EPS controller and motor integrated power group structure, assembly method and system

Abstract

The present invention discloses an EPS controller and motor integrated power group structure, comprising a motor, an EPS controller and a housing; the EPS controller comprises a PCB electrically connected to the PIN female terminal of the motor and electronic components arranged on the PCB, the PCB is assembled on a mounting seat, and a connector is welded on the PCB; the mounting seat is fixed to the motor; the housing is mounted on the mounting seat and is covered outside the PCB; the connector extends out of the housing through a through hole of the housing, wherein the housing, the PCB and the mounting seat are located in the axial direction of the motor. The EPS controller and motor integrated power group structure provided by the present invention integrates the motor and the EPS controller into one, reduces the assembly space required for the assembly of the two, and can adapt to a relatively narrow installation space. The present invention also provides an assembly method of the EPS controller and motor integrated power group structure and an EPS system.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile steering, and more specifically, to an EPS controller and motor integrated power group structure, an assembly method of the EPS controller and motor integrated power group structure, and an EPS system. Background Art

[0002] EPS (Electric Power Steering) system is designed on the basis of traditional mechanical steering system, mainly composed of torque / angle sensor, vehicle speed sensor, electronic control unit and deceleration mechanism, etc. EPS system not only improves the portability of automobile steering operation and high-speed stability, but also improves the active safety of automobile, so EPS system has become a hot spot in the development of automotive electronic technology.

[0003] In the prior art, the controller and the motor of the EPS system are separated from each other, which takes up a lot of assembly space and cannot adapt to a relatively narrow installation space.

[0004] Therefore, how to solve the problem that the controller and the motor in the EPS system are separated from each other and occupy more assembly space is an urgent problem to be solved by technical personnel in this field. Summary of the invention

[0005] In view of this, the present invention provides an EPS controller and motor integrated power group structure, which integrates the motor and the EPS controller into one, reduces the assembly space required for assembling the two, and can adapt to a relatively narrow installation space. The present invention also provides an assembly method of the EPS controller and motor integrated power group structure and an EPS system.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] An EPS controller and motor integrated power group structure, comprising:

[0008] Motor;

[0009] An EPS controller, the EPS controller comprising a PCB electrically connected to the PIN female terminal of the motor and electronic components arranged on the PCB, the PCB being assembled on a mounting seat, and a connector being correspondingly welded to the PCB; the mounting seat being fixed to the motor;

[0010] A shell is installed on the mounting seat and covers the outside of the PCB; the connector extends out of the shell through a through hole of the shell; wherein the shell, the PCB and the mounting seat are located in the axial direction of the motor.

[0011] Optionally, the EPS controller and motor integrated power group structure further includes a support frame, the PCB includes a control board and a power board, the control board, the power board and the mounting seat are stacked in sequence; the control board and the power board are electrically connected to the connector, and the lower surface of the control board is fixedly connected to the first end surface of the support frame, the upper surface of the power board is fixedly connected to the second end surface of the support frame, and is electrically connected to the PIN female terminal of the motor; the support frame, the power board and the mounting seat are fixedly connected;

[0012] The end of the control board and the end of the power board are connected to each other and form a "U" shape;

[0013] The control board and the power board are of an integrated structure; the bending portion at the connection between the control board and the power board is made by a Semi-flex process; or, the control board and the power board are separated from each other, and the control board and the power board are connected to each other via a pin header.

[0014] Optionally, in the above-mentioned EPS controller and motor integrated power group structure, the connector includes a power connector, a signal connector and a TAS connector; the signal connector and the TAS connector are welded to the control board; and the power connector is welded to the power board.

[0015] Optionally, in the above-mentioned EPS controller and motor integrated power group structure, the mounting seat is a cast mounting seat.

[0016] Optionally, in the above-mentioned EPS controller and motor integrated power group structure, a gap is provided between the mounting seat and the lower surface of the power board, and the gap is filled with thermal conductive adhesive.

[0017] Optionally, in the above-mentioned EPS controller and motor integrated power group structure, a sealing ring is provided between the mounting seat and the motor;

[0018] The motor is provided with a mounting groove, and the sealing ring is arranged in the mounting groove.

[0019] Optionally, the connector is provided with an annular connector U-shaped groove, and a first protrusion is provided at a position of the shell opposite to the annular connector U-shaped groove; and / or the mounting seat is provided with an annular mounting seat U-shaped groove, and a second protrusion is provided at a position of the shell opposite to the annular mounting seat U-shaped groove.

[0020] An assembly method of an EPS controller and a motor integrated power group structure, the EPS controller and the motor integrated power group structure comprising a motor, an EPS controller and a housing, wherein the EPS controller comprises a PCB electrically connected to a PIN female terminal of the motor and electronic components arranged on the PCB, the PCB is assembled on a mounting seat, and a connector is correspondingly welded on the PCB; the mounting seat is fixed to the motor; the housing is mounted on the mounting seat and covered outside the PCB; the connector extends out of the housing through a through hole of the housing; the assembly method comprises:

[0021] 1) preparing the EPS controller, assembling the PCB with electronic components mounted on the mounting seat, and then assembling the housing on the mounting seat;

[0022] 2) Install the mounting base on the motor so that the housing, the PCB and the mounting base are located in the axial direction of the motor.

[0023] Optionally, the EPS controller and motor integrated power group structure also includes a support frame, the PCB is installed on the support frame, the support frame is fixed to the mounting seat, the PCB includes a control board and a power board, the control board, the power board and the mounting seat are stacked in sequence; the control board and the power board are electrically connected to the connector, and the lower surface of the control board is fixedly connected to the first end face of the support frame, the upper surface of the power board is fixedly connected to the second end face of the support frame, and is electrically connected to the PIN female terminal of the motor; the connector includes a power connector, a signal connector and a TAS connector; the signal connector and the TAS connector are welded to the control board; the power connector is welded to the power board; the connector is provided with a U-shaped groove of a ring connector, and a first protrusion is provided at a position where the shell is opposite to the U-shaped groove of the ring connector; the mounting seat is provided with a U-shaped groove of an annular mounting seat, and a second protrusion is provided at a position where the shell is opposite to the U-shaped groove of the annular mounting seat. In the above assembly method, step 1) includes:

[0024] 11) Flatten the "U"-shaped PCBs connected as one, solder some electronic components of the control board to the upper surface of the control board by reflow soldering, solder some electronic components of the power board to the lower surface of the power board, and then crimp the PIN female terminals of the motor to the upper surface of the power board; wherein the bending part at the connection between the control board and the power board is made by the Semi-flex process;

[0025] 12) Flip the flattened PCB 180 degrees, solder the remaining electronic components of the control board to the lower surface of the control board by reflow soldering, solder the remaining electronic components of the power board to the upper surface of the power board, assemble the connector to the control board so that the PIN pins of the signal connector and the PIN pins of the TAS connector pass through the control board; then solder the PIN pins of the signal connector and the PIN pins of the TAS connector to the lower surface of the control board by selective soldering, and solder the PIN female terminal of the motor to the upper surface of the power board;

[0026] 13) Connect the lower surface of the control board and the first end surface of the support frame through a fixing member, then bend the PCB into a U-shape, pass the PIN pins of the power connector through the power board, and connect the upper surface of the power board and the second end surface of the support frame through the fixing member; then weld the PIN pins of the power connector to the lower surface of the power board by selective welding;

[0027] 14) Use the fixings to connect the support frame, power board and mounting seat, then apply sealant to the U-shaped groove of the annular connector and the U-shaped groove of the annular mounting seat, and then assemble the housing to the mounting seat;

[0028] Alternatively, the step 1) comprises:

[0029] 11) Soldering some electronic components of the control board and the upper PIN pins of the pin row to the upper surface of the control board by reflow soldering, and soldering the remaining electronic components of the control board to the lower surface of the control board by reflow soldering; assembling the connector to the control board so that the PIN pins of the signal connector and the PIN pins of the TAS connector pass through the control board, and soldering the PIN pins of the signal connector and the PIN pins of the TAS connector to the lower surface of the control board by selective soldering; connecting the lower surface of the control board and the first end surface of the support frame by a fixing member;

[0030] 12) Soldering some electronic components of the power board to the upper surface of the power board by reflow soldering, crimping the PIN female terminal of the motor to the upper surface of the power board and then soldering; Soldering the remaining electronic components of the power board to the lower surface of the power board by reflow soldering, and then connecting the upper surface of the power board and the second end surface of the support frame by a fixing member, so that the lower PIN pins of the pin row are located on the lower surface of the power board, the PIN pins of the power connector pass through the power board, and the lower PIN pins of the pin row are welded to the lower surface of the power board, and the PIN pins of the power connector are welded to the lower surface of the power board by selective welding;

[0031] 13) Connect the support frame, power board and mounting base through the fixing parts, then apply sealant to the U-shaped groove of the annular connector and the U-shaped groove of the annular mounting base, and then assemble the housing to the mounting base.

[0032] Optionally, in the above assembly method, step 2) includes:

[0033] 21) Install the sealing ring into the mounting groove on the top of the motor;

[0034] 22) Fit the two positioning pins onto the motor with interference fit;

[0035] 23) Assemble the mounting base to the assembled motor using two locating pins;

[0036] 24) Use fixings to connect and tighten the mounting base and the motor.

[0037] An EPS system includes an EPS controller and a motor-integrated power group structure, wherein the EPS controller and the motor-integrated power group structure are the EPS controller and the motor-integrated power group structure described in any one of the above technical solutions.

[0038] The EPS controller and motor integrated power group structure provided by the present invention integrates the motor and the EPS controller into one, thereby reducing the assembly space required for assembling the two and being able to adapt to relatively narrow installation spaces. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0040] Figure 1 A schematic diagram of the structure of an EPS controller and a motor integrated power group structure provided in an embodiment of the present invention;

[0041] Figure 2 An exploded diagram of the EPS controller and motor integrated power group structure provided in an embodiment of the present invention;

[0042] Figure 3 A schematic diagram of the structure of a first PCB provided in an embodiment of the present invention;

[0043] Figure 4 A schematic structural diagram of a second PCB provided in an embodiment of the present invention.

[0044] in, Figure 1-Figure 4 middle:

[0045] Shell 1; connector 2; PCB 3; control board 31; power board 32; pin header 33; support frame 4; mounting base 5; motor 6; sealing ring 7; fixing part 8, fixing part 9; fixing part 10. DETAILED DESCRIPTION

[0046] The embodiment of the present invention discloses an EPS controller and motor integrated power group structure, which integrates the motor and the EPS controller into one, reduces the assembly space required for assembling the two, and can adapt to a relatively narrow installation space. The embodiment of the present invention also discloses an assembly method of the EPS controller and motor integrated power group structure, and an EPS system.

[0047] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0048] See also Figure 1-Figure 4 An embodiment of the present invention provides an EPS controller and motor integrated power group structure, including a motor 6, an EPS controller and a housing 1; the EPS controller includes a PCB3 electrically connected to the PIN female terminal of the motor 6 and electronic components arranged on the PCB3, the PCB3 is assembled on the mounting seat 5, and the PCB3 is correspondingly welded with a connector 2; the mounting seat 5 is fixed to the motor 6; the housing 1 is installed on the mounting seat 5 and is covered outside the PCB3; the connector 2 extends out of the housing 1 through a through hole of the housing 1; the housing 1, the PCB3 and the mounting seat 5 are located in the axial direction of the motor 6.

[0049] It can be understood that the housing 1 is disposed outside the PCB 3, and correspondingly, the housing 1 is also disposed outside the EPS controller, so that the motor 6 and the EPS controller are integrated into one.

[0050] The EPS controller and motor integrated power group structure provided in this embodiment integrates the motor 6 and the EPS controller into one, thereby reducing the assembly space required for assembling the two and being able to adapt to a relatively narrow installation space.

[0051] In some embodiments of the present invention, the above-mentioned EPS controller and motor integrated power group structure further includes a support frame 4. According to the function, the PCB 3 includes a control board 31 and a power board 32, and the control board 31, the power board 32 and the mounting seat 5 are stacked in sequence, that is, the control board 31, the power board 32 and the mounting seat 5 are all in the axial direction of the motor 6 (it should be noted here that, specifically in normal use, the control board 31 is located at the top layer, the power board 32 is located in the middle, the mounting seat 5 is located at the bottom, and the mounting seat 5 is above the motor 6, the upper surface of the control board 31 is closer to the connector 2 than the lower surface of the control board 31, the lower surface of the control board 31 is placed opposite to the upper surface of the power board 32, and the lower surface of the power board 32 is closer to the mounting seat 5 than the upper surface of the power board 32). The control board 31 and the power board 32 are electrically connected to the corresponding connectors 2, and the lower surface of the control board 31 is fixedly connected to the first end surface of the support frame 4; the upper surface of the power board 32 is fixedly connected to the second end surface of the support frame 4 and electrically connected to the PIN female terminal of the motor 6.

[0052] In some embodiments of the present invention, Figure 3 As shown, the end of the control board 31 and the end of the power board 32 are interconnected to form a "U" shape, and the control board 31 and the power board 32 are an integrated structure, and the bending part at the connection between the control board 31 and the power board 32 is made by a Semi-flex process.

[0053] In other embodiments of the present invention, Figure 4 As shown, the end of the control board 31 and the end of the power board 32 are connected to each other and form a "U" shape. The control board 31 and the power board 32 are separated from each other, and the control board 31 and the power board 32 are connected to each other through the pin header 33. Figure 3 and Figure 4 As shown, the end of the control board 31 and the end of the power board 32 refer to the corresponding parts of the “U”-shaped bottom control board 31 and the power board 32 .

[0054] In the technical solution provided in this embodiment, PCB3 can not only realize an integrated "U"-shaped structure through Semi-flex technology, but also connect the upper and lower PCB boards (i.e., control board 31 and power board 32) through pin headers 33. Both of these design schemes perfectly combine the PCB and other structural parts of the EPS controller (such as support frame 4, housing 1), making the overall height of the EPS controller smaller.

[0055] In a specific implementation, the support frame 4 is a frame-like structure with a certain space in the middle to accommodate the electronic components on the PCB 3, that is, a frame-like structure to accommodate the electronic components located on the lower surface of the control board 31 and the electronic components located on the upper surface of the power board 32.

[0056] In other embodiments of the present invention, the control board 31 and the power board 32 may also be supported by support columns, so that a columnar structure for accommodating electronic components is formed between the control board 31 and the power board 32. In practical applications, any structure that can achieve support and connection can be used as the connection structure between the control board 31 and the power board 32.

[0057] In addition, in some embodiments, the power board 32 and the control board 31 may also be placed opposite to each other parallel to the axial direction of the motor 6. In this case, the support frame 4 is directly connected to the mounting seat 5 to fix the support frame 4 and the PCB 3 to the mounting seat 5. In other embodiments, the electronic components on the power board 32 and the electronic components on the control board 31 may also be integrated on a PCB 3, that is, the power board 32 and the control board 31 are integrated on a PCB.

[0058] Specifically, in the above-mentioned EPS controller and motor integrated power group structure, the connector 2 is used to electrically connect with the corresponding part in the corresponding PCB 3. Among them, in some embodiments of the present invention, the connector 2 includes a power connector, a signal connector and a TAS connector (TAS: Torque Angle Sensor, TAS connector is a torque angle connector); the signal connector and the TAS connector are welded to the control board 31; the power connector is welded to the power board 32. In actual applications, the number of PIN pins of the power connector, the signal connector and the TAS connector is determined according to actual needs. For example, in a specific application, the number of PIN pins of the power connector is 2, the number of PIN pins of the signal connector is 3, and the number of PIN pins of the TAS connector is 12. This embodiment does not limit the number of PIN pins of the three. The connector 2 can be prepared by insert injection molding, and the material that can be used is PBT-GF30 (PBT: polybutylene terephthalat; PBT-GF30 is an engineering plastic with 30% glass fiber added to PBT).

[0059] It should be noted that the connection between the signal connector and the TAS connector and the control board 31 may be other connection methods besides welding, such as welding, riveting, etc., and the preferred connection method of the present invention is welding. The connection between the power connector and the power board 32 may be other connection methods besides welding, such as welding, riveting, etc., and the preferred connection method of the present invention is welding.

[0060] There is also a breathable membrane structure inside the connector 2. If there is a pressure difference during normal use, the breathable membrane structure is used to balance the internal and external pressure difference between the EPS controller and the motor-integrated power group structure during use.

[0061] The housing 1 can also be prepared by injection molding, and the material that can be used is PBT-GF30. The housing 1 is sealed with the connector 2 and the mounting seat 5 respectively, so as to achieve the requirements of a specific waterproof level, such as IP6K9K.

[0062] In the above-mentioned EPS controller and motor integrated power group structure, the mounting seat 5 is a cast mounting seat 5, which can not only realize the interconnection between the EPS controller and the motor 6, but also promote the heat dissipation of the high-power device of the power board 32 in the PCB 3 of the EPS controller. The material of the mounting seat 5 can be selected from ADC12 (ADC: Aluminum-Alloy Die Castings, a Japanese aluminum alloy grade, also known as No. 12 aluminum material, Al-Si-Cu alloy, a die-cast aluminum alloy, suitable for cylinder head cover, sensor bracket, cover, cylinder body, etc., and the implementation standard is: JIS H 5302-2000 "Aluminum Alloy Die Castings".), of course, the mounting seat 5 can also be made of other materials, which is not limited in this embodiment. Furthermore, in order to improve the heat dissipation performance of the EPS controller and the motor 6, a gap is set between the mounting base 5 and the lower surface of the power board 32, and the gap is filled with thermal conductive adhesive. The heat generated by the electronic components on the power board 32 is transferred to the mounting base 5 through the thermal conductive adhesive, and the mounting base 5 transfers the heat outward through the motor 6 and other steering structures. At the same time, the heat of the motor 6 is also transferred outward through other steering structures to accelerate the heat dissipation process of the EPS controller and the motor integrated power group structure.

[0063] The support frame 4 can be an injection-molded frame, and the material PBT-GF30 can be selected. The support frame 4 is used as a skeleton structure to support and connect the control board 31 and the power board 32 of the PCB 3. The structure of the support frame 4 is suitable for the above two PCB design solutions.

[0064] Motor 6 can be determined by comprehensively considering factors such as performance and cost. For example, a permanent magnet synchronous three-phase motor can be used. The rated torque and rated power of the motor can be determined according to actual application requirements. For example, in a specific implementation, a motor with a rated torque greater than 6Nm and a rated power greater than 800W can be used.

[0065] Optionally, in the above-mentioned EPS controller and motor integrated power group structure, a sealing ring 7 is provided between the mounting seat 5 and the motor 6; the motor 6 is provided with a mounting groove, and the sealing ring 7 is arranged in the mounting groove. The sealing ring 7 can be an "O" type sealing ring.

[0066] The above-mentioned mounting seat 5 can be fixed to the motor 6 through the fixing member 10, wherein the fixing member 10 between the mounting seat 5 and the motor 6 can be selected according to actual needs. For example, in some embodiments of the present invention, the fixing member 10 uses an M5 bolt, the length of the bolt is 18 mm, and the number of bolts is determined according to actual needs; the PCB3 is fixed to the support frame 4 through the fixing member 8, wherein the fixing member 8 between the PCB3 and the support frame 4 can be selected according to actual needs. For example, in some embodiments of the present invention, the fixing member 8 uses an M2.5 self-tapping screw, and the length of the self-tapping screw is 8 mm, and the number of self-tapping screws is determined according to actual needs; the support frame 4 is fixed to the mounting seat 5 through the fixing member 9, wherein the fixing member 9 between the support frame 4 and the mounting seat 5 can be selected according to actual needs. For example, in some embodiments of the present invention, the fixing member 9 uses an M3 self-tapping screw, and the length of the self-tapping screw is 10 mm, and the number of self-tapping screws is determined according to actual needs.

[0067] In order to improve the sealing of the connection process between the housing 1 and the mounting seat 5 and the connector 2. The connector 2 is provided with an annular connector U-shaped groove, and the housing 1 is provided with a first protrusion at the position opposite to the annular connector U-shaped groove; and / or the mounting seat 5 is provided with an annular mounting seat U-shaped groove, and the housing 1 is provided with a second protrusion at the position opposite to the annular mounting seat U-shaped groove. Before the housing 1 is assembled to the mounting seat 5, sealant is applied to the annular connector U-shaped groove and the annular mounting seat U-shaped groove. When the housing 1 is assembled to the mounting seat 5, the first protrusion is docked with the annular connector U-shaped groove, and the second protrusion is docked with the annular mounting seat U-shaped groove. It can be understood that the first protrusion matches the shape and size of the annular connector U-shaped groove, and the second protrusion matches the shape and size of the annular mounting seat U-shaped groove. The annular connector U-shaped groove is located at the periphery of the connector, and matches the shape of the periphery of the connector 2 and the shape of the through hole of the housing 1. The annular mounting seat U-shaped groove is located at the edge of the mounting seat 5, and matches the shape of the corresponding mounting part of the housing 1.

[0068] Since the sealant is applied between the first protrusion and the U-shaped groove of the annular connector, the sealing between the housing and the connector is improved, and since the sealant is applied between the second protrusion and the U-shaped groove of the annular mounting seat, the sealing between the housing 1 and the mounting seat 5 is improved. It can be seen that the EPS controller and the motor integrated power group structure ensures the sealing through the sealing ring and the sealant.

[0069] The EPS controller and motor integrated power group structure provided in this embodiment mainly realizes functions such as sensor signal conditioning, MCU minimum system, motor drive, etc. In addition, in order to meet the normal operation of the hardware system and the reliability requirements of the system, this EPS controller and motor integrated power group structure also needs to include a basic power processing module, a communication module, a Failsafe module, etc.

[0070] In the EPS controller and motor integrated power group structure, PCB3 includes a control board 31 and a power board 32. The control board 31 includes: a power processing module, an MCU (Microcontroller Unit) minimum system, a torque sensor power supply module, a torque sensor conditioning circuit module, a temperature sensor module and a CAN communication module; the power board 32 includes: a motor drive module and a motor current sampling module. The functions of the above modules are introduced below:

[0071] The function of the power processing module is to provide a stable and reliable voltage for the system. The power processing module reduces the battery voltage to the voltage required by the logic chip, sensor, other power-consuming devices and chips, such as 5V, 3.3V, etc. The power processing module is also required to be able to filter out interference signals on the power line and reduce the system's external transmission interference through the power line.

[0072] The torque sensor power supply module is responsible for providing power to the external torque sensor, meeting the power supply requirements of the external torque sensor, and can not be damaged when a short circuit to the power supply or a short circuit to the ground occurs. The main function of the torque sensor conditioning circuit module is to transmit the torque signal to the MCU after filtering. This function refers to the existing mature technology.

[0073] The MCU minimum system includes the MCU responsible for the EPS control algorithm, as well as the clock and reset circuits required for the MCU to operate.

[0074] The CAN communication module is mainly used to obtain engine speed and vehicle speed signals in a vehicle with a CAN network, and realizes the functions of data calibration and program download. It also has the function of waking up the ECU (ECU: Electronic Control Unit). This function refers to the existing mature technology.

[0075] The motor drive module is used to drive the motor 6 to work. The motor 6 is required to be able to control the forward and reverse rotation and the current value of the motor 6, so a 3-phase bridge drive is used to achieve this. The switching frequency of the control signal is determined according to actual needs, and the 6 power tubes of the 3-phase bridge can be controlled separately. The motor current sampling module is used to detect the working current of the motor and realize the closed-loop control of the motor current to meet the output torque requirements calculated by the algorithm. This control technology refers to the existing mature technology.

[0076] The temperature sensor module is used to collect the temperature of power devices and PCB in electronic components. When the temperature exceeds a certain range, the program will limit the torque output of the EPS system. When the temperature reaches the maximum value that the power device can withstand, the program will directly shut down the system output. This technology refers to the existing mature technology.

[0077] The integrated EPS controller and motor integrated power group structural components provided in this embodiment can save space size well while realizing the electric power steering control function. In a specific implementation, this structure can be connected to the steering gear through a claw at the bottom of the motor 6, and the overall height is relatively small. Among the two PCB3 provided in this embodiment, the scheme in which the control board 31 and the power board 32 are connected as one can reduce the connectors (such as the pin header 33) between the boards, making the manufacturing process simpler while greatly improving the reliability and EMC (EMC: Electro Magnetic Compatibility, electromagnetic compatibility, refers to the comprehensive evaluation of the interference size (EMI) and anti-interference ability (EMS) of electronic products in the electromagnetic field. It is one of the most important indicators of product quality. The measurement of electromagnetic compatibility consists of a test site and a test instrument. The purpose of EMC testing is to detect the impact of electromagnetic radiation generated by electrical products on the human body, the public power grid and other electrical products that work normally.) performance.

[0078] The EPS controller and motor integrated power group structure provided in this embodiment has fewer components and lower complexity, which not only simplifies assembly but also significantly reduces manufacturing costs. At the same time, the mounting base 5 can be used to dissipate heat over a large area of ​​high-heat electronic components on the power board 32, resulting in a better heat dissipation effect. In addition, the control board 31 and the power board 32 of PCB3 are separated by the support frame 4, which can prevent the heat on the power board 32 from being transferred to the control board 31, greatly improving the stability of the controller system working at high temperatures. The overall design of the EPS controller and motor integrated power group structure is more compact, and a greater power drive can be achieved in a smaller space, which is more conducive to the overall layout of the EPS.

[0079] The embodiment of the present invention further provides an assembly method of an EPS controller and a motor integrated power group structure, wherein the EPS controller and the motor integrated power group structure comprises a motor 6, an EPS controller and a housing 1; the EPS controller comprises a PCB 3 electrically connected to a PIN female terminal of the motor 6 and electronic components arranged on the PCB 3, the PCB 3 is assembled on a mounting seat 5, and a connector 2 is correspondingly welded to the PCB 3; the mounting seat 5 is fixed to the motor 6; the housing 1 is mounted on the mounting seat 5 and is covered outside the PCB 3; the connector 2 extends out of the housing 1 through a through hole of the housing 1; the assembly method comprises:

[0080] 1) Prepare an EPS controller, assemble the PCB 3 with electronic components mounted on the mounting seat 5, and then assemble the housing 1 on the mounting seat 5;

[0081] 2) Install the mounting base 5 on the motor 6 so that the housing 1 , the PCB 3 and the mounting base 5 are located in the axial direction of the motor 6 .

[0082] Specifically, the above step 1) includes:

[0083] 11) Flatten the integrated "U"-shaped PCB3, solder some electronic components of the control board 31 to the upper surface of the control board 31 by reflow soldering, solder some electronic components of the power board 32 to the lower surface of the power board 32, and then crimp the motor PIN female terminal to the upper surface of the power board 32 according to the feasibility of the structural design and process; wherein, the bent portion at the connection between the control board and the power board 32 is made by the Semi-flex process.

[0084] 12) Flip the flattened PCB3 180 degrees, solder the remaining electronic components of the control board 31 to the lower surface of the control board 31 by reflow soldering, solder the remaining electronic components of the power board 32 to the upper surface of the power board 32, assemble the connector to the control board (for example, assemble it to the control board 31 by 4 M2.5 self-tapping screws), so that the PIN pins of the signal connector and the PIN pins of the TAS connector pass through the control board; then solder the PIN pins of the signal connector and the PIN pins of the TAS connector to the lower surface of the control board 31 by selective welding, and solder the PIN female terminal of the motor to the upper surface of the power board 32.

[0085] 13) Connect the lower surface of the control board 31 and the first end surface of the support frame 4 through a fixing (such as an M2.5 self-tapping screw), then bend the PCB 3 into a U-shape, let the PIN pin of the power connector 2 pass through the power board 32, and connect the upper surface of the power board 32 and the second end surface of the support frame 4 through a fixing (such as an M2.5 self-tapping screw); then weld the PIN pin of the power connector 2 to the lower surface of the power board 32 by selective welding. It can be understood that a avoidance structure is provided at the corresponding position of the control board 31 to provide an avoidance space for the PIN pin of the power connector, and the PIN pin of the power connector does not need to pass through the control board. In order to avoid better, or to achieve avoidance when the avoidance structure of the control board is small, the PIN pin of the power connector can adopt a bending structure. Based on this, when the PCB is bent into a U-shape, the PIN pin of the power connector passes through the power board 32, and then the PIN pin of the power connector is welded to the lower surface of the power board 32 by selective welding to achieve the connection between the PIN pin of the power connector and the power board 32.

[0086] 14) Use fixings (such as M3 self-tapping screws) to connect the support frame 4, the power board 32 and the mounting seat 5, then apply sealant to the U-shaped groove of the annular connector and the U-shaped groove of the annular mounting seat, and then assemble the housing 1 onto the mounting seat 5.

[0087] Alternatively, step 1) comprises:

[0088] 11) Solder some electronic components of the control board 31 and the PIN pins on the upper side of the pin row 33 to the upper surface of the control board 31 by reflow soldering, and solder the remaining electronic components of the control board 31 to the lower surface of the control board 31 by reflow soldering; assemble the connector to the control board so that the PIN pins of the signal connector and the PIN pins of the TAS connector pass through the control board, and solder the PIN pins of the signal connector 2 and the PIN pins of the TAS connector 2 to the lower surface of the control board 31 by selective soldering; connect the lower surface of the control board 31 and the first end surface of the support frame 4 by a fixing member (such as an M2.5 self-tapping screw);

[0089] 12) Solder some electronic components of the power board 32 to the upper surface of the power board 32 by reflow soldering, crimp the PIN female terminal of the motor to the upper surface of the power board 32 and then solder; Solder the remaining electronic components of the power board 32 to the lower surface of the power board 32 by reflow soldering, and then connect the upper surface of the power board 32 and the second end surface of the support frame 4 by a fixing member, so that the lower PIN pins of the pin row are located on the lower surface of the power board 32, the PIN pins of the power connector pass through the power board 32, and the lower PIN pins of the pin row are soldered to the lower surface of the power board 32, and the PIN pins of the power connector are soldered to the lower surface of the power board 32 by selective soldering;

[0090] 13) Connect the support frame 4, the power board 32 and the mounting seat 5 through fixings (such as M3 self-tapping screws), then apply sealant to the U-shaped groove of the annular connector and the U-shaped groove of the annular mounting seat, and then assemble the housing 1 on the mounting seat 5.

[0091] The above step 2) includes:

[0092] 21) Assemble the sealing ring 7 into the mounting groove on the top of the motor 6;

[0093] 22) Fit the two positioning pins onto the motor 6 by interference fit;

[0094] 23) Assemble the mounting base 5 onto the assembled motor 6 through two positioning pins;

[0095] 24) Use fixing parts (such as 3 M5 bolts) to connect and fasten the mounting base 5 and the motor 6; wherein, the 3 bolt holes of the mounting base 5 are designed as through holes, the 3 bolt holes of the motor 6 are tapped, and the bottom of the M5 bolts are coated with anti-loosening glue to prevent loosening; a clearance fit is usually adopted between the motor 6 and the mounting base 5.

[0096] The embodiment of the present invention also provides an EPS system, including an EPS controller and an integrated motor power group structure, wherein the EPS controller and the integrated motor power group structure are the EPS controller and the integrated motor power group structure provided in the above embodiment. Since the above EPS controller and the integrated motor power group structure have the above beneficial effects, the EPS system including the EPS controller and the integrated motor power group structure has corresponding effects, which need not be elaborated here.

[0097] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0098] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An EPS controller and motor integrated power group structure, characterized in that: include: Motor; An EPS controller, the EPS controller comprising a PCB electrically connected to the PIN female terminal of the motor and electronic components arranged on the PCB, the PCB being assembled on a mounting seat, and a connector being welded to the PCB, and a breathable membrane structure being provided inside the connector; the mounting seat being fixed to the motor; A housing, the housing being mounted on the mounting seat and covering the outside of the PCB; The connector extends out of the housing through a through hole of the housing; wherein the housing, the PCB and the mounting seat are located in the axial direction of the motor; A support frame, the PCB includes a control board and a power board, the control board, the power board and the mounting seat are stacked in sequence; the control board and the power board are electrically connected to the connector, and the lower surface of the control board is fixedly connected to the first end face of the support frame, the upper surface of the power board is fixedly connected to the second end face of the support frame, and is electrically connected to the PIN female terminal of the motor; the support frame, the power board and the mounting seat are fixedly connected.

2. The EPS controller and motor integrated power pack structure according to claim 1 is characterized in that: The end of the control board and the end of the power board are connected to each other and form a "U" shape; The control board and the power board are an integrated structure, and the bending part at the connection between the control board and the power board is made by a semi-flex process; or, the control board and the power board are separated from each other, and the control board and the power board are connected to each other through a pin header.

3. The EPS controller and motor integrated power pack structure according to claim 2 is characterized in that: The connector includes a power connector, a signal connector and a TAS connector; the signal connector and the TAS connector are welded to the control board; and the power connector is welded to the power board.

4. The EPS controller and motor integrated power pack structure according to claim 2 is characterized in that: A gap is provided between the mounting seat and the lower surface of the power board, and the gap is filled with thermal conductive adhesive.

5. The EPS controller and motor integrated power pack structure according to claim 1 is characterized in that: A sealing ring is provided between the mounting seat and the motor; The motor is provided with a mounting groove, and the sealing ring is arranged in the mounting groove.

6. The EPS controller and motor integrated power pack structure according to claim 1, characterized in that: The connector is provided with an annular connector U-shaped groove, and the position of the shell opposite to the annular connector U-shaped groove is provided with a first protrusion; and / or the mounting seat is provided with an annular mounting seat U-shaped groove, and the position of the shell opposite to the annular mounting seat U-shaped groove is provided with a second protrusion.

7. A method for assembling an EPS controller and a motor integrated power group structure, characterized in that: The EPS controller and motor integrated power group structure comprises a motor, an EPS controller and a housing, wherein the EPS controller comprises a PCB electrically connected to the PIN female terminal of the motor and electronic components arranged on the PCB, the PCB is assembled on a mounting seat, and a connector is welded corresponding to the PCB; the mounting seat is fixed to the motor; the housing is mounted on the mounting seat and covered outside the PCB; the connector extends out of the housing through a through hole of the housing; the EPS controller and motor integrated power group structure also comprises a support frame; the assembly method comprises: 1) preparing the EPS controller, assembling the PCB with electronic components installed on the mounting seat, and then assembling the housing on the mounting seat, the PCB is installed on a support frame, the support frame is fixed to the mounting seat, the PCB includes a control board and a power board, the control board, the power board and the mounting seat are stacked in sequence; the control board and the power board are electrically connected to the connector, and the lower surface of the control board is fixedly connected to the first end surface of the supporting frame, and the upper surface of the power board is fixedly connected to the second end surface of the supporting frame; 2) Install the mounting base on the motor so that the housing, the PCB and the mounting base are located in the axial direction of the motor, and the power board is electrically connected to the PIN female terminal of the motor.

8. The assembly method according to claim 7, characterized in that: The connector includes a power connector, a signal connector and a TAS connector; the signal connector and the TAS connector are welded to the control board; the power connector is welded to the power board; the connector is provided with an annular connector U-shaped groove, and the housing is provided with a first protrusion at a position opposite to the annular connector U-shaped groove; the mounting seat is provided with an annular mounting seat U-shaped groove, and the housing is provided with a second protrusion at a position opposite to the annular mounting seat U-shaped groove, and the step 1) includes: 11) Flatten the "U"-shaped PCBs connected as one, solder some electronic components of the control board to the upper surface of the control board by reflow soldering, solder some electronic components of the power board to the lower surface of the power board, and then crimp the PIN female terminals of the motor to the upper surface of the power board; wherein the bending part at the connection between the control board and the power board is made by the Semi-flex process; 12) Flip the flattened PCB 180 degrees, solder the remaining electronic components of the control board to the lower surface of the control board by reflow soldering, solder the remaining electronic components of the power board to the upper surface of the power board, assemble the connector to the control board so that the PIN pins of the signal connector and the PIN pins of the TAS connector pass through the control board; then solder the PIN pins of the signal connector and the PIN pins of the TAS connector to the lower surface of the control board by selective soldering, and solder the PIN female terminal of the motor to the upper surface of the power board; 13) Connect the lower surface of the control board and the first end surface of the support frame through a fixing member, then bend the PCB into a U-shape, pass the PIN pins of the power connector through the power board, and connect the upper surface of the power board and the second end surface of the support frame through the fixing member; then weld the PIN pins of the power connector to the lower surface of the power board by selective welding; 14) Use the fixings to connect the support frame, power board and mounting seat, then apply sealant to the U-shaped groove of the annular connector and the U-shaped groove of the annular mounting seat, and then assemble the housing to the mounting seat; Alternatively, the step 1) comprises: 11) Soldering some electronic components of the control board and the upper PIN pins of the pin row to the upper surface of the control board by reflow soldering, and soldering the remaining electronic components of the control board to the lower surface of the control board by reflow soldering; assembling the connector to the control board so that the PIN pins of the signal connector and the PIN pins of the TAS connector pass through the control board, and soldering the PIN pins of the signal connector and the PIN pins of the TAS connector to the lower surface of the control board by selective soldering; connecting the lower surface of the control board and the first end surface of the support frame by a fixing member; 12) Soldering some electronic components of the power board to the upper surface of the power board by reflow soldering, crimping the PIN female terminal of the motor to the upper surface of the power board and then soldering; Soldering the remaining electronic components of the power board to the lower surface of the power board by reflow soldering, and then connecting the upper surface of the power board and the second end surface of the support frame by a fixing member, so that the lower PIN pins of the pin row are located on the lower surface of the power board, the PIN pins of the power connector pass through the power board, and the lower PIN pins of the pin row are welded to the lower surface of the power board, and the PIN pins of the power connector are welded to the lower surface of the power board by selective welding; 13) Connect the support frame, power board and mounting base through the fixing parts, then apply sealant to the U-shaped groove of the annular connector and the U-shaped groove of the annular mounting base, and then assemble the housing to the mounting base.

9. The assembly method according to claim 7, characterized in that: The step 2) comprises: 21) Install the sealing ring into the mounting groove on the top of the motor; 22) Fit the two positioning pins onto the motor with interference fit; 23) Assemble the mounting base to the assembled motor using two locating pins; 24) Use fixings to connect and tighten the mounting base and the motor.

10. An EPS system, characterized in that: It comprises an EPS controller and a motor integrated power group structure, wherein the EPS controller and the motor integrated power group structure is the EPS controller and the motor integrated power group structure as described in any one of claims 1-6.

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