Motor controller

• US 9,769,962 B2
• Filed: 10/19/2015
• Issued: 09/19/2017
• Est. Priority Date: 11/29/2014
• Status: Active Grant

• Current Assignee: Zhongshan Broad-Ocean Motor Company Limited
• Original Assignee: Zhongshan Broad-Ocean Motor Company Limited
• Inventors: Huang, Fengtai, Mohr, Bertrand Robert
• Primary Examiner(s): Ip, Paul
• Application Number:
  US14/887,303
• Publication Number:
  US 20160157391A1
• Time in Patent Office: 701 Days
• Field of Search: 318139, 318767, 318782, 361699, 248637
• CPC Class Codes: H05K 7/20872 Liquid coolant without phase change
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change

Abstract

A motor controller, including: a box body, a capacitor module, and an inverse module. The box body includes a chamber, and a radiator is disposed in the chamber. The radiator divides the chamber to yield a first chamber and a second chamber. The inverse module is disposed on an upper surface of the radiator in the first chamber. The capacitor module is disposed on a lower surface of the radiator in the second chamber. The radiator includes a cooling waterway, and a water inlet and a water outlet that communicate with the cooling waterway. The cooling waterway is adapted to cool the capacitor module and the inverse module.

Claims

1. A motor controller, comprising:

a) a box body comprising a chamber;

b) a capacitor module;

c) an inverter module; and

d) a radiator comprising an upper surface, a lower surface, a cooling waterway, a water inlet, and a water outlet;

wherein;

the radiator is disposed in the chamber and divides the chamber to yield a first chamber and a second chamber;

the inverter module is disposed on the upper surface of the radiator and in the first chamber;

the capacitor module is disposed on the lower surface of the radiator and in the second chamber;

the water inlet and the water outlet communicate with the cooling waterway; and

the cooling waterway is in contact with the capacitor module and the inverter module and is adapted to cool the capacitor module and the inverter module.

2. The motor controller of claim 1, wherein the inverter module comprises an insulated gate bipolar transistor (IGBT) module, a drive circuit board, and a control circuit board;

the drive circuit board and the control circuit board are disposed on an upper surface of the IGBT module in sequence;

a needle bed stretches downwards from a bottom of the IGBT module;

the upper surface of the radiator is provided with grooves, and the needle bed on the IGBT module stretches into the grooves on the upper surface of the radiator.

3. The motor controller of claim 2, wherein the inverter module outputs a three-phase alternating current via a group of AC copper bars which is clung to a bottom wall of the first chamber;

a passageway is disposed on the radiator beneath the group of AC copper bars;

the passageway is connected to the grooves to form the cooling waterway;

the grooves communicate with the water inlet, and the passageway communicates with the water outlet.

4. The motor controller of claim 2, wherein the box body is provided with a low-voltage signal connector which is electrically connected to the control circuit board.

5. The motor controller of claim 4, wherein a water supply connector and a water outlet connector are disposed on a side of the box body;

the water supply connector is connected to the water inlet of the cooing waterway, and the water outlet connector is connected to the water outlet of the cooling waterway.

6. The motor controller of claim 1, wherein an external direct current power is input into the inverter module via a laminated busbar;

the inverter module is electrically connected to the capacitor module via a direct current copper bar;

a bottom wall of the first chamber is provided with support platforms, and the laminated busbar is clung to an upper surface of the support platforms.

7. The motor controller of claim 6, wherein the support platforms are two in number;

the two support platforms are positioned at two sides of the bottom wall of the first chamber, separately;

a resistance capacitance snubber circuit board is disposed between the two support platforms, and is electrically connected to the laminated busbar.

8. The motor controller of claim 6, wherein the box body is provided with a low-voltage signal connector which is electrically connected to the control circuit board.

9. The motor controller of claim 8, wherein a water supply connector and a water outlet connector are disposed on a side of the box body;

the water supply connector is connected to the water inlet of the cooing waterway, and the water outlet connector is connected to the water outlet of the cooling waterway.

10. A motor controller, comprising:

a) a box body comprising a chamber;

b) a capacitor module;

c) an inverter module; and

d) a radiator comprising an upper surface, a lower surface, a cooling waterway, a water inlet, and a water outlet;

wherein;

the radiator is disposed in the chamber and divides the chamber to yield a first chamber and a second chamber;

the inverter module is disposed on the upper surface of the radiator and in the first chamber;

the capacitor module is disposed on the lower surface of the radiator and in the second chamber;

the water inlet and the water outlet communicate with the cooling waterway;

the cooling waterway is adapted to cool the capacitor module and the inverter module;

the inverter module is electrically connected to the capacitor module via a direct current copper bar;

an external direct current power is input into the inverter module via a laminated busbar;

a bottom wall of the first chamber is provided with support platforms, and the laminated busbar is clung to an upper surface of the support platforms;

a first terminal box is disposed on a lateral surface of a bottom of the box body;

three-phase AC output terminals are disposed on the first terminal box;

a sensor circuit board is disposed on the bottom wall of the first chamber, and is electrically connected to a control circuit board;

the sensor circuit board is provided with three current sensors, and a first terminal is disposed in a middle of each current sensor; and

one end of the first terminal is connected to an AC copper bar, and another end of the first terminal passes through the current sensor and the bottom wall of the first chamber, and stretches into the first terminal box to electrically connect to one of the three-phase AC output terminals.

11. The motor controller of claim 10, wherein a second terminal box is disposed on the lateral surface of the bottom of the box body and a direct current input terminal is disposed on the second terminal box;

two second terminals are disposed inside the first chamber;

one end of the second terminals is connected to the laminated busbar, and another end of the second terminals passes through the bottom wall of the first chamber, and stretches into the second terminal box to electrically connect to the direct current input terminal.

12. The motor controller of claim 11, wherein the support platforms are two in number;

the two support platforms are positioned at two sides of the bottom wall of the first chamber, separately;

a resistance capacitance snubber circuit board is disposed between the two support platforms, and is electrically connected to the laminated busbar.

13. The motor controller of claim 11, wherein a common mode filter is sleeved on the second terminals, and the second terminals pass through the common mode filter.

14. The motor controller of claim 11, wherein the box body is provided with a low-voltage signal connector which is electrically connected to the control circuit board.

15. The motor controller of claim 14, wherein a water supply connector and a water outlet connector are disposed on a side of the box body;

the water supply connector is connected to the water inlet of the cooing waterway, and the water outlet connector is connected to the water outlet of the cooling waterway.

16. The motor controller of claim 11, wherein the control circuit board is electrically connected to a drive circuit board via board to board connectors;

the sensor circuit board is electrically connected to the control circuit board via bunched wires.

17. The motor controller of claim 10, wherein the support platforms are two in number;

the two support platforms are positioned at two sides of the bottom wall of the first chamber, separately;

a resistance capacitance snubber circuit board is disposed between the two support platforms, and is electrically connected to the laminated busbar.

18. The motor controller of claim 10, wherein the box body is provided with a low-voltage signal connector which is electrically connected to the control circuit board.

19. The motor controller of claim 18, wherein a water supply connector and a water outlet connector are disposed on a side of the box body;

the water supply connector is connected to the water inlet of the cooing waterway, and the water outlet connector is connected to the water outlet of the cooling waterway.

20. The motor controller of claim 10, wherein the control circuit board is electrically connected to a drive circuit board via board to board connectors;

the sensor circuit board is electrically connected to the control circuit board via bunched wires.

21. A motor controller, comprising:

a) a box body comprising a chamber;

b) a capacitor module;

c) an inverter module; and

d) a radiator comprising an upper surface, a lower surface, a cooling waterway, a water inlet, and a water outlet;

wherein;

the radiator is disposed in the chamber and divides the chamber to yield a first chamber and a second chamber;

the inverter module is disposed on the upper surface of the radiator and in the first chamber;

the capacitor module is disposed on the lower surface of the radiator and in the second chamber;

the water inlet and the water outlet communicate with the cooling waterway;

the cooling waterway is adapted to cool the capacitor module and the inverter module;

the inverter module comprises an insulated gate bipolar transistor (IGBT) module, a drive circuit board, and a control circuit board;

the drive circuit board and the control circuit board are disposed on an upper surface of the IGBT module in sequence;

a needle bed stretches downwards from a bottom of the IGBT module;

the upper surface of the radiator is provided with grooves;

the needle bed on the IGBT module stretches into the grooves on the upper surface of the radiator;

the inverter module outputs a three-phase alternating current via a group of AC copper bars;

the group of AC copper bars is clung to a bottom wall of the first chamber;

a passageway is disposed on the radiator beneath the group of AC copper bars;

the passageway is connected to the grooves to form the cooling waterway;

the grooves communicate with the water inlet and the passageway communicates with the water outlet; and

the box body is provided with a low-voltage signal connector which is electrically connected to the control circuit board.

22. The motor controller of claim 21, wherein a water supply connector and a water outlet connector are disposed on a side of the box body;

the water supply connector is connected to the water inlet of the cooing waterway, and the water outlet connector is connected to the water outlet of the cooling waterway.