The power domain integrated controller is an industry first-ever development. Through the sharing of hardware circuits, the integration of software functions, and the integrated-housing design technology, it realizes the deep integration of seven major functions: motor controller, steering motor controller, air-compressor controller, electric accessory power distribution, complete vehicle DC/DC, DC charging circuit, and insulation detection. The number of high-voltage connection points is reduced by 25%. The connection of high-voltage wiring harness is simplified, the wiring harness layout is standardized and looks neat to improve the aesthetic qualities of wire harnessing design. High-voltage power distribution is brought under centralized monitoring and management for high safety. The weight is reduced by 50% and the volume is reduced by 40%, which improves the lightweight of the product. At the same time, platform-based products adaptable to 6-7m buses, 8-11m coaches and 8-12m buses are developed, meeting the demands of vehicles of different length and motors of different power ranges.
Based on the advantages of SiC module like voltage withstanding, low loss, high efficiency and compact size, the power domain integrated controller is the first of its kind in the commercial vehicle industry to adopt a new generation of power semiconductor SiC module. At the same time, it adopts the overmodulation control algorithm to improve the voltage utilization rate, and variable carrier frequency control technology is used to reduce switching loss, enabling a maximum efficiency ≥ 99.5%. The proportion of areas with an efficiency greater than or equal to 90% is ≥ 92% and the high-efficiency area is widened by 3%. As a result, the energy consumption of the whole vehicle is reduced by 4% and the driving range is thus increased.
The controller has also made major breakthroughs in isolation protection and pioneered the 2-meter 72-hour waterproof technology, meaning that the power domain integrated controller does not show any trace of water ingress and can still work normally even though it has been immersed under the water at a depth of 2m for 72 hours. With such excellent isolation protection performance, the controller can support the safe and reliable operation of vehicles in urban waterlogging scenarios and maintenance cost is also reduced. At the same time, the protection grade of the controller reaches IP6K9K, which means that it can still work normally after being sprayed by a high-temperature and high-pressure water gun at a temperature of 85°C and a pressure of 8-10 MPa.
The power domain integrated controller can also monitor the motor output torque and verify the motor position signal in real time, so as to realize online detection of the health status of the drive system and ensure the safe operation of the vehicle. At the same time, based on the active damping compensation and adaptive torque adjustment, it ensures the quick responsiveness of torque output of the drive system, reduces the jitter and main reduction driver clashing sound in case of sudden change in driving conditions, and improves driving comfort.
