A motor controller assembly for driving an automobile cooling fan

Abstract

The present invention discloses a motor controller assembly for driving an automotive cooling fan, belonging to the field of motor technology. The motor controller assembly comprises a heat sink and a rear end cover. The heat sink is provided with a connector mounting area, a conductive connector is fixed to the connector mounting area, and an enclosure is provided on the conductive connector. The heat sink is provided with three through-holes, and a first conductive link, a second conductive link, and a third conductive link are embedded in the three through-holes. The conductive connector is embedded with a first conductive sheet, a second conductive sheet, and a third conductive sheet. The first conductive sheet, the second conductive sheet, and the third conductive sheet are respectively welded to the first conductive link, the second conductive link, and the third conductive sheet. The other ends of the first conductive sheet, the second conductive sheet, and the third conductive sheet are respectively welded to three phase electrical pins of a PCBA board. The controller assembly facilitates the connection between the PCBA board and the stator assembly while also ensuring better sealing performance.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a motor controller assembly for driving an automobile cooling fan. Background Art

[0002] The cooling fan motor of a car is a DC motor installed on the car. Its function is to drive the fan to dissipate heat from the engine. The current motor structure mainly includes a stator, an outer rotor, a heat sink, a PCBA board and a rear cover. The stator is fixed on the front of the heat sink. A central axis is set on the front of the heat sink. The outer rotor is rotatably mounted on the central axis and sleeved on the outside of the stator. The PCBA board is fixed to the back of the heat sink. The rear end cover is fixed to the back of the heat sink and covers the PCB. The heat sink is provided with a wiring harness assembly that is convenient for connecting to the car power supply. The wiring harness generally includes a positive wiring harness, a negative wiring harness, a speed control wiring harness, and an ignition wiring harness can also be added.

[0003] Patent No. 202111286404.8 discloses an outer rotor motor for driving an automobile cooling fan, including a controller assembly, the controller assembly including a shell consisting of a heat sink and a rear end cover, a conductive bracket and a PCBA board are arranged in the shell, a central axis is arranged on the front of the heat sink, an armature assembly is installed on the front of the heat sink, an outer rotor assembly is rotatably installed on the central axis, an inductor mounting area, a conductive bracket mounting area, a wiring harness connector area and a control board mounting area are provided on the heat sink, the conductive bracket is placed in the conductive bracket mounting area, an inductor is provided in the inductor mounting area, a wiring harness conductive pin is provided in the wiring harness connector area, the inductor and the wiring harness conductive pin are both welded and fixed to the corresponding conductive holes on the PCBA board, Three through holes are provided on the heat sink in the conductive bracket mounting area, and the conductive bracket includes three mounting hole portions. A semi-enclosed terminal protection portion is provided on the outer periphery of the mounting hole portion, and the terminal protection portion and the mounting hole portion are connected by a connecting rod. The back of the connecting rod is provided with positioning grooves with two ends extending toward the terminal protection portion and the mounting hole portion respectively. A conductive connecting rod is installed on each mounting hole portion, one end of the conductive connecting rod is inserted into the corresponding mounting hole portion and passes through the through hole, the middle part of the conductive connecting rod is embedded in the corresponding positioning groove, the tail end of the conductive connecting rod is a connecting terminal and is in the corresponding terminal protection portion, the connecting terminal is inserted into the corresponding conductive hole on the PCBA board and is welded and fixed, and the conductive connecting rod electrically connects the armature assembly with the PCBA board.However, the connection between the PCBA board and the armature assembly (stator assembly) of this patent is not very reasonable, and has the following disadvantages: 1. The PCBA board is connected to the stator winding through a conductive bracket, and the conductive bracket is placed in the conductive bracket placement area, and then three conductive connecting rods are used to penetrate the mounting hole part and the heat sink of the conductive connecting rod. Then one end of the conductive connecting rod is welded to the PCBA board, and the other end is welded to the intermediate phase ring. Since the conductive bracket itself is not fixed and is only restricted by the conductive connecting rod, the conductive bracket may become loose; 2. This fixing method has poor sealing performance. Since the conductive connecting rod needs to penetrate the mounting part and the heat sink of the conductive bracket, the heat sink is provided with a sealing sleeve with elastic deformation, which facilitates the passage of the conductive connecting rod and has a sealing effect. However, after the motor is used for a long time, the sealing sleeve will age and cause the seal to fail. Once the seal fails, a gap will be formed between the sealing sleeve and the conductive connecting rod, which is easy for water to enter, resulting in internal short circuit and damage to the PCB. A board; 3. The PCBA board in this controller assembly includes a PCB board, on which MOS devices, capacitors and some other components are arranged. This PCB board is fixed on the heat sink to transfer heat to the heat sink. However, since the MOS devices and capacitors on the PCB board generate a lot of heat, the temperature of the PCB board will be relatively high, and the temperature of the components around these components with high heat generation will also be relatively high. This will easily cause the surrounding low-heat generation components to always work in a harsh environment with a relatively high temperature, reducing reliability. Moreover, when the power of the motor increases, the motor is limited by the installation space and it is difficult to increase its size. In this way, the heat dissipation efficiency is not improved, which causes the temperature of the low-power components around the components with high heat generation to be too high and overheat protection to shut down, thereby affecting the normal operation of the car's cooling system. Therefore, the structure of this PCBA board limits the power of the motor and cannot be made too large. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a motor controller assembly for driving an automobile cooling fan, which can make the connection between the PCBA board and the stator assembly more convenient while ensuring better sealing performance.

[0005] In order to solve the above technical problems, the technical solution of the present invention is: a motor controller component for driving an automobile cooling fan, comprising a shell consisting of a heat sink and a rear end cover, a central axis being provided on the front of the heat sink, a PCBA board being provided in the shell, an inductor mounting area, a wiring harness connector area and a control board mounting area being provided on the heat sink, an inductor being provided in the inductor mounting area, the PCBA board being provided on the control board mounting area, a wiring harness connection structure for connecting the PCBA board to an external wiring harness being installed in the wiring harness connector area, a connecting seat mounting area being further provided on the heat sink, a conductive connecting seat being fixed in the connecting seat mounting area, a bottom of the conductive connecting seat being sealed with the heat sink, an enclosure being provided on the conductive connecting seat, and an end of the enclosure being provided at the end of the enclosure. A sealing ring mounting groove is provided on the surface, and three through holes are provided on the heat dissipation seat in the surrounding cavity. The first conductive link, the second conductive link and the third conductive link for connecting to the three-phase winding of the stator assembly are embedded in the three through holes. A hole sealing structure for sealing the through holes is installed in the surrounding cavity. The first conductive sheet, the second conductive sheet and the third conductive sheet are embedded in the conductive connection seat. One end of the first conductive sheet, the second conductive sheet and the third conductive sheet are all extended into the surrounding cavity and are all provided with hooks. The hooks on the first conductive sheet, the second conductive sheet and the third conductive sheet are correspondingly sleeved on the first conductive link, the second conductive link and the third conductive link and welded to fix them. The other ends of the first conductive sheet, the second conductive sheet and the third conductive sheet are respectively welded to the three phase electrical pins of the PCBA board.

[0006] As a preferred solution, the connection seat installation area is provided with an installation groove, the enclosed cavity corresponds to the installation groove, the through hole is located in the installation groove, and the hole sealing structure is provided in the installation groove.

[0007] As a preferred solution, the hole sealing structure includes a sealing plate arranged in the mounting groove, and three sealing nests are provided on the sealing plate, which are embedded in the through hole in a one-to-one correspondence. A sealing ridge is provided on the plate surface of the sealing plate and is sealed with the bottom of the mounting groove. A sealing pressure plate is provided above the sealing plate, and a clamping portion for pressing the sealing pressure plate and the sealing plate is provided on the surrounding cavity. A through hole is provided on the sealing pressure plate for facilitating the passage of the sealing nest, and the first conductive connecting rod, the second conductive connecting rod and the third conductive connecting rod all pass through the sealing nest and are sealed with the sealing nest.

[0008] As a preferred solution, the wiring harness connection structure includes a conductive bracket made of insulating material, the conductive bracket is fixed to the wiring harness installation area on the heat sink, the area inside the heat sink is connected to the wiring harness installation area through a mounting notch, the external wiring harness is fixed to the wiring harness installation area through a wiring harness fixing block, the conductive bracket is provided with a sealing insert, the sealing insert is embedded in the mounting notch, the sealing insert is provided with a sealing groove section connected with a circle of sealing grooves on the heat sink, the conductive bracket is also provided with an inductor mounting seat located in the inductor installation area, the inductor is installed on the inductor mounting seat, and the conductive bracket is provided with a negative conductive sheet and a positive conductive sheet. The negative conductive sheet and the speed regulating conductive sheet, the negative conductive sheet, the positive conductive sheet and the speed regulating conductive sheet pass through the sealing insert and extend into the wiring harness installation area, one end of the negative conductive sheet is welded to the negative wiring harness on the wiring harness fixing block, the other end of the negative conductive sheet is welded to one end of the inductor wiring harness, the other end of the inductor wiring harness is welded to one end of the negative connecting sheet, the other end of the negative connecting sheet is welded to the negative pin of the PCBA board assembly, one end of the positive conductive sheet is welded to the positive wiring harness on the wiring harness fixing block, one end of the speed regulating conductive sheet is welded to the speed regulating wiring harness on the wiring harness fixing block, the other ends of the positive conductive sheet and the speed regulating conductive sheet are welded to the positive pin and speed regulating pin of the PCBA board

[0009] As a preferred solution, the conductive bracket includes the inductor mounting seat, the sealing insert and the conductive sheet embedded connecting frame. The inductor mounting seat and the conductive sheet embedded connecting frame are provided with screw mounting parts. The conductive sheet embedded connecting frame is arranged on the outside of the PCBA board. A support column leaning against the board surface of the PCBA board is provided below the conductive sheet embedded connecting frame. The positive conductive sheet, the speed regulating conductive sheet and the negative connecting sheet are all embedded in the conductive sheet embedded connecting frame.

[0010] As a preferred solution, the positive electrode conductive sheet, the speed regulating conductive sheet and the negative electrode connecting sheet are all connected by connecting ribs that are easy to punch out, and the connecting ribs are exposed outside the conductive sheet embedded in the connecting frame.

[0011] As a preferred solution, the sealing insert is provided with snap-in grooves on both sides of the installation notch, the heat sink is provided with an operation window located in the wiring harness installation area, a sealing cover is installed at the operation window, and the wiring harness installation area is sealed with glue.

[0012] As a preferred solution, the PCBA board includes a lower PCB board and an upper PCB board, the lower PCB board is provided with fixing holes for convenient bolt fixing, the lower PCB board is provided with a component group with high heat generation, the upper PCB board is provided with a component group with low heat generation, the lower PCB board is fixed with a positive pin seat, a negative pin seat, a speed control pin seat and three winding pin seats, the lower PCB board is provided with a support structure for supporting the upper PCB board, the positive pin seat is provided with a positive wiring harness connection The positive pin is connected to the upper PCB board, the negative pin is provided on the negative pin seat for connecting the negative wire harness, the speed regulating pin seat is provided with a speed regulating pin for connecting the speed regulating wire harness, and the three winding pin seats are respectively provided with phase electrical pins welded to the lower PCB board for electrical connection to the three-phase windings of the motor stator. The positive pin, negative pin and speed regulating pin all pass through the upper PCB board and are welded to the upper PCB board and the lower PCB board. The three winding pin seats are also provided with connecting pins for connecting the upper PCB board and the lower PCB board.

[0013] As a preferred solution, the three winding pin seats have the same structure. The winding pin seat includes a winding seat body, the lower end of the winding seat body is provided with at least two insertion protrusions, and the lower PCB board is provided with an insertion positioning hole for facilitating the positioning of the insertion protrusions. The winding seat body is provided with a first mounting portion and a second mounting portion, and the lower ends of the first mounting portion and the second mounting portion are both provided with a first avoidance groove and a second avoidance groove. The phase electric pins and the connecting pins are respectively embedded in the first mounting portion and the second mounting portion, and the upper ends of the phase electric pins and the connecting pins are exposed. The lower ends of the phase electric pins and the connecting pins are respectively located in the first avoidance groove and the second avoidance groove and exposed, and the lower ends of the phase electric pins and the connecting pins are welded and fixed to the lower PCB board.

[0014] As a preferred solution, the support structure includes several supporting protrusions, which support the upper PCB board, and the lower ends of the phase power pins and the connecting pins are bent and welded to the upper surface solder points of the lower PCB board.

[0015] After adopting the above technical solution, the effect of the present invention is as follows: since the heat sink is also provided with a connection seat installation area, a conductive connection seat is fixed in the connection seat installation area, the bottom of the conductive connection seat is sealed with the heat sink, the conductive connection seat is provided with an enclosure, and the end surface of the enclosure is provided with a sealing ring installation groove, the heat sink is provided with three through holes in the enclosure, and the three through holes are embedded with a first conductive link, a second conductive link and a third conductive link for connecting to the three-phase winding of the stator assembly, and a hole sealing structure for sealing the through holes is installed in the enclosure, and the conductive connection seat is embedded with a first conductive sheet, a second conductive sheet and a third conductive sheet, one end of the first conductive sheet, the second conductive sheet and the third conductive sheet are all extended into the enclosure and are all provided with a hook, the hooks on the first conductive sheet, the second conductive sheet and the third conductive sheet are correspondingly sleeved on the first conductive link, the second conductive link and the third conductive link and welded fixed, and the other ends of the first conductive sheet, the second conductive sheet and the third conductive sheet are respectively welded to the three phase electrical pins of the PCBA board. Therefore, the front and back of the entire enclosure are sealed with a good sealing effect. The welding positions of the first conductive sheet, the second conductive sheet, the third conductive sheet, and the first conductive connecting rod, the second conductive connecting rod, and the third conductive connecting rod are located inside the enclosure, thereby better isolating the PCBA board from the outside and preventing water from entering the PCBA board and causing damage to components. In addition, the conductive connection seat is fixed on the heat sink and is not easy to shake, thereby preventing the welding points from loosening.

[0016] In addition, since the connecting seat installation area is provided with an installation groove, the enclosure corresponds to the installation groove, the through hole is located in the installation groove, and the hole sealing structure is provided in the installation groove, the installation groove is also used to provide protection to a certain extent, and even if water seeps in, it can be prevented from flowing into the outside of the installation groove and the enclosure.

[0017] Furthermore, since the hole sealing structure includes a sealing plate arranged in the mounting groove, the sealing plate is provided with three sealing nests which are embedded in the through hole in a one-to-one correspondence, the plate surface of the sealing plate is provided with a sealing ridge which is sealed with the bottom of the mounting groove, a sealing pressure plate is provided above the sealing plate, and a pressing portion for pressing the sealing pressure plate and the sealing plate is provided on the surrounding cavity, and a through hole is provided on the sealing pressure plate for facilitating the sealing nest to pass through, the first conductive connecting rod, the second conductive connecting rod and the third conductive connecting rod all pass through the sealing nest and are sealed with the sealing nest. First, the sealing nest can be embedded in the through hole, and the sealing nest can be used to achieve the sealing of the three conductive connecting rods, and can also seal the through hole. Secondly, the sealing ridge on the sealing plate is squeezed and sealed with the bottom of the mounting groove, so as to seal again, which can better protect the gap between the through hole and the sealing nest. Due to the thickness of the heat sink, the sealing contact part between the sealing nest and the through hole is not thick, and the sealing part between the sealing nest and the conductive connecting rod is the height of the entire sealing nest. In comparison, the gap between the sealing nest and the through hole is more prone to sealing failure. Therefore, the above structure can improve the sealing effect between the sealing nest and the through hole, and the sealing reliability is higher.

[0018] The heat dissipation device is installed in the heat dissipation device, and the heat dissipation device is installed in the heat dissipation device. The heat dissipation device is installed in the heat dissipation device, and the heat dissipation device is installed in the heat dissipation device. The heat dissipation device is installed in the heat dissipation device, and the heat dissipation device is installed in the heat dissipation device. One end of the inductor's wiring harness is welded, and the other end of the inductor's wiring harness is welded to one end of the negative connecting piece. The other end of the negative connecting piece is welded to the negative pin of the PCBA board assembly. One end of the positive conductive piece is welded to the positive wiring harness on the wiring harness fixing block. One end of the speed regulating conductive piece is welded to the speed regulating wiring harness on the wiring harness fixing block. The other ends of the positive conductive piece and the speed regulating conductive piece are welded to the positive pin and the speed regulating pin of the PCBA board. Therefore, the conductive bracket is not only convenient to be embedded in the installation notch and fixed, but the sealing groove section can also be connected with a whole circle of sealing groove of the heat sink, which is convenient for glue filling and sealing, thereby improving the sealing performance; the conductive bracket is provided with a negative conductive piece connected to the negative wiring harness and a positive conductive piece connected to the positive wiring harness. The inductor is connected between the negative conductive piece and the negative connecting piece. In this way, the large current is directly conducted through the wider negative conductive piece, avoiding heat accumulation on the PCBA board, making it suitable for use in high-current motors.

[0019] Furthermore, the conductive bracket includes the inductor mounting seat, the sealing insert, and the conductive sheet embedded connecting frame. Screw mounting portions are provided on the inductor mounting seat and the conductive sheet embedded connecting frame. The conductive sheet embedded connecting frame is disposed on the outside of the PCBA board. Support columns are provided below the conductive sheet embedded connecting frame, resting against the surface of the PCBA board. The positive conductive sheet, speed regulating conductive sheet, and negative connecting sheet are all embedded in the conductive sheet embedded connecting frame. The conductive bracket can be conveniently and removably secured to the heat sink via the screw mounting portions, while the conductive sheet embedded connecting frame is supported on the surface of the PCBA board via the support columns, thereby reducing deformation. This also facilitates the securement of the positive conductive sheet, speed regulating conductive sheet, and negative connecting sheet, preventing deformation of the conductive sheet embedded connecting frame that could cause contact with the PCBA board.

[0020] Furthermore, since the positive electrode conductive sheet, the speed regulating conductive sheet and the negative electrode connecting sheet are all connected by connecting ribs that are easily punched out, the connecting ribs are exposed outside the conductive sheet embedding connection frame. In this way, the positive electrode conductive sheet, the speed regulating conductive sheet and the negative electrode connecting sheet can be integrally formed and embedded in the conductive bracket during the molding process. The connecting ribs can then be punched out during use, thus ensuring that the positive electrode conductive sheet, the speed regulating conductive sheet and the negative electrode connecting sheet are accurately embedded in the position.

[0021] Since the PCBA board includes a lower PCB board and an upper PCB board, the lower PCB board is provided with fixing holes for convenient bolt fixing, the lower PCB board is provided with a component group with high heat generation, the upper PCB board is provided with a component group with low heat generation, the lower PCB board is fixed with a positive pin seat, a negative pin seat, a speed control pin seat and three winding pin seats, the lower PCB board is provided with a supporting structure for supporting the upper PCB board, and the positive pin seat is provided with a positive pin seat for connecting the positive wiring harness. The positive pin, the negative pin for connecting the negative wiring harness is provided on the negative pin seat, the speed regulating pin for connecting the speed regulating wiring harness is provided on the speed regulating pin seat, and the three winding pin seats are respectively provided with phase electrical pins welded to the lower PCB board for electrical connection to the three-phase windings of the motor stator. The positive pin, negative pin and speed regulating pin all pass through the upper PCB board and are welded to both the upper PCB board and the lower PCB board. The three winding pin seats are also provided with connecting pins for connecting the upper PCB board and the lower PCB board. Therefore, the PCBA assembly includes two layers of PCB boards, and the upper PCB board is supported by a support structure. There is a gap between the two PCB boards. This makes it convenient to place the component group with high heat generation on the lower PCB board. The heat generated by these component groups is directly transferred from the lower PCB board to the heat sink of the motor for dissipation. At the same time, the component group with low heat generation is placed on the upper PCB board. The temperature of the lower PCB board does not have much impact on the components on the upper PCB board. This avoids overheating and motor shutdown protection, thus meeting the requirements of higher power motors.

[0022] Since the three winding pin holders have the same structure, the winding pin holder includes a winding seat body, the lower end of the winding seat body is provided with at least two insertion protrusions, and the lower PCB board is provided with an insertion positioning hole for facilitating the positioning of the insertion protrusions. The winding seat body is provided with a first mounting portion and a second mounting portion, and the lower ends of the first mounting portion and the second mounting portion are both provided with a first avoidance groove and a second avoidance groove. The phase power pins and the connecting pins are respectively embedded in the first mounting portion and the second mounting portion, and the upper ends of the phase power pins and the connecting pins are exposed. The lower ends of the phase power pins and the connecting pins are respectively located in the first avoidance groove and the second avoidance groove and exposed, and the lower ends of the phase power pins and the connecting pins are welded and fixed to the lower PCB board. The winding base body of the winding pin base can be conveniently positioned with respect to the lower PCB board by inserting the protrusion, thereby ensuring more accurate welding between the lower ends of the phase electrical pins and the lower PCB board. In addition, the lower ends of the phase electrical pins on the first mounting portion are welded to the lower PCB board, and the connecting pins connect the lower PCB board and the upper PCB board for communication. The first avoidance groove and the second avoidance groove can facilitate the exposure of the lower ends of each pin, making it easier to observe the welding condition of the lower ends. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention will be further described below with reference to the accompanying drawings and examples.

[0024] Figure 1 It is a structural stereogram of an embodiment of the present invention;

[0025] Figure 2 is a perspective view of the controller assembly with the rear end cover hidden;

[0026] Figure 3 is a structural stereogram of an embodiment of the present invention from another angle;

[0027] Figure 4 It is a three-dimensional diagram of the heat sink;

[0028] Figure 5 It is a three-dimensional diagram of the conductive connection seat;

[0029] Figure 6 is a three-dimensional diagram of the sealing plate;

[0030] Figure 7 is a perspective view of the sealing plate;

[0031] Figure 8 is a perspective view of the other side of the sealing plate;

[0032] Figure 9 is a perspective cutaway view of the controller assembly;

[0033] Figure 10 This is a three-dimensional diagram of the PCBA board and the conductive bracket;

[0034] Figure 11 This is a three-dimensional image of the PCBA board with the upper PCB hidden;

[0035] Figure 12 It is a three-dimensional diagram of the conductive bracket;

[0036] In the figure: 1. Heat sink; 101. Control panel mounting area; 102. Inductor mounting area; 103. Connector mounting area; 104. Wiring harness connector area; 105. Mounting notch; 106. Sealing groove; 107. Peripheral sealing groove; 108. Surrounding edge; 109. Mounting groove; 1010. Through hole; 1011. Positioning boss; 1012. Sealing cover; 1013. Center axis; 2. Rear end cover; 201. Sealing cover plate; 3. Negative wiring harness; 4. Ignition wiring harness; 5. Adjustment Wire harness; 6. Positive wire harness; 7. Conductive connector; 701. Enclosure; 702. Sealing ring mounting groove; 703. Positioning hole; 8. Inductor; 9. PCBA board; 901. Lower PCB board; 902. Upper PCB board; 903. Phase power pin; 904. Capacitor; 905. Winding pin seat; 9051. First mounting portion; 9052. Second mounting portion; 9053. First avoidance groove; 9054. Second avoidance groove; 906. Negative pin seat; 907. Positive pin seat ; 908, speed control pin seat; 909, connecting pin; 9010, negative pin; 9011, positive pin; 9012, speed control pin; 9013, ignition pin; 9014, support protrusion; 10, third conductive sheet; 11, second conductive sheet; 12, first conductive sheet; 1201, hook; 13, conductive bracket; 1301, inductor mounting seat; 1302, conductive sheet embedded in the connecting frame; 1303, sealing insert; 1304, card slot; 1305, sealing slot section; 13 06. Connecting rib; 1307. Support column; 1308. Screw mounting portion; 14. Negative conductive sheet; 15. Positive conductive sheet; 16. Ignition conductive sheet; 17. Speed ​​regulating conductive sheet; 18. Wire harness fixing block; 19. First conductive link; 20. Second conductive link; 21. Third conductive link; 22. Sealing plate; 2201. Sealing nesting; 2202. Inner ring sealing rib; 2203. Outer ring sealing rib; 23. Sealing pressure plate; 24. Negative connecting piece; 2301. Through hole. DETAILED DESCRIPTION

[0037] The present invention is further described in detail below through specific examples.

[0038] like Figures 1 to 12 As shown, a motor controller assembly for driving an automobile cooling fan includes a housing consisting of a heat sink 1 and a rear end cover 2. A central axis 1013 is provided on the front of the heat sink 1, and the central axis 1013 of the heat sink 1 is used to install an outer rotor.

[0039] like Figure 2 and Figure 4 As shown, a PCBA board 9 is provided in the housing, and an inductor 8 mounting area 102, a harness connector area 104 and a control board mounting area 101 are provided on the heat sink 1. The inductor 8 mounting area 102 is provided with an inductor 8, and the PCBA board 9 is provided on the control board mounting area 101 by bolts. The harness connector area 104 is provided with a harness connection structure for connecting the PCBA board 9 to an external harness. A connecting seat mounting area 103 is also provided on the heat sink 1, and a conductive connecting seat 7 is fixed in the connecting seat mounting area 103. The bottom of the conductive connecting seat 7 is sealed with the heat sink 1, as shown Figure 5 As shown, a cavity 701 is provided on the conductive connection seat 7, and a sealing ring installation groove 702 is provided on the end face of the cavity 701, and a sealing cover plate 201 is also installed on the rear end cover 2 to seal the cavity 701. The sealing cover plate can be opened first to facilitate the welding operation of each hook 1201 and the first conductive connecting rod 19, the second conductive connecting rod 20 and the third conductive connecting rod 21.

[0040] The heat sink 1 is provided with three through holes 1010 in the enclosure 701. The first conductive link 19, the second conductive link 20 and the third conductive link 21 for connecting to the three-phase winding of the stator assembly are embedded in the three through holes 1010. A hole sealing structure for sealing the through holes 1010 is installed in the enclosure 701. The first conductive sheet 12, the second conductive sheet 11 and the third conductive sheet 10 are embedded in the conductive connection seat 7. One end of the first conductive sheet 12, the second conductive sheet 11 and the third conductive sheet 10 all extend into the enclosure 701 and are each provided with a hook 1201. The hooks 1201 on the first conductive sheet 12, the second conductive sheet 11 and the third conductive sheet 10 are correspondingly sleeved on the first conductive link 19, the second conductive link 20 and the third conductive link 21 and welded to fix them. The other ends of the first conductive sheet 12, the second conductive sheet 11 and the third conductive sheet 10 are respectively welded to the three phase electrical pins 903 of the PCBA board 9.

[0041] The connection seat installation area 103 is provided with an installation groove 109 , the enclosure 701 corresponds to the installation groove 109 , the through hole 1010 is located in the installation groove 109 , and the hole sealing structure is provided in the installation groove 109 .

[0042] For example Figures 2 to 4As shown, a positioning structure is provided between the connection base mounting area 103 of the heat sink 1 and the conductive connection base 7 to facilitate positioning of the conductive connection base 7. In this embodiment, the positioning structure includes a positioning groove or positioning hole 703 provided on the conductive connection base 7. Correspondingly, a positioning boss 1011 corresponding to the positioning groove or positioning hole 703 is provided on the connection base mounting area 103 of the heat sink 1. The heat sink 1 is provided with a peripheral edge 108 that encloses the connection base mounting area 103. The connection base mounting area 103 is provided with a peripheral sealing groove 107 for mounting a sealing ring.

[0043] like Figures 6 to 9 As shown, the hole sealing structure includes a sealing plate 22 arranged in the mounting groove 109, and three sealing nests 2201 are provided on the sealing plate 22, which are embedded in the through hole 1010 in a one-to-one correspondence. A sealing ridge is provided on the plate surface of the sealing plate 22 for sealing with the bottom of the mounting groove 109. A sealing pressure plate 23 is provided above the sealing plate 22, and a clamping portion for pressing the sealing pressure plate 23 and the sealing plate 22 is provided on the surrounding cavity 701. A through hole 2301 is provided on the sealing pressure plate 23 for facilitating the passage of the sealing nest 2201. The first conductive connecting rod 19, the second conductive connecting rod 20 and the third conductive connecting rod 21 all pass through the sealing nest 2201 and seal with the sealing nest 2201.

[0044] In this embodiment, the sealing ridges include an outer ring sealing ridge 2203 and an inner ring sealing ridge 2202. The outer ring sealing ridge 2203 is arranged on the outer periphery of the sealing plate 22, and the number of the inner ring sealing ridges 2202 is at least three and respectively surrounds the corresponding sealing nests 2201. In this way, the outer ring sealing ridge 2203 and the inner ring sealing ridge 2202 can be used to better seal and avoid leakage from the gap between the sealing nest 2201 and the through hole 1010.

[0045] like Figure 2 、 Figure 10 and Figure 12As shown, the wiring harness connection structure includes a conductive bracket 13 made of insulating material, the conductive bracket 13 is fixed to the wiring harness installation area on the heat sink 1, the area inside the heat sink 1 is connected to the wiring harness installation area through the installation gap 105, and the external wiring harness is fixed to the wiring harness installation area through the wiring harness fixing block 18, and a sealing insert 1303 is provided on the conductive bracket 13, and the sealing insert 1303 is embedded in the installation gap 105. The sealing insert 1303 is provided with a sealing groove section 1305 connected with a circle of sealing grooves 106 on the heat sink 1, and the conductive bracket 13 is also provided with an inductor mounting seat 1301 located in the inductor 8 installation area 102, and the inductor 8 is installed on the inductor mounting seat 1301. The conductive bracket 13 is provided with a negative conductive sheet 14 and a positive conductive sheet 1 5 and the speed regulating conductive sheet 17, the negative conductive sheet 14, the positive conductive sheet 15 and the speed regulating conductive sheet 17 pass through the sealing insert 1303 and extend into the wiring harness installation area, one end of the negative conductive sheet 14 is welded to the negative wiring harness 3 on the wiring harness fixing block 18, the other end of the negative conductive sheet 14 is welded to one end of the wiring harness of the inductor 8, the other end of the wiring harness of the inductor 8 is welded to one end of the negative connecting sheet 24, the other end of the negative connecting sheet 24 is welded to the negative pin 9010 of the PCBA board 9 assembly, one end of the positive conductive sheet 15 is welded to the positive wiring harness 6 on the wiring harness fixing block 18, one end of the speed regulating conductive sheet 17 is welded to the speed regulating wiring harness 5 on the wiring harness fixing block 18, and the other end of the positive conductive sheet 15 and the speed regulating conductive sheet 17 are welded to the positive pin 9011 and the speed regulating pin 9012 of the PCBA board 9

[0046] Among them, the conductive bracket 13 includes the inductor mounting seat 1301, the sealing block 1303 and the conductive sheet embedded connecting frame 1302. The inductor mounting seat 1301 and the conductive sheet embedded connecting frame 1302 are provided with a screw mounting portion 1308. The conductive sheet embedded connecting frame 1302 is arranged on the outside of the PCBA board 9. A support column 1307 is provided below the conductive sheet embedded connecting frame 1302, which rests on the board surface of the PCBA board 9. The positive conductive sheet 15, the speed regulating conductive sheet 17 and the negative connecting sheet 24 are all embedded in the conductive sheet embedded connecting frame 1302.

[0047] The positive electrode conductive sheet 15 , the speed regulating conductive sheet 17 and the negative electrode connecting sheet 24 are all connected by connecting ribs 1306 which are easy to be punched out. The connecting ribs 1306 are exposed outside the conductive sheet embedded connecting frame 1302 .

[0048] The sealing insert 1303 is provided with a clamping groove 1304 clamped on both sides of the installation notch 105, and the heat sink 1 is provided with an operation window located in the wiring harness installation area, and a sealing cover 1012 is installed at the operation window. The wiring harness installation area is sealed with glue.

[0049] In this embodiment, the wiring harness connection structure also includes an ignition conductive sheet 16, and an ignition wiring harness 4 is also provided on the wiring harness fixing block 18. The ignition conductive sheet 16 is embedded in the sealing insert 1303, and one end of the ignition conductive sheet 16 is welded and fixed to the ignition wiring harness 4, and the other end of the ignition conductive sheet 16 is welded to the ignition pin 9013 of the PCBA board 9.

[0050] The positive conductive sheet 15 is provided with a positive jack for convenient insertion of the positive pin 9011, the speed regulating conductive sheet 17 is provided with a speed regulating jack for convenient insertion of the speed regulating pin 9012, and the negative connecting sheet 24 is provided with a negative jack for convenient insertion of the negative pin 9010. Both the negative connecting sheet 24 and the negative conductive sheet 14 are provided with welding slots for convenient mounting and welding to the wiring harness of the inductor 8.

[0051] like Figure 2 、 Figure 10 and Figure 11 As shown, the PCBA board 9 includes a lower PCB board 901 and an upper PCB board 902. The lower PCB board 901 is provided with fixing holes for convenient bolt fixing. The lower PCB board 901 is provided with a component group with high heat generation, and the upper PCB board 902 is provided with a component group with low heat generation. The lower PCB board 901 is fixed with a positive pin seat 907, a negative pin seat 906, a speed control pin seat 908 and three winding pin seats 905. The lower PCB board 901 is provided with a supporting structure for supporting the upper PCB board 902. The positive pin seat 907 is provided with a positive pin 9011 for connecting the positive wiring harness 6. The pole pin holder 906 is provided with a negative pin 9010 for connecting to the negative wiring harness 3, and the speed regulation pin holder 908 is provided with a speed regulation pin 9012 for connecting to the speed regulation wiring harness 5. The three winding pin holders 905 are respectively provided with phase electrical pins 903 welded to the lower PCB board 901 for electrical connection to the three-phase windings of the motor stator. The positive pin 9011, negative pin 9010, and speed regulation pin 9012 all pass through the upper PCB board 902 and are welded to the upper PCB board 902 and the lower PCB board 901. The three winding pin holders 905 are also provided with a connecting pin 909 for connecting the upper PCB board 902 and the lower PCB board 901.

[0052] Among them, the three winding pin holders 905 have the same structure. The winding pin holder 905 includes a winding seat body, and the lower end of the winding seat body is provided with at least two insertion protrusions. The lower PCB board 901 is provided with an insertion positioning hole 703 for facilitating the positioning of the insertion protrusions. The winding seat body is provided with a first mounting portion 9051 and a second mounting portion 9052. The lower ends of the first mounting portion 9051 and the second mounting portion 9052 are both provided with a first avoidance groove 9053 and a second avoidance groove 9054. The phase power pin 903 and the connecting pin 909 are respectively embedded in the first mounting portion 9051 and the second mounting portion 9052. The upper ends of the phase power pin 903 and the connecting pin 909 are both exposed, and the lower ends of the phase power pin 903 and the connecting pin 909 are respectively located in the first avoidance groove 9053 and the second avoidance groove 9054 and exposed. The lower ends of the phase power pin 903 and the connecting pin 909 are welded and fixed to the lower PCB board 901.

[0053] The support structure includes several support protrusions 9014, which support the upper PCB board 902. The lower ends of the phase power pins 903 and the connecting pins 909 are bent and welded to the upper surface solder points of the lower PCB board 901.

[0054] Among them, in the PCBA board 9 in this embodiment, the component group with high heat generation includes multiple MOS devices and multiple capacitors 904. The MOS device is arranged in the middle of the lower PCB board 901, and the positive pin seat 907, the negative pin seat 906, the speed control pin seat 908 and the three winding pin seats 905 are arranged on the periphery of the MOS device. The multiple capacitors 904 are located on the same side of the upper PCB board 902. In this way, the multiple MOS devices are located in the middle of the lower PCB board 901, which can conduct heat from the center to the surrounding areas, and the heat dissipation effect is better. The multiple capacitors 904 are located on the same side of the upper PCB board 902 to reduce the mutual heat influence between the capacitors 904 and the MOS devices.

[0055] At least one of the positive pin seat 907, the negative pin seat 906, the speed regulation pin seat 908 and the three winding pin seats 905 is provided with a positioning protrusion, and a positioning hole corresponding to the positioning protrusion is provided on the upper PCB board 902, and the positioning protrusion can be accurately inserted into the positioning hole.

[0056] The air circuit system, actuators such as servo motors, gear transmission mechanisms, and lead screw and nut mechanisms mentioned in this embodiment are all conventional technologies. The specific structures and principles of the air cylinder, motor, and other transmission mechanisms, as well as other designs, are disclosed in detail in the "Mechanical Design Manual, Fifth Edition," the 28th edition, published in Beijing in April 2008. These are prior art and their structures are clear. The SMC training material "Modern Practical Pneumatic Technology, 3rd Edition," published by the Machinery Industry Press on August 1, 2008, discloses in detail the vacuum components, gas circuits, and program control, demonstrating that the air circuit structure in this embodiment is also prior art and clear. The book "Motor Drive and Speed ​​Regulation," published by the Chemical Industry Press on July 1, 2015, also provides detailed descriptions of motor control and travel switches. Therefore, the circuits and air circuit connections are clear. The above-described embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Any modifications and alterations to the technical solution of the present invention, without departing from the spirit of the present invention, should fall within the scope of protection defined by the claims.

Claims

1. A motor controller assembly for driving an automotive cooling fan, comprising a housing consisting of a heat sink and a rear end cover. The heat sink has a central axis disposed on its front surface. A PCBA is disposed within the housing. The heat sink has an inductor mounting area, a wiring harness connector area, and a control board mounting area. The inductor mounting area has an inductor disposed therein. The PCBA is disposed on the control board mounting area. The wiring harness connector area has a wiring harness connection structure for connecting the PCBA to an external wiring harness. The assembly is characterized by: The heat dissipation seat is also provided with a connecting seat mounting area, and a conductive connecting seat is fixed in the connecting seat mounting area, and the bottom of the conductive connecting seat is sealed with the heat dissipation seat, and the conductive connecting seat is provided with an enclosure cavity, and the end face of the enclosure cavity is provided with a sealing ring mounting groove, and three through-holes are provided on the heat dissipation seat in the enclosure cavity, and the three through-holes are embedded with a first conductive link, a second conductive link and a third conductive link for connecting to the three-phase winding of the stator assembly. A hole sealing structure for sealing the through-holes is installed in the enclosure cavity, and the conductive connecting seat is embedded with a first conductive sheet, a second conductive sheet and a third conductive sheet, and one end of the first conductive sheet, the second conductive sheet and the third conductive sheet are all extended into the enclosure cavity and are all provided with hooks, and the hooks on the first conductive sheet, the second conductive sheet and the third conductive sheet are correspondingly sleeved on the first conductive link, the second conductive link and the third conductive link and welded fixed, and the other ends of the first conductive sheet, the second conductive sheet and the third conductive sheet are respectively welded to the three phase electrical pins of the PCBA board.

2. The motor controller assembly for driving an automobile cooling fan according to claim 1, wherein: The connection seat installation area is provided with an installation groove, the enclosed cavity corresponds to the installation groove, the through hole is located in the installation groove, and the hole sealing structure is provided in the installation groove.

3. The motor controller assembly for driving an automobile cooling fan according to claim 2, wherein: The hole sealing structure includes a sealing plate arranged in the mounting groove, and three sealing nests are provided on the sealing plate, which are embedded in the through hole in a one-to-one correspondence. A sealing ridge is provided on the plate surface of the sealing plate and is sealed with the bottom of the mounting groove. A sealing pressure plate is provided above the sealing plate, and a pressing portion for pressing the sealing pressure plate and the sealing plate is provided on the surrounding cavity. A through hole is provided on the sealing pressure plate for facilitating the sealing nest to pass through. The first conductive connecting rod, the second conductive connecting rod and the third conductive connecting rod all pass through the sealing nest and are sealed with the sealing nest.

4. A motor controller assembly for driving an automobile cooling fan according to any one of claims 1 to 3, characterized in that: The wiring harness connection structure includes a conductive bracket made of insulating material, the conductive bracket is fixed to the wiring harness installation area on the heat sink, the area inside the heat sink is connected to the wiring harness installation area through a mounting notch, the external wiring harness is fixed to the wiring harness installation area through a wiring harness fixing block, a sealing insert is provided on the conductive bracket, the sealing insert is embedded in the mounting notch, the sealing insert is provided with a sealing groove section connected with a circle of sealing grooves on the heat sink, the conductive bracket is also provided with an inductor mounting seat located in the inductor installation area, the inductor is installed on the inductor mounting seat, and a negative conductive sheet, a positive conductive sheet and a speed regulating plate are provided in the conductive bracket. Conductive sheet, the negative conductive sheet, positive conductive sheet and speed regulating conductive sheet pass through the sealing insert and extend into the wiring harness installation area, one end of the negative conductive sheet is welded to the negative wiring harness on the wiring harness fixing block, the other end of the negative conductive sheet is welded to one end of the inductor wiring harness, the other end of the inductor wiring harness is welded to one end of the negative connecting sheet, the other end of the negative connecting sheet is welded to the negative pin of the PCBA board assembly, one end of the positive conductive sheet is welded to the positive wiring harness on the wiring harness fixing block, one end of the speed regulating conductive sheet is welded to the speed regulating wiring harness on the wiring harness fixing block, and the other ends of the positive conductive sheet and the speed regulating conductive sheet are welded to the positive pin and speed regulating pin of the PCBA board.

5. The motor controller assembly for driving an automobile cooling fan according to claim 4, characterized in that: The conductive bracket includes the inductor mounting seat, the sealing insert and the conductive sheet embedded connecting frame. The inductor mounting seat and the conductive sheet embedded connecting frame are provided with screw mounting parts. The conductive sheet embedded connecting frame is arranged on the outside of the PCBA board. A support column resting on the board surface of the PCBA board is provided below the conductive sheet embedded connecting frame. The positive conductive sheet, the speed regulating conductive sheet and the negative electrode connecting sheet are all embedded in the conductive sheet embedded connecting frame.

6. The motor controller assembly for driving an automobile cooling fan according to claim 5, characterized in that: The positive electrode conductive sheet, the speed regulating conductive sheet and the negative electrode connecting sheet are all connected by connecting ribs that are easy to be punched out, and the connecting ribs are exposed outside the conductive sheet embedded in the connecting frame.

7. The motor controller assembly for driving an automobile cooling fan according to claim 6, characterized in that: The sealing insert is provided with clamping grooves on both sides of the installation notch, the heat sink is provided with an operation window at the wiring harness installation area, a sealing cover is installed at the operation window, and the wiring harness installation area is sealed with glue.

8. The motor controller assembly for driving an automobile cooling fan according to claim 7, characterized in that: The PCBA board includes a lower PCB board and an upper PCB board. The lower PCB board is provided with fixing holes for convenient bolt fixing. The lower PCB board is provided with a component group with high heat generation, and the upper PCB board is provided with a component group with low heat generation. The lower PCB board is fixed with a positive pin seat, a negative pin seat, a speed control pin seat and three winding pin seats. The lower PCB board is provided with a support structure for supporting the upper PCB board. The positive pin seat is provided with a positive lead for connecting the positive wire harness. The negative pin is provided on the negative pin seat and is used to connect the negative wiring harness. The speed regulating pin seat is provided with a speed regulating pin for connecting the speed regulating wiring harness. The three winding pin seats are respectively provided with phase electrical pins welded to the lower PCB board and used to be electrically connected to the three-phase windings of the motor stator one by one. The positive pin, negative pin and speed regulating pin all pass through the upper PCB board and are welded to both the upper PCB board and the lower PCB board. The three winding pin seats are also provided with connecting pins for connecting the upper PCB board and the lower PCB board.

9. The motor controller assembly for driving an automobile cooling fan according to claim 8, characterized in that: The three winding pin seats have the same structure. The winding pin seat includes a winding seat body. The lower end of the winding seat body is provided with at least two insertion protrusions. The lower PCB board is provided with an insertion positioning hole for facilitating the positioning of the insertion protrusions. The winding seat body is provided with a first mounting portion and a second mounting portion. The lower ends of the first mounting portion and the second mounting portion are both provided with a first avoidance groove and a second avoidance groove. The phase power pins and the connecting pins are respectively embedded in the first mounting portion and the second mounting portion. The upper ends of the phase power pins and the connecting pins are exposed. The lower ends of the phase power pins and the connecting pins are respectively located in the first avoidance groove and the second avoidance groove and exposed. The lower ends of the phase power pins and the connecting pins are welded and fixed to the lower PCB board.

10. The motor controller assembly for driving an automobile cooling fan according to claim 9, characterized in that: The support structure includes a plurality of support protrusions, which support the upper PCB board. The lower ends of the phase power pins and the communication pins are bent and welded to the upper surface solder points of the lower PCB board.

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