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<p>The electric vehicle motor controller drives the motor to work by modulating the output sine wave through the inverter bridge, which is an important part of the electric vehicle control strategy.</p><p><br></p><p>At present, <a href="https://www.vectorque.com" rel="noopener noreferrer" target="_blank">motor controllers</a> are becoming more integrated. The integration forms include: single main drive controller, three-in-one controller (integrated: EHPS controller + ACM controller + DC/DC), and five-in-one controller (integrated: EHPS control) Controller + ACM controller + DC/DC + PDU + dual-source EPS controller), passenger car controller (integrated: main drive + DC/DC).</p><p><br></p><p>Due to the continuous integration of the motor controller, its structure and functions are becoming more and more complex. The current all-in-one integrated motor control includes:</p><p><br></p><p>(1) Power distribution circuit: provide power distribution for each branch of the integrated controller, such as fuse, TM contactor, electric defrost circuit power supply, electric power steering circuit power supply, electric air conditioning circuit power supply, etc.;</p><p><br></p><p>(2) Auxiliary power supply: provide power for the control circuit (such as VCU), and provide isolated power for the drive circuit;</p><p><br></p><p>(3) IGBT drive circuit: receives control signals, drives IGBTs and feeds back the status, providing isolation and protection;</p><p><br></p><p>(4) DSP circuit: Receive VCU control instructions, make feedback, detect sensor information such as motor system speed and temperature, and transmit motor control signals through instructions;</p><p><br></p><p>(5) Structure and heat dissipation system: Provide heat dissipation for the motor controller to ensure the safety of the controller.</p><p><br></p><p>Due to the complex operating conditions and changeable environment of electric vehicles, the thermal design of the motor controller must be fully considered during the design of the motor controller. At present, the performance of the motor controller must be simulated and analyzed by computer before it is put into production, such as:</p><p><br></p><p>(1) The overall systemic simulation of the controller, which mainly focuses on the rationality of the design of the cooling water channel and the simulation of the internal environment temperature of the controller;</p><p><br></p><p>(2) The simulation of the key modules of the controller, which mainly simulates the key capacitors and copper bars used in the controller, and simulates the temperature of the capacitor through the heat flux density;</p><p><br></p><p>(3) Simulation of the key single board of the controller, which mainly simulates the ambient temperature of the single board and the heat dissipation of the key parts on the single board.</p><p><br></p><p>(4) Simulation of the core chip of the controller, mainly including IGBT and main power module simulation. Through accurate simulation, the maximum ability of the core chip IGBT of the controller can be exerted.</p><p><br></p><p>For more complex operating conditions, further simulation analysis of the motor controller is required (such as: rated, overload typical operating conditions simulation, locked-rotor special operating conditions simulation, periodic load, nonlinear load to determine the maximum capacity of the controller) In order to make the designed motor controller meet the high precision requirements.</p>
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