阅读说明：本技术 用于电动汽车的电机控制器及电动汽车 (Motor controller for electric automobile and electric automobile ) 是由 陈人楷 夏一帆 王坚 朱晨菡 彭再武 于 2018-12-14 设计创作，主要内容包括：本发明公开了一种用于电动汽车的电机控制器及电动汽车,电机控制器包括PCB板及SiC功率模块；PCB板上集成接口板模块、控制板模块、驱动板模块及电源板模块,驱动板模块与SiC功率模块通过贴装的方式连接成一体；接口板模块从整车控制器接收整车信号,并且将发送至控制板模块；控制板模块根据整车信号生成电机控制信号,并且发送至驱动板模块；驱动板模块根据电机控制信号来控制SiC功率模块的开通或关断,以控制驱动电机的输出转速及扭矩；电源板模块将接收到的输入电压转换为不同的输出电压。本发明总体结构紧凑,提高了开关频率,减小了开关损耗,提高了空间利用率及效率,从而极大地提高了功率密度。(The invention discloses a motor controller for an electric automobile and the electric automobile, wherein the motor controller comprises a PCB (printed Circuit Board) and a SiC power module; an interface board module, a control board module, a drive board module and a power board module are integrated on the PCB, and the drive board module and the SiC power module are connected into a whole in a surface mounting mode; the interface board module receives a vehicle signal from the vehicle controller and sends the vehicle signal to the control board module; the control panel module generates a motor control signal according to the vehicle signal and sends the motor control signal to the drive panel module; the drive plate module controls the SiC power module to be switched on or switched off according to the motor control signal so as to control the output rotating speed and the torque of the drive motor; the power panel module converts the received input voltage into different output voltages. The invention has compact overall structure, improves the switching frequency, reduces the switching loss, and improves the space utilization rate and efficiency, thereby greatly improving the power density.)

1. A motor controller for an electric automobile is characterized by comprising a PCB and a SiC power module;

the PCB is integrated with an interface board module, a control board module, a drive board module and a power board module, and the drive board module and the SiC power module are connected into a whole in a surface mounting mode;

the control panel module is respectively and electrically connected with the interface board module, the power board module and the drive board module, and the power board module is also electrically connected with the drive board module;

the interface board module is configured to receive a vehicle signal from a vehicle controller of the electric vehicle and send the vehicle signal to the control board module;

the control panel module is configured to generate a motor control signal according to the received vehicle signal and send the motor control signal to the drive panel module;

the drive plate module is configured to control the SiC power module to be switched on or switched off according to the received motor control signal so as to control the output rotating speed and the torque of a drive motor of the electric automobile;

the power board module is configured to convert a received input voltage into different output voltages and supply the different output voltages to the control board module and the driver board module, respectively.

2. The motor controller of claim 1, wherein the motor controller comprises a case and a cover plate;

the cover plate is covered on the box body so as to form a closed space in the box body;

the PCB and the SiC power module are respectively arranged in the closed space.

3. The motor controller according to claim 2, wherein the housing has a plurality of positioning pins, the cover has a plurality of positioning holes, the positioning pins are in one-to-one correspondence with the positioning holes, and each positioning pin is engaged with a corresponding positioning hole, so that the cover is covered on the housing.

4. The motor controller of claim 2, further comprising a seal ring;

the cover plate is provided with a sealing groove at the position contacting with the box body, and the sealing ring is arranged in the sealing groove.

5. The motor controller of claim 2, wherein said motor controller further comprises a low voltage interface;

the low-voltage interface is electrically connected with the interface board module and is configured to receive the vehicle signals;

the box body is provided with a protective supporting plate, the low-voltage interface is arranged in the protective supporting plate, and the position of the low-voltage interface is subjected to dispensing treatment;

the low-voltage interfaces include 12V and 24V low-voltage interfaces.

6. The motor controller of claim 5, wherein the interface board module is provided with a first X capacitor, a first Y capacitor and an inductor group;

the interface board module is configured to filter the received vehicle signal through the first X capacitor, the first Y capacitor and the inductance group.

7. The motor controller according to claim 2, wherein the motor controller further comprises a dc bus bar and an ac bus bar, and the case is provided with a dc input interface and an ac output interface;

the direct-current bus is electrically connected with the direct-current input interface, and the alternating-current bus is electrically connected with the alternating-current output interface;

and the direct current input interface and the alternating current output interface are respectively provided with a metal shielding waterproof joint and are respectively used for electrically connecting a double-layer shielding cable.

8. The motor controller of claim 7, further comprising a discharge circuit electrically connected to the dc bus bar;

the discharge loop comprises a support capacitor and a discharge resistor;

the discharge resistor is arranged at the bottom in the box body, and the bottom in the box body is coated with a heat dissipation material;

the discharge resistor is used for releasing the electric energy stored in the supporting capacitor.

9. The motor controller of claim 7, further comprising a second X capacitor and a second Y capacitor;

the second X capacitor and the second Y capacitor are respectively electrically connected with the direct current busbar.

10. The motor controller of claim 7, wherein the control board module comprises a voltage acquisition unit;

the voltage acquisition unit is electrically connected with the linear busbar and is configured to acquire a voltage signal of the linear busbar.

11. The motor controller according to claim 7, further comprising a U-phase current collection unit, a V-phase current collection unit, and a W-phase current collection unit;

the alternating-current bus comprises a U-phase bus, a V-phase bus and a W-phase bus;

the alternating current output interface comprises a U-phase output interface, a V-phase output interface and a W-phase output interface;

the U-phase bus bar is electrically connected with the U-phase output interface, and the U-phase current acquisition unit is configured to acquire a current signal of the U-phase bus bar;

the V-phase bus bar is electrically connected with the V-phase output interface, and the V-phase current acquisition unit is configured to acquire a current signal of the V-phase bus bar;

the W-phase busbar is electrically connected with the W-phase output interface, and the W-phase current acquisition unit is configured to acquire a current signal of the W-phase busbar.

12. A motor controller according to any of claims 2 to 11, further comprising a heat sink;

the radiator comprises a cooling liquid water inlet and a cooling liquid water outlet which are respectively arranged on the box body;

and a linear liquid flow path is formed between the cooling liquid water inlet and the cooling liquid water outlet, is arranged at the position of the SiC power module and is used for dissipating heat of the SiC power module.

13. The motor controller of claim 12, wherein said heat sink is a Pin-fin heat sink structure.

14. An electric vehicle, characterized in that the electric vehicle comprises the motor controller for an electric vehicle according to any one of claims 1 to 13.

Technical Field

The invention relates to the technical field of motor control, in particular to a motor controller for an electric automobile and the electric automobile.

Background

With the increasing demand of power density, the motor controller is used as a core component of an electric vehicle, and the problems of reliable function, safety, space heat dissipation and the like are increasingly prominent, so that the development towards high density becomes a development trend of a single electric control product.

The existing motor controller for the electric automobile has the defects of limited switching frequency, low space utilization rate and efficiency and multiple fault points, and simultaneously, the safety, vibration, heat dissipation, compact structure and the like are all required to be improved, and the existing stage design cannot meet different configuration requirements in the aspect of compatible design.

Disclosure of Invention

The following presents a simplified summary of one or more aspects in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that is presented later.

The invention aims to overcome the defects of limited switching frequency, low space utilization rate and low efficiency of a motor controller in the prior art, and provides a motor controller for an electric automobile and the electric automobile, which have high power density, safety and reliability.

The technical problem is solved by the following technical scheme:

a motor controller for an electric vehicle includes a PCB (Printed Circuit Board) and a SiC (silicon carbide) power module;

the PCB is integrated with an interface board module, a control board module, a drive board module and a power board module, and the drive board module and the SiC power module are connected into a whole in a surface mounting mode;

the control panel module is respectively and electrically connected with the interface board module, the power board module and the drive board module, and the power board module is also electrically connected with the drive board module;

the interface board module is configured to receive a vehicle signal from a vehicle controller of the electric vehicle and send the vehicle signal to the control board module;

the control panel module is configured to generate a motor control signal according to the received vehicle signal and send the motor control signal to the drive panel module;

the drive plate module is configured to control the SiC power module to be switched on or switched off according to the received motor control signal so as to control the output rotating speed and the torque of a drive motor of the electric automobile;

the power board module is configured to convert a received input voltage into different output voltages and supply the different output voltages to the control board module and the driver board module, respectively.

In the scheme, the PCB adopts a four-in-one design, namely the interface board module, the control board module, the drive board module and the power board module are integrated on the PCB, so that the required space is greatly reduced, and the power density of the motor controller is also improved. The wiring harness is not required to be connected between the boards, the vibration resistance is improved, the fault rate is reduced, meanwhile, the wiring is arranged inside the boards, and the integral anti-interference capability is improved.

In the scheme, the driving board module and the SiC power module are connected into a whole in a mounting mode, a gate pole signal is not interfered, and the anti-interference capability is improved.

Optionally, the motor controller includes a box body and a cover plate;

the cover plate is covered on the box body so as to form a closed space in the box body;

the PCB and the SiC power module are respectively arranged in the closed space.

Optionally, a plurality of positioning pins are arranged on the box body, a plurality of positioning holes are formed in the cover plate, the positioning pins correspond to the positioning holes one to one, and each positioning pin is matched with the corresponding positioning hole, so that the cover plate is covered on the box body.

In this scheme, prevent effectively through the design of locating pin and locating hole that the screw location is inaccurate problem.

Optionally, the motor controller further comprises a sealing ring;

the cover plate is provided with a sealing groove at the position contacting with the box body, and the sealing ring is arranged in the sealing groove.

Optionally, the motor controller further comprises a low voltage interface;

the low-voltage interface is electrically connected with the interface board module and is configured to receive the vehicle signals;

the box body is provided with a protective supporting plate, the low-voltage interface is arranged in the protective supporting plate, and the position of the low-voltage interface is subjected to dispensing treatment;

the low-voltage interfaces include 12V and 24V low-voltage interfaces.

In the scheme, the motor controller is compatible with two low-voltage control platforms of 12V and 24V, meanwhile, different power modules can be compatible under the condition that a mechanical interface is not changed so as to adapt to different power requirements, flexible configuration can be realized, and the motor controller is applied to different types of electric automobiles.

Optionally, a first X capacitor, a first Y capacitor, and an inductor group are disposed on the interface board module;

the interface board module is configured to filter the received vehicle signal through the first X capacitor, the first Y capacitor and the inductance group.

In the scheme, the received signal of the whole vehicle is filtered, so that the influence of conducted interference is reduced.

Optionally, the motor controller further comprises a dc bus and an ac bus, and the box body is provided with a dc input interface and an ac output interface;

the direct-current bus is electrically connected with the direct-current input interface, and the alternating-current bus is electrically connected with the alternating-current output interface;

and the direct current input interface and the alternating current output interface are respectively provided with a metal shielding waterproof joint and are respectively used for electrically connecting a double-layer shielding cable.

In the scheme, the direct-current busbars are positive and negative laminated busbars (the positive and negative busbars are overlapped together, so that stray inductance is effectively reduced).

In the scheme, the five high-voltage wires are all shielded in a double-layer shielding mode with two ends grounded.

Optionally, the motor controller further includes a discharge loop, and the discharge loop is electrically connected to the dc bus;

the discharge loop comprises a support capacitor and a discharge resistor;

the discharge resistor is arranged at the bottom in the box body, and the bottom in the box body is coated with a heat dissipation material;

the discharge resistor is used for releasing the electric energy stored in the supporting capacitor.

In the scheme, when the power is off, the energy stored in the supporting capacitor is discharged through the discharge resistor, and the discharge resistor discharges continuously to generate a large amount of heat, so that the discharge resistor is arranged at the bottom of the box body, and the bottom of the box body is coated with a heat dissipation material to dissipate heat of the discharge resistor.

Optionally, the motor controller further includes a second X capacitor and a second Y capacitor;

the second X capacitor and the second Y capacitor are respectively electrically connected with the direct current busbar.

In the present embodiment, in order to better improve EMS (Electro Magnetic sensitivity) and reduce EMI (Electro Magnetic Interference), the second X capacitor and the second Y capacitor are respectively electrically connected to the dc bus to filter out differential and common mode Interference.

Optionally, the control board module comprises a voltage acquisition unit;

the voltage acquisition unit is electrically connected with the linear busbar and is configured to acquire a voltage signal of the linear busbar.

In the scheme, the positive and negative laminated busbars are provided with the high-voltage sampling wire harness, sampling signals are sent to the high-voltage detection port of the control panel module, and whether undervoltage or overvoltage is input or not is judged through logic, so that the safety of the whole machine is further improved.

Optionally, the motor controller further includes a U-phase current collection unit, a V-phase current collection unit, and a W-phase current collection unit;

the alternating-current bus comprises a U-phase bus, a V-phase bus and a W-phase bus;

the alternating current output interface comprises a U-phase output interface, a V-phase output interface and a W-phase output interface;

the U-phase bus bar is electrically connected with the U-phase output interface, and the U-phase current acquisition unit is configured to acquire a current signal of the U-phase bus bar;

the V-phase bus bar is electrically connected with the V-phase output interface, and the V-phase current acquisition unit is configured to acquire a current signal of the V-phase bus bar;

the W-phase busbar is electrically connected with the W-phase output interface, and the W-phase current acquisition unit is configured to acquire a current signal of the W-phase busbar.

In this scheme, the U-phase current acquisition unit, the V-phase current acquisition unit, and the W-phase current acquisition unit may be implemented by current sensors.

Drawings

The features and advantages of the present disclosure will be better understood upon reading the detailed description of embodiments of the disclosure in conjunction with the following drawings. In the drawings, components are not necessarily drawn to scale, and components having similar relative characteristics or features may have the same or similar reference numerals.

Fig. 1 is a first structural diagram of an interior of a housing of a motor controller for an electric vehicle according to a preferred embodiment of the present invention.

Fig. 2 is a second structural diagram of the interior of the box of the motor controller for an electric vehicle according to the preferred embodiment of the invention.

Fig. 3 is a schematic structural diagram of an exterior of a housing of a motor controller for an electric vehicle according to a preferred embodiment of the invention.

Description of reference numerals:

case 1

Dowel hole 11

Protective support plate 12

Cover plate 2

Positioning hole 21

PCB board 3

Interface board module 31

Control panel module 32

Drive plate module 33

Power strip module 34

SiC power module 4

Low-voltage interface 5

High-voltage interface 6

DC input interface 61

AC output interface 62

DC bus bar 71

AC bus bar 72

Support capacitor 81

Discharge resistor 82

Current sensor 83

Coolant inlet 91

Liquid flow path 92

Coolant outlet 93

In specific implementation, any two current acquisition units are adopted in the U-phase current acquisition unit, the V-phase current acquisition unit and the W-phase current acquisition unit, and the other current signal acquisition port is reserved.

For example, the current signal of the U-phase busbar and the current signal of the W-phase busbar are respectively acquired by two current sensors, and after the acquisition, the current signal of the V-phase busbar is calculated by the current signals of the U-phase busbar and the W-phase busbar.

Optionally, the motor controller further comprises a heat sink;

the radiator comprises a cooling liquid water inlet and a cooling liquid water outlet which are respectively arranged on the box body;

and a linear liquid flow path is formed between the cooling liquid water inlet and the cooling liquid water outlet, is arranged at the position of the SiC power module and is used for dissipating heat of the SiC power module.

In this scheme, because of the water course of coolant liquid does not turn, so the flow resistance is little.

Optionally, the heat sink adopts a Pin-fin (a heat dissipation structure of the heat sink) heat dissipation structure.

In the scheme, the radiator adopts a Pin-fin radiating structure, so that the effective radiating area is increased, the flow resistance is lower, and the radiating performance is better.

An electric vehicle comprises the motor controller for the electric vehicle.

On the basis of the common knowledge in the field, the preferred conditions can be combined randomly to obtain the preferred embodiments of the invention.

The positive progress effects of the invention are as follows:

the motor controller for the electric automobile provided by the invention has the advantages of compact overall structure, excellent heat dissipation effect and excellent compatibility, improves the switching frequency, reduces the switching loss, and improves the space utilization rate and efficiency, thereby greatly improving the power density and further improving the stability and reliability of the electric automobile provided by the invention.