Air compressor controller and assembly method of air compressor controller

Abstract

The application provides an air compressor controller and an assembling method of the air compressor controller. The air compressor controller comprises a box body which is a closed box body formed by an upper cover plate, a lower cover plate and a box body welding assembly. A circuit board assembly is arranged in the box body. The circuit board assembly comprises a control board assembly, a driving board assembly and a filter assembly which are electrically connected with each other. The control board assembly comprises a control board PCB and a control signal adapter plate PCB. The driving board assembly comprises a driving board PCB. The driving board PCB is integrated with an air compressor power module (SIC) and a hydrogen pump power module (IGBT). The power module of the hydrogen pump, the power module of the air compressor and the driving module are integrated on one PCB board, high-voltage power modules and power driving modules are designed on one board, space is fully utilized, the number of circuit boards and the difficulty of line connection are reduced, the types of materials are reduced, the assembling reliability is improved, and the assembling difficulty is reduced.

Description

Technical Field

[0001] This application relates to the field of fuel cell technology, specifically to an air compressor controller and an assembly method for the air compressor controller. Background Technology

[0002] With increasing environmental pollution and dwindling petroleum resources, the hydrogen energy industry has received widespread development and attention. In recent years, the hydrogen fuel cell industry has experienced rapid growth, with an increasing variety of fuel cell systems. Power density, cost, ease of use, and reliability are key factors determining the market competitiveness of fuel cell systems. Fuel cell systems have numerous components and complex structures. Currently, components are becoming increasingly mature and stable, and highly integrated design is the main direction of technological development.

[0003] The basic principle of a fuel cell is the electrochemical reaction between oxygen in the air at the cathode and hydrogen at the anode. Therefore, a fuel cell system requires the coordinated operation of four systems: a hydrogen supply system, an air supply system, a cooling system, and the fuel cell itself. An air compressor and a hydrogen pump are essential components. The air compressor (ACP) is a device that compresses gases and has broad applications in industrial production. In the fuel cell air supply system, the air compressor draws in air, compresses it, and then supplies it to the fuel cell system. The hydrogen pump (HRB) is a hydrogen recirculation pump whose main function is to recycle the hydrogen remaining from the reaction, improving hydrogen utilization efficiency.

[0004] In existing technologies, the air compressor controller and hydrogen pump controller of fuel cells are designed independently. Heat dissipation devices need to be designed separately for the power devices of the hydrogen pump and the power devices of the air compressor. This makes the layout difficult and wastes resources. Therefore, there is an urgent need for a highly integrated two-in-one controller. Summary of the Invention

[0005] To address the inconvenience of installation and layout caused by the independent control of air compressors and hydrogen pumps in existing technologies, this application integrates the power module of the hydrogen pump with the power module and drive module of the air compressor on a single PCB board, thereby making reasonable use of space and achieving simplified assembly.

[0006] This application provides an air compressor controller, including a housing. The housing is a closed housing formed by an upper cover plate, a lower cover plate, and a frame-shaped housing welded assembly. A circuit board assembly is disposed within the housing. The circuit board assembly includes a control board assembly and a drive board assembly. The control board assembly includes a control board PCB, and the drive board assembly includes a drive board PCB. The control board PCB and the drive board PCB are electrically connected. The drive board PCB integrates an air compressor power module and a hydrogen pump power module. The housing also has air compressor power distribution terminals and hydrogen pump power distribution terminals, and the drive board PCB is connected to both the air compressor power distribution terminals and the hydrogen pump power distribution terminals. This air compressor controller integrates a hydrogen pump power module (IGBT) and an air compressor power module (SiC) on the drive board PCB. Through a shared-board design of the high-voltage power module and the power drive module, the height of the product is significantly reduced (<80mm), achieving efficient space utilization. Furthermore, since both the air compressor power module and the hydrogen pump power module are located on the air compressor drive board, they can share a common heat dissipation system, effectively reducing the types and quantities of materials and lowering production costs. Simultaneously, the control board PCB is connected to the drive board PCB, and the drive board PCB is connected to the hydrogen pump power distribution terminals and the air compressor power distribution terminals, simplifying cable connections and minimizing the risk of vibration and electromagnetic interference.

[0007] Preferably, a mounting plate is provided inside the enclosure welding assembly. The mounting plate is integrally formed with the enclosure welding assembly. The mounting plate divides the space inside the enclosure into an upper cavity above the mounting plate and a lower cavity below the mounting plate. The control board assembly is disposed in the upper cavity, and the drive board assembly is disposed in the lower cavity. By providing a mounting plate inside the enclosure, dividing the space into an upper cavity and a lower cavity, and with the control board assembly and drive board respectively disposed in the upper and lower cavities, high and low voltage separation can be achieved, improving electrical safety performance.

[0008] Preferably, the mounting plate is provided with a mounting portion, and the circuit board assembly is fixedly connected to the mounting plate through the mounting portion. Thermal grease is applied to the mounting portion. The drive board assembly or control board assembly is mounted on the mounting plate through the mounting portion. Thermal grease is applied at least at the mounting position (mounting portion) between the drive board assembly or control board assembly and the mounting plate to transfer the heat generated by the circuit board as much as possible, avoid overheating damage, and improve the safety performance of the product.

[0009] Preferably, the enclosure contains water channels suspended within it, with at least a portion of the water channels in contact with the mounting plate. This suspension maximizes the contact area between the water channels and the internal space, effectively dissipating heat from the power module and lowering the overall temperature of the enclosure. This prevents overheating damage to other electronic components, maximizing product safety. Since the power module is mounted on the mounting plate, which is relatively hot, the water channels' partial contact with the plate allows for efficient heat transfer, reducing the plate's temperature and facilitating heat conduction from the power module towards the mounting plate, thus improving heat dissipation efficiency. Preferably, the mounting plate has a recessed design forming a water storage cavity. The water channels also include baffles that cover the water storage cavity and are welded to the mounting plate to form the water channels. Water channels are formed by welding water channel baffles to the housing welding components. In other words, the mounting plate on the housing welding components is welded to the water channel baffles to form water channels. Since the mounting plate is directly part of the water channels, the heat dissipation efficiency can be maximized.

[0010] Preferably, the water channel baffle is provided with fins that extend into the water storage cavity. This application provides fins on the water channel baffle, and the fins extend into the water storage cavity. The fins increase the contact area between the water source in the water storage cavity and the water channel baffle, thereby improving heat dissipation efficiency.

[0011] Preferably, the welded assembly of the housing has a water inlet and a water outlet at both ends, with the air compressor power terminal and the hydrogen pump power terminal located between the water inlet and the water outlet. By providing a water inlet and a water outlet at both ends of the welded assembly, the water channel spans across both ends of the housing, maximizing its length and improving heat dissipation. Furthermore, placing the air compressor power terminal and the hydrogen pump power terminal between the inlet and outlet fully utilizes space and avoids wasting it.

[0012] Preferably, the circuit board assembly further includes a filtering component, which comprises a two-stage EMC filter at the input end and an amorphous magnetic ring filter at the output end. By providing a two-stage EMC filter at the input end and an amorphous magnetic ring filter at the output end, the electromagnetic compatibility (EMC) immunity of the product can be effectively improved.

[0013] Preferably, the two-stage EMC filtering component adopts a CLCLC filtering scheme. Using a CLCLC filtering scheme can significantly reduce electromagnetic interference, enabling the product to meet EMC requirements.

[0014] Preferably, the amorphous magnetic ring filter assembly includes an air compressor output magnetic ring and a hydrogen pump output magnetic ring.

[0015] Preferably, an upper sealing ring is provided between the upper cover plate and the housing welding assembly, and a lower sealing ring is provided between the lower cover plate and the housing welding assembly. By providing sealing rings between the housing welding assembly and the upper and lower cover plates, the upper and lower cavities can be fully sealed, preventing moisture and impurities from entering the housing through the gaps between the upper and lower cover plates and the housing welding assembly, thus avoiding electrical safety issues and further improving product reliability.

[0016] This application also provides an assembly method for an air compressor controller. The air compressor controller includes a housing, which is formed by an upper cover plate, a lower cover plate, and a housing welding assembly. A control board assembly and a drive board PCB are disposed inside the housing. The drive board PCB integrates an air compressor power module and a hydrogen pump power module. The housing is provided with air compressor power distribution terminals and hydrogen pump power distribution terminals. The assembly method includes: first, welding the air compressor power module and the hydrogen pump power module onto the drive board PCB; then, fixing the welded drive board PCB onto the housing welding assembly; and subsequently, connecting the air compressor power distribution terminals and the hydrogen pump power distribution terminals to the drive board PCB wiring harness. Since the drive board PCB of this application integrates the air compressor power module and the hydrogen pump power module, its overall volume is relatively large. If the drive board PCB is connected to the air compressor power distribution terminals and the hydrogen pump power distribution terminals wiring harness first, the wiring harness will restrict the movement and adjustment of the drive board PCB, and the connection is prone to loosening during adjustment. This application allows for free adjustment of the installation position by first installing the driver board PCB and then connecting the wiring harness, thus avoiding loosening of the connection due to wire harness rubbing.

[0017] Preferably, the housing welding assembly is further provided with a mounting plate, which divides the housing welding assembly into an upper cavity and a lower cavity. The control board assembly includes a control board PCB and a control signal adapter board PCB. The assembly method includes: installing the welded drive board PCB into the lower cavity, then flipping the housing, installing the control board PCB and the control signal adapter board PCB into the upper cavity, and then electrically connecting the control board PCB to the drive board PCB and the control signal adapter board PCB respectively.

[0018] Compared with existing technologies, this application has at least the following technical advantages: The air compressor controller of this application integrates a hydrogen pump power module (IGBT) and an air compressor power module (SiC) on the drive board PCB. Through a shared-board design of the high-voltage power module and the power drive module, the product height is significantly reduced (<90mm), achieving efficient space utilization. Furthermore, since both the air compressor power module and the hydrogen pump power module are located on the air compressor drive board, they can share a common heat dissipation system, effectively reducing the types and quantities of materials and lowering production costs. Simultaneously, the control board PCB is connected to the drive board PCB, and the drive board PCB is connected to the hydrogen pump power distribution terminals and the air compressor power distribution terminals, simplifying cable connections and minimizing vibration and electromagnetic interference. Attached Figure Description

[0019] Figure 1 This is an exploded view of the air compressor controller of this application.

[0020] Figure 2 This is a perspective view of the air compressor controller of this application.

[0021] Figure 3 This is a perspective view of the air compressor controller of this application from another angle.

[0022] Figure 4 This is a side view of the air compressor controller of this application.

[0023] Figure 5 This is a top view of the air compressor controller of this application.

[0024] Figure 6 This is a cross-sectional view of the air compressor controller of this application.

[0025] Figure 7 This is a bottom view of the air compressor controller of this application.

[0026] Figure 8 This is a schematic diagram of the drive board of the air compressor controller of this application.

[0027] The components shown in the diagram are as follows: 1. Upper cover plate; 2. Lower cover plate; 3. Housing welding assembly; 31. Mounting plate; 32. Water channel; 321. Partition plate; 322. Fin; 33. Mounting base; 34. Water channel inlet; 35. Water channel outlet; 36. Hydrogen pump power distribution terminal; 37. Air compressor power distribution terminal; 4. Control signal adapter board PCB; 5. Control board PCB; 6. EMC two-stage filter assembly; 7. Drive board PCB; 71. Air compressor power module; 72. Hydrogen pump power module; 8. Hydrogen pump output magnetic ring; 9. Air compressor output magnetic ring. Detailed Implementation

[0028] To more clearly illustrate the overall concept of this application, a detailed explanation is provided below with reference to the accompanying drawings.

[0029] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0030] Furthermore, it should be understood that in the description of this application, terms such as "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential," indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Positional relationships such as "upstream" and "downstream" are based on the positional relationships during normal fluid flow.

[0031] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0032] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0033] In this application, unless otherwise expressly specified and limited, the "above" or "below" of the second feature can mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples.

[0034] like Figure 1-8 As shown, this application provides an air compressor controller, including a housing and a circuit board assembly disposed within the housing. The housing is an enclosed housing. The circuit board assembly includes a control board assembly, a drive board assembly, and a filter assembly. The control board assembly includes a control board PCB5 and a control signal adapter board PCB4. The drive board assembly includes a drive board PCB7, on which an air compressor power module 71 and a hydrogen pump power module 72 are integrated. This air compressor controller integrates the hydrogen pump power module (IGBT) 72 and the air compressor power module 71 (SiC) on the drive board PCB7. Through a shared board design of the high-voltage power module and the power drive module, the product height is significantly reduced (<80mm), achieving efficient space utilization. Furthermore, since both the air compressor power module 71 and the hydrogen pump power module 72 are located on the air compressor drive board, they can share a single heat dissipation system, effectively reducing the types and quantities of materials and lowering production costs. Meanwhile, the control signal adapter board PCB4 is connected to the control board PCB5, the control board PCB5 is connected to the drive board PCB7, and the drive board PCB7 is connected to the hydrogen pump power distribution terminal 36 and the air compressor power distribution terminal 37. The cable connection is simple and does not easily generate vibration and electromagnetic interference.

[0035] In this application, the enclosure is a rectangular closed enclosure formed by an enclosure welding assembly 3, an upper cover plate 1, and a lower cover plate 2. The enclosure welding assembly 3 is a frame structure formed by four side plates. The upper cover plate 1 and the lower cover plate 2 are fixedly connected to the upper and lower ends of the enclosure welding assembly 3 to seal it. Specifically, the upper cover plate 1 and the lower cover plate 2 are flat structures with flanges extending downwards and outwards. Screw holes are provided on the flanges, and screw posts are provided on the enclosure welding assembly 3. The upper cover plate 1 and the lower cover plate 2 are fixedly connected to the screw posts on the enclosure welding assembly 3 through the screw holes on the flanges to seal the enclosure welding assembly 3. Furthermore, multiple heat dissipation ribs are provided on the upper cover plate 1 and the lower cover plate 2. The presence of these ribs strengthens the enclosure and increases its surface area, improving heat dissipation and enhancing product reliability. In this application, the upper cover plate 1 and the lower cover plate 2 are identical in shape and material, and the upper cover plate 1 and the lower cover plate 2 can be used interchangeably. During the installation process, there will be no rework due to incorrect cover plate installation, thus improving assembly efficiency.

[0036] In this application, the upper end of the housing welding assembly 3 is provided with an upper sealing groove, and an upper sealing ring is provided in the upper sealing groove. The upper cover plate 1 and the upper end of the housing welding assembly 3 are sealed by the upper sealing ring. The lower end of the housing welding assembly 3 is provided with a lower sealing groove, and a lower sealing ring is provided in the lower sealing groove. The housing welding assembly 3 and the lower cover plate 2 are sealed by the lower sealing ring. By providing sealing rings between the housing welding assembly 3 and the upper cover plate 1 and the lower cover plate 2, the upper and lower cavities can be fully sealed, preventing moisture and impurities from entering the housing through the gaps between the upper and lower cover plates 2 and the housing welding assembly 3, thus preventing electrical safety problems and further improving the reliability of the product.

[0037] In this application, mounting bases 33 are also provided at the four corners of the housing welding assembly 3, through which the controller can be installed and fixed with other components. In this application, the mounting base 33 includes a fixing plate parallel to the upper cover plate 1 and the lower cover plate 2, and two triangular connecting plates at both ends that connect the fixing plate and the housing welding assembly 3 respectively. The fixing plate is provided with bolt holes, through which the controller can be connected with other components. Due to the stability of the triangle, the triangular connecting plate can ensure reliable fixing between the fixing plate and the housing welding assembly 3, avoid damage to the fixing plate, and improve the connection strength.

[0038] In this application, the drive board PCB7 is equipped with a current sensor, a capacitor, an air compressor power module 71, a hydrogen pump power module 72, welding terminals, etc.; through the common board design, the hydrogen pump power module 72 and the air compressor power module 71 drive module are set on the same circuit board, which can realize the rational use of space and reduce costs.

[0039] In this application, the filtering components include a two-stage EMC filtering component 6 and an amorphous magnetic ring filtering component. The input terminal uses the two-stage EMC filtering component 6 with a CLCLC filtering scheme, using a PCBA as the carrier for conduction, filtering, and grounding. The output terminal uses an amorphous magnetic ring for filtering. This design effectively improves the controller's immunity to EMC interference and enhances product reliability. In this application, the two-stage EMC filtering component 6 includes an EMC board (PCB) and common-mode inductors, X capacitors, and Y capacitors mounted on the EMC board. The amorphous magnetic ring filtering component includes an air compressor output magnetic ring 9 (ACP magnetic ring) and a hydrogen pump output magnetic ring 8 (HRB magnetic ring). This structure meets the requirements of EMC class 3.

[0040] In this application, a mounting plate 31 is provided in the middle of the enclosure welding assembly 3. The mounting plate 31 is integrally formed with the enclosure welding assembly 3. The mounting plate 31 divides the space inside the enclosure welding assembly 3 into an upper cavity located between the mounting plate 31 and the upper cover plate 1, and a lower cavity located between the mounting plate 31 and the lower cover plate 2. The control board assembly is located in the upper cavity, and the drive board assembly is located in the lower cavity. This application utilizes the mounting plate 31 to divide the enclosure into upper and lower spaces, and respectively installs the high-voltage drive board and the low-voltage control board in the lower and upper cavities, respectively. This achieves high and low voltage separation, improves electrical safety performance, and further enhances the product's EMC resistance. It is worth noting that the mounting plate 31 only separates the upper and lower cavities; the mounting plate 31 is provided with a wire passage that allows wires to pass through, enabling the drive board assembly and the control board assembly to be electrically connected via the wire passage.

[0041] In this application, the mounting plate 31 is a plate with a certain thickness. The mounting plate 31 has multiple mounting portions for fixing various mounting modules. In this application, the mounting portions are screw posts. Screw holes are provided on the control board assembly and the drive board assembly, allowing them to be connected to the mounting plate 31 via screws. The installation process is simple and convenient. Simultaneously, thermally conductive grease is applied between the control board assembly and the drive board assembly and the mounting plate 31. That is, thermally conductive grease is applied to the mounting portions of the control board assembly and the drive board assembly. The thickness of the thermally conductive grease is at least 0.15mm, possessing insulating and thermally conductive properties. The heat generated by the circuit board assembly during controller operation can be transferred to the mounting plate 31 through the thermally conductive grease, accelerating heat transfer and improving product reliability. It is understood that other materials with insulating and thermally conductive properties can also be used instead of the thermally conductive grease. Furthermore, since the mounting plate 31 is part of the enclosure welding assembly, it is typically made of aluminum sheet, and the screw posts on the mounting plate 31 are also made of aluminum. Aluminum has excellent thermal conductivity, so the heat generated by the circuit board assembly can be directly transferred to the mounting plate 31 through the screw posts, further improving the controller's heat dissipation performance and reliability. Additionally, for ease of installation, the screw holes on the control board assembly and drive board correspond one-to-one with the screw posts on the mounting plate 31 assembly. This design ensures that the corresponding PCB board material can only be matched with the corresponding screw post, preventing workers from installing the PCB board material in the wrong position and requiring rework, thus improving assembly convenience. Furthermore, to prevent screws from falling from the upper cavity to the lower cavity or vice versa during PCB board installation, which would necessitate flipping and disassembling the enclosure, a fall-prevention baffle is also provided on the enclosure welding assembly 3. Moreover, to improve the versatility of the controller, the module mounting surface of the mounting plate is compatible with various power devices of different specifications.

[0042] In this application, a water channel 32 is also provided inside the controller. The water channel 32 is suspended inside the housing, and the control board assembly and the drive board assembly are in contact with the water channel 32. Since the water channel 32 is suspended inside the controller, it can not only directly cool the control board and drive board assemblies, but also dissipate heat from the environment inside the controller, reducing the ambient temperature inside the controller and preventing excessively high ambient temperatures from affecting the service life of electrical components. In this application, a water channel inlet 34 and a water channel outlet 35 are provided on the housing welding assembly 3. The water channel inlet 34 and the water channel outlet 35 are respectively connected to the two ends of the water channel 32. Water pipes can be connected to the water channel inlet 34 and the water channel outlet 35. Water flows into the water channel 32 from the water channel inlet 34 and flows out of the water channel 32 from the water channel outlet 35. The continuous flow of cold water into the water channel 32 can effectively remove the heat generated by the heating plate assembly and prevent the electrical components from overheating and being damaged.

[0043] Specifically, the mounting plate 31 of this application is installed in the middle of the housing welding assembly 3. The mounting plate 31 is recessed to form a water storage cavity for accommodating water. A partition plate 321 is provided above the water storage cavity, covering the water storage cavity and welded to the mounting plate 31. The partition plate 321 and the water storage cavity cooperate to form a sealed water channel 32. One end of the water channel 32 is connected to the water channel inlet 34 of the housing welding assembly 3, and the other end of the water channel 32 is connected to the water channel outlet 35 on the housing welding assembly 3. The partition plate 321 and the mounting plate 31 are connected by friction welding, which can effectively seal the water channel 32 and prevent safety hazards caused by water leakage in the water channel 32. At the same time, the mounting plate 31 is reused as the wall of the water channel 32, which saves materials and space. On the other hand, the water in the water channel 32 is in direct contact with the mounting plate 31, eliminating the need for other heat conduction devices, resulting in high heat transfer efficiency and good heat dissipation.

[0044] In this application, fins 322 are provided on the baffle 321 of the water channel 32. The fins 322 are strip-shaped and parallel sheet structures. The fins 322 extend into the water channel 32, and the water in the water channel 32 can flow in the gap between adjacent fins 322. The fins 322 can fully transfer the heat on the baffle 321 of the water channel 32 to the water in the water channel 32, further improving the heat dissipation efficiency.

[0045] In this application, the housing welding assembly 3 is provided with an air compressor power distribution terminal 37 and a hydrogen pump power distribution terminal 36. The water inlet 34 and the water outlet 35 are respectively located at both ends of the air compressor power distribution terminal 37 and the hydrogen pump power distribution terminal 36. The water channel 32 spans across both ends of the housing. The water channel 32 has the longest length and the best heat dissipation effect. At the same time, the air compressor power distribution terminal 37 and the hydrogen pump power distribution terminal 36 are located between the water inlet and the water outlet, which can make full use of the space and avoid space waste.

[0046] This application also provides an assembly method for an air compressor controller. The air compressor controller of this application includes a housing, which is surrounded by an upper cover plate 1, a lower cover plate 2, and a housing welding assembly 3. A mounting plate 31 is also provided inside the housing welding assembly 3. The mounting plate 31 divides the housing into an upper cavity and a lower cavity. The housing contains a control board PCB 5, a drive board PCB 7, a control signal adapter board PCB 4, an EMC two-stage filter assembly 6, an air compressor output magnetic ring 9, a hydrogen pump output magnetic ring 8, input terminals, an air compressor power distribution terminal 47, a hydrogen pump power distribution terminal 36, etc. The drive board PCB 7 integrates an air compressor power module 2 and a hydrogen pump power module 72.

[0047] The controller installation process for this application is as follows: Step 1: Install and fix the water pipe inlet, water pipe outlet, air compressor power distribution terminal 37, hydrogen pump power distribution terminal 36, and input terminal onto the housing welding assembly 3.

[0048] Step 2: Assemble the PCB board of the EMC two-stage filter component 6 into the lower cavity of the cabinet welding component 3, and connect the input terminal and the EMC two-stage filter component 6 through a copper busbar.

[0049] Step 3: Solder the air compressor power module 71 (SIC) and the hydrogen pump power module 72 (IGBT) on the drive board PCB7. The SIC is the main power module of the air compressor controller and the IGBT is the main power module of the hydrogen pump controller. Then, apply 0.15mm thick thermal grease to the screw posts of the housing welding assembly 3, and fix the drive board PCB7 to the screw posts with screws. The drive board PCB7 is installed in the lower cavity of the housing welding assembly 3.

[0050] Step 4: Install the lower sealing ring in the lower sealing groove, then fix the lower cover plate 2 to the box welding assembly 3, and flip the box welding assembly 3 over.

[0051] Step 5: Install the air compressor output magnetic ring 9 and the hydrogen pump output magnetic ring 8 inside the housing welding assembly 3.

[0052] Step 6: Install the control signal adapter board PCB4 and connect the air compressor power distribution terminal 37 and the hydrogen pump power distribution terminal 36 to the wiring harness of the drive board PCB7.

[0053] Step 7: Install the control board PCB5, connect the control board PCB5 to the driver board PCB7 wiring harness, and connect the control board PCB5 to the control signal adapter board PCB4 wiring harness.

[0054] Step 8: Install the upper sealing ring in the upper sealing groove, and then fix the upper cover plate 1 to the box welding assembly 3. The installation is now complete.

[0055] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. All equivalent changes and modifications made in accordance with the present invention are covered by the scope of the claims of the present invention, and will not be listed here.

Claims

1. An air compressor controller comprising a box, the box being a closed box surrounded by an upper cover plate, a lower cover plate and a frame-shaped box welding assembly, a circuit board assembly is arranged in the box, the circuit board assembly comprises a control board assembly and a drive board assembly, the control board assembly comprises a control board PCB, the drive board assembly comprises a drive board PCB, the control board PCB is electrically connected with the drive board PCB, characterized in that, The drive board PCB integrates an air compressor power module and a hydrogen pump power module. The housing is also equipped with air compressor power distribution terminals and hydrogen pump power distribution terminals. The drive board PCB is connected to the air compressor power distribution terminals and the hydrogen pump power distribution terminals respectively. An installation plate is provided inside the box welding assembly. The installation plate is integrally formed with the box welding assembly. The installation plate divides the space inside the box into an upper cavity located above the installation plate and a lower cavity located below the installation plate. The control board assembly is located in the upper cavity, and the drive board assembly is located in the lower cavity. The box is provided with a water channel, which is suspended inside the box and is at least partially in contact with the mounting plate; The mounting plate is recessed to form a water storage cavity for accommodating water sources. The water channel is also provided with a water channel baffle, which covers the water storage cavity. The water channel baffle is welded to the mounting plate to form the water channel.

2. The air compressor controller of claim 1, wherein, The mounting plate is provided with a mounting part, and the circuit board assembly is fixedly connected to the mounting plate through the mounting part. Thermal grease is provided on the mounting part.

3. The air compressor controller of claim 1, wherein, The waterway baffle is provided with fins that extend into the water storage cavity.

4. The air compressor controller of claim 1, wherein, The two ends of the box welding assembly are provided with water inlet and water outlet, and the air compressor power distribution terminal and the hydrogen pump power distribution terminal are located between the water inlet and the water outlet.

5. The air compressor controller according to claim 1, characterized in that, The circuit board assembly also includes a filtering component, which includes a two-stage EMC filtering component at the input end and an amorphous magnetic ring filtering component at the output end.

6. The air compressor controller according to claim 5, characterized in that, The EMC two-stage filtering component adopts the CLCLC filtering scheme.

7. The air compressor controller according to claim 5, characterized in that, The amorphous magnetic ring filter assembly includes an air compressor output magnetic ring and a hydrogen pump output magnetic ring.

8. The air compressor controller according to claim 1, characterized in that, An upper sealing ring is provided between the upper cover plate and the box body welding assembly, and a lower sealing ring is provided between the lower cover plate and the box body welding assembly.

9. An assembly method for an air compressor controller, employing the air compressor controller as described in claim 1, wherein the air compressor controller includes a housing, the housing being formed by an upper cover plate, a lower cover plate, and a housing welding assembly, and a control board assembly and a drive board PCB are disposed within the housing, characterized in that, The drive board PCB integrates an air compressor power module and a hydrogen pump power module, and the housing is provided with air compressor power distribution terminals and hydrogen pump power distribution terminals. The assembly method includes: first, welding the air compressor power module and the hydrogen pump power module onto the drive board PCB; then, fixing the welded drive board PCB onto the housing welding assembly; subsequently, connecting the air compressor power distribution terminals and the hydrogen pump power distribution terminals to the drive board PCB wiring harness.

10. The assembly method of an air compressor controller according to claim 9, characterized in that, The enclosure welding assembly is further provided with a mounting plate, which divides the enclosure welding assembly into an upper cavity and a lower cavity. The control board assembly includes a control board PCB and a control signal adapter PCB. The assembly method includes: installing the welded drive board PCB into the lower cavity; then, flipping the enclosure and installing the control board PCB and the control signal adapter PCB into the upper cavity; then, electrically connecting the control board PCB to the drive board PCB and the control signal adapter PCB respectively.

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