Integrated controller, electric control power device and electric control power device assembling method

Abstract

The invention relates to the technical field of automobile electronic controllers, and particularly discloses an integrated controller, an electric control power device and an electric control power device assembling method. The integrated controller comprises a connector assembly, a main control board, a supporting seat and a driving board which are sequentially arranged from top to bottom, a first receding hole penetrates through the supporting seat, a second receding hole penetrates through the driving board, the connector assembly and the main control board are arranged in a spaced mode, and the supporting seat and the driving board are arranged in a spaced mode; a plurality of controller heat dissipation layers are arranged at the top of the supporting seat, a plurality of plug-in pins are arranged at the top of the plug-in assembly, the plug-in pins are electrically connected with the main control board, fisheye pin headers are connected to the supporting seat in a penetrating mode, the main control board is electrically connected with the driving board through the fisheye pin headers, the driving board is fixedly connected to the bottom of the supporting seat, and a motor heat dissipation layer is arranged below the driving board. The motor heat dissipation layer is arranged at the top of the motor assembly; and the rotating shaft penetrates through the first avoiding hole and the second avoiding hole. According to the integrated controller, the main control board and the driving board are arranged in a layered mode, and modular integration is achieved.

Description

Technical Field

[0001] This invention relates to the field of automotive electronic controller technology, and more particularly to an integrated controller, an electric power unit, and an assembly method for the electric power unit. Background Technology

[0002] As a core power unit in electric vehicles, industrial equipment, and other fields, the integration, reliability, and spatial layout efficiency of the electric power system directly affect the overall performance, cost, and development cycle. In existing technologies, traditional designs generally adopt a split layout, where the motor and controller are arranged as two independent physical modules, or a non-coaxial integration method is used. This type of structure has long faced several prominent drawbacks in practical applications.

[0003] First, space utilization is low. Split or non-coaxial layouts mean that the controller typically occupies a significant amount of additional installation space in the radial or axial direction of the motor. Within the limited space of a vehicle and various steering and drive products, this design makes product layout difficult, severely restricts the compactness of the overall structure, increases installation complexity, extends product development cycles, raises manufacturing costs, and increases the difficulty of subsequent management and maintenance.

[0004] Secondly, the system suffers from poor integration and weak electromagnetic compatibility. Because the controller and motor are physically separated, the power and signal transmission paths between them are long, making them susceptible to electromagnetic interference, which affects control accuracy and reliability. Furthermore, traditional controllers often integrate power supply, drive, and control modules onto a single PCB board, resulting in high coupling between modules and poor versatility and portability. This highly integrated single-board design often requires replacing the entire board in case of a partial failure, leading to high maintenance costs. Moreover, interference from various power modules to the control module further degrades the overall electromagnetic compatibility of the system.

[0005] Furthermore, collaborative work efficiency is limited. In non-coaxial integration solutions, it is difficult to achieve precise alignment between the axes of the controller and the motor, which may lead to deviations in power transmission, affecting the dynamic response speed and transmission efficiency of the system, and is not conducive to application scenarios requiring high performance.

[0006] Although some improvements have attempted to bring controller components closer to the motor side, most still employ parallel or lateral stacking integration, failing to achieve a truly coaxial integrated layout. Such designs often suffer from problems such as messy internal wiring, unclear heat dissipation paths, inconvenient maintenance, and insufficient modular expansion capabilities, and still pose potential risks in terms of thermal management and reliability under long-term high-load operation. Summary of the Invention

[0007] The purpose of this invention is to provide an integrated controller, an electric power unit, and an assembly method for the electric power unit, by setting up the main control board and the drive board in layers to achieve modular integration.

[0008] To achieve this objective, the present invention adopts the following technical solution:

[0009] An integrated controller is assembled on a motor assembly, the top of which has a rotating shaft extending out. The integrated controller includes, from top to bottom, a connector assembly, a main control board, a support base, and a drive board. The connector assembly and the main control board are spaced apart, as are the support base and the drive board. The main control board sends received information to the drive board, which then controls the operation of the motor assembly based on the information. The top of the support base has several controller heat dissipation layers, and the top of the connector assembly has several plug-in P-type heat dissipation layers. IN pin, the plug-in PIN pin is electrically connected to the main control board, the support base is connected to a fisheye pin header, the main control board and the drive board are electrically connected through the fisheye pin header, the drive board is fixed to the bottom of the support base, a motor heat dissipation layer is provided below the drive board, the motor heat dissipation layer is located on the top of the motor assembly; the support base has a first clearance hole, the drive board has a second clearance hole, the cross-sectional projection of the second clearance hole covers the cross-sectional projection of the first clearance hole, and the rotating shaft passes through the first clearance hole and the second clearance hole.

[0010] As an optional technical solution for the integrated controller, the top of the fisheye pin header is connected to a plurality of first fisheye pins, and the bottom of the fisheye pin header is connected to a second fisheye pin. The number of first fisheye pins and second fisheye pins is the same, and each first fisheye pin is electrically connected to one second fisheye pin. The first fisheye pins are connected to the main control board by a crimping process, and the second fisheye pins are connected to the drive board by a crimping process.

[0011] As an optional technical solution for the integrated controller, the support base is made of ADC12 material.

[0012] An electronically controlled power unit includes a motor assembly, an ECU housing, and the aforementioned integrated controller. The ECU housing has a downward-opening receiving groove. The groove wall and the top of the motor assembly form a receiving cavity. The integrated controller is disposed within the receiving cavity. The plug-in pin is inserted into the bottom of the receiving groove, and the plug-in pin portion extends out of the receiving cavity.

[0013] As an optional technical solution for the electronically controlled power unit, the electronically controlled power unit also includes a vent plug, which is inserted into the ECU housing and connects the accommodating cavity to the outside.

[0014] As an optional technical solution for the electronically controlled power device, the motor assembly includes a motor housing and a motor body disposed within the motor housing, the output end of the motor body being connected to the rotating shaft; one of the outer sidewalls of the ECU cover and the sidewall of the motor housing is circumferentially distributed with a number of buckles, and the other is circumferentially distributed with a number of locking points, the number of buckles and locking points being the same, and each buckle is matched and engaged with one locking point.

[0015] As an optional technical solution for the electric power unit, the motor housing is made of aluminum.

[0016] As an optional technical solution for the electric power device, the top of the motor assembly and the opening of the receiving groove are respectively provided with a sealing ring groove, and the other is provided with an annular protrusion. The annular protrusion extends into the sealing ring groove, and the sealing ring groove is filled with sealant.

[0017] As an optional technical solution for the electric power device, the outer side wall of the motor assembly is provided with several mounting ears, and the motor assembly is connected to the outside through the mounting ears.

[0018] An assembly method for an electrically controlled power unit, applied to the aforementioned electrically controlled power unit, includes the following steps:

[0019] S10: The fisheye pin header is pressed into the drive board using a crimping process;

[0020] S20: Apply thermal adhesive to the top of the motor assembly. After the thermal adhesive has cured to form the motor heat dissipation layer, position the drive board using the motor assembly, and then use the first bolt to fasten the drive board to the top of the motor assembly.

[0021] S30: Apply the heat dissipation adhesive to the top of the support base. After the heat dissipation adhesive has cured to form the controller heat dissipation layer, position the main control board with the support base and then use the second bolt to fasten the main control board to the top of the support base.

[0022] S40: The assembly of the main control board and the support base is positioned by means of the drive board, and then the assembly of the main control board and the support base is assembled onto the assembly of the drive board and the fisheye pin header by a pressing process.

[0023] S50: The fisheye pin header is pressed into the main control board using a crimping process;

[0024] S60: Position the connector assembly using the support base, and then use a pressing process to assemble the connector assembly onto the main control board, the support base, the drive board and the fisheye pin header, so that the connector pin is pressed into one of the main control board or the drive board, and then use a third bolt to fasten the connector assembly to the top of the main control board.

[0025] S70: Position the ECU housing using the plug-in PIN and snap the ECU housing onto the motor assembly.

[0026] The beneficial effects of this invention are:

[0027] This integrated controller achieves a highly compact axial integration of the motor assembly and the integrated controller by stacking the connector assembly, main control board, support base, and drive board from top to bottom, with first and second clearance holes through which the motor shaft passes. This shortens the electrical signal transmission path, ensures the dynamic response and anti-interference capabilities of devices using the integrated controller, and improves versatility and project development efficiency. This layout fully utilizes axial and radial space, significantly reducing the axial height and overall volume of the integrated controller, solving the problem of large space occupation in traditional split or non-coaxial layouts. The main control board and drive board are separated by the support base and arranged in layers; the connector assembly is separated from the main control board; and the support base is separated from the drive board. This optimizes electromagnetic compatibility and helps control electromagnetic interference. When a fault occurs in one area of ​​the main control board or drive board, only the corresponding component needs to be replaced, thereby reducing rework material and management costs, and thus contributing to improved versatility and project development efficiency of the integrated controller. Meanwhile, a motor heat dissipation layer is set below the drive board, and a controller heat dissipation layer is set on the top of the support base, providing an independent and efficient heat dissipation path for the drive board and the main control board. This effectively improves the heat dissipation effect of power components and control chips, ensuring the stability and reliability of the device under long-term high load.

[0028] The electronically controlled power unit (ECU) is housed within a cavity formed by the ECU housing and the top of the motor assembly, sealing the integrated controller entirely within. This creates a complete, highly integrated modular structure, protecting the internal precision electronic components from external moisture, dust, and mechanical damage, thus improving the environmental adaptability and reliability of the integrated controller. These improvements achieve the integration of the motor assembly and the integrated controller, significantly shortening the power and signal transmission path and improving the dynamic response speed and coordination efficiency of the ECU. The compact integration allows for more flexible and convenient placement of the ECU within the vehicle, solving the problem of limited installation space. Simultaneously, the modular design facilitates assembly and maintenance, enhancing the convenience of the ECU in both production and use.

[0029] This assembly method for the electrically controlled power unit achieves efficient and modular assembly through steps such as positioning structure, pressing process, and layered application and curing of thermal adhesive. The entire process is logically clear and highly operable, with a particular emphasis on pressing instead of welding and the application of snap-fit ​​connections. This significantly simplifies the assembly process, reduces reliance on manual skills, lowers production costs, and increases the level of automation, facilitating automated production line assembly. Thus, while ensuring product consistency and reliability, it substantially improves assembly efficiency and reduces assembly costs. Furthermore, the modular assembly process facilitates production line organization and allows for later repair or replacement of specific modules, enhancing the maintainability of the electrically controlled power unit. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the integrated controller provided in an embodiment of the present invention;

[0031] Figure 2 This is an exploded view of the integrated controller provided in an embodiment of the present invention;

[0032] Figure 3 This is a schematic diagram of the structure of the electrically controlled power device provided in an embodiment of the present invention;

[0033] Figure 4 This is an exploded view of the electrically controlled power device provided in an embodiment of the present invention;

[0034] Figure 5 This is a cross-sectional view of the electronically controlled power device provided in an embodiment of the present invention;

[0035] Figure 6 This is a flowchart of the assembly method of the electronically controlled power device provided in the embodiment of the present invention.

[0036] In the picture:

[0037] 100. Integrated controller; 110. Connector assembly; 111. Plug-in pin; 120. Main control board; 130. Support base; 131. Controller heat dissipation layer; 132. First clearance hole; 140. Driver board; 141. Second clearance hole; 150. Fisheye pin header; 151. First fisheye pin; 152. Second fisheye pin; 160. Third bolt; 170. Second bolt; 180. First bolt;

[0038] 200. Motor assembly; 201. Sealing ring groove; 202. Clamping point; 210. Rotating shaft; 220. Motor heat dissipation layer;

[0039] 300. ECU cover; 301. Clip; 302. Annular protrusion; 303. Mounting ear;

[0040] 400. Vent plug; 410. Plug body; 420. Sealing ring. Detailed Implementation

[0041] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions. Furthermore, "above," "on top of," and "over" the first feature in relation to the second feature includes the first feature directly above and diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "under," and "below" the first feature in relation to the second feature includes the first feature directly below and diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0043] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0044] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0045] like Figure 1 and Figure 2As shown, the present invention provides an integrated controller 100, assembled on a motor assembly 200. A rotating shaft 210 extends from the top of the motor assembly 200. The integrated controller 100 includes a connector assembly 110, a main control board 120, a support base 130, and a drive board 140 arranged sequentially from top to bottom. The connector assembly 110 and the main control board 120 are spaced apart, and the support base 130 and the drive board 140 are spaced apart. The main control board 120 is used to send received information to the drive board 140, and the drive board 140 is used to control the operation of the motor assembly 200 according to the information. The top of the support base 130 is provided with several controller heat dissipation layers 131, and the top of the connector assembly 110 is provided with... A number of plug-in pins 111 are electrically connected to the main control board 120. A fisheye pin header 150 is threaded through the support base 130. The main control board 120 and the drive board 140 are electrically connected through the fisheye pin header 150. The drive board 140 is fixed to the bottom of the support base 130. A motor heat dissipation layer 220 is provided below the drive board 140 and is located on the top of the motor assembly 200. The support base 130 has a first clearance hole 132, and the drive board 140 has a second clearance hole 141. The cross-sectional projection of the second clearance hole 141 covers the cross-sectional projection of the first clearance hole 132. The rotating shaft 210 passes through the first clearance hole 132 and the second clearance hole 141.

[0046] The integrated controller 100 achieves a highly compact axial integration of the motor assembly 200 and the integrated controller 100 by stacking the connector assembly 110, main control board 120, support base 130, and drive board 140 from top to bottom, and by providing a first clearance hole 132 and a second clearance hole 141 through which the motor shaft passes. This shortens the electrical signal transmission path, ensures the dynamic response capability and anti-interference capability of the device using the integrated controller 100, and improves versatility and project development efficiency. The above layout makes full use of axial and radial space, significantly reducing the axial height and overall volume of the integrated controller 100, and solving the problem of large space occupation in traditional split or non-coaxial layouts. The main control board 120 and the drive board 140 are separated and layered by a support base 130. The connector assembly 110 is separated from the main control board 120, and the support base 130 is separated from the drive board 140. This optimizes electromagnetic compatibility and helps control electromagnetic interference. When a fault occurs in one area of ​​the main control board 120 or the drive board 140, only the corresponding component needs to be replaced, thereby reducing rework material costs and management costs, and thus helping to improve the versatility of the integrated controller 100 and the efficiency of project development. At the same time, a motor heat dissipation layer 220 is set below the drive board 140, and a controller heat dissipation layer 131 is set on top of the support base 130. This provides independent and efficient heat dissipation paths for the drive board 140 and the main control board 120, effectively improving the heat dissipation effect of power components and control chips, and ensuring the stability and reliability of the device under long-term high load.

[0047] In this embodiment, both the main control board 120 and the driver board 140 are PCBAs (Printed Circuit Board Assemblies), but they have different shapes and sizes.

[0048] In this embodiment, a plurality of first fisheye pins 151 are inserted into the top of the fisheye pin header 150, and a second fisheye pin 152 is inserted into the bottom of the fisheye pin header 150. The number of first fisheye pins 151 and second fisheye pins 152 is the same, and each first fisheye pin 151 is electrically connected to one second fisheye pin 152. The first fisheye pins 151 are connected to the main control board 120 by a crimping process, and the second fisheye pins 152 are connected to the drive board 140 by a crimping process.

[0049] By setting a first fisheye pin 151 and a second fisheye pin 152 at the top and bottom of the fisheye pin header 150 respectively and connecting the main control board 120 and the drive board 140 through a crimping process, a stable and reliable electrical connection and mechanical fixation between the main control board 120 and the drive board 140 are achieved. Compared with the traditional welding process, the crimping process not only avoids problems such as incomplete soldering and thermal stress that may be caused by welding, but also simplifies the assembly process, reduces process complexity and production costs, and improves the consistency and reliability of the connection, which is conducive to automated production, thereby improving the overall assembly efficiency and yield rate.

[0050] For example, the support base 130 is made of ADC12 material.

[0051] The aluminum support base 130 possesses excellent thermal conductivity, serving not only as a structural component providing support and positioning but also as a crucial heat transfer medium. It effectively dissipates heat generated by components on the main control board 120 and drive board 140 quickly and efficiently, creating thermal isolation between the two circuit boards. This optimizes the overall heat dissipation structure, prevents heat buildup, and enhances the heat dissipation efficiency and long-term operational stability of the integrated controller 100.

[0052] like Figures 1 to 5 As shown, the present invention also provides an electronically controlled power device, including a motor assembly 200, an ECU (Electronic Control Unit) housing 300 and the aforementioned integrated controller 100. The ECU housing 300 has a downward-opening receiving groove, the groove wall of which and the top of the motor assembly 200 form a receiving cavity. The integrated controller 100 is disposed in the receiving cavity, and a plug-in pin 111 is inserted into the bottom of the receiving groove, with a portion of the plug-in pin 111 extending out of the receiving cavity.

[0053] The electronically controlled power unit (ECU) is housed within a cavity formed by the ECU housing 300 and the top of the motor assembly 200, sealing the integrated controller 100 within. This creates a complete, highly integrated modular structure, protecting the internal precision electronic components from external moisture, dust, and mechanical damage, thus improving the environmental adaptability and reliability of the integrated controller 100. These improvements achieve the integration of the motor assembly 200 and the integrated controller 100, significantly shortening the power and signal transmission path and improving the dynamic response speed and coordination efficiency of the ECU. The compact integration allows for more flexible and convenient placement of the ECU within the vehicle, solving the problem of limited installation space. Simultaneously, the modular design facilitates assembly and maintenance, enhancing the convenience of the ECU in both production and use.

[0054] In this embodiment, the electronically controlled power unit further includes a vent plug 400, which is inserted into the ECU housing 300 and connects the accommodating cavity to the outside. Specifically, the ECU housing 300 is provided with a vent hole, and the vent plug 400 includes a plug body 410 and a sealing ring 420. The plug body 410 is inserted into the vent hole, and the sealing ring 420 is clamped between the hole wall of the vent hole and the plug body 410.

[0055] By installing a vent plug 400 on the ECU housing 300, the internal pressure of the accommodating cavity is kept balanced with the external atmospheric pressure. This design can promptly expel the heat generated by the internal components during operation, preventing excessive pressure or temperature caused by heat generated by the components within the cavity. This avoids expansion and deformation of the housing, protects the integrity of the sealing structure, mitigates the risk of sealant failure, and ensures the long-term sealing reliability and service life of the electronically controlled power unit under complex operating conditions.

[0056] For example, the motor assembly 200 includes a motor housing and a motor body disposed within the motor housing, with the output end of the motor body connected to the rotating shaft 210; one of the outer side wall of the ECU cover 300 and the side wall of the motor housing has a plurality of snap fasteners 301 evenly distributed circumferentially, and the other has a plurality of locking points 202 evenly distributed circumferentially. The number of snap fasteners 301 and locking points 202 is the same, and each snap fastener 301 is matched and engaged with one locking point 202. Specifically, the locking points 202 are disposed on the side wall of the motor housing, and the snap fasteners 301 are disposed on the outer side wall of the ECU cover 300.

[0057] By utilizing the interlocking of clips 301 on the ECU housing 300 and locking points 202 on the motor housing, the housing can be quickly installed and reliably secured. This clip-on connection method eliminates the need for complex tools or numerous fasteners, simplifying the assembly process and significantly improving the assembly efficiency of the electronically controlled power unit. Simultaneously, the cooperation between clips 301 and locking points 202 ensures axial and radial positioning of the housing, guaranteeing assembly accuracy and structural stability, and improving the production consistency and reliability of the electronically controlled power unit.

[0058] Specifically, the motor body includes components such as stator windings and rotor assemblies. The specific structure and working principle of the stator windings and rotor assemblies are common knowledge in the field and well known to those skilled in the art. They are not the focus of this embodiment and will not be elaborated here.

[0059] Furthermore, the motor housing is made of aluminum.

[0060] The aluminum motor housing satisfies the need for lightweight construction while also leveraging aluminum's excellent thermal conductivity. The aluminum housing effectively dissipates heat generated inside the motor and on the adjacent drive plate 140 to the external environment, improving the overall heat dissipation efficiency of the electronic control power unit and ensuring the stable performance of the motor assembly 200 and integrated controller 100 under high-temperature conditions.

[0061] In this embodiment, a sealing ring groove 201 is recessed in one of the top of the motor assembly 200 and the opening of the receiving groove, while an annular protrusion 302 is protruding in the other. The annular protrusion 302 extends into the sealing ring groove 201, and the sealing ring groove 201 is filled with sealant. Specifically, the sealing ring groove 201 is located on the top of the motor assembly 200, and the annular protrusion 302 is located at the opening of the receiving groove.

[0062] By setting mutually cooperating sealing ring grooves 201 and annular protrusions 302, and filling the grooves with sealant, a reliable sealing barrier is constructed between the motor assembly 200 and the ECU housing 300. This structural design achieves the dual functions of radial limiting and radial sealing, effectively preventing moisture, dust, and other contaminants from intruding into the device. This significantly improves the protection level and environmental adaptability of the electronically controlled power unit, ensuring its stable operation under harsh conditions such as humidity and dust.

[0063] For example, the outer side wall of the motor assembly 200 is provided with a plurality of mounting ears 303, and the motor assembly 200 is connected to the outside through the mounting ears 303.

[0064] Mounting ears 303 provide a standardized and reliable mounting interface for the entire electric control power unit, facilitating its easy installation onto the vehicle or other main equipment. Simultaneously, the regularly arranged mounting ears 303 act as reinforcing ribs, enhancing the structural rigidity and overall stability of the motor housing. This allows for better absorption and distribution of installation stress and operational vibrations, thereby improving the mechanical reliability of the electric control power unit.

[0065] like Figures 1 to 6 As shown, the present invention also provides an assembly method for an electrically controlled power device, applicable to the aforementioned electrically controlled power device, comprising the following steps:

[0066] Step 1: Press the fisheye pin header 150 into the drive board 140 using a crimping process.

[0067] Step 2: Apply thermal adhesive to the top of the motor assembly 200. After the thermal adhesive has cured to form the motor heat dissipation layer 220, use the motor assembly 200 to position the drive plate 140, and then use the first bolt 180 to fasten the drive plate 140 to the top of the motor assembly 200.

[0068] Step 3: Apply thermal adhesive to the top of the support base 130. After the thermal adhesive has cured to form the controller heat dissipation layer 131, use the support base 130 to position the main control board 120, and then use the second bolt 170 to fasten the main control board 120 to the top of the support base 130.

[0069] Step 4: Position the assembly of the main control board 120 and the support base 130 using the drive board 140, and then use a pressing process to assemble the assembly of the main control board 120 and the support base 130 onto the assembly of the drive board 140 and the fisheye pin header 150.

[0070] Step 5: Press the fisheye pin header 150 into the main control board 120 using a crimping process.

[0071] Step 6: Position the connector assembly 110 using the support base 130, and then use a crimping process to assemble the connector assembly 110 onto the assembly of the main control board 120, support base 130, drive board 140 and fisheye pin header 150, so that the connector pin 111 is pressed into one of the main control board 120 or drive board 140. Then use the third bolt 160 to fasten the connector assembly 110 to the top of the main control board 120.

[0072] Step 7: Position the ECU cover 300 using the plug-in PIN pin 111, and snap the ECU cover 300 onto the motor assembly 200.

[0073] Specifically, the top of the motor assembly 200 is provided with a first pin, the drive plate 140 has a through first pin hole, and the first pin can be matched and inserted into the first pin hole; the edge of the support base 130 is provided with a positioning post, the edge of the main control board 120 is provided with a post clearance groove, and the positioning post passes through the post clearance groove; the top of the drive plate 140 is provided with a phase wire connector, the support base 130 has a through connector clearance hole, and the phase wire connector passes through the connector clearance hole; the top of the support base 130 is provided with a second pin, the connector assembly 110 has a through second pin hole, and the second pin is matched and inserted into the second pin hole; the ECU cover 300 has a through PIN hole, the plug pin 111 passes through the through PIN hole, and the hole wall of the through PIN hole and the side wall of the plug pin 111 are fixedly connected by UA glue.

[0074] In this embodiment, after step seven, the following steps are included: installing the vent plug 400 onto the ECU cover 300.

[0075] This assembly method for the electrically controlled power unit achieves efficient and modular assembly through steps such as positioning structure, pressing process, and layered application and curing of thermal adhesive. The entire process is logically clear and highly operable, with a particular emphasis on pressing instead of welding and the application of snap-fit ​​connections. This significantly simplifies the assembly process, reduces reliance on manual skills, lowers production costs, and increases the level of automation, facilitating automated production line assembly. Thus, while ensuring product consistency and reliability, it substantially improves assembly efficiency and reduces assembly costs. Furthermore, the modular assembly process facilitates production line organization and allows for later repair or replacement of specific modules, enhancing the maintainability of the electrically controlled power unit.

[0076] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. An integrated controller, assembled on a motor assembly (200), wherein a rotating shaft (210) extends from the top of the motor assembly (200), characterized in that, The integrated controller includes, from top to bottom, a connector assembly (110), a main control board (120), a support base (130), and a drive board (140). The connector assembly (110) and the main control board (120) are spaced apart, and the support base (130) and the drive board (140) are spaced apart. The main control board (120) sends received information to the drive board (140), and the drive board (140) controls the operation of the motor assembly (200) according to the information. The top of the support base (130) is provided with several controller heat dissipation layers (131), and the top of the connector assembly (110) is provided with several plug-in pins (111). The plug-in pins (111) are electrically connected to the main control board (120). A fisheye pin header (150) is threaded through the support base (130). The main control board (120) and the drive board (140) are electrically connected through the fisheye pin header (150). The drive board (140) is fixed to the bottom of the support base (130). A motor heat dissipation layer (220) is provided below the drive board (140). The motor heat dissipation layer (220) is located on the top of the motor assembly (200). The support base (130) has a first clearance hole (132). The drive board (140) has a second clearance hole (141). The cross-sectional projection of the second clearance hole (141) covers the cross-sectional projection of the first clearance hole (132). The rotating shaft (210) passes through the first clearance hole (132) and the second clearance hole (141).

2. The integrated controller according to claim 1, characterized in that, The top of the fisheye pin header (150) is connected to a plurality of first fisheye pins (151), and the bottom of the fisheye pin header (150) is connected to a second fisheye pin (152). The number of first fisheye pins (151) and second fisheye pins (152) is the same, and each first fisheye pin (151) is electrically connected to one second fisheye pin (152). The first fisheye pins (151) are connected to the main control board (120) by a crimping process, and the second fisheye pins (152) are connected to the drive board (140) by a crimping process.

3. The integrated controller according to claim 1 or 2, characterized in that, The support base (130) is made of ADC12 material.

4. An electrically controlled power unit, characterized in that, The device includes a motor assembly (200), an ECU housing (300), and an integrated controller as described in any one of claims 1-3. The ECU housing (300) has a downward-opening receiving groove, the groove wall of which, together with the top of the motor assembly (200), forms a receiving cavity. The integrated controller is disposed within the receiving cavity, and the plug-in pin (111) is inserted into the bottom of the receiving groove, with a portion of the plug-in pin (111) extending out of the receiving cavity.

5. The electrically controlled power device according to claim 4, characterized in that, The electronically controlled power unit also includes a vent plug (400), which is inserted into the ECU housing (300) and connects the accommodating cavity to the outside.

6. The electrically controlled power device according to claim 4, characterized in that, The motor assembly (200) includes a motor housing and a motor body disposed within the motor housing. The output end of the motor body is connected to the rotating shaft (210). One of the outer sidewalls of the ECU cover (300) and the sidewall of the motor housing is circumferentially distributed with a plurality of buckles (301), and the other is circumferentially distributed with a plurality of locking points (202). The number of buckles (301) and locking points (202) is the same, and each buckle (301) is matched and engaged with one locking point (202).

7. The electrically controlled power device according to claim 6, characterized in that, The motor housing is made of aluminum.

8. The electrically controlled power device according to claim 4, characterized in that, The top of the motor assembly (200) and the opening of the receiving groove are respectively provided with a sealing ring groove (201) and an annular protrusion (302) on the other side. The annular protrusion (302) extends into the sealing ring groove (201) and the sealing ring groove (201) is filled with sealant.

9. The electrically controlled power device according to claim 4, characterized in that, The outer side wall of the motor assembly (200) is provided with a plurality of mounting ears (303), and the motor assembly (200) is connected to the outside through the mounting ears (303).

10. A method for assembling an electrically controlled power unit, applied to the electrically controlled power unit according to any one of claims 4-9, characterized in that, Includes the following steps: S10: The fisheye pin header (150) is pressed into the drive plate (140) using a crimping process; S20: Apply heat dissipation adhesive to the top of the motor assembly (200). After the heat dissipation adhesive has cured to form the motor heat dissipation layer (220), position the drive plate (140) with the motor assembly (200), and then use the first bolt (180) to fasten the drive plate (140) to the top of the motor assembly (200). S30: Apply the heat dissipation adhesive to the top of the support base (130). After the heat dissipation adhesive has cured to form the controller heat dissipation layer (131), position the main control board (120) with the support base (130), and then use the second bolt (170) to fasten the main control board (120) to the top of the support base (130). S40: The assembly of the main control board (120) and the support base (130) is positioned by means of the drive board (140), and then the assembly of the main control board (120) and the support base (130) is assembled onto the assembly of the drive board (140) and the fisheye pin header (150) by means of the pressing process. S50: The fisheye pin header (150) is pressed into the main control board (120) using a crimping process; S60: Position the connector assembly (110) using the support base (130), and then use a crimping process to assemble the connector assembly (110) onto the assembly of the main control board (120), the support base (130), the drive board (140), and the fisheye pin header (150), so that the plug pin (111) is pressed into one of the main control board (120) or the drive board (140), and then use a third bolt (160) to fasten the connector assembly (110) to the top of the main control board (120); S70: Position the ECU housing (300) using the plug-in pin (111) and snap the ECU housing (300) onto the motor assembly (200).

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