的朝向底盖3的外侧壁上设有箱体导流筋701，底盖3上设有底盖导流筋303，主箱体1与底盖3扣合安装后形成冷却通道7，箱体导流筋701和底盖导流筋303均位于冷却通道7内。
如图6，主箱体1的朝向底盖3的外侧壁上设置冷却通道7的侧壁和箱体导流筋701，箱体导流筋701位于冷却通道7内，可以对冷却液进行了有效分流，同时最大程度的减小流阻，提高冷却效率，需要说明的是，箱体导流筋701沿冷却通道7的中心轴设置，将冷却通道7划分为两部分冷却液的通道，箱体导流筋701设置的空心结构，更利于每个冷却液通道的散热效果，以及可以提高整个冷却通道的散热效率。如图7，底盖3上与箱体导流筋701相对应的位置设置底盖导流筋303，底盖3和主箱体1扣合后形成冷却通道7，底盖导流筋303和箱体导流筋701位于冷却通道7内部，且二者位置相对、端面相抵或留有间隙，设置为降低冷却液的流阻，同时可以起到加强筋的作用来提高焊接时的结构强度，减少主箱体1上冷却通道7与焊接位置的距离，提高焊接工艺后结构的可靠性。底盖3的安装面上设有倒角结构，以有效提高安装便捷性。
可选地，交流母排总成103的所述三相铜排铜柱和交流母排绝缘架为注塑一体结构。注塑制作工艺简单，绝缘和密封效果好，质量小，并可以提高交流母排总成103的整体结构强度，便于安装。
基于上述实施例提供的集成式车用逆变器总成，本申请还提供一种车辆， 包括集成式车用逆变器总成。具有该集成式车用逆变器总成的车辆，车用逆变器总成的集成度高，电磁兼容等级高，整车满足功能安全要求和工作效率高。

Claims (10)

  1. 一种集成式车用逆变器总成，包括：
    主箱体(1)，所述主箱体(1)的两端分别盖设有顶盖(2)和底盖(3)并且三者形成容置空间，所述主箱体(1)的侧壁上固定连接有低压连接器附线束总成(101)、高压线束总成(102)、交流母排总成(103)和滤波磁环(104)，所述底盖(3)上设有进水管(301)和出水管(302)；
    所述容置空间内设置有冷却通道(7)、控制基板总成(4)、屏蔽板(5)和图像处理单元(Image Processing Unit,IPU)总成(6)，所述冷却通道(7)的两端分别连接所述进水管(301)和所述出水管(302)，所述屏蔽板(5)设置在所述控制基板总成(4)和所述IPU总成(6)之间，所述控制基板总成(4)固定在所述屏蔽板(5)上朝向所述顶盖(2)的第一侧，所述IPU总成(6)设置在所述屏蔽板(5)的第二侧且固定连接在所述主箱体(1)上，所述低压连接器附线束总成(101)能够穿过所述主箱体(1)的侧壁连接所述控制基板总成(4)，所述高压线束总成(102)的线鼻子一端与所述IPU总成(6)连接以传递直流输入信号，所述滤波磁环(104)穿过所述高压线束总成(102)与所述主箱体(1)连接，所述交流母排总成(103)的三相铜排铜柱一端与所述IPU总成(6)的驱动板(601)连接以实现三相交流信号的传递，所述驱动板(601)与所述控制基板总成(4)通过板间排线传递控制信号。
  2. 根据权利要求1所述的集成式车用逆变器总成，还包括接线盖板(8)和透气塞(9)，所述接线盖板(8)和所述透气塞(9)设于所述主箱体(1)的侧壁上且与所述侧壁上的接线孔和透气孔配合安装。
  3. 根据权利要求1所述的集成式车用逆变器总成，其中，所述IPU总成(6)还包括电流传感器(603)、以及固定在所述驱动板(601)上的工作电容(602)、独立封装功率模块(604)和直流接线座总成(605)，所述电流传感器(603)安装在备用电路板上，所述三相铜排铜柱穿过所述电流传感器(603)以检测电流信号；所述直流接线座总成(605)包括铜排(6051)、转接铜柱(6052)、吸收电容(6053)和直流磁环(6054)，连接螺栓(606)穿过直流磁环(6054)依次将所述驱动板(601)、所述转接铜柱(6052)、所述吸收电容(6053)和所述铜排(6051)连接。
  4. 根据权利要求1所述的集成式车用逆变器总成，其中，所述主箱体(1)与所述底盖(3)之间通过搅拌摩擦焊连接。
  5. 根据权利要求1所述的集成式车用逆变器总成，其中，所述主箱体(1)的朝向所述底盖(3)的外侧壁上设有箱体导流筋(701)，所述底盖(3)上设有底盖导流筋(303)，所述主箱体(1)与所述底盖(3)扣合安装后形成所述 冷却通道(7)，所述箱体导流筋(701)和所述底盖导流筋(303)位于所述冷却通道(7)内。
  6. 根据权利要求1所述的集成式车用逆变器总成，其中，所述顶盖(2)和所述屏蔽板(5)上分别设有突出筋(201)且所述突出筋(201)在所述控制基板总成(4)的四周交错布置。
  7. 根据权利要求3所述的集成式车用逆变器总成，其中，所述工作电容(602)的底部与所述主箱体(1)之间涂覆散热胶。
  8. 根据权利要求2所述的集成式车用逆变器总成，还包括密封圈，所述密封圈设置在所述接线盖板(8)和所述主箱体(1)之间。
  9. 根据权利要求1所述的集成式车用逆变器总成，其中，所述交流母排总成(103)的所述三相铜排铜柱和交流母排绝缘架为注塑一体结构。
  10. 一种车辆，包括权利要求1-9中任意一项所述集成式车用逆变器总成。
PCT/CN2022/086058 2021-04-13 2022-04-11 集成式车用逆变器总成和车辆 WO2022218249A1 (zh)

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