INTEGRATED MOTOR CONTROLLER, ELECTRIC ASSEMBLY, AND VEHICLE

An integrated motor controller includes a charging connector, a battery connector, a first charging circuit, and a second charging circuit. The first charging circuit is connected with the charging connector and the battery connector, and includes a first control switch. The first control switch is configured to control on/off of the first charging circuit. The second charging circuit is connected with the charging connector and the battery connector, and includes a boost module and a second control switch. The second control switch is configured to control on/off of the second charging circuit.

FIELD

The present disclosure relates to the field of vehicle technologies, and more particularly, to an integrated motor controller, an electric assembly, and a vehicle.

BACKGROUND

In the related art, a battery of a vehicle can be fast charged usually on a direct current (DC) high-voltage charging pile corresponding to a charging voltage of the vehicle, and has a specific requirement for the charging voltage, resulting in relatively low charging versatility of the vehicle and poor user experience.

SUMMARY

The present disclosure is to resolve at least one of technical problems existing in the related art. Therefore, the present disclosure provides an integrated motor controller. The integrated motor controller is applicable to different charging voltages, and has advantages such as high versatility and convenient charging. The present disclosure further provides an electric assembly having the above integrated motor controller.

The present disclosure further provides a vehicle having the above electric assembly.

An integrated motor controller according to an embodiment of a first aspect of the present disclosure includes a charging connector, a battery connector, a first charging circuit, and a second charging circuit. The first charging circuit is connected with the charging connector and the battery connector, and includes a first control switch. The first control switch is configured to control on/off of the first charging circuit. The second charging circuit is connected with the charging connector and the battery connector, and includes a boost module and a second control switch. The second control switch is configured to control on/off of the second charging circuit.

The integrated motor controller according to the embodiments of the present disclosure is applicable to different charging voltages, and has advantages such as high versatility and convenient charging.

According to some examples of the present disclosure, the integrated motor controller further includes an alternating current (AC) charging and discharging connector, and an AC charging and discharging circuit. The AC charging and discharging circuit includes an on-board charger (OBC) and a direct current (DC)/DC converter, the OBC is connected with the AC charging and discharging connector, and the DC/DC converter is connected with the battery connector.

According to some examples of the present disclosure, the charging connector includes a DC charging connector. The boost module includes a motor coil and an electrical control bridge arm. The motor coil is a coil of a driving motor. The motor coil is connected with the second charging circuit. The electrical control bridge arm is a bridge arm of an insulated gate bipolar transistor (IGBT) module of a motor controller. The electrical control bridge arm is connected with the motor coil.

According to some examples of the present disclosure, the integrated motor controller further includes a boost capacitor and a smoothing capacitor. The boost capacitor is connected with the charging connector, the battery connector, and the IGBT module. The smoothing capacitor is connected with the IGBT module and the battery connector.

According to some examples of the present disclosure, the integrated motor controller further includes a capacitor housing, a positive battery electrode connection plate, a negative battery electrode connection plate, an output connection plate, a positive charging electrode connection plate, and a negative charging electrode connection plate. The boost capacitor and the smoothing capacitor are mounted to the capacitor housing. The positive battery electrode connection plate is mounted to the capacitor housing. The positive battery electrode connection plate is connected with a positive electrode of the battery connector and a positive electrode of the smoothing capacitor. The negative battery electrode connection plate is mounted to the capacitor housing. The negative battery electrode connection plate is connected with a negative electrode of the battery connector and a negative electrode of the smoothing capacitor. The output connection plate is mounted to the capacitor housing. The output connection plate is connected with the smoothing capacitor and the IGBT module. The positive charging electrode connection plate is mounted to the capacitor housing. The positive charging electrode connection plate is connected with a positive electrode of the charging connector and the boost capacitor. The negative charging electrode connection plate is mounted to the capacitor housing. The negative charging electrode connection plate is connected with a negative electrode of the charging connector, the boost capacitor, the smoothing capacitor, and the negative battery electrode connection plate.

According to some examples of the present disclosure, the capacitor housing has a first side edge, a second side edge, a third side edge, and a fourth side edge connected in a circumferential direction of the capacitor housing. The positive battery electrode connection plate, the negative battery electrode connection plate, and the negative charging electrode connection plate are mounted to the first side edge. The output connection plate is mounted to the second side edge. The positive charging electrode connection plate is mounted to the third side edge.

According to some examples of the present disclosure, the integrated motor controller further includes a circuit safety protection member. The circuit safety protection member is mounted to the capacitor housing. The circuit safety protection member is connected with the negative battery electrode connection plate and the negative electrode of the smoothing capacitor.

According to some examples of the present disclosure, the integrated motor controller further includes a charging side magnetic ring and a battery side magnetic ring. The charging side magnetic ring is mounted to an outer peripheral surface of the capacitor housing. The charging connector is connected to the positive charging electrode connection plate and the negative charging electrode connection plate through an intermediate connector. The charging side magnetic ring is sleeved on the intermediate connector. The battery side magnetic ring is mounted to the outer peripheral surface of the capacitor housing. The battery side magnetic ring is sleeved on the battery connector.

According to some examples of the present disclosure, the integrated motor controller further includes a heat dissipation metal plate and heat transfer cement. The heat dissipation metal plate is attached to the capacitor housing. A first surface of the heat transfer cement in a thickness direction of the heat transfer cement is attached to the heat dissipation metal plate. A second surface of the heat transfer cement in the thickness direction is attached to a box.

According to some examples of the present disclosure, the integrated motor controller further includes a box, a driving board, a control board, and a power device. A first chamber is disposed on a first side of the box in a thickness direction of the box. A second chamber is arranged on a second side of the box in the thickness direction. The IGBT module is mounted to the first chamber. The driving board is mounted to the first chamber. The driving board is connected with the IGBT module. The control board is mounted to the first chamber. The control board is connected with the driving board. The power device is mounted to the second chamber, and is connected with the control board.

According to some examples of the present disclosure, the box includes a first water channel and a second water channel. The first water channel is configured to be in communication with a water inlet pipe. The second water channel is configured to be in communication with a water outlet pipe. The integrated motor controller further includes a water channel cover plate. The water channel cover plate is connected with the box. The water channel cover plate is configured to cover the first water channel and the second water channel. The water channel cover plate includes a third water channel. The third water channel is in communication with the first water channel and the second water channel. A cooling liquid in the first water channel flows into the third water channel to dissipate heat for the IGBT module. A cooling liquid in the third water channel flows into the second water channel to dissipate heat for the power device.

According to some examples of the present disclosure, multiple IGBT modules are arranged. The third water channel includes multiple cooling cavities disposed in a length direction of the third water channel. The multiple cooling cavities are in one-to-one correspondence with the multiple IGBT modules. Each of the cooling cavities includes a water inlet and a water outlet. A water inlet of a first one of two adjacent cooling cavities is adjacent to and in communication with a water outlet of a second one of the two adjacent cooling cavities. The first water channel is in communication with the water inlet of the cooling cavity adjacent to the first water channel. The second water channel is in communication with the water outlet of the cooling cavity adjacent to the second water channel. At least one partition plate is disposed on a side of the water channel cover plate facing the box. The partition plate is configured to prevent communication between the second water channel and a water inlet and a water outlet adjacent to the second water channel.

According to some examples of the present disclosure, the second water channel includes a transition section and an annular section. The transition section is brought into communication with the water outlet of the cooling cavity adjacent to the transition section. The annular section surrounds the power device. The annular section is configured to dissipate heat for the power device. A first end of the annular section is connected with an end of the transition section. A second end of the annular section includes a water outlet hole. A depth of the annular section is greater than a depth of the first water channel. The depth of the annular section is greater than a depth of the transition section.

According to some examples of the present disclosure, the integrated motor controller further includes a water inlet pipe and a water outlet pipe. The water inlet pipe is mounted to the box. The water inlet pipe is in communication with the first water channel. The water outlet pipe is mounted to the box. The water outlet pipe is in communication with the water outlet hole. The water outlet pipe and the water inlet pipe are vertically disposed.

According to some examples of the present disclosure, the integrated motor controller includes a charging connector, a battery connector, a first charging circuit, and a second charging circuit. The charging connector is configured to connect to a charging device. The battery connector is configured to connect to a battery pack. The first charging circuit is connected with the charging connector and the battery connector. The second charging circuit is connected with the charging connector and the battery connector. The second charging circuit includes a boost module. One of the first charging circuit and the second charging circuit is turned on.

According to some examples of the present disclosure, when a voltage provided by the charging device is greater than a first voltage, the first charging circuit is turned on. When the voltage provided by the charging device is not greater than the first voltage, the second charging circuit is turned on.

According to some examples of the present disclosure, the boost module includes an electrical control bridge arm and three motor coils. The electrical control bridge arm includes a three-phase bridge arm including three bridge arms. First ends of the three motor coils are respectively connected with midpoints of the three bridge arms, and second ends of the three motor coils are connected with the charging connector.

An electric assembly according to an embodiment of a second aspect of the present disclosure is provided. The electric assembly includes the integrated motor controller according to the above embodiment of the first aspect of the present disclosure.

The electric assembly according to the embodiments of the present disclosure is applicable to different charging voltages through the above integrated motor controller, and has advantages such as high versatility and convenient charging.

A vehicle according to an embodiment of a third aspect of the present disclosure is provided. The vehicle includes the electric assembly according to the above embodiment of the second aspect of the present disclosure.

The vehicle according to the embodiments of the present disclosure is applicable to different charging voltages through the above electric assembly, and has advantages such as high versatility and convenient charging.

Additional aspects and advantages of the present disclosure are to be partially given in the following description, some of which become apparent from the following description or may be learned by practice of the present disclosure.

NUMERALS

DETAILED DESCRIPTION

Embodiments of the present disclosure are described in detail below, and examples of the embodiments are shown in accompanying drawings. Same or similar reference numerals throughout represent same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary, and used for explaining the present disclosure only, and should not be construed as a limitation on the present disclosure.

In the description of the present disclosure, it should be understood that orientation or position relationships indicated by the terms such as “center”, “up”, “down”, “front”, “rear”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, and “outside” are based on orientation or position relationships shown in the accompanying drawings, and are used for convenience and simplification of description of the present disclosure only, rather than indicating or implying that the indicated apparatus or element needs to have a particular orientation or to be constructed and operated in a particular orientation. Therefore, the terms should not be construed as a limitation on the present disclosure.

It should be noted that, terms “first” and “second” are merely used for description, and cannot be construed as indicating or implying relative importance or implicitly indicating a quantity of indicated technical features. Therefore, features defined by “first” and “second” may explicitly or implicitly include one or more such features. Further, in the description of the present disclosure, unless otherwise stated, “multiple” means two or more than two.

An integrated motor controller1according to an embodiment of the present disclosure is described below with reference to the accompanying drawings.

As shown inFIG.1toFIG.10, the integrated motor controller1according to an embodiment of the present disclosure includes a charging connector100, a battery connector110, a first charging circuit200, and a second charging circuit300.

The first charging circuit200is connected with the charging connector100and the battery connector110. The first charging circuit200is provided with a first control switch210. The first control switch210is configured to control on/off of the first charging circuit200. The second charging circuit300is connected with the charging connector100and the battery connector110. The second charging circuit300is provided with a boost module310and a second control switch320. The second control switch320is configured to control on/off of the second charging circuit300.

For example, the first control switch210and the second control switch320may be contactors. The charging connector100and the battery connector110may be plugs. Moreover, the charging connector100may be connected with an external charging device. For example, the charging connector100may be connected with a charging pile. The battery connector110may be connected with a battery pack of a vehicle.

In the integrated motor controller1according to this embodiment of the present disclosure, the first charging circuit200is connected with the charging connector100and the battery connector110, and the first charging circuit200is provided with the first control switch210configured to control the on/off of the first charging circuit200. In this way, when the charging connector100is connected with a charging device with a relatively high voltage (the voltage being not less than 750 V), for example, when the charging connector100is connected with a charging device with a charging voltage of 750 V, the first control switch210may be in an on state (e.g., the first control switch is turned on), so that a current may directly charge the battery connector110through the first charging circuit200, thereby achieving fast charging of the battery pack.

In addition, the second charging circuit300is connected with the charging connector100and the battery connector110, and the second charging circuit300is provided with the boost module310and the second control switch320configured to control the on/off of the second charging circuit300. In this way, when the charging connector100is connected with a charging device with a relatively low voltage (the voltage being less than 750 V), for example, when the charging connector100is connected with a charging device with a charging voltage of 470 V, the second control switch320may be in the on state (e.g., the second control switch is turned on), so that the current may flow through the second charging circuit300, the boost module310may boost a voltage of the second charging circuit300, the voltage of the second charging circuit300may be boosted to above 630 V, and then the battery pack may be fast charged.

Moreover, when the charging connector100is not connected with the charging device, the first control switch210and the second control switch320both may be in an off state (e.g., the control switches are turned off). When the charging connector100is connected with the charging device, the integrated motor controller1may detect an output voltage of the charging device. If a charging voltage is relatively high, the first control switch210is turned on, and the second control switch320is turned off. The charging device may directly charge the battery pack through the first charging circuit200. If the charging voltage is relatively low, the second control switch320is turned on, and the first control switch210is turned off. The charging device may perform boosting through the boost module310of the second charging circuit300, and then charge a battery.

In this way, the first control switch210and the second control switch320are generally not turned off simultaneously, to reduce a voltage fluctuation during the charging, thereby maintaining a stable charging voltage. In addition, the controlling on and off of the first control switch210and the second control switch320can cause the charging connector100to be connected to the battery connector110through different charging circuits, to ensure that the charging voltage is high enough to achieve the fast charging of the battery pack, and prevent the battery pack from being damaged due to an excessively high charging voltage, thereby ensuring good safety. Therefore, the integrated motor controller1according to this embodiment of the present disclosure is applicable to multiple charging devices, and can achieve the fast charging of the battery pack regardless of the output voltage of the charging device, so that charging is more convenient and time-efficient.

In this way, the integrated motor controller1according to this embodiment of the present disclosure is applicable to different charging voltages, and has advantages such as high versatility and convenient charging.

In some embodiments of the present disclosure, as shown inFIG.1, the integrated motor controller1further includes an alternating current (AC) charging and discharging connector400and an AC charging and discharging circuit410.

The AC charging and discharging circuit410is provided with an on-board charger (OBC)411and a direct current (DC)/DC converter412. The OBC411is connected with the AC charging and discharging connector400. The DC/DC converter412is connected with the battery connector110.

The OBC411can dynamically adjust a charging voltage parameter and a charging current parameter based on a charging current and a charging voltage required for the battery pack, so as to charge the battery pack and protect the battery pack. Moreover, an in-vehicle discharging connector420may be connected with the OBC411, to charge an item that needs to be charged by a passenger with an AC.

In this way, the AC charging and discharging connector400may provide access to an AC power supply, and the battery may be charged through the AC power supply. The OBC411can adjust a parameter of an AC voltage. A magnitude of the charging voltage is changed while converting the AC into the DC, so as to charge the battery pack.

Moreover, the DC/DC converter412can perform voltage and current stabilization on a DC flowing through the OBC411, and may convert a low-voltage charging current into a high-voltage charging current, to achieve the fast charging of the battery pack. In addition, the battery pack may also transmit the AC to the AC charging and discharging connector400through the AC charging and discharging circuit410, so that the AC charging and discharging connector400may supply power to an electric appliance in the vehicle that uses the AC power supply.

In some embodiments of the present disclosure, the charging connector100is a DC charging connector100. The boost module310includes a motor coil312and an electrical control bridge arm316.

The motor coil312is a coil of a driving motor311. The motor coil312is connected with the second charging circuit300. The electrical control bridge arm316is a bridge arm of an insulated gate bipolar transistor (IGBT) module315of a motor controller313. The electrical control bridge arm316is connected with the motor coil312. In this way, a current flowing through the second charging circuit300may flow through the motor coil312and the electrical control bridge arm316in sequence, to form the boost module310through the motor coil312and the electrical control bridge arm316, and boost the current of the second charging circuit300, thereby achieving the fast charging of the battery.

In this way, the boost module310and the motor controller313share the bridge arm of the IGBT module315of the motor controller313, and the boost module310and the driving motor311share the motor coil312. Electronic devices such as an inductor, a diode, and a switching device do not need to be additionally arranged, which reduces a quantity of parts, and reduces production costs, thereby helping reduce a volume of an electric assembly2.

Moreover, since the driving motor311is generally a three-phase motor, that is, the driving motor311has three sets of motor coils312, each of the three sets of motor coil312of the driving motor311is applied to the boost module310, so that a probability of a ripple current generated by the second charging circuit300can be reduced, thereby further ensuring stability of an input voltage of the battery pack.

In some embodiments of the present disclosure, the integrated motor controller1further includes a boost capacitor640and a smoothing capacitor630.

The boost capacitor640is connected with the charging connector100, the battery connector110, and the IGBT module315. The smoothing capacitor630is connected with the IGBT module315and the battery connector110. When the battery pack supplies power to the IGBT module315for vehicle driving, a current of the battery pack first flows through the smoothing capacitor630, which may absorb a ripple current in the current flowing to the battery connector110and store energy. In this way, the battery pack performs filtering and maintains a stable voltage and current when supplying power to the IGBT module315. During boost charging, a boosted current of the motor coil312flows through the IGBT module315to the smoothing capacitor630, so that the smoothing capacitor630absorbs the boosted ripple current of the circuit and stores energy. In this way, the voltage is stable when the current flows to the battery pack during charging.

In this way, voltage stability of the battery connector110is maintained, thereby maintaining stability of the charging voltage and a discharging voltage of the battery pack. However, the smoothing capacitor630and the motor coil may form an L/C circuit. The boost capacitor640is arranged/configured to absorb a ripple current in a current inputted from the charging connector100, and filter the current inputted from the charging connector100, so that a voltage of the current inputted from the charging connector100is stable.

In some embodiments of the present disclosure, as shown inFIG.6, the integrated motor controller1further includes a capacitor housing500, a positive battery electrode connection plate/sheet510, a negative battery electrode connection plate/sheet520, an output connection plate/sheet530, a positive charging electrode connection plate/sheet540, and a negative charging electrode connection plate/sheet550.

The boost capacitor640and the smoothing capacitor630are mounted to the capacitor housing500. The positive battery electrode connection sheet510is mounted to the capacitor housing500. The positive battery electrode connection sheet510is connected with a positive electrode of the battery connector110and a positive electrode of the smoothing capacitor630. The negative battery electrode connection sheet520is mounted to the capacitor housing500. The negative battery electrode connection sheet520is connected with a negative electrode of the battery connector110and a negative electrode of the smoothing capacitor630. The output connection sheet530is mounted to the capacitor housing500. The output connection sheet530is connected with the smoothing capacitor630and the IGBT module315. The positive charging electrode connection sheet540is mounted to the capacitor housing500. The positive charging electrode connection sheet540is connected with a positive electrode of the charging connector100and the boost capacitor640. The negative charging electrode connection sheet550is mounted to the capacitor housing500. The negative charging electrode connection sheet550is connected with a negative electrode of the charging connector100, the boost capacitor640, the smoothing capacitor630, and the negative battery electrode connection sheet520.

For example, to enhance heat dissipation of the boost capacitor640and the smoothing capacitor630, a heat dissipation metal plate591and heat transfer cement592are arranged on the capacitor housing500. The heat dissipation metal plate591is attached to the capacitor housing500. A first surface5921of the heat transfer cement592is attached to the heat dissipation metal plate591. A second surface5922of the heat transfer cement592is attached to an electric control box. In other words, the heat transfer cement592is arranged between the heat dissipation metal plate591and the electric control box, which helps heat of the capacitor be transferred to the electric control box through the heat transfer cement592as a medium to dissipate the heat of the capacitor. To facilitate wire harness wiring, the capacitor housing500may be further constructed with structures such as a wire harness fixing groove505or a cable tie hole506.

The boost capacitor640and the smoothing capacitor630may be integrated into the capacitor housing500, which facilitates arrangement and saves an assembly space. Therefore, the capacitor housing500may fix the positive battery electrode connection sheet510, the negative battery electrode connection sheet520, the output connection sheet530, the positive charging electrode connection sheet540, and the negative charging electrode connection sheet550. The positive battery electrode connection sheet510, the negative battery electrode connection sheet520, the output connection sheet530, the positive charging electrode connection sheet540, and the negative charging electrode connection sheet550may be exposed from the capacitor housing500. In this way, the battery pack is connected with the smoothing capacitor630, and the boost capacitor640is connected with the charging connector100. Therefore, the connection is more reliable, and assembly efficiency is higher.

In some embodiments of the present disclosure, as shown inFIG.6, the capacitor housing500has a first side edge501, a second side edge502, a third side edge503, and a fourth side edge504connected end to end in a circumferential direction of the capacitor housing500. The positive battery electrode connection sheet510, the negative battery electrode connection sheet520, and the negative charging electrode connection sheet550are mounted to the first side edge501. The output connection sheet530is mounted to the second side edge502. The positive charging electrode connection sheet540is mounted to the third side edge503.

In this way, the positive battery electrode connection sheet510, the negative battery electrode connection sheet520, and the negative charging electrode connection sheet550may be spaced apart from the output connection sheet530and the positive charging electrode connection sheet540, to avoid positional interference between multiple components and facilitate mounting. In addition, a short circuit may be prevented from occurring among the multiple components during a power-up to maintain an unobstructed circuit.

In some embodiments of the present disclosure, as shown inFIG.5, the integrated motor controller1further includes a circuit safety protection member600.

The circuit safety protection member600is mounted to the capacitor housing500. The circuit safety protection member600is connected with the negative battery electrode connection sheet520and the negative electrode of the smoothing capacitor630. For example, the circuit safety protection member600may be a fuse. The integrated motor controller1further includes a negative input plate/sheet590. Two ends of the circuit safety protection member600are respectively connected with the negative input sheet590and the negative battery electrode connection sheet520. The negative battery electrode connection sheet520is connected with the negative electrode of the smoothing capacitor630. The negative battery electrode connection sheet520is connected with the negative electrode of the smoothing capacitor630through the circuit safety protection member600and the negative input sheet590. The negative battery electrode connection sheet520is mounted to the first side edge501.

Therefore, when an overcurrent and temperature rise in the circuit occur as a result of a current flowing through the negative battery electrode connection sheet520and a current of the smoothing capacitor630being excessively large, the circuit safety protection member600may be disconnected, to cut off the current of the circuit and then avoid damage to the battery pack. This improves safety during charging and discharging of the battery pack.

In some embodiments of the present disclosure, as shown inFIG.4, the integrated motor controller1further includes a charging side magnetic ring610and a battery side magnetic ring620.

The charging side magnetic ring610is mounted to an outer peripheral surface of the capacitor housing500. The charging connector100is connected to the positive charging electrode connection sheet540and the negative charging electrode connection sheet550through an intermediate connector120. The charging side magnetic ring610is sleeved on the intermediate connector120. The battery side magnetic ring620is mounted to the outer peripheral surface of the capacitor housing500. The battery side magnetic ring620is sleeved on the battery connector110.

In this way, the charging side magnetic ring610can block external electromagnetic interference to the intermediate connector120, and the battery side magnetic ring620can block the external electromagnetic interference to the battery connector110. Therefore, the external electromagnetic interference to the battery may be avoided, and the voltage of the battery pack during the charging and discharging is more stable.

Moreover, a magnetic ring mounting position593configured for the battery side magnetic ring620to be mounted may be provided on the capacitor housing500, so that the charging side magnetic ring610and the battery side magnetic ring620may be both integrated into the capacitor housing500. Therefore, integration of the capacitor housing500can be improved, so that a structure of the capacitor housing500is more compact, to save the assembly space and achieve a better anti-electromagnetic interference effect of the capacitor housing500.

An operating process of the integrated motor controller1is described with reference to the accompanying drawings.

When the battery pack supplies power to the driving motor, the current of the battery pack flows to the battery connector110, flows from the positive electrode of the battery connector110to the smoothing capacitor630through the positive battery electrode connection sheet510, then is supplied to the IGBT module315through the output connection sheet530, and is converted by the IGBT module315to the AC, which flows to the driving motor311. The current flows from the negative electrode of the battery connector110to the circuit safety protection member600through the negative battery electrode connection sheet520, flows to the smoothing capacitor630through the negative input sheet590, then is supplied to the IGBT module315through the output connection sheet530, and is converted by the IGBT module315to the AC, which flows to the driving motor311.

When the battery pack is charged and the charging voltage is less than 750 V, after the charging current flows through the charging side magnetic ring610through the charging connector100, the charging current flows from the negative electrode of the charging connector100to the negative battery electrode connection sheet520through the negative charging electrode connection sheet550, and then flows from the battery connector110to the battery pack. The charging current flows from the positive electrode of the charging connector100to the motor coil312and the IGBT module315, and is boosted at the motor coil312. The boosted current flows to the positive battery electrode connection sheet510, and then flows from the battery connector110to the battery pack.

In some embodiments of the present disclosure, as shown inFIG.3,FIG.4,FIG.7, andFIG.8, the integrated motor controller1further includes a box700, a driving board730, a control board740, and a power device750.

A first side701of the box700in a thickness direction is provided with a first chamber710. A second side702of the box700in the thickness direction is provided with a second chamber720. The IGBT module315is mounted to the first chamber710. The driving board730and the control board740are mounted to the first chamber710. The driving board730is connected with the IGBT module315and the control board740. The power device750is mounted to the second chamber720and is connected with the control board740. The control board740is connected with a vehicle controller.

In other words, the first chamber710and the second chamber720are respectively arranged on two sides of the box700in the thickness direction. In this way, a side wall between the first chamber710and the second chamber720may separate the IGBT module315, the driving board730, and the control board740from the power device750, which effectively reduces electromagnetic interference of the power device750on the IGBT module315, the driving board730, and the control board740, and improves effectiveness of electric control. Moreover, each of the IGBT module315, the driving board730, the control board740, and the power device750can be integrated into the box700. The box700may fix the IGBT module315, the driving board730, the control board740, and the power device750. In this way, the structure is more compact, which helps reduce an overall volume of the integrated motor controller1, and facilitates the mounting.

In some embodiments, the first chamber710may be divided into multiple small chambers, and the second chamber720may also be divided into multiple small chambers. The power device750is provided with an AC inductor, a DC inductor, a metal-oxide-semiconductor field-effect transistor (MOS) transistor, and an induction transformer. The AC inductor, the DC inductor, the MOS transistor, and the induction transformer are placed in the small chambers of the second chamber720. In this way, electromagnetic interference between multiple power modules is further avoided, which helps improve electromagnetic compatibility.

In addition, a wiring hole is provided between the first chamber710and the second chamber720. A wire harness may pass through the wiring hole to bring an electric device in the first chamber710into communication with an electric device in the second chamber720, to facilitate electrical connection between a component in the first chamber710and a component in the second chamber720.

For example, the control board740, the driving board730, and the IGBT module315are stacked in sequence. An electromagnetic shielding plate is arranged between the control board740and the driving board730, to prevent the IGBT module315during operation from interfering with the control board740.

The integrated motor controller1may be provided with an upper cover760and a lower cover770. The upper cover760may be configured to cover the first chamber710, to protect the component in the first chamber710, for example, the IGBT module315, the driving board730, and the control board740, and avoid positional interference between an external component and the IGBT module315, the driving board730, the control board740, and the like. In addition, the lower cover770may be configured to cover the second chamber720, to protect the power device750and avoid positional interference between another component and the power device750.

In some embodiments of the present disclosure, as shown inFIG.9andFIG.10, the integrated motor controller1further includes a water channel cover plate800. The water channel cover plate800may be integrally connected to the box700through friction welding.

The water channel cover plate800is provided with a third water channel810. The box700is provided with a first water channel712and a second water channel711. The water channel cover plate800is connected with the box700. The water channel cover plate800is configured to cover the first water channel712and the second water channel711. The third water channel810is in communication with the first water channel712and the second water channel711. A cooling liquid in the first water channel712flows into the third water channel810to dissipate heat for the IGBT module315. A cooling liquid in the third water channel810flows into the second water channel711to dissipate heat for the power device750.

In other words, the third water channel810, the first water channel712, and the second water channel711form a connected water channel. The cooling liquid in the third water channel810, the cooling liquid in the first water channel712, and the cooling liquid in the second water channel711may be shared. In some embodiments, the cooling liquid in the third water channel810, the cooling liquid in the first water channel712, and the cooling liquid in the second water channel711may circulate with each other. The IGBT module315may seal the third water channel810, to avoid leakage of the cooling liquid in the third water channel810, the cooling liquid in the first water channel712, and the cooling liquid in the second water channel711. In addition, the cooling liquid in the third water channel810may cool down the IGBT module315, to prevent the IGBT module315from being damaged due to a high temperature and maintain the IGBT module315at a low temperature and stable operation thereof.

In addition, the first water channel712and the second water channel711may be sealed through the water channel cover plate800, to avoid leakage of the cooling liquid in the first water channel712and the cooling liquid in the second water channel711. The cooling liquid in the second water channel711may exchange heat with the power device750through an outer wall of the second water channel711. In this way, a temperature of the power device750may be reduced, so that the power device750is maintained at a low temperature, and then operation stability of the power device750may be improved, thereby preventing the power device750from being damaged due to the high temperature.

Moreover, the third water channel810, the first water channel712, and the second water channel711are in communication with each other. A flow path of the cooling liquid is longer. The cooling liquid in the first water channel712may flow into the third water channel810to dissipate heat for the IGBT module315, and the cooling liquid in the third water channel810may also flow into the second water channel711to dissipate heat for the power device750. This may increase a utilization rate of the cooling liquid, and enables the cooling liquid to fully exchange heat with the power device750and the IGBT module315.

Further, as shown inFIG.9, the third water channel810includes multiple cooling cavities811arranged in a length direction of the third water channel. Multiple IGBT modules315are arranged. The multiple cooling cavities811are in one-to-one correspondence with the multiple IGBT modules315. In this way, each cooling cavity811may exchange heat with the IGBT module315corresponding thereto, to dissipate heat for the IGBT module315. The water channel cover plate800is provided with a sealing groove840surrounding the water channel cover plate800. A sealing ring is arranged in the sealing groove840. The sealing ring fills a gap between the IGBT module315and the water channel cover plate800. Each IGBT module315may have a better sealing effect on the cooling cavity811corresponding thereto, to ensure sealing performance of the third water channel810, and avoid leakage of a cooling liquid in the cooling cavity811.

Moreover, each cooling cavity811includes a water inlet812and a water outlet813. The water inlet812and the water outlet813that are adjacent to each other of two adjacent cooling cavities811are in communication with each other. The first water channel712is brought into communication with the water inlet812of the cooling cavity811adjacent to the first water channel. The second water channel711is brought into communication with the water outlet813of the cooling cavity811adjacent to the second water channel. At least one partition plate820is arranged on a side of the water channel cover plate800facing the box700. The partition plate820is configured to prevent the water inlet812and the water outlet813that are adjacent to each other from being brought into communication with the second water channel711.

In other words, the partition plate820may partition the second water channel711and the third water channel810. Cooling liquids in adjacent cooling cavities811may be maintained in communication with each other through the water inlet812and the water outlet813. In this way, the cooling liquid in the third water channel810can flow through each of the cooling cavities811. This avoids a case that no cooling liquid exists in some cooling cavities811as a result of the cooling liquid directly flowing to the second water channel711, and helps improve a cooling effect of the third water channel810on the IGBT module315. In this way, the multiple IGBT modules315can stably exchange heat with the cooling cavities811.

For example, one of two outermost cooling cavities811may be brought into communication with the second water channel711through the water outlet813, and the other of the two cooling cavities811may be brought into communication with the first water channel712through the water inlet812. In this way, the cooling liquid in the first water channel712may enter the third water channel810through the water inlet812of one of the outermost cooling cavities811, and flow back to the second water channel711through the water outlet813of the other one of the cooling cavities811. Therefore, circulation of the cooling liquid in the first water channel712, the cooling liquid in the third water channel810, and the cooling liquid in the second water channel711is achieved, and the cooling liquid can completely flow through the second water channel711and the third water channel810, which helps increase the utilization rate of the cooling liquid.

In some embodiments of the present disclosure, as shown inFIG.7, the second water channel711includes a transition section713and an annular section714.

The transition section713is brought into communication with the water outlet813of the cooling cavity811adjacent to the transition section. The annular section714surrounds the power device750, and is configured to dissipate heat for the power device750. A first end715of the annular section714is connected with an end of the transition section713. A second end716of the annular section714is provided with a water outlet hole717. An outer wall of the annular section714is configured to dissipate heat for the power device750.

Based on the above, the cooling liquid flows into the first water channel712and then into the cooling cavity811adjacent to the first water channel712. Then the cooling liquid in the third water channel810flows through the multiple cooling cavities811in sequence in a direction from the first water channel712to the transition section713. Next, the cooling liquid flows from the cooling cavity811adjacent to the transition section713to the transition section713, and finally flows from the transition section713to the annular section714, and is discharged from the water outlet hole717of the annular section714.

Moreover, a contact area between the annular section714and the power device750is larger, and a structure of the annular section714is more compact, which occupies a smaller space. Through the heat dissipation for the power device750by the annular section714, a heat exchange effect of the second water channel711and the power device750may be improved, and then the power device750can be quickly cooled down, thereby achieving a better heat dissipation effect.

In addition, a depth of the annular section714is greater than a depth of the first water channel712and a depth of the transition section713. In this way, on the one hand, a volume of the annular section714may be larger, and the annular section714may accommodate more cooling liquids, thereby improving the heat dissipation effect of the annular section714on the power device750. On the other hand, transition between the first water channel712and the third water channel810may be smoother, transition between the transition section713and the third water channel810may be smoother, and the circulating flow of the cooling liquid between the second water channel711and the third water channel810may be smoother, so that the cooling liquid can fully exchange heat with the power device750and the IGBT module315, to further improve the heat dissipation effect of the power device750and the heat dissipation effect of the IGBT module315.

For example, the annular section714surrounds the induction transformer of the power device750in a “U” shape to dissipate heat. The MOS transistor, the AC inductor, and the DC inductor of the power device750are located outside the “U”-shaped annular section714, and are attached to the outer wall of the annular section714.

In some embodiments of the present disclosure, as shown inFIG.7andFIG.8, the integrated motor controller1further includes a water inlet pipe900and a water outlet pipe910.

The water inlet pipe900is mounted to the box700and is in communication with the first water channel712. The water outlet pipe910is mounted to the box700and is in communication with the water outlet hole717. In this way, the cooling liquid may flow into the first water channel712, the third water channel810, and the second water channel711through the water inlet pipe900. The cooling liquid may be discharged through the water outlet hole717and the water outlet pipe910. In other words, after the cooling liquid fully exchanges heat with the power device750and the IGBT module315, the cooling liquid in the first water channel712, the cooling liquid in the third water channel810, and the cooling liquid in the second water channel711may be discharged through the water outlet pipe910. The cooling liquid in the first water channel712, the cooling liquid in the third water channel810, and the cooling liquid in the second water channel711are replenished through the water inlet pipe900, to maintain sufficient cooling liquids in the first water channel712, the third water channel810, and the second water channel711, and maintain the cooling liquids at a relatively low temperature, so as to improve cooling effects of the second water channel711and the third water channel810on the power device750and the IGBT module315.

In addition, the water outlet pipe910and the water inlet pipe900are vertically arranged. For example, the water inlet pipe900may be arranged on a side of the box700, and the water outlet pipe910may be arranged on an adjacent side of the box700. In this way, positional interference between the water inlet pipe900and the water outlet pipe910may be avoided, to facilitate arrangement. In addition, lengths of the second water channel711and the third water channel810may be set to be relatively large, so that the second water channel711and the third water channel810can cover most of the box700, which further improves the cooling effects of the second water channel711and the third water channel810on the power device750and the IGBT module315. In addition, the cooling liquid in the second water channel711and the cooling liquid in the third water channel810can reduce a temperature of the box700, and then may further dissipate heat for another component mounted to the box700, thereby improving a heat dissipation effect of the box700.

For example, since the water outlet pipe910is relatively long as a result of the above arrangement, a pressing plate911may be added. The pressing plate911is mounted to the box700, and the water outlet pipe910is sandwiched between the pressing plate and the box700, to fix a position of the water outlet pipe910relative to the box700.

An integrated motor controller1according to another embodiment of the present disclosure includes a charging connector100, a battery connector110, a first charging circuit200, and a second charging circuit300.

The charging connector100is configured to connect to a charging device. For example, the charging connector100may be connected with a charging pile. The battery connector110is configured to connect to a battery pack. The first charging circuit200is connected with the charging connector100and the battery connector110. The second charging circuit300is connected with the charging connector100and the battery connector110. The second charging circuit300is provided with a boost module310. One of the first charging circuit200and the second charging circuit300is turned on.

The first charging circuit200is connected with the charging connector100and the battery connector110. In this way, when the charging connector100is connected with a charging device with a relatively high voltage (e.g., the voltage being not less than 750 V), for example, when the charging connector100is connected with a charging device with a charging voltage of 750 V, the first charging circuit200is in an on state, so that a current may directly charge the battery connector110through the first charging circuit200, thereby achieving fast charging of a battery pack.

In addition, the second charging circuit300is connected with the charging connector100and the battery connector110, and the second charging circuit300is provided with the boost module310. In this way, when the charging connector100is connected with a charging device with a relatively low voltage (e.g., the voltage being less than 750 V), for example, when the charging connector100is connected with a charging device with a charging voltage of 470 V, the second charging circuit300is in an on state, and the boost module310may boost a voltage of the second charging circuit300, so that the voltage of the second charging circuit300may be boosted to above 630 V, and then the battery pack may be fast charged.

In this way, the integrated motor controller1according to this embodiment of the present disclosure is applicable to different charging voltages, and has advantages such as high versatility and convenient charging.

In some embodiments of the present disclosure, when a voltage provided by the charging device is greater than a preset value, the first charging circuit200is turned on. In this case, the first charging circuit200is turned on, and the second charging circuit300is turned off. The charging device may directly charge the battery pack through the first charging circuit200. When the voltage provided by the charging device is not greater than the preset value, the second charging circuit300is turned on. In this case, the second charging circuit300is turned on, and the first charging circuit200is turned off. The charging device may perform boosting through the boost module310of the second charging circuit300, and then charge a battery. In addition, when the charging connector100is not connected with the charging device, the first charging circuit200and the second charging circuit300are both in an off state.

In some embodiments of the present disclosure, the boost module310includes a motor coil312and an electrical control bridge arm316. Three sets of motor coils312are arranged. The electrical control bridge arm316includes three-phase bridge arms, which include three bridge arms. First ends of the three sets of motor coils312are respectively connected with midpoints of the three-phase bridge arms. Second ends of the three sets of motor coils312are each connected with the charging connector100. In this way, a current flowing through the second charging circuit300may flow through the motor coil312and the three-phase bridge arms in sequence, to form the boost module310through the motor coil312and the three-phase bridge arms, and boost the current of the second charging circuit300, thereby achieving the fast charging of the battery. The boost module310includes the three sets of motor coils312and the three-phase bridge arms. Therefore, a probability of a ripple current generated by the second charging circuit300can be reduced, and stability of an input voltage of the battery pack is further ensured.

An electric assembly2according to an embodiment of a second aspect of the present disclosure is described below with reference to the accompanying drawings. The electric assembly2includes the integrated motor controller1in the above embodiments of a first aspect of the present disclosure.

In some embodiments, referring toFIG.1, the electric assembly2further includes the driving motor311and a transmission3. The water outlet pipe910of the integrated motor controller1may be in communication with a cooling liquid channel of the transmission3. In this way, the cooling liquid in the water channel of the integrated motor controller1may dissipate heat for the IGBT module315and the power device750, and then flow to the cooling liquid channel of the transmission3to dissipate heat for the driving motor311and the transmission3. A three-phase output terminal of the driving motor311is connected with the IGBT module315. A coil of the driving motor311is connected with the charging connector100.

The electric assembly2according to the embodiments of the present disclosure is applicable to different charging voltages through the above integrated motor controller1, and has advantages such as high versatility and convenient charging.

As shown inFIG.11, a vehicle3according to an embodiment of a third aspect of the present disclosure is provided. The vehicle3includes the electric assembly according to the above embodiment of the second aspect of the present disclosure.

The vehicle3according to the embodiments of the present disclosure is applicable to different charging voltages through the above electric assembly2, and has advantages such as high versatility and convenient charging.

Other compositions and operations of the integrated motor controller1, the electric assembly2, and the vehicle3in the embodiments of the present disclosure are known to a person of ordinary skill in the art, and therefore are not described in detail herein.

In the description of this specification, the description of reference terms such as “an embodiment”, “some embodiments”, “an exemplary embodiment”, “an example”, “a specific example”, or “some examples” means that features, structures, materials, or characteristics described based on the embodiment or example are included in at least one embodiment or example of the present disclosure. In this specification, schematic descriptions of the above terms do not necessarily refer to the same embodiment or example. In addition, the described features, structures, materials, or characteristics may be combined in a proper manner in any one or more embodiments or examples.

Although the embodiments of the present disclosure have been shown and described, a person of ordinary skill in the art should understand that various changes, modifications, substitutions, and variations may be made to the embodiments without departing from the principles and spirit of the present disclosure, and the scope of the present disclosure is defined by the claims and their equivalents.