The three core components of a new energy electric vehicle are: the power battery, the motor, and the motor controller. Today, we'll discuss the motor controller, one of these three components.
According to the definition in GB/T18488.1-2015 "Drive Motor System for Electric Vehicles - Part 1: Technical Conditions", a motor controller is a device that controls the energy transfer between the power source and the drive motor, consisting of a control signal interface circuit, a drive motor control circuit, and a drive circuit.
Functionally, the new energy electric vehicle controller converts the DC power from the power battery of the new energy electric vehicle into AC power for the drive motor, and communicates with the vehicle controller through the communication system to control the speed and power required by the vehicle.
Analyzing from the outside in, the first step: From the outside, the motor controller is essentially an aluminum box, a low-voltage connector, a high-voltage bus connector with two holes, a three-phase connector with three holes for connecting to the motor (multi-in-one connectors do not have a three-phase connector), one or more vent valves, and two water inlet/outlet ports. The aluminum box typically has two covers: a large cover and a wiring cover. The large cover allows the controller to be fully opened, while the wiring cover is used to connect the controller's bus connector and the three-phase connector.
From the inside, once the controller is opened, you can see the internal structure and electronic components of the entire motor controller. Some controllers, depending on the customer's needs, will have an opening protection switch placed at the wiring cover.
The internal components mainly include: three-phase copper busbars, busbar copper busbars, copper busbar support frames, three-phase and busbar wiring brackets, EMC filter boards, busbar capacitors, control boards, drive boards, adapter boards, IGBTs, current sensors, EMC magnetic rings, and discharge resistors, etc.
