阅读说明：本技术 电动车用电机控制器集成组件的控制方法以及电动车 (Control method of motor controller integrated assembly for electric vehicle and electric vehicle ) 是由 段云 胡金龙 张力 刘竹园 王景瑜 章恒亮 李玉刚 刘亚军 卜言柱 胡宜豹 周建 于 2021-09-14 设计创作，主要内容包括：本发明公开了一种电动车用电机控制器集成组件的控制方法以及电动车,控制器与定子组件安装为一体；其中,控制器与位于电机壳体外部的电源电连接,实现控制器的电源输入；控制器与位于电机壳体外部的中控装置双向通信连接,其中,中控装置将中控指令发送给控制器,控制器将电动车的轮动信号发送给中控装置,作为防盗输入信号；控制器与定子组件的绕组相线电连接；本发明在实现控制器与电机的一体集成基础上,控制过程简单且稳定可靠,还可以极大程度地简化控制器的线束结构,也不会给电机内部的安装布局以及散热造成过多负担,同时不会影响电动车的常规驱动性能。(The invention discloses a control method of a motor controller integrated assembly for an electric vehicle and the electric vehicle, wherein the controller and a stator assembly are installed into a whole; the controller is electrically connected with a power supply positioned outside the motor shell to realize power supply input of the controller; the controller is in bidirectional communication connection with a central control device positioned outside the motor shell, wherein the central control device sends a central control instruction to the controller, and the controller sends a wheel movement signal of the electric vehicle to the central control device to serve as an anti-theft input signal; the controller is electrically connected with a winding phase line of the stator assembly; on the basis of realizing the integrated integration of the controller and the motor, the control process is simple, stable and reliable, the wire harness structure of the controller can be greatly simplified, excessive burden on the installation layout and heat dissipation in the motor can be avoided, and the conventional driving performance of the electric vehicle can not be influenced.)

1. A control method of a motor controller integrated assembly for an electric vehicle is characterized in that the motor controller integrated assembly comprises a controller for realizing drive control of a motor, a stator assembly fixedly installed and connected with a motor shaft, and a permanent magnet rotor assembly, wherein the stator assembly is positioned in a motor shell, and the controller and the stator assembly are installed into a whole; the control method comprises the following control processes:

the controller is electrically connected with a power supply positioned outside the motor shell to realize power supply input of the controller;

the controller is in bidirectional communication connection with a central control device located outside a motor shell, wherein the central control device sends a central control instruction to the controller, and the controller sends a wheel movement signal of the electric vehicle to the central control device to serve as an anti-theft input signal;

and the controller is electrically connected with a winding phase line of the stator assembly and sends a PWM driving signal to the stator assembly.

2. The control method according to claim 1, wherein the central control device is electrically connected with the power supply to realize power supply input of the central control device; the central control device is provided with a DCDC module, and the DCDC module gives 1 or more controllable power output signals based on the state control of the motor, wherein the controllable power output signals comprise at least 1 controller DC power signal output to the controller and an instrument DC power signal output to an electric vehicle instrument structure.

3. The control method according to claim 2, wherein the meter DC power supply signal is controlled by a loop voltage constant voltage control, the loop voltage constant voltage control is performed by performing constant voltage detection on the meter DC power supply signal, the constant voltage detection signal is input to a PID regulator, and the PID regulator outputs a constant voltage source PWM signal as the meter DC power supply signal; and 1 or more loop short-circuit protection circuits are arranged between the constant voltage source PWM signal and the PID regulator.

4. The control method according to claim 2, wherein the electric vehicle meter structure comprises a horn and/or a lamp; the central control device is electrically connected with the electric vehicle instrument structure and used for realizing the drive control of the electric vehicle instrument structure.

5. The control method according to claim 1, wherein the central control device is provided with an anti-theft module and a vibration module, the anti-theft module takes a wheel motion signal output by a wheel motion sensor as an input signal, and the vibration module identifies the vibration signal; meanwhile, the central control device acquires an anti-theft instruction through an external remote controller, enters an anti-theft mode after receiving the anti-theft instruction, and sends a vehicle locking instruction to the controller when the anti-theft module identifies a wheel-moving signal and the vibration module identifies a vibration signal.

6. The control method according to claim 1, wherein the central control device is in communication connection with an external remote controller and/or an operation and maintenance center, and communication data between the central control device and the operation and maintenance center are stored in a cloud mode.

7. The control method of claim 1, wherein the central control command comprises an electric door lock signal, a handle signal and a brake signal.

8. The control method according to claim 1, wherein the motor housing is internally filled with an insulating coolant; the controller comprises a circuit board and a heat dissipation aluminum plate which are fixedly arranged on the end surface of the stator assembly respectively, and the circuit board is sleeved on the periphery of the motor shaft; and each MOS pipe of the circuit board is respectively and fixedly installed on a heat dissipation aluminum plate positioned on the periphery of the circuit board.

9. An electric vehicle, characterized in that a control method according to one of claims 1-8 is used.

10. The electric vehicle of claim 9, wherein the central control device is integrally installed in an instrument structure of the electric vehicle; the power supply is arranged on the electric vehicle frame positioned at the bottom of the middle part.

Technical Field

The invention belongs to the field of electric vehicle drive control, and particularly relates to a control method of an electric vehicle motor controller integrated assembly.

Background

With the technical development of motor drive control technology, subject to harsh compact installation requirements, in the field of household electric tools and electric tools, motors and controllers are basically installed in an integrated manner, and because the working power of the motors in the field of household electric tools and electric tools is low, after the motors and the controllers are integrated, the heat dissipation problem is small, which also becomes a key factor for realizing the integrated integration of the motors and the controllers in the fields.

Specifically, for the field of electric vehicles, because the brushless permanent magnet synchronous motor has the advantages of compact structure, high power density and gradually improved technology, in the field of electric vehicles, a high-power brushless permanent magnet synchronous motor (the power is usually at least more than 200W, and much of the power is more than 500W-1 KW) is usually adopted as a driving motor of the electric vehicle, and because the control requirement of the brushless permanent magnet synchronous motor is high, the brushless permanent magnet synchronous motor is also called a technical threshold and a barrier for popularization and application of the permanent magnet synchronous motor. At present, the field of electric vehicles is that a controller manufacturer designs a controller through motor indexes provided by the whole electric vehicle manufacturer. Therefore, a controller manufacturer and a motor manufacturer become two independent product development systems, and are finally connected together through a large line of an electric vehicle whole factory, so that a driving system of an electric vehicle needs to be connected with more independent modules, the wiring harnesses are more, the whole wiring terminals are increased, the wiring is complex, the types of motor controllers are more, and standardization or series modularization cannot be formed.

The invention patent with publication number CN111082602A discloses a hub motor with a built-in control system, which proposes to arrange the control system on a stator assembly, the control system is connected with a motor wire assembly, the interior of a motor shell is cooled by insulating cooling liquid, and then a pressure balance between the interior and the exterior of the motor shell is realized by arranging an oil-proof ventilation valve with an oil-proof ventilation film on the motor shell and arranging a ventilation pipe structure on the wire assembly. However, the oil-proof vent valve and the vent pipe adopted by the scheme are exposed outside, so that not only is the hidden danger of liquid leakage existed, but also the hidden danger is caused by the service life of the wire assembly, so that the quality hidden danger exists in the adopted heat dissipation scheme, and the applicant finds that after the motor for the electric vehicle is integrated with the controller thereof, the risk of electromagnetic interference still exists, and meanwhile, the problems of integrated control layout and the like of other function control modules of the electric vehicle, such as an anti-theft module, a vibration module and a DCDC power module, are solved.

Based on the research experience of the inventor in the field of the electric vehicle for years, research and development teams respectively provided with the motor and the controller are provided, so that a technical scheme is expected to be sought to realize the integrated integration of the motor and the controller in the field of the electric vehicle.

Disclosure of Invention

In view of the above, the present invention provides a control method for a motor controller integrated component for an electric vehicle and an electric vehicle, which are based on the realization of the integrated integration of a controller and a motor, and have simple, stable and reliable control process, and can greatly simplify the wire harness structure of the controller, and also do not cause excessive burden on the installation layout and heat dissipation inside the motor, and at the same time, do not affect the conventional driving performance of the electric vehicle.

The technical scheme of the invention is as follows:

a control method of a motor controller integrated assembly for an electric vehicle is disclosed, wherein the motor controller integrated assembly comprises a controller for realizing driving control of a motor, a stator assembly fixedly installed and connected with a motor shaft, and a permanent magnet rotor assembly, the stator assembly is positioned in the motor shell, and the controller and the stator assembly are installed into a whole; the control method comprises the following control processes:

the controller is electrically connected with a power supply positioned outside the motor shell to realize power supply input of the controller;

the controller is in bidirectional communication connection with a central control device located outside a motor shell, wherein the central control device sends a central control instruction to the controller, and the controller sends a wheel movement signal of the electric vehicle to the central control device to serve as an anti-theft input signal;

and the controller is electrically connected with a winding phase line of the stator assembly and sends a PWM driving signal to the stator assembly.

Preferably, the central control device is electrically connected with the power supply to realize power supply input of the central control device; the central control device is provided with a DCDC module, and the DCDC module gives 1 or more controllable power output signals based on the state control of the motor, wherein the controllable power output signals comprise at least 1 controller DC power signal output to the controller and an instrument DC power signal output to an electric vehicle instrument structure.

Preferably, the instrument DC power signal is controlled by a loop voltage constant voltage, the loop voltage constant voltage control is performed by performing constant voltage detection on the instrument DC power signal, the constant voltage detection signal is input to a PID regulator, and the PID regulator outputs a constant voltage source PWM signal as the instrument DC power signal; and 1 or more loop short-circuit protection circuits are arranged between the constant voltage source PWM signal and the PID regulator.

Preferably, the electric vehicle instrument structure comprises a horn and/or a lamp; the central control device is electrically connected with the electric vehicle instrument structure and used for realizing the drive control of the electric vehicle instrument structure.

Preferably, the central control device is provided with an anti-theft module and a vibration module, the anti-theft module takes a wheel motion signal output by a wheel motion sensor as an input signal, and the vibration module identifies the vibration signal; meanwhile, the central control device acquires an anti-theft instruction through an external remote controller, enters an anti-theft mode after receiving the anti-theft instruction, and sends a vehicle locking instruction to the controller when the anti-theft module identifies a wheel-moving signal and the vibration module identifies a vibration signal.

Preferably, the central control device is in communication connection with an external remote controller and/or an operation and maintenance center, and communication data between the central control device and the operation and maintenance center is stored in a cloud mode.

Preferably, the central control command comprises an electric door lock signal, a handle turning signal and a brake signal.

Preferably, the motor shell is internally filled with insulating cooling liquid; the controller comprises a circuit board and a heat dissipation aluminum plate which are fixedly arranged on the end surface of the stator assembly respectively, and the circuit board is sleeved on the periphery of the motor shaft; and each MOS pipe of the circuit board is respectively and fixedly installed on a heat dissipation aluminum plate positioned on the periphery of the circuit board.

Preferably, an electric vehicle employs the control method as described above.

Preferably, the central control device is integrally installed in an instrument structure of the electric vehicle; the power supply is arranged on the electric vehicle frame positioned at the bottom of the middle part.

According to the electric vehicle control system, a controller and a motor are integrated, then a central control device is arranged outside a motor shell, on the basis of realizing the integrated integration of the controller and the motor, the specific splitting of a control main body structure of the electric vehicle is realized through the central control device, specifically, the controller is in two-way communication connection with the central control device positioned outside the motor shell, the central control device sends a central control instruction to the controller, the controller sends a wheel movement signal of the electric vehicle to the central control device to serve as an anti-theft input signal, the control technology is simple, stable and reliable in control process, the wiring harness structure of the controller can be simplified to a great extent, too much burden cannot be caused on the installation layout and heat dissipation inside the motor, and the conventional driving performance of the electric vehicle cannot be influenced; therefore, the wiring harness connection layout of the motor controller integrated assembly for the electric vehicle is obviously optimized, so that the application process of the motor controller integrated assembly for the electric vehicle is powerfully promoted, and the motor controller product can realize standardization and series modularization.

Drawings

FIG. 1 is a schematic structural diagram of an integrated motor controller assembly for an electric vehicle according to an embodiment of the present disclosure;

FIG. 2 is a schematic diagram of signals at an output of a controller according to an embodiment of the present application;

FIG. 3 is a schematic diagram of an electrical connection structure between a controller and a central control device and a power supply according to an embodiment of the present disclosure;

FIG. 4 is a schematic diagram of a power output control process of the DCDC module according to an embodiment of the present application;

FIG. 5 is a schematic diagram of a loop voltage constant voltage control process according to an embodiment of the present application;

FIG. 6 is a schematic diagram of an anti-theft control process according to an embodiment of the present application;

FIG. 7 is a schematic diagram of a communication connection structure between a central control device and an external structure according to an embodiment of the present application;

fig. 8 is a schematic structural diagram of a controller mounted on an end surface of a stator assembly according to an embodiment of the present application.

Detailed Description

The embodiment of the invention discloses a control method of a motor controller integrated assembly for an electric vehicle, wherein the motor controller integrated assembly comprises a controller for realizing driving control of a motor, a stator assembly fixedly installed and connected with a motor shaft, and a permanent magnet rotor assembly, wherein the stator assembly is positioned in a motor shell, and the controller and the stator assembly are installed into a whole; wherein, the controller comprises the following control processes: the controller is electrically connected with a power supply positioned outside the motor shell to realize power supply input of the controller; the controller is in bidirectional communication connection with a central control device positioned outside the motor shell, wherein the central control device sends a central control instruction to the controller, and the controller sends a wheel movement signal of the electric vehicle to the central control device to serve as an anti-theft input signal; and the controller is electrically connected with a winding phase line of the stator assembly and sends a PWM driving signal to the stator assembly.

The embodiment of the invention also provides an electric vehicle which adopts the control method.

In order to make those skilled in the art better understand the technical solution of the present invention, the technical solution in the embodiment of the present invention will be clearly and completely described below with reference to the drawings in the embodiment of the present invention, and it is obvious that the described embodiment is only a part of the embodiment of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Referring to fig. 1, a motor controller integrated assembly 1 for an electric vehicle includes a controller 10 for implementing driving control of a motor, a stator assembly 30 fixedly mounted and connected to a motor shaft 20, and a permanent magnet rotor assembly 40, wherein the stator assembly 30 is located inside a motor housing 50, and the controller 10 and the stator assembly 30 are integrally mounted; in the present embodiment, the motor as a whole employs a permanent magnet synchronous motor; it should be noted that the mounting structures of the stator assembly 30, the permanent magnet rotor assembly 40 and the motor housing 50 are all common knowledge, and the detailed description thereof is omitted here.

The present embodiment proposes a control method of the integrated assembly 1 of the motor controller 10 for the motor vehicle, wherein please refer to fig. 2 and fig. 3 in combination, the control method comprises the following control processes:

the controller 10 is electrically connected to a power supply 3 (i.e., a battery, which may be configured to have a communication function) located outside the motor housing 50, so as to realize power input of the controller 10; the controller 10 is in bidirectional communication connection with the central control device 2 located outside the motor housing 50 (485 communication protocols can be adopted in this embodiment, and other known wired or wireless communication methods can also be adopted, and this embodiment is not particularly limited), wherein the central control device 2 sends a central control instruction to the controller 10, and the controller 10 (provided with the wheel motion sensor) sends a wheel motion signal of the electric vehicle to the central control device 2 as an anti-theft input signal; the controller 10 is electrically connected with a winding phase line of the stator assembly 30 and sends a PWM driving signal to the stator assembly 30;

referring to fig. 2 in conjunction with fig. 3, in the present embodiment, the output end of the controller 10 (fig. 2 is labeled as an integrated controller 10) specifically includes a three-phase power signal output end U, V, W connected to the winding of the stator assembly 30, hall signal output ends HA, HB, and HC connected to three phases of the hall assemblies, and a DC power signal end (shown as +5V) of the hall signal line; a power supply output end power supply + connected with the power supply 3; a communication terminal a, a communication terminal B, a rotation signal output terminal P _ SD and a power signal terminal (shown as +15V) connected to the central control device 2; in order to realize the emergency starting of the motor, the controller 10 in this embodiment is further provided with a starting signal end, which is electrically connected with an external emergency starting key through an emergency starting line;

preferably, please further combine fig. 2 and fig. 3 to show that, in the present embodiment, the central control device 2 is electrically connected to the power supply 3 to realize the power supply input of the central control device 2; in order to further implement the integrated installation layout of the central control device 2, please further refer to fig. 4, the central control device 2 is provided with a DCDC module, the DCDC module controls to provide 1 or more controllable power output signals based on the state of the motor, where the controllable power output signals include at least 1 controller DC power signal output to the controller 10 and an instrument DC power signal output to the instrument structure of the electric vehicle, the instrument structure of the electric vehicle includes a speaker and various lamps or other known instrument structures, and the embodiment is not particularly limited; the central control device 2 is electrically connected with the electric vehicle instrument structure and is used for realizing the driving control of the electric vehicle instrument structure;

specifically, in the present embodiment, the controllable power output signals include +15V DC power signals and +5V DC power signals output to the controller 10, and +12V meter DC power signals output to the electric vehicle meter structure, and are used for supplying power to various meter structures such as lamps and speakers of the whole vehicle.

Preferably, as further shown in fig. 5, in order to implement stable constant voltage power supply to the meter structure, in the present embodiment, the meter DC power signal is controlled by using a loop voltage constant voltage, the loop voltage constant voltage control is performed by performing constant voltage detection on the meter DC power signal (specifically, VT13 sampling is performed on 12V, although other methods may be used to implement constant voltage sampling), the constant voltage detection signal is input to the PID regulator, and the PID regulator outputs a constant voltage source PWM signal, which is used as the meter DC power signal; 1 or more loop short-circuit protection circuits are arranged between a constant voltage source PWM signal and a PID regulator; specifically, in the present embodiment, 2 loop short-circuit protection circuits are provided between the constant-voltage source PWM signal (AH value and AL value) and the PID controller, and specifically include: overcurrent protection IS implemented by comparator IS1 and shoot-through protection IS implemented by comparator IS 2.

Preferably, please refer to fig. 3 and fig. 6, in order to further realize the integrated installation layout of the central control device 2, in the present embodiment, the central control device 2 is provided with an anti-theft module and a vibration module, the anti-theft module takes the wheel movement signal output by the controller 10 (specifically, output by the wheel movement sensor provided on the controller 10) as an input signal, and the vibration module recognizes the vibration signal through the vibration sensor; meanwhile, the central control device 2 obtains an anti-theft instruction through the external remote controller 4, enters an anti-theft mode after receiving the anti-theft instruction, and sends a vehicle locking instruction to the controller 10 when the anti-theft module identifies a wheel-moving signal and the vibration module identifies a vibration signal.

Preferably, in order to further realize the integrated installation layout of the central control device 2, please refer to fig. 3, in the present embodiment, various conventional modules of electric vehicle driving are disposed on the central control device 2, such as: the electric brake system comprises a SPEED display module (SD), a cruise module (XH), an electric brake module (ABS), a voltage selection module (DYXZ), a push-to-talk module (YJ), a wire-through module (YXT), a brake module (SC), a handle turning module (SPEED) and an electric door lock module (DMS), wherein a central control command sent by the central control device 2 to the controller 10 in a communication mode comprises an electric door lock signal output by the electric door lock module (DMS), a handle turning signal output by the handle turning module (SPEED), a brake signal output by the brake module (SC), a cruise signal output by the cruise module (XH), an electric brake signal output by the electric brake module (ABS), a voltage selection signal output by the voltage selection module (DYXZ) and signals output by the push-to-talk module (YJ) and the wire-through module (YXT), which can be sent to the controller 10 specifically through a 485 communication protocol, so that the conventional communication performance of the electric vehicle is realized, meanwhile, the wiring harness layout structure of the controller 10 can be greatly simplified, and the heat generated inside the motor housing 50 can be reduced.

On the basis of the above embodiments, please refer to fig. 1, fig. 3 and fig. 8, this embodiment further specifically proposes a control connection structure of an integrated assembly of a motor controller 10 for an electric vehicle, wherein the controller 10 is installed on an end surface of a stator assembly 30; the controller 10 is connected to a power supply outside the motor housing 50 and is connected with the central control device 2 outside the motor housing 50 in a bidirectional communication mode;

preferably, in the present embodiment, the wire harness of the controller 10 includes a phase line 11, a communication line 12 (including A, B communication line), a movement signal line 13, a power supply line 14, and an emergency start line 15; wherein, the phase line 11 is electrically connected with the phase line of the winding of the stator assembly 30, and the wire harness extends to the outside of the motor shell 50 after penetrating through the motor shaft 20; the communication line 12 and the wheel-movement signal line 13 are respectively connected to the central control device 2, and the power line 14 of the controller 10 is connected to the power supply 3; the hall wires 16 of the controller 10 are electrically connected with the hall assembly 31 of the stator assembly 30; the central control device 2 is electrically connected with the electric vehicle instrument structure and is used for realizing the driving control of the electric vehicle instrument structure; further preferably, in the present embodiment, a harness insertion passage 21 is provided inside the motor shaft 20, and the harness inserted into the motor housing 50 is led out concentratedly through the harness insertion sheath 22.

Preferably, in the present embodiment, the antitheft module is connected to the signal line for wheel movement of the controller 10; the DCDC module is respectively connected to a power line of the controller 10 and a power line of the electric vehicle meter structure.

Preferably, as further shown in fig. 7, in order to implement intelligent communication management with the outside, in the present embodiment, the central control device 2 and the external remote controller 4 may specifically use a conventional key for remote control, or may use an electronic product such as a mobile phone to implement remote communication connection; remote communication connection is further established between the central control device 2 and the operation and maintenance center 5, and communication data between the central control device 2 and the operation and maintenance center 5 are stored by the cloud 6, so that later maintenance of a driving system of the electric vehicle is facilitated.

Preferably, referring to fig. 8 in particular, in order to further facilitate the heat dissipation effect inside the motor housing 50, in the present embodiment, the inside of the motor housing 50 is filled with an insulating cooling liquid (specifically, insulating cooling oil 60); the controller 10 comprises a circuit board 10a and a heat-dissipating aluminum plate 10b which are respectively and fixedly installed on the end surface of the stator assembly 30, and the circuit board 10a is sleeved on the periphery of the motor shaft 20; and the MOS transistors 10c of the circuit board 10a are respectively fixedly mounted on a heat-dissipating aluminum plate 10b located on the periphery of the circuit board 10 a; particularly preferably, in the present embodiment, the circuit board 10a is in a circular shape, and the heat dissipating aluminum plate 10b is in a ring shape; in the embodiment, the circuit board 10a further has a plurality of electrolytic capacitors 10d and a single chip microcomputer chip 10e, and these electronic components are selected by the conventional techniques of those skilled in the art, so detailed descriptions thereof are omitted;

the embodiment also provides an electric vehicle which adopts the control method and the control connection structure; preferably, in the present embodiment, the central control device 2 is integrally installed in the instrument structure of the electric vehicle; the power supply 3 is mounted on a motor-driven carriage (not shown) at the bottom of the middle, further contributing to simplification of the wiring harness threading, and to compactness of the mounting as a whole.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.