Electric vehicle controller

Abstract

The invention discloses an electric vehicle controller which comprises an upper cover, a base, a power circuit board and a capacitor circuit board, the upper cover is fixedly connected with the base, the capacitor circuit board is positioned on a circuit board supporting pad, the power circuit board is positioned between the circuit supporting pad and the base, and a screw sequentially penetrates through the capacitor circuit board, the circuit supporting pad and the power circuit board to be connected with the base. The capacitor circuit board and the power circuit board are arranged separately, the capacitor circuit board can adopt an electrolytic capacitor, the power circuit board adopts a traditional SMT technology, capacitor failure does not need to be worried about, the production cost is reduced, and the reliability is high.

Description

Technical Field

[0001] This application relates to the technical field of electric vehicle controllers, and particularly to an electric vehicle controller. Background Art

[0002] In an electric vehicle controller in the prior art such as CN219802926U, 18 MOS transistors and capacitors are fixedly installed and electrically connected on a PCBA circuit board, resulting in a complex structure of the PCBA circuit board and great processing difficulty. Summary of the Invention

[0003] To improve the above problems, this application provides a circuit board connection structure and an electric vehicle controller, manufacturing different circuit boards with different processes to avoid the difficulties caused by single-process manufacturing.

[0004] The electric vehicle controller provided by this application adopts the following technical solutions:

[0005] An electric vehicle controller includes: an upper cover, a base, a power circuit board, and a capacitor circuit board. The upper cover is fixedly connected to the base. The capacitor circuit board is positioned on a circuit board support pad, and the power circuit board is positioned between the circuit support pad and the base. Screws sequentially pass through the capacitor circuit board, the circuit support pad, the power circuit board, and are connected to the base.

[0006] Further, the circuit board support pad includes a vertical positioning portion and a horizontal positioning portion. Among them, multiple horizontal positioning portions are connected by a horizontal connecting portion, and multiple vertical positioning portions are connected by a vertical connecting portion. The middle of the horizontal connecting portion extends vertically, and circular through holes are provided in the middle of both the vertical positioning portion and the horizontal positioning portion. A rectangular through hole is provided on one side of the circular through hole.

[0007] Further, a conductive sheet is provided between the power circuit board and the circuit support pad, and the conductive sheet is electrically connected to the power circuit board.

[0008] Further, it includes a first bending section, a connecting section, and a second bending section formed by integral bending. The bending directions of the first bending section and the second bending section relative to the connecting section are the same. The first bending section has a first through hole, and the second bending section has a second through hole. The first through hole penetrates through the first bending section, and the second through hole penetrates through the second bending section.

[0009] Further, the upper cover includes a vertical section and a horizontal section. Among them, the horizontal section vertically extends from the middle of the vertical section. The horizontal section has three horizontal recessed portions, and the center lines of the three horizontal recessed portions are on the same straight line. The vertical section has two vertical recessed portions, and the center lines of the two vertical recessed portions are on the same straight line. A ventilation portion is provided between the two vertical recessed portions. The horizontal recessed portions and the vertical recessed portions are recessed into the lower surface of the upper cover.

[0010] Further, the power circuit board has a first mounting hole, a second mounting hole, a third mounting hole, a fourth mounting hole, and a fifth mounting hole. The first mounting hole, the second mounting hole, and the third mounting hole are located on a first straight line, and the fourth mounting hole and the fifth mounting hole are located on a second straight line. The first straight line is perpendicular to the second straight line, and a conductive sheet is connected in each mounting hole.

[0011] Further, the upper cover includes an upper surface, and the upper surface includes a flat area and a protruding area. The protruding area includes a first protrusion and a second protrusion. A plurality of buckle grooves are provided on one side of the second protrusion, and one buckle groove is provided on one side of the first protrusion. The second protrusion is perpendicular to the first protrusion, and the flat area is located on both sides of the second protrusion.

[0012] Further, it further includes a control circuit board which is electrically connected to the power circuit board. The capacitor circuit board has positive and negative connection terminals, and the control circuit board has motor three-phase line connection terminals. The capacitor on the capacitor circuit board is a first capacitor, and the power circuit board has a second capacitor.

[0013] Further, the first capacitor is an ordinary electrolyte electrolytic capacitor, the second capacitor is a polymer or solid electrolytic capacitor, and a MOS transistor is provided on the power circuit board.

[0014] The beneficial effects of the present invention are as follows:

[0015] The capacitor circuit board and the power circuit board are separately provided. The capacitor circuit board can use electrolytic capacitors, and the power circuit board can adopt the traditional SMT process without worrying about capacitor failure, reducing production costs and having high reliability. Description of the Drawings

[0016] Figure 1 is the three-dimensional view of the circuit board connection structure of the present invention Figure 1 ;

[0017] Figure 2 is the three-dimensional view of the circuit board connection structure of the present invention Figure 2 ;

[0018] Figure 3 is the three-dimensional view of the electric vehicle controller of the present invention;

[0019] Figure 4 is the sectional view of the electric vehicle controller of the present invention;

[0020] Figure 5 is the three-dimensional view of the circuit board connection structure of the present invention Figure 3 ;

[0021] Figure 6 is the structure diagram of the upper cover;

[0022] Figure 7 is the connection structure diagram of the protective cover;

[0023] Figure 8 is the structural diagram of the protective cover;

[0024] Figure 9 is the top view of the protective cover;

[0025] Figure 10 is the view of the lower surface of the upper cover;

[0026] Figure 11 is the sectional view of the electric vehicle controller;

[0027] Figure 12 is the sectional view of the upper cover;

[0028] Figure 13 is the top view of the upper cover;

[0029] Figure 14 is the three-dimensional view of the upper cover.

[0030] Figure 15 is the structure after removing the main circuit board Figure 1 ; Figure 16 is the structure after removing the main circuit board Figure 2 ; Figure 17 is the structure after installing the main circuit board Figure 1 ; Figure 18 is the structure after installing the main circuit board Figure 2 ; Figure 19 is the structure after installing the main circuit board Figure 3 ;

[0031] Figure 20 is the conductive sheet positioning structure Figure 1 ;

[0032] Figure 21 is the conductive sheet positioning structure Figure 2 ;

[0033] Figure 22 is the structural diagram of the MOS circuit board;

[0034] Figure 23 is the structural diagram of the electric vehicle;

[0035] Figure 24 is the three-dimensional view of the conductive sheet of the present invention;

[0036] Figure 25 is the top view of the conductive sheet of the present invention;

[0037] Figure 26 is the sectional view of the electric vehicle controller of the present invention;

[0038] Figure 27 is the structural diagram of the electric vehicle controller of the present invention;

[0039] Figure 28 is a three-dimensional view of the support pad of the present invention;

[0040] Figure 29 is a cross-sectional view of the electric vehicle controller of the present invention at A-A;

[0041] Figure 30 is a structural diagram of the electric vehicle controller of the present invention; Detailed implementation manners

[0042] An electric vehicle controller includes: an upper cover, a base, a power circuit board, and a capacitor circuit board. The upper cover is fixedly connected to the base. The capacitor circuit board is positioned on the circuit board support pad. The power circuit board is positioned between the circuit support pad and the base. Screws sequentially pass through the capacitor circuit board, the circuit support pad, the power circuit board, and are connected to the base.

[0043] Further, the circuit board support pad includes a vertical positioning portion and a horizontal positioning portion. Among them, multiple horizontal positioning portions are connected by a horizontal connecting portion, multiple vertical positioning portions are connected by a vertical connecting portion, the middle of the horizontal connecting portion and the vertical connecting portion extends vertically, circular through holes are provided in the middle of the vertical positioning portion and the horizontal positioning portion, and a rectangular through hole is provided on one side of the circular through hole.

[0044] Further, a conductive sheet is provided between the power circuit board and the circuit support pad, and the conductive sheet is electrically connected to the power circuit board.

[0045] Further, the upper cover includes a vertical section and a horizontal section. Among them, the horizontal section vertically extends from the middle of the vertical section. The horizontal section has three horizontal recessed portions, and the center lines of the three horizontal recessed portions are located on the same straight line. The vertical section has two vertical recessed portions, and the center lines of the two vertical recessed portions are located on the same straight line. A ventilation portion is provided between the two vertical recessed portions. The horizontal recessed portions and the vertical recessed portions are recessed into the lower surface of the upper cover.

[0046] As Figure 1 and Figure 5 shown, the electric vehicle controller includes a control circuit board 11, a power circuit board 12, and a capacitor circuit board 13. The control circuit board 11 is electrically connected to the power circuit board 12. The capacitor circuit board 13 has positive and negative connection terminals 131. The control circuit board 11 has motor three-phase line connection terminals 111. The capacitor on the capacitor circuit board 13 is a first capacitor 132. The power circuit board 12 has a second capacitor 121.

[0047] As Figure 2As shown, the first capacitor 132 is an ordinary electrolytic capacitor with electrolyte, and the second capacitor 121 is a polymer or solid electrolytic capacitor. A MOS transistor 122 is provided on the power circuit board 12. The electrolytic capacitor has a relatively high capacitance and can provide stable DC power energy storage for the circuit on the capacitor circuit board to ensure the stable operation of the circuit under different working conditions. The polymer or solid electrolytic capacitor, with its good high-frequency characteristics, can effectively filter high-frequency clutter on the power circuit board, improving the efficiency and stability of power conversion. The MOS transistor 122, as a key component on the power circuit board, can efficiently control the on-off of the current, achieve precise adjustment of power, and meet the power requirements of the electric vehicle under different driving conditions.

[0048] As Figure 3 and Figure 4 shown, the upper cover 21 is fixedly connected to the aluminum base 22. The power circuit board 12 and the capacitor circuit board 13 are arranged on the aluminum base 22, and screws connect the capacitor circuit board 13, the power circuit board 12 and the aluminum base 22.

[0049] This capacitor PCB separates the bus capacitor, also known as the starting capacitor, in the circuit of the electric vehicle controller. Through the screw and base locking structure, this capacitor PCB, the large-current conductive bus bar, and the lower-layer power circuit board are clamped together. The conductive lines on the capacitor PCB contact the large-current conductive bus bar, and then through the large-current conductive bus bar, contact the conductive lines on the lower-layer power circuit board to form a complete large-current connection for the circuit. *Since the lower-layer power board must use the SMT mounting process, and the temperature requirement for the SMT mounting process is very high, the internal electrolyte of the ordinary electrolytic capacitor will expand and liquefy at high temperatures, causing the electrolytic capacitor to fail. Therefore, the electrolytic capacitor must use a solid electrolytic capacitor without electrolyte, but the cost of the solid capacitor is very high. Or place the ordinary capacitor in the upper main board design, resulting in high material and production costs through the reserved connection device. This patented capacitor PCB uses the wave soldering process, can solder ordinary electrolytic capacitors, and realizes the large-current connection through the above-mentioned patented utility. The advantage of this patent is that the used electrolytic capacitor has a low cost and a simple production process.

[0050] In the second embodiment, as Figure 6 and Figure 7 shown, the upper cover 26 includes an upper surface 21. The upper surface 21 includes a flat area 211 and a protruding area 212. The protruding area 212 includes a first protrusion 2121 and a second protrusion 2122. A plurality of snap grooves 21221 are provided on one side of the second protrusion 2122, and one snap groove 21221 is provided on one side of the first protrusion 2121. The second protrusion 2122 is perpendicular to the first protrusion 2121. The flat area 211 is located on both sides of the second protrusion 2122. The protective cover 28 has a snap 281, and the snap 281 is connected to the snap groove 21221.

[0051] Further, a plurality of wiring clamps 21222 are provided on the other side of the second protruding portion 2122, and a plurality of wiring clamps 21222 are provided on the other side of the first protruding portion 2121.

[0052] As Figure 8 and Figure 9 shown, the protective cover 28 includes a first cover portion 282 and a second cover portion 283, wherein the first cover portion 282 is vertically connected to the second cover portion 283. One side of the first cover portion 282 is provided with a buckle 281, and a plurality of buckles 281 are provided on one side of the second cover portion 283. The first cover portion 282 is snap-connected to the first protruding portion 2121, and the second cover portion 283 is snap-connected to the second protruding portion 2122.

[0053] Further, the protective cover 28 is T-shaped.

[0054] Further, two wiring through holes 2821 are provided on the other side of the first cover portion 282, and three wiring through holes 2821 are provided on the other side of the second cover portion 283.

[0055] As Figure 14 shown, the upper cover includes an upper surface 21, and the upper surface 21 includes a flat area 211 and a protruding area 212. The protruding area 212 has a recessed portion 22, and there are three countersunk head grooves 23 in the middle of the recessed portion 22. A communication groove 24 is provided between every two countersunk head grooves 23. A step 25 is provided in the countersunk head groove 23. The step 25 includes a second step 251 and a first step 252. The first step 252 is provided with a first slot hole 2521 for placing a nut, and the second step 251 is provided with a second slot hole 2511. A rectangular opening 25111 is provided in the middle of the second slot hole 2511. The first slot hole 2521 and the second slot hole 2511 have different depths. The shape of the special-shaped opening can be customized according to the shape and size of the large-current conducting component such as the large-current conducting busbar 27. For example, if the conducting busbar 27 is flat, it can be designed into a corresponding flat shape.

[0056] As Figure 13 shown, the flat area 211 is provided on both sides of the protruding area 212, and the height of the protruding area 212 is higher than the height of the flat area 211. Further, the protruding area 212 is H-shaped. Further, the flat area 211 is II-shaped.

[0057] As Figure 8 shown, the first slot hole 2521 is a square slot hole, and the second slot hole 2511 is a rectangular slot hole. According to different fixing methods, the first slot hole 2521 can be designed into various shapes, such as square, circular, etc. In this embodiment, the first slot hole 2521 is a square slot hole, and the design of the square slot hole is convenient for matching with a square nut to improve the fixing stability.

[0058] Further, the depth of the second slot hole 2511 is greater than that of the first slot hole 2521.

[0059] As Figure 10 and Figure 11 shown, the first step 252 extends towards the lower surface, and a cylindrical groove 2522 is provided on the bottom surface of the first step 252. The design of the cylindrical groove 2522 can reduce the weight of the cover plate to a certain extent, and at the same time, it can also serve as a buffer structure for the stress concentration area to improve the structural stability. The shape of the concave structure can be changed according to actual needs, such as designed as a square groove, a polygonal groove, etc., to meet different mechanical property requirements and spatial layouts.

[0060] Further, the second step 251 extends towards the lower surface, and a rectangular groove 2512 is formed on the bottom surface of the second step 251.

[0061] The upper cover is a component of the controller. At the first slot hole 2521, the nut can be pre-embedded during injection molding, or a square groove can be left during injection molding to place the nut. In addition to the above methods, threads can also be provided in the first slot hole 2521 to directly screw the nut in; or an elastic clamping structure can be provided in the first slot hole 2521 to clamp and fix the nut with a special structure. The rectangular opening 25111 of the second slot hole 2511 is used for the large-current conductive busbar 27 to pass through, and the surrounding space of the rectangular opening 25111 of the second slot hole 2511 forms a waterproof glue groove space with the upper cover 26 after the large-current conductive busbar 27 passes through.

[0062] Further, the upper cover 26 is placed on the first step 252. Through the support of the first step 252, the upper cover 26 can effectively cover the internal components of the controller, playing a role of protection and sealing. There can be various connection methods between the upper cover 26 and the first step 252, such as bolt connection, snap connection, or bonding with a sealant, etc., to improve the connection stability and sealing performance.

[0063] Further, the large-current conductive busbar 27 passes through the rectangular opening 25111, and a waterproof glue groove space is formed between the large-current conductive busbar 27 and the second slot hole 2511.

[0064] In the third embodiment, as shown in FIG. 15, the support pad 313 is disposed on the MOS circuit board 312 and is in contact connection with the MOS circuit board 312. The main circuit board 314 is electrically connected to the MOS circuit board 312 and is disposed above the support pad 313. The inner wall of the base 311 is provided with support bars 3111, and the main circuit board 314 is positioned by the support bars 3111. The support bars 3111 provide a stable support foundation for the main circuit board 314, ensuring that the main circuit board 314 maintains a fixed position during the operation of the controller, and preventing the main circuit board 314 from shifting due to vibration or other external forces, which may affect the stability of the electrical connection and the performance of the controller.

[0065] To enhance the stability of the main circuit board 314 in the length direction, the support bars 3111 extend along the length direction of the base 311, reducing the risk of deformation or damage to the main circuit board 314 due to uneven stress.

[0066] Two positioning posts 3112 are vertically provided on one side of the support bar 3111. The positioning posts 3112 can further accurately define the position of the main circuit board 314. Acting together with the support bars 3111, they position the main circuit board 314 from multiple directions, improving the accuracy and stability of the installation of the main circuit board 314, ensuring the position accuracy of the main circuit board 314 within the base 311, and being beneficial to the reliability of the electrical connection.

[0067] Multiple positioning posts 3112 are vertically provided on the inner wall. The multiple positioning posts 3112 position and support the main circuit board 314 from multiple angles, further enhancing the stability of the main circuit board 314 within the base 311, preventing the main circuit board 314 from shaking in all directions, improving the stability of the entire support structure, and ensuring the reliable operation of the electric vehicle controller.

[0068] The MOS circuit board 312 is provided with a female socket 3121, and the main circuit board 314 is provided with a male socket 3141. The female socket 3121 is connected to the male socket 3141. This plug-in electrical connection method makes the electrical connection between the main circuit board 314 and the MOS circuit board 312 more convenient and fast. At the same time, it is also convenient for disassembly and installation when circuit board repair or replacement is required, improving the maintainability of the controller.

[0069] The screw passes through the MOS circuit board 312 and is fastened to the base 311. The support pad 313 is T-shaped. The horizontal section 3132 of the support pad 313 has a mounting hole 3131, and the mounting hole 3131 is sleeved outside the screw. The design of the T-shaped support pad 313 can not only provide good support for the main circuit board 314, but also the cooperation between the mounting hole 3131 in its horizontal section and the screw enables the support pad 313 to be stably fixed on the MOS circuit board 312, avoiding displacement of the support pad 313 during use and ensuring the stability of the support for the main circuit board 314.

[0070] As shown in FIGS. 16 and 18, the support pad 313 also has a vertical section 3131, where the vertical section 3131 extends along the width direction of the base 311. The main body of the main circuit board 314 is supported by the horizontal section 3132 of the support pad 313, one side in the width direction of the main circuit board 314 is supported by the vertical section 3131 of the support pad 313, and one side in the length direction of the main circuit board 314 is supported by the positioning post 3112 and the support bar 3111. This all-round support method supports and positions the main circuit board 314 from different directions, fully ensuring the stability of the main circuit board 314 in the base 311, effectively reducing the shaking of the main circuit board 314 caused by vibration or external forces, and improving the overall stability and reliability of the electric vehicle controller.

[0071] As shown in FIG. 19, an electric vehicle controller 32 includes the above-mentioned busbar arrangement structure and also includes an upper cover 321. The upper cover 321 is connected to the base 311 by screws. The connection between the upper cover 321 and the base 311 not only provides protection for components such as the circuit board inside the electric vehicle controller 32, preventing damage caused by external factors such as dust and water vapor, but also enhances the overall structural strength of the controller and improves its impact resistance.

[0072] As shown in FIG. 17, heat dissipation fins 3113 are provided on the lower side of the base 311. The heat dissipation fins 3113 can effectively increase the contact area between the base 311 and the air, improve the heat dissipation efficiency, and timely dissipate the heat generated by the MOS circuit board 312 and the main circuit board 314 during operation, preventing the circuit board from degrading or being damaged due to overheating, and extending the service life of the electric vehicle controller 32.

[0073] Mounting flanges 3114 are provided on both sides of the base 311. The mounting flanges 3114 enable the electric vehicle controller 32 to be conveniently installed at a specific position on the electric vehicle. By connecting the mounting flanges 3114 to the corresponding mounting parts on the electric vehicle, the convenience and stability of installation are improved, ensuring that the electric vehicle controller 32 can be firmly fixed at the required position during the operation of the electric vehicle.

[0074] In the fourth embodiment, as shown in FIG. 20, a conductive sheet positioning structure 41 of an electric vehicle controller includes a MOS circuit board 411, and the MOS circuit board 411 has a first mounting hole 4111, a second mounting hole 4112, a third mounting hole 4113, a fourth mounting hole 4114, and a fifth mounting hole 4115. The first mounting hole 4111, the second mounting hole 4112, and the third mounting hole 4113 are located on a first straight line, the fourth mounting hole 4114 and the fifth mounting hole 4115 are located on a second straight line, and the first straight line is perpendicular to the second straight line. The beneficial effect of this layout design is that through the specific mounting hole layout, it provides an accurate position reference for the installation and positioning of the conductive sheet, and at the same time provides an orderly interface for the connection between the MOS circuit board 411 and other components such as the capacitor circuit board and the base, which helps to improve the compactness and stability of the internal structure of the entire controller.

[0075] In order to be able to distribute the current more evenly, reduce the local overheating phenomenon caused by current concentration, and improve the electrical performance and reliability of the MOS circuit board 411, the distance between the first mounting hole 4111 and the second mounting hole 4112 is equal to the distance between the second mounting hole 4112 and the third mounting hole 4113.

[0076] As shown in FIG. 21, it further includes a capacitor circuit board 412, wherein the capacitor circuit board 412 is electrically connected to the MOS circuit board 411, and a sixth mounting hole 4121 and a seventh mounting hole 4122 are formed on the capacitor circuit board 412. The sixth mounting hole 4121 is aligned with the fourth mounting hole 4114, and the seventh mounting hole 4122 is aligned with the fifth mounting hole 4115. This alignment design facilitates the connection and positioning between the capacitor circuit board 412 and the MOS circuit board 411, ensures the accurate electrical connection between the two, and at the same time is conducive to rapid positioning during the installation process, improving the assembly efficiency.

[0077] The capacitor circuit board 412 is disposed above the MOS circuit board 411, and a conductive sheet is disposed between the capacitor circuit board 412 and the MOS circuit board 411.

[0078] As shown in FIG. 22, a fourth conductive sheet 4134 is disposed between the sixth mounting hole 4121 and the fourth mounting hole 4114, and a fifth conductive sheet 4135 is disposed between the seventh mounting hole 4122 and the fifth mounting hole 4115.

[0079] The first mounting hole 4111 is fixed with a first conductive sheet 4131, the second mounting hole 4112 is fixed with a second conductive sheet 4132, and the third mounting hole 4113 is fixed with a third conductive sheet 4133. These conductive sheets not only play the role of electrical connection, but also assist in fixing the MOS circuit board 411 to the base 422, enhancing the stability of the overall structure. At the same time, they can optimize the current path in the circuit, improve the conduction efficiency of the circuit, and reduce energy loss.

[0080] As shown in FIG. 23, an electric vehicle controller 42 includes the above-mentioned conductive sheet positioning structure, as well as an upper cover 421 and a base 422. The upper cover 421 and the base 422 are connected by screws, and the screws pass through the first mounting hole 4111, the second mounting hole 4112, the third mounting hole 4113, the fourth mounting hole 4114, and the fifth mounting hole 4115 to connect the MOS circuit board 411 to the base 422. This connection method makes the structure of the entire controller more compact, and the connection between each component is firm and reliable. By using the mounting holes on the MOS circuit board 411 for connection, not only are additional connection structures reduced, but also the accurate positioning of the MOS circuit board 411 on the base 422 can be ensured, which is beneficial to improving production efficiency and product consistency.

[0081] Heat dissipation fins 4221 are provided on the lower side of the base 422. The heat dissipation fins 4221 prevent the decline of circuit performance, component aging, and even damage caused by overheating, extend the service life of the controller, and ensure its stable operation under various working conditions. Mounting flanges 4222 are provided on both sides of the base 422. The design of the mounting flanges 4222 facilitates the installation and fixation of the electric vehicle controller 42 on the electric vehicle, avoids component damage or poor electrical connection caused by vibration or shaking, and improves the reliability and stability of the entire system.

[0082] In Embodiment 5, as shown in FIG. 24, a conductive sheet 51 includes a first bent section 511, a connecting section 512, and a second bent section 513 that are integrally bent and formed. The bending directions of the first bent section 511 and the second bent section 513 with respect to the connecting section 512 are the same. As shown in FIG. 2, the first bent section 511 has a first through hole 5111, and the second bent section 513 has a second through hole 5131. The first through hole 5111 penetrates through the first bent section 511, and the second through hole 5131 penetrates through the second bent section 513.

[0083] The above-mentioned integrally bent and formed design makes the conductive sheet 51 have good integrity and mechanical strength. Compared with the L-shaped conductive structure, problems such as possible poor contact and looseness are avoided, ensuring the stability and reliability of current transmission. At the same time, the one-piece forming process reduces the production process, lowers the production cost, and improves the production efficiency.

[0084] To reduce the precision requirements for installation and improve the convenience of installation, the first through-hole 5111 is an oval hole for connecting external wires to the first bent section 511, and the second through-hole 5131 is a round hole for connecting the MOS transistor circuit board to the second bent section 513.

[0085] To arrange the conductive sheet 51 compactly, reduce the occupied space, and facilitate connection with other electrical components at the same time, the first bent section 511 and the second bent section 513 have the same bending direction. The angle between the first bent section 511 and the connecting section 512 is 90 degrees, and the angle between the second bent section 513 and the connecting section 512 is 90 degrees. The first bent section 511 and the second bent section 513 are parallel.

[0086] As shown in FIGS. 26 and 27, an electric vehicle controller includes: the conductive sheet 51 as described above, a cover body 52, a support pad 53, an aluminum base 54, a MOS transistor circuit board 55. The first bent section 511 is fixed on the upper surface of the cover body 52, the support pad 53 is positioned on the upper surface of the second bent section 513, the cover body 52 is in contact connection with the support pad 53, the MOS transistor circuit board 55 is fixed to the lower part of the second bent section 513, the MOS transistor circuit board 55 is connected to the aluminum base 54, and the screw 56 sequentially passes through the support pad 53, the second through-hole 5131, the MOS transistor circuit board 55 and is connected to the aluminum base 54.

[0087] Further, a cavity 521 is formed on the lower surface of the cover body 52, the support pad 53 is provided with a countersunk hole 531, and the screw 56 is accommodated in the cavity 521 and the countersunk hole 531.

[0088] Further, a rectangular through-hole 522 is formed on the lower surface of the cover body 52, the connecting section 512 passes through the rectangular through-hole 522, and a rectangular through-hole 532 is provided on one side of the countersunk hole 531, and the connecting section 512 passes through the rectangular through-hole 532.

[0089] Further, the rectangular through-hole 532 is located directly below the rectangular through-hole 522.

[0090] In Embodiment 6, as shown in FIG. 28, a circuit board support pad 61 includes a vertical positioning portion 611 and a horizontal positioning portion 612. Among them, a plurality of horizontal positioning portions 612 are connected by a horizontal connecting portion 613, and a plurality of vertical positioning portions 611 are connected by a vertical connecting portion 614. The middle of the horizontal connecting portion 613 and the vertical connecting portion 614 extends vertically. Circular through-holes 615 are provided in the middle of both the vertical positioning portion 611 and the horizontal positioning portion 612, and a rectangular through-hole 616 is provided on one side of the circular through-hole 615. In addition, a rectangular hole is provided to form a limit around the conductive sheet, improve the support strength, facilitate a compact structure, and be beneficial to miniaturization. Further, the circular through-hole 615 is a stepped hole.

[0091] Further, a positioning protrusion 617 is provided on one side of the vertical positioning portion 611, and the height of the positioning protrusion 617 is higher than that of the horizontal connecting portion 613. Further, the positioning protrusion 617 is rectangular. Further, the height of the horizontal connecting portion 613 is lower than the upper surface of the horizontal positioning portion 612. Further, the horizontal connecting portion 613 extends between the positioning protrusions 617.

[0092] As shown in FIGS. 29 and 30, an electric vehicle controller 62 includes: the circuit board support pad 61 as described above, a capacitor circuit board 621, an aluminum base 622, and a MOS circuit board 623. The capacitor circuit board 621 is positioned on the circuit board support pad 61, and the MOS circuit board 623 is positioned between the circuit support pad 61 and the aluminum base 622. Screws pass through the capacitor circuit board 621, the circular through hole 615, the MOS circuit board 623, and the aluminum base 622.

[0093] Further, the capacitor circuit board 621 and the MOS circuit board 623 are electrically connected through an electrical connector 624. Further, a conductive sheet 625 is provided between the MOS circuit board 623 and the circuit support pad 61, and the conductive sheet 625 is electrically connected to the MOS circuit board 623.

[0094] Note that the above is only the preferred embodiment of the present invention and the technical principles applied. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein. Various obvious changes, re-adjustments, and substitutions can be made by those skilled in the art without departing from the protection scope of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments. Without departing from the concept of the present invention, more other equivalent embodiments can be included.

Claims

1. An electric vehicle controller, characterized in that: Comprising: An upper cover, a base, a power circuit board and a capacitor circuit board. The upper cover is fixedly connected to the base. The capacitor circuit board is positioned on the circuit board support pad. The power circuit board is positioned between the circuit support pad and the base. Screws sequentially pass through the capacitor circuit board, the circuit support pad, the power circuit board and are connected to the base.

2. The electric vehicle controller according to claim 1, wherein: The circuit board support pad includes a vertical positioning portion and a horizontal positioning portion. Among them, multiple horizontal positioning portions are connected by a horizontal connecting portion. Multiple vertical positioning portions are connected by a vertical connecting portion. The middle of the horizontal connecting portion and the vertical connecting portion extends vertically. Circular through holes are provided in the middle of the vertical positioning portion and the horizontal positioning portion. A rectangular through hole is provided on one side of the circular through hole.

3. The electric vehicle controller according to claim 2, characterized in that: A conductive sheet is provided between the power circuit board and the circuit support pad. The conductive sheet is electrically connected to the power circuit board.

4. The electric vehicle controller according to claim 3, wherein: Comprising a first bending section, a connecting section and a second bending section formed by integral bending. The bending directions of the first bending section and the second bending section relative to the connecting section are the same. The first bending section has a first through hole. The second bending section has a second through hole. The first through hole penetrates through the first bending section. The second through hole penetrates through the second bending section.

5. The electric vehicle controller according to claim 4, wherein: The upper cover includes a vertical section and a horizontal section. Among them, the horizontal section vertically extends from the middle of the vertical section. The horizontal section has three horizontal recessed portions. The center lines of the three horizontal recessed portions are on the same straight line. The vertical section has two vertical recessed portions. The center lines of the two vertical recessed portions are on the same straight line. A ventilation portion is provided between the two vertical recessed portions. The horizontal recessed portions and the vertical recessed portions are recessed into the lower surface of the upper cover.

6. The electric vehicle controller according to claim 5, wherein: The power circuit board has a first mounting hole, a second mounting hole, a third mounting hole, a fourth mounting hole, a fifth mounting hole. The first mounting hole, the second mounting hole, and the third mounting hole are on the first straight line. The fourth mounting hole and the fifth mounting hole are on the second straight line. The first straight line is perpendicular to the second straight line. A conductive sheet is connected in each mounting hole.

7. The electric vehicle controller according to claim 6, wherein: The upper cover includes an upper surface. The upper surface includes a flat area and a protruding area. The protruding area includes a first protruding portion and a second protruding portion. Among them, a plurality of buckle grooves are provided on one side of the second protruding portion. A buckle groove is provided on one side of the first protruding portion. The second protruding portion is perpendicular to the first protruding portion. The flat area is located on both sides of the second protruding portion.

8. The electric vehicle controller according to claim 7, wherein: It further includes a control circuit board. The control circuit board is electrically connected to the power circuit board. The capacitor circuit board has positive and negative connection terminals. The control circuit board has motor three-phase line connection terminals. The capacitor on the capacitor circuit board is the first capacitor. The power circuit board has a second capacitor.

9. The circuit board connection structure according to claim 8, wherein: The first capacitor is a common electrolytic capacitor with electrolyte. The second capacitor is a polymer or solid electrolytic capacitor. MOS transistors are provided on the power circuit board.

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