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CN-122001185-A - One-driving-two integrated controller power brick structure of commercial vehicle and heat dissipation control method thereof

CN122001185ACN 122001185 ACN122001185 ACN 122001185ACN-122001185-A

Abstract

The invention discloses a one-driving-two integrated controller power brick structure of a commercial vehicle and a heat dissipation control method thereof, which are specially applied to the commercial vehicle driven by double motors, wherein elements such as a filter assembly, a bus capacitor, a power module assembly, a control board and the like are integrated in a specific inversion brick shell, a heat dissipation device is arranged at the bottom of the inversion brick, a heat dissipation water channel is of a U-shaped parallel design, each power module is ensured to be fully cooled, uneven heat dissipation caused by overhigh water temperature is prevented, the heat dissipation distance is prolonged, the heat dissipation effect is improved, the pressure drop difference of two water flow branches is reduced by arranging a plurality of fixed-section orifices at the water inlet of the heat dissipation water channel, the current limiting effect is achieved, in addition, a triangular guide structure is arranged at the water channel branch port to guide the water flow direction, secondary current equalization is carried out by the orifices of the power module, the water channel is designed into a water channel with unequal width, the heat source area is realized under the action of the guide ribs, and the resistance is reduced in a non-heat source area.

Inventors

  • LIU WENGUANG
  • WANG FANGZHENG
  • CHE HUAJUN
  • LIU XI

Assignees

  • 江苏大学

Dates

Publication Date
20260508
Application Date
20260209

Claims (10)

  1. 1. The utility model provides a power brick structure of an integrated controller of a commercial vehicle, which is characterized by comprising a power brick shell (9) and a motor shell (11) with an additional cavity; A capacitor metal shell is arranged on the rear half part of the power brick shell (9), a bus capacitor core pack group (4) is arranged in the capacitor metal shell, a core pack anode copper plate (3) and a core pack cathode copper plate (5) are respectively arranged on the upper and lower parts of the bus capacitor core pack group (4), the capacitor metal shell is sealed by a bus capacitor cover plate (2), a filter component (1) is arranged on the rear side surface of the capacitor metal shell and used for inhibiting electromagnetic interference, a power module (7) is arranged on the front half part of the power brick shell (9) and used for converting direct current into alternating current of a motor, a driving plate (6) is arranged on the power module (7) and used for controlling the switching operation of the power module (6), a current sensor (8) is arranged on the front end surface of the power brick shell (9) and used for monitoring current change in real time, and sending feedback signals to the driving plate (6) so as to ensure that an inverter of the power module (7) outputs stable current; the power brick shell (9) and all the components placed by the power brick shell are integrally placed in a cavity additionally arranged in the motor shell (11), so that the integration of the motor and the controller is realized, and meanwhile, the additionally arranged cavity can shield electromagnetic interference of the arm.
  2. 2. The integrated controller power brick structure of a commercial vehicle of claim 1 wherein the heat sink comprises a hot water spreader, a multi-stage flow equalization assembly, and a zoned adaptive water channel; the whole path of the heat dissipation water channel is of a U-shaped parallel double-channel structure, the heat dissipation water channel extends along the arrangement direction of the power module (7), the two water channels are symmetrically distributed in parallel, the water inlet ends of the two parallel water channels are commonly connected to a total water inlet, the water outlet ends of the two parallel water channels are commonly connected to a total water outlet, and the total water inlet and the total water outlet are respectively connected with a water inlet and a water outlet of a motor shell (11); The multistage flow equalizing assembly is arranged at the water inlet end, the branch port and the power module of the parallel water channels and comprises a fixed-section orifice (16), a guide structure (17) and a power module orifice (18), wherein the fixed-section orifice (16) is communicated with the total water inlet, water flows through the fixed-section orifice (16) and then enters the branch port to reduce the pressure drop difference of the two branches, the guide structure (17) is fixed on the inner wall of the branch port, is triangular in shape and is in seamless joint with the inlet edges of the two parallel water channels, and guides the water flow to uniformly enter the two parallel water channels; The partition adaptive water channel is positioned in the parallel water channel and corresponds to a power module heat source area, and comprises a narrow deep channel, a wide shallow channel and guide ribs (19) which are in seamless connection and are integrally formed with the inner wall of the water channel, wherein the guide ribs (19) are arranged in parallel with the water flow direction, the heat source area is correspondingly arranged as the narrow deep channel, the guide ribs (19) are used for improving the water flow speed of the narrow deep channel, enhancing the turbulence effect and enhancing the heat exchange, and the non-heat source area is arranged as the wide shallow channel, so that the water flow resistance is reduced, and the unnecessary power consumption is reduced.
  3. 3. The integrated controller power brick structure for a commercial vehicle according to claim 2, wherein the heat dissipating device further comprises a heat dissipating groove (15) provided at a position corresponding to the bus bar capacitor core pack (4) at the bottom of the power brick case.
  4. 4. The power brick structure of an integrated controller for a commercial vehicle according to claim 3, wherein sealing grooves are provided at the total water inlet, the total water outlet and the fixed-section orifice (16) of the heat dissipation water channel.
  5. 5. The power brick structure of the integrated controller of the commercial vehicle according to claim 4, wherein the added cavity is positioned on the axial end face of the motor housing (11), the central axis of the cavity is parallel to the central axis of the motor, and the output end of the power module (7) positioned in the cavity can be directly connected with the wiring terminal of the motor through a short-distance copper bar.
  6. 6. The power brick structure of the integrated controller of the commercial vehicle according to claim 5, wherein the inner wall of the cavity is provided with a plurality of axial guide ribs which are uniformly distributed on the circumference of the cavity and are matched with guide grooves on the outer wall of the power brick shell (9) for positioning the power brick shell; The bottom of the cavity is provided with an annular positioning shoulder, and after the power brick shell is embedded, the end face of the power brick shell is tightly attached to the positioning shoulder to realize axial positioning.
  7. 7. The power brick structure of the integrated controller of the commercial vehicle, as set forth in claim 6, is characterized in that copper bar perforations are arranged at the bottom of the cavity for connecting the power brick with the wiring terminal of the motor winding, and sealing grooves are arranged at the bottom edge of the cavity for installing sealing rings to seal the cavity and the power brick.
  8. 8. The power brick structure of an integrated controller for a commercial vehicle according to claim 5, wherein the additional cavity is integrally cast with the motor housing (11) and belongs to an extension structure of the motor housing.
  9. 9. The power brick structure of an integrated controller for a commercial vehicle according to claim 1, wherein the capacitor metal shell is filled with glue, which is used for enhancing the structural strength of the capacitor on one hand and isolating electromagnetic interference between the capacitor and the filter and the power module on the other hand.
  10. 10. The heat dissipation control method based on the power brick structure of the integrated controller of the commercial vehicle as claimed in claim 1 is characterized by comprising the following steps: Step1, introducing cooling water and primary flow equalization, namely after an external cooling system pressurizes low-temperature cooling water, injecting the low-temperature cooling water through a water inlet nozzle of a motor shell (11), accurately butting the water inlet nozzle with a total water inlet at the bottom of a power brick shell (9), sealing the water inlet nozzle with a sealing ring of a sealing groove (14) to prevent leakage, and enabling the cooling water to flow through a fixed-section orifice (16) at the total water inlet to realize flow partial pressure through aperture limitation to initially balance the water inlet pressure of two parallel water channels and avoid branch flow deviation; Step 2, diversion guiding and secondary flow equalizing are carried out on the water flow, namely cooling water passing through the orifice (16) with a fixed section enters a water channel branch port and is evenly diverted to two parallel main water channels under the guidance of the triangular guiding structure (17); Cooling water flows to the power module (7) area along the parallel main water channel, and secondary flow equalization is completed when the cooling water passes through the power module orifice (18), so that the water flow is ensured to cover the heat dissipation bottom surface of the power module at a uniform flow rate; Step 3, regional enhanced heat dissipation, namely cooling water enters a narrow and deep channel corresponding to a heat source region in the parallel water channel, the cross section of the channel is reduced, the water flow speed is increased, meanwhile, turbulence is formed under the action of guide ribs (19), and the cooling water is quickly exchanged with heat generated by the power module (7) to lead out the temperature; meanwhile, the heat generated by the bus capacitor is transferred to a square heat dissipation groove (15) at the bottom of the power brick shell (9) through the bottom surface of the bus capacitor core pack (4), and heat is conducted to the cooling water channel by heat conduction gel in the heat dissipation groove (15), so that synchronous heat dissipation of the bus capacitor and the power module (7) is realized; And 4, discharging and circulating cooling water, namely converging the cooling water of the two parallel water channels at a main water outlet after heat dissipation is completed, enabling the cooling water to flow out through a water outlet nozzle of a motor shell (11) in butt joint with the main water outlet, enabling the flowing high-temperature cooling water to enter a cooling system for cooling, and then pressurizing and injecting the cooling water into a water inlet nozzle of the motor shell again to form closed loop circulation for continuous heat dissipation.

Description

One-driving-two integrated controller power brick structure of commercial vehicle and heat dissipation control method thereof Technical Field The invention belongs to the technical field of power electronic equipment of new energy automobiles, and particularly relates to a 'power brick' -type packaging structure which has high power density, high reliability and easy cooling and integration and is suitable for new energy commercial vehicles. Background With the increasingly strict global energy transformation and environmental protection requirements, new energy commercial vehicles (including pure electric trucks, buses, logistics vehicles and hydrogen fuel cell commercial vehicles) are rapidly developed. As its core power source, the development of electric drive systems is advancing toward high power, high power density, high reliability, and low cost. In the control system of the new energy automobile, the main drive inverter is used as a heart of the electric drive system to convert the direct current output by the power electricity into alternating current meeting the requirement of the driving motor, and the core performance of the main drive inverter depends on an internal power semiconductor module (such as an IGBT module or a SiC MOSFET module). To meet the demanding requirements of vehicle applications, a modular packaging form called "power brick" has been developed. Power brick generally refers to a standardized, compact, easy to install and cool form of power semiconductor device package. The application of the 'power brick' type controller structure is still not common for the current development process of the new energy commercial vehicle, and the application of the 'power brick' type controller structure is difficult to realize on a large scale mainly due to the severe environmental adaptability and reliability heat dissipation requirements, the diversity of power levels and topological structures and other factors. Disclosure of Invention In order to solve the complex working condition faced in the running process of the commercial vehicle, the invention designs a one-to-two integrated power brick module which is specially applied to the commercial vehicle driven by double motors. The power brick integrates elements such as a filter assembly, a bus capacitor, a shielding plate, a power module assembly, a control board and the like in a shell of the power brick, so that a lightweight controller power brick module with low space occupation rate, easy assembly and high heat dissipation efficiency is formed. In order to achieve the above desired effects, the present invention adopts the following technical scheme: In commercial vehicle electric drive systems, the layout design of the motor and controller directly affects the performance of the vehicle, space utilization and reliability of the system. The present arrangement is more effective in addressing the particular challenges faced in designing commercial vehicles than conventional controller designs (controllers for commercial vehicle electric drive systems are typically independently arranged from the electric motor). The layout scheme of the power brick is used as an advanced design scheme, and a mode of directly integrating the power brick into the motor shell is adopted, so that the space is effectively saved, and the overall efficiency of the system is improved. The invention will explain this scheme in detail, expand the technical details and analyze its practical application advantage in commercial vehicles. The design and layout of the power brick are that in an electric driving system of a new energy automobile, an inverter is used for converting direct current into alternating current and driving a motor. In the conventional electric drive system in which the inverter and the motor are arranged as two independent modules, the power brick (i.e., the inverter module) is skillfully designed as a part of the motor housing in the drive system of the commercial vehicle designed in the present invention, thereby realizing an integrated layout of the motor and the controller. Through this design scheme, the dc-to-ac converter module can more compactly with the motor combination, saved a large amount of spaces for the space utilization of whole car has obtained promoting by a wide margin. In the concrete layout of the power brick, a special cavity structure is additionally arranged on the motor shell for placing the power brick. The cavity structure of the part not only can effectively contain the power brick, but also can provide good electromagnetic shielding performance, and further weakens the influence of electromagnetic interference on the whole electric drive system. The components in the power brick are designed through precise layout and integration, so that the whole inverter module is more compact and concise in an electric driving system. The power brick comprises a plurality of important components such as a multistage filt