阅读说明：本技术 一种高功率密度的电机控制器 (Motor controller with high power density ) 是由 周阳 姜耀伟 杨大成 康国良 徐光照 李杰培 梁玉 于 2019-11-11 设计创作，主要内容包括：本发明公开了一种高功率密度的电机控制器,包括：与高压配电系统的直流母线相连的直流输入侧,以及用于与电机的U/V/W相分别相连的交流输出侧,以及连接于直流输入侧和交流输出侧之间用于实现电机控制的电机控制电路,电机控制电路包括并联的多组IGBT模块、支撑电容以及放电电阻；交流输出侧连接线上还设有电流传感器；还包括盒体,盒体内设置有截面为横向的T型的屏蔽托板,T型的屏蔽托板将盒体内腔分割为设置于T型的短板外侧的直流强电区,设置于T型的长板下方的交流强电区以及设置于T型的长板上方的弱电控制区；弱电控制区内设置有主控板,直流输入侧设置在直流强电区内,交流输出侧、多组IGBT模块设置在交流强电区。本发明的电磁兼容性设计合理。(The invention discloses a motor controller with high power density, which comprises: the motor control circuit comprises a direct current input side connected with a direct current bus of a high-voltage distribution system, an alternating current output side used for being respectively connected with a U/V/W phase of a motor, and a motor control circuit connected between the direct current input side and the alternating current output side and used for realizing motor control, wherein the motor control circuit comprises a plurality of groups of IGBT modules, a supporting capacitor and a discharging resistor which are connected in parallel; a current sensor is also arranged on the connecting line of the alternating current output side; the box body is internally provided with a T-shaped shielding supporting plate with a transverse section, the T-shaped shielding supporting plate divides the inner cavity of the box body into a direct current strong current area arranged outside the short plate of the T-shaped shielding supporting plate, an alternating current strong current area arranged below the long plate of the T-shaped shielding supporting plate and a weak current control area arranged above the long plate of the T-shaped shielding supporting plate; the weak current control area is internally provided with a main control board, the direct current input side is arranged in the direct current strong current area, and the alternating current output side and the multiple groups of IGBT modules are arranged in the alternating current strong current area. The electromagnetic compatibility of the invention is reasonable in design.)

1. A high power density motor controller, comprising: the motor control circuit comprises a direct current input side connected with a direct current bus of a high-voltage distribution system, alternating current output sides used for being respectively connected with U/V/W phases of a motor, and a motor control circuit connected between the direct current input side and the alternating current output sides and used for realizing motor control, wherein the motor control circuit comprises a plurality of groups of IGBT modules (7), a supporting capacitor (9) and a discharging resistor (14) which are connected in parallel; at least two phases of connecting wires in the U/V/W phase of the alternating current output side are also provided with a current sensor (12);

the box body (1) is internally provided with a T-shaped shielding supporting plate (15) with a transverse section, the T-shaped shielding supporting plate (15) divides the inner cavity of the box body (1) into a direct current strong current area arranged on the outer side of a T-shaped short plate, an alternating current strong current area arranged below a T-shaped long plate and a weak current control area arranged above the T-shaped long plate;

the weak current control area is internally provided with a main control board (16), the direct current input side is arranged in the direct current strong current area, and the alternating current output side and the multiple groups of IGBT modules (7) are arranged in the alternating current strong current area.

2. The high power density motor controller of claim 1 wherein the dc input side comprises: the direct-current bus bar (11) comprises a direct-current bus bar positive connecting bar (1101) and a direct-current bus bar negative connecting bar (1102) which are arranged in a laminated mode, and two ends of the direct-current bus bar positive connecting bar (1101) and two ends of the direct-current bus bar negative connecting bar (1102) are respectively connected with a supporting capacitor (9) and the direct-current connector (5); insulating powder is sprayed on the surfaces of the direct-current busbar positive connecting bar (1101) and the direct-current busbar negative connecting bar (1102) or insulating adhesive tapes are wound on the surfaces of the direct-current busbar positive connecting bar and the direct-current busbar negative connecting bar for local insulation protection.

3. The high power density motor controller according to claim 2, wherein two magnetic rings (13) are sleeved on the dc bus bar positive connecting bar (1101) and the dc bus bar negative connecting bar (1102), and the discharge resistor (14) is installed between the two magnetic rings (13) and below the dc bus bar (11).

4. The high power density motor controller according to claim 1, characterized in that the main control board (16) is connected to the signal connector (6) by a wire; the main control board (16) comprises a main control board mother board (1601) and a main control board daughter board (1602) which are arranged in a stacked mode, wherein the main control board mother board (1601) is installed above a T-shaped long board of the shielding supporting plate (15), and the main control daughter board is installed on the main control mother board.

5. The high power density motor controller according to claim 1, wherein the ac output side comprises an ac connector (4) and an ac busbar (10), one end of the ac busbar (10) is led out from the ac end of the IGBT module (7), the other end of the ac busbar is connected to the ac connector (4), the IGBT module (7) is fixed on the heat sink (3), and the driving board (8) is directly fixed on the IGBT module (7). And the support capacitor (9) is connected with the direct current end of the IGBT module (7) and is arranged on the bottom plate (103) of the box body (1) or the radiator (3).

6. The high power density motor controller according to claim 4 or 5, wherein the box body (1) comprises a front side wall (101), a rear side wall, a left side wall, a right side wall (102), a bottom plate (103) and a cover plate (2), the DC connector (5) and the AC connector (4) are arranged on the front side wall (101), and the plurality of sets of IGBT modules (7) are fixed on the bottom plate (103) through the heat sink (3).

7. High power density motor controller according to claim 6, characterized in that the signal connector (6) is provided on the left or right side wall (102).

Technical Field

The invention relates to the field of motor control, in particular to a motor controller with high power density.

Background

The motor controller is used as an electric energy conversion unit between a power supply and a motor and is a core functional component of the electric transmission system. The power density is one of the most intuitive technical indexes for measuring the motor controller, and the higher the power density is, the smaller the volume and the weight of the motor controller under the condition of certain output capacity. The structural scheme of the high power density motor controller needs to comprehensively consider the following factors:

and (4) heat dissipation design. The higher the power density of the motor controller is, the larger the heat productivity in unit volume is, and if the heat dissipation design is unreasonable, the reliability of a large number of temperature sensitive electric elements in the motor controller is affected.

And (4) insulating design. The compact structural arrangement reduces the electric clearance and creepage distance between the various charged bodies, and the electric safety is ensured by an additional insulation design.

And (4) electromagnetic compatibility design. The more compact the motor controller structure is, the more severe the electromagnetic environment is, the more the internal devices are exposed to the electromagnetic fields of each other, and the isolation of strong current and weak current, the isolation of alternating current and direct current, the filter design and the like need to be considered.

The technical background of the invention focuses on a structural design scheme for realizing high power density of a motor controller, which not only can meet the requirements of heat dissipation and insulation of the motor controller, but also has excellent electromagnetic compatibility.

Disclosure of Invention

The invention provides a high-power-density motor controller, which is used for solving the technical problem of electromagnetic interference in high power density.

In order to solve the technical problems, the technical scheme provided by the invention is as follows:

a high power density motor controller comprising: the motor control circuit comprises a direct current input side connected with a direct current bus of a high-voltage distribution system, an alternating current output side used for being respectively connected with a U/V/W phase of a motor, and a motor control circuit connected between the direct current input side and the alternating current output side and used for realizing motor control, wherein the motor control circuit comprises a plurality of groups of IGBT modules, a supporting capacitor and a discharging resistor which are connected in parallel; at least two phases of connecting wires in the U/V/W phase at the AC output side are also provided with current sensors;

the box body is internally provided with a T-shaped shielding supporting plate with a transverse section, the T-shaped shielding supporting plate divides the inner cavity of the box body into a direct current strong current area arranged outside the short plate of the T-shaped shielding supporting plate, an alternating current strong current area arranged below the long plate of the T-shaped shielding supporting plate and a weak current control area arranged above the long plate of the T-shaped shielding supporting plate;

the weak current control area is internally provided with a main control board, the direct current input side is arranged in the direct current strong current area, and the alternating current output side and the multiple groups of IGBT modules are arranged in the alternating current strong current area.

Preferably, the direct current input side comprises: the direct-current bus comprises a direct-current bus positive connecting bar and a direct-current bus negative connecting bar which are arranged in a laminated mode, and two ends of the direct-current bus positive connecting bar and the direct-current bus negative connecting bar are respectively connected with a supporting capacitor and a direct-current connector; and insulating powder is sprayed on the surfaces of the direct-current busbar positive connecting bar and the direct-current busbar negative connecting bar or an insulating tape is wound on the surfaces of the direct-current busbar positive connecting bar and the direct-current busbar negative connecting bar to perform local insulation protection.

Preferably, two magnetic rings are sleeved on the positive connecting bar and the negative connecting bar of the direct-current busbar, and the discharge resistor is arranged between the two magnetic rings and located below the direct-current busbar.

Preferably, the main control board is connected with the signal connector through a wire; the main control board comprises a main control board mother board and a main control board daughter board which are arranged in a stacked mode, wherein the main control board mother board is installed above the T-shaped long board of the shielding supporting plate, and the main control daughter board is installed on the main control mother board.

Preferably, the alternating current output side comprises an alternating current connector and an alternating current busbar, one end of the alternating current busbar is led out from an alternating current end of the IGBT module, the other end of the alternating current busbar is connected with the alternating current connector, the IGBT module is fixed on the radiator, and the driving board is directly fixed on the IGBT module. And the support capacitor is connected with the direct current end of the IGBT module and is arranged on the bottom plate of the box body or the radiator.

Preferably, the box body includes preceding lateral wall, back lateral wall, left side wall, right side wall, bottom plate and apron, and direct current connector and alternating current connector set up on preceding lateral wall, and the multiunit IGBT module passes through the radiator to be fixed on the bottom plate.

Preferably, the signal connector is provided on the left or right side wall.

The invention has the following beneficial effects:

1. the motor controller with high power density has high space utilization rate, is beneficial to miniaturization and light weight of the motor controller, obviously divides and isolates strong current and weak current, alternating current and direct current areas in the motor controller, and has reasonable design of electromagnetic compatibility.

2. In a preferred scheme, the high-power-density motor controller is provided with the magnetic ring at the direct-current end for filtering, has better electromagnetic compatibility, is suitable for controlling various motors (including a generator and a motor), and can be widely applied to the field of pure electric vehicles or hybrid electric vehicles. In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided.

The present invention will be described in further detail below with reference to the accompanying drawings.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:

fig. 1 is a cross-sectional view of a high power density motor controller in accordance with a preferred embodiment of the present invention.

Fig. 2 is a schematic diagram of the main circuit principle of the high power density motor controller of the preferred embodiment of the present invention.

Fig. 3 is a schematic perspective view of a high power density motor controller according to a preferred embodiment of the present invention.

Fig. 4 is an exploded view of a high power density motor controller according to a preferred embodiment of the present invention.

Fig. 5 is a top view of a high power density motor controller cover of a preferred embodiment of the present invention hidden.

Fig. 6 is a top view of the high power density motor controller cover plate, main control plate, and shielding pallet of the preferred embodiment of the present invention after they are concealed.

The reference numerals in the figures denote:

1. a box body; 101. a front side wall; 102. a right side wall; 103. a base plate; 2. a cover plate; 3. a heat sink; 4. an AC connector; 5. a DC connector; 6. a signal connector; 7. an IGBT module; 8. a drive plate; 9. a support capacitor; 10. an alternating current bus bar; 11. a direct current bus bar; 1101. a direct current busbar positive electrode connecting bar; 1102. a DC bus negative electrode connecting bar; 12. a current sensor; 13. a magnetic ring; 14. a discharge resistor; 15. a shielding support plate; 16. a main control board; 1601. a master control board mother board; 1602. a main control board; 17. a sealing strip.

Detailed Description

The embodiments of the invention will be described in detail below with reference to the drawings, but the invention can be implemented in many different ways as defined and covered by the claims.

Referring to fig. 1 and 2, the high power density motor controller of the present invention includes: the motor control circuit comprises a direct current input side connected with a direct current bus bar of a high-voltage distribution system, an alternating current output side used for being respectively connected with a U/V/W phase of a motor, and a motor control circuit connected between the direct current input side and the alternating current output side and used for realizing motor control, wherein the motor control circuit comprises a plurality of groups of IGBT modules 7, a supporting capacitor 9 and a discharging resistor 14 which are connected in parallel; at least two phase connecting lines of the U/V/W at the AC output side are also provided with current sensors 12 (three phases can be arranged or only two phases can be arranged); the box body 1 is also included, a T-shaped shielding supporting plate 15 with a transverse section is arranged in the box body 1, the T-shaped shielding supporting plate 15 divides the inner cavity of the box body 1 into a direct current strong current area arranged on the outer side of a T-shaped short plate, an alternating current strong current area arranged below a T-shaped long plate and a weak current control area arranged above the T-shaped long plate; the weak current control area is internally provided with a main control board 16, the direct current input side is arranged in the direct current strong current area, and the alternating current output side and the plurality of groups of IGBT modules 7 are arranged in the alternating current strong current area. And strong current and weak current, alternating current and direct current region in the motor controller are obviously divided and isolated, and the design of electromagnetic compatibility is reasonable. The space utilization rate is high, and the motor controller is beneficial to miniaturization and light weight.

In this embodiment, the main control board 16 is configured to convert an external input control power supply to supply power to the control circuit and the drive board 8, and has functions of logic control of the motor controller, data sampling and analysis, pulse signal generation of the IGBT module 7, state monitoring, fault protection, and external communication; and the driving board 8 is used for receiving the pulse signal of the main control board 16 to drive the IGBT module 7 to work, and has the functions of collecting the temperature signal of the IGBT module 7, fault feedback, protection and the like.

In this embodiment, referring to fig. 3, 4, 5, and 6, the dc input side includes: the direct-current bus bar 11 comprises a direct-current bus bar positive connecting bar 1101 and a direct-current bus bar negative connecting bar 1102 which are mutually arranged in a laminated manner, and two ends of the direct-current bus bar positive connecting bar 1101 and two ends of the direct-current bus bar negative connecting bar 1102 are respectively connected with the supporting capacitor 9 and the direct-current connector 5; two magnetic rings 13 are sleeved on the positive connecting bar 1101 of the direct-current busbar and the negative connecting bar 1102 of the direct-current busbar for realizing the filtering function. The discharge resistor 14 is installed between the two magnetic rings 13 and below the dc bus bar 11, and is installed on the bottom plate 103 of the box 1 or the heat sink 3. Insulating powder is sprayed on the surfaces of the direct-current busbar positive connecting bar 1101 and the direct-current busbar negative connecting bar 1102 or insulating tapes are wound to perform local insulation protection.

In this embodiment, the box body 1 includes the front side wall 101, the rear side wall, the left side wall, the right side wall 102, bottom plate 103 and apron 2 (box body is upper, lower both ends opening, by preceding, back, left side, right side four lateral walls, or by preceding, back, left side, right side, five lateral walls enclose and close to form down), the up end of box body 1 is equipped with apron 2, apron 2 can dismantle between the up end of bolt and box body 1 through the periphery setting and be connected, and be equipped with sealing strip 17 between the contact surface of apron 2 and box body 1, the opening on the lateral wall is used for installing the radiator under the box body 1, can dismantle the link between bolt and the box body 1 lower lateral wall that radiator 3 set up through the periphery, and be equipped with sealing strip 17 between the contact surface of radiator 3 and box body 1 lower lateral wall, in this embodiment radiator 3 belongs to the liquid cooling radiator. The dc connector 5 and the ac connector 4 are provided on the front side wall 101, and the plurality of sets of IGBT modules 7 are fixed to the bottom plate 103 via the heat sink 3. The main control board 16 is connected to the signal connector 6 through a wire, and the signal connector 6 is disposed on the left or right sidewall 102. The main control board 16 includes a main control board mother board 1601 and a main control board daughter board 1602 which are stacked on each other, wherein the main control board mother board 1601 is installed above the T-shaped long board of the shielding supporting board 15, and the main control daughter board is installed on the main control mother board. The main control board 16 adopts an upper and lower laminated board form to meet the requirement of structural compactness.

In this embodiment, the ac output side includes ac connector 4 and ac busbar 10, and ac busbar 10 has one end led out from the ac end of IGBT module 7 and the other end connected to ac connector 4, and IGBT module 7 is fixed on heat sink 3, and drive board 8 is directly fixed on IGBT module 7. The support capacitor 9 is connected with the direct current end of the IGBT module 7 and is installed on the bottom plate 103 of the box body or the radiator 3 nearby. The current sensor 12 may be mounted on part or all of the ac busbar 10, or may be mounted on part or all of the ac connector 4, or may be mounted on a side wall of the box body 1.

The long plate of the shield support plate 15 is placed above the driving plate 8 and fixed to the heat sink 3 or the case 1. Referring to fig. 4, one end of the shielding support plate 15 is fixed to the heat sink 3, and the other end is fixed to the right sidewall 102 of the case 1. The shielding supporting plate 15, the box body 1, the cover plate 2, the radiator 3 and the supporting capacitor 9 are used for isolating the alternating current strong current part, the direct current strong current part and the weak current control part of the motor controller in space, and electromagnetic interference among the three parts is reduced. In this embodiment, the supporting capacitor 9 is disposed between the dc voltage enhancement region and the ac voltage enhancement region, and plays a role in connecting the dc voltage enhancement region and the ac voltage enhancement region.

In this embodiment, the ac connector 4, the dc connector 5, and the signal connector 6 are all panel-mounted connectors; the AC connector 4 and the DC connector 5 can be single-core, multi-core or replaced by a cable clamp; preferably, the ac busbar 10 and the dc busbar 11 may be replaced by a cable.

In conclusion, the invention has high space utilization rate, is beneficial to the miniaturization and the light weight of the motor controller, obviously divides and isolates strong current and weak current, alternating current and direct current areas in the motor controller, and simultaneously sets the magnetic ring 13 at the direct current end for filtering, thereby having reasonable design of electromagnetic compatibility.

The high-power-density motor controller provided by the invention is suitable for controlling various motors (including a generator and a motor), and can be widely applied to the field of pure electric vehicles or hybrid electric vehicles.

The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.