Motor box with adapter, converter, controller, large line, tail light, electric car

Abstract

The application discloses a motor box, an adapter, a converter, a controller, a large wire, a tail light and an electric vehicle. The motor box comprises an MCU circuit, a communication circuit, a controller circuit and a converter circuit. The MCU circuit is connected with the communication circuit, the controller circuit and the converter circuit. The MCU circuit comprises an MCU chip. The converter circuit converts the voltage of a storage battery to a rated safe voltage to supply power to electric vehicle electrical components. The converter circuit comprises a PWM driving circuit, an electronic switch circuit, an inductor circuit, a freewheeling circuit, a filter circuit and a voltage acquisition circuit. The application has the advantages of bus control of electric vehicle electrical structure, high intelligence, simple structure, convenient installation and maintenance, low cost and high reliability.

Description

Technical Field

[0001] In the field of electric vehicle technology, specifically "electric vehicle electrical systems". Background Technology

[0002] For ease of description, the following abbreviations will be used:

[0003] "Main wires" refers to the wire harnesses connecting the electrical components of an electric vehicle. They are usually bundled together and connected to various electrical components, and are sometimes called wire harnesses.

[0004] "Electric vehicles" refers to battery-powered vehicles, including four-wheeled electric cars, electric sightseeing vehicles, electric sweepers, electric forklifts, children's vehicles, electric bicycles, electric-assisted bicycles, electric motorcycles, and electric tricycles.

[0005] A "plug" refers to an electronic device with prongs at the end of a wire that enables an electrical connection.

[0006] "Wire end" refers to a short section of wire coming out of an electrical component.

[0007] "Headlights" refers to the high or low beam headlights used for illumination at the front of small electric vehicles.

[0008] "Daylight lights," also known as driving lights or daytime running lights, refer to the lights that illuminate when an electric vehicle is turned on.

[0009] "Night light" refers to the light that illuminates when the headlights of an electric vehicle are turned on. It is used for driving at night and is equivalent to the parking lights of a large vehicle.

[0010] "Headlight assembly" refers to a component installed on the front handlebars or dashboard of an electric vehicle, used for illumination and also displaying the vehicle's parameters. Alternatively, it can be a component that originally provided simple headlight illumination but, after applying the adapter circuit of this invention, adds an instrument display function. It is also called a lamp head or combination headlight.

[0011] "Instrument cluster" refers to a component at the front of an electric vehicle that displays the vehicle's parameters, including components integrated with the headlights. Alternatively, it may be a component that, after incorporating the adapter circuit of this invention, adds the functions of connecting and processing electrical signals from the vehicle's front end. It is also called a meter head.

[0012] A "combination switch" refers to a component installed on the handlebars or dashboard that combines multiple switches, such as a light switch, turn signal switch, horn switch, three-position switch, or cruise control switch. A combination of two switches is called a two-in-one switch, three switches is called a three-in-one switch, and four switches is called a four-in-one switch. Currently, three-in-one switches are the most commonly used in the market.

[0013] A "combination throttle" refers to a component mounted on the handlebars or dashboard, consisting of multiple switches combined with the throttle, such as single or multiple combinations of light switches, turn signals, horn switches, park (P) switches, reverse switches, third gear switches, cruise control switches, etc. A combination of two switches is called a two-in-one throttle, three switches is called a three-in-one throttle, and four switches is called a four-in-one throttle. Currently, two-in-one throttles are the most commonly used in the market.

[0014] "Electronic switching tubes" generally refer to Darlington transistors, IGBT transistors, or MOSFETs.

[0015] "Vehicle front electrical appliances" refers to all electrical appliances near the front instrument panel of an electric vehicle, such as ignition switch, brake switch, reverse switch, gear switch, P gear switch, repair switch, cruise control switch, various lights, wipers, horn, doors, air conditioner, audio system, etc.

[0016] A "converter" is a component that converts battery voltage (48V, 72V to 300V) to a lower voltage (usually 24V for large vehicles and 12V for small vehicles).

[0017] "Previous patent" refers to Chinese patent "CN202220040948X".

[0018] The connection between the motor box and the controller described in the previous patent relies on a wiring harness. This wiring harness includes single or multiple combination signal lines for throttle signal, brake signal, lockout line, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft / hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, power supply positive terminal, and power supply negative terminal. This connection method involves too many and complex wires, is prone to wiring errors, is too costly, has many potential failure points, and reduces reliability.

[0019] Furthermore, this motor box does not include a converter function. However, electric vehicles approved by the national standard require a safe 12V low-voltage voltage. Therefore, electric vehicles need a converter to convert the high voltage (greater than 48V) of the battery to a low 12V voltage. This necessitates the installation of an additional electrical component, increasing cost, requiring more installation space, adding wiring, adding a production step, increasing power consumption, and creating another potential point of failure. Summary of the Invention

[0020] The present invention aims to improve upon the aforementioned shortcomings of the previous patent by making some important improvements.

[0021] This invention adds a communication method to the connection between the motor box or converter and the controller, replacing the original wiring harness with a communication cable. If a single-wire half-duplex communication mode (LIN or single-wire UART communication) is used, one cable replaces more than ten original cables. This simplifies wiring, minimizes connection errors, reduces costs, minimizes potential failure points, and increases reliability.

[0022] By utilizing the communication follow-up switch circuit of this motor box or converter, and in conjunction with the human-machine interface of the adapter, the electric vehicle electrical system (including the motor box or converter and controller) can be turned on and off using a remote control, mobile APP or NFC card via communication cable, without the need for a dedicated switch such as an ignition lock.

[0023] The indirect overload protection mode of this invention achieves power control and overcurrent protection of the converter circuit output based on the input power supply voltage and PWM duty cycle value. This saves the cost of resistor sampling circuits, operational amplifier circuits, current acquisition circuits, and comparator circuits found in traditional converters, while improving reliability. Because fewer components, the failure rate is naturally lower. This is also an innovation.

[0024] This motor box or converter provides operating power to the controller, saving the cost of the controller's primary power supply circuit.

[0025] Furthermore, this motor box incorporates a converter function, utilizing the MCU chip, power circuit, communication circuit, battery voltage detection circuit, casing, production process, and inspection process of the shared motor box, thus saving material and labor costs. It also reduces installation space, wiring, production process, power consumption of one component, and potential point of failure. This highlights the novelty and practicality of this motor box.

[0026] An electric motor housing, the electric motor housing comprising an MCU circuit, a communication circuit, a controller circuit, and a converter circuit.

[0027] The MCU circuit is connected to the communication circuit, the controller circuit, and the converter circuit.

[0028] The MCU circuit contains an MCU chip.

[0029] The converter circuit converts the battery voltage to a rated safe voltage to power the electrical components of the electric vehicle. Typically, large vehicles use 24V and small vehicles use 12V.

[0030] The converter circuit includes a PWM drive circuit, an electronic switch circuit, an inductor circuit, a freewheeling circuit, a filter circuit, and a voltage acquisition circuit.

[0031] The MCU chip includes an internal PWM module, and the output pins of the MCU circuit are connected to the PWM drive circuit and the voltage acquisition circuit. The electronic switch circuit is connected to the PWM drive circuit and also to the inductor circuit. The freewheeling circuit is connected to the inductor circuit. The filter circuit is connected to both the inductor circuit and the freewheeling circuit.

[0032] The electronic switching circuit includes an electronic switching transistor. MOSFETs are the most common, especially n-channel ones.

[0033] The PWM drive circuit includes the drive circuit required for the control electrode of the electronic switch, consisting of resistors, capacitors, and transistors, or implemented by a dedicated drive chip. The capacitors include bootstrap capacitors and Miller capacitors. The former is low-cost but complex, while the latter is simple but expensive.

[0034] The inductor circuit includes an inductor, typically a high-power inductor with a magnetic core and a capacity greater than 10uH.

[0035] The freewheeling circuit includes a freewheeling diode.

[0036] The filter circuit includes electrolytic capacitors, typically greater than 100uF.

[0037] The voltage acquisition circuit includes a resistor voltage divider circuit.

[0038] The communication circuit is connected to the adapter via a mainline cable. This mainline cable includes communication lines. The motor box is connected to the adapter via the mainline cable and exchanges data bidirectionally according to the communication protocol. This is the basic structure of the electric vehicle bus control system.

[0039] The controller circuit is connected to the controller. The motor box transmits the signals required by the controller from the adapter via the main line according to the communication protocol, and outputs them to the controller after conversion by the controller circuit. The motor box also transmits the signals output by the controller to the adapter via the main line according to the communication protocol after conversion by the controller circuit. The circuit structure is described in the previous patent.

[0040] Some models of the motor box also include a foot brake detection circuit, which is connected to the foot brake switch. The MCU circuit is connected to the foot brake detection circuit. If the foot brake switch is connected to the front adapter, or if the vehicle does not have a foot brake switch (such as a two-wheeled vehicle), the foot brake detection circuit is omitted. This is optional.

[0041] Some models of the motor box also include a taillight control circuit, which is connected to the taillight. The MCU circuit is connected to the taillight control circuit. The taillight signal from the adapter is transmitted to the motor box via the main line according to the communication protocol, and then the taillight is controlled by the taillight control circuit.

[0042] If the taillights are directly controlled by the adapter, the taillight control circuit can be eliminated. However, this would increase the number of wires in the main wiring harness, making the structure more complex.

[0043] The taillight control circuit includes an electronic switch overcurrent protection circuit, as described in the previous patent.

[0044] If the adapter centrally controls the taillights via a dedicated line, the taillight control circuit can be omitted. This is optional.

[0045] Some models of the motor box include a communication follow-up switch circuit, as described in Chinese patent CN201822156710X. This communication follow-up switch circuit connects the communication line and the power circuit, switching the motor box's power supply on and off based on the signal from the communication line. This eliminates the need for an ignition switch cable and ignition lock. This structure allows the adapter to control the operating status of the motor box and controller, enabling system power on / off via remote control, mobile app, or NFC card.

[0046] The controller circuit includes a motor communication circuit. The motor communication circuit is connected to the controller via a motor cable.

[0047] The motor wiring includes a communication line. The number of wires varies depending on the communication mode; this invention preferably uses a single-wire half-duplex mode, requiring only one wire.

[0048] The motor box exchanges data bidirectionally with the controller via the motor cable according to the communication protocol.

[0049] The communication line replaces the existing wiring harness of the motor box. This wiring harness includes single or multiple combination signal lines for throttle signal, brake signal, lock signal, reverse, third gear, cruise control, P gear, anti-theft motor, one-key repair, soft / hard start, rated voltage switching, motor learning, motor linear speed, and motor linear speed. See previous patent.

[0050] With the improvements made by this invention, the connection between the motor box and the controller becomes particularly simple.

[0051] The motor wiring between the motor box and the controller is centralized into a single socket. This reduces production line steps and labor costs compared to multiple plugs. However, if multiple plugs are used, the motor box and the controller will still function without issue.

[0052] The motor wiring is divided into communication mode and wiring harness mode.

[0053] The motor wiring in the communication mode includes a positive power supply line, a negative power supply line, and a communication line. If the controller does not have a communication follow-up switch circuit, the wiring also includes a latching line for switching the controller's operating power.

[0054] The motor wiring harness includes single or multiple combination signal lines for throttle signal, brake signal, lockout line, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft and hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, power supply positive terminal, and power supply negative terminal.

[0055] The positive and negative power lines refer to the power lines inside the controller that connect to the battery. Connecting them to the motor box from here is more convenient. Alternatively, a separate socket can be used to connect the battery externally, but this complicates the wiring to the motor box.

[0056] For some models of the motor housing, to reduce the cost of the controller, the motor wiring also includes a working power output line to provide primary power to the controller. The controller internally requires a 10-18V MOSFET working power supply and a 3.3-5.0V power supply for the MCU system input from this MOSFET. The former is called the primary power supply, and the latter is called the secondary power supply. This eliminates the cost of the controller's primary power supply circuit. For wiring harness configurations, the latching output line can be replaced with the working power output line. Preferably, the voltage of the working power output line is 15V. If the controller requires its own independent primary power supply, the output line of the converter circuit can be omitted. This is optional.

[0057] The motor box includes a housing and a PCB circuit board. The housing includes a bottom shell. The bottom shell is the side that holds the PCB circuit board in place. In some models of the motor box, for waterproofing and dustproofing, the connectors and sockets of the PCB circuit board face downwards or at an angle, while the bottom shell faces upwards or at an angle. This is optional, but this installation method is the safest.

[0058] The converter circuit includes an overload protection circuit. This is to protect the converter circuit and prevent it from burning out. It also prevents short circuits in electric vehicles from causing fires.

[0059] The overload protection circuit is divided into direct control mode and indirect control mode.

[0060] The direct control mode includes a resistor sampling circuit, an operational amplifier circuit, a current acquisition circuit, and a comparator circuit. The MCU circuit is connected to the current acquisition circuit. The operational amplifier circuit is connected to both the current acquisition circuit and the resistor sampling circuit. The comparator circuit is connected to both the MCU circuit and the resistor sampling circuit. The operational amplifier circuit includes an operational amplifier chip. If the MCU chip includes an internal operational amplifier module, the operational amplifier circuit can be omitted. The comparator circuit includes a comparator. If the MCU chip includes an internal comparator module, the comparator circuit can be omitted. The resistor sampling circuit includes a sampling resistor and a signal output filter circuit. The MCU circuit limits the current based on the output value of the operational amplifier circuit. The MCU circuit implements overload or short-circuit protection based on the output of the comparator circuit, typically triggered by an interrupt routine of the MCU chip. The advantage of this mode is that the current limiting value and overload threshold value are relatively accurate and consistent; the disadvantage is the high circuit cost.

[0061] The indirect control mode includes an input power supply voltage acquisition circuit. The MCU circuit is connected to the input power supply voltage acquisition circuit. The input power supply voltage acquisition circuit includes a voltage divider resistor circuit for adjusting the input voltage range of the power signal to the MCU chip's ADC channel. The MCU chip roughly implements power control and overcurrent protection of the converter circuit output based on the input power supply voltage and PWM duty cycle. The converter's output power is proportional to the product of voltage and duty cycle; this is the basis for current limiting. If the product suddenly increases beyond the limit, it is considered an overload or short circuit, and protection is activated. The advantage of this mode is low cost, completely eliminating the cost of operational amplifier circuits, comparator circuits, and sampling resistor circuits. The disadvantage is that the limit values ​​are not accurate and consistency is poor.

[0062] For high-power converter output, the converter circuit also includes a temperature detection circuit and a fan control circuit. Because high-power converters generate a lot of heat, a fan is necessary for cooling. The MCU circuit connects the temperature detection circuit and the fan control circuit. The temperature detection circuit includes a temperature sensor. The fan control circuit includes an electric fan. When the MCU circuit detects that the heatsink temperature is higher than the set value, it starts the electric fan to cool it down. If the temperature still cannot be lowered, the output power is reduced, and an alarm is triggered. Low-power converter circuits do not require a temperature detection circuit and a fan control circuit; heat dissipation is achieved through the casing.

[0063] A converter comprising converter circuitry of the motor housing.

[0064] One end of the converter is connected to a main cable, and bidirectionally exchanges data with the adapter through the main cable according to the communication protocol. The other end is connected to a wire harness or communication line, and is connected to the controller through the wire harness or communication line, and transmits signals bidirectionally.

[0065] The wiring harness includes single or multiple combination signal lines for throttle signal, brake signal, lockout line, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft and hard start, rated voltage switching, motor learning, motor linear speed, motor linear speed, power supply positive terminal, and power supply negative terminal.

[0066] Some models of the converter also include the taillight control circuit, which is connected to the taillight.

[0067] Some models of the converter also include a foot brake detection circuit, which is connected to the foot brake switch. Small electric vehicles do not have a foot brake detection circuit.

[0068] In some models of the converter, to reduce the cost of the controller, the wiring harness or communication line also includes a power output line to provide a primary power supply to the controller. That is, the controller can eliminate its own primary power supply circuit, typically generating 15V.

[0069] An adapter is provided that connects to the motor box or the converter via a main cable and exchanges data bidirectionally with the motor box or the converter according to a communication protocol.

[0070] The adapter includes an MCU circuit, a functional circuit, a communication circuit, and a functional socket circuit.

[0071] The MCU circuit includes an MCU chip and connects to the functional circuit and the communication circuit. The functional socket circuit connects to the functional circuit and the communication circuit.

[0072] The functional circuit includes a combination throttle circuit, a combination switch circuit, a voice broadcast circuit, an electronic fuse circuit, a lighting control circuit, an instrument display circuit, and a human-machine interaction circuit. The combination throttle circuit, the combination switch circuit, the voice broadcast circuit, the electronic fuse circuit, the lighting control circuit, the instrument display circuit, and the human-machine interaction circuit are all connected to the MCU circuit.

[0073] The functional socket circuit includes a single-row socket and / or a double-row socket corresponding to the functional circuit, and is connected to the functional circuit. The single-row socket and / or the double-row socket are respectively connected to the vehicle's front electrical components.

[0074] The functional socket circuit includes a single-row or double-row mainline socket. The mainline socket connects to a mainline cable. The mainline cable includes a communication cable, the front end of which connects to the adapter, and the rear end connects to a converter or motor box.

[0075] The voice broadcasting circuit includes a voice chip circuit and a power amplifier circuit. The voice chip circuit is connected to the power amplifier circuit, and the power amplifier circuit is connected to a speaker. The voice chip circuit is connected to the MCU circuit and is used to play the electric vehicle's parameters (including fault information) and corresponding operation sounds.

[0076] The electronic fuse circuit is connected to the MCU circuit. The electronic fuse circuit includes an electronic switch circuit, a sampling resistor circuit, and a comparator circuit. The sampling resistor circuit is connected to the comparator circuit, and the MCU circuit is connected to both the electronic switch circuit and the comparator circuit. The electronic fuse circuit monitors the current of all electrical appliances in the vehicle or at the front of the vehicle; if an overcurrent occurs, it cuts off the power supply, thereby protecting the associated electrical appliances.

[0077] The lighting control circuit is connected to the MCU circuit. The lighting control circuit is also connected to the combination throttle circuit, the combination switch circuit, the electronic fuse circuit, and the instrument display circuit, and is used to control and display the status of the electric vehicle's lights. The lighting control circuit also includes a flashing circuit. The flashing circuit includes an electronic switch tube and is connected to the MCU circuit.

[0078] The instrument display circuit is connected to the MCU circuit and is used to display the vehicle's status and parameters.

[0079] The human-machine interface circuit is connected to the MCU circuit and is used by the vehicle owner to operate the electric vehicle for power on / off and anti-theft functions. It includes a connection circuit for the remote control, mobile app, or NFC card.

[0080] The adapter connects to the power supply circuit of the motor box or converter via the communication line and controls its switching. The working principle is described in Chinese Patent CN201822156710X. In this way, the operating status of the motor box and controller is controlled by the adapter, and the electric vehicle's electrical system can be switched on and off using a remote control, mobile app, or NFC card, eliminating the need for a dedicated switch such as an ignition lock.

[0081] A large wire, one end of which is connected to the motor box or the converter, and the other end of which is connected to the adapter.

[0082] The main cable includes a communication cable. The motor box or the converter exchanges data bidirectionally with the adapter via the main cable according to a communication protocol.

[0083] The main line includes the output line of the converter circuit, which is used to provide power to the electrical components at the front of the vehicle. Typically, the main vehicle uses 24V and the passenger vehicle uses 12V.

[0084] The simplest type of wire has only four wires: power, ground, and communication. If the negative terminal is grounded, there are only three wires.

[0085] For applications where the adapter centrally controls taillights, the main wiring also includes non-communication wires, such as night light wires, left turn light wires, right turn light wires, reversing light wires, and brake light wires.

[0086] For the application of the adapter to control the taillights according to the communication protocol, one plug is used at each end of the main wire.

[0087] A controller that connects to the motor housing or the converter via a wiring harness or communication connection and transmits signals bidirectionally.

[0088] The wiring harness connection includes single or multiple combinations of signals such as throttle signal, brake signal, lockout signal, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft and hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, power supply positive terminal, and power supply negative terminal.

[0089] The communication connection includes a communication line, a positive power terminal, and a negative power terminal. The number of wires in the communication line varies depending on the communication mode; the simplest is a single-wire half-duplex communication mode, which requires only one wire. The controller includes an MCU circuit and a communication circuit. The communication circuit connects to the motor box or the converter via the communication line, transmitting data bidirectionally according to the communication protocol. Replacing the aforementioned wiring harness with a communication line reduces costs and increases reliability.

[0090] To save on the cost of the controller's primary power supply circuit, the wiring harness or communication connection also includes a working power output line to provide its own primary power. This working power output line provides 10-18V. The controller can omit its own primary power supply circuit, typically generating 15V.

[0091] The controller includes an MCU circuit and a motor control circuit. The MCU circuit is connected to the motor control circuit. The motor control circuit includes a three-phase bridge arm upper and lower motor phase line drive circuit, a three-phase bridge arm upper and lower electronic switch transistor circuit, a motor rotor position sensor circuit, a sampling resistor circuit, a comparator circuit, and an operational amplifier circuit. This falls within the scope of traditional motor control circuits.

[0092] The control signals required by the controller are collected and processed by the adapter and transmitted to the motor box or converter via the main line according to the communication protocol, and then processed by the motor box or converter before being transmitted.

[0093] The internal parameters and fault information that the controller needs to output are processed by the motor box or converter and then transmitted to the adapter via the main line according to the communication protocol.

[0094] A taillight, the taillight being connected to the motor box or the converter, and connected to the adapter via the main wire.

[0095] The taillight includes a lamp body, a wiring harness, and a plug. The wiring harness connects the lamp body and the plug. The plug connects to the motor housing or the converter.

[0096] The lamp body includes a taillight assembly. The taillight assembly includes a night light, left and right turn signals, and brake lights; some also include a reversing light and / or fog lights. The ground wire or power wire of the taillight assembly is shared. The outgoing wires of the taillight assembly are connected together to the plug.

[0097] The taillights are divided into integrated taillights and split taillights. The taillight assembly of the integrated taillight is housed in a single lamp body. The turn signals of the split taillights are housed in two separate lamp bodies.

[0098] The taillights are classified into two types: common anode mode and common ground mode. In the common anode mode, all positive terminals of the taillight assembly are connected to a single positive terminal, while in the common ground mode, all negative terminals of the taillight assembly are connected to a single negative terminal.

[0099] The taillight switch information is transmitted by the adapter to the motor box or converter via the main line according to the communication protocol.

[0100] An electric vehicle, wherein the electric vehicle is equipped with the motor box, or the adapter, or the converter, or the main cable, or the controller, or the taillight.

[0101] Effects of the invention:

[0102] This invention adds a communication method to the connection between the motor box and the controller, replacing the original wiring harness with a communication cable. If a single-wire half-duplex communication mode (LIN or single-wire UART communication) is used, one cable replaces more than ten original cables. This simplifies wiring, minimizes connection errors, reduces costs, minimizes potential failure points, and increases reliability.

[0103] The communication of this motor box or converter follows the switching circuit and works with the human-machine interface of the adapter. It uses a remote control, mobile APP or NFC card to complete the power on / off of the electric vehicle electrical system (including the motor box or converter and controller) via communication cable, without the need for a dedicated power switch such as an ignition lock.

[0104] The indirect overload protection mode of this invention achieves power control and overcurrent protection of the converter circuit output based on the input power supply voltage and PWM duty cycle value. This saves the cost of resistor sampling circuits, operational amplifier circuits, current acquisition circuits, and comparator circuits found in traditional converters, while improving reliability. Because fewer components, the failure rate is naturally lower. This is also an innovation.

[0105] This motor box or converter provides operating power to the controller, saving the cost of the controller's primary power supply circuit.

[0106] Furthermore, this motor box incorporates a converter function, utilizing the MCU chip, power circuit, communication circuit, battery voltage detection circuit, casing, production process, and inspection process of the shared motor box, thus saving material and labor costs. It also reduces installation space, wiring, production process, power consumption of one component, and potential point of failure. This highlights the novelty and practicality of this motor box. Attached Figure Description

[0107] Figure 1 Application system circuit for split taillight motor box of large electric vehicle.

[0108] Figure 2 Application system circuit for integrated taillight motor box of small electric vehicle.

[0109] Figure 3 Motor box circuit.

[0110] Figure 4 Converter circuit.

[0111] Figure 5 Current limiting and protection circuit for converter direct control mode.

[0112] Figure 6 : Converter temperature control circuit. Detailed Implementation

[0113] Figure 1 This is a circuit diagram for a split taillight motor box application system in a large electric vehicle. The front electrical components are directly connected to an adapter. After signal processing, the signals are transmitted to the motor box (or converter) via a mains cable according to the communication protocol. The motor box (or converter) then sends signals to the controller, left taillight, and right taillight respectively. The switch information for the left and right taillights is centrally transmitted from the adapter via the communication cable. The foot brake signal, and signals that the controller and motor box or converter need to transmit, are then transmitted to the adapter via the communication cable. The adapter can be connected to an external instrument cluster or has its own built-in instrument cluster. Controller parameters and fault information can also be announced via voice.

[0114] The converter's input power comes from the controller. Inside the controller, this input power is directly connected to the positive and negative terminals of the battery. The converter's output powers the left and right taillights. It also powers the vehicle's front electrical systems via a mains cable.

[0115] Figure 2This is a circuit diagram for the integrated taillight motor box application system of a small electric vehicle. The front electrical components are directly connected to an adapter. After signal processing, the signals are transmitted to the motor box (or converter) via a mains cable according to the communication protocol. The motor box (or converter) then sends signals to the controller and taillight respectively. Taillight switch information is centrally transmitted from the adapter via the communication line. Signals that the controller, motor box, or converter needs to transmit are then transmitted to the adapter via the communication line. The adapter can be connected to an external instrument cluster or has its own built-in instrument cluster. Controller parameters and fault information can also be announced via voice.

[0116] The converter's input power comes from the controller. Inside the controller, this input power is directly connected to the positive and negative terminals of the battery. The converter's output powers the taillights and, via a mains cable, the front electrical components of the vehicle.

[0117] Figure 3 Motor box circuit.

[0118] The motor box circuit is divided into four main parts. The MCU circuit is the core of the motor box, containing the MCU chip, also known as a microcontroller. It is an intelligent chip that implements relevant algorithms and control through software programming.

[0119] The main technical parameters to consider when selecting an MCU chip are: operating speed, temperature range, number of GPIOs, FLASH size, RAM size, and external communication port mode. Many microcontrollers on the market can meet these requirements, including multiple brands from manufacturers such as Microchip, Freescale, ST, Infineon, and Cypress. Furthermore, there are also many domestic brands available.

[0120] The communication circuit primarily handles communication with the adapter. Communication modes include UART, Lin, CAN, I2C, RS485, and GPIO analog communication. In low-end products such as electric bicycles, electric motorcycles, and electric tricycles, UART, I2C, and GPIO analog communication are generally chosen. In high-end applications such as electric cars, electric patrol cars, electric sightseeing vehicles, and electric fire trucks, RS485, Lin, and CAN communication are typically used. The specific circuit varies depending on the communication mode.

[0121] The UART, I2C, and GPIO analog communication ports are directly connected. However, communication is master-slave based, and generally, the master communication module requires a pull-up resistor on its communication line. This invention recommends using an adapter as the master module and the motor box as the slave module.

[0122] For Lin, I2C, and 485 communication modes, a separate communication driver chip or circuit is required. Many models of these chips are available and can be found on professional websites. In this case, the communication circuit needs to be designed in accordance with these communication driver chips or circuits. Specific circuit details can be found in the relevant chip's datasheet. Some MCU chips already integrate the driver chip for this communication mode; in this case, no additional components are needed, and the communication line can be directly led out.

[0123] The controller circuit is responsible for interacting with the controller. There are two interaction methods: harness mode and communication mode.

[0124] The wiring harness contains many wires, including: throttle signal, brake signal, lockout wire, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft / hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, power supply positive, power supply negative, and working power output wires (single or multiple combinations of signals). Among these, the motor's linear speed, motor's linear speed, power supply positive, and power supply negative are the controller's output signal lines. The other signal lines are output from the motor box or converter and are used to control the controller. The working power output line is the primary power supply from the motor box or converter to the controller, designed to save costs.

[0125] The communication mode requires very few wires, including: a positive power supply wire, a negative power supply wire, a communication line, and a working power output line. The communication mode is selected as single-wire half-duplex, which can be implemented using GPIO pins or UART, requiring only one wire. The working power output line is selected as a 15V output, directly powering the controller. The motor box or converter, as well as the controller's power on / off, are entirely controlled by the adapter via the communication line, and can be operated remotely via a remote control, mobile app, or NFC card.

[0126] The taillight control circuit connects to the taillights, and its switch is transmitted via an adapter through a communication line, decoded by the motor box or converter. If the taillights are centrally controlled by the adapter, the taillight control circuit is eliminated. The adapter controls the taillights via multiple dedicated lines.

[0127] Compared to the previous patent, this invention adds a converter circuit section.

[0128] The converter circuit is responsible for converting the battery voltage into the voltage required by the electric vehicle through DC / DC conversion, typically 12V and 24V.

[0129] The converter circuit includes a PWM drive circuit, an electronic switch circuit, an inductor circuit, a freewheeling circuit, a filter circuit, and a voltage acquisition circuit.

[0130] The MCU chip selected is one with a PWM module. The PWM drive circuit consists of transistors, resistors, bootstrap capacitors, and Miller capacitors at the gate of the MOSFETs, thus saving costs. The electronic switching circuit uses a 75NF75 NMOS transistor. The inductor circuit uses a 12uH magnetic ring inductor, and the PWM period is 16kHz. The freewheeling circuit uses a 20100 freewheeling diode. The filter circuit uses a 470uF / 25V electrolytic capacitor. The voltage acquisition circuit uses a 10K / 5.1K voltage divider circuit. This is the main circuit of the converter.

[0131] Figure 5 The current limiting and protection circuit in the direct-control mode of the converter is part of the converter circuit and consists of a resistor sampling circuit, an operational amplifier circuit, a current acquisition circuit, and a comparator circuit. The signal from the resistor sampling circuit is amplified by the operational amplifier circuit, passes through the current acquisition circuit, and is then connected to the ADC input of the MCU chip to obtain the current value. The signal from the resistor sampling circuit is input to the comparator circuit, and then connected to the interrupt input pin of the MCU chip to achieve overcurrent or short-circuit protection. A 0.010mR sampling resistor, an LM358 operational amplifier, and a comparator can be selected to implement this.

[0132] Figure 6 This is the temperature control circuit for the converter, and also part of the converter circuitry. It's used in high-power converters. The circuit also includes a temperature detection circuit and a fan control circuit. When the MCU circuit detects that the heatsink temperature is higher than the set value, it starts the electric fan to cool it down. If the temperature still cannot be lowered, the output power is reduced, and an alarm is triggered. Low-power converter circuits do not require temperature detection and fan control circuits; they rely on the casing for heat dissipation.

[0133] The embodiments and descriptions above are merely illustrative of the principles of the present invention and one example. Various changes and modifications may be made based on these principles, and all such changes and modifications fall within the scope of protection of the present invention.

Claims

1. A motor box, characterized in that: The motor box includes an MCU circuit, a communication circuit, a controller circuit, a taillight control circuit, and a converter circuit; The MCU circuit is connected to the communication circuit, the controller circuit, the taillight control circuit, and the converter circuit; The MCU circuit includes an MCU chip; The converter circuit converts the battery voltage to a rated safe voltage to power the electrical components of the electric vehicle. The converter circuit includes a PWM drive circuit, an electronic switch circuit, an inductor circuit, a freewheeling circuit, a filter circuit, and a voltage acquisition circuit. The MCU chip includes an internal PWM module; the output pins of the MCU circuit are connected to the PWM drive circuit and the voltage acquisition circuit; the electronic switch circuit is connected to the PWM drive circuit and the inductor circuit; the freewheeling circuit is connected to the inductor circuit; the filter circuit is connected to the inductor circuit and the freewheeling circuit. The electronic switching circuit includes an electronic switching transistor; The PWM drive circuit includes the drive circuit required for the control electrode of the electronic switch tube, which consists of resistors, capacitors and transistors; or it may be composed of a dedicated drive chip. The inductor circuit includes an inductor; The freewheeling circuit includes a freewheeling diode; The filter circuit includes an electrolytic capacitor; The voltage acquisition circuit includes a resistor voltage divider circuit; The converter circuit includes an overload protection circuit; the overload protection circuit is divided into direct control mode and indirect control mode; the direct control mode includes a resistor sampling circuit, an operational amplifier circuit, a current acquisition circuit, and a comparator circuit; the MCU circuit is connected to the current acquisition circuit; the operational amplifier circuit is connected to the current acquisition circuit and the resistor sampling circuit; the comparator circuit is connected to the MCU circuit and the resistor sampling circuit; the operational amplifier circuit includes an operational amplifier chip; the comparator circuit includes a comparator; the resistor sampling circuit includes a sampling resistor and a signal output filter circuit; the MCU circuit limits the current based on the output value of the operational amplifier circuit; the MCU circuit implements overload or short-circuit protection based on the output of the comparator circuit; the indirect control mode includes an input power supply voltage acquisition circuit; the MCU circuit is connected to the input power supply voltage acquisition circuit; the input power supply voltage acquisition circuit includes a voltage divider resistor circuit for adjusting the input voltage range of the power supply signal to the ADC channel of the MCU chip; the MCU chip implements power control and overcurrent protection of the converter circuit output based on the input power supply voltage and the PWM duty cycle value; The communication circuit is connected to the adapter via a main line; the main line includes a communication line; the motor box is connected to the adapter via the main line and exchanges data bidirectionally according to the communication protocol. The controller circuit is connected to the controller; the motor box transmits the signals required by the controller from the adapter via the main line according to the communication protocol, and outputs them to the controller after conversion by the controller circuit; the motor box transmits the signals output by the controller to the adapter via the main line according to the communication protocol after conversion by the controller circuit. The motor wiring between the motor box and the controller is divided into communication mode and wiring harness mode. The motor wiring in communication mode includes a positive power supply wire, a negative power supply wire, and a communication wire. The motor wiring in wiring harness mode includes single or multiple combination signal wires for throttle signal, brake signal, lockout wire, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft and hard start, rated voltage switching, motor learning, motor linear speed, motor linear speed, positive power supply, and negative power supply. The motor box includes a taillight control circuit and is connected to the taillight; the MCU circuit is connected to the taillight control circuit; the taillight signal from the adapter is transmitted to the motor box via the main line according to the communication protocol, and then the taillight is controlled by the taillight control circuit.

2. The motor box according to claim 1, characterized in that: The motor box includes a foot brake detection circuit and is connected to a foot brake switch; The MCU circuit is connected to the foot brake detection circuit.

3. The motor box according to claim 1, characterized in that: The motor box includes a communication follow-up switch circuit; the communication follow-up switch circuit is connected to a communication line and a power supply circuit, and switches the operating power of the motor box according to the signal of the communication line.

4. A motor box according to claim 1, characterized in that: The motor wiring between the motor box and the controller is centralized in one socket.

5. A motor housing according to claim 1, characterized in that: The motor wiring includes a power output line for providing primary power to the controller.

6. A motor box according to claim 1, characterized in that: The motor box includes a housing and a PCB circuit board; the housing includes a bottom shell; the bottom shell is the side on which the PCB circuit board is fixed; the plug and socket side of the PCB circuit board faces downward or at an angle downward, and the bottom shell faces upward or at an angle upward.

7. A motor box according to claim 1, characterized in that: The converter circuit includes a temperature detection circuit and a fan control circuit; the MCU circuit connects the temperature detection circuit and the fan control circuit; the temperature detection circuit includes a temperature sensor; the fan control circuit includes an electric fan.

8. A converter, characterized in that: The converter includes the converter circuit of the motor box according to any one of claims 1 to 7; One end of the converter is connected to a main cable, and bidirectionally exchanges data with the adapter through the main cable according to the communication protocol. The other end is connected to a wire harness or communication line, and is connected to the controller through the wire harness or communication line, and transmits signals bidirectionally. The wiring harness includes single or multiple combination signal lines for throttle signal, brake signal, lockout line, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft and hard start, rated voltage switching, motor learning, motor linear speed, motor linear speed, power supply positive terminal, and power supply negative terminal.

9. A converter according to claim 8, characterized in that: The converter includes the taillight control circuit and is connected to the taillight.

10. A converter according to claim 8, characterized in that: The converter includes a foot brake detection circuit and is connected to a foot brake switch.

11. A converter according to claim 8, characterized in that: The wiring harness or communication line of the converter also includes a working power output line for providing a primary power supply to the controller.

12. An adapter, wherein the adapter is connected via a main cable to a motor box according to any one of claims 1 to 7 or a converter according to any one of claims 8 to 11, and exchanges data bidirectionally with the motor box or the converter according to a communication protocol; The adapter includes an MCU circuit, a functional circuit, a communication circuit, and a functional socket circuit; The MCU circuit includes an MCU chip and is connected to the functional circuit and the communication circuit; the functional socket circuit is connected to the functional circuit and the communication circuit. The functional circuit includes a combination throttle circuit, a combination switch circuit, a voice broadcast circuit, an electronic fuse circuit, a lighting control circuit, an instrument display circuit, and a human-machine interaction circuit; the combination throttle circuit, the combination switch circuit, the voice broadcast circuit, the electronic fuse circuit, the lighting control circuit, the instrument display circuit, and the human-machine interaction circuit are all connected to the MCU circuit; The functional socket circuit includes a single-row socket and / or a double-row socket corresponding to the functional circuit, and is connected to the functional circuit; the single-row socket and / or the double-row socket are respectively connected to the vehicle's front electrical components; The functional socket circuit includes a single-row or double-row main wire socket; the main wire socket is connected to a main wire; the main wire includes a communication line, the front end of which is connected to the adapter, and the rear end of which is connected to a converter or motor box; The voice broadcasting circuit includes a voice chip circuit and a power amplifier circuit. The voice chip circuit is connected to the power amplifier circuit, and the power amplifier circuit is connected to a speaker. The voice chip circuit is connected to the MCU circuit and is used to play the parameters and operation corresponding sounds of the electric vehicle. The electronic fuse circuit is connected to the MCU circuit; the electronic fuse circuit includes an electronic switch circuit, a sampling resistor circuit, and a comparator circuit; the sampling resistor circuit is connected to the comparator circuit, and the MCU circuit is connected to the electronic switch circuit and the comparator circuit; the electronic fuse circuit monitors the current of all electrical appliances in the vehicle or in front of the vehicle, and cuts off the power supply if an overcurrent occurs, thereby protecting the associated electrical appliances; The lighting control circuit is connected to the MCU circuit; The lighting control circuit is connected to the combination throttle circuit, the combination switch circuit, the electronic fuse circuit, and the instrument display circuit, and is used to control and display the status of the electric vehicle lights; the lighting control circuit also includes a flashing circuit; The flash circuit includes an electronic switching tube and is connected to the MCU circuit; The instrument display circuit is connected to the MCU circuit and is used to display the vehicle's status and parameters; The human-machine interaction circuit is connected to the MCU circuit and is used by the vehicle owner to operate the electric vehicle for power on / off and anti-theft functions. The adapter connects to the power supply circuit of the motor box or converter via the communication line and controls its switching.

13. A large wire, characterized in that: One end of the main wire is connected to the motor box according to any one of claims 1 to 7 or the converter according to any one of claims 8 to 11, and the other end is connected to the adapter according to claim 12. The main line includes a communication line; the motor box or the converter exchanges data bidirectionally with the adapter via the main line according to a communication protocol. The main line includes the output line of the converter circuit, which is used to provide power to the vehicle's front electrical components; The main line includes power lines, ground lines, and communication lines.

14. A controller, characterized in that: The controller is connected via a wiring harness or communication connection to the motor box according to any one of claims 1 to 7 or the converter according to any one of claims 8 to 11, and transmits signals bidirectionally; The wiring harness connection includes single or multiple combination signals such as throttle signal, brake signal, lockout signal, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft and hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, power supply positive terminal, and power supply negative terminal. The communication connection includes a communication line, a positive power supply terminal, and a negative power supply terminal; the controller includes an MCU circuit and a communication circuit; the communication circuit is connected to the motor box or the converter through the communication line and transmits data bidirectionally according to the communication protocol. The controller includes an MCU circuit and a motor control circuit; the MCU circuit is connected to the motor control circuit; the motor control circuit includes a three-phase bridge arm upper and lower motor phase line drive circuit, a three-phase bridge arm upper and lower electronic switch tube circuit, a motor rotor position sensor circuit, a sampling resistor circuit, a comparator circuit, and an operational amplifier circuit. The control signals required by the controller are collected and processed by the adapter and transmitted to the motor box or converter through the main line according to the communication protocol, and then processed by the motor box or converter before being transmitted. The internal parameters and fault information that the controller needs to output are processed by the motor box or converter and then transmitted to the adapter via the main line according to the communication protocol.

15. A taillight, characterized in that: The taillight is connected to the motor box according to any one of claims 1 to 7 or the converter according to any one of claims 8 to 11, and is connected to the adapter according to claim 12 via the large wire; The taillight includes a lamp body, a wiring harness, and a plug; the wiring harness connects the lamp body and the plug; the plug connects to the motor box or the converter. The lamp body includes a taillight assembly; the taillight assembly includes a night light, left and right turn signals and a brake light; the ground wire or power wire of the taillight assembly is shared; the outgoing wires of the taillight assembly are all plugged into the plug; The taillights are divided into integrated taillights and split taillights; the taillight components of the integrated taillights are placed in one lamp body; the turn signals of the split taillights are placed in two lamp bodies respectively. The taillights are of two types: common anode mode and common ground mode. In the common anode mode, all positive terminals of the taillight assembly are connected to one positive terminal, and in the common ground mode, all negative terminals of the taillight assembly are connected to one negative terminal. The taillight switch information is transmitted by the adapter to the motor box or converter via the main line according to the communication protocol.

16. An electric vehicle, characterized in that: The electric vehicle is equipped with a motor box as described in any one of claims 1 to 7, or a converter as described in any one of claims 8 to 11, or an adapter as described in claim 12, or a main wire as described in claim 13, or a controller as described in claim 14, or a taillight as described in claim 15.

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