WO2025246786A1 - 控制器、双电机驱动装置及车辆 - Google Patents

控制器、双电机驱动装置及车辆

Info

Publication number
WO2025246786A1
WO2025246786A1 PCT/CN2025/092211 CN2025092211W WO2025246786A1 WO 2025246786 A1 WO2025246786 A1 WO 2025246786A1 CN 2025092211 W CN2025092211 W CN 2025092211W WO 2025246786 A1 WO2025246786 A1 WO 2025246786A1
Authority
WO
WIPO (PCT)
Prior art keywords
power module
controller
motor
plate
water
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/CN2025/092211
Other languages
English (en)
French (fr)
Inventor
陈雷
陈鹏
卢健铭
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Guangzhou Automobile Group Co Ltd
Original Assignee
Guangzhou Automobile Group Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN202421172557.9U external-priority patent/CN222674088U/zh
Priority claimed from CN202410666128.5A external-priority patent/CN121077162A/zh
Application filed by Guangzhou Automobile Group Co Ltd filed Critical Guangzhou Automobile Group Co Ltd
Publication of WO2025246786A1 publication Critical patent/WO2025246786A1/zh
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics

Definitions

  • This application relates to the field of vehicle equipment, and mainly to a controller, a dual-motor drive device, and a vehicle.
  • the dual-motor drive device includes a controller and two motors.
  • the controller needs to be able to independently control the operation of the two motors. Therefore, the controller includes two power modules, two drive boards, a capacitor, a shielding board, and a control board.
  • the arrangement structure between the power modules, drive boards, capacitors, shielding boards, and control boards is not compact enough, resulting in a large overall size of the controller.
  • the purpose of this application is to provide a controller, a dual-motor drive device and a vehicle to solve the problem of the large size of existing controllers.
  • a controller includes a support frame, a power module assembly, a control circuit board, a shielding plate, a second drive board, and a capacitor assembly.
  • the power module assembly includes a first power module and a second power module, which are stacked.
  • the control circuit board is stacked on the side of the first power module opposite to the second power module and is electrically connected to the first power module.
  • the shielding plate is disposed between the first power module and the control circuit board.
  • the second drive board is stacked on the side of the second power module opposite to the first power module and is electrically connected to both the second power module and the control board.
  • the capacitor assembly is arranged side-by-side with at least one of the power module assembly and the second drive board and is electrically connected to both the first and second power modules.
  • the support frame is fixedly connected to at least one of the power module assembly, the control circuit board, the shielding plate, and the second drive board.
  • the stacking of the control circuit board, the shielding plate, the power module assembly, and the second drive board, and the side-by-side arrangement of the capacitor assembly with at least one of the power module assembly and the second drive board reduces the number of layers in the controller and its height, resulting in a more compact and smaller controller structure.
  • the capacitor assembly is arranged side by side with the control circuit board and the second drive board; the shielding plate is flat, and the projection of the shielding plate in the normal direction covers the capacitor assembly and the power module assembly, making the structure composed of the power module assembly, the control circuit board, the shielding plate, the second drive board and the capacitor assembly more compact.
  • control circuit board includes a control board and a first drive board.
  • the first drive board is electrically connected to both the control board and the first power module, and the second drive board is electrically connected to the control board.
  • the control board and the first drive board are arranged on the same plane and integrated into one unit, making the structure more compact.
  • the edge of the first drive board is directly opposite the edge of the first power module, and the edge of the control board is directly opposite the edge of the capacitor assembly.
  • the control board is arranged in full use of the remaining position of the plane where the first drive board is located, making the overall structure of the controller more compact, and the wiring harness leading out from the edge of the first drive board and connected to the first power module can be set to be shorter.
  • the power module assembly further includes a water-cooled plate, which is fixedly connected to the support frame and stacked between the first power module and the second power module.
  • the first power module and the second power module are respectively disposed on two sides of the water-cooled plate.
  • the water-cooled plate is provided with water-cooling channels for cooling the first power module and the second power module.
  • the water-cooled plate allows for simultaneous cooling of both the first and second power modules, and the first and second power modules can be fixedly connected to the support frame via the water-cooled plate.
  • the water-cooled plate is flat and includes a first side and a second side.
  • the first side and the second side are positioned opposite each other, and the area of the first side and the second side is larger than the area of the other sides of the water-cooled plate.
  • the first power module is fixed on the first side and the second power module is fixed on the second side. This reduces the thickness of the water-cooled plate while ensuring the cooling effect on the first power module and the second power module, thereby making the controller structure more compact and smaller in size.
  • the first power module is welded to the first side, and the second power module is welded to the second side; or the water-cooled plate has a first window on the first side and a second window on the second side, both the first and second windows are connected to the water-cooling channel, the first power module is sealed to the first window, and the second power module is sealed to the second window.
  • the support frame includes a base plate located on the side of the capacitor assembly and the second drive board away from the shielding plate, and the capacitor assembly is attached to the base plate.
  • the base plate is provided with a first cooling channel at the position corresponding to the capacitor assembly, and the first cooling channel is used to cool the capacitor assembly, thereby improving the cooling effect of the controller.
  • the support frame further includes a first flow channel column and a second flow channel column. Both the first and second flow channel columns protrude from the surface of the base plate. One end of the first flow channel column is connected to the water outlet of the first cooling channel, and the other end is connected to the water inlet of the water cooling channel. One end of the second flow channel column is connected to the water outlet of the water cooling channel, so that the water cooling channel and the first cooling channel form a series channel, which facilitates the pipe connection between the water cooling channel, the first cooling channel and the coolant supply device.
  • the second drive board is fixed on the base plate; the base plate is provided with a second cooling channel at the position corresponding to the second drive board, the second cooling channel is used to cool the second drive board, and the end of the second flow channel column away from the water-cooled plate is connected to the water inlet end of the second cooling channel, thereby improving the cooling effect of the controller.
  • the controller further includes a first support column and a second support column.
  • One end of the first support column is fixed to the base plate, and the other end is the free end of the first support column.
  • a water-cooling plate is fixed to the free end of the first support column, and a first space is formed between the water-cooling plate and the base plate for accommodating the second drive board and the second power module.
  • One end of the second support column is fixed to the base plate, and the other end is the free end of the second support column.
  • a shielding plate is fixed to the free end of the second support column, and a second space is formed between the shielding plate and the base plate for installing the second drive board, the power module assembly, and the capacitor assembly.
  • the capacitor assembly includes a capacitor and a filter.
  • the input terminal of the filter is connected to an external three-phase power line, and the output terminal of the filter is connected to the input terminal of the capacitor.
  • the output terminal of the capacitor faces the power module assembly.
  • the input terminals of the first power module and the second power module face the output terminal of the capacitor and are both electrically connected to the output terminal of the capacitor.
  • the capacitor and the base plate are encapsulated as a single unit, which reduces the volume of the capacitor and the base plate, thereby reducing the overall volume of the controller; and/or the controller further includes a three-phase connector, which includes a first three-phase copper busbar and a second three-phase copper busbar.
  • One end of the first three-phase copper busbar is connected to the output terminal of the first power module, and the other end is used to connect to the first motor of the dual-motor drive device.
  • One end of the second three-phase copper busbar is connected to the output terminal of the second power module, and the other end is used to connect to the second motor of the dual-motor drive device.
  • the first three-phase copper busbar is at least partially attached to the side of the base plate opposite to the second drive plate
  • the second three-phase copper busbar is at least partially attached to the side of the base plate opposite to the second drive plate, so that the coolant inside the base plate can cool the first three-phase copper busbar and the second three-phase copper busbar.
  • a dual-motor drive device includes a housing, motors, a controller, and electrical connectors.
  • the housing has a motor mounting cavity and a controller mounting cavity, and is provided with a water inlet channel and a water outlet channel.
  • the motors include a first motor and a second motor, both of which are installed in the motor mounting cavity.
  • the controller is installed in the controller mounting cavity.
  • the water inlet end of the first cooling channel is connected to the water inlet channel, and the water outlet end of the second cooling channel is connected to the water outlet channel.
  • the electrical connectors include a first electrical connector and a second electrical connector.
  • the first electrical connector is disposed between the first motor and the controller and is electrically connected to a first power module of the first motor and the controller.
  • the second electrical connector is disposed between the second motor and the controller and is electrically connected to a second power module of the second motor and the controller.
  • a vehicle includes a body, wheels, and a dual-motor drive unit, wherein the dual-motor drive unit is fixed to the body and the wheels are connected to the motors via transmission.
  • control circuit board, shielding plate, power module assembly and second drive board are stacked, and the capacitor assembly is arranged side by side with at least one of the power module assembly, control circuit board, shielding plate and second drive board, which reduces the number of stacked layers of the controller and reduces the height of the controller, thereby making the controller structure more compact and smaller in size.
  • the dual-motor drive device of this application includes a housing, a motor, an electrical connector, and the aforementioned controller.
  • the controller is smaller in size, making it easier to arrange on the housing of the dual-motor drive device.
  • the controller mounting cavity for mounting the controller can be made smaller, resulting in a more compact structure and smaller size for the dual-motor drive device.
  • the vehicle described in this application including the aforementioned dual-motor drive unit, makes the overall structure of the vehicle more compact.
  • Figure 1 is a schematic diagram of the structure of a dual-motor drive device in one embodiment.
  • Figure 2 is an exploded view of Figure 1 after the end cap and cover plate have been removed.
  • Figure 3 is a schematic diagram of the structure of the motor control housing in one embodiment.
  • Figure 4 is a schematic diagram of the controller in one embodiment.
  • Figure 5 is a schematic diagram of the controller shown in Figure 4 from a low-angle view.
  • Figure 6 is an explosion diagram of the controller shown in Figure 4 after the metal cover has been removed.
  • Figure 7 shows the positional relationship between the capacitor assembly and the power module assembly.
  • Figure 8 is a schematic diagram of the support structure in one embodiment, wherein the dashed lines indicate the positions of the first cooling channel and the second cooling channel.
  • the terms “installation,” “connection,” and “linkage” should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
  • a vehicle includes a body, wheels, and a dual-motor drive unit, the dual-motor drive unit being fixed to the body, and the wheels being connected to the motors for transmission, so that the vehicle moves under the drive of the motors of the dual-motor drive unit.
  • the dual-motor drive device includes a housing 20, a motor 30, a controller 10, and an electrical connector 40.
  • the housing 20 has a motor mounting cavity 201 and a controller mounting cavity 202.
  • the controller 10 is installed in the controller mounting cavity 202.
  • the motor 30 includes a first motor 301 and a second motor 302, both of which are installed in the motor mounting cavity 201.
  • the electrical connector 40 includes a first electrical connector 401 and a second electrical connector 402.
  • the first electrical connector 401 is disposed between the first motor 301 and the controller 10 and is electrically connected to both.
  • the second electrical connector 402 is disposed between the second motor 302 and the controller 10 and is electrically connected to both, enabling the controller 10 to control the operation of the first motor 301 and the second motor 302 respectively.
  • the electrical connector 40 can be a copper busbar, but it can also be other conductive structures.
  • the motor mounting cavity 201 includes a first motor mounting cavity and a second motor mounting cavity, which are coaxially arranged.
  • the first motor 301 is installed in the first motor mounting cavity
  • the second motor 302 is installed in the second motor mounting cavity.
  • the controller mounting cavity 202 is located on one side of the first motor mounting cavity and the second motor mounting cavity in the circumferential direction, which shortens the distance between the first motor 301 and the controller 10 and between the second motor 302 and the controller 10, that is, shortens the total length of the first electrical connector 401 and the second electrical connector 402.
  • the wheel includes a first wheel end and a second wheel end.
  • the first wheel end is driven by a first motor 301
  • the second wheel end is driven by a second motor 302, so that the first motor 301 and the second motor 302 drive the two wheel ends (i.e., the first wheel end and the second wheel end) to rotate respectively. That is, the first wheel end and the second wheel end are driven independently by the first motor 301 and the second motor 302 respectively, forming a distributed dual-motor drive device.
  • the wheel includes a first wheel end and a second wheel end.
  • the first motor 301 and the second motor 302 are simultaneously connected to the first wheel end and the second wheel end for transmission.
  • the first wheel end and the second wheel end are respectively connected to the two output half shafts of the differential.
  • the first motor 301 and the second motor 302 are both connected to the differential, so that one or both of the first motor 301 and the second motor 302 drive the first wheel end and the second wheel end to rotate simultaneously, forming a dual-motor electric drive device.
  • the housing 20 includes a motor control housing 205, an end cap 206, and a cover plate 207.
  • the motor mounting cavity 201 and the controller mounting cavity 202 are both disposed on the motor control housing 205.
  • the end cap 206 is fixed to the end of the motor control housing 205 to seal the opening of the motor mounting cavity 201.
  • the cover plate 207 is fixed to the motor control housing 205 to seal the opening of the controller mounting cavity 202.
  • a speed reducer is also provided between the end cover 206 and the motor control housing 205.
  • the speed reducer is connected to the output end of the motor 30, and the motor 30 is connected to the wheel end via the speed reducer.
  • the controller 10 includes a support frame 1, a power module assembly 2, a control circuit board 3, a shielding plate 4, a second drive board 5, and a capacitor assembly 6.
  • the support frame 1 is fixedly connected to the outer casing 20, and at least one of the power module assembly 2, the control circuit board 3, the shielding plate 4, and the second drive board 5 is fixed to the support frame 1.
  • the power module assembly 2 includes a first power module 21 and a second power module (in the embodiments shown in Figures 6 and 7, the second power module is located on the side of the water-cooled plate 23 opposite to the first power module 21), and the first power module 21 and the second power module are stacked.
  • the control circuit board 3 is stacked on the side of the first power module 21 opposite to the second power module, and the control circuit board 3 is electrically connected to the first power module 21.
  • the shielding plate 4 is stacked between the first power module 21 and the control circuit board 3, and the second drive board 5 is stacked on the side of the second power module opposite to the first power module 21.
  • the second drive board 5 is located on the side of the shielding plate 4 opposite to the control circuit board 3, and the second drive board 5 is electrically connected to both the second power module and the control board 31.
  • the capacitor assembly 6 is electrically connected to the first power module 21 and the second power module, and is arranged side by side with at least one of the power module assembly 2 and the second drive board 5.
  • layered arrangement refers to the arrangement in the vertical (Z-axis) direction, and the projections in the Z-axis direction overlap.
  • “Side-by-side arrangement” refers to the arrangement in the horizontal (X-axis) or front-back (Y-axis) directions, and the projections in the horizontal or front-back directions overlap.
  • the size of the power module assembly 2 in the width direction of the controller 10 is reduced without significantly increasing the height direction.
  • the height of the capacitor assembly 6 is larger than that of the second power module.
  • the height of the capacitor assembly 6 is close to or equal to the sum of the height of the power module assembly 2 and the height of the second drive board 5.
  • the capacitor assembly 6 is placed within the width space of one of the power modules when the two power modules are arranged side by side. This ensures that arranging the capacitor assembly 6 side by side with the power module assembly 2 and the second drive board 5 does not substantially increase the width dimension of the controller 10.
  • "close to" means approximately equal.
  • the height of the stacked power module assembly 2 and the second drive board 5 and the thickness of the capacitor assembly 6 is within ⁇ 10mm, then the height of the stacked power module assembly 2 and the second drive board 5 is close to the thickness of the capacitor assembly 6.
  • the second drive board 5 and the control circuit board 3 are set separately, so that the height of the second drive board 5 and the power module component 2 after being stacked is close to or equal to the height of the capacitor component 6, thereby making the overall structure of the controller 10 more compact.
  • the control circuit board 3 includes a control board 31 and a first drive board 32.
  • the control board 31 and the first drive board 32 are arranged on the same plane and integrated into one unit.
  • the first drive board 32 is electrically connected to the control board 31 and the first power module 21.
  • the second drive board 5 is electrically connected to the control board 31.
  • High-voltage AC power flows to the first power module 21 and the second power module after being regulated by the capacitor assembly 6.
  • the first power module 21 is electrically connected to the first motor 301 through the first electrical connector 401, and the second power module is electrically connected to the second motor 302 through the second electrical connector 402.
  • the control circuit board 3 is electrically connected to the first power module 21 and to the second power module through the second drive board 5, so that the control circuit board 3 can control the operation of the first power module 21 and the second power module, thereby controlling the first motor 301 and the second motor 302.
  • control board 31 and the first drive board 32 are integrated into one unit, making the structure of the control board 31 and the first drive board 32 more compact, reducing the space required to install the control board 31 and the first drive board 32, and further reducing the overall volume of the controller 10.
  • the second drive board 5, the second power module, the first power module 21, the shielding plate 4, and the control circuit board 3 are stacked, facilitating the electrical connection between the second drive board 5 and the second power module, and between the first power module 21 and the control circuit board 3.
  • This arrangement makes the overall structure of the controller 10 more compact and reduces its size.
  • the shielding plate 4 is positioned between the first power module 21 and the control circuit board 3 to prevent the high-voltage current from the first power module 21 from interfering with the signal of the control circuit board 3.
  • the support frame 1 is fixedly connected to the housing 20, thereby fixing the controller 10 as a whole on the housing 20.
  • the control circuit board 3 is set on the opening side of the controller mounting cavity 202, which facilitates the maintenance of the control board 31.
  • the shielding plate 4 is flat, and the projection of the shielding plate 4 in the normal direction covers the capacitor assembly 6 and the power module assembly 2.
  • the normal direction is the direction in which the control circuit board 3, the shielding plate 4, the power module assembly 2 and the second drive board 5 are stacked. That is, after the capacitor assembly 6 and the power module assembly 2 are installed, their edges are less than or equal to the edges of the shielding plate 4, and the edges of the control circuit board 3 are less than or equal to the edges of the shielding plate 4, so that the shielding plate 4 can completely shield the magnetic field of the capacitor assembly 6 and the power module assembly 2, and prevent the magnetic field of the capacitor assembly 6 and the power module assembly 2 from interfering with the control circuit board 3.
  • the edges of the plane containing the capacitor assembly 6 and the power module assembly 2, the edge of the shielding plate 4, and the edge of the control circuit board 3 are aligned, making the overall structure of the controller 10 more compact.
  • the edge of the first drive board 32 is directly opposite the edge of the first power module 21, so that when a wire harness is led out from the edge of the first drive board 32 to connect to the first power module 21, the length of the wire harness between the first drive board 32 and the first power module 21 can be shortened.
  • the edge of the control board 31 is directly opposite the edge of the capacitor assembly 6, so that the remaining space of the plane where the first drive board 32 is located can be fully utilized to arrange the control board 31, thereby making the overall structure of the controller 10 compact.
  • the edges of the first drive board 32, the first power module 21, the second power module, and the second drive board 5 are all aligned.
  • the wiring harness connecting the second drive board 5 and the control board 31 is located on the control board 31 near the first drive board 32, which shortens the length of the wiring harness between the control board 31 and the second drive board 5. Furthermore, the wiring harness connecting the control board 31 and the second drive board 5 and the wiring harness connecting the first drive board 32 and the first power module 21 can be integrated together, reducing the space required for wiring.
  • the power module assembly 2 also includes a water-cooled plate 23, which is fixedly connected to the support frame 1 and is located between the first power module 21 and the second power module.
  • the first power module 21 and the second power module are respectively disposed on two sides of the water-cooled plate 23, so that the first power module 21 and the second power module are fixedly connected to the support frame 1 through the water-cooled plate 23.
  • the water-cooled plate 23 is equipped with water-cooling channels for cooling the first power module 21 and the second power module.
  • coolant flows within the water-cooling channels, the heat generated by the operation of the first power module 21 and the second power module is transferred to the coolant through the water-cooled plate 23 and carried away by the coolant from the controller 10, thus cooling the controller 10. Since the first power module 21 and the second power module are respectively located on two sides of the water-cooled plate 23, both modules can be cooled simultaneously, reducing the temperature difference between them and resulting in better cooling performance.
  • the water-cooled plate 23 is flat and includes a first side and a second side.
  • the first and second sides are positioned opposite each other, and the area of the first and second sides is larger than the area of the other sides of the water-cooled plate 23.
  • the first power module 21 is fixed on the first side, and the second power module is fixed on the second side. This reduces the thickness of the water-cooled plate 23 while ensuring the installation area and cooling effect of the first and second power modules, making the structure of the power module assembly 2 more compact.
  • the first power module 21 is welded to the first side and the second power module is welded to the second side, which makes the connection between the first power module 21, the second power module and the water-cooled plate 23 convenient.
  • the water-cooled plate 23 does not need to be provided with additional structures for fixing the first power module 21 and the second power module, which makes the structure of the water-cooled plate 23 simple and small in size.
  • the water-cooled plate 23 has a first opening on its first side, which communicates with a water-cooling channel.
  • a first power module 21 is sealed to the first opening, allowing it to contact the coolant and improving the heat transfer efficiency between the power module 21 and the coolant, thus enhancing the cooling effect.
  • the first power module 21 can be fixed to the first side of the water-cooled plate 23 with screws.
  • a sealing ring is provided at the first opening on the first side, and the power module 21 abuts against the sealing ring to achieve a sealed connection between the power module 21 and the first opening.
  • the water-cooled plate 23 has a second opening on its second side, which communicates with a water-cooling channel.
  • a second power module is sealed to the second opening, allowing it to contact the coolant and improving the heat transfer efficiency between the power module and the coolant, thus enhancing the cooling effect.
  • the second power module can be fixed to the second side of the water-cooled plate 23 with screws.
  • a sealing ring is provided at the second opening on the second side, and the power module abuts against the sealing ring to achieve a sealed connection between the power module and the second opening.
  • the support frame 1 includes a base plate 11, a first support column 14, and a second support column 15.
  • the base plate 11 is located on the side of the capacitor assembly 6 and the second drive plate 5 away from the shielding plate 4.
  • the base plate 11 is fixedly connected to the outer shell 20.
  • One end of the first support column 14 is fixed to the base plate 11, and the other end is the free end of the first support column 14.
  • a water-cooling plate 23 is fixed to the free end of the first support column 14.
  • a first space for accommodating the second drive plate 5 and the second power module is formed between the water-cooling plate 23 and the base plate 11.
  • one end of the second support column 15 is fixed to the base plate 11, and the other end is the free end of the second support column 15.
  • the shielding plate 4 is fixed to the free end of the second support column 15.
  • a second space for installing the second drive plate 5 and the power module assembly 2 is formed between the shielding plate 4 and the base plate 11.
  • the first support column 14 and the second support column 15 both protrude from the same side surface of the base plate 11.
  • the length of the second support column 15 along its axial direction is greater than the length of the first support column 14. Therefore, the second space includes the first space.
  • the base plate 11, the first support column 14, and the second support column 15 are integrally formed, which facilitates production and reduces costs.
  • the support frame 1 further includes a skirt, which is connected to the base plate 11 and protrudes from the surface of the base plate 11, so that the support frame 1 forms a shell structure with at least one opening.
  • the support frame 1 may not have a skirt, which can reduce the volume of the support frame 1, facilitate the connection and wiring of the wiring harness, and thus make the overall size of the controller 10 smaller and the cost lower.
  • a first cooling channel 111 is provided on the base plate 11 at the position corresponding to the capacitor assembly 6, and the first cooling channel 111 is used to cool the capacitor assembly 6.
  • the capacitor assembly 6 is in close contact with the base plate 11 to avoid gaps between the capacitor assembly 6 and the base plate 11, which would reduce the heat transfer efficiency of the capacitor assembly 6 to the base plate 11 and affect the cooling effect of the capacitor assembly 6.
  • the capacitor assembly 6 includes a capacitor 61 and a filter 62.
  • the input terminal of the filter 62 is connected to an external three-phase power line, and the output terminal of the filter 62 is connected to the input terminal of the capacitor 61.
  • the output terminal of the capacitor 61 faces the power module assembly 2.
  • the input terminals of the first power module 21 and the second power module face the output terminal of the capacitor 61 and are both electrically connected to the output terminal of the capacitor 61. This reduces the electrical connection distance between the first power module 21 and the second power module and the capacitor 61, making the structure more compact.
  • capacitor 61 and filter 62 form an L-shape.
  • the position of the first cooling channel 111 corresponds to the position of capacitor 61, meaning that the first cooling channel 111 is only used to cool capacitor 61.
  • a busbar copper bus 63 is provided at the end of filter 62 facing away from capacitor 61, and the busbar copper bus 63 is used to connect to a high-voltage AC power supply.
  • capacitor 61 is encapsulated as a single unit with base plate 11, eliminating the need for connectors and further reducing the size of controller 10. Moreover, capacitor 61 and base plate 11 are fixed together by encapsulation, making capacitor 61 fit more closely with base plate 11 and improving the cooling effect on capacitor 61.
  • the second drive board 5 is fixed on the base plate 11, and the base plate 11 is provided with a second cooling channel 112 at the position corresponding to the second drive board 5.
  • the second cooling channel 112 is used to cool the second drive board 5 and improve the overall heat dissipation effect of the controller 10.
  • the support frame 1 also includes a first flow channel column 12 and a second flow channel column 13. Both the first flow channel column 12 and the second flow channel column 13 protrude from the surface of the base plate 11. One end of the first flow channel column 12 is connected to the water outlet of the first cooling channel 111, and the other end is connected to the water inlet of the water cooling channel. One end of the second flow channel column 13 is connected to the water outlet of the water cooling channel, and the end of the second flow channel column 13 away from the water cooling plate 23 is connected to the water inlet of the second cooling channel 112.
  • first cooling channel 111, the water cooling channel and the second cooling channel 112 form a series structure, which facilitates the connection between the first cooling channel 111, the water cooling channel and the second cooling channel 112 and the water tank that provides the coolant, and simplifies the pipe connection structure.
  • the second drive plate 5 is attached to the base plate 11 to improve the cooling effect on the second drive plate 5.
  • the outer casing 20 has an inlet channel 203 and an outlet channel 204.
  • the inlet end of the first cooling channel 111 is connected to the inlet channel 203, and the outlet end of the second cooling channel 112 is connected to the outlet channel 204.
  • the inlet end of the inlet channel 203 is connected to the water tank, and the outlet end of the outlet channel 204 is connected to the water tank, so that the water tank, the inlet channel 203, the first cooling channel 111, the water-cooled channel, the second cooling channel 112, and the outlet channel 204 are sequentially connected to form a cooling circulation channel.
  • the outer casing 20 has a partition between the motor mounting cavity 201 and the controller mounting cavity 202.
  • the water inlet channel 203 and the water outlet channel 204 are set on the partition.
  • the water inlet of the first cooling channel 111 and the water outlet of the second cooling channel 112 are both set on the side of the bottom plate 11 away from the water cooling plate 23, so that the water inlet end of the first cooling channel 111 and the water outlet end of the second cooling channel 112 can correspond to the positions of the water inlet channel 203 and the water outlet channel 204 respectively, which facilitates the connection between the water inlet end of the first cooling channel 111 and the water inlet channel 203, and the connection between the water outlet end of the second cooling channel 112 and the water outlet channel 204.
  • the first motor 301 and the second motor 302 operate at higher temperatures, meaning their operating temperatures are higher than those of the controller 10.
  • the controller 10 After the controller 10 is installed on the housing 20, its base plate 11 is close to the first motor 301 and the second motor 302.
  • the first cooling channel 111 and the second cooling channel 112 By setting the first cooling channel 111 and the second cooling channel 112 on the base plate 11, the heat transferred from the first motor 301 and the second motor 302 to the controller 10 is quickly dissipated, preventing the controller 10 from overheating and burning out.
  • water is used as the coolant, but it is not limited to water as the coolant.
  • Other media, such as oil, can also be used.
  • the controller 10 also includes a three-phase connector 7, which includes a first three-phase copper busbar 71 and a second three-phase copper busbar 72.
  • One end of the first three-phase copper busbar 71 is connected to the output end of the first power module 21, and the other end is connected to the first motor 301 of the dual-motor drive device through the first electrical connector 401.
  • One end of the second three-phase copper busbar 72 is connected to the output end of the second power module, and the other end is connected to the second motor 302 of the dual-motor drive device through the second electrical connector 402.
  • the first three-phase copper busbar 71 is at least partially attached to the side of the base plate 11 opposite to the second drive plate 5, so that the coolant in the base plate 11 can cool the first three-phase copper busbar 71.
  • the second three-phase copper busbar 72 is at least partially attached to the side of the base plate 11 opposite to the second drive plate 5, so that the coolant in the base plate 11 can cool the second three-phase copper busbar 72.
  • the first three-phase copper busbar 71 includes a first connecting segment, a second connecting segment, and a third connecting segment, which are connected in sequence.
  • the second three-phase copper busbar 72 includes a fourth connecting segment, a fifth connecting segment, and a sixth connecting segment, which are connected in sequence.
  • the first connecting section and the fourth connecting section are spaced apart and fixed together by insulating material to form the first connecting part 73.
  • the first connecting part 73 is generally flat, and its large surface is in contact with the base plate 11, increasing the contact area between the first connecting part 73 and the base plate 11 and improving the cooling effect on the first three-phase copper busbar 71 and the second three-phase copper busbar 72.
  • the first connecting section is connected to the first electrical connector 401, and the fourth connecting section is connected to the second electrical connector 402.
  • the third connecting segment and the sixth connecting segment are spaced apart and fixed together by insulating material to form the third connecting part 75.
  • the third connecting part 75 is provided corresponding to the output terminal of the first power module 21 and the output terminal of the second power module, and the third connecting segment is connected to the output terminal of the first power module 21, and the sixth connecting segment is connected to the output terminal of the second power module.
  • the second connecting segment and the fifth connecting segment are spaced apart and fixed together by insulating material to form the second connecting portion 74.
  • the second connecting portion 74 is disposed between the first connecting portion 73 and the third connecting portion 75, and the second connecting segment connects the first connecting segment and the third connecting segment, while the fifth connecting segment connects the fourth connecting segment and the sixth connecting segment.
  • the second connecting portion 74 is flat, which reduces its size in the front-rear direction of the controller 10, thereby making the structure of the controller 10 more compact.
  • the controller 10 is provided with a metal cover plate 8 above the second connection portion 74.
  • the metal cover plate 8 is used to shield the magnetic field generated when the first three-phase copper busbar 71 and the second three-phase copper busbar 72 conduct electricity, so as to avoid signal interference to the operation of the control circuit board 3.
  • the metal cover plate 8 and the shielding plate 4 are configured as an integral structure.
  • the controller 10 further includes a connecting copper busbar 9, and the output terminal of the capacitor 61 is connected to the input terminal of the first power module 21 and the output terminal of the connecting capacitor 61 is connected to the input terminal of the second power module via the connecting copper busbar 9.
  • the controller 10 further includes a current sensor electrically connected to the drive board.
  • the first three-phase copper busbar 71 and the second three-phase copper busbar 72 are both equipped with current sensors, which are used to detect the current on the first three-phase copper busbar 71 and the second three-phase copper busbar 72.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
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Abstract

本申请提供了一种控制器、双电机驱动装置及车辆，将控制电路板、屏蔽板、功率模块组件和第二驱动板层叠设置，电容组件与功率模块组件、控制电路板、屏蔽板和第二驱动板中的至少一者并排布置，使得减小了控制器的层叠数量，减小控制器的高度尺寸，进而使得控制器的结构更加紧凑，体积更小。

Description

控制器、双电机驱动装置及车辆
相关申请的交叉引用
本申请要求于2024年05月27日提交中国专利局，申请号为202410666128.5，申请名称为“控制器、双电机驱动装置及车辆”、于2024年05月27日提交中国专利局，申请号为202421172557.9，申请名称为“控制器、双电机驱动装置及车辆”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及车辆设备领域，主要涉及一种控制器、双电机驱动装置及车辆。
背景技术
双电机驱动装置包含有控制器以及两个电机，控制器需要能够独立控制两个电机工作，因此，控制器包含有两个功率模块、两个驱动板、一个电容、一块屏蔽板和一个控制板，但是，现有技术中，功率模块、驱动板、电容、屏蔽板和控制板之间的布置结构不够紧凑，导致控制器的整体尺寸较大。
发明内容
鉴于上述现有技术的不足之处，本申请的目的在于提供一种控制器、双电机驱动装置及车辆，解决现有的控制器体积大的问题。
为了达到上述目的，本申请采取了以下技术方案：
一种控制器，包括支撑架、功率模块组件、控制电路板、屏蔽板、第二驱动板以及电容组件；功率模块组件包括第一功率模块和第二功率模块，第一功率模块和第二功率模块层叠设置；控制电路板层叠设置在第一功率模块背离第二功率模块的一侧，控制板与第一功率模块电连接；屏蔽板设置在第一功率模块与控制电路板之间；第二驱动板层叠设置在第二功率模块背离第一功率模块的一侧，第二驱动板与第二功率模块和控制板均电连接；电容组件与功率模块组件和第二驱动板中的至少一者并排布置，且与第一功率模块和第二功率模块电连接，支撑架与功率模块组件、控制电路板、屏蔽板和第二驱动板中的至少一者固定连接。其中，将控制电路板、屏蔽板、功率模块组件和第二驱动板层叠设置，电容组件与功率模块组件和第二驱动板中的至少一者并排布置，使得减小了控制器的层叠数量，减小控制器的高度尺寸，进而使得控制器的结构更加紧凑，体积更小。
在本申请的一些方案中，电容组件与控制电路板和第二驱动板并排设置；屏蔽板呈平板状，屏蔽板在法向方向的投影覆盖电容组件以及功率模块组件，使得功率模块组件、控制电路板、屏蔽板、第二驱动板以及电容组件组成的结构更加紧凑。
在本申请的一些方案中，控制电路板包括控制板和第一驱动板，第一驱动板与控制板和第一功率模块均电连接，第二驱动板与控制板电连接；控制板与第一驱动板布置在同一平面上，控制板与第一驱动板集成为一体，使得结构更加紧凑。
在本申请的一些方案中，第一驱动板的边沿位置与第一功率模块的边沿位置正对，控制板的边沿位置与电容组件的边沿位置正对，充分利用第一驱动板所在平面的其余位置布置控制板，使得控制器的整体结构更加紧凑，而且从第一驱动板边沿引出且与第一功率模块连接的线束能够设置得更短。
在本申请的一些方案中，功率模块组件还包括水冷板，水冷板与支撑架固定连接，且水冷板层叠设置第一功率模块和第二功率模块之间，第一功率模块和第二功率模块分别设置在水冷板的两个侧面上；水冷板上设有水冷通道，水冷通道用于对第一功率模块和第二功率模块冷却。通过水冷板的设置，使得能够同时对第一功率模块和第二功率模块冷却，而且第一功率模块和第二功率模块能够通过水冷板与支撑架固定连接。
在本申请的一些方案中，水冷板呈平板状，水冷板包括第一侧面和第二侧面，第一侧面和第二侧面的位置相对，且第一侧面和第二侧面的面积大于水冷板的其它侧面的面积；第一功率模块固定在第一侧面上，第二功率模块固定在第二侧面上，使得在保证对第一功率模块和第二功率模块的冷却效果的情况下，减小了水冷板的厚度尺寸，进而使得控制器的结构更加紧凑，体积更小。
在本申请的一些方案中，第一功率模块与第一侧面焊接连接，第二功率模块与第二侧面焊接连接；或水冷板在第一侧面上开设有第一开窗，水冷板在第二侧面上开设有第二开窗，第一开窗和第二开窗均与水冷通道连通，第一功率模块密封连接在第一开窗上，第二功率模块密封连接在第二开窗上。
在本申请的一些方案中，支撑架包括底板，底板位于电容组件和第二驱动板背离屏蔽板的一侧，且电容组件与底板贴合，底板对应电容组件的位置设有第一冷却通道，第一冷却通道用于对电容组件冷却，提高了控制器的冷却效果。
在本申请的一些方案中，支撑架还包括第一流道柱体和第二流道柱体，第一流道柱体和第二流道柱体均凸起于底板的表面，第一流道柱体的一端连通第一冷却通道的出水端，另一端连通水冷通道的进水口，第二流道柱体的一端连通水冷通道的出水口，使得水冷通道与第一冷却通道形成串接通道，方便水冷通道和第一冷却通道与冷却液提供装置之间的管道连接。
在本申请的一些方案中，第二驱动板固定在底板上；底板对应第二驱动板的位置设有第二冷却通道，第二冷却通道用于对第二驱动板冷却，第二流道柱体远离水冷板的一端与第二冷却通道的进水端连通，提高了控制器的冷却效果。
在本申请的一些方案中，控制器还包括第一支撑柱和第二支撑柱，第一支撑柱的一端固定在底板上，另一端为第一支撑柱的自由端，水冷板固定在第一支撑柱的自由端上，水冷板与底板之间形成用于容纳第二驱动板和第二功率模块的第一空间，第二支撑柱的一端固定在底板上，另一端为第二支撑柱的自由端，屏蔽板固定在第二支撑柱的自由端上，屏蔽板与底板之间形成用于安装第二驱动板、功率模块组件以及电容组件的第二空间。
在本申请的一些方案中，电容组件包括电容和滤波器，滤波器的输入端与外部的三相电线连接，滤波器的输出端与电容的输入端连接，电容的输出端朝向功率模块组件；第一功率模块和第二功率模块的输入端朝向电容的输出端，且均与电容的输出端电连接。
在本申请的一些方案中，电容与底板灌封为一体，使得能够减小电容和底板的体积，进而减小控制器的整体体积；及/或控制器还包括三相连接器，三相连接器包括第一三相铜排和第二三相铜排，第一三相铜排的一端与第一功率模块的输出端连接，另一端用于与双电机驱动装置的第一电机连接，第二三相铜排的一端与第二功率模块的输出端连接，另一端用于与双电机驱动装置的第二电机连接；第一三相铜排至少部分与底板背离第二驱动板的一侧贴合，第二三相铜排至少部分与底板背离第二驱动板的一侧贴合，使得底板内部的冷却液能够对第一三相铜排和第二三相铜排进行冷却。
一种双电机驱动装置，包括外壳、电机、控制器以及电连接件；外壳上形成有电机安装腔和控制器安装腔，外壳上设置有进水通道和出水通道；电机包括第一电机和第二电机，第一电机和第二电机均安装在电机安装腔内；控制器安装在控制器安装腔内，第一冷却通道的进水端与进水通道连通，第二冷却通道的出水端与出水通道连通；电连接件包括第一电连接件和第二电连接件，第一电连接件设置在第一电机与控制器之间，且与第一电机和控制器的第一功率模块电连接，第二电连接件设置在第二电机与控制器之间，且与第二电机和控制器的第二功率模块电连接。
一种车辆，包括车体、车轮以及双电机驱动装置，双电机驱动装置固定在车体上，车轮与电机传动连接。
有益效果：本申请的控制器中，将控制电路板、屏蔽板、功率模块组件和第二驱动板层叠设置，电容组件与功率模块组件、控制电路板、屏蔽板和第二驱动板中的至少一者并排布置，使得减小了控制器的层叠数量，减小控制器的高度尺寸，进而使得控制器的结构更加紧凑，体积更小。
本申请的双电机驱动装置，包括外壳、电机、电连接件以及上述控制器，其中，控制器的体积更加小，进而更加方便布置在双电机驱动装置的外壳上，也就是说，能够将用于安装控制器的控制器安装腔设置得更小，使得双电机驱动装置的结构更加紧凑、体积更小。
本申请的车辆，包括上述双电机驱动装置，使得车辆的整体的结构更紧凑。
附图说明
图1是一实施例中的双电机驱动装置的结构示意图。
图2是图1拆去端盖和盖板后的爆炸示意图。
图3是一实施例中的电机电控壳体的结构示意图。
图4是一实施例中的控制器的结构示意图。
图5是图4所示的控制器在仰视视角的结构示意图。
图6是图4所示的控制器拆去金属盖板后的爆炸示意图。
图7是电容组件与功率模块组件之间的位置关系图。
图8是一实施例中的支架的结构示意图，其中，虚线表示第一冷却通道和第二冷却通道的位置。
主要元件符号说明：1-支撑架；11-底板；111-第一冷却通道；12-第一流道柱体；13-第二流道柱体；112-第二冷却通道；14-第一支撑柱；15-第二支撑柱；2-功率模块组件；21-第一功率模块；23-水冷板；3-控制电路板；31-控制板；32-第一驱动板；4-屏蔽板；5-第二驱动板；6-电容组件；61-电容；62-滤波器；63-母线铜排；7-三相连接器；71-第一三相铜排；72-第二三相铜排；73-第一连接部，74-第二连接部，75-第三连接部；8-金属盖板；9-连接铜排；10-控制器；20-外壳；201-电机安装腔；202-控制器安装腔；203-进水通道；204-出水通道；205-电机电控壳体；206-端盖；207-盖板；30-电机；301-第一电机；302-第二电机；40-电连接件；401-第一电连接件；402-第二电连接件。
具体实施方式
本申请提供一种控制器、双电机驱动装置及车辆，为使本申请的目的、技术方案及效果更加清楚、明确，以下参照附图并举实施例对本申请进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本申请，并不用于限定本申请的保护范围。
在本申请的描述中，需要理解的是，术语“上”、“下”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请和简化描述，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。
在本申请的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体连接；可以是机械连接，也可以是电连接或可以相互通讯；可以是直接连接，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，可以根据具体情况理解上述术语在本申请中的具体含义。
一种车辆，包括车体、车轮以及双电机驱动装置，双电机驱动装置固定在车体上，车轮与电机传动连接，使得车辆在双电机驱动装置的电机的驱动下移动。
参阅图1-3，双电机驱动装置包括外壳20、电机30、控制器10和电连接件40。外壳20形成有电机安装腔201和控制器安装腔202，控制器10安装在控制器安装腔202内，电机30包括第一电机301和第二电机302，第一电机301和第二电机302均安装在电机安装腔201内，电连接件40包括第一电连接件401和第二电连接件402，第一电连接件401设置在第一电机301与控制器10之间，且与第一电机301和控制器10电连接，第二电连接件402设置在第二电机302与控制器10之间，且与第二电机302和控制器10电连接，使得控制器10能够分别控制第一电机301和第二电机302工作。其中，电连接件40可以为铜排，但也可以是其他导电结构。
在图1和图2所示实施例中，电机安装腔201包括第一电机安装腔和第二电机安装腔，第一电机安装腔和第二电机安装腔同轴设置，第一电机301安装在第一电机安装腔内，第二电机302安装在第二电机安装腔内，控制器安装腔202设置在第一电机安装腔和第二电机安装腔周向的一侧，使得减短了第一电机301与控制器10以及第二电机302与控制器10之间的距离，即减短了第一电连接件401和第二电连接件402的总长度。
在一些实施例中，车轮包括第一轮端和第二轮端，第一轮端与第一电机301传动连接，第二轮端与第二电机302传动连接，使得第一电机301和第二电机302分别驱动两轮端(即第一轮端和第二轮端)旋转，即第一轮端和第二轮端分别由第一电机301和第二电机302独立驱动，形成分布式双电机驱动装置。
在一些实施例中，车轮包括第一轮端和第二轮端，第一电机301和第二电机302同时与第一轮端、第二轮端传动连接，例如：第一轮端和第二轮端分别连接在差速器的两根输出半轴上，第一电机301和第二电机302均与差速器连接，使得第一电机301和第二电机302中的一者或者两者同时驱动第一轮端和第二轮端旋转，形成双电机电驱装置。
在一些实施例中，外壳20包括电机电控壳体205、端盖206和盖板207，电机安装腔201和控制器安装腔202均设置在电机电控壳体205上，端盖206固定在电机电控壳体205的端部，用于密封电机安装腔201的开口，盖板207固定在电机电控壳体205上，用于密封控制器安装腔202的开口。
在一些实施例中，端盖206与电机电控壳体205之间还设置有减速器，减速器与电机30的输出端连接，且电机30通过减速器与轮端传动连接。
参阅图4-图7，控制器10包括支撑架1、功率模块组件2、控制电路板3、屏蔽板4、第二驱动板5以及电容组件6。其中，支撑架1与外壳20固定连接，功率模块组件2、控制电路板3、屏蔽板4和第二驱动板5中的至少一者固定在支撑架1上。功率模块组件2包括第一功率模块21和第二功率模块(在图6和图7所示的实施例中，第二功率模块位于水冷板23背离第一功率模块21的一侧)，第一功率模块21和第二功率模块层叠设置。控制电路板3层叠设置在第一功率模块21背离第二功率模块的一侧，控制电路板3与第一功率模块21电连接。屏蔽板4层叠设置在第一功率模块21与控制电路板3之间，第二驱动板5层叠设置在第二功率模块背离第一功率模块21的一侧，第二驱动板5位于屏蔽板4背离控制电路板3的一侧，第二驱动板5与第二功率模块和控制板31均电连接。电容组件6与第一功率模块21和第二功率模块电连接，且与功率模块组件2和第二驱动板5中的至少一者并排布置。
其中，层叠设置是指在上下(Z轴)方向设置，而且在Z方向的投影存在重合。并排布置是指在左右(X轴)或者前后(Y轴)方向设置设置，而且在左右或者前后方向的投影存在重合。
上述中，通过将第一功率模块21和第二功率模块上下层叠布置，减小了功率模块组件2在控制器10的宽度方向的尺寸，而又没有过多增加高度方向的尺寸，而电容组件6的高度尺寸比第二功率模块的高度尺寸大，本申请通过将电容组件6与功率模块组件2和第二驱动板5中的至少一者并排布置，相对于功率模块组件2、驱动板、屏蔽板4、控制板和电容均层叠设置的技术方案，减少了元件层叠的层数，降低了控制器10的高度尺寸。
在一些实施例中，电容组件6的高度尺寸与功率模块组件2的高度尺寸和第二驱动板5的高度尺寸之和接近或者相等，通过将电容组件6与功率模块组件2和第二驱动板5并排设置，相对于第一功率模块21和第二功率模块并排设置技术方案，利用了两功率模块并排布置时的其中一块功率模块的宽度空间设置电容组件6，使得电容组件6与功率模块组件2和第二驱动板5并排设置也基本不会增加控制器10宽度方向的尺寸。其中，这里的接近即略相等，示例地：功率模块组件2和第二驱动板5层叠后的高度与电容组件6的厚度之差在±10mm的范围内，则功率模块组件2和第二驱动板5层叠后的高度与电容组件6的厚度接近。
本实施例中，通过第二驱动板5与控制电路板3分体设置，使得第二驱动板5和功率模块组件2层叠布置后的高度尺寸与电容组件6的高度尺寸接近或者相等，进而使得控制器10的整体结构更加紧凑。
控制电路板3包括控制板31和第一驱动板32，控制板31与第一驱动板32布置在同一平面上，并集成为一体，第一驱动板32与控制板31和第一功率模块21均电连接，第二驱动板5与控制板31电连接。高压交流电通过电容组件6调节后流动至第一功率模块21和第二功率模块上，第一功率模块21通过第一电连接件401与第一电机301电连接，第二功率模块通过第二电连接件402与第二电机302电连接，控制电路板3与一功率模块21电连接，以及通过第二驱动板5与第二功率模块电连接，使得控制电路板3能够控制第一功率模块21和第二功率模块工作，实现对第一电机301和第二电机302的控制。
其中，控制板31与第一驱动板32集成为一体，使得控制板31和第一驱动板32的结构更加紧凑，减小了安装控制板31和第一驱动板32所需要的空间，进一步减小了控制器10的整体体积。
上述中，将第二驱动板5、第二功率模块、第一功率模块21、屏蔽板4以及控制电路板3层叠设置，使得第二驱动板5与第二功率模块靠近，方便第二驱动板5与第二功率模块之间的电连接，第一功率模块21与控制电路板3靠近，方便第一功率模块21与控制电路板3之间的电连接，使得控制器10的整体结构更加紧凑，而且能够减小控制器10的体积。屏蔽板4设置在第一功率模块21与控制电路板3之间，能够防止第一功率模块21的高压电流对控制电路板3的信号干扰。
在将控制器10安装在外壳20上时，支撑架1与外壳20固定连接，实现将控制器10的整体固定在外壳20上，而且控制电路板3设置在控制器安装腔202的开口一侧，方便对控制板31进行检修。
在一些实施例中，屏蔽板4呈平板状，屏蔽板4在法向方向的投影覆盖电容组件6以及功率模块组件2，法向方向即为控制电路板3、屏蔽板4、功率模块组件2与第二驱动板5层叠的方向，即电容组件6和功率模块组件2安装后，其边沿小于或者等于屏蔽板4的边沿，控制电路板3的边沿小于或者等于屏蔽板4的边沿，使得屏蔽板4能够完全屏蔽电容组件6以及功率模块组件2的磁场，避免电容组件6以及功率模块组件2的磁场对控制电路板3产生干扰。
在一些实施例中，电容组件6和功率模块组件2所在平面的结构边沿、屏蔽板4的边沿以及控制电路板3的边沿正对，使得控制器10的整体结构更加紧凑。
在一些实施例中，第一驱动板32的边沿位置与第一功率模块21的边沿位置正对，使得从第一驱动板32的边沿位置引出线束连接第一功率模块21时，能够减短第一驱动板32与第一功率模块21之间的线束长度。
在一些实施例中，控制板31的边沿位置与电容组件6的边沿位置正对，使得能够充分利用第一驱动板32所在平面的其余空间布置控制板31，进而使得控制器10的整体结构紧凑。
在一些实施例中，第一驱动板32的边沿、第一功率模块21的边沿、第二功率模块的边沿以及第二驱动板5的边沿均正对，连接第二驱动板5和控制板31的线束设置在控制板31靠近第一驱动板32的位置，使得减短了控制板31与第二驱动板5之间的线束长度，而且连接控制板31与第二驱动板5之间的线束和连接第一驱动板32与第一功率模块21的线束可以集成在一起，减小布线所需要的空间。
功率模块组件2还包括水冷板23，水冷板23与支撑架1固定连接，且水冷板23位于第一功率模块21和第二功率模块之间，第一功率模块21和第二功率模块分别设置在水冷板23的两个侧面上，实现第一功率模块21和第二功率模块通过水冷板23与支撑架1固定连接。
水冷板23上设有水冷通道，水冷通道用于对第一功率模块21和第二功率模块冷却。当水冷通道内存在流动的冷却液时，第一功率模块21和第二功率模块工作所产生的热量通过水冷板23传递至冷却液，并通过冷却液带出控制器10外，实现对控制器10的冷却降温。其中，由于第一功率模块21和第二功率模块分别设置在水冷板23的两个侧面上，因此能够对第一功率模块21和第二功率模块同时冷却，减小第一功率模块21和第二功率模块的温度差，使得冷却效果更优。
水冷板23呈平板状，水冷板23包括第一侧面和第二侧面，第一侧面和第二侧面的位置相对，且第一侧面和第二侧面的面积大于水冷板23的其它侧面的面积。第一功率模块21固定在第一侧面上，第二功率模块固定在第二侧面上，使得在保证第一功率模块21和第二功率模块的安装面积以及冷却效果的基础上，减小水冷板23的厚度，使得功率模块组件2的结构更加紧凑。
在一些实施例中，第一功率模块21与第一侧面焊接连接，第二功率模块与第二侧面焊接连接，使得第一功率模块21、第二功率模块与水冷板23之间的连接方便，而且水冷板23也不需要额外设置用于固定第一功率模块21、第二功率模块的结构，使得水冷板23的结构简单、体积小。
在一些实施例中，水冷板23在第一侧面上开设有第一开窗，第一开窗与水冷通道连通，第一功率模块21密封连接在第一开窗上，使得第一功率模块21能够与冷却液接触，提高第一功率模块21与冷却液之间的热传递效率，提高冷却效果。其中，第一功率模块21可以通过螺钉固定在水冷板23的第一侧面上，第一侧面在第一开窗处设置密封圈，而且第一功率模块21与密封圈抵接，实现第一功率模块21与第一开窗之间的密封连接。同样的，水冷板23在第二侧面上开设有第二开窗，第二开窗与水冷通道连通，第二功率模块密封连接在第二开窗上，使得第二功率模块能够与冷却液接触，提高第二功率模块与冷却液之间的热传递效率，提高冷却效果。其中，第二功率模块可以通过螺钉固定在水冷板23的第二侧面上，第二侧面在第二开窗处设置密封圈，而且第二功率模块与密封圈抵接，实现第二功率模块与第二开窗之间的密封连接。
参阅图8，支撑架1包括底板11、第一支撑柱14和第二支撑柱15，底板11位于电容组件6和第二驱动板5背离屏蔽板4的一侧，底板11与外壳20固定连接，第一支撑柱14的一端固定在底板11上，另一端为第一支撑柱14的自由端，水冷板23固定在第一支撑柱14的自由端上，水冷板23与底板11之间形成用于容纳第二驱动板5和第二功率模块的第一空间。同样的，第二支撑柱15的一端固定在底板11上，另一端为第二支撑柱15的自由端，屏蔽板4固定在第二支撑柱15的自由端上，屏蔽板4与底板11之间形成用于安装第二驱动板5和功率模块组件2的第二空间。
其中，第一支撑柱14和第二支撑柱15均凸起于底板11的同一侧表面，第二支撑柱15沿其轴向的长度大于第一支撑柱14的长度，因此第二空间包含了第一空间。
在一些实施例中，底板11、第一支撑柱14和第二支撑柱15一体成型，使得方便生产，降低成本。
在一些实施例中，支撑架1还包括裙边，裙边与底板11连接，且凸起于底板11的表面，使得支撑架1形成至少一面开口的壳体结构。在其他实施例中，支撑架1也可以不设置有裙边，使得可以减少支撑架1的体积，方便线束的连接以及布线，进而使得控制器10的整体的体积更小，成本更低。
在一些实施例中，底板11对应电容组件6的位置设有第一冷却通道111，第一冷却通道111用于对电容组件6冷却。其中，电容组件6与底板11贴合，避免电容组件6与底板11之间存在间隙而降低电容组件6对底板11的热传递效率，影响电容组件6的冷却效果。
参阅图6-图8，在一些实施例中，电容组件6包括电容61和滤波器62，滤波器62的输入端与外部的三相电线连接，滤波器62的输出端与电容61的输入端连接，电容61的输出端朝向功率模块组件2；第一功率模块21和第二功率模块的输入端朝向电容61的输出端，且均与电容61的输出端电连接，使得减短了第一功率模块21和第二功率模块与电容61之间的电连接距离，使得结构更加紧凑。
在图7所示的实施例中，电容61和滤波器62组成L形，第一冷却通道111的位置与电容61的位置对应，即第一冷却通道111只用于对电容61进行冷却。滤波器62在背离电容61的一端设置有母线铜排63，母线铜排63用于与高压交流电源连接。
在一些实施例中，电容61与底板11灌封为一体，省去了连接件，使得进一步减小控制器10的体积，而且，电容61与底板11通过灌封的形式固定在一起，使得电容61与底板11之间更加贴合，提高对电容61的冷却效果。
在一些实施例中，第二驱动板5固定在底板11上，底板11对应第二驱动板5的位置设有第二冷却通道112，第二冷却通道112用于对第二驱动板5冷却，提高控制器10整体的散热效果。
支撑架1还包括第一流道柱体12和第二流道柱体13，第一流道柱体12和第二流道柱体13均凸起于底板11的表面，第一流道柱体12的一端连通第一冷却通道111的出水端，另一端连通水冷通道的进水口，第二流道柱体13的一端连通水冷通道的出水口，第二流道柱体13远离水冷板23的一端与第二冷却通道112的进水端连通，使得第一冷却通道111、水冷通道与第二冷却通道112形成串联结构，方便第一冷却通道111、水冷通道和第二冷却通道112与提供冷却液的水箱之间的连接，简化了管道连接结构。
在一些实施例中，第二驱动板5与底板11贴合，提高对第二驱动板5的冷却效果。
在一些实施例中，外壳20上形成有进水通道203和出水通道204，第一冷却通道111的进水端与进水通道203连通，第二冷却通道112的出水端与出水通道204连通，进水通道203的进水端连接水箱，出水通道204的出水端与水箱连接，使水箱、进水通道203、第一冷却通道111、水冷通道、第二冷却通道112以及出水通道204依次连通形成冷却循环通道。
其中，外壳20在电机安装腔201与控制器安装腔202之间设有隔板，进水通道203和出水通道204设置在隔板上，第一冷却通道111的进水口和第二冷却通道112的出水口均设置在底板11背离水冷板23的一侧，使得第一冷却通道111的进水端和第二冷却通道112的出水端能够分别与进水通道203和出水通道204的位置对应，方便第一冷却通道111的进水端与进水通道203之间的连接以及第二冷却通道112的出水端与出水通道204之间的连接。
在控制器10的结构中，电容组件6和功率模块组件2内流通高压交流电，因此容易产生热量，通过在底板11上设置第一冷却通道111和第二冷却通道112，以及在功率模块组件2上设置水冷板23，提高电容组件6和功率模块组件2散热效果。
双电机驱动装置中，第一电机301和第二电机302工作时的温度较高，即第一电机301和第二电机302的工作温度高于控制器10的工作温度，控制器10安装在外壳20上后，控制器10的底板11靠近第一电机301和第二电机302，通过在底板11上设置第一冷却通道111和第二冷却通道112，实现对第一电机301和第二电机302向控制器10方向传递的热量被快速排出，避免控制器10温度过高而导致烧坏。
本申请中，以水作为冷却液仅是一个实施例，但并不是限制冷却液只能是水，还可以是其他介质，比如：油。
控制器10还包括三相连接器7，三相连接器7包含有第一三相铜排71和第二三相铜排72，第一三相铜排71的一端与第一功率模块21的输出端连接，另一端通过第一电连接件401与双电机驱动装置的第一电机301连接，第二三相铜排72的一端与第二功率模块的输出端连接，另一端通过第二电连接件402与双电机驱动装置的第二电机302连接。
其中，第一三相铜排71至少部分与底板11背离第二驱动板5的一侧贴合，使得底板11内的冷却液能够对第一三相铜排71进行冷却。同样的，第二三相铜排72至少部分与底板11背离第二驱动板5的一侧贴合，使得底板11内的冷却液能够对第二三相铜排72进行冷却。
在图6所示的实施例中，第一三相铜排71包括第一连接段、第二连接段和第三连接段，第一连接段、第二连接段和第三连接段依次连接，第二三相铜排72包括第四连接段、第五连接段和第六连接段，第四连接段、第五连接段和第六连接段依次连接。
第一连接段和第四连接段间隔设置，且通过绝缘材料固定在一起，形成第一连接部73。第一连接部73大致呈平板状，且第一连接部73的大面与底板11贴合，增加了第一连接部73与底板11之间接触面积，提高了对第一三相铜排71与第二三相铜排72的冷却效果。其中，第一连接段与第一电连接件401连接，第四连接段与第二电连接件402连接。
第三连接段和第六连接段间隔设置，且通过绝缘材料固定在一起，形成第三连接部75。第三连接部75对应第一功率模块21的输出端以及第二功率模块的输出端设置，且第三连接段与第一功率模块21的输出端连接，第六连接段与第二功率模块的输出端连接。
第二连接段和第五连接段间隔设置，且通过绝缘材料固定在一起，形成第二连接部74。第二连接部74设置在第一连接部73与第三连接部75之间，且第二连接段连接第一连接段和第三连接段，第五连接段连接第四连接和第六连接段。其中，第二连接部74呈扁平状，使得减小了第二连接部74在控制器10前后方向的尺寸，进而使得控制器10的结构更加紧凑。
在一些实施例中，控制器10在第二连接部74的上方设有金属盖板8，金属盖板8用于屏蔽第一三相铜排71和第二三相铜排72导电时所产生的磁场，避免对控制电路板3的工作产生信号干扰。在其实施例中，金属盖板8与屏蔽板4设置为一体结构
在一些实施例中，控制器10还包括连接铜排9，电容61的输出端与第一功率模块21的输入端之间以及连接电容61的输出端与第二功率模块的输入端之间均通过连接铜排9连接。
在一些实施例中，控制器10还包括电流传感器，电流传感器与驱动板电连接，第一三相铜排71和第二三相铜排72上均套设有电流传感器，电流传感器用于检测第一三相铜排71和第二三相铜排72上的电流。
可以理解的是，对本领域普通技术人员来说，可以根据本申请的技术方案及其发明构思加以等同替换或改变，而所有这些改变或替换都应属于本申请的保护范围。

Claims (15)

  1. 一种控制器，其特征在于，包括：
    功率模块组件，包括第一功率模块和第二功率模块，所述第一功率模块和所述第二功率模块层叠设置；
    控制电路板，层叠设置在所述第一功率模块背离所述第二功率模块的一侧，所述控制电路板与所述第一功率模块电连接；
    屏蔽板，层叠设置在所述第一功率模块与所述控制电路板之间；
    第二驱动板，层叠设置在所述第二功率模块背离所述第一功率模块的一侧，所述第二驱动板与所述第二功率模块和所述控制电路板均电连接；
    电容组件，与所述功率模块组件和所述第二驱动板中的至少一者并排布置，且与所述第一功率模块和所述第二功率模块电连接；
    支撑架，与所述功率模块组件、所述控制电路板、所述屏蔽板和所述第二驱动板中的至少一者固定连接。
  2. 根据权利要求1所述的控制器，其特征在于，
    所述电容组件与所述功率模块组件和所述第二驱动板并排设置；
    所述屏蔽板呈平板状，所述屏蔽板在法向方向的投影覆盖所述电容组件以及所述功率模块组件。
  3. 根据权利要求2所述的控制器，其特征在于，
    所述控制电路板包括控制板和第一驱动板，所述第一驱动板与所述控制板和所述第一功率模块均电连接，所述第二驱动板与所述控制板电连接；
    所述控制板与所述第一驱动板布置在同一平面上，所述控制板与所述第一驱动板集成为一体。
  4. 根据权利要求3所述的控制器，其特征在于，所述第一驱动板的位置与所述第一功率模块的位置正对，所述控制板的位置与所述电容组件的位置正对。
  5. 根据权利要求1-4中任一项所述的控制器，其特征在于，
    所述功率模块组件还包括水冷板，所述水冷板与所述支撑架固定连接，且所述水冷板层叠设置在所述第一功率模块和所述第二功率模块之间，所述第一功率模块和所述第二功率模块分别设置在所述水冷板的两个侧面上；
    所述水冷板上设有水冷通道，所述水冷通道用于对所述第一功率模块和所述第二功率模块冷却。
  6. 根据权利要求5所述的控制器，其特征在于，
    所述水冷板呈平板状，所述水冷板包括第一侧面和第二侧面，所述第一侧面和所述第二侧面的位置相对，且所述第一侧面和所述第二侧面的面积大于所述水冷板的其它侧面的面积；
    所述第一功率模块固定在所述第一侧面上，所述第二功率模块固定在所述第二侧面上。
  7. 根据权利要求6所述的控制器，其特征在于，
    所述第一功率模块与所述第一侧面焊接连接，所述第二功率模块与所述第二侧面焊接连接；或
    所述水冷板在所述第一侧面上开设有第一开窗，所述水冷板在所述第二侧面上开设有第二开窗，所述第一开窗和所述第二开窗均与所述水冷通道连通，所述第一功率模块密封连接在所述第一开窗上，所述第二功率模块密封连接在所述第二开窗上。
  8. 根据权利要求5所述的控制器，其特征在于，
    所述支撑架包括底板，所述底板位于所述电容组件和所述第二驱动板背离所述屏蔽板的一侧，且所述电容组件与所述底板贴合，所述底板对应所述电容组件的位置设有第一冷却通道，所述第一冷却通道用于对所述电容组件冷却。
  9. 根据权利要求8所述的控制器，其特征在于，所述支撑架还包括第一流道柱体和第二流道柱体，所述第一流道柱体和所述第二流道柱体均凸起于所述底板的表面，所述第一流道柱体的一端连通所述第一冷却通道的出水端，另一端连通所述水冷通道的进水口，所述第二流道柱体的一端连通所述水冷通道的出水口。
  10. 根据权利要求9所述的控制器，其特征在于，
    所述第二驱动板固定在所述底板上；
    所述底板对应所述第二驱动板的位置设有第二冷却通道，所述第二冷却通道用于对所述第二驱动板冷却，所述第二流道柱体远离所述水冷板的一端与所述第二冷却通道的进水端连通。
  11. 根据权利要求8所述的控制器，其特征在于，所述控制器还包括第一支撑柱和第二支撑柱，所述第一支撑柱的一端固定在所述底板上，另一端为所述第一支撑柱的自由端，所述水冷板固定在所述第一支撑柱的自由端上，所述水冷板与所述底板之间形成用于容纳所述第二驱动板和所述第二功率模块的第一空间，所述第二支撑柱的一端固定在所述底板上，另一端为所述第二支撑柱的自由端，所述屏蔽板固定在所述第二支撑柱的自由端上，所述屏蔽板与所述底板之间形成用于安装所述第二驱动板、所述功率模块组件以及所述电容组件的第二空间。
  12. 根据权利要求8所述的控制器，其特征在于，
    所述电容组件包括电容和滤波器，所述滤波器的输入端与外部的三相电线连接，所述滤波器的输出端与所述电容的输入端连接，所述电容的输出端朝向所述功率模块组件；
    所述第一功率模块和所述第二功率模块的输入端朝向所述电容的输出端，且均与所述电容的输出端电连接。
  13. 根据权利要求12所述的控制器，其特征在于，
    所述电容与所述底板灌封为一体；及/或
    所述控制器还包括三相连接器，所述三相连接器包含有第一三相铜排和第二三相铜排，所述第一三相铜排的一端与所述第一功率模块的输出端连接，另一端用于与双电机驱动装置的第一电机连接，所述第二三相铜排的一端与所述第二功率模块的输出端连接，另一端用于与双电机驱动装置的第二电机连接；所述第一三相铜排至少部分与所述底板背离所述第二驱动板的一侧贴合，所述第二三相铜排至少部分与所述底板背离所述第二驱动板的一侧贴合。
  14. 一种双电机驱动装置，其特征在于，包括：
    外壳，形成有电机安装腔和控制器安装腔，所述外壳上设置有进水通道和出水通道；
    电机，包括第一电机和第二电机，所述第一电机和所述第二电机均安装在所述电机安装腔内；
    如权利要求10-13中任一项所述的控制器，安装在所述控制器安装腔内，所述第一冷却通道的进水端与所述进水通道连通，第二冷却通道的出水端与所述出水通道连通；
    电连接件，包括第一电连接件和第二电连接件，所述第一电连接件设置在所述第一电机与所述控制器之间，且与所述第一电机和所述控制器的第一功率模块电连接，所述第二电连接件设置在所述第二电机与所述控制器之间，且与所述第二电机和所述控制器的第二功率模块电连接。
  15. 一种车辆，其特征在于，包括车体、车轮以及如权利要求14所述的双电机驱动装置，所述双电机驱动装置固定在所述车体上，所述车轮与所述电机传动连接。
PCT/CN2025/092211 2024-05-27 2025-04-29 控制器、双电机驱动装置及车辆 Pending WO2025246786A1 (zh)

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