Brushless motor frequency conversion controller

Abstract

The brushless motor frequency conversion controller comprises a shell, a PCB assembly and an EMC assembly, the shell comprises an upper cover and a lower cover, the upper cover and the lower cover are detachably connected, the upper cover is provided with a plurality of input terminals and a plurality of output terminals, the PCB assembly is arranged on the side, away from the upper cover, of the lower cover, and the EMC assembly is arranged on the side, away from the upper cover, of the lower cover. The input terminal and the output terminal penetrate through the lower cover in the thickness direction of the lower cover, the input terminal and the output terminal are electrically connected with the PCB assembly, the output terminal is used for being connected with a motor lead, the EMC assembly is arranged on the upper cover, and the EMC assembly is electrically connected with the input terminal to switch on a circuit. According to the brushless motor frequency conversion controller, the input terminal is arranged, so that the brushless motor frequency conversion controller can be conveniently connected with the motor lead, and the motor lead does not need to be directly welded with the PCB assembly. The EMC assembly is directly connected to the PCB assembly through the input terminal, and the EMC assembly and the PCB assembly do not need to be welded through a wire, thereby reducing the wiring difficulty, facilitating the production and assembly through automatic equipment, remarkably improving the production efficiency, and improving the product quality.

Description

Technical Field

[0001] The present application relates to the field of controller technology, and in particular to a brushless motor variable frequency controller. Background Art

[0002] The controller for power tools is a device that controls the mechanical quantity, working sequence and operation mode of power tools by controlling the electrical parameters of the power tools. It is mainly connected to the brushless motor in the power tools. With the continuous advancement of lithium battery technology and the changing needs of consumers, the power tool industry is showing a trend of cordless, lithium battery, integration and intelligence. As the core component of power tools, the controller plays a key role in promoting the development of this trend.

[0003] like Figure 1 As shown, the controller for electric tools on the market usually includes a PCB component 3, a switch 9 and an EMC component 4. The EMC component 4 is connected to the PCB component 3 via two input wires 200, the motor is connected to the PCB component 3 via three output wires 100, and the switch 9 is connected to the PCB component 3 via a flat cable.

[0004] In the existing controller, the three output lines 100 and the two input lines 200 are directly soldered to the circuit board of the PCB assembly 3. During the production process, they can only be manually soldered, and cannot be produced and assembled by automated equipment, resulting in low production efficiency and the quality of manual soldering cannot be guaranteed. Summary of the invention

[0005] In order to solve one of the above-mentioned technical defects, a brushless motor frequency conversion controller is provided in an embodiment of the present application to solve the technical problem in the prior art that the output line and the input line need to be directly soldered on the circuit board, resulting in the inability to perform automated production.

[0006] The present invention adopts the following technical solution:

[0007] Brushless motor variable frequency controller, including:

[0008] A housing, the housing comprising an upper cover and a lower cover, the upper cover and the lower cover are detachably connected, and the lower cover is provided with a plurality of input terminals and a plurality of output terminals;

[0009] A PCB assembly, wherein the PCB assembly is arranged on a side of the lower cover away from the upper cover, the input terminal and the output terminal both penetrate the upper cover along the thickness direction of the lower cover, the input terminal and the output terminal are both electrically connected to the PCB assembly, and the output terminal is used to connect a motor lead;

[0010] An EMC component is disposed on the upper cover, and the EMC component is electrically connected to the input terminal.

[0011] Optionally, the lower cover, the input terminal and the output terminal are made into an integral part by an insert injection molding process;

[0012] Alternatively, a plurality of through holes are arranged on the lower cover, and the input terminal and the output terminal are respectively arranged through the corresponding through holes, and the input terminal and the corresponding through hole are interference fit, and the output terminal and the corresponding through hole are interference fit.

[0013] Optionally, the upper cover and the lower cover are buckled together, and a wire connection cavity is formed between the upper cover and the lower cover;

[0014] The output terminal comprises a pin piece and a main body;

[0015] The pin piece passes through the lower cover and is connected to the PCB assembly. The main body is located in the wire connection cavity. The main body is provided with a connection port and a wire pressing screw hole, and the wire pressing screw hole is connected to the connection port.

[0016] One end of the motor lead can be inserted into the wiring port, and the wire pressing screw can be threadedly connected to the wire pressing screw hole to press the motor lead.

[0017] Optionally, the brushless motor variable frequency controller includes a connecting piece;

[0018] The connecting piece is located between the upper cover and the lower cover, and the connecting piece includes a main piece body and a bending piece;

[0019] The main sheet body is attached to the upper cover and / or the lower cover and is electrically connected to the input terminal. The bending sheet passes through the upper cover, and the bending sheet is respectively connected to the main sheet body and the EMC component.

[0020] Optionally, the upper cover is provided with a connection hole;

[0021] A thread groove is provided on one side of the input terminal facing the upper cover;

[0022] One end of the fastener passes through the upper cover and the connecting piece in sequence and is threadedly connected to the thread groove, and the other end of the fastener is limited on the upper cover.

[0023] Optionally, an annular retaining shell is provided on a side of the lower cover facing away from the upper cover, and a PCB accommodating groove is formed between the annular retaining shell and the lower cover;

[0024] The PCB assembly is located inside the annular retaining shell, and the PCB assembly partially extends out of the PCB accommodating groove;

[0025] The PCB receiving groove is filled with sealant.

[0026] Optionally, a support block is provided on a side of the lower cover facing away from the upper cover;

[0027] The inner wall of the annular retaining shell is provided with ribs;

[0028] The PCB assembly includes a main control circuit board. When the PCB assembly is installed on the lower cover, the support block and the clamp are respectively limited to two sides of the main control circuit board along the thickness direction to fix the main control circuit board.

[0029] Optionally, the PCB assembly includes a bracket, a heat sink and a plurality of power tubes;

[0030] The bracket is arranged on a side of the main control circuit board away from the lower cover;

[0031] A plurality of positioning grooves are arranged on the bracket;

[0032] Each of the power tubes is disposed in a corresponding positioning groove, each of the power tubes is located in a plane parallel to the main control circuit board, and each of the power tubes is connected to the main control circuit board;

[0033] The heat sink is arranged on a side of the bracket away from the main control circuit board, and the heat sink is in contact with the power tube;

[0034] Wherein, the sealant covers each of the power tubes.

[0035] Optionally, the bracket is connected to the main control circuit board via a fastener;

[0036] The edge of the bracket is provided with a plurality of claws, and the edge of the heat dissipation block is provided with a step;

[0037] Each of the clamping claws is clamped on the step.

[0038] Optionally, an EMC containing groove is provided on a side of the upper cover facing away from the lower cover, and the EMC component is arranged in the EMC containing groove;

[0039] The EMC containing groove is filled with sealant.

[0040] Optionally, the bottom wall of the EMC containing tank is provided with supporting ribs;

[0041] The peripheral side wall of the EMC containing groove is provided with a positioning buckle;

[0042] The EMC component includes a control circuit board. When the EMC component is installed on the upper cover, the positioning buckles and the supporting ribs are located on both sides of the control circuit board along the thickness direction.

[0043] Optionally, the brushless motor variable frequency controller includes a lead sleeve and a cable sleeve;

[0044] A wire connection cavity and two avoidance openings communicating with the wire connection cavity are formed between the upper cover and the lower cover;

[0045] The lead sleeve and the cable sleeve are both arranged on the housing, and the lead sleeve and the cable sleeve respectively seal the corresponding avoidance openings;

[0046] The lead sleeve is provided with a threading hole, and the cable sleeve is provided with a threading groove;

[0047] The motor lead can extend through the threading hole to the wire connection cavity and be connected to the output terminal, and the cable connecting the switch can extend through the threading groove to the wire connection cavity and be connected to the PCB assembly.

[0048] By adopting the above technical solution, the present application has the following beneficial effects:

[0049] In the brushless motor frequency conversion controller of the present application, by setting the input terminal, it is convenient to connect with the motor lead, without the need to directly weld the motor lead to the PCB assembly. In the present application, the EMC assembly is directly connected to the PCB assembly through the input terminal, and there is no need to weld the EMC assembly and the PCB assembly through wires, which reduces the wiring difficulty and facilitates production and assembly through automated equipment, effectively improving production efficiency and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0051] Figure 1 A schematic diagram showing the structure of a brushless motor frequency conversion controller in the prior art is shown;

[0052] Figure 2 A schematic diagram showing the structure of a brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0053] Figure 3 An exploded diagram of a brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0054] Figure 4 A schematic diagram showing the matching structure of the upper cover and the annular retaining shell of the brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0055] Figure 5 Show Figure 4 Another perspective of the picture;

[0056] Figure 6 A schematic diagram showing the structure of the input terminal of the brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0057] Figure 7 A schematic diagram showing the structure of the output terminals of the brushless motor frequency conversion controller provided in an embodiment of the present application;

[0058] Figure 8 A top view of a brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0059] Fig. 9 An exploded view of a PCB assembly of a brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0060] Fig.10 A schematic diagram showing the structure of a bracket of a brushless motor frequency conversion controller provided in an embodiment of the present application is shown;

[0061] Fig.11 A schematic diagram showing the structure of the EMC component and the upper cover of the brushless motor frequency conversion controller provided in an embodiment of the present application in a separated state;

[0062] Fig.12 Show Fig.11 Enlarged view of part A in the middle;

[0063] Fig.13 Another perspective view of the brushless motor frequency conversion controller provided by the embodiment of the present application is shown;

[0064] Fig.14 A schematic diagram showing an upper cover and a lower cover of a brushless motor frequency conversion controller provided in an embodiment of the present application in a separated state;

[0065] Fig.15 Show Fig.14 Another perspective of the picture.

[0066] In the figure: 1. lower cover; 11. input terminal; 111. threaded groove; 12. output terminal; 121. pin piece; 122. main body; 1221. wiring port; 1222. crimping screw hole; 13. support block; 14. sealing groove; 2. upper cover; 21. connecting hole; 22. sealing plate; 3. PCB assembly; 31. PCB receiving groove; 32. bracket; 321. positioning groove; 322. through hole; 323. claw; 33. heat sink; 331. step; 34. power tube; 35. main control circuit board; 36. heat sink; 37. bridge stack ; 38, capacitor; 4, EMC component; 41, EMC containing groove; 411, supporting rib; 412, positioning buckle; 413, pin hole; 42, control circuit board; 421, pin socket; 43, common mode inductor; 5, connecting piece; 51, main sheet; 52, bending piece; 6, annular baffle; 61, pressing rib; 62, plug-in part; 7, lead sleeve; 8, cable sleeve; a, fastener; 9, switch; 100, motor lead; 200, input line; b, sealant; c, sealing cap; d, extrusion strip; e, wire connection cavity; f, input part. DETAILED DESCRIPTION

[0067] In order to make the technical solutions and advantages in the embodiments of the present application more clearly understood, the exemplary embodiments of the present application are further described in detail below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than an exhaustive list of all the embodiments. It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict.

[0068] See also Figures 1 to 15 As shown, the embodiment of the present disclosure provides a brushless motor frequency conversion controller, which includes: a housing, a PCB assembly 3 and an EMC assembly 4, the housing includes an upper cover 2 and a lower cover 1, the upper cover 2 and the lower cover 1 are detachably connected, the lower cover 1 is provided with a plurality of input terminals 11 and a plurality of output terminals 12, the PCB assembly 3 is arranged on a side of the lower cover 1 away from the upper cover 2, the input terminal 11 and the output terminal 12 both penetrate the upper cover 2 along the thickness direction of the lower cover 2, the input terminal 11 and the output terminal 12 are both electrically connected to the PCB assembly 3, the output terminal 12 is used to connect the motor lead 100, the EMC assembly 4 is arranged on the upper cover 2, and the EMC assembly 4 and the input terminal 11 are electrically connected.

[0069] In the brushless motor variable frequency controller of the present application, by setting the input terminal 11, it can be conveniently connected to the motor lead 100, without directly welding the motor lead 100 to the PCB component 3. In the present application, the EMC component 4 is directly connected to the PCB component 3 through the input terminal 11, and there is no need to weld the EMC component 4 and the PCB component 3 through wires, which reduces the wiring difficulty, facilitates production and assembly through automated equipment, effectively improves production efficiency, and improves product quality.

[0070] It should be noted that the functions and working principles of the PCB component 31 and the EMC component 42 are common knowledge and conventional technical means in the field. Technical personnel in the field know or can easily obtain relevant information, and this application will not elaborate on them.

[0071] In some possible implementations, the lower cover 1, the input terminal 11, and the output terminal 12 are made into an integral part by an insert molding process. By making the lower cover 1, the input terminal 11, and the output terminal 12 into an integral part by an insert molding process, the assembly process is simplified, and a product including multiple parts can be produced in one operation, which reduces the subsequent assembly steps, reduces the overall manufacturing cost, and improves the production efficiency.

[0072] In some possible implementation schemes, a plurality of through holes are provided on the lower cover 1, that is, after the lower cover 1 is injection molded, a plurality of through holes are formed, and the input terminal 11 and the output terminal 12 are respectively passed through the corresponding through holes, and the input terminal 11 and the corresponding through holes are interference fit, and the output terminal 12 and the corresponding through holes are interference fit, and the output terminal 12 and the input terminal 11 will not fall off easily.

[0073] In some possible implementation schemes, the upper cover 2 and the lower cover 1 are buckled together to form a wire connection cavity e between the upper cover 2 and the lower cover 1. Figure 7 As shown, the output terminal 12 includes a pin piece 121 and a main body 122, the pin piece 121 passes through the lower cover 1 and is connected to the PCB assembly 3, the main body 122 is located in the wire wiring cavity e, and the main body 122 is provided with a wiring port 1221 and a wire pressing screw hole 1222, the wire pressing screw hole 1222 is connected to the wiring port 1221, one end of the motor lead 100 can be inserted into the wiring port 1221, and the wire pressing screw can be threadedly connected to the wire pressing screw hole 1222 to press the motor lead 100. In this way, the motor lead 100 is pressed, which facilitates the quick connection or disassembly of the motor lead 100 and the output terminal 12.

[0074] In some possible implementations, such as Fig.11As shown, the brushless motor variable frequency controller includes a connecting piece 5, which is located between the upper cover 2 and the lower cover 1. The connecting piece 5 includes a main piece 51 and a bending piece 52. The main piece 51 is attached to the upper cover 2 and / or the lower cover 1 to stabilize the posture. The main piece 51 is electrically connected to the input terminal 11, and the bending piece 52 passes through the upper cover 2, and the bending piece 52 is respectively connected to the main piece 51 and the EMC component 4. The bending piece 52 and the main piece 51 are integrally formed. Fig.12 As shown, the upper cover 2 may be provided with a pin hole 413, and the bending piece 52 is provided through the pin hole 413. In the embodiment of the present disclosure, two input terminals 11 may be provided on the lower cover 1, and similarly, the controller is provided with a corresponding connecting piece 5 for each input terminal 11. The connecting piece 5 and the input terminal 11 realize the connection of the EMC component 4 and the PCB component 3 to conduct the circuit.

[0075] See also Figure 3 and Fig.11 As shown, a connecting piece 5 is provided in the conductive wiring cavity e, and the end of the input terminal 11 away from the pin piece 121 is assembled with the connecting piece 5, and the connecting piece 5 extends to the surface of the upper cover 2 and is connected to the EMC component 4. The input terminal 11 and the EMC component 4 are connected by the connecting piece 5, which can further improve the production efficiency. When the fastener a (bolt) is tightened with the input terminal 11, the connecting piece 5 is pressed to the surface of the input terminal 11 by the cap body of the fastener a.

[0076] In some possible implementations, see Figure 6 and Fig.11 As shown, the upper cover 2 is provided with a connection hole 21, and a thread groove 111 is provided on the side of the input terminal 11 facing the upper cover 2. One end of the fastener a (bolt) passes through the upper cover 2 and the connecting piece 5 (such as the main piece body 51) in sequence and is threadedly connected to the thread groove 111, and the other end of the fastener a is limited on the upper cover 2. This structure not only realizes the fixing of the connecting piece 5 to the input terminal 11, but also realizes the connection and fixing of the upper cover 2 and the lower cover 1. A sealing cap c is detachably provided on the connection hole 21, and the sealing cap c closes the connection hole 21 to prevent the cap body of the fastener a (the fastener a can be a bolt) from being corroded by moisture in the air, and protects the bolt while preventing other conductive objects from contacting the bolt.

[0077] Combination Fig.11 and Fig.15 As shown, the EMC component 4 is connected to an input part f. It can be clearly seen from the above structural design that the signal is input to the EMC component 4 from the input part, and the signal output by the EMC component 4 is sequentially transmitted to the PCB component 3 by the connecting piece 5 and the input terminal 11. Finally, the PCB component 3 outputs the processed signal to the motor through the three output terminals 12.

[0078] In some possible embodiments, combined with Figure 2 and Figure 3 As shown, an annular retaining shell 6 is provided on the side of the lower cover 1 facing away from the upper cover 2, a PCB accommodating groove 31 is formed between the annular retaining shell 6 and the lower cover 1, the PCB assembly 3 is located on the inner side of the annular retaining shell 6, the PCB assembly 3 partially extends out of the PCB accommodating groove 31, and the PCB accommodating groove 31 is filled with sealant b.

[0079] like Figure 8 and Fig. 9 As shown, the sealant b can seal and immerse the main control circuit board 35 to the edge of the end of the annular retaining shell 6 away from the outer shell, and the main control circuit board 35 is further fixed and its anti-vibration performance is enhanced through the immersion effect of the sealant b. At the same time, the use of the sealant b can also play a protective role such as moisture-proof and dust-proof, thereby extending the service life of the controller.

[0080] The PCB assembly 3 includes a main control circuit board 35, an IGBT, a capacitor 38, a resistor and a heat sink 36. The IGBT, the capacitor 38 and the resistor are all welded to the main control circuit board 35. The heat sink 36 is attached to the IGBT for heat dissipation. A cable interface is provided on the main control circuit board 35. The output terminal 12 and the input terminal 11 both penetrate the main control circuit board 35 and are welded to the main control circuit board 35. The sealant b can be sealed with epoxy resin to firmly fix the various components of the circuit board together to form an integral structure, thereby improving the mechanical strength of the circuit board, making it more resistant to external shocks and vibrations, and reducing the risk of line shedding and solder joint breakage. In an industrial environment, the circuit board is easily corroded by dust, moisture, chemical liquids and other harmful substances, resulting in short circuits, leakage and other problems. Epoxy resin has excellent waterproof, wear-resistant, chemical corrosion-resistant and other properties, which can effectively isolate these external harmful substances and protect the circuit board from damage.

[0081] In some possible implementations, see Figure 4 As shown, a support block 13 is provided on the side of the lower cover 1 facing away from the upper cover 2, a pressure rib 61 is provided on the inner wall of the annular retaining shell 6, and the PCB assembly 3 includes a main control circuit board 35. When the PCB assembly 3 is installed on the lower cover 1, the support block 13 and the pressure rib 61 are respectively limited to the two sides of the main control circuit board 35 along the thickness direction to fix the main control circuit board 35.

[0082] In this embodiment, the PCB assembly 3 includes a bracket 32, a heat sink 33 and a plurality of power tubes 34. The bracket 32 ​​is arranged on the side of the main control circuit board 35 away from the lower cover 1. A plurality of positioning grooves 321 are arranged on the bracket 32. Each of the power tubes 34 is respectively arranged in a corresponding positioning groove 321. Each of the power tubes 34 is located in a plane parallel to the main control circuit board 35. Each of the power tubes 34 is connected to the main control circuit board 35. The heat sink 33 is arranged on the side of the bracket 32 ​​away from the main control circuit board 35. The heat sink 33 is in contact with the power tube 34, wherein the sealant b covers each of the power tubes 34.

[0083] A mounting groove is provided on the edge of one side of the lower cover 1 facing away from the upper cover 2, and a plug-in portion that can be inserted into the mounting groove is provided on the side of the annular baffle shell 6 close to the lower cover 1. Glue can be applied to the plug-in portion or the mounting groove, and the annular baffle shell 6 and the lower cover 1 are fixedly connected by glue, so that the installation of the annular baffle shell 6 is more convenient and quick, and the stable control of the speed of the controller is also improved.

[0084] It should be noted that, in the present application, the output signal of the controller is calculated by the following formula to achieve stable speed control of the controller:

[0085]

[0086] Where k(t) represents the output signal of the controller at time t, q b represents the proportional gain of the controller, v d Indicates the set speed of the controller, v s (t) represents the actual speed at time t, q n represents the integral gain of the controller, q v represents the differential speed of the controller, dt represents the integral of time, represents the time derivative.

[0087] By installing the power tube 34 on the main control circuit board 35, the power tube 34 can be horizontally arranged in the bracket 32. When sealing, the glue can completely immerse the entire power tube 34, so that the power tube 34 is not in contact with the air, which can provide better electrical insulation and mechanical protection, and effectively prevent water mist or iron powder from falling on the power tube 34. At the same time, the surface of the heat sink 33 is in contact with the surface of the power tube 34, so that the heat dissipation efficiency of the power tube 34 is not affected, ensuring that the heat can be timely and effectively conducted through the heat sink, which not only maintains the heat dissipation efficiency of the power tube 34 after packaging, but also further improves its working stability and service life. It should be noted that in this application, the actual service life of the power tube is calculated by the following formula:

[0088]

[0089] Among them, S represents the actual service life, S0 represents the service life at the reference temperature, H represents the activation energy of the power tube, β represents a constant, and W e represents the ambient temperature of the power tube, P represents the heat generation rate of the power tube, μ represents the heat dissipation efficiency of the power tube, W0 represents the reference temperature, and e represents an exponential function with e as the base.

[0090] See also Fig. 9 As shown, the PCB assembly 3 includes a main control circuit board 35, a power tube 34, a bracket 32, a capacitor 38, a bridge stack 37 and a heat sink 33. The capacitor 38 and the bridge stack 37 are welded on the surface of the main control circuit board 35. The main control circuit board 35 can be placed in the PCB receiving groove 31. Six power tubes 34 can be provided. The surface of the bracket 32 ​​is provided with a plurality of positioning grooves 321 for installing the power tube 34. The positioning grooves 321 are provided with through holes 322. The bracket 32 ​​is installed with the main control circuit board 35 by bolts. The power tube 34 is horizontally installed in the positioning groove 321, and the pins of the power tube 34 face the through holes. 322 is bent, and after passing through the through hole 322, it is welded to the main control circuit board 35. The surface of the heat sink 33 is fitted with the surface of the power tube 34, and heat exchange is generated between the heat sink 33 and the power tube 34. The PCB receiving groove 31 is provided with a sealant b, which can completely immerse the power tube 34, has good electrical insulation performance, and can significantly improve the insulation resistance between the main control circuit board 35 and the power tube 34, the capacitor 38 and the bridge stack 37, reduce the risk of leakage current and metal migration, and reduce the impact of transient current. It should be noted that in this application, the instantaneous current is calculated by the following formula:

[0091]

[0092] Among them, I start represents the instantaneous current, L represents the inductance of the motor winding, It represents the speed of change of current, R represents the resistance of the motor winding, and i represents the current.

[0093] In some possible implementations, see Fig. 9 As shown, the bracket 32 ​​is connected to the main control circuit board 35 through a fastener a, and a plurality of claws 323 are provided on the edge of the bracket 32. A step 331 is provided on the edge of the heat sink 33. Each of the claws 323 is clamped on the step 331, so that the position of the heat sink 33 is fixed, and the bottom of the heat sink 33 is tightly fitted with the surface of the power tube 34 to ensure that the heat of the power tube 34 can be transferred to the heat sink 33. A heat sink 36 is provided on the surface of the bridge stack 37. The bridge stack 37 is vertically arranged on the main control circuit board 35, and the bottom surface of the heat sink 36 is fitted with the side wall of the bridge stack 37 to prevent the sealing glue from immersing the bridge stack 37 and the heat sink 36, resulting in the inability to dissipate heat.

[0094] In some possible implementations, see Fig.11 and Fig.13 As shown, an EMC containing groove 41 is provided on the side of the upper cover 2 facing away from the lower cover 1, and the EMC component 4 is provided in the EMC containing groove 41, and the EMC containing groove 41 is filled with sealant b. The EMC component 4 includes a control circuit board 42, a common mode inductor 43 and a capacitor 38, and the common mode inductor 43 and the capacitor 38 are welded on the control circuit board 42. The sealant b at least covers the control circuit board 42.

[0095] Sealant b is also provided in the EMC containing groove 41. Sealant b can effectively fix the components on the control circuit board 42 to prevent the components from falling off or being damaged due to vibration, impact or falling. Sealant b can form a protective film to prevent the circuit board from being corroded by the external environment such as dust, moisture, chemical solvents, etc., thereby improving the weather resistance and service life of the EMC component 4. The EMC component 4 includes a control circuit board 42, a common mode inductor 43 and a capacitor. The common mode inductor 43 and the capacitor are welded on the control circuit board 42.

[0096] The control circuit board 42 is provided with a pin hole 421. The bent piece 52 at one end of the connecting piece 5 away from the input terminal 11 extends to the EMC containing groove 41 and passes through the pin hole 421. The connecting piece 5 and the control circuit board 42 are fixedly connected by welding. After welding, the control circuit board 42 can be locked in the EMC containing groove 41 by the connecting piece 5.

[0097] In some possible implementations, see Fig.11 and Fig.12 As shown, the bottom wall of the EMC containing groove 41 is provided with a supporting rib 411, the peripheral side wall of the EMC containing groove 41 is provided with a positioning buckle 412, and the EMC assembly 4 includes a control circuit board 42. When the EMC assembly 4 is installed on the upper cover 2, the positioning buckle 412 and the supporting rib 411 are limited to the two sides of the control circuit board 42 along the thickness direction. The control circuit board 42 is fixed in the EMC containing groove 41 to prevent the control circuit board 42 from being offset during welding.

[0098] The EMC containing groove 41 is provided with sealant b. After the control circuit board 42 is placed in the EMC containing groove 41 and electrically connected to the connecting piece 5, the EMC component 4 is fixed in the EMC containing groove 41 by the sealant b. The sealant b immerses the control circuit board 42, while the common-mode inductor 43 and the capacitor only immerse their pins. The surfaces of the common-mode inductor 43 and the capacitor are exposed to the air, thereby improving the heat dissipation efficiency.

[0099] In some possible implementations, see Fig.14 and Fig.15As shown, the brushless motor frequency conversion controller includes a lead sleeve 7 and a cable sleeve 8, two avoidance openings connected to the wire wiring cavity e are formed between the upper cover 2 and the lower cover 1, the lead sleeve 7 and the cable sleeve 8 are both arranged on the shell, and the lead sleeve 7 and the cable sleeve 8 respectively close the corresponding avoidance openings, a threading hole is arranged on the lead sleeve 7, and a threading groove is arranged on the cable sleeve 8. The motor lead 100 can pass through the threading hole to extend to the wire wiring cavity e and be connected to the output terminal 12, and the cable connecting the switch 9 can pass through the threading groove to extend into the wire wiring cavity e and be connected to the PCB assembly 3.

[0100] A lead sleeve 7 and a cable sleeve 8 are provided at the edge of the conductive wiring cavity, and one end of the lead sleeve 7 and the cable sleeve 8 extends to the side wall of the lower cover 1. The output wire (motor lead 100) for the motor can enter the conductive wiring cavity through the lead sleeve 7 and be connected to the output terminal 12. The cable for the key switch 9 can enter the conductive wiring cavity through the cable sleeve 8 and be connected to the PCB assembly 3. The lead sleeve 7 and the cable sleeve 8 can fix the position of the cable of the key switch 9 and the output wire of the motor to prevent the cable and the output wire from shaking and causing the connection to loosen.

[0101] The lower cover 1 and the upper cover 2 can be detachably connected by a fastener a (such as a bolt). When wiring, the upper cover 2 can be removed first to make wiring more convenient. The input terminal 11 can be in the shape of a hexagonal prism to prevent the input terminal 11 from slipping and rotating in the positioning groove 321 provided on the lower cover 1 when the fastener a is tightened with the input terminal 11.

[0102] See also Fig.14 and Fig.15 As shown, the edge of the lower cover 1 is provided with a sealing groove 14, and a sealing glue b is provided in the sealing groove 14. The edge of the upper cover 2 is provided with a sealing plate 22 that can be matched and inserted into the sealing groove 14. The conductive wiring cavity is provided with a lead sleeve 7 and a cable sleeve 8. The lead sleeve 7 and the cable sleeve 8 are both made of elastic rubber. After the lower cover 1 is combined with the upper cover 2, the inner walls of the lower cover 1 and the upper cover 2 press the surface of the lead sleeve 7 and the cable sleeve 8. The surface of the lead sleeve 7 and / or the cable sleeve 8 is provided with a raised extrusion strip d. When the extrusion strip d is squeezed by the upper cover 2 or the lower cover 1, elastic deformation is generated to avoid the formation of gaps around the lead sleeve 7 and the cable sleeve 8. The sealing plate 22 is inserted into the sealing groove 14, so that the surrounding side of the conductive wiring cavity is effectively sealed. The inner wall of the threading hole on the lead sleeve 7 is closely attached to the outer wall of the motor lead 100 to avoid the formation of a gap between the two. The threading groove on the cable sleeve 8 is closely attached to the surrounding side of the cable connected to the switch 9 to avoid the formation of a gap between the two.

[0103] The upper cover 2 and the upper cover 2 are sealed by sealant, which effectively prevents dust from entering the conductive wiring cavity and prevents dust and water from falling on the connection of the output line and corroding it. The output terminal 12 is welded to the PCB component 3, and the two ends of the input terminal 11 are connected to the PCB component 3 and the EMC component 4. By setting the input terminal 11 in the conductive wiring cavity e, the input end of the PCB component 3 can also be dustproof and waterproof.

[0104] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is also intended to include these modifications and variations.

Claims

1. Brushless motor frequency conversion controller, characterized in that: include: A housing, the housing comprising an upper cover and a lower cover, the upper cover and the lower cover are detachably connected, and the lower cover is provided with a plurality of input terminals and a plurality of output terminals; A PCB assembly, wherein the PCB assembly is arranged on a side of the lower cover away from the upper cover, the input terminal and the output terminal both penetrate the upper cover along the thickness direction of the lower cover, the input terminal and the output terminal are both electrically connected to the PCB assembly, and the output terminal is used to connect a motor lead; An EMC component is disposed on the upper cover, and the EMC component is electrically connected to the input terminal.

2. The brushless motor frequency conversion controller according to claim 1, characterized in that: The lower cover, the input terminal and the output terminal are made into an integral part by an insert injection molding process; Alternatively, a plurality of through holes are arranged on the lower cover, and the input terminal and the output terminal are respectively arranged through the corresponding through holes, and the input terminal and the corresponding through hole are interference fit, and the output terminal and the corresponding through hole are interference fit.

3. The brushless motor frequency conversion controller according to claim 1, characterized in that: The upper cover and the lower cover are buckled together, and a wire connection cavity is formed between the upper cover and the lower cover; The output terminal comprises a pin piece and a main body; The pin piece passes through the lower cover and is connected to the PCB assembly. The main body is located in the wire connection cavity. The main body is provided with a connection port and a wire pressing screw hole, and the wire pressing screw hole is connected to the connection port. One end of the motor lead can be inserted into the wiring port, and the wire pressing screw can be threadedly connected to the wire pressing screw hole to press the motor lead.

4. The brushless motor frequency conversion controller according to claim 1, characterized in that: Including connecting piece; The connecting piece is located between the upper cover and the lower cover, and the connecting piece includes a main piece body and a bending piece; The main sheet body is attached to the upper cover and / or the lower cover and is electrically connected to the input terminal. The bending sheet passes through the upper cover and is respectively connected to the main sheet body and the EMC component.

5. The brushless motor frequency conversion controller according to claim 4, characterized in that: The upper cover is provided with a connection hole; A thread groove is provided on one side of the input terminal facing the upper cover; One end of the fastener passes through the upper cover and the connecting piece in sequence and is threadedly connected to the thread groove, and the other end of the fastener is limited on the upper cover.

6. The brushless motor frequency conversion controller according to claim 1, characterized in that: A ring-shaped retaining shell is disposed on one side of the lower cover away from the upper cover, and a PCB accommodating groove is formed between the ring-shaped retaining shell and the lower cover; The PCB assembly is located inside the annular retaining shell, and the PCB assembly partially extends out of the PCB accommodating groove; The PCB receiving groove is filled with sealant.

7. The brushless motor frequency conversion controller according to claim 6, characterized in that: A support block is provided on one side of the lower cover away from the upper cover; The inner wall of the annular retaining shell is provided with ribs; The PCB assembly includes a main control circuit board. When the PCB assembly is installed on the lower cover, the support block and the clamp are respectively limited to two sides of the main control circuit board along the thickness direction to fix the main control circuit board.

8. The brushless motor frequency conversion controller according to claim 6, characterized in that: The PCB assembly includes a bracket, a heat sink and a plurality of power tubes; The bracket is arranged on a side of the main control circuit board away from the lower cover; A plurality of positioning grooves are arranged on the bracket; Each of the power tubes is disposed in a corresponding positioning groove, each of the power tubes is located in a plane parallel to the main control circuit board, and each of the power tubes is connected to the main control circuit board; The heat dissipation block is arranged on a side of the bracket away from the main control circuit board, and the heat dissipation block is in contact with the power tube; Wherein, the sealant covers each of the power tubes.

9. The brushless motor frequency conversion controller according to claim 8, characterized in that: The bracket is connected to the main control circuit board through a fastener; The edge of the bracket is provided with a plurality of claws, and the edge of the heat dissipation block is provided with a step; Each of the clamping claws is clamped on the step.

10. The brushless motor frequency conversion controller according to claim 1, characterized in that: An EMC containing groove is provided on a side of the upper cover away from the lower cover, and the EMC component is arranged in the EMC containing groove; The EMC containing groove is filled with sealant.

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