CN111769728A - A highly integrated motor control system - Google Patents

Abstract

The invention discloses a highly integrated motor control system, which relates to the field of Insulated Gate Bipolar Transistor (IGBT), and comprises a control and drive integrated circuit board, an IGBT module, a capacitor, a three-phase output bus bar, a shielding cover for a sensor, a three-phase copper bar injection molding part and a radiator for the IGBT.

Description

A highly integrated motor control system

technical field

The invention relates to the field of IGBTs, in particular to a highly integrated motor control system.

Background technique

The traditional motor control system is generally large in structure and loose in the interior. It usually adopts bolt connection, wire harness connection, etc., and thermal grease needs to be filled between components, which not only results in large volume and weight, but also the thermal resistance of the system is generally relatively high. Large, reliability is not ideal.

Moreover, the components are generally small in size, and the assembly one by one, whether it is wire harness connection or bolting, requires manual operation, the production efficiency is relatively low, and it is not suitable for automated batch manufacturing.

SUMMARY OF THE INVENTION

The purpose of the present invention is to provide a highly integrated motor control system, which adopts different methods of direct interconnection welding technology, and has better reliability and consistency than the solutions on the market. The design has the advantages of compact structure, high integration, Light weight, flexible platform expansion and other technical features, at the same time, the traditional bolt connection and wire harness connection are omitted in the design, the assembly is simpler, suitable for automated batch manufacturing, and also provides a technological basis for assembly with a higher degree of automation.

A highly integrated motor control system, including a control and drive integrated circuit board, an IGBT module, a capacitor, a three-phase output busbar, a sensor shield, a three-phase copper bar injection molding and an IGBT radiator, the IGBT module is welded On the IGBT radiator, each phase of the IGBT module is composed of upper bridge and lower bridge root IGBT tubes, and the root IGBT tubes are arranged horizontally side by side. The IGBT collector and IGBT emitter of the IGBT module and the capacitor output copper bar of the capacitor connection, and its output end is connected to the three-phase output busbar;

The capacitor and the three-phase copper-bar injection molded parts are respectively installed on both sides of the IGBT radiator, a shielding cover for the sensor is arranged under the three-phase output busbar, and the three-phase output busbar is integrated with the three-phase copper-bar injection molded parts. Forming, the control-drive integrated circuit board is fixedly connected to the casing of the capacitor and the three-phase copper-bar injection molding through the circuit-board mounting post and the circuit-board fixing support, and covers the three-phase output busbar.

Preferably, the IGBT collector of the upper bridge and the IGBT emitter of the lower bridge of the IGBT module are respectively connected to the positive and negative poles of the capacitor output copper bars of the capacitor, and the IGBT gate of the IGBT module is directly integrated with the control and drive circuit board soldering.

Preferably, the IGBT module consists of IGBT tubes arranged side by side to form a three-phase full bridge.

Preferably, the capacitor is installed in the capacitor installation slot on the left side of the IGBT radiator, the three-phase copper bar injection molded part is installed in the injection part mounting plate on the right side of the IGBT radiator, and the IGBT radiator There is a water pipe at the front and rear.

Preferably, the IGBT module is directly welded on the IGBT welding boss on the IGBT heat sink by a vacuum welding process, and a temperature sensor setting block is provided on the rear side of the IGBT welding boss.

Preferably, the drive integrated circuit board is provided with a shielding cover slot, and a magnetic induction chip and a temperature sensor bracket are also installed at the bottom thereof, and the temperature sensor bracket is located directly above the temperature sensor setting block.

Preferably, the outer side of the capacitor is further provided with a high-voltage DC positive input terminal and a high-voltage DC negative input terminal, and the top of the capacitor is provided with a control board limit hole, and the capacitor output copper bar is also connected with a bus voltage sampling pin , the bus voltage sampling pin is also welded on the control-drive integrated circuit board.

Preferably, the outer side of the three-phase copper bar injection molding is further provided with a three-phase copper outlet.

The advantages of the present invention lie in that: the structure is simple, the direct interconnection welding process in different ways is adopted, and the reliability and consistency are better compared with the solutions on the market. The design has the advantages of compact structure, high integration, light weight, and flexible platform expansion. At the same time, the traditional bolt connection and wire harness connection are omitted in the design, the assembly is simpler, it is suitable for automated batch manufacturing, and it also provides a technological basis for higher automation assembly.

Description of drawings

Fig. 1 is the structure exploded view of the front side view of the device of the present invention;

Fig. 2 is the structure exploded view of the rear side view of the device of the present invention;

Among them, 1. Control and drive integrated circuit board, 101, Shield cover slot, 102, Magnetic induction chip, 103, Temperature sensor bracket, 2. IGBT module, 201, IGBT collector, 202, IGBT emitter, 203, IGBT gate Pole, 3. Capacitor, 301, HVDC Positive Input Terminal, 302, HVDC Negative Input Terminal, 303, Capacitor Output Copper Bar, 304, Bus Voltage Sampling Pin, 305, Control Board Limit Hole, 306, Circuit Board Mounting Column, 4. Three-phase output busbar, 5. Shielding cover for sensor, 6. Three-phase copper bar injection molding, 601, Circuit board fixing support, 602, Three-phase copper outlet, 7. Heat sink for IGBT, 701. Capacitor mounting slot, 702, injection molding mounting plate, 703, water pipe, 8. IGBT welding boss, 801, temperature sensor setting block.

Detailed ways

In order to make the technical means, creation features, achievement goals and effects realized by the present invention easy to understand, the present invention will be further described below in conjunction with the specific embodiments.

As shown in Figures 1 to 2, a highly integrated motor control system includes a control and drive integrated circuit board 1, an IGBT module 2, a capacitor 3, a three-phase output busbar 4, a sensor shield 5, a three-phase copper The injection molded parts 6 and the IGBT radiator 7 are arranged. The IGBT module 2 is welded on the IGBT radiator 7. Each phase of the IGBT module 2 is composed of two IGBT tubes on the upper bridge and the lower bridge, and the two IGBT tubes are horizontally arranged side by side. Arrangement, the IGBT collector 201 and the IGBT emitter 202 of the IGBT module 2 are connected to the capacitor output copper bar 303 of the capacitor 3, and its output end is connected to the three-phase output bus bar 4;

The capacitor 3 and the three-phase copper bar injection molded parts 6 are respectively installed on both sides of the IGBT radiator 7, the three-phase output busbar 4 is provided with a sensor shield 5, and the three-phase output busbar 4 is connected to the three-phase output busbar 4. The phase copper bar injection part 6 is integrally formed, and the control-drive integrated circuit board 1 is fixedly connected to the casing of the capacitor 3 and the three-phase copper bar injection part 6 through the circuit board mounting post 306 and the circuit board fixing support 601 respectively, and is Cover the three-phase output busbar 4.

The capacitor 3 and the three-phase copper-bar injection molded parts 6 are respectively installed on both sides of the IGBT radiator 7, the three-phase output busbar 4 is provided with a sensor shield 5, and the three-phase output busbar 4 is connected to the three-phase output busbar 4. The phase copper bar injection part 6 is integrally formed, and the control-drive integrated circuit board 1 is fixedly connected to the shell of the capacitor 3 and the three-phase copper bar injection part 6 through the circuit board mounting post 306 and the circuit board fixing support 601 respectively, and is Cover the three-phase output busbar 4.

The IGBT collector 201 of the upper bridge and the IGBT emitter 202 of the lower bridge of the IGBT module 2 are respectively connected to the positive and negative poles of the capacitor output copper bar 303 of the capacitor 3, and the IGBT gate 203 of the IGBT module 2 is directly connected. Solder with the control and drive integrated circuit board 1.

The IGBT module 2 consists of 6 IGBT tubes arranged side by side to form a three-phase full bridge.

The capacitor 3 is installed in the capacitor installation slot 701 on the left side of the IGBT radiator 7, and the three-phase copper bar injection molding 6 is installed in the injection part mounting plate 702 on the right side of the IGBT radiator 7. The IGBT uses The front and rear ends of the radiator 7 are each provided with a water pipe 703 .

The IGBT module 2 is directly welded on the IGBT welding boss 8 on the IGBT radiator 7 through a vacuum welding process, and a temperature sensor setting block 801 is provided on the rear side of the IGBT welding boss 8. Soldering bosses 8 are used to solder the IGBT module 2 and the IGBT heat sink 7 and ensure an effective electrical clearance with the IGBT heat sink 7.

The drive integrated circuit board 1 is provided with a shielding cover slot 101, and a magnetic induction chip 102 and a temperature sensor bracket 103 are also installed at the bottom thereof, and the temperature sensor bracket 103 is located directly above the temperature sensor setting block 801.

The outer side of the capacitor 3 is also provided with a high-voltage DC positive input terminal 301 and a high-voltage DC negative input terminal 302, and the top of the capacitor 3 is provided with a control board limit hole 305, and the capacitor output copper bar 303 is also connected to the bus voltage. The sampling pin 304, the bus voltage sampling pin 304 is also welded on the control-drive integrated circuit board 1. The bus voltage sampling pin 304 is used to control the control and drive integrated circuit board 1 to collect the bus voltage, and is directly welded with the control and drive integrated circuit board 1 .

A three-phase copper outlet 602 is also provided on the outer side of the three-phase copper bar injection molding 6 .

Specific implementation and principle:

Single-tube packaged high-current IGBT module 2 is selected. The three-phase full bridge consists of 6 single tubes. The upper and lower bridges of the same-phase bridge arm are arranged 180 degrees complementary to form a one-phase bridge arm, and the 6 tubes are arranged side by side to form a three-phase bridge arm. The phase full bridge is directly welded with the radiator through the vacuum welding process, which not only saves space, but also saves the traditional thermal grease and reduces the thermal resistance of the system;

The IGBT radiator 7 is designed in an integrated manner with the capacitor mounting slot 701 and the injection molding mounting plate 702. The IGBT radiator 7 is designed with a fin structure to increase the effective heat dissipation area. The upper and lower parts of the radiator are welded by friction welding process, and the structure is more Compact, the surface of the radiator is nickel-plated;

The capacitor 3 is installed in the capacitor installation slot 701, which is located on the side of the IGBT module. The capacitor output copper bar 303 of the capacitor 3 and the input terminal of the IGBT module 2 are directly connected by a laser welding process, instead of the conventional bolt fastening connection, reducing the main circuit inductance , while improving system reliability;

The temperature sensor setting block 801 is located on the IGBT welding boss 8 near the IGBT module, and is located at the water outlet position of the IGBT radiator 7, a groove is designed on the temperature sensor setting block 801, and the temperature sensor is pre-fixed on the temperature sensor bracket 103, The temperature sensor bracket 103 is welded on the control-drive integrated circuit board 1. After the control-drive integrated circuit board 1 is installed, the temperature sensor is just in the groove, and the groove is pre-embedded with thermally conductive silica gel, which has the effect of fixing and heat transfer;

The three-phase output busbar 4 of the controller and the three-phase copper bus injection molding part 6 adopt an integrated injection molding process, and are directly welded with the output terminal of the IGBT module 2 by a laser welding process, and the other end of the three-phase output busbar 4 is directly connected to the three-phase motor. winding connection;

The phase current sensor adopts magnetic induction chip technology to replace the traditional HALL sensor technology. The magnetic induction chip is integrated on the control and drive integrated circuit board. The sensor shield 5 is integrated with the three-phase output busbar 4. The three-phase output is directly below the chip. Busbar 4, the three-phase output busbar 4 is below the sensor shielding cover 5, the three-phase output busbar 4 and the sensor shielding cover 5 are insulated by injection molding materials, and the sensor shielding cover 5 is fixed by injection molding;

The control-drive integrated circuit board 1 adopts an integrated design. The integrated circuit board is fixed on the casing of the capacitor 3 and the three-phase copper bar injection molding 6. The drive pad is soldered to the gate pin of the IGBT module 2, and at the same time Weld directly with the positive pin of capacitor 3 for bus voltage sampling.

Based on the above, the present invention has a simple structure, adopts different direct-connect interconnection welding processes, and is more reliable and consistent than the solutions on the market. The design has the advantages of compact structure, high integration, light weight, flexible platform expansion, etc. At the same time, the traditional bolt connection and wire harness connection are omitted in the design, the assembly is simpler, it is suitable for automated batch manufacturing, and it also provides a technological basis for higher automation assembly.

It is known from the technical common sense that the present invention can be realized by other embodiments without departing from its spirit or essential characteristics. Accordingly, the above-disclosed embodiments are, in all respects, illustrative and not exclusive. All changes within the scope of the present invention or within the scope equivalent to the present invention are encompassed by the present invention.

Claims (8)

1. The highly integrated motor control system is characterized by comprising a control and drive integrated circuit board (1), an IGBT module (2), a capacitor (3) and a three-phase output busbar (4), a shielding cover (5) for a sensor, a three-phase copper bar injection molding part (6) and a radiator (7) for the IGBT, wherein the IGBT module (2) is welded on the radiator (7) for the IGBT, each phase of the IGBT module (2) is composed of 2 IGBT tubes of an upper bridge and a lower bridge, the 2 IGBT tubes are horizontally arranged side by side, an IGBT collector electrode (201) and an IGBT emitter electrode (202) of the IGBT module (2) are connected with a capacitor output copper bar (303) of the capacitor (3), and the output end of the IGBT module is connected with the three-phase output busbar (4);

electric capacity (3) and three-phase copper bar injection molding (6) install respectively in the both sides of radiator (7) for the IGBT, female (4) below of arranging of three-phase output is equipped with shield cover (5) for the sensor, and female (4) of three-phase output and three-phase copper bar injection molding (6) integrated into one piece, control drive integration circuit board (1) is respectively through circuit board erection column (306) and circuit board fixing support (601) fixed connection on shell and three-phase copper bar injection molding (6) of electric capacity (3) to cover female (4) of three-phase output.

2. A highly integrated motor control system according to claim 1, characterized in that: an IGBT collector electrode (201) of an upper bridge and an IGBT emitter electrode (202) of a lower bridge of the IGBT module (2) are respectively connected with the positive electrode and the negative electrode of a capacitance output copper bar (303) of a capacitance (3), and an IGBT gate pole (203) of the IGBT module (2) is directly welded with the control and drive integrated circuit board (1).

3. A highly integrated motor control system according to claim 1, characterized in that: and the IGBT module (2) is formed by arranging 6 IGBT tubes side by side to form a three-phase full bridge.

4. A highly integrated motor control system according to claim 1, characterized in that: the capacitor (3) is arranged in a capacitor mounting groove (701) on the left side of the radiator (7) for the IGBT, the three-phase copper bar injection molding piece (6) is arranged in an injection molding piece mounting plate (702) on the right side of the radiator (7) for the IGBT, and the front end and the rear end of the radiator (7) for the IGBT are respectively provided with a water pipe (703).

5. A highly integrated motor control system according to claim 1, characterized in that: the IGBT module (2) is directly welded on an IGBT welding boss (8) on the radiator (7) for the IGBT through a vacuum welding process, and a temperature sensor setting block (801) is arranged on the rear side of the IGBT welding boss (8).

6. A highly integrated motor control system according to claim 5, wherein: be equipped with shield cover slot (101) on drive integration circuit board (1), and magnetic induction chip (102) and temperature sensor support (103) are still installed to its bottom, temperature sensor support (103) are located temperature sensor and set up directly over piece (801).

7. A highly integrated motor control system according to claim 1, characterized in that: the outside of electric capacity (3) still is equipped with positive input terminal (301) of high voltage direct current and high voltage direct current negative input terminal (302), and the top of electric capacity (3) is equipped with spacing hole of control panel (305), still be connected with busbar voltage sampling pin (304) on electric capacity output copper bar (303), busbar voltage sampling pin (304) still weld on control drive integrated circuit board (1).

8. A highly integrated motor control system according to claim 1, characterized in that: and a three-phase copper bar outlet (602) is also arranged on the outer side of the three-phase copper bar injection molding piece (6).

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