CN108233820B - Integrated electrical module for BSG motor controller - Google Patents
Integrated electrical module for BSG motor controller Download PDFInfo
- Publication number
- CN108233820B CN108233820B CN201611168190.3A CN201611168190A CN108233820B CN 108233820 B CN108233820 B CN 108233820B CN 201611168190 A CN201611168190 A CN 201611168190A CN 108233820 B CN108233820 B CN 108233820B
- Authority
- CN
- China
- Prior art keywords
- power module
- module
- dbc
- heat dissipation
- motor controller
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- 239000000758 substrate Substances 0.000 claims abstract description 23
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 19
- 229910052802 copper Inorganic materials 0.000 claims abstract description 19
- 239000010949 copper Substances 0.000 claims abstract description 19
- 230000017525 heat dissipation Effects 0.000 claims abstract description 15
- 238000003466 welding Methods 0.000 claims abstract description 13
- 239000003990 capacitor Substances 0.000 claims abstract description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000000741 silica gel Substances 0.000 claims abstract description 9
- 229910002027 silica gel Inorganic materials 0.000 claims abstract description 9
- 239000002131 composite material Substances 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 abstract description 6
- 238000000034 method Methods 0.000 abstract description 4
- 239000010410 layer Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P29/00—Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Combinations Of Printed Boards (AREA)
Abstract
The integrated electric module for the BSG motor controller mainly comprises a heat dissipation substrate, a capacitor module, a power module and a current sensor, wherein the power module mainly comprises a DBC, a chip, a shell and silica gel, the chip is welded on an upper copper plate of the DBC, the silica gel is filled in an inner cavity of the shell, and the capacitor module is fixed on the heat dissipation substrate and is electrically connected with an input end of the power module; the power module is directly welded on the radiating substrate; the current sensor is arranged on the output side of the power module and fixed on the heat dissipation substrate. The invention integrates and modularizes main core electric components of the motor controller, adopts ultrasonic welding between the electric components to replace the traditional bolt connection scheme, simplifies the assembly process, reduces the space occupied by the whole electric components, and is more suitable for the development requirements of small-sized light-weight and automatic production of the BSG motor controller.
Description
Technical Field
The present invention relates to motor controllers, and more particularly, to an integrated electrical module for a BSG motor controller.
Background
The BSG (Belt DRIVEN STARTER Generator) system is a device which can increase the rotation speed of an engine from zero to above idle speed in a very short time through Belt transmission so as to realize quick start-stop of an automobile, and the system belongs to a weak hybrid technology and can achieve the oil saving effect of 5-10%. The development trend of the existing BSG system is integrated BSG, namely, a BSG motor and a motor controller are integrated, so that the requirement of the whole vehicle on a small-sized and light-weight BSG system is met. The power module is used as a core electric component of the motor controller, the module design structure of the power module is generally divided into five layers, namely a silica gel protective layer, a chip, welding flux and a DBC plate (ceramic copper clad laminate) from top to bottom, and the welding flux and a copper substrate (or an aluminum silicon carbide substrate), and the existing power module mainly adopts an integrally packaged independent module structure, and the structural form of the power module directly determines the layout of the internal electric component of the motor controller. The basic assembly process of the core electricity of the existing motor controller is as follows: 1) Fixing the power module on a heat dissipation substrate; 2) The capacitor module is connected with the input end of the power module through a bolt; 3) The three-phase polar plate is connected with the output end of the power module through a bolt; the assembly structure occupies larger space, has complex assembly process, is not beneficial to automatic production, and is difficult to meet the development requirements of small-sized light-weight and automatic production of the BSG motor controller.
Disclosure of Invention
The present invention has been made to solve the above problems, and an object of the present invention is to provide an integrated electrical module for a BSG motor controller.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
The integrated electric module for the BSG motor controller mainly comprises a heat dissipation substrate, a capacitor module, a power module and a current sensor, wherein the power module mainly comprises a DBC, a chip, a shell and silica gel, the chip is welded on an upper copper plate of the DBC, the silica gel is filled in an inner cavity of the shell, and the capacitor module is fixed on the heat dissipation substrate and is electrically connected with an input end of the power module; the power module is directly welded on the radiating substrate; the current sensor is arranged on the output side of the power module and is fixed on the heat dissipation substrate.
The output end of the capacitor module is of a composite busbar structure, and cuboid pins led out of the composite busbar structure are connected with an upper copper plate of the DBC in an ultrasonic welding mode.
Three-phase polar plates are inlaid on the current sensor shell, each three-phase polar plate consists of three polar plates, and cuboid pins are led out from one end of each polar plate and are connected with an upper copper plate of the DBC in an ultrasonic welding mode.
The other end of the polar plate is in a forked cuboid structure.
The integrated electrical module provided by the invention integrates and modularizes main core electrical components of the motor controller, adopts ultrasonic welding between the electrical components to replace the traditional bolt connection scheme, simplifies the assembly process, reduces the occupied space of the whole electrical components, and is more suitable for the development requirements of small-sized light-weight and automatic production of the BSG motor controller.
Drawings
Fig. 1 is a schematic perspective view of an integrated electrical module according to the present invention.
Fig. 2 is a schematic cross-sectional view of an integrated electrical module according to the present invention.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples.
As shown in fig. 1 and 2, the integrated electrical module for a BSG motor controller according to the present invention is mainly composed of a heat dissipation substrate 1, a capacitor module 2, a power module 3, and a current sensor 4; the power module 3 mainly comprises a DBC5, a chip 6, a shell 7 and silica gel 10, wherein the chip 6 is welded on a copper plate at the upper layer of the DBC5, and a copper plate at the lower layer of the DBC5 is directly welded on the heat dissipation substrate 1; the capacitor module 2 is fixed on the radiating substrate 1, the output end of the capacitor module is a composite busbar structure 8, and the composite busbar structure 8 is connected with a DBC5 upper copper plate in the structure of the power module 3 in an ultrasonic welding mode; the current sensor 4 is arranged at the output side of the power module 3 and is fixed on the radiating substrate 1, a three-phase polar plate 9 is embedded on the shell of the current sensor, the three-phase polar plate 9 consists of three independent polar plates, one end of the three-phase polar plate 9 is connected with a DBC5 upper copper plate in the structure of the power module 3 in an ultrasonic welding mode, and the other end of the three-phase polar plate 9 presents a forked cuboid structure; the three-phase polar plate 9 can be connected with the motor three-phase polar plate passing through the current sensor through resistance welding.
The specific manufacturing process of the invention is as follows: the chip 6 is welded on the upper copper plate of the DBC5, the lower copper plate of the DBC5 is welded on the heat dissipation substrate 1, then the shell 7 is fixed on the heat dissipation substrate 1, the capacitor module 2 is fixed on the heat dissipation substrate, cuboid pins led out by the busbar structure 8 at the output end are contacted with the upper copper plate of the DBC5, the current sensor 4 is fixed on the output side of the power module, cuboid pins led out by one end of the three-phase polar plate 9 arranged on the shell are contacted with the upper copper plate of the DBC5, the cuboid pins led out by the busbar structure 8, the cuboid pins led out by one end of the three-phase polar plate 9 are welded with the upper copper plate of the DBC5 in an ultrasonic welding mode, and the silica gel 10 is filled in the shell 7.
The invention integrates and modularizes main core electric components in the BSG motor controller, which is beneficial to the development requirements of small-sized light-weight and automatic production of the BSG motor controller.
Claims (1)
1. The utility model provides an integrated electrical module for BSG motor controller, includes radiating substrate, electric capacity module, power module and current sensor, and power module includes DBC, chip, shell and silica gel, and the chip welds on DBC's upper copper, and silica gel fills in shell inner chamber, its characterized in that: the capacitor module is fixed on the heat dissipation substrate and is electrically connected with the input end of the power module; the power module is directly welded on the radiating substrate; the current sensor is arranged on the output side of the power module and is fixed on the heat dissipation substrate;
The DBC lower copper plate is directly welded on the heat dissipation substrate; the output end of the capacitor module is of a composite busbar structure, and the composite busbar structure is connected with a copper plate at the upper layer of the DBC in the power module structure in an ultrasonic welding mode; a three-phase polar plate is inlaid on the shell of the current sensor, the three-phase polar plate consists of three independent polar plates, one end of the three-phase polar plate is connected with a DBC upper copper plate in the power module structure in an ultrasonic welding mode, and the other end of the three-phase polar plate presents a bifurcated cuboid structure; the three-phase polar plate is connected with the motor three-phase polar plate passing through the current sensor through resistance welding.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201611168190.3A CN108233820B (en) | 2016-12-16 | 2016-12-16 | Integrated electrical module for BSG motor controller |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201611168190.3A CN108233820B (en) | 2016-12-16 | 2016-12-16 | Integrated electrical module for BSG motor controller |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN108233820A CN108233820A (en) | 2018-06-29 |
| CN108233820B true CN108233820B (en) | 2024-06-11 |
Family
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201611168190.3A Active CN108233820B (en) | 2016-12-16 | 2016-12-16 | Integrated electrical module for BSG motor controller |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN108233820B (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111614212B (en) * | 2020-06-20 | 2023-07-14 | 上海汽车电驱动有限公司 | Motor controller of BSG system and integrated BSG system |
| CN115038312A (en) * | 2022-06-24 | 2022-09-09 | 中国第一汽车股份有限公司 | Power packaging module of motor controller |
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| JP2009106046A (en) * | 2007-10-23 | 2009-05-14 | Hitachi Ltd | Power converter for vehicle |
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Also Published As
| Publication number | Publication date |
|---|---|
| CN108233820A (en) | 2018-06-29 |
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