Street lamp controller structure convenient to install and installation method

Abstract

The invention discloses a street lamp controller structure convenient to install and an installation method, belongs to the field of controllers, solves the problem that a controller in the prior art is inconvenient to install, and adopts the technical scheme that the street lamp controller structure comprises a shell, a cover plate and an electronic element, the shell is provided with a containing cavity and an opening end communicated with the containing cavity, and the cover plate is used for closing the opening end; the cover plate comprises a center installation area used for installing an electronic element and a peripheral matching area surrounding the center installation area, the electronic element is fixed to the center installation area, at least part of the electronic element protrudes out of the center installation area, and the peripheral matching area is provided with a wire harness leading-out block and an installation positioning piece. The wire harness leading-out block is provided with a wire harness outlet for a connecting wire harness of the electronic component to penetrate to the outside, and the shell is provided with a positioning matching part matched with the installation positioning piece. According to the invention, the controller is more convenient to install.

Description

Technical Field

[0001] This invention relates to the field of controllers, and in particular to a street light controller structure and installation method that are easy to install. Background Technology

[0002] Currently, most common street light controllers adopt a built-in structure, such as the controller housing for a smart grid frequency conversion energy-saving street light disclosed in Chinese patent CN102933050A. In this design, the electronic components of the controller need to be pre-installed and fixed inside the housing, then sealed with a cover. The wiring harness is led out through the side wall of the housing, and sealant is applied to the mating surfaces between the housing and the cover to achieve waterproofing. However, this device suffers from several drawbacks. First, because the housing is a deeply enclosed cavity, and the cover is only used for later sealing, the electronic components must be installed and wired within the small, concealed housing. During operation, tools and visibility are limited by the side wall of the housing, making it difficult to align connectors or tighten screws, resulting in low construction efficiency and a high risk of errors. Second, the housing and cover lack an effective pre-alignment structure during assembly. Relying solely on screw tightening makes it difficult to ensure precise alignment before applying sealant, easily leading to uneven sealant distribution, localized sealant breakage, or sealant overflow, thus affecting the overall sealing reliability and making it difficult to consistently meet high protection level requirements. Summary of the Invention

[0003] The purpose of this invention is to provide a street light controller structure that is easy to install, solving the problem of inconvenient installation of existing controllers and making controller installation more convenient.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a street light controller structure that is easy to install, comprising a housing, a cover plate, and electronic components. The housing has a receiving cavity and an open end communicating with the receiving cavity. The cover plate is used to close the open end and is welded to the housing. The cover plate includes a central mounting area for mounting the electronic components and a peripheral mating area surrounding the central mounting area. The electronic components are fixed to the central mounting area, and at least partially protrude from the central mounting area. The peripheral mating area is provided with a wire harness lead-out block and a mounting positioning component. The wire harness lead-out block has a wire harness outlet for the connecting wire harness of the electronic components to pass through to the outside. The housing is provided with a positioning mating part that mates with the mounting positioning component.

[0005] After adopting the above technical solution, the present invention has the following advantages: Dividing the cover plate into a central mounting area and a peripheral mating area forms a clear functional zoning layout, realizing the separation of electronic component mounting, housing mating, and wire harness lead-out functions. The central mounting area is specifically used to fix electronic components protruding from this area, allowing the fixing and wiring processes of electronic components to be carried out in an open, unobstructed space. This minimizes problems such as alignment difficulties, tool interference, and limited vision caused by blind operation in the narrow space of the housing's deep cavity, significantly improving assembly efficiency and wiring accuracy. The peripheral mating area integrates wire harness lead-out blocks and mounting positioning components, wherein the mounting positioning components and the positioning mating part of the housing form a relatively precise positioning pair. Before welding the housing and cover plate, rapid centering and circumferential limiting can be achieved to prevent misalignment from causing the sealing surface to shift. This provides a more stable foundation for subsequent welding and sealing, ensuring the airtightness of the street light controller structure. Since the positioning and welding operations are concentrated in the peripheral mating area, while the electronic components in the central mounting area are located inside and do not participate in the mating, the two do not interfere with each other in space. This not only ensures the stability and repeatability of the welding process but also minimizes the direct impact of the high-temperature welding heat-affected zone on the electronic components, improving product reliability. In addition, the wiring harness lead-out block in the peripheral mating area standardizes the lead-out path of the electronic component connection wiring harness through the wiring harness outlet, making the wiring harness arrangement more regular, orderly, aesthetically pleasing, and neat.

[0006] Furthermore, there are two mounting positioning components and two positioning mating parts, and the two mounting positioning components are symmetrically arranged along the diagonal direction of the cover plate.

[0007] By adopting the aforementioned technical solution, two positioning components are set at diagonal positions. After they cooperate with the corresponding positioning mating parts on the shell, the two translational degrees of freedom and rotational degrees of freedom can be constrained at the same time, so as to realize the positioning between the cover plate and the shell. This avoids the rotation or slippage around a certain axis that may occur when positioning only a single point or two points on the same side. This ensures that the cover plate is accurately aligned and there is no circumferential deflection during the closing process, providing a more stable foundation for subsequent welding and sealing.

[0008] Furthermore, one of the mounting positioning component and the positioning mating part is a positioning post, and the other of the mounting positioning component and the positioning mating part is a positioning hole.

[0009] Using the aforementioned technical solution, the positioning pin can be smoothly inserted into the corresponding positioning hole, enabling the cover plate and the shell to be quickly and accurately aligned before welding.

[0010] Furthermore, the opening end of the housing is provided with a stepped portion, and the cover plate is provided with sealing ribs circumferentially surrounding the central mounting area, the sealing ribs abutting against the stepped portion.

[0011] Using the aforementioned technical solution, the circumferential sealing rib and the step portion abut against each other to form a continuous sealing contact zone. Compared with the flat fitting sealing method, the raised structure of the sealing rib can increase the contact pressure of the mating surface, improve the initial sealing effect, and at the same time define a precise welding area for the subsequent welding sealing process.

[0012] Furthermore, the connecting harness of the electronic component is provided with an integrally formed flexible seal, which is used to fill the outlet of the harness.

[0013] Through the above technical solution, the integrally molded flexible seal is seamlessly integrated with the wire harness body, improving the sealing performance between the flexible seal and the wire harness body. The positional relationship between the two remains fixed, which can minimize the risk of the flexible seal shifting or moving relative to the connecting wire harness due to vibration or slight pulling of the wire harness during equipment operation. This ensures that the flexible seal is always stably filled in the wire harness outlet, maintaining the integrity of the sealing structure. Furthermore, the flexible seal can adaptively fill the geometric space of the wire harness outlet. With its elastic deformation capability, the flexible seal tightly fits the inner wall of the wire harness outlet, ensuring the sealing performance between the flexible seal and the wire harness outlet.

[0014] Furthermore, there are two wire harness lead-out blocks, and the housing is provided with a clearance notch to avoid the wire harness lead-out blocks. The two wire harness lead-out blocks are respectively located at opposite ends of the cover plate. One of the two wire harness lead-out blocks is provided for leading out power wire harnesses, and the other of the two wire harness lead-out blocks is provided for leading out data wire harnesses.

[0015] The above technical solution achieves physical isolation between power harnesses and data harnesses, allowing them to be led out in an orderly manner along both sides of the cover plate. This minimizes the impact of electromagnetic interference generated when the power harness transmits high current on the signal transmission of the data harness, ensuring the accuracy of data acquisition and control commands.

[0016] Furthermore, the cover plate is provided with a foolproof part so that the housing interferes with the foolproof part when misaligned.

[0017] Through the above technical solution, the design of the error-proof part provides a clear assembly instruction for the installation of the housing, greatly shortening the direction confirmation time during assembly. Once the direction is wrong, the error-proof part will physically interfere with the housing to prevent the assembly from continuing, thus eliminating the possibility of misassembly as much as possible from a structural perspective.

[0018] Furthermore, the housing has a clearance notch at the opening end, the wire harness lead-out block has a plug-in part, and the cover plate has a plug-in hole. The wire harness lead-out block is pre-fixed by plugging the plug-in part into the plug-in hole on the cover plate, and after the cover plate and the housing are assembled, the wire harness lead-out block is clamped between the clearance notch of the cover plate and the housing.

[0019] Through the above technical solutions, the plug-in pre-fixed structure enables rapid positioning of the wire harness lead-out block. Without additional fasteners, the lead-out block can be stably fixed to the preset position on the cover plate, minimizing displacement and deflection during assembly, significantly improving assembly efficiency. Simultaneously, it ensures the positional accuracy of the power and data harness interfaces, providing a more accurate reference for subsequent wiring operations. Secondly, the clamping force formed after the cover plate and housing are assembled secures the lead-out block from both sides, providing stronger resistance to vibration and impact. This minimizes the risk of loosening or displacement of the lead-out block due to high-frequency vibration during equipment operation, ensuring stable wire harness interface connections. Thirdly, the adaptable design of the clearance notch ensures overall assembly sealing. The clearance notch matches the shape and size of the lead-out block, allowing for a tight fit between the cover plate and housing during assembly. This minimizes gaps caused by lead-out block protrusions, providing a smoother and more continuous mating surface for subsequent welding and sealing, further improving the overall sealing reliability.

[0020] Furthermore, the housing has symmetrical lugs at both ends, the lugs are located in the peripheral mating area, and the lugs have connection holes for connecting with external structures.

[0021] With the above technical solution, the lug is located in the peripheral mating area, which concentrates the external installation load and the external force during use in the peripheral mating area, thereby effectively dispersing the installation stress and reducing the damage to electronic components caused by installation stress concentration or long-term alternating load.

[0022] Another objective of this invention is to disclose a street light controller installation method, which includes the street light controller structure described above that is easy to install. The street light controller installation method includes S1: inverting the cover plate and fixing the electronic components to the cover plate.

[0023] S2: Pass the connecting wire harness of the electronic components out of the wire harness outlet;

[0024] S3: Adjust the housing to align the positioning element and the positioning mating part, and install the housing onto the cover plate;

[0025] S4: The shell and cover are welded together using ultrasonic waves.

[0026] Through the above technical solution, step S1 involves inverting the cover plate and directly fixing electronic components on it, allowing installation, wiring, and debugging to be completed in an unobstructed open space, minimizing alignment difficulties, tool interference, and visual limitations caused by blind operation in deep cavities. Step S2, with the wire harness lead-out block already in place, allows the connecting wire harness to be directly passed through the wire harness outlet, with a clear path and no need for subsequent wire threading. Step S3 utilizes positioning components and positioning mating parts to achieve rapid and accurate pre-alignment between the housing and the cover plate, providing a uniform and stable joint interface for welding. Step S4 employs ultrasonic welding to form a continuous and dense fusion seal. The steps are tightly and orderly connected, simplifying the operation process, reducing the human error rate, and ensuring the assembly quality and long-term operational stability of the controller through the synergy of structure and process. Attached Figure Description

[0027] The present invention will be further described below with reference to the accompanying drawings:

[0028] Figure 1 A schematic diagram of the installation-friendly street light controller structure of the present invention;

[0029] Figure 2 Another perspective structural diagram of the street light controller structure of the present invention, which is easy to install;

[0030] Figure 3 This is a top view of the conveniently installed street light controller structure of the present invention;

[0031] Figure 4 An exploded view of the structure of the conveniently installed street light controller of the present invention;

[0032] Figure 5 A cross-sectional view of the structure of the conveniently installed street light controller of the present invention;

[0033] Figure 6 This is a schematic diagram of the cover plate in this invention;

[0034] Figure 7 This is a schematic diagram of the structure of the housing of the present invention;

[0035] Figure 8 This is a schematic diagram of the wire harness lead-out block of the present invention;

[0036] In the diagram, 10 is the housing; 11 is the receiving cavity; 12 is the open end; 13 is the positioning mating part; 14 is the stepped part; 141 is the horizontal bearing surface; 142 is the vertical limiting surface; 15 is the clearance notch; 16 is the viewing window; 20 is the cover plate; 21 is the central mounting area; 22 is the peripheral mating area; 23 is the wire harness lead-out block; 231 is the wire harness outlet; 232 is the plug-in part; 24 is the mounting positioning part; 25 is the sealing rib; 26 is the plug-in hole; 27 is the lug; and 271 is the connection hole. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0038] The terms "first," "second," "third," "fourth," etc. (if present) in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein.

[0039] It should be understood that in the various embodiments of the present invention, the number of each process does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0040] It should be understood that in this invention, "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or device.

[0041] It should be understood that in this invention, "multiple" refers to two or more. "And / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, X and / or Y can represent: X alone, X and Y simultaneously, or Y alone. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "Contains X, Y, and Z", "Contains X, Y, and Z" means that all three X, Y, and Z are contained; "Contains X, Y, or Z" means that one of X, Y, and Z is contained; "Contains X, Y, and / or Z" means that any one, two, or three of X, Y, and Z are contained.

[0042] The technical solution of the present invention will be described in detail below with reference to specific embodiments. The following specific embodiments may be combined or substituted with each other according to the actual situation, and the same or similar concepts or processes may not be described again in some embodiments.

[0043] Example 1:

[0044] like Figures 1 to 8As shown, the present invention provides a street light controller structure that is easy to install, including a housing 10, a cover plate 20, and electronic components. The housing 10 has a receiving cavity 11 and an open end 12 communicating with the receiving cavity 11. The cover plate 20 is used to close the open end 12 and is welded to the housing 10. The cover plate 20 includes a central mounting area 21 for mounting electronic components and a peripheral mating area 22 surrounding the central mounting area 21. The electronic components are fixed to the central mounting area 21 and at least partially protrude from the central mounting area 21. The peripheral mating area 22 is provided with a wire harness lead-out block 23 and a mounting positioning member 24. The wire harness lead-out block 23 is provided with a wire harness outlet 231 for the connecting wire harness of the electronic components to pass through to the outside. The housing 10 is provided with a positioning mating part 13 that cooperates with the mounting positioning member 24.

[0045] The cover plate 20 is divided into a central mounting area 21 and a peripheral mating area 22, forming a clear functional zoning layout. This achieves a separate layout for the installation of electronic components and the mating with the housing 10, as well as the wiring harness lead-out function. The central mounting area 21 is specifically used to fix electronic components protruding from this area, allowing the fixing and wiring processes of electronic components to be carried out in an open and unobstructed space, which greatly improves assembly efficiency and wiring accuracy. It also avoids problems such as alignment difficulties, tool interference, and limited vision caused by blind operation in the confined space inside the housing 10. The peripheral mating area 22 integrates the wiring harness lead-out block 23 and the mounting positioning component 24. The mounting positioning component 24 and the positioning mating part 13 of the housing 10 form a relatively precise positioning pair, which is achieved between the housing 10 and the cover plate. Before welding, rapid centering and circumferential positioning can be achieved, minimizing the risk of misalignment and sealing surface displacement. This provides a more stable foundation for subsequent welding and sealing, ensuring the airtightness of the street light controller structure. Since positioning and welding operations are concentrated in the peripheral mating area 22, while the electronic components in the central mounting area 21 are located inside and do not participate in the mating, the two do not interfere with each other in space. This not only ensures the stability and repeatability of the welding process but also minimizes the direct impact of the high-temperature welding heat-affected zone on the electronic components, improving product reliability. Furthermore, the wiring harness lead-out block 23 in the peripheral mating area 22 standardizes the lead-out path of the electronic component connection wiring harness through the wiring harness outlet 231, making the wiring harness arrangement more regular, orderly, aesthetically pleasing, and neat.

[0046] Specifically, there are two mounting positioning components 24 and two positioning mating parts 13. The mounting positioning components 24 are symmetrically arranged along the diagonal direction of the cover plate 20, and the positioning mating parts 13 are symmetrically arranged along the diagonal direction of the housing 10. The two can simultaneously constrain the translational degree of freedom and the circumferential rotational degree of freedom in two orthogonal directions, so as to realize the positioning between the cover plate 20 and the housing 10. This avoids the rotation or slippage around a certain axis that may occur when positioning only a single point or two points on the same side, thereby ensuring that the cover plate 20 is accurately aligned and there is no circumferential deflection during the closing process, providing a more stable foundation for subsequent welding and sealing.

[0047] In this embodiment, the mounting positioning element 24 is a positioning post, and the positioning mating part 13 is a positioning hole. The positioning post can be smoothly inserted into the corresponding positioning hole, achieving rapid and accurate alignment of the cover plate 20 and the shell 10 before welding. It should be noted that in this embodiment, the two positioning posts have the same diameter, which ensures that the cover plate 20 is subjected to uniform force during the positioning process. The shapes of the mounting positioning element 24 and the positioning mating part 13 are interchangeable, that is, the mounting positioning element 24 can also be set as a positioning hole, and the corresponding positioning mating part 13 can be set as a positioning post. The specific configuration can be flexibly adjusted according to the actual processing technology, mold structure, and production assembly requirements.

[0048] To improve the sealing of the space where electronic components are located after the housing 10 and the bottom cover are enclosed, the opening end 12 of the housing 10 is recessed inward to form a ring-shaped concave step 14. The horizontal bearing surface 141 of the step 14 extends circumferentially along the opening end 12 of the housing 10, and the vertical limiting surface 142 of the step 14 is arranged axially along the housing 10. Together, they constitute the step 14. The vertical limiting surface 142 is located outside the horizontal bearing surface 141, which can form an external physical sealing barrier. The cover plate 20 is provided with sealing ribs 25 circumferentially surrounding the central mounting area 21. The sealing ribs 25 abut against the step 14. The abutment between the circumferential sealing ribs 25 and the step 14 forms a continuous sealing contact zone. Compared with the flat fitting sealing form, the protruding structure of the sealing ribs 25 can increase the contact pressure of the mating surface, improve the initial sealing effect, and define a precise welding area for the subsequent welding sealing process.

[0049] Furthermore, the connecting wire harness of the electronic components is equipped with an integrally molded flexible seal. The flexible seal is used to fill the gap space of the wire harness outlet 231. The flexible seal is made of elastic materials such as silicone and EPDM rubber. It is seamlessly fused with the wire harness body through an integral molding process, eliminating the interface gap between the flexible seal and the wire harness body. This fundamentally improves the sealing performance of the two. The positional relationship between the two remains fixed, which can minimize the risk of the flexible seal shifting or moving relative to the connecting wire harness due to vibration or slight pulling of the wire harness during equipment operation. This ensures that the flexible seal is always stably filled in the wire harness outlet 231, maintaining the integrity of the sealing structure. In addition, the flexible seal, with its own elastic deformation capability, can adaptively fill the geometric space of the wire harness outlet 231. Even if there is a slight dimensional deviation in the wire harness outlet 231, it can still fit tightly against the inner wall of the wire harness outlet 231 through its own deformation, forming an interference fit. This further ensures the sealing performance between the flexible seal and the wire harness outlet 231, and forms a synergistic protection with the double sealing structure between the housing 10 and the cover plate 20, blocking the path of external dust and moisture into the electronic component housing space in all directions.

[0050] To optimize the internal and external wiring layout of the street light controller and improve the neatness of wiring harness management and the stability of signal transmission, this embodiment provides two wiring harness lead-out blocks 23, which are respectively installed at opposite ends of the cover plate 20. The housing 10 has clearance notches 15 that match the shape of the wiring harness lead-out blocks 23 to ensure that the cover plate 20 and housing 10 are assembled without interference and fit tightly. The two wiring harness lead-out blocks 23 adopt a functional partition design; one of the two wiring harness lead-out blocks 23 is used for leading out power wiring harnesses, and the other is used for leading out data wiring harnesses. The physical isolation layout of the power harness and data harness can minimize the impact of electromagnetic interference generated when the power harness transmits high current on the signal transmission of the data harness, ensuring the accuracy of data acquisition and the real-time issuance of control commands. At the same time, the orderly lead-out of the power harness and data harness along both sides of the cover plate 20 avoids the problems of harness tangling, pulling and wear caused by traditional centralized lead-out, reduces the difficulty of wiring troubleshooting during later maintenance, and works in conjunction with the adaptation design of the housing 10 to avoid the notch 15 to ensure the sealing and structural compactness of the whole machine assembly.

[0051] The wire harness lead-out block 23 is provided with a plug-in part 232, and the cover plate 20 is provided with a plug-in hole 26. The wire harness lead-out block 23 is plugged into and pre-fixed with the plug-in hole 26 on the cover plate 20 through the plug-in part 232, so as to avoid the wire harness lead-out block 23 from shifting or deflecting during the assembly process, which greatly improves the assembly efficiency. After the cover plate 20 and the housing 10 are assembled, the wire harness lead-out block 23 is clamped between the cover plate 20 and the housing 10 through the clearance notch 15, which has stronger resistance to vibration and impact. It can avoid the problem of the wire harness lead-out block 23 loosening or shifting due to high frequency vibration during the operation of the equipment, and ensure the stability of the wire harness interface connection as much as possible.

[0052] To facilitate routine inspection and maintenance of internal electronic components, a viewing window 16 is provided at the location corresponding to the central mounting area 21 of the housing 10. This allows for visual inspection without disassembling the welded sealing structure between the housing 10 and the cover plate 20. The viewing window 16 includes a window panel and matching seals. The window panel is made of a highly transparent and weather-resistant material, such as polycarbonate (PC), which allows for clear observation of the operating status of electronic components, such as the on / off status of indicator lights and any abnormal damage. It can also withstand complex outdoor conditions such as high and low temperatures and impacts. The window panel is detachably fixed to the pre-set mounting position of the housing 10, such as through a snap-fit ​​connection. After installation, a sealing gasket is added to the contact surface between the window panel and the housing 10 to ensure that the airtightness of the space containing the electronic components is not affected as much as possible, preventing the intrusion of dust and moisture. When maintenance is required, the window panel can be removed simply by disassembling the fasteners. Workers and external tools can then directly access the housing 10 to inspect, debug, or replace electronic components without damaging the welded sealing structure between the housing 10 and the cover plate 20. This minimizes the risk of secondary seal failure, significantly improves the convenience and efficiency of maintenance, and preserves the original protection level of the entire machine.

[0053] To facilitate the installation of the street light controller on an external structure (such as a street light pole), the housing 10 has symmetrical lugs 27 at both ends. The lugs 27 are located in the peripheral mating area 22 and have connection holes 271 for connecting to the external structure. During installation, countersunk screws, pan head screws, bolts, and other fasteners can be inserted into the connection holes 271 to directly achieve a stable connection between the controller and the external structure. This concentrates external installation loads and forces during use within the peripheral mating area 22, effectively dispersing installation stress and reducing damage to electronic components caused by stress concentration or long-term alternating loads.

[0054] Understandably, in other embodiments, when the number of mounting positioning components and positioning mating parts is set to three, the three are evenly distributed in a triangular pattern around the periphery of the cover / shell. Utilizing the inherent stability of the triangular structure, the anti-interference capability of the positioning pair is further enhanced. Even if subjected to slight external impact or vibration during assembly, the relative positional accuracy of the cover and shell can be maintained relatively stably, minimizing positioning deviation. When the number is set to four, the four can be symmetrically distributed in a rectangle along the four corners of the cover / shell, so that the positioning force is evenly distributed in the periphery of the mating area. This is suitable for assembly scenarios of large-sized cover plates and shells, effectively reducing local stress concentration caused by the large size of the components. At the same time, it further strengthens the constraint effect on the circumferential deflection of the cover plate, ensuring that the fitting gap of the mating surface is uniform after the cover is closed, providing better preconditions for the welding sealing process.

[0055] To further enhance the error-proofing effect, in other embodiments, the two positioning posts / positioning holes can be designed with different diameters. This differentiated size design forms a size-proofing structure. When the cover plate is mated with the housing at the wrong angle or direction, the positioning post with the mismatched diameter cannot be inserted into the positioning hole, thereby directly eliminating the risk of reverse assembly at the structural level and minimizing serious assembly errors such as wire harness outlet misalignment, welding area offset, and interface function confusion caused by reverse assembly.

[0056] Because of the symmetry in the outline and mating structure of the housing and cover plate, assembly defects such as misalignment of the wiring harness outlet and displacement of the welding area are easily caused by misjudgment of the assembly direction. To minimize such problems, it is understandable that in other embodiments, the cover plate is provided with a foolproof part, so that the housing will physically interfere with the foolproof part when misaligned. The design of the foolproof part provides a clear assembly indication for the installation of the housing, greatly shortening the direction confirmation time during assembly. Once the assembly direction is incorrect, the foolproof part will form a hard interference with the housing, directly preventing the assembly operation from continuing, thus structurally eliminating the possibility of misassembly as much as possible. In this embodiment, the anti-misfit part is specifically designed as a rib structure, and the housing is provided with a corresponding clearance opening adapted to the rib. When the cover plate and the housing are assembled in the correct direction, the rib can be smoothly inserted into the clearance opening without causing any obstruction to the tight fit between the cover plate and the housing. If the cover plate and the housing are assembled in reverse, the rib will not be able to be inserted into the clearance opening, but will instead make rigid contact with the end face of the housing, thereby forming an assembly limit and preventing a series of problems such as subsequent welding failure, interface function confusion, and wire harness pulling damage caused by reverse assembly as much as possible.

[0057] Example 2:

[0058] This embodiment discloses a street light controller installation method, including the street light controller structure with convenient installation described in the above embodiment. The street light controller installation method includes S1: inverting the cover plate and fixing the electronic components to the cover plate;

[0059] S2: Pass the connecting wire harness of the electronic components out of the wire harness outlet;

[0060] S3: Adjust the housing to align the positioning element and the positioning mating part, and install the housing onto the cover plate;

[0061] S4: The shell and cover are welded together using ultrasonic waves.

[0062] Step S1 involves inverting the cover plate and directly fixing electronic components onto it, allowing installation, wiring, and debugging to be completed in an unobstructed open space, minimizing alignment difficulties, tool interference, and limited vision issues associated with blind operation in deep cavities. Step S2, with the wire harness lead-out block already in place, allows the connecting wire harness to be directly passed through the wire harness outlet, with a clear path and no need for subsequent wire threading. Step S3 utilizes positioning components and positioning mating parts to achieve rapid and precise pre-alignment between the housing and the cover plate, providing a uniform and stable joint interface for welding. Step S4 employs ultrasonic welding to weld the open end of the housing to the cover plate, forming... The continuous and dense welded seal, due to the inverted design of the cover plate in S1, is key to preventing deformation, damage, and bulging of the housing. After the cover plate is inverted, its back side (non-electronic component mounting surface) can stably fit against the tooling table. The tooling can provide more comprehensive and uniform support for the cover plate. The pressure applied during ultrasonic welding will be concentrated on the sealing ribs and steps of the mating area between the cover plate and the housing, rather than the housing area. The steps are tightly and orderly connected, which simplifies the operation process, reduces the rate of human error, and ensures the assembly quality and long-term operational stability of the controller through the synergy of structure and process.

[0063] In addition to the preferred embodiments described above, the present invention has other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection claimed by the present invention.

Claims

1. A street light controller structure that is easy to install, comprising a housing (10), a cover plate (20), and electronic components, wherein the housing (10) has a receiving cavity (11) and an opening end (12) communicating with the receiving cavity (11), and the cover plate (20) is used to close the opening end (12) and is welded to the housing (10), characterized in that: The cover plate (20) includes a central mounting area (21) for mounting the electronic component and a peripheral mating area (22) surrounding the central mounting area (21). The electronic component is fixed to the central mounting area (21) and at least partially protrudes from the central mounting area (21). The peripheral mating area (22) is provided with a wire harness lead-out block (23) and a mounting positioning member (24). The wire harness lead-out block (23) is provided with a wire harness outlet (231) for the connecting wire harness of the electronic component to pass through to the outside. The housing (10) is provided with a positioning mating part (13) that mates with the mounting positioning member (24).

2. The street light controller structure with convenient installation according to claim 1, characterized in that, Two mounting positioning components (24) and two positioning mating parts (13) are provided, and the two mounting positioning components (24) are symmetrically arranged along the diagonal direction of the cover plate (20).

3. The street light controller structure with convenient installation according to claim 2, characterized in that, One of the mounting positioning component (24) and the positioning mating part (13) is a positioning post, and the other of the mounting positioning component (24) and the positioning mating part (13) is a positioning hole.

4. The street light controller structure with convenient installation according to claim 1, characterized in that, The housing (10) has a stepped portion (14) at the open end (12), and the cover plate (20) has a sealing rib (25) circumferentially surrounding the central mounting area (21), and the sealing rib (25) abuts against the stepped portion (14).

5. The street light controller structure with convenient installation according to claim 4, characterized in that, The connecting harness of the electronic component is provided with an integrally formed flexible seal, which is used to fill the outlet (231) of the harness.

6. The street light controller structure with convenient installation according to claim 1, characterized in that, Two wire harness lead-out blocks (23) are provided. The housing (10) is provided with a clearance notch (15) to avoid the wire harness lead-out blocks (23). The two wire harness lead-out blocks (23) are respectively provided at opposite ends of the cover plate (20). One of the two wire harness lead-out blocks (23) is provided for leading out power wire harnesses, and the other of the two wire harness lead-out blocks (23) is provided for leading out data wire harnesses.

7. The street light controller structure with convenient installation according to claim 1, characterized in that, The cover plate (20) is provided with a foolproof part so that the housing (10) interferes with the foolproof part when misaligned.

8. The street light controller structure with convenient installation according to claim 1, characterized in that, The housing (10) has a clearance notch (15) at the opening end (12), the wire harness lead-out block (23) has a plug-in part (232), and the cover plate (20) has a plug-in hole (26). The wire harness lead-out block (23) is pre-fixed by plugging the plug-in part (232) into the plug-in hole (26) on the cover plate (20). After the cover plate (20) and the housing (10) are assembled, the wire harness lead-out block (23) is clamped between the clearance notch (15) of the cover plate (20) and the housing (10).

9. The street light controller structure with convenient installation according to claim 1, characterized in that, The housing (10) has symmetrical lugs (27) at both ends. The lugs (27) are located in the peripheral mating area (22). The lugs (27) are provided with connection holes (271) for connecting with external structures.

10. A method for installing a street light controller, characterized in that, The street light controller structure includes any one of claims 1 to 9, and the installation method of the street light controller includes S1: inverting the cover plate (20) and fixing the electronic components on the cover plate (20); S2: Pass the connecting wire harness of the electronic component out of the wire harness outlet (231); S3: Adjust the housing (10) to align the positioning part and the positioning mating part (13), and install the housing (10) on the cover plate (20); S4: The housing (10) and the cover plate (20) are welded together by ultrasonic waves.

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