The Development Of Electric Vehicle Motor Driver Based On Reinforced Reliability

Along with the rapid development of global economy, energy conservation andenvironment protection becomes a great challenge for all the countries in the world. As forthe international R&D conditions, Battery Electric Vehicle and Hybrid Electric Vehiclewhich integrate a variety of new and high technologies are leading to a revolution andbetokening a bright future of automotive industry in the world. Over the recent years, thegovernments and transnational corporations around the world have invested large amountof fund, which is increasing year by year. The proportion of the investment in coretechnologies such as power battery and motor control system is relatively high. Ourcountry is also determined to develop energy-saving environment-friendly vehicles and toquicken the pace in R&D of new-energy vehicles.Reliability and cost have long been major problems in development of electricvehicle, while reliability is also the primary performance index for popularization andsurvival of electric vehicle. Over the years, most of the electric vehicle driversmanufactured by the large automotive corporations in the world have been extended fromindustrial products by improving the performance indexes directly with not muchconsideration with vehicle application conditions. This driver is designed with fullconsideration of the service conditions and in allusion to the deficiencies of the existingdrivers. IPM is selected for the power conversion assembly of the driver to reduceintermediate links and to increase the reliability of the key points in the system. Instructure design aspect, resistance to shock and interference immunity are improved in thegeneral shielding and securing of the main components such as support capacitor, HFdecoupling capacitor, drive board and master control board. The water-cooling plate of thepower module is redesigned in accordance with the new concept, reducing the generaltemperature of the driver dramatically and improving the service life of the elements in thecircuit board. A method combining hardware and software is adopted to minimizemisoperation and to ensure the reliable protection of the driver. The testing and road test ofthe sample vehicle further testified the correctness of the design concept of this driver.In this controller, from the viewpoint of design, the electric vehicle driver is subjectedto special intensified design and optimization in multiple aspects such as selection ofelements/components, derating design, thermal design, anti-shock design andfault-tolerant design in order to improve the reliability of the controller. It intends, without increasing the BOM cost of the product significantly, to achieve the vehicle-applicablelevel and to provide with a new idea for exploring the design of electric vehicle drivers.