CN202385445U - Water-cooled motor controller for high-power-density electric vehicle - Google Patents
Water-cooled motor controller for high-power-density electric vehicle Download PDFInfo
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- CN202385445U CN202385445U CN2011205521933U CN201120552193U CN202385445U CN 202385445 U CN202385445 U CN 202385445U CN 2011205521933 U CN2011205521933 U CN 2011205521933U CN 201120552193 U CN201120552193 U CN 201120552193U CN 202385445 U CN202385445 U CN 202385445U
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Abstract
The utility model relates to a water-cooled motor controller for a high-power-density electric vehicle. An opening is formed at the bottom of one side of a shell; a water-cooled heat radiator is arranged at the opening; a power module, a direct current (DC) bus support capacitor, a pre-electrification resistor, a main relay and a current sensor are respectively arranged in the shell; the power module is arranged on the upper surface of the water-cooled heat radiator; the DC bus support capacitor, the pre-electrification resistor, the main relay and the current sensor are respectively fixed in the shell body through bolts; the power module, the DC bus support capacitor and the main relay are connected through a converge busbar to form a high tension loop; power factor correction capacitors are fixedly arranged on the converge busbar; a driving circuit board which is used for driving the power module is arranged above the power module; a separation plate and a control circuit board are sequentially arranged above the driving circuit board; and a plurality of power cable connector assemblies which are used for mounting power cables are arranged on the sidewall of the shell in a penetrating manner. The water-cooled motor controller for the high-power-density electric vehicle has the advantages of strong heat-radiating capability, high power density and good electromagnetic compatibility, is flexible and convenient to operate and safe and reliable to use.
Description
Technical field
The utility model relates to a kind of water-cooled machine controller.Particularly relate to a kind of employing modularized design mode, flexible configuration, the high power density used for electric vehicle water-cooled machine controller of easy-to-connect.
Background technology
Because environmental protection and energy problem have day by day seriously promoted developing rapidly of ev industry, its core is to replace combustion engine powered system with power drive system or oily electric hybrid drive system, partially or completely replaces fuel oil as vehicular energy with battery.Electric machine controller integrates microelectric technique, power electronic technology, thermodynamics, modern control theory, electromagnetic compatibility technology etc. as the key components and parts of electric automobile, receives the attention of domestic and international auto vendor and scientific research institution day by day.
The motor in electric automobile controller of exploitation is of a great variety at present, but the following problem of ubiquity:
The volume and weight of 1 electric machine controller is difficult to reach the demand for development of electric automobile to parts lightweight, high integration;
The caloric value of 2 electric machine controller internal power modules is big, and the internal structure layout is unreasonable and dispel the heat the inhomogeneous direct useful life that influences controller;
Still there is still unsolved technical barrier in the electromagnetic isolation between optimization, main control module and the power model of busbar distributed constant of confluxing in 3 electric machine controllers etc., and the reliability level of controller still need improve.
Summary of the invention
The utility model technical problem to be solved is that the high power density used for electric vehicle water-cooled machine that a kind of flexible operation is easy, internal structure is rationally distributed, heat-sinking capability is strong, power density is high, Electro Magnetic Compatibility is good, safe and reliable controller is provided.
The technical scheme that the utility model adopted is: a kind of high power density used for electric vehicle water-cooled machine controller; Include the loam cake of housing and housing; The bottom of said housing one side is formed with opening; Described opening part is provided with water-filled radiator; Be respectively arranged with power model, dc bus in the described housing and support electric capacity, power on resistance, main relay and current sensor in advance; Wherein said power model is arranged on the upper surface of water-filled radiator, and described dc bus supports electric capacity, powers on resistance, main relay and current sensor respectively through being bolted in the housing in advance, and described power model, dc bus support electric capacity and main relay connects and composes high tension loop through the busbar that confluxes; Be set with power factor correction electric capacity on the described busbar that confluxes; The top of described power model is provided with the drive circuit board that is used to drive this power model, and the top of said drive circuit board is disposed with division board and control circuit board, and what on the sidewall of described housing, run through is provided with a plurality of power cable connectors that are used to install the power cable.
The described busbar that confluxes is through being bolted to the top that dc bus supports electric capacity and main relay.
Described housing is provided with a plurality of external installation feet.
Described housing and loam cake adopt the moulding of compression casting mode time processing, and thickness of shell is 4～5mm.
The described busbar that confluxes adopts copper plate to be bent into, and copper plate electroplating surfaces with tin thickness is 7～12 μ m, and the positive/negative plate surface is provided with the PET single face glue of 0.25mm, is provided with the PET double faced adhesive tape of 0.25mm between the positive/negative plate, and dielectric voltage withstand reaches 5000V.
Be respectively arranged with power battery pack voltage input end mouth on the sidewall of described housing, and the ac output end mouth of this electric machine controller.
The water channel of described water-filled radiator is the back-shaped structure of curve that is formed by groove, and is provided with water inlet and delivery port, and the water channel degree of depth is 6mm, and the water pipe caliber is DN20.
Described power model is made up of first half-bridge, second half-bridge and the 3rd half-bridge of three identical built-in fly-wheel diodes, and each half-bridge is handled the power of the highest 600V, 600A.
Described power factor correction electric capacity is made up of the first power factor correction electric capacity, the second power factor correction electric capacity and the 3rd power factor correction electric capacity that three parallel connections are provided with.
The built-in loop that powers in advance of described power in advance resistance and main relay formation electric machine controller; Described power model, dc bus support electric capacity and power factor correction electric capacity are for being connected in parallel; It is anodal that a end after the parallel connection connects power battery pack through the loop that powers in advance; The other end connects the power battery pack negative pole; Described drive circuit board is that power model provides drive signal, first half-bridge of power model, second half-bridge and the output of the 3rd half-bridge draw the A phase that is connected motor respectively, B mutually and C mutually.
The high power density used for electric vehicle water-cooled machine controller of the utility model, flexible operation is easy, internal structure is rationally distributed, heat-sinking capability is strong, power density is high, Electro Magnetic Compatibility is good, safe and reliable.The built-in loop that powers in advance of this controller; Can compatible permagnetic synchronous motor, automobile-used drive motors type commonly used such as asynchronous induction machine; And have abundant external interface so that the car load controlled function to be provided, and not only can be used for pure electric automobile, also can be used for hybrid vehicle.
Advantage and effect are:
1 motor in electric automobile controller internal structure is rationally distributed, and device volume is little, and is in light weight, has good Electro Magnetic Compatibility.The water channel design of optimizing has significantly improved the heat-sinking capability of device, makes its power density surpass 6kVA/kg, fully satisfies the demand for development of electric automobile to parts lightweight, high integration.
2 motor in electric automobile controllers adopt the modularized design mode, flexible configuration, and easy-to-connect, built-in multiple faults defencive function has very high fail safe and reliability.
3 motor in electric automobile controllers can either be realized the motor-driven function, also have energy recovery function, can significantly promote the continual mileage of car load; Complete machine has abundant external signal interface, and is furnished with the CAN communication module, is convenient to the optimal control of vehicle.
Description of drawings
Fig. 1 is the high power density used for electric vehicle water-cooled machine controller internal structure sketch map of the utility model;
Fig. 2 is the high power density used for electric vehicle water-cooled machine controller external structure sketch map of the utility model;
Fig. 3 is the blast structural diagrams intention of the high power density used for electric vehicle water-cooled machine controller of the utility model;
Fig. 4 is the structural representation of water-filled radiator in the high power density used for electric vehicle water-cooled machine controller of the utility model;
Fig. 5 is the electrical schematic diagram of the high power density used for electric vehicle water-cooled machine controller of the utility model.
Among the figure:
1: loam cake 2: housing
3: water-filled radiator 4: power model
5: dc bus supports electric capacity 6: busbar confluxes
7: resistance 8 in advance powers on: main relay
9: power factor correction electric capacity 10: control circuit
11: power cable connector 12: current sensor
13: division board 14: drive circuit board
15: mounting bracket
Embodiment
Below in conjunction with embodiment and accompanying drawing the high power density used for electric vehicle water-cooled machine controller of the utility model is made detailed description.
Like Fig. 1, Fig. 2, shown in Figure 3; The high power density used for electric vehicle water-cooled machine controller of the utility model; Include the loam cake 1 and housing 2 that adopt the moulding of compression casting mode time processing, the bottom of said housing 2 one sides is formed with opening, and described opening part is provided with water-filled radiator 3; Be respectively arranged with power model 4, dc bus in the described housing 2 and support electric capacity 5, power on resistance 7, main relay 8 and current sensor 12 in advance; Wherein said power model 4 is arranged on the upper surface of water-filled radiator 3; The first half-bridge 4a, the second half-bridge 4b and the 3rd half-bridge 4c by three built-in fly-wheel diodes form, and each half-bridge can be handled the power of the highest 600V, 600A; Described dc bus supports electric capacity 5, powers on resistance 7, main relay 8 and current sensor 12 respectively through being bolted in the housing 2 in advance; Described power model 4, dc bus support electric capacity 5 and main relay 8 connects and composes high tension loop through the busbar 6 that confluxes; The described busbar 6 that confluxes is through being bolted to the top that dc bus supports electric capacity 5 and main relay 8; Be set with power factor correction electric capacity 9 on the described busbar 6 that confluxes, this power factor correction electric capacity is made up of the first power factor correction electric capacity 9a, the second power factor correction electric capacity 9b and the 3rd power factor correction electric capacity 9c that three parallel connections are provided with; The top of described power model 4 is provided with the drive circuit board 14 that is used to drive this power model 4; The top of said drive circuit board 14 is disposed with division board 13 and control circuit board 10, and a plurality of power cable connectors 11 that are used to install the power cable are set on the sidewall of described housing 2; Be respectively arranged with the ac output end mouth of power battery pack voltage input end mouth and this electric machine controller on the sidewall of described housing 2, four mounting brackets 15 pass through bolt in the outside of housing 2.
Be provided with division board 13 between power model 4 and the control circuit 10, have electrical interference between the two hardly, guaranteed the operate as normal of power model, control circuit.Control circuit 10 has resolver treatment circuit and encoder processing circuit by vehicle-mounted 12V storage battery power supply, can compatible permagnetic synchronous motor, automobile-used drive motors type commonly used such as asynchronous induction machine.Control circuit 10 has abundant external interface in addition; Can gather key switch input signal, brake pedal switching signal, reversing switch signal and two-way accelerator pedal signal; Possess functions such as the protection of control line under-voltage, output overcurrent protection, overvoltage protection, motor overload protection and controller overtemperature protection, other control device is realized the optimal control of car load jointly in CAN communication module capable of using and the car.
The high power density used for electric vehicle water-cooled machine controller of the utility model can produce the radio noise up to 800MHz during operation, need to consider electric screen and electromagnetic shielding, and under the condition of being equal in weight, the electric conductivity of aluminium is superior to copper, and cost is more cheap.1 equal aluminium 6063 conducts process raw material described housing 2 with loam cake; Electromagnetic wave increases with the increase of the decay in electric conducting material with frequency, conductivity; Particularly electromagnetic wave has kelvin effect in good conductor; Consider the requirement of volume, weight and the extrusion process of electric machine controller, the final design thickness of housing is 4～5mm, and this thickness can satisfy the electromagnetic shielding requirement of each frequency range.
The described busbar 6 that confluxes adopts the thick copper plate of 1.5mm to be bent into, and copper plate electroplating surfaces with tin thickness is 7～12 μ m, and the positive/negative plate surface is provided with the PET single face glue of 0.25mm, is provided with the PET double faced adhesive tape of 0.25mm between the positive/negative plate, and dielectric voltage withstand reaches 5000V.
As shown in Figure 4, described water-filled radiator 3 aluminium 6060 are as processing raw material, and overall dimension is 186mm*200mm*20mm; Water channel is the back-shaped structure of curve that is formed by groove; And be provided with water inlet 3a and delivery port 3b, and the water channel degree of depth is 6mm, the water pipe caliber is DN20.Cooling water gets into water-filled radiator 3 from water inlet 3a, and the heat that sends through heat-conducting silicone grease absorbed power module 4 is also discharged through delivery port 3b.Through the optimization Simulation design, the heat-sinking capability of the water-filled radiator 3 of the utility model is able to significantly improve, and the maximum temperature rise under the operating mode service conditions makes the power density of controller surpass 6kVA/kg less than 35K.Because water-filled radiator 3 adopts the pattern of independent processing, and the profile according to the different capacity module customizes easily, avoid in addition owing to repeat the cost rising that mould development causes.
As shown in Figure 5; The built-in loop that powers in advance of described power in advance resistance 7 and main relay 8 formation electric machine controllers; Described power model 4, dc bus support electric capacity 5 and power factor correction electric capacity 9 for being connected in parallel; It is anodal that a end after the parallel connection connects power battery pack through the loop that powers in advance, and the other end connects the power battery pack negative pole.Described drive circuit board 14 provides drive signal for power model 4, the first half-bridge 4a of power model 4, the second half-bridge 4b and the 3rd half-bridge 4c output draw the A phase that is connected motor respectively, B mutually and C mutually.
The built-in loop that powers in advance of described power in advance resistance 7 and main relay 8 these electric machine controllers of formation; When direct-flow input end applies power battery pack voltage; The resistance 7 that powers in advance supports electric capacity 5 with dc bus and constitutes the RC charge circuit, and 10 pairs of dc buss of control circuit support the magnitude of voltage at electric capacity 5 two ends and monitor, and shows that pre-charge process finishes if magnitude of voltage reaches setting threshold; The control circuit 10 adhesive main relays 8 and resistance 7 bypasses that will power in advance get into normal mode of operation.
Power factor correction electric capacity 9 is connected in parallel between the both positive and negative polarity of power model 4; Because power model 4 receives the influence of inductance in the major loop in the HF switch process; Can produce the instantaneous voltage spike; Utilize power factor correction electric capacity 9 effectively to suppress, prevent that overvoltage protection from frequently appearring in electric machine controller, helps improving the reliability level of complete machine.
Claims (10)
1. high power density used for electric vehicle water-cooled machine controller; Include the loam cake (1) of housing (2) and housing (2); It is characterized in that; The bottom of said housing (2) one sides is formed with opening; Described opening part is provided with water-filled radiator (3); Be respectively arranged with power model (4), dc bus in the described housing (2) and support electric capacity (5), power on resistance (7), main relay (8) and current sensor (12) in advance; Wherein said power model (4) is arranged on the upper surface of water-filled radiator (3), and described dc bus supports electric capacity (5), powers on resistance (7), main relay (8) and current sensor (12) respectively through being bolted in the housing (2) in advance, and described power model (4), dc bus support electric capacity (5) and main relay (8) connects and composes high tension loop through the busbar that confluxes (6); Be set with power factor correction electric capacity (9) on the described busbar that confluxes (6); The top of described power model (4) is provided with the drive circuit board (14) that is used to drive this power model, and the top of said drive circuit board (14) is disposed with division board (13) and control circuit board (10), and what on the sidewall of described housing (2), run through is provided with a plurality of power cable connectors (11) that are used to install the power cable.
2. high power density used for electric vehicle water-cooled machine controller according to claim 1 is characterized in that, the described busbar that confluxes (6) is through being bolted to the top that dc bus supports electric capacity (5) and main relay (8).
3. high power density used for electric vehicle water-cooled machine controller according to claim 1 is characterized in that described housing (2) is provided with a plurality of external installation feet (15).
4. high power density used for electric vehicle water-cooled machine controller according to claim 1 is characterized in that, described housing (2) and loam cake (1) adopt the moulding of compression casting mode time processing, and thickness of shell is 4～5mm.
5. high power density used for electric vehicle water-cooled machine controller according to claim 1; It is characterized in that; The described busbar that confluxes (6) adopts copper plate to be bent into, and copper plate electroplating surfaces with tin thickness is 7～12 μ m, and the positive/negative plate surface is provided with the PET single face glue of 0.25mm; Be provided with the PET double faced adhesive tape of 0.25mm between the positive/negative plate, dielectric voltage withstand reaches 5000V.
6. high power density used for electric vehicle water-cooled machine controller according to claim 1 is characterized in that, is respectively arranged with power battery pack voltage input end mouth on the sidewall of described housing (2), and the ac output end mouth of this electric machine controller.
7. high power density used for electric vehicle water-cooled machine controller according to claim 1; It is characterized in that; The water channel of described water-filled radiator (3) is the back-shaped structure of curve that is formed by groove; And be provided with water inlet (3a) and delivery port (3b), and the water channel degree of depth is 6mm, the water pipe caliber is DN20.
8. high power density used for electric vehicle water-cooled machine controller according to claim 1; It is characterized in that; Described power model (4) is made up of first half-bridge (4a), second half-bridge (4b) and the 3rd half-bridge (4c) of three identical built-in fly-wheel diodes, and each half-bridge is handled the power of the highest 600V, 600A.
9. high power density used for electric vehicle water-cooled machine controller according to claim 1; It is characterized in that described power factor correction electric capacity (9) is made up of the first power factor correction electric capacity (9a), the second power factor correction electric capacity (9b) and the 3rd power factor correction electric capacity (9c) that three parallel connections are provided with.
10. high power density used for electric vehicle water-cooled machine controller according to claim 1; It is characterized in that; The built-in loop that powers in advance of described power in advance resistance (7) and main relay (8) formation electric machine controller; Described power model (4), dc bus support electric capacity (5) and power factor correction electric capacity (9) are for being connected in parallel; It is anodal that a end after the parallel connection connects power battery pack through the loop that powers in advance; The other end connects the power battery pack negative pole, and described drive circuit board (14) provides drive signal for power model (4), first half-bridge (4a) of power model (4), second half-bridge (4b) and the output of the 3rd half-bridge (4c) draw be connected motor respectively A phase, B phase and C mutually.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2011205521933U CN202385445U (en) | 2011-12-26 | 2011-12-26 | Water-cooled motor controller for high-power-density electric vehicle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2011205521933U CN202385445U (en) | 2011-12-26 | 2011-12-26 | Water-cooled motor controller for high-power-density electric vehicle |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN202385445U true CN202385445U (en) | 2012-08-15 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2011205521933U Expired - Lifetime CN202385445U (en) | 2011-12-26 | 2011-12-26 | Water-cooled motor controller for high-power-density electric vehicle |
Country Status (1)
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| CN (1) | CN202385445U (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104934825A (en) * | 2015-06-19 | 2015-09-23 | 芜湖德孚转向***有限公司 | Copper conductor structure of driving bracket |
| CN104981139A (en) * | 2014-04-12 | 2015-10-14 | 湖北文理学院 | Motor controller control panel shielding structure |
| CN106945617A (en) * | 2015-12-02 | 2017-07-14 | 法雷奥电机控制***公司 | It is intended to the electronic architecture powered for the motor for motor vehicles |
-
2011
- 2011-12-26 CN CN2011205521933U patent/CN202385445U/en not_active Expired - Lifetime
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104981139A (en) * | 2014-04-12 | 2015-10-14 | 湖北文理学院 | Motor controller control panel shielding structure |
| CN104934825A (en) * | 2015-06-19 | 2015-09-23 | 芜湖德孚转向***有限公司 | Copper conductor structure of driving bracket |
| CN104934825B (en) * | 2015-06-19 | 2017-06-20 | 安徽德孚转向***股份有限公司 | The copper conductor structure of driving arm |
| CN106945617A (en) * | 2015-12-02 | 2017-07-14 | 法雷奥电机控制***公司 | It is intended to the electronic architecture powered for the motor for motor vehicles |
| CN106945617B (en) * | 2015-12-02 | 2022-04-26 | 法雷奥电机控制***公司 | Electronic architecture intended to power an electric machine for a motor vehicle |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| CX01 | Expiry of patent term | ||
| CX01 | Expiry of patent term |
Granted publication date: 20120815 |