US-12627249-B2 - Inverter apparatus used in motor controller, motor controller, and vehicle

US12627249B2US 12627249 B2US12627249 B2US 12627249B2US-12627249-B2

Abstract

This application provides an inverter apparatus used in a motor controller, a motor controller, and a vehicle. The inverter apparatus includes a capacitor module, a power module, and a first heat sink. The power module includes a plurality of power transistors, and the plurality of power transistors are arranged in a flat manner in a direction perpendicular to a direction in which the power module and the first heat sink are stacked. The first heat sink is configured to dissipate heat for the power transistors in the power module, so that the power transistors operate in a proper temperature environment. The inverter apparatus provided in this application has a compact structure layout and high integration. This is conducive to implementing a miniaturization embodiment of the motor controller, and reducing difficulty of disassembling and assembling internal parts of the motor controller and costs.

Inventors

Kang Yu
Weilong Zhang
Ming Sun

Assignees

Huawei Digital Power Technologies Co., Ltd.

Dates

Publication Date: 20260512
Application Date: 20240201
Priority Date: 20230207

Claims (18)

1 . An inverter apparatus used in a motor controller, the inverter apparatus comprising: a capacitor module; a power module; and a first heat sink, wherein the power module and the first heat sink are disposed in a stacked manner on the capacitor module, and wherein the power module comprises a plurality of power transistors arranged in a flat manner in a direction perpendicular to a direction in which the power module and the first heat sink are stacked; the capacitor module further comprises a plurality of capacitor connection terminals, each of the capacitor connection terminals is configured to connect to one of the power transistors, the plurality of capacitor connection terminals are arranged on an upper surface of the capacitor module along the first heat sink, orthographic projections of the capacitor connection terminals and the first heat sink on the upper surface of the capacitor module do not overlap, and the upper surface of the capacitor module is a surface that is of the capacitor module and that faces the first heat sink.
2 . The inverter apparatus according to claim 1 , wherein the first heat sink is disposed in a stacked manner on the capacitor module, the power module is disposed in a stacked manner on a side that is of the first heat sink and that is away from the capacitor module, and the plurality of power transistors are arranged in a flat manner on the side that is of the first heat sink and that is away from the capacitor module.
3 . The inverter apparatus according to claim 1 , wherein the inverter apparatus further comprises a sheet metal clip, two ends of the sheet metal clip are respectively clamped and fastened to the power module and the capacitor module, and the sheet metal clip is configured to fasten the power module, the first heat sink, and the capacitor module in the direction in which the power module and the first heat sink are stacked.
4 . The inverter apparatus according to claim 1 , wherein the inverter apparatus comprises a plurality of groups of first power terminals, each group of the first power terminals comprises at least one first power terminal, each of the first power terminals is configured to connect to one of the power transistors and the capacitor module, and the plurality of groups of first power terminals are sequentially arranged along a side of the first heat sink.
5 . The inverter apparatus according to claim 1 , wherein a metal connection layer is disposed between the first heat sink and the power module, the metal connection layer is fastened to both the first heat sink and the power module, and two surfaces that are of the metal connection layer and that are disposed opposite to each other in the direction in which the power module and the first heat sink are stacked are in contact with the first heat sink and the power module respectively.
6 . The inverter apparatus according to claim 1 , wherein the inverter apparatus comprises a first circuit board, the power module and the first heat sink are disposed in a stacked manner between the capacitor module and the first circuit board, and the first circuit board is electrically connected to the plurality of power transistors.
7 . The inverter apparatus according to claim 1 , wherein an upper surface of the capacitor module comprises a plurality of second support columns, the inverter apparatus comprises a second circuit board, and the plurality of second support columns are configured to fasten the second circuit board and the capacitor module, wherein in the direction in which the power module and the first heat sink are stacked, a height of each of the second support columns is less than a stacked height of the power module and the first heat sink; and the plurality of second support columns are sequentially arranged along the other side of the first heat sink, and orthographic projections of the plurality of second support columns and the first heat sink on the upper surface of the capacitor module do not overlap.
8 . The inverter apparatus according to claim 2 , wherein the inverter apparatus further comprises a second heat sink, and the second heat sink is disposed in a stacked manner on a side that is of the power module and that is away from the first heat sink.
9 . The inverter apparatus according to claim 6 , wherein an upper surface of the capacitor module comprises a plurality of first support columns, and the plurality of first support columns are configured to fasten the first circuit board and the capacitor module, wherein in the direction in which the power module and the first heat sink are stacked, a height of each of the first support columns is greater than or equal to a stacked height of the power module and the first heat sink; and the plurality of first support columns are sequentially arranged along a side of the first heat sink, and orthographic projections of the plurality of first support columns and the first heat sink on the upper surface of the capacitor module do not overlap.
10 . The inverter apparatus according to claim 6 , wherein the inverter apparatus comprises a second circuit board, and the second circuit board and the power module are disposed side by side between the capacitor module and the first circuit board.
11 . The inverter apparatus according to claim 7 , wherein there are a plurality of copper bar connectors between a surface that is of the second circuit board and that faces the capacitor module and the upper surface of the capacitor module, and each of the copper bar connectors is electrically connected to one of the power transistors.
12 . A motor controller comprising: a motor controller housing; an inverter apparatus; and a three-phase copper bar assembly, wherein the motor controller housing is configured to accommodate the inverter apparatus and the three-phase copper bar assembly, and wherein the inverter apparatus comprises: a capacitor module, a power module, and a first heat sink, wherein the power module and the first heat sink are disposed in a stacked manner on the capacitor module, and wherein: the power module comprises a plurality of power transistors, and the plurality of power transistors are arranged in a flat manner in a direction perpendicular to a direction in which the power module and the first heat sink are stacked; the capacitor module further comprises a plurality of capacitor connection terminals, each of the capacitor connection terminals is configured to connect to one of the power transistors, the plurality of capacitor connection terminals are arranged on an upper surface of the capacitor module along the first heat sink, orthographic projections of the capacitor connection terminals and the first heat sink on the upper surface of the capacitor module do not overlap, and the upper surface of the capacitor module is a surface that is of the capacitor module and that faces the first heat sink; the motor controller housing comprises a bottom housing and a cover plate, the inverter apparatus is disposed between the bottom housing and the cover plate, and the capacitor module is fastened to the bottom housing; and the inverter apparatus and the three-phase copper bar assembly are arranged in parallel in the motor controller housing in a direction perpendicular to a direction in which the power module and the first heat sink are stacked.
13 . The motor controller according to claim 12 , wherein the first heat sink is disposed in a stacked manner on the capacitor module, the power module is disposed in a stacked manner on a side that is of the first heat sink and that is away from the capacitor module, and the plurality of power transistors are arranged in a flat manner on the side that is of the first heat sink and that is away from the capacitor module.
14 . The motor controller according to claim 12 , wherein the inverter apparatus further comprises a sheet metal clip, two ends of the sheet metal clip are respectively clamped and fastened to the power module and the capacitor module, and the sheet metal clip is configured to fasten the power module, the first heat sink, and the capacitor module in the direction in which the power module and the first heat sink are stacked.
15 . The motor controller according to claim 12 , wherein the inverter apparatus comprises a plurality of groups of first power terminals, each group of the first power terminals comprises at least one first power terminal, each of the first power terminals is configured to connect to one of the power transistors and the capacitor module, and the plurality of groups of first power terminals are sequentially arranged along a side of the first heat sink.
16 . The motor controller according to claim 12 , wherein a metal connection layer is disposed between the first heat sink and the power module, the metal connection layer is fastened to both the first heat sink and the power module, and two surfaces that are of the metal connection layer and that are disposed opposite to each other in the direction in which the power module and the first heat sink are stacked are in contact with the first heat sink and the power module respectively.
17 . The motor controller according to claim 12 , wherein a side wall of the motor controller housing comprises a copper bar assembly mounting hole, one end of the three-phase copper bar assembly extends into the bottom housing through the copper bar assembly mounting hole and is electrically connected to a plurality of power transistors through a plurality of output copper bar connectors, and orthographic projections of the copper bar assembly mounting hole, the first heat sink, and the capacitor module on the side wall do not overlap.
18 . A vehicle comprising: a motor; and a motor controller comprising: a motor controller housing; an inverter apparatus; and a three-phase copper bar assembly, wherein the motor controller housing is configured to accommodate the inverter apparatus and the three-phase copper bar assembly, and wherein the inverter apparatus comprises: a capacitor module, a power module, and a first heat sink, wherein the power module and the first heat sink are disposed in a stacked manner on the capacitor module, and wherein: the power module comprises a plurality of power transistors, and the plurality of power transistors are arranged in a flat manner in a direction perpendicular to a direction in which the power module and the first heat sink are stacked; the capacitor module further comprises a plurality of capacitor connection terminals, each of the capacitor connection terminals is configured to connect to one of the power transistors, the plurality of capacitor connection terminals are arranged on an upper surface of the capacitor module along the first heat sink, orthographic projections of the capacitor connection terminals and the first heat sink on the upper surface of the capacitor module do not overlap, and the upper surface of the capacitor module is a surface that is of the capacitor module and that faces the first heat sink; the motor controller housing comprises a bottom housing and a cover plate, the inverter apparatus is disposed between the bottom housing and the cover plate, and the capacitor module is fastened to the bottom housing; and the inverter apparatus and the three-phase copper bar assembly are arranged in parallel in the motor controller housing in a direction perpendicular to a direction in which the power module and the first heat sink are stacked; wherein the three-phase copper bar assembly is electrically connected to the motor.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to Chinese Patent Application No. 202320273722.9, filed on Feb. 7, 2023, which is hereby incorporated by reference in its entirety. TECHNICAL FIELD This application relates to the field of motor controller technologies, and in particular, to an inverter apparatus used in a motor controller, a motor controller, and a vehicle. BACKGROUND A motor controller in an electric vehicle is used to convert a direct current provided by a power battery into an alternating current to supply power to a drive motor, to drive wheels of the electric vehicle by using the drive motor. However, the motor controller implements conversion between an alternating current voltage and a direct current voltage by switching between a turn-on state and a turn-off state of a power module. Frequent turn-on and turn-off of the power module generate a large amount of heat. Generally, a heat sink needs to be disposed inside the motor controller to dissipate heat for the power module. In addition, the heat sink usually uses cooling liquid to improve a heat dissipation capability and needs to dissipate heat for a circuit device such as a capacitor. Consequently, an internal structure of the motor controller is complex and the motor controller has a large size. This not only affects an entire vehicle layout, but also causes complex maintenance, disassembly, and assembly operations of the motor controller. SUMMARY This application provides an inverter apparatus that has a compact structure layout and that can reduce disassembly and assembly difficulty, a motor controller, and a vehicle. According to a first aspect, this application provides an inverter apparatus used in a motor controller. The inverter apparatus includes a capacitor module, a power module, and a first heat sink, where the power module and the first heat sink are disposed in a stacked manner on the capacitor module. The power module includes a plurality of power transistors, and the plurality of power transistors are arranged in a flat manner in a direction perpendicular to a direction in which the power module and the first heat sink are stacked. In this embodiment, the direction in which the power module and the first heat sink are stacked is a first direction, and the power module and the first heat sink are stacked in the first direction. The plurality of power transistors are arranged in a flat manner in the direction perpendicular to the first direction. That is, the plurality of power transistors are arranged in a flat manner in a plane perpendicular to the first direction. In an embodiment, the plane perpendicular to the first direction may be a surface that is of the first heat sink and that faces the power module in the first direction. Compared with a manner in which the plurality of power transistors are disposed in a stacked manner in the first direction, this solution is conducive to reducing a length of the inverter apparatus in the first direction, and effectively utilizing a mounting area of the first heat sink, so as to implement a miniaturization embodiment of the motor controller. In this embodiment, the power module is electrically connected to the capacitor module, and the power module is configured to convert a direct current into an alternating current. The direct current transmitted to the inverter apparatus sequentially flows to the capacitor module and the power module. The capacitor module is configured to receive the direct current. An output terminal of the capacitor module is electrically connected to an input terminal of the power module. The direct current is transmitted to the power module through the capacitor module and then converted into the alternating current. An output terminal of the power module is electrically connected to an input terminal of a motor. The power module transmits the alternating current to the motor to drive the motor to run. In this embodiment, the first heat sink is configured to dissipate heat for the power module. The first heat sink and the power module are disposed in a stacked manner. When cooling liquid flows into the first heat sink, the cooling liquid can exchange heat with the power module, and the first heat sink takes the heat away from the power module, so as to reduce a temperature of the inverter apparatus in a stable working state, thereby implementing temperature control on the motor controller. In this application, the inverter apparatus has a compact structure layout. The inverter apparatus is used in the motor controller. This improves integration of the motor controller, and is conducive to implementing a miniaturization embodiment of the motor controller and optimizing an entire vehicle layout. Compared with a manner in which the capacitor module, the power module, and the first heat sink are arranged in a flat manner side by side, in this application, the power module and the first heat sink are disposed in a stacked manner o