Electric vehicle motor controller and controller assembly modularization unit structure mode

Abstract

Provided are an electric vehicle alternating-current motor controller and a modularization unit structure and layout mode of a controller assembly. A power semiconductor module, a driving control board unit thereof, an aluminum electrolytic capacitor integration module, an output terminal component module 3 with a built-in current sensor, and a component unit 4 formed by a contactor 4a, a power fuse protector 4b and a diverter 4c are included and are arranged on an inner bottom plate of a radiating aluminum outer shell 5 in sequence. A plastic inner cover 6 seals the power semiconductor module, the driving control board unit 1 thereof, the capacitor integration module 2 and the output terminal component module 3 with the built-in current sensor in a sealed space, and the motor controller is formed. An outer cover 7 again seals input binding posts 2c and 2d of the motor controller, output binding posts 3f, 3g and 3h and the component unit 4 formed by the contactor 4a, the power fuse protector 4b and the diverter 4c in a sealed outer shell formed with the radiating aluminum outer shell 5, and the motor controller assembly is formed.

Description

Technical field: [0001] The present invention relates to the modularized unit structure layout mode of the AC motor controller and the controller assembly of the small electric vehicle, specifically: a power semiconductor module and its drive control board unit 1; an aluminum electrolytic capacitor integrated module 2; a current sensor built in Output terminal component module 3; power measurement and protection component unit 4 such as contactor 4a, power fuse 4b, shunt 4c, and a heat-dissipating airtight shell composed of heat-dissipating aluminum shell 5, plastic inner cover 6, and outer cover 7 constitute a small electric vehicle Use the structural layout of the AC motor controller or controller assembly. Background technique: [0002] Electric vehicles do not burn fossil fuels to generate power, and are environmentally friendly and less polluting. They have become the development direction of future automobiles. At present, small pure electric vehicles, electric golf c...

AI Technical Summary

Problems solved by technology

[0008] Since the power circuit is composed of discrete components connected in parallel, the problem of voltage and current sharing is more prominent; the pulse current of the main circuit causes strong electromagnetic field radiation interference in the entire circuit structure space due to the complex structure; the ESR value of the aluminum electrolytic capacitor of the main circuit is large, and the load There is no heat dissipation design for the heat generated during work, which leads to a high internal temperature rise of the controller and reduced reliability of components; especially the large number of controller components, the manufacturing work is time-consuming and laborious

[0009] Motor controller products using parallel integration of components are not specifically for electric vehicle applications. Many products are only marketed in the field of AC electric control forklifts. Therefore, controllers used in high-speed electric vehicles have serious defects in vibration reliability.

[0010] In addition, the installation of the motor controller requires a specific smooth metal surface, which is coated with heat-conducting silicone grease and precisely bonded to the bottom plate of the controller to ensure maximum heat conduction and heat dissipation generated by power. The installation and use of the controller brings a lot of inconvenience

[0011] When there is a motor controller and contactors, power fuses, shunts and other measurement and protection devices to form a controller assembly, the structural compatibility of each part is not good, and another shell is needed for external protection. There is a motor controller assembly It is not easy to achieve miniaturization and other problems

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