CN115390489B

CN115390489B - Modularized integrated electric drive controller and driving method thereof

Info

Publication number: CN115390489B
Application number: CN202211013613.XA
Authority: CN
Inventors: 高源�
Original assignee: Zhejiang Yikong Power System Co ltd
Current assignee: Zhejiang Yikong Power System Co ltd
Priority date: 2022-08-23
Filing date: 2022-08-23
Publication date: 2023-04-28
Anticipated expiration: 2042-08-23
Also published as: CN115390489A

Abstract

The invention discloses a modularized integrated electric drive controller and a driving method thereof, wherein the driving method of the modularized integrated electric drive controller is used for carrying out integrated modularization on a power system of a new energy automobile and comprises the following steps of S1: for the control circuit module, peripheral circuits of the VCU module, the BMS module, the DCDC module and the OBC module are integrated on the basis of an inverter control structure through a control board, and an original micro-processing chip of the MCU module is reserved. The invention discloses a modularized integrated electric drive controller and a driving method thereof, wherein a control circuit module, a DCDC and OBC integrated power module, an MCU power module and a PDU module are sequentially arranged on a mechanical structure module, so that the functional integration level of parts on an xEV is greatly improved from the function angle, and the cost performance of an inverter product is improved; greatly improves the production efficiency from the production angle, reduces the assembly offline inspection difficulty and reduces the after-sale cost.

Description

Modularized integrated electric drive controller and driving method thereof

Technical Field

The invention belongs to the technical field of power systems of new energy automobiles, and particularly relates to a modularized integrated electric drive controller and a driving method of the modularized integrated electric drive controller.

Background

The inverter, the whole Vehicle Controller (VCU), the BMS (battery management system), the DCDC and the OBC are important high-voltage system core components related to the power system of the new energy automobile, and respectively take important functional roles, so that the cost is high. In the respective structural designs of the parts, the inverter comprises a control circuit structure and a driving power structure; the whole vehicle controller comprises a control circuit structure required by the whole vehicle control function of the new energy automobile; the BMS includes a control circuit structure required for battery pack management; the DCDC comprises a high-voltage power circuit and a control circuit for charging a 12V storage battery; the OBC comprises a high-voltage power circuit with an automobile charging function, a control circuit and a charging pile interaction circuit. The PDU is a power distribution unit of a high-voltage loop of the new energy automobile, is used as a transfer station of the high-voltage loop, and reduces the cost of the whole high-voltage system.

The power driving circuit of the inverter has independent functions, but the control circuit and other control circuits share the same point. Therefore, in the state that the function roles of the power system of the new energy automobile are difficult to adjust, the common part of the control circuit design is utilized to carry out function integration design, so that the function roles of the new energy automobile can be simplified. The method is beneficial to reducing the volume and the weight of the power system of the new energy automobile, saving the assembly space of the whole automobile, reducing the harness cost of the whole automobile and further reducing the overall production cost of the xEV power system.

In the existing multifunctional integrated products on the market, although there are products integrating power system parts such as xEV battery control, electric drive control, whole vehicle system control, DCDC, OBC and power distribution units, the control circuits in many products are not integrated, and a plurality of microprocessor chips are used for independent work, only mechanical integration. On the basis of circuit integration, part of the product is in a mechanical stacking state, and the production assembly and the process are complex. Although the goal of product integration is achieved, the difficulty of product production and the difficulty of offline testing are high, and the production efficiency and the overall cost competitiveness of the product are affected. After the product is produced, the method has no feasibility of simplified repair and has higher after-sale cost.

Accordingly, the above problems are further improved.

Disclosure of Invention

The invention mainly aims to provide a modularized integrated electric drive controller and a driving method thereof, wherein a control circuit module, a DCDC and OBC integrated power module, an MCU power module and a PDU module are sequentially arranged on a mechanical structure module, so that the functional integration level of parts on an xEV is greatly improved from the function point of view, and the cost performance of an inverter product is improved; greatly improves the production efficiency from the production angle, reduces the assembly offline inspection difficulty and reduces the after-sale cost. The overall volume, weight and production cost of parts of the power system of the electric automobile are greatly reduced, and the promotion significance on the improvement of the whole automobile performance is great.

In order to achieve the above object, the present invention provides a driving method of a modularized integrated electric drive controller, which is used for performing integrated modularization on a power system of a new energy automobile, and comprises the following steps:

step S1: for the control circuit module, peripheral circuits of the VCU module, the BMS module, the DCDC module and the OBC module are integrated on the basis of an inverter control structure through a control board, and an original micro-processing chip of the MCU module is reserved, so that after a power supply circuit of the control board obtains power supply capacity, peripheral circuits comprising a digital signal sampling circuit, an analog signal sampling circuit, a digital signal output circuit, a high-low side driving output circuit and a LIN communication circuit are added, and further, the control and operation functions of all high-voltage parts of the electric drive controller are obtained on one control board;

step S2: for the DCDC and OBC integrated power module, the DCDC module and the OBC module are shared by power circuit transformers, so that the original two paths of input units and two paths of output units are changed into one path of input units, one path of output units and one path of input and output units through the shared power circuit transformers;

step S3: for the MCU power module, after the power semiconductor IGBT and the current sensor are respectively in pressure connection with the driving circuit board through a separate wiring line, fixing treatment is carried out on the power semiconductor IGBT and the current sensor and the three-phase output copper bar, so that the power semiconductor IGBT and the current sensor are used as independent MCU power output;

step S4: for the PDU module, three paths of external output are realized through three paths of high-voltage branching lines, and independent fuses are arranged outside power supply loops of each path of high-voltage branching line, so that the fuses are independently replaced when damaged;

step S5: for the mechanical structure module, the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are sequentially installed on the mechanical structure module, so that the integrated modularized electric drive controller is obtained.

As a further preferable technical solution of the above technical solution, in step S1, the signal circuit for interaction and inspection of the OBC module and the charging post is set through the original micro-processing chip (+logic chip) of the MCU module.

As a further preferable technical solution of the foregoing technical solution, in step S5, the mechanical structure module sequentially installs the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module in the main casing, and then covers the upper cover plate on the main casing, so that the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are integrated in the mechanical structure module, and the upper cover plate is provided with a fuse cover plate, so that the fuse cover plate covers the fuses of the three high-voltage branches of the PDU module, and then the damaged fuses are independently replaced by opening the fuse cover plate.

In order to achieve the above object, the present invention further provides a modularized integrated electric drive controller, which is applied to the driving method of the modularized integrated electric drive controller, and comprises a control circuit module, a DCDC and OBC integrated power module, an MCU power module, a PDU module and a mechanical structure module, wherein:

for the control circuit module, peripheral circuits of the VCU module, the BMS module, the DCDC module and the OBC module are integrated on the basis of an inverter control structure through a control board, and an original micro-processing chip of the MCU module is reserved, so that after a power supply circuit of the control board obtains power supply capacity, peripheral circuits comprising a digital signal sampling circuit, an analog signal sampling circuit, a digital signal output circuit, a high-low side driving output circuit and a LIN communication circuit are added, and further, the control and operation functions of all high-voltage parts of the electric drive controller are obtained on one control board;

for the DCDC and OBC integrated power module, the DCDC module and the OBC module are shared by power circuit transformers, so that the original two paths of input units and two paths of output units are changed into one path of input units, one path of output units and one path of input and output units through the shared power circuit transformers;

for the MCU power module, after the power semiconductor IGBT and the current sensor are respectively in pressure connection with the driving circuit board through a separate wiring line, fixing treatment is carried out on the power semiconductor IGBT and the current sensor and the three-phase output copper bar, so that the power semiconductor IGBT and the current sensor are used as independent MCU power output;

for the PDU module, three paths of external output are realized through three paths of high-voltage branching lines, and independent fuses are arranged outside power supply loops of each path of high-voltage branching line, so that the fuses are independently replaced when damaged;

for the mechanical structure module, the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are sequentially installed on the mechanical structure module, so that the integrated modularized electric drive controller is obtained.

As a further preferable technical scheme of the technical scheme, the mechanical structure module is used for sequentially installing the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module in the main shell, and then the upper cover plate is covered on the main shell, so that the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are integrated in the mechanical structure module, and the upper cover plate is provided with a fuse cover plate, so that the fuse cover plate covers three high-voltage separated wires of the PDU module, and damaged fuses are independently replaced by opening the fuse cover plate.

Drawings

Fig. 1A is a schematic diagram of a modular integrated electro-driver controller and a driving method thereof according to the present invention.

Fig. 1B is a schematic structural diagram of a modular integrated electro-driver controller and a driving method thereof according to the present invention.

Fig. 2 is a schematic structural diagram of a control circuit module of the modular integrated electro-driver controller and the driving method thereof according to the present invention.

Fig. 3 is a schematic structural diagram of a DCDC and OBC integrated power module of the modular integrated electro-driver controller and the driving method thereof according to the present invention.

Fig. 4 is a schematic structural diagram of an MCU power module of the modular integrated electro-driver controller and driving method thereof according to the present invention.

Fig. 5 is a schematic structural diagram of a PDU module of the modular integrated electro-driver controller and the driving method thereof according to the present invention.

Fig. 6 is a schematic structural diagram of a mechanical structure module of the modular integrated electro-driver controller and the driving method thereof according to the present invention.

The reference numerals include: 100. a control circuit module; 110. a control board; 120. a low-voltage signal connector of the whole vehicle; 200. the DCDC and OBC integrated power module; 210. a first housing; 220. an input unit; 230. an output unit; 240. an input/output unit is considered; 300. an MCU power module; 310. a power semiconductor IGBT; 320. a current sensor; 330. a driving circuit board; 340. three-phase output copper bars; 350. a thin film capacitor; 400. a PDU module; 410. a copper bar base; 420. a filter capacitor; 430. a fuse; 500. a mechanical structure module; 510. a main housing; 520. an upper cover plate; 521. and a fuse cover plate.

Detailed Description

The following description is presented to enable one of ordinary skill in the art to make and use the invention. The preferred embodiments in the following description are by way of example only and other obvious variations will occur to those skilled in the art. The basic principles of the invention defined in the following description may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.

In a preferred embodiment of the present invention, it should be noted by those skilled in the art that the power system, the processing chip, etc. of the new energy automobile to which the present invention relates can be regarded as the prior art.

Preferred embodiments.

The invention discloses a driving method of a modularized integrated electric drive controller, which is used for carrying out integrated modularization on a power system of a new energy automobile and comprises the following steps:

It should be noted that, in the present embodiment, the steps S1 to S4 are not strictly sequential, but are all in parallel relationship, so that the integrated assembly is performed in step S5.

Specifically, in step S1, a signal circuit for interaction and inspection of the OBC module and the charging post is set through an original micro-processing chip (+logic chip) of the MCU module.

More specifically, in step S5, the mechanical structure module sequentially installs the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module in the main casing, and then covers the upper cover plate on the main casing, so that the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are integrated in the mechanical structure module, and the upper cover plate is provided with a fuse cover plate, so that the fuse cover plate covers the three high-voltage separated-wire fuses of the PDU module, and the damaged fuses are independently replaced by opening the fuse cover plate.

The invention also discloses a modularized integrated electric drive controller, which is applied to the driving method of the modularized integrated electric drive controller, and comprises a control circuit module, a DCDC and OBC integrated power module, an MCU power module, a PDU module and a mechanical structure module, wherein:

Specifically, the mechanical structure module is arranged on the main shell body in sequence with the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module, and then the upper cover plate is covered on the main shell body, so that the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are integrated on the mechanical structure module, and the upper cover plate is provided with a fuse cover plate, so that the fuse cover plate covers three high-voltage branching fuses of the PDU module, and the damaged fuses are independently replaced by opening the fuse cover plate.

The utility model provides a modularization integrated form electricity drives controller, includes control circuit module 100, DCDC and OBC integrated power module 200, MCU power module 300, PDU module 400 and mechanical structure module 500, control circuit module 100 DCDC and OBC integrated power module 200, MCU power module 300 with PDU module 400 all install in mechanical structure module 500, wherein:

the mechanical structure module 500 includes a main housing 510 and an upper cover 520, the upper cover 520 is fixedly connected with the main housing 510, and the control circuit module 100, the DCDC and OBC integrated power module 200, the MCU power module 300 and the PDU module 400 are located in a containing cavity formed by surrounding the main housing 510 and the upper cover 520;

the control circuit module 100 includes a control board 110 and a vehicle low-voltage signal connector 120, where the control board 110 is electrically connected to the vehicle low-voltage signal connector 120;

the DCDC and OBC integrated power module 200 includes a first housing 210, an input unit 220, an output unit 230, a compromise input/output unit 240 and a common power transformer, wherein the input unit 220, the output unit 230, the compromise input/output unit 240 and the common power transformer are all mounted on the first housing 210, and the input unit 220, the output unit 230 and the compromise input/output unit 240 are all electrically connected with the common power transformer;

the MCU power module 300 includes a power semiconductor IGBT310, a current sensor 320, a driving circuit board 330, and a three-phase output copper bar 340, wherein the power semiconductor IGBT310, the current sensor 320, and the three-phase output copper bar 340 are all mounted on the driving circuit board 330, and the power semiconductor IGBT310, the current sensor 320, and the three-phase output copper bar 340 are all electrically connected with the driving circuit board 330;

the PDU module 400 includes a copper bar base 410, a plurality of filter capacitors 420, and a plurality of fuses 430, wherein the fuses 430 and the filter capacitors 420 are mounted on the copper bar base 410, and each fuse is connected to a different pair of external output circuits.

Specifically, the upper cover 520 is further provided with a fuse cover 521, the fuse cover 521 covers the fuse 430 of the PDU module 400, and the main housing 510 is provided with a water channel structure.

More specifically, the control board 110 further includes a digital signal sampling circuit, an analog signal sampling circuit, a digital signal output circuit, a high-low side driving output circuit, and a LIN communication circuit.

Further, the MCU power module 300 further includes a thin film capacitor 350, and the thin film capacitor 350 is electrically connected to the driving circuit board 330.

Still further, the control circuit module 100, the DCDC and OBC integrated power module 200, the MCU power module 300 and the PDU module 400 are provided with mounting structures (including mounting holes and mounting slots, etc., which are convenient to be mounted on a mechanical structure module).

Preferably, the invention designs a six-in-one electric drive controller product which integrates a control circuit and modularly designs a high-voltage power circuit aiming at the problems that the functions of a core power part system of an xEV (new energy automobile) are independent and cannot be replaced, and the overall volume, the weight, the production cost and the whole vehicle application cost are high.

The product can realize MCU, VCU, BMS, OBC, DCDC, PDU functions. Wherein, the microprocessor of MCU is combined with the peripheral circuit to realize MCU, VCU, BMS, DCDC, OBC control integration function; the high-voltage power module is simply and modularly assembled, and the DCDC and the OBC high-voltage power part are integrated to be used as an independent power module; the MCU high-voltage power part is used as an independent module; the PDU acts as a high voltage independent module. The assembly process of the product assembly only needs to assemble the independent modules, so that the assembly process and time are greatly simplified; the independent modules require testing to be completed before assembly, thus greatly shortening the assembly offline testing time.

The modularized six-in-one electric drive controller can integrate all parts of a high-voltage loop in the xEV into one part. The whole vehicle high-voltage wiring harness, the high-voltage connector and the communication wiring harness are greatly reduced, and the overall size, weight and production cost of the xEV high-voltage system parts are reduced; has important significance for improving the market competitiveness of the product by xEV, and is easy to realize and popularize in mass production.

Fig. 1 is a schematic diagram of a modularized six-in-one electric drive controller according to the present invention, where the six-in-one electric drive can be divided into a control circuit module, a DCDC & OBC integrated power module (DCDC and OBC integrated power module), an MCU power module, a PDU power module, and a mechanical structure module (mechanical module).

According to the fixation scheme and the working state of the integrated inverter on the xEV, the principle of each module is as follows:

1) Control circuit module

In the design of the control structure module scheme, on the basis of an inverter control structure, VCU, BMS, DCDC, OBC peripheral circuits are integrated, only an MCU original micro-processing chip is reserved, and after the design of increasing the power supply capacity of a power supply circuit, the external circuits such as digital signal sampling, analog signal sampling, digital signal output, high-low side driving output and LIN communication are added, so that the functions of the parts are realized. The signal circuit for interaction and inspection of the OBC and the charging pile also uses the same microprocessor and logic chip to realize the functions, so that the control and operation functions of all high-voltage parts are realized on one PCBA part, and the material cost is greatly reduced.

2) DCDC and OBC integrated power module

The DCDC power circuit topology is a phase-shifting full-bridge topology structure; the OBC power circuit topology is a PFC+ full bridge circuit topology. The DCDC and OBC adopt the mode of sharing the two power circuit transformers, inputting the original two paths into the two paths for output, and changing the mode of sharing the power circuit transformers into 1 path input, 1 path output and 1 path for input and output functions. The integrated miniaturization design of the DCDC and the OBC power circuit is realized, and the integrated power module is used as an independent and miniaturized integrated power module in the assembly.

3) MCU power module

The MCU power module mainly comprises a power semiconductor IGBT, a current sensor, a driving PCBA and a three-phase output copper bar. And after the power semiconductor current sensor is in pressure connection with the driving PCBA through a separate line, the power semiconductor current sensor is finally fixed with the three-phase copper bar to be used as an independent MCU power circuit module.

4) PDU power circuit module

The scheme realizes a 3-way high-voltage branching scheme, realizes 3-way external output, and aims to supply power to a 1-way air conditioner compressor, a 1-way whole vehicle PTC and a 1-way battery PTC system. In PDU part design, design three-way fuse in the power supply return circuit respectively, avoid external load equipment to damage and cause the influence to the assembly. The fuse part is designed with a small maintenance cover plate, and when the fuse is damaged, the fuse can be independently detached and replaced so as to reduce the after-sale maintenance cost.

5) Mechanical structure module

The mechanical structure module mainly comprises: and the main shell, the upper cover plate, the water channel and other independent modules are provided with carriers.

The invention has the beneficial effects that:

in the electric drive inverter control circuit, only an original microprocessor chip is adopted, VCU, BMS, DCDC, OBC control and interaction functions with the charging pile are integrated, the use quantity of the microprocessor chip is greatly reduced, and the total part cost is greatly reduced.

The DCDC and OBC functional module integrated miniaturized design, the MCU power module integrated design and the PDU module independent design scheme are adopted. The basic performance test can be completed when the parts are packaged. The assembly process difficulty, the assembly offline test time and the assembly offline test content are reduced.

By adopting the design of an internal independent module, when the after-sale problem occurs, the PDU peripheral problem can be solved by replacing a fuse. The independent power circuit is damaged, the damaged power module can be replaced locally, other independent modules are not affected, and the after-sale cost is greatly reduced.

The invention discloses a six-in-one product for integrating VCU, BMS (part of), DCDC, OBC peripheral circuits and circuit functions interacted with a charging pile in a main drive inverter and realizing the functions of main high-voltage parts of a new energy automobile.

The product is internally divided into: the control circuit module, the DCDC and OBC power module, the MCU power module and the PDU power module take the mechanical module as a carrier, the design and the distribution of parts are clearly divided, and the PDU function is a fuse replacement function reserved for peripheral equipment. Each module can be split and detected, so that the assembly difficulty and the assembly offline test time are reduced, and the production cost is greatly reduced; the internal module can be independently replaced when a problem occurs, so that the after-sale maintenance cost is greatly reduced, and the scheme is reliable and easy to realize and popularize in mass production.

It should be noted that technical features such as a power system and a processing chip of the new energy automobile related to the present application should be regarded as the prior art, and specific structures, working principles, and control modes and spatial arrangement modes possibly related to the technical features should be selected conventionally in the art, and should not be regarded as the invention point of the present application, and the present application is not further specifically developed and detailed.

Modifications of the embodiments described above, or equivalents of some of the features may be made by those skilled in the art, and any modifications, equivalents, improvements or etc. within the spirit and principles of the present invention are intended to be included within the scope of the present invention.

Claims

1. The driving method of the modularized integrated electric drive controller is used for carrying out integrated modularization on a power system of a new energy automobile and is characterized by comprising the following steps of:

2. The driving method of a modular integrated electro-driver controller according to claim 1, wherein in step S1, the signal circuit for interaction and inspection of the OBC module and the charging post is set through an original micro-processing chip of the MCU module.

3. The driving method of a modular integrated electric drive controller according to claim 2, wherein in step S5, the mechanical structure module sequentially installs the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module on the main housing, and then covers the upper cover plate on the main housing, so that the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are integrated on the mechanical structure module, and the upper cover plate is provided with a fuse cover plate, so that the fuse cover plate covers three high-voltage-split fuses of the PDU module, and the damaged fuses are independently replaced by opening the fuse cover plate.

4. A modular integrated electro-driver controller, applied to the driving method of the modular integrated electro-driver controller according to any one of claims 1-3, comprising a control circuit module, a DCDC and OBC integrated power module, an MCU power module, a PDU module and a mechanical structure module, wherein:

5. The modular integrated electro-driver controller of claim 4, wherein the mechanical structure module sequentially mounts the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module to the main housing, and then covers the upper cover plate to the main housing, so that the control circuit module, the DCDC and OBC integrated power module, the MCU power module and the PDU module are integrated to the mechanical structure module, and the upper cover plate is provided with a fuse cover plate, so that the fuse cover plate covers three high voltage branch fuses of the PDU module, and the damaged fuses are independently replaced by opening the fuse cover plate.