WO2024067242A1 - Electric motor controller and vehicle - Google Patents

Abstract

An electric motor controller and a vehicle. The electric motor controller comprises a micro-control unit (MCU) module, a battery management system (BMS) module, a direct-current converter (DC/DC) module and a power distribution unit (PDU) module. The electric motor controller further comprises a high-voltage distribution box module, which comprises an MCU fuse, an MCU relay and a fast-charge relay, wherein the MCU fuse and the MCU relay are connected in series and are in communication with the micro-control unit MCU module and a battery unit, and the fast-charge relay is in communication with a fast-charge socket and the battery unit.

Description

Motor Controllers and Vehicles

This application claims the priority of the Chinese patent application filed with the China Patent Office on September 29, 2022, with application number 202222601537.6 and invention name “A Motor Controller and Vehicle”, the entire contents of which are incorporated by reference in this application.

Technical Field

The present application relates to the technical field of motor control, for example, to a motor controller and a vehicle.

Background technique

In the related technology, it is usually necessary to separately equip a high-voltage distribution box to cooperate with the motor controller. Therefore, a separate space needs to be reserved on the whole vehicle to install the high-voltage distribution box, and the space utilization rate is low. At the same time, due to the addition of the high-voltage distribution box, the weight of the whole vehicle is increased, which is inconsistent with the existing lightweight design concept, resulting in waste of resources, and also increases the connection wiring harness and connectors, increases the structural cost, and increases the probability of failure. In addition, the high-voltage distribution box needs to be separately designed, molded, and assembled, which is relatively costly.

Summary of the invention

The present application provides a motor controller.

The vehicle has a battery unit and a fast charging socket. The motor controller includes a microcontroller unit MCU module, a battery management system BMS module, a direct current converter DC/DC module, a power distribution unit PDU module and a high-voltage distribution box module. The high-voltage distribution box module includes an MCU fuse, an MCU relay and a fast charging relay. The MCU fuse and the MCU relay are connected in series and connect the microcontroller unit MCU module with the battery unit. The fast charging relay connects the fast charging socket and the battery unit.

Optionally, the high-voltage distribution box module further includes a maintenance switch disposed on the outside of the motor controller housing, the maintenance switch being connected between the microcontroller unit MCU module and the battery unit, and the maintenance switch being able to be disconnected or connected.

Optionally, the MCU relay includes a first MCU relay and a second MCU relay, the first MCU relay connects the positive pole of the micro control unit MCU module with the positive pole of the battery unit, and the second MCU relay connects the negative pole of the micro control unit MCU module with the negative pole of the battery unit.

Optionally, the fast charging relay includes a first fast charging relay and a second fast charging relay, the first fast charging relay connects the positive pole of the battery cell with the positive pole of the fast charging socket, and the second fast charging relay connects the negative pole of the battery cell with the negative pole of the fast charging socket.

Optionally, it further includes an insulation detection module and a PCB circuit board, and the battery management system BMS module, the power distribution unit PDU module and the insulation detection module are integrated on the PCB circuit board.

Optionally, the vehicle has an air pump interface and an oil pump interface, and the motor controller also includes a first DC/AC module and a second DC/AC module, the first DC/AC module is electrically connected to the air pump interface, and the second DC/AC module is electrically connected to the oil pump interface.

Optionally, the micro control unit MCU module includes an MCU power module, an MCU power module driver board, an MCU power module control board, a thin film capacitor and a filter module;

The motor controller further comprises an insulation detection module and a PCB circuit board, and the battery management system BMS module, the power distribution unit PDU module and the insulation detection module are integrated on the PCB circuit board;

The MCU power module, the MCU power module driving board, the film capacitor, the DC/DC converter module, the first DC/AC module, and the second DC/AC module are arranged on the lower layer of the motor controller housing;

The MCU fuse, the fast charge relay, and the MCU relay are arranged on a first side of the upper layer of the motor controller housing.

The MCU power module control board, the filter module, and the PCB circuit board are arranged The second side of the upper layer of the motor controller housing.

Optionally, a shielding plate is also included, and the shielding plate is configured to isolate the MCU fuse, the fast charging relay, the MCU relay from the MCU power module control board, the filter module, and the PCB circuit board.

Optionally, it also includes an inlet water nozzle, an outlet water nozzle and a cooling water pipeline. The cooling water enters through the inlet water nozzle, passes through the first DC/AC module, the DC converter DC/DC module, the thin film capacitor, the MCU power module, the MCU power module driver board, and the cooling water pipeline under the second DC/AC module in sequence, and then flows out from the outlet water nozzle.

The present application also proposes a vehicle, comprising the aforementioned motor controller.

The present application structurally integrates the high-voltage distribution box module and the motor controller, and there is no need to set up a separate high-voltage distribution box, saving the cost of separate design, mold opening and assembly of the high-voltage distribution box. At the same time, there is no need to reserve a separate location on the vehicle to install the high-voltage distribution box, thereby improving space utilization, achieving weight reduction goals, and meeting lightweight requirements. Secondly, after integration, the connection harness can be reduced, the number of failure points can be reduced, reliability can be increased, and product competitiveness can be increased.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a schematic diagram of the structure of a motor controller provided by an embodiment;

The reference numerals in FIG1 are described as follows:
1-DC converter DC/DC module; 21-MCU fuse; 22-maintenance switch; 23-first
MCU relay; 24-second MCU relay; 25-first fast charging relay; 26-second fast charging relay; 3-PCB circuit board; 41-first DC/AC module; 42-second DC/AC module; 51-MCU power module; 52-MCU power module driver board; 53-MCU power module control board; 54-film capacitor; 55-filter module; 61-inlet water nozzle; 62-outlet water nozzle.

Detailed ways

The words "first", "second", etc. mentioned in this article are only for the convenience of describing two or more structures or components with the same or similar structures and/or functions, and do not imply any special limitation on the order and/or importance.

Please refer to FIG. 1 , which is a schematic diagram of the structure of a motor controller provided by an embodiment.

The present application provides a motor controller. The vehicle has a battery unit and a fast charging socket. The motor controller includes a microcontroller unit (MCU) module, a battery management system (BMS) module, a direct current (DC) converter (DC/DC) module 1, a power distribution unit (PDU) module, and a high-voltage distribution box module, wherein:

The microcontroller unit MCU module is used to convert direct current into three-phase alternating current, and realizes the speed and torque changes of the motor by adjusting the frequency and size of the current; the microcontroller unit MCU module includes an MCU power module 51, an MCU power module driver board 52, an MCU power module control board 53, a film capacitor 54 and a filter module 55; the battery management system BMS module is used for the control and management of the vehicle battery; the DC converter DC/DC module 1 is used to convert high-voltage direct current into low-voltage direct current; the power distribution unit PDU module is used for power distribution.

The high-voltage distribution box module includes an MCU fuse 21, MCU relays 23, 24 and fast-charging relays 25, 26. The MCU fuse 21 is connected in series with the MCU relays 23, 24 and connects the microcontroller unit MCU module and the battery unit. The MCU relays 23, 24 control the on-off of the circuit between the microcontroller unit MCU module and the battery unit. The MCU fuse 21 protects the circuit. For example, when an overload or short-circuit fault occurs in the system circuit, the current passing through the MCU fuse 21 will increase, and the overload current or short-circuit current will heat the MCU fuse 21. When the temperature of the MCU fuse 21 exceeds the protection temperature, the MCU fuse 21 will melt, cutting off the circuit between the microcontroller unit MCU module and the battery unit, thereby protecting the circuit. The fast-charging relays 25, 26 connect the fast-charging socket and the battery unit, thereby controlling the on-off of the circuit between the fast-charging socket and the battery unit.

It can be seen that the present application integrates the high-voltage distribution box module and the motor controller into a structure, and there is no need to set up a high-voltage distribution box separately, thus saving the cost of separate design, mold opening and assembly of the high-voltage distribution box. At the same time, there is no need to reserve a separate space on the vehicle to install the high-voltage distribution box, which improves space utilization, achieves weight reduction goals, and meets lightweight requirements; secondly, after integration, it can reduce connecting wiring harnesses, reduce failure points, increase reliability, and increase product competitiveness.

Among them, the MCU relays 23, 24 include a first MCU relay 23 and a second MCU relay 24. The first MCU relay 23 connects the positive pole of the microcontroller unit MCU module with the positive pole of the battery unit, and the second MCU relay 24 connects the negative pole of the microcontroller unit MCU module with the negative pole of the battery unit, thereby forming a closed loop between the battery unit and the microcontroller unit MCU module.

Among them, the fast charging relays 25, 26 include a first fast charging relay 25 and a second fast charging relay 26. The first fast charging relay 25 connects the positive pole of the battery cell with the positive pole of the fast charging socket, and the second fast charging relay 26 connects the negative pole of the battery cell with the negative pole of the fast charging socket, thereby forming a closed loop between the battery cell and the fast charging socket.

The high-voltage distribution box module further includes a maintenance switch 22 disposed on the outside of the motor controller housing. The maintenance switch 22 is connected between the microcontroller unit MCU module and the battery unit. The maintenance switch 22 can be disconnected or connected.

In one embodiment, the maintenance switch 22 is actually a plug-in switch. When the system needs to be repaired, the operator can manually pull out the maintenance switch 22 to cut off the circuit between the MCU module and the battery unit, and then perform the maintenance operation to improve the safety of the operation. When the maintenance is completed, the maintenance switch 22 can be plugged in again, and the system can work normally.

Please continue to refer to Figure 1. The motor controller of the present application also includes an insulation detection module and a PCB circuit board 3. The battery management system BMS module, the power distribution unit PDU module and the insulation detection module are integrated on the PCB circuit board 3.

Since both the battery management system BMS module and the power distribution unit PDU module need to integrate the insulation detection function, setting them separately will cause functional redundancy, increase costs, and reduce product competitiveness. Based on this, this application adopts in-depth board-level integration to integrate the battery management system BMS module, the power distribution unit PDU module and the insulation detection module on the same PCB circuit board 3, avoiding functional redundancy, reducing the number of chips and wiring harnesses, saving space, reducing costs, and improving product competitiveness.

For example, the vehicle has an air pump interface and an oil pump interface. The motor controller provided in the present application further includes a first direct current/alternating current (DC/AC) module 41 and a second direct current/alternating current (DC/AC) module 42. The first direct current/alternating current (DC/AC) module 41 is connected to the air pump interface. The port is electrically connected to supply power to the electric air compressor through the air pump port; the second DC/AC module 42 is electrically connected to the oil pump port to supply power to the rotating oil pump motor through the oil pump port.

After being highly physically integrated into a housing, the present application also relatively optimizes the position of each module to reduce the volume of the entire device.

Exemplarily, the present application adopts an upper and lower double-layer arrangement as a whole, wherein: the high-voltage modules that require heat dissipation: MCU power module 51, MCU power module driver board 52, thin film capacitor 54, DC converter DC/DC module 1, first DC/AC DC/AC module 41 and second DC/AC DC/AC module 42 are arranged on the lower layer of the motor controller housing; the high-voltage modules that do not require heat dissipation: MCU fuse 21, fast charging relay 25, 26, MCU relay 23, 24 are arranged on the first side of the upper layer of the motor controller housing; the low-voltage modules that do not require heat dissipation: MCU power module control board 53, filter module 55, PCB circuit board 3 are arranged on the second side of the upper layer of the motor controller housing.

As set above, this application arranges the high-voltage module that needs heat dissipation on the lower layer of the motor controller housing, and the module that does not need heat dissipation on the upper layer of the motor controller housing, based on comprehensive consideration of heat dissipation and high and low voltage isolation. The high-voltage module and the low-voltage module are arranged in partitions. On the one hand, it is convenient to cool the lower module through the cooling water channel, improve the heat dissipation effect, and extend the service life; on the other hand, it ensures high and low voltage isolation, optimizes EMC (Electro Magnetic Compatibility) in the structural layout, and improves the EMC level of the whole machine. At the same time, through the above-mentioned structural optimization, the internal space of the motor controller housing is fully utilized, the power density is improved, and the outer envelope and interface of the motor controller assembly are guaranteed to remain unchanged, meeting customer requirements with the advantages of product continuity and cost savings.

In addition, in order to further improve the EMC level, the upper high-voltage module and the low-voltage module can be separated by a shielding plate, which can also serve as a support for the upper module.

Optionally, the motor controller of the present application also includes an inlet water nozzle 61, an outlet water nozzle 62 and a cooling water pipe. The cooling water enters through the inlet water nozzle 61, passes through the first DC/AC module 41, the DC converter DC/DC module 1, the thin film capacitor 54, the MCU power module 51, the MCU power module driver board 52, and the cooling water pipe under the second DC/AC module 42, and then flows out from the outlet water nozzle 62.

Since the heat generated by the first DC/AC module 41, the second DC/AC module 42, the DC converter DC/DC module 1 and the film capacitor 54 is smaller than the heat generated by the MCU power module 51 and the MCU power module driver board 52; The temperature resistance is worse than that of the first DC/AC module 41, the second DC/AC DC/AC module 42, the MCU power module 51, and the MCU power module driver board 52. The film capacitor 54 is highly sensitive to temperature, and the increase in temperature will reduce the life of the film capacitor 54. The first DC/AC DC/AC module 41 and the second DC/AC DC/AC module 42 have low power and low heat generation. Therefore, the above-mentioned circulation method is adopted to cool the first DC/AC DC/AC module 41, the DC converter DC/DC module 1, the film capacitor 54, the MCU power module 51, the MCU power module driver board 52, and the second DC/AC DC/AC module 42 in turn to ensure that each module can work normally and improve the service life of each module.

The present application also provides a vehicle, comprising the aforementioned motor controller.

The vehicle of the present application includes the aforementioned motor controller, and therefore has the same technical effects as the aforementioned motor controller, which will not be repeated here.

Claims (10)

1. A motor controller, a vehicle having a battery unit and a fast charging socket, the motor controller comprising a micro control unit (MCU) module, a battery management system (BMS) module, a direct current converter (DC/DC) module (1), a power distribution unit (PDU) module and a high-voltage distribution box module, wherein the high-voltage distribution box module comprises an MCU fuse (21), an MCU relay (23, 24) and a fast charging relay (25, 26), the MCU fuse (21) and the MCU relay (23, 24) are connected in series and connect the micro control unit (MCU) module with the battery unit, and the fast charging relay (25, 26) connects the fast charging socket with the battery unit.
2. According to the motor controller of claim 1, the high-voltage distribution box module also includes a maintenance switch (22) arranged on the outside of the motor controller housing, the maintenance switch (22) is connected between the micro control unit MCU module and the battery unit, and the maintenance switch (22) can be disconnected or connected.
3. According to the motor controller of claim 1, the MCU relay (23, 24) comprises a first MCU relay (23) and a second MCU relay (24), the first MCU relay (23) connecting the positive pole of the micro control unit MCU module with the positive pole of the battery unit, and the second MCU relay (24) connecting the negative pole of the micro control unit MCU module with the negative pole of the battery unit.
4. According to the motor controller of claim 1, the fast charging relay (25, 26) includes a first fast charging relay (25) and a second fast charging relay (26), the first fast charging relay (25) connects the positive pole of the battery cell with the positive pole of the fast charging socket, and the second fast charging relay (26) connects the negative pole of the battery cell with the negative pole of the fast charging socket.
5. The motor controller according to any one of claims 1 to 4, further comprising an insulation detection module and A PCB circuit board (3), on which the battery management system BMS module, the power distribution unit PDU module and the insulation detection module are integrated.
6. According to the motor controller according to any one of claims 1 to 4, the vehicle has an air pump interface and an oil pump interface, and the motor controller also includes a first DC/AC module (41) and a second DC/AC module (42), the first DC/AC module (41) is electrically connected to the air pump interface, and the second DC/AC module (42) is electrically connected to the oil pump interface.
7. According to the motor controller of claim 6, the micro control unit MCU module comprises an MCU power module (51), an MCU power module driving board (52), an MCU power module control board (53), a film capacitor (54) and a filter module (55);

   The motor controller further comprises an insulation detection module and a PCB circuit board (3), and the battery management system BMS module, the power distribution unit PDU module and the insulation detection module are integrated on the PCB circuit board (3);

   The MCU power module (51), the MCU power module driving board (52), the thin film capacitor (54), the DC/DC converter module (1), the first DC/AC module (41), and the second DC/AC module (42) are arranged on the lower layer of the motor controller housing;

   The MCU fuse (21), the fast charging relay (25, 26), and the MCU relay (23, 24) are arranged on a first side of an upper layer of a housing of the motor controller,

   The MCU power module control board (53), the filter module (55), and the PCB circuit board (3) are arranged on the second side of the upper layer of the motor controller housing.
8. The motor controller according to claim 7 further comprises a shielding plate, wherein the shielding plate is provided The invention is to isolate the MCU fuse (21), the fast charging relay (25, 26), the MCU relay (23, 24) from the MCU power module control board (53), the filter module (55), and the PCB circuit board (3).
9. According to claim 7, the motor controller further comprises an inlet water nozzle (61), an outlet water nozzle (62) and a cooling water pipeline, wherein the cooling water enters through the inlet water nozzle (61), passes through the first DC/AC module (41), the DC converter DC/DC module (1), the thin film capacitor (54), the MCU power module (51), the MCU power module driver board (52), and the cooling water pipeline below the second DC/AC module (42) in sequence, and then flows out from the outlet water nozzle (62).
10. A vehicle, comprising a motor controller as claimed in any one of claims 1 to 9.