Platform motor controller and manufacturing method thereof

Abstract

The invention provides a platform motor controller and a manufacturing method thereof. The motor controller comprises a main body part, a capacitor core, an insulating piece, a main connecting piece and a cover plate. The main body part forms an accommodating space, a capacitor core, an insulating piece and a main connecting piece are sequentially arranged in the main body part along a first direction, and the cover plate covers the top of the accommodating space. The connecting piece selectively penetrates through the glue pouring groove in the first face of the main body part and is electrically connected with the main connecting piece, and / or an avoiding window is formed in the second face of the main body part, a sealing piece is arranged in the avoiding window, and the connecting piece penetrates through the sealing piece and extends out of the line. The two paths can be used independently or in a combined mode, so that decoupling design of the position of the connecting piece and the sealing structure can be achieved only by modifying the windowing position of the mold. When the layout of the core assembly of the main body part is kept unchanged, different interface requirements can be quickly met by adjusting the welding point or the windowing position, the main body structure does not need to be redesigned or the whole mold does not need to be opened, the universality of the platform is remarkably improved, and the customization cost is eliminated.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicles, and in particular to a platform-based motor controller and its manufacturing method. Background Technology

[0002] As the brain of the electric drive system in new energy vehicles, the motor controller undertakes the dual mission of energy conversion and power regulation. Its core function is to efficiently convert the direct current output from the power battery into three-phase alternating current, precisely driving the motor, while simultaneously adjusting key parameters such as torque and speed in real time to ensure vehicle responsiveness and optimal energy efficiency. The reliability of this component directly affects the vehicle's range, acceleration performance, and ride smoothness, making it a crucial hub for ensuring the stability and safety of electric vehicle power output. In the current context of industrial technology upgrades, the high integration, lightweight design, and platform compatibility of motor controllers have become key indicators of industry competitiveness.

[0003] However, to meet stability requirements such as waterproofing and shock resistance, the sealing structure of the external interfaces (such as high-voltage power interfaces) of existing motor controllers is often tightly bound to the geometric position of the housing. This rigid layout results in extremely limited space for interface position adjustment, making it difficult to adapt to the wiring harness routing or spatial constraints of different vehicle manufacturers. When customers propose differentiated interface requirements, manufacturers must redesign the controller housing structure, create molds to manufacture dedicated housings, and repeatedly conduct sealing verification and electromagnetic compatibility testing for the new layout. Each customized design requires investment in the entire chain of costs from R&D and mold making to production, which not only prolongs the development cycle but also leads to high unit costs due to the inability to reuse platform solutions, severely restricting product iteration efficiency and market response speed.

[0004] Therefore, there is currently no good solution to this problem. Summary of the Invention

[0005] In order to overcome the above-mentioned technical defects, the purpose of this invention is to provide a platform-based motor controller and its manufacturing method.

[0006] The first aspect of this invention discloses a platform-based motor controller, which includes a main body, a capacitor core, an insulating component, a main connector, and a cover plate. The main body extends along a first direction and forms a receiving space; a capacitor core, an insulating component, and a main connector are sequentially arranged in the receiving space along the first direction; a cover plate covers the top surface of the receiving space; the main body also includes a first surface and a second surface arranged at intervals along a second direction; the first surface has a potting groove, and a potting sealant is arranged in the potting groove; the second surface is the side wall of the main body; the second direction is perpendicular to the first direction. The main connector is electrically connected to the capacitor core; the motor controller also includes at least one connector; the wiring method of the at least one connector includes: - At least one connector passes through the potting sealant and extends outward, and is electrically connected to the main connector; And / or, - A clearance window is provided on the side wall of the main body, and a seal is provided inside the clearance window; at least one connector passes through the seal and extends outward, and is electrically connected to the main connector.

[0007] Preferably, when a clearance window is provided on the side wall of the main body and a sealing element is provided inside the clearance window, the sealing element includes a first part and a second part; The first part is made of rigid material; the second part is arranged around the outer periphery of the first part and is made of flexible material.

[0008] Preferably, the seal is configured such that the extension direction is inclined relative to the first direction; the third direction is perpendicular to both the first and second directions. The side of the clearance window is configured to correspond to the shape of the seal on the third direction, so that the seal can slide along that side of the clearance window to the installation position.

[0009] Preferably, the second part of the seal includes a first protrusion and a second protrusion that are spaced apart from each other along a second direction; when the seal is in the installation position, both the first protrusion and the second protrusion are in contact with the side wall of the clearance window.

[0010] Preferably, the connector includes an interface portion and an adapter portion; The interface extends along the second direction and passes through the seal; both ends of the adapter are fixed and electrically connected to the adapter and the main connector, respectively, so that the interface is electrically connected to the main connector through the adapter.

[0011] Preferably, the first part of the seal has a through hole for the interface part to pass through; The inner circumferential side of the through hole is also provided with a third part of the seal, which fits against the interface when the interface passes through the seal; The third part is made of flexible material.

[0012] Preferably, the adapter is electrically connected to the interface and the main connector by welding.

[0013] Preferably, the adapter portion is at least partially attached to the main body portion so that the connector can exchange heat with the main body portion through the adapter portion.

[0014] The second aspect of this application also provides a method for manufacturing a platform-based motor controller as described in any of the foregoing embodiments, comprising: S100, hot-pressing together a main connector and an insulating member; S200. Secure the connector to the seal; S300. Weld the connector to the main connector and fix it in place. S400. Solder and fix the main connector, insulating parts and capacitor core. S500: The main connector, insulating component, capacitor core, and connector are fixedly connected to the main body as a whole; S600. The main body is injected with glue through the glue injection tank to form a glue-filled fastener; S700: Cover and fix the cover plate to the surface of the main body to encapsulate the main connector, insulator, capacitor core and connector.

[0015] Preferably, when a clearance window is provided on the side wall of the main body, and a sealing element is provided inside the clearance window; at least one connector passes through the sealing element and extends outward, and is electrically connected to the main connector, S200, fixing the connector and the sealing element includes: S201. Insert the interface part into the through hole of the seal and fit it with the third part; S300, Welding and fixing the connector to the main connector includes: S301. Weld one end of the adapter to the main connector and fix it in place, and weld the other end to the interface part. S500, the main connector, insulating component, capacitor core, and connector are fixedly connected to the main body as a whole, including: S501. Slide the interface and seal along the clearance window to the installation position.

[0016] Compared with existing technologies, the above technical solution has the following advantages: 1. The platform-based motor controller provided by this invention achieves a decoupling design between the position of external connectors and the sealing structure by setting two optional paths: a potting seal or a clearance window seal in the main body. The core is that when the potting groove is located at any position on the first surface (potting surface), only the position of the connector's protrusion point within the potting groove needs to be adjusted and welded to the main connector, ultimately being filled, fixed, and sealed by the potting seal in one go; when the clearance window is located at any position on the second surface (window surface), only the position of the clearance window corresponding to the main body mold needs to be modified. The layout of the core components of the main body remains completely unchanged. This design completely removes the constraints of interface position on the overall structure of the controller. The same main body can quickly adapt to different interface requirements by simply adjusting the welding point position or the mold window position, without redesigning the main structure or opening a new mold, significantly improving the platform's versatility and eliminating customization costs. 2. When using the clearance window design, the seal employs a composite structure where a rigid first part provides support and a flexible second part fills the gap, balancing installation strength and dynamic sealing reliability. The inclined side of the seal mates with the corresponding inclined surface of the clearance window to form a guide, significantly reducing assembly difficulty and minimizing the risk of wear on the flexible part during sliding installation. Furthermore, the flexible structure of the second part, with its inner and outer double-layer protrusions arranged opposite each other along the second direction (front-back direction), tightly fits against the sidewall of the clearance window at the installation position, forming a double dynamic sealing barrier. The flexible third part, added to the inner circumference of the through-hole, tightly wraps around the interface, forming a radial sealing ring, which, together with the second part, constitutes a double-layer sealing guarantee, effectively isolating the internal and external environments. 3. The connector's interface passes directly through the seal along the second direction: this facilitates precise alignment and tight fit during assembly by inserting it into the seal's through-hole in a straight line, and also provides a vertical interface to simplify the vehicle's wiring harness plugging and unplugging operations. Both ends of the adapter are welded to the interface and main connector to achieve metallurgical bonding, ensuring extremely low contact resistance, high mechanical strength, and excellent vibration and thermal fatigue resistance at the connection point. Simultaneously, the tight fit between the adapter and the main body establishes an efficient heat conduction channel, transferring the heat generated during operation to the main body's metal structure for diffused heat dissipation, optimizing internal thermal management and improving overall reliability. 4. This manufacturing method achieves high-efficiency production through a modular pre-integration and step-by-step assembly strategy. The core of this method lies in: first, hot-pressing and fixing the main connectors, insulating components, and connecting parts in an open space; then, assembling the seals and precision welding them to form a complete circuit module; subsequently, the module is installed into the main body, utilizing the inclined guide structure of the clearance window to achieve one-step sliding positioning of the sealing components; finally, assembly is completed through potting and sealing with a cover plate. This process design ensures that critical electrical connections are completed under optimal operating conditions, guaranteeing welding reliability and sealing quality; at the same time, modular assembly significantly simplifies the overall assembly complexity, and combined with the sliding positioning design, significantly reduces the difficulty of installing precision components, enabling the same production line to efficiently adapt to different interface specification requirements. Attached Figure Description

[0017] Figure 1 A three-dimensional structural schematic diagram of one embodiment of the platform-based motor controller provided in this application; Figure 2 A three-dimensional structural schematic diagram of another embodiment of the platform-based motor controller provided in this application. Figure 3 An exploded structural diagram of one embodiment of the platform-based motor controller provided in this application; Figure 4 An exploded structural diagram of another embodiment of the platform-based motor controller provided in this application; Figure 5A three-dimensional structural diagram of the seal in the platform-based motor controller provided in this application; Figure 6 A partial structural diagram of the platform-based motor controller provided in this application; Figure 7 A schematic diagram of the mating structure of the seals and connectors in the platform-based motor controller provided in this application; Figure 8 A schematic diagram of the mating structure of the connectors and main connectors in the platform-based motor controller provided in this application.

[0018] Attached reference numeral: 100, motor controller; 1. Main body; 11. First surface; 111. Glue filling tank; 112. Glue filling sealant; 12. Second surface; 2. Capacitor core; 3. Insulating components; 4. Main connectors; 5. Cover plate; 6. Avoidance windows; 7. Seal; 71. First part; 711. Through hole; 72. Second part; 721. First protrusion; 722. Second protrusion; 73. Third part; 8. Connector; 81. Interface section; 811. Protrusion; 82. Adapter section; z, first direction; y, second direction; x, third direction. Detailed Implementation

[0019] The advantages of the present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments.

[0020] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims.

[0021] The terminology used in this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. The singular forms “a,” “the,” and “the” as used in this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0022] It should be understood that although the terms first, second, third, etc., may be used in this disclosure to describe various information, such information should not be limited to these terms. These terms are used only to distinguish information of the same type from one another. For example, without departing from the scope of this disclosure, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to determination." In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0023] In the description of this invention, unless otherwise specified and limited, it should be noted that the terms "installation", "connection" and "linking" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components. They can be direct connections or indirect connections through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0024] In the following description, suffixes such as "module," "part," or "unit" used to denote elements are used only for the convenience of the description of the invention and have no specific meaning in themselves. Therefore, "module" and "part" can be used interchangeably.

[0025] Please see Figures 1-4 , Figure 1 A three-dimensional structural schematic diagram of one embodiment of the platform-based motor controller provided in this application; Figure 2 A three-dimensional structural schematic diagram of another embodiment of the platform-based motor controller provided in this application; Figure 3 An exploded structural diagram of one embodiment of the platform-based motor controller provided in this application; Figure 4 An exploded structural diagram of another embodiment of the platform-based motor controller provided in this application.

[0026] like Figures 1-4 As shown, the first aspect of the present invention discloses a platform-based motor controller 100, which includes a main body 1, a capacitor core 2, an insulating component 3, a main connector 4, and a cover plate 5. The main body 1 extends along the first direction z and forms a receiving space; within the receiving space, a capacitor core 2, an insulating component 3, and a main connector 4 are sequentially arranged along the first direction z; a cover plate 5 covers the top surface of the receiving space; the main body 1 also includes a first surface 11 and a second surface 12 arranged at intervals along the second direction y; the first surface 11 has a potting groove 111, and a potting sealant 112 is provided in the potting groove 111; the second surface 12 is the side wall of the main body 1; the second direction y is perpendicular to the first direction z; The main connector 4 is electrically connected to the capacitor core 2; The motor controller 100 also includes at least one connector 8; the wiring method of the at least one connector 8 includes: - At least one connector 8 passes through the potting sealant 112 and extends outward, and is electrically connected to the main connector 4; And / or, - A clearance window 6 is provided on the side wall of the main body 1, and a sealing element 7 is provided inside the clearance window 6; at least one connector 8 passes through the sealing element 7 and extends outward, and is electrically connected to the main connector 4.

[0027] This can be understood as follows: the motor controller 100 provided in this application offers two solutions for external connection. One is to exit from the potting surface, and the other is to exit from the side of the main body 1. This achieves a decoupling design between the position of the connector 8 and the sealing structure. When the connector 8 exits from the first surface 11 (potting surface), it is only necessary to adjust the position of the protrusion point of the connector 8 in the potting groove 111 and weld it to the main connector 4, and finally, the potting seal 112 fills, fixes, and seals it at one time. When the connector 8 exits from the second surface 12 (i.e., the side wall of the main body 1), it can also exit from any position on the second surface 12, only requiring modification of the position of the clearance window 6 corresponding to the mold of the main body 1. The layout of the core components of the main body 1 remains completely unchanged. Of course, those skilled in the art will understand that one of the above two solutions can be selected for use, or both can be used, thereby achieving complete standardization and adapting to different customers through one solution.

[0028] This design completely removes the constraints of the interface position on the overall structure of the motor controller 100. The same main body 1 can be quickly adapted to different interface requirements by simply adjusting the position of the welding point or the position of the mold opening, without the need to redesign the main structure or open the overall mold, which significantly improves the versatility of the platform and eliminates customization costs.

[0029] The above is an explanation of the basic concept of this application. The specific structure of each component in this application will be described below with reference to the accompanying drawings.

[0030] Please see Figures 5-7 , Figure 5A three-dimensional structural diagram of the seal in the platform-based motor controller provided in this application; Figure 6 A partial structural diagram of the platform-based motor controller provided in this application; Figure 7 A schematic diagram of the mating structure of the seals and connectors in the platform-based motor controller provided in this application.

[0031] First, the possible specific structure and fitting relationship of the seal 7 will be explained.

[0032] like Figures 5-7 As shown, and in combination Figures 1-4 It is understood that when a clearance window 6 is provided on the side wall of the main body 1, and a sealing element 7 is provided inside the clearance window 6, the sealing element 7 includes a first part 71 and a second part 72. The first part 71 is made of rigid material; the second part 72 is arranged around the outer periphery of the first part 71 and is made of flexible material.

[0033] When using the avoidance window 6 design, the seal 7 employs a rigid-flexible composite structure. The rigid first part 71 provides structural support for the main body, ensuring the stability of the connector 8 during installation; the flexible second part 72 is arranged around the outer perimeter, utilizing its deformation capacity to tightly fill the assembly gap between the seal 7 and the side wall of the avoidance window 6. This design balances installation strength with the reliability of dynamic sealing, effectively resisting the effects of vibration and thermal expansion and contraction during vehicle operation, preventing the intrusion of moisture or dust due to seal failure, and maintaining the overall protection level of the motor controller 100 while ensuring flexible and variable interface positions.

[0034] Furthermore, the seal 7 is configured such that its extension direction is inclined relative to the first direction z; the third direction x is perpendicular to both the first direction z and the second direction y. The side of the clearance window 6 is configured to correspond to the shape of the side of the seal 7 along the third direction x, so that the seal 7 can slide along that side of the clearance window 6 to the installation position.

[0035] The inclined design of the seal 7's sidewall forms a guiding fit with the corresponding side of the clearance window 6, simplifying the assembly operation to a linear sliding along a predetermined inclined surface. On the one hand, this structure significantly reduces assembly difficulty and positioning accuracy requirements, improving production efficiency. On the other hand, the flexible material of the second part 72 is prone to wear due to friction when in contact with the rigid main body 1. The inclined sliding design effectively reduces the contact area and relative friction distance between the edge of the seal 7 and the rigid edge of the clearance window 6, greatly reducing the risk of scratch damage to the flexible seal 7 during installation, protecting the integrity of the sealing structure, and ensuring long-term sealing reliability.

[0036] In the second direction y, the structure of the seal 7 is also not limited.

[0037] In one possible implementation, the second portion 72 of the seal 7 includes a first protrusion 721 and a second protrusion 722 that are spaced apart from each other along the second direction y; when the seal 7 is in the installation position, both the first protrusion 721 and the second protrusion 722 are in contact with the side wall of the clearance window 6.

[0038] This can be understood as follows: the first protrusion 721 and the second protrusion 722, which are relatively spaced apart on the flexible second part 72, tightly fit the inner and outer walls of the avoidance window 6 respectively after the seal 7 reaches the installation position. This double-layer protrusion structure forms a front and rear double dynamic sealing barrier, significantly increasing the sealing contact surface. The protrusions made of flexible material continuously compensate for gap changes, effectively isolating the risk of external environment penetration along the axial direction of the connector 8, and further improving the sealing reliability of the motor controller 100 under vibration or temperature difference conditions.

[0039] The above describes the possible specific structure of the seal 7 provided in this application. The specific structure of the connector 8 will be described below.

[0040] Please see Figure 8 , Figure 8 A schematic diagram of the mating structure of the connectors and main connectors in the platform-based motor controller provided in this application.

[0041] like Figures 7-8 As shown, and in combination Figures 1-6 It is understood that, in one possible implementation, connector 8 includes an interface part 81 and a transition part 82; The interface portion 81 extends along the second direction y and passes through the seal 7; the two ends of the adapter portion 82 are fixed and electrically connected to the interface portion 81 and the main connector 4 respectively, so that the interface portion 81 is electrically connected to the main connector 4 through the adapter portion 82.

[0042] The connector 8 adopts a separate design for the interface section 81 and the adapter section 82. The interface section 81 passes through the seal 7 in a straight line along the second direction y. Firstly, this facilitates the insertion of the interface section 81 into the through hole 711 of the seal 7 during assembly, ensuring precise alignment and tight fit with the flexible sealing structure. Secondly, it provides a standard interface direction perpendicular to the controller housing for external connections, greatly simplifying the space requirements for plugging and unplugging the vehicle wiring harness. The adapter section 82 acts as an internal bridge connecting the interface section 81 and the main connector 4, making the internal circuit layout completely independent of the external interface position, providing support for the core platform design. Furthermore, when the connector 8 is located in different positions, the same specification adapter section 82 can be used to achieve electrical connection between the main connector 4 and the interface section 81. Only the position and angle of the adapter section 82 need to be adjusted, thereby further reducing production costs.

[0043] It should be noted that the specific fit between the connector 8 and the seal 7 is not limited.

[0044] In one possible implementation, the first part 71 of the seal 7 has a through hole 711 for the interface part 81 to pass through; The inner circumferential side of the through hole 711 is also provided with a third part 73 of the sealing element 7. When the interface part 81 passes through the sealing element 7, the third part 73 fits with the interface part 81. Part 3, section 73, describes flexible materials.

[0045] A flexible third part 73 is added inside the through hole 711 of the rigid first part 71 of the seal 7, forming a radial sealing ring specifically for the interface part 81. When the interface part 81 passes through the through hole 711, the flexible third part 73 tightly wraps its outer peripheral surface, eliminating the microscopic gap between the interface part 81 and the inner wall of the through hole 711. This, together with the sidewall seal formed by the second part 72, constitutes a double sealing guarantee, maximizing the sealing performance of the motor controller 100.

[0046] Furthermore, the interface section 81 may also include more positioning designs to achieve precise positioning of the interface section 81. In one possible implementation, such as... Figure 7 As shown, the interface portion 81 is also provided with two protrusions 811 extending relative to each other in the first direction z. This is so that when the interface portion 81 is in the installation position, the two protrusions 811 engage with the two sides of the first part 71 of the seal 7 in the first direction z, thereby completing the positioning of the interface portion 81 in the second direction y, further simplifying the installation and improving the assembly accuracy.

[0047] Secondly, the specific connection method and setting position of the adapter 82 and the interface 81 are not limited.

[0048] In one possible implementation, the adapter 82 is electrically connected to the interface 81 and the main connector 4 by welding.

[0049] Furthermore, the adapter 82 is at least partially attached to the main body 1 so that the connector 8 can exchange heat with the main body 1 through the adapter 82.

[0050] On the one hand, by welding the adapter 82 to the interface 81 and the adapter 82 to the main connector 4, the electrical connection and fixation can be achieved, ensuring extremely low contact resistance and high mechanical strength at the connection points. This effectively resists vibration fatigue and thermal cycling stress during long-term operation, ensuring the long-term reliability and stability of the electrical connection and reducing potential failure points. On the other hand, the heat dissipation design, with the adapter 82 attached to the main body 1, allows the heat generated by the main connector 4 and connector 8 during operation to be directly conducted to the metal structure of the main body 1 through the adapter 82 and diffused. The large heat capacity and surface area of ​​the main body 1, along with other possible heat dissipation measures (such as water cooling of the motor controller 100 through water channels), are utilized for heat dissipation. This integrated heat dissipation method optimizes the internal thermal management of the motor controller 100, helping to reduce the operating temperature of critical connection points and electronic components, thereby further improving the overall reliability and service life of the motor controller 100.

[0051] The above describes the possible structure of the platform-based motor controller 100 provided in this application.

[0052] The second aspect of this application also provides a method for manufacturing a platform-based motor controller as described in any of the foregoing embodiments, comprising: S100, hot-pressing the main connector 4 and the insulating member 3 together; S200. Fix the connector 8 to the seal 7; S300. Weld and fix the connector 8 to the main connector 4. S400. Solder the main connector 4, the insulating component 3 and the capacitor core 2 to fix them in place; S500, The main connector 4, the insulating component 3, the capacitor core 2 and the connector 8 are fixedly connected to the main body 1 as a whole; S600, The main body 1 is injected with glue through the glue injection tank 111 to form a glue injection seal 112; S700, Cover plate 5 is placed over and fixed to the surface of main body 1 to encapsulate main connector 4, insulating component 3, capacitor core 2 and connector 8.

[0053] This manufacturing method employs a hierarchical modular pre-integration strategy. First, the core electrical components (main connector 4, insulation component 3) are thermo-pressed to form a stable base unit (S100), and the pre-fixation of connector 8 and seal 7 is completed independently (S200), as well as the welding of connector 8 to main connector 4 (S300). Then, capacitor cores 2 are integrated to form a complete circuit module (S400). This pre-integrated module is then installed as a whole into the main body 1 (S500), and fixation and sealing are achieved through potting (S600), finally encapsulated by cover plate 5 (S700). This process significantly improves assembly efficiency and quality: the core circuit connections are precisely manipulated in an open space, ensuring welding and insulation reliability; the assembly of the main body 1 is simplified to module positioning and potting sealing, greatly reducing overall assembly complexity and error rate.

[0054] Furthermore, in one possible implementation, when a clearance window 6 is provided on the side wall of the main body 1, and a sealing element 7 is provided inside the clearance window 6; at least one connector 8 passes through the sealing element 7 and extends outward, and is electrically connected to the main connector 4, S200, fixing the connector 8 to the sealing element 7 includes: S201. Insert the interface part 81 into the through hole 711 of the seal 7 and fit it with the third part 73. S300, Welding and fixing the connector 8 to the main connector 4 includes: S301. Weld one end of the adapter 82 to the main connector 4 and fix it in place, and weld the other end to the interface 81 and fix it in place. S500, the main connector 4, the insulating component 3, the capacitor core 2, and the connector 8 are fixedly connected to the main body 1 as a whole, including: S501. Slide the interface part 81 and the seal 7 along the clearance window 6 to the installation position.

[0055] This can be understood as follows: when the connector 8 protrudes from the clearance window 6, only the interface 81 and the seal 7 need to be pre-assembled before being connected as a whole to the main connector 4 via welding through the adapter 82. Furthermore, when the main connector 4, the insulator 3, the capacitor core 2, and the connector 8 are fixedly connected to the main body 1 as a whole, the clearance window 6 naturally acts as a guide, allowing the interface 81 and the seal 7 to slide naturally to their installation position when the entire assembly is in place, significantly reducing the difficulty of positioning precision components in a confined space. This step-by-step, refined operation balances sealing quality, connection reliability, and assembly efficiency.

[0056] It should be noted that the embodiments of the present invention have better implementability and are not intended to limit the present invention in any way. Any person skilled in the art may use the above-disclosed technical content to change or modify it into equivalent effective embodiments. However, any modifications or equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A platform-based motor controller, characterized in that, The motor controller includes a main body, a capacitor core, an insulating component, a main connector, and a cover plate; The main body extends along a first direction and forms a receiving space; a capacitor core, an insulating component, and a main connector are sequentially arranged in the receiving space along the first direction; a cover plate covers the top surface of the receiving space; the main body also includes a first surface and a second surface arranged at intervals along a second direction; the first surface has a potting groove, and a potting sealant is provided in the potting groove; the second surface is a side wall of the main body; the second direction is perpendicular to the first direction; The main connector is electrically connected to the capacitor core; the motor controller further includes at least one connector; the wiring method of the at least one connector includes: - The at least one connector passes through the potting sealant and extends outward, and is electrically connected to the main connector; And / or, - A clearance window is provided on the side wall of the main body, and a sealing element is provided inside the clearance window; at least one connector passes through the sealing element and extends outward, and is electrically connected to the main connector.

2. The platform-based motor controller as described in claim 1, characterized in that, When a clearance window is provided in the side wall of the main body and a sealing element is provided inside the clearance window, the sealing element includes a first part and a second part; The first part is made of a rigid material; the second part is arranged around the outer periphery of the first part and is made of a flexible material.

3. The platform-based motor controller as described in claim 2, characterized in that, The seal is configured such that its extension direction is inclined relative to the first direction; the third direction is perpendicular to both the first and second directions. The side of the clearance window is configured to correspond to the shape of the seal on the third direction, so that the seal can slide along that side of the clearance window to the installation position.

4. The platform-based motor controller as described in claim 3, characterized in that, The second part of the seal includes a first protrusion and a second protrusion that are spaced apart from each other along the second direction; when the seal is in the installation position, both the first protrusion and the second protrusion are in contact with the side wall of the clearance window.

5. The platform-based motor controller as described in claim 2, characterized in that, The connector includes an interface section and an adapter section; The interface portion extends along the second direction and passes through the seal; both ends of the adapter portion are fixed and electrically connected to the adapter portion and the main connector respectively, so that the interface portion is electrically connected to the main connector through the adapter portion.

6. The platform-based motor controller as described in claim 5, characterized in that, The first part of the seal has a through hole for the interface portion to pass through; The inner circumferential side of the through hole is also provided with a third part of the sealing element, and when the interface portion passes through the sealing element, the third part fits against the interface portion; The third part is made of flexible material.

7. The platform-based motor controller as described in claim 5, characterized in that, The adapter is electrically connected to the interface and the main connector by welding.

8. The platform-based motor controller as described in claim 5, characterized in that, The adapter portion is at least partially attached to the main body portion so that the connector can exchange heat with the main body portion through the adapter portion.

9. A method for manufacturing a platform-based motor controller as described in any one of claims 1-8, characterized in that, include: S100. Heat-press the main connector and the insulating component to fix them; S200. Secure the connector to the seal; And / or, S200, pass the sealant through the potting groove; S300. Weld the connector to the main connector to fix it in place; S400. Solder the main connector, the insulating component, and the capacitor core to fix them in place; S500, The main connector, the insulating component, the capacitor core, and the connector are fixedly connected to the main body as a whole; S600. Apply glue to the main body through the glue-filling groove to form a glue-filling fixing component; S700. Cover and fix the cover plate to the surface of the main body to encapsulate the main connector, the insulating component, the capacitor core and the connector.

10. The manufacturing method as described in claim 9, characterized in that, When a clearance window is provided on the side wall of the main body, and a sealing element is provided inside the clearance window; when at least one connector passes through the sealing element and extends outward, and is electrically connected to the main connector, step S200, fixing the connector to the sealing element, includes: S201. Insert the interface part into the through hole of the seal and fit it with the third part; S300, welding and fixing the connector to the main connector includes: S301. Weld one end of the adapter to the main connector and fix it in place, and weld the other end to the interface part and fix it in place. S500, fixing the main connector, the insulating component, the capacitor core, and the connector as a whole to the main body includes: S501. Slide the interface and the seal along the clearance window to the installation position.

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