Electric motorcycle controller and assembling method thereof

Abstract

The invention provides an electric motorcycle controller and an assembling method thereof, and relates to the technical field of electric vehicle control, and the electric motorcycle controller comprises a power module which is formed by welding a power tube and a copper strip patch on a power board; a bonding pad is arranged on the back surface of the control panel, and the power module is directly integrated on the back surface of the control panel through patch welding; pET sheets are adhered to the two sides of the long edge of the bottom shell, and heat-conducting glue is poured into the bottom shell to form a sealing layer; the stamping installation parts are clamped in the groove positions on the two sides of the short edge of the bottom shell, and after the stamping installation parts are locked through stamping locking screws, the installation faces, the convex hulls and the locking points of the stamping installation parts form a force bearing triangular structure. According to the electric motorcycle controller, the copper bars are used for replacing copper sleeves and pin headers, so that current and drive connection of the power board and the control board is achieved; after PET sheets are pasted on the two sides of the long edge of the bottom shell, glue is poured into the bottom shell, so that water prevention, creepage distance protection, heat capacity heat absorption and heat conduction are achieved, and a force-bearing triangular structure is formed to enable the controller to be installed on a whole vehicle and connected stably.

Description

Technical Field

[0001] The present invention relates to the technical field of electric vehicle control, and in particular to an electric motorcycle controller and an assembly method thereof. Background Art

[0002] Currently, electric motorcycle (e-motorcycle) controllers generally adopt a layered structure design. In actual applications, since the power tube, copper sleeve and pin header are welded to the aluminum-based power board, and the electricity is conducted through the aluminum sleeve and connected to the control board through the pin header, a clearance space of ≥5mm must be reserved between the power board and the control board to avoid interference between the circuits. This causes the height of the whole machine to exceed the standard, affecting the compactness of the design. The pin header connection is easy to loosen in an environment of continuous vibration, causing instantaneous signal interruption, resulting in a system failure rate of >3‰, affecting the reliability and stability of the product.

[0003] Moreover, the packaging surface of the power tube is close to the back of the control board, causing heat to accumulate in the closed cavity, making it difficult to dissipate heat effectively. The die-cast aluminum base shell is installed in one piece. In order to protect the creepage safety distance, the outer diameter of the copper sleeve must be large. The power board occupies a large area, and the aluminum base plate and copper sleeve are expensive. They cannot adapt to the installation requirements of different models, limiting the compatibility of the product. Summary of the Invention

[0004] In view of this, in order to solve the common circuit connection and heat dissipation defects of electric motorcycle controllers, the purpose of the present invention is to propose an electric motorcycle controller and an assembly method thereof, which realizes zeroing of the layer spacing through an integrated circuit module, eliminates the influence of the pin header connection, adopts a composite heat dissipation and waterproof design, improves the heat capacity and heat absorption capacity, and establishes a heat dissipation path of the power tube, potting glue, bottom shell and air to adapt to the installation requirements of different models.

[0005] To achieve the above object, the present invention provides the following technical solutions: Based on the above objectives, in a first aspect, the present invention provides an electric motorcycle controller, comprising: The power module is composed of power tubes and copper strips soldered to the power board; A control board, wherein a soldering pad is provided on the back of the control board, and the power module is directly integrated on the back of the control board by surface mount soldering; The bottom shell has PET sheets on both sides of the long sides, and thermal conductive glue is poured inside to form a sealing layer; The stamped mounting piece is clamped in the slots on both sides of the short side of the bottom shell. After the stamped mounting piece is locked by the stamped locking screws, the mounting surface, convex bulge and locking point of the stamped mounting piece form a load-bearing triangle structure.

[0006] The electric motorcycle controller of the present invention uses copper bars instead of copper sleeves and pin headers to achieve current and drive connection between the power board and the control board; after PET sheets are pasted on both sides of the long sides of the bottom shell, glue is poured into the inside to achieve waterproofing, creepage distance protection, heat absorption and heat conduction, forming a load-bearing triangle structure so that the controller can be installed on the whole vehicle and connected firmly.

[0007] As a further solution of the present invention, the copper bar is a long strip conductor with a thickness of 0.6-1.0 mm and an aspect ratio of ≥5:1, and is used to replace traditional copper sleeves and pin headers to achieve current and signal transmission.

[0008] As a further solution of the present invention, the thermal conductivity of the thermal conductive adhesive is ≥1W / m·℃, and the heat conduction path is: power tube heat → potting adhesive layer → bottom shell → air; IP67 grade waterproof sealing; creepage distance protection (voltage resistance ≥3kV).

[0009] As a further solution of the present invention, the load-bearing triangular structure is composed of the mounting surface, convex hull and locking point of the stamped mounting part, and the shear force resistance is ≥800N.

[0010] As a further solution of the present invention, a thermal grease layer is coated on the bottom shell boss, and the power module is directly integrated on the back of the control board by patch welding, and placed on the thermal grease layer of the bottom shell boss, and is tightened and locked with the bottom shell locking screws.

[0011] As a further solution of the present invention, the control board is fixed to the boss by using four M3 bottom shell locking screws.

[0012] As a further solution of the present invention, the control board is further provided with a first capacitor cover and a second capacitor cover, and the first capacitor cover and the second capacitor cover are snapped into a pre-position of the control board.

[0013] As a further solution of the present invention, after the stamped mounting piece is clamped in the slots on both sides of the short side of the bottom shell, it is locked to the bottom shell using two M3 stamped locking screws.

[0014] As a further solution of the present invention, PET sheets are pasted on both sides of the long sides of the bottom shell and glue is poured into the inside to complete the assembly.

[0015] In a second aspect, the present invention further provides a method for assembling an electric motorcycle controller, comprising the following steps: (a) Solder the power tube and copper strip patch to the power board to form a power module; (b) Solder the power module chip to the pad on the back of the control board; (c) Apply thermal grease to the bottom shell boss, insert the control board assembly, and tighten it with the bottom shell locking screws; (d) snapping the first capacitor cover and the second capacitor cover into place on the control board; (e) Insert the stamped mounting parts into the short side slots of the bottom shell and secure them with stamped locking screws to form a load-bearing triangular structure; (f) Paste a PET sheet on the inner side of the long side of the bottom shell, inject thermal conductive glue and cure it.

[0016] As a further solution of the present invention, step (b) adopts a secondary reflow process with a peak temperature of 245°C ± 5°C and a time above liquidus of 50 seconds.

[0017] As a further solution of the present invention, in step (f), the glue pouring pressure is 0.2 MPa, the glue layer thickness is 3 mm±0.1 mm, and after curing, fixed supports for the first capacitor cover and the second capacitor cover are formed.

[0018] Compared with the prior art, the electric motorcycle controller and assembly method thereof proposed in the present invention have the following beneficial effects: 1. This invention optimizes the electrical connection between the power board and the control board, eliminating the traditional copper sleeve and pin header connections and reducing the height difference between components. Compared with existing technologies, this invention significantly reduces the overall height, adapting to a wider range of electric motorcycle models, improving the adaptability of the installation space, and reducing the overall height of the controller. The use of interchangeable stamped mounting parts allows for the replacement of stamped parts of different shapes to suit different vehicle models, enhancing the controller's installation adaptability and flexibility.

[0019] 2. In the present invention, the power tube and copper bar are directly connected to the back of the control board through patch welding, replacing the traditional pin / female header connection method. This connection method enhances the strength and consistency of the electrical connection, greatly improves the reliability of the controller in high-vibration environments, and avoids the risk of signal loss due to loose pin / female header connections. Due to the integrated connection method, the electrical connection of the controller is more stable in long-term use and is less susceptible to changes in the external environment (such as vibration, temperature fluctuations, etc.). By eliminating the traditional fitting design between the power tube and the control board, the heat dissipation on the surface of the power board is no longer close to the control board, thereby ensuring a smooth heat dissipation convection path. The heat dissipation effect is significantly improved, which can effectively avoid the problem of controller overheating due to heat accumulation.

[0020] 3. Because the thermal conductivity of the potting compound (≥1W / m·°C) is much higher than that of air (0.025W / m·°C), it effectively improves heat absorption and heat dissipation. When the controller is operating at high power, it can quickly transfer heat to the aluminum shell or the outside air, avoiding the formation of a confined space and improving heat dissipation efficiency. The PET sheets on both sides of the bottom shell and the internal potting compound form a complete waterproof protective layer, ensuring that the electric motorcycle controller can operate stably in harsh environments (such as rain and humidity). The potting compound not only provides waterproofing but also enhances creepage distance protection to ensure electrical safety. The potting compound is easy to use and can effectively waterproof the package. The capacitor cover only requires preliminary positioning, and the position of the capacitor cover is fixed after the potting compound hardens. This simplified process improves production efficiency and reduces production costs.

[0021] 4. The present invention reduces additional material costs by eliminating the traditional copper sleeve and pin header connection method. In addition, the use of integrated patch welding technology reduces the assembly links of multiple components in the production process, further reducing manufacturing costs; the simplified structure and packaging process make the assembly of the controller faster. The use of potting glue packaging not only has a good waterproof effect, but also avoids the use of traditional waterproof rings and complex seals, thereby improving the work efficiency of the production line; through optimized heat dissipation design and waterproof packaging, the internal components of the controller are no longer in a high-temperature environment, reducing damage to the components caused by overheating. Waterproof and creepage distance protection also enhance the reliability of the controller in extreme environments and extend the service life of the vehicle; through the design of stamped mounting parts, the mounting parts can be quickly replaced according to the needs of the vehicle model, and the mounting surface adopts a triangular positioning structure to ensure the stability and reliability of the controller. This design greatly reduces the complexity of installation and maintenance.

[0022] To sum up, the electric motorcycle controller provided by the present invention has significant advantages in structural design, heat dissipation performance, waterproofness, reliability, production efficiency and cost control. It can not only effectively improve the working performance and service life of the electric motorcycle controller, but also reduce production and maintenance costs, and enhance the market competitiveness of the product.

[0023] These and other aspects of the present application will be more clearly understood in the following description of the embodiments. It should be understood that the above general description and the following detailed description are merely exemplary and explanatory and cannot limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or related technologies, the following briefly introduces the drawings required for the exemplary embodiments or related technical descriptions. The drawings are used to provide a further understanding of the present invention and constitute part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the drawings: Figure 1 The figure is a schematic structural diagram of an electric motorcycle controller according to an embodiment of the present invention.

[0025] Figure 2 This is a disassembled schematic diagram of an electric motorcycle controller according to an embodiment of the present invention.

[0026] Figure 3 The figure is a schematic structural diagram of a power module in an electric motorcycle controller according to an embodiment of the present invention.

[0027] Figure 4 This is a schematic cross-sectional structural diagram of an electric motorcycle controller in an embodiment of the present invention, in which a control board is assembled by locking screws of a bottom shell.

[0028] Figure 5 This is a schematic cross-sectional structural diagram of a stamped mounting part in an electric motorcycle controller according to an embodiment of the present invention, which is assembled by stamped locking screws.

[0029] Markings in the figure: 1-power tube, 2-copper bar, 3-power board, 4-power module, 5-control board, 6-bottom shell, 7-bottom shell locking screw, 8-first capacitor cover, 9-second capacitor cover, 10-PET sheet, 11-stamping mounting part, 12-stamping locking screw. DETAILED DESCRIPTION

[0030] Below, the present application is further described in conjunction with the accompanying drawings and specific implementation methods. It should be noted that, under the premise of no conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0031] To make the purpose, technical solutions and advantages of the present invention more clearly understood, the following is a further detailed description of the embodiments of the present invention in conjunction with specific embodiments and with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application.

[0032] It should be noted that all expressions using "first" and "second" in the embodiments of the present invention are intended to distinguish two non-identical entities or non-identical parameters with the same name. Therefore, "first" and "second" are used for convenience of expression only and should not be understood as limitations on the embodiments of the present invention. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, other steps or units inherent to a process, method, system, product, or device that includes a series of steps or units.

[0033] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0034] The flowcharts shown in the accompanying drawings are for illustrative purposes only and do not necessarily include all contents and operations / steps, nor must they be executed in the order described. For example, some operations / steps may be decomposed, combined, or partially merged, so the actual execution order may vary depending on the actual situation.

[0035] The following describes some embodiments of the present application in detail with reference to the accompanying drawings. In the absence of conflict, the following embodiments and features therein may be combined with each other.

[0036] See also Figures 1 to 5 As shown, an embodiment of the present invention provides an electric motorcycle controller, including a power module 4, a control board 5, a bottom shell 6 and a stamped mounting part 11; the power module 4 is composed of a power tube 1 and a copper bar 2 soldered to a power board 3; a soldering pad is provided on the back of the control board 5, and the power module 4 is directly integrated on the back of the control board 5 by patch welding; PET sheets 10 are pasted on both sides of the long side of the bottom shell 6, and thermal conductive glue is poured inside to form a sealing layer; the stamped mounting part 11 is clamped in the slots on both sides of the short side of the bottom shell 6, and after the stamped mounting part 11 is locked by the stamped locking screw 12, the mounting surface, convex bulge and locking point of the stamped mounting part 11 form a load-bearing triangle structure.

[0037] The electric motorcycle controller of the present invention uses a copper bar 2 instead of a copper sleeve and a pin header to achieve current and drive connection between the power board 3 and the control board 5; PET sheets 10 are pasted on both sides of the long sides of the bottom shell 6 and then glue is poured into the inside to achieve waterproofing, creepage distance protection, heat absorption and heat conduction, forming a load-bearing triangle structure so that the controller can be installed on the whole vehicle and connected firmly.

[0038] In this embodiment, the copper bar 2 is a long strip conductor with a thickness of 0.6-1.0 mm and an aspect ratio of ≥5:1, and is used to replace traditional copper sleeves and pin headers to achieve current and signal transmission.

[0039] In this embodiment, the thermal conductivity of the thermal conductive adhesive is ≥1W / m·°C, and the heat conduction path is: heat from the power tube 1 → potting adhesive layer → bottom shell 6 → air; IP67 waterproof sealing; creepage distance protection voltage ≥3kV.

[0040] Since the thermal conductivity of the potting compound is ≥1W / m·℃, which is much higher than the air's 0.025W / m·℃, it effectively improves the heat absorption and heat dissipation effects. When the controller is running at high power, it can quickly transfer heat to the aluminum shell or the outside air to avoid the formation of a confined space, thereby improving the heat dissipation efficiency. Through the application of the PET sheets 10 on both sides of the bottom shell 6 and the internal potting compound, a complete waterproof protective layer is formed, ensuring that the electric motorcycle controller can work stably in harsh environments such as rain and humidity. The potting compound not only provides a waterproof effect, but also enhances creepage distance protection to ensure electrical safety. The potting compound is easy to operate and can be used for efficient waterproof packaging. The capacitor cover only needs to be initially positioned, and the position of the capacitor cover can be fixed after the potting compound hardens. This simplified process improves production efficiency and reduces production costs.

[0041] In this embodiment, the load-bearing triangular structure is composed of the mounting surface, convex bulge and locking point of the stamped mounting part 11, and the shear force resistance is ≥800N.

[0042] In this embodiment, a thermal grease layer is coated on the boss of the bottom shell 6. The power module 4 is directly integrated on the back of the control board 5 by patch welding and placed on the thermal grease layer of the boss of the bottom shell 6. The bottom shell locking screws 7 are used for compression and locking. Among them, the control board 5 is compressed and fixed to the boss with 4 M3 bottom shell locking screws 7.

[0043] In this embodiment, the control board 5 is further provided with a first capacitor cover 8 and a second capacitor cover 9 , which are snapped into a pre-positioned position on the control board 5 .

[0044] In this embodiment, the stamped mounting parts 11 are snapped into the slots on both sides of the short side of the bottom shell 6 and then fixed to the bottom shell 6 using two M3 stamped locking screws 12. PET sheets 10 are attached to both sides of the long side of the bottom shell 6 and glue is poured into the interior to complete the assembly.

[0045] By optimizing the electrical connection between the power board 3 and the control board 5, the present invention eliminates the traditional copper sleeve and pin header connections, reducing the height difference between components. Compared with the existing technology, the present invention significantly reduces the overall height, adapting to a wider range of electric motorcycle models, improving the adaptability of the installation space, and reducing the overall height of the controller. The use of interchangeable stamped mounting parts 11 allows for replacement of stamped parts of different shapes according to the requirements of different vehicle models, enhancing the controller's installation adaptability and flexibility.

[0046] An embodiment of the present invention further provides a method for assembling an electric motorcycle controller, comprising the following steps: a. Solder the power tube 1 and the copper bar 2 to the power board 3 to form a power module 4; b. Solder the power module 4 chip to the pad on the back of the control board 5; c. Apply thermal grease to the bottom shell 6 boss, insert the control board 5 assembly, and tighten it with the bottom shell locking screws 7; d. Clamp the first capacitor cover 8 and the second capacitor cover 9 into the control board 5 for pre-positioning; e. Insert the stamped mounting piece 11 into the short side slot of the bottom shell 6 and lock it with the stamped locking screws 12 to form a load-bearing triangular structure; f. Paste the PET sheet 10 on the inner side of the long side of the bottom shell 6, pour in thermal conductive glue and cure it.

[0047] In this embodiment, step b uses a secondary reflow process with a peak temperature of 245°C ± 5°C and a time above liquidus of 50 seconds. In step f, the glue filling pressure is 0.2 MPa and the glue layer thickness is 3 mm ± 0.1 mm. After curing, the first capacitor cover 8 and the second capacitor cover 9 are fixed.

[0048] In the present invention, the power tube 1 and the copper bar 2 are directly connected to the back of the control board 5 by patch welding, replacing the traditional pin / female header connection method. This connection method enhances the strength and consistency of the electrical connection, greatly improves the reliability of the controller in high-vibration environments, and avoids the risk of signal loss due to loose pin / female header connections. Due to the integrated connection method, the electrical connection of the controller is more stable in long-term use and is less susceptible to external environmental changes such as vibration and temperature fluctuations. By eliminating the traditional fitting design between the power tube 1 and the control board 5, the heat dissipation on the surface of the power board 3 is no longer close to the control board 5, thereby ensuring the smooth flow of the heat dissipation convection path. The heat dissipation effect is significantly improved, which can effectively avoid the problem of controller overheating due to heat accumulation.

[0049] The present invention reduces additional material costs by eliminating the traditional copper sleeve and pin header connection method. In addition, the use of integrated patch welding technology reduces the assembly links of multiple components in the production process, further reducing manufacturing costs; the simplified structure and packaging process make the assembly of the controller faster. The use of potting glue packaging not only has a good waterproof effect, but also avoids the use of traditional waterproof rings and complex seals, thereby improving the work efficiency of the production line; through optimized heat dissipation design and waterproof packaging, the internal components of the controller are no longer in a high-temperature environment, reducing the damage to the components caused by overheating. Waterproof and creepage distance protection also enhance the reliability of the controller in extreme environments and extend the service life of the vehicle; through the design of the stamped mounting part 11, the mounting parts can be quickly replaced according to the needs of the vehicle model, and the mounting surface adopts a triangular positioning structure to ensure the stability and reliability of the controller. This design greatly reduces the complexity of installation and maintenance.

[0050] To sum up, the electric motorcycle controller provided by the present invention has significant advantages in structural design, heat dissipation performance, waterproofness, reliability, production efficiency and cost control. It can not only effectively improve the working performance and service life of the electric motorcycle controller, but also reduce production and maintenance costs, and enhance the market competitiveness of the product.

[0051] The above are exemplary embodiments disclosed in the present invention, but it should be noted that various changes and modifications may be made without departing from the scope of the embodiments disclosed in the claims. The functions, steps and / or actions of the method claims according to the disclosed embodiments described herein do not need to be performed in any particular order. In addition, although the elements disclosed in the embodiments of the present invention may be described or required in individual form, they may also be understood as multiple unless expressly limited to the singular.

[0052] It should be understood that, as used herein, the singular form "a" or "an" is intended to include the plural form as well, unless the context clearly supports an exception. It should also be understood that, as used herein, "and / or" refers to any and all possible combinations of one or more of the items listed in association. The serial numbers of the embodiments disclosed in the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0053] Those skilled in the art should understand that the discussion of any of the above embodiments is merely illustrative and is not intended to limit the scope of the disclosure of the present invention (including the claims) to these examples. Within the spirit of the present invention, the technical features of the above embodiments or different embodiments may be combined, and many other variations exist in different aspects of the above embodiments, which are not provided in detail for the sake of clarity. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric motorcycle controller, characterized in that: include: A power module (4) is composed of a power tube (1) and a copper bar (2) soldered to a power board (3); A control board (5), wherein a soldering pad is provided on the back of the control board (5), and the power module (4) is directly integrated on the back of the control board (5) by patch welding; The bottom shell (6) has PET sheets (10) attached to both sides of the long sides, and a thermal conductive adhesive is poured inside to form a sealing layer; The stamped mounting part (11) is clamped in the slots on both sides of the short side of the bottom shell (6). After the stamped mounting part (11) is locked by the stamped locking screws (12), the mounting surface, the convex bulge and the locking point of the stamped mounting part (11) form a load-bearing triangle structure.

2. The electric motorcycle controller according to claim 1, characterized in that: The copper strip (2) is a long strip conductor with a thickness of 0.6-1.0 mm and an aspect ratio of ≥5:

1.

3. The electric motorcycle controller according to claim 2, characterized in that: The thermal conductivity of the thermally conductive adhesive is ≥1W / m·°C, and the heat conduction path is: heat from the power tube (1), the potting adhesive layer, the bottom shell (6) to the air.

4. The electric motorcycle controller according to claim 3, characterized in that: The load-bearing triangular structure is composed of the mounting surface, convex hull and locking point of the stamped mounting part (11), and has a shear resistance of ≥800N.

5. The electric motorcycle controller according to claim 1, characterized in that: A thermal conductive silicone grease layer is coated on the boss of the bottom shell (6), and the power module (4) is directly integrated on the back of the control board (5) by patch welding and placed on the thermal conductive silicone grease layer of the boss of the bottom shell (6), and is tightened and locked using the bottom shell locking screws (7).

6. The electric motorcycle controller according to claim 5, characterized in that: The control board (5) is fixed to the boss by four M3 bottom shell locking screws (7).

7. The electric motorcycle controller according to claim 6, characterized in that: The control board (5) is further provided with a first capacitance cover (8) and a second capacitance cover (9), and the first capacitance cover (8) and the second capacitance cover (9) are snapped into a pre-position of the control board (5).

8. The electric motorcycle controller according to claim 7, characterized in that: After the stamped mounting piece (11) is clamped in the slots on both sides of the short side of the bottom shell (6), it is locked to the bottom shell (6) using two M3 stamped locking screws (12).

9. The electric motorcycle controller according to claim 8, characterized in that: After the PET sheets (10) are attached to both sides of the long sides of the bottom shell (6), glue is poured into the interior to complete the assembly.

10. An assembly method for an electric motorcycle controller according to any one of claims 1 to 9, characterized in that: The method comprises the following steps: Soldering the power tube (1) and the copper bar (2) to the power board (3) to form a power module (4); Solder the power module (4) chip to the back pad of the control board (5); Apply thermal grease to the boss of the bottom shell (6), insert the control board (5) assembly, and tighten it with the bottom shell locking screws (7); The first capacitor cover (8) and the second capacitor cover (9) are clamped into the control board (5) for pre-positioning; Insert the stamped mounting piece (11) into the short side slot of the bottom shell (6) and lock it with the stamped locking screw (12) to form a load-bearing triangular structure; A PET sheet (10) is pasted on the inner side of the long side of the bottom shell (6), and heat-conducting glue is poured and solidified.

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