A waterproof structure for a controller, a design method thereof, and its vehicle

Abstract

This invention discloses a waterproof controller structure, a design method for a waterproof controller structure, and a vehicle, relating to the field of waterproof electrical connections. The design method for the waterproof controller structure includes the following steps: confirming the controller's waterproof rating; selecting the connector model; designing the housing interface; and designing the height and length of the water-retaining edge. The waterproof controller structure uses the aforementioned design method and includes a housing and a water-retaining edge. The housing has a housing interface for installing the connector. The vehicle includes the aforementioned waterproof controller structure. This invention can complete the design of the water-retaining edge of the controller, meet the waterproof function requirements for connectors with low waterproof ratings, support multi-vehicle adaptation through platform-based design, effectively shorten the development cycle, reduce development costs, and achieve high reliability.

Description

Technical Field

[0001] This invention belongs to the field of electrical connection waterproofing technology, and specifically relates to a waterproof structure for a controller, a design method thereon, and a vehicle thereof. Background Technology

[0002] As automotive electronic and electrical architectures gradually shift towards regional control and central computing, off-the-shelf product development concepts are gradually replacing traditional development models. The platform-based development of automotive controller structures is increasingly showing a trend towards standardization and modularization. Waterproof design of the controller structure is a crucial component of the overall controller design. The key to waterproof design is protecting the connectors exposed to the housing. Currently, for controllers with low waterproof requirements in automobiles, the entire structure is non-sealed. The waterproof structure of their connectors is typically designed specifically for the vehicle's assembly location and operating environment, resulting in poor structural versatility and difficulty in adapting to the needs of different vehicle models. Summary of the Invention

[0003] The purpose of this invention is to provide a waterproof structure for a controller, a design method thereof, and a vehicle thereof, in order to solve one or more technical problems existing in the prior art.

[0004] The technical solution adopted to solve the above-mentioned technical problems is as follows: This invention discloses a method for designing a waterproof structure for a controller, comprising the following steps: Confirm the controller's waterproof rating; Select the connector model; Design the housing interface; Design the height and length of the water-retaining edge.

[0005] The present invention offers at least the following advantages: First, it confirms the waterproof rating of the controller. Based on this rating, it ensures that the designed waterproof structure of the controller meets the requirements of the waterproof structure design method. Second, it selects the connector model. Since multiple connectors are installed inside the controller housing, the shape and size of each connector are determined according to its model. Third, it designs the housing interface based on the shape and size of the connector, ensuring that the housing interface is suitable for connector insertion. Fourth, it designs the height and length of the water-retaining edge to block water from the portion of the connector extending beyond the housing interface. Finally, it designs a waterproof structure for the controller using the waterproof structure design method, ensuring that the waterproof structure meets the waterproof function for the connector.

[0006] The controller's waterproof structure design method, through platform-based design, supports adaptation to multiple vehicle models, effectively shortens the development cycle, reduces development costs, and ensures high reliability.

[0007] As a further improvement to the above technical solution, the selection of the connector model includes the following steps: Based on the product functions of the controller, select the model that meets the electrical performance requirements and determine the shape of the connector.

[0008] As a further improvement to the above technical solution, the design of the housing interface includes the following steps: Design the shape of the housing interface; Design the gap between the housing interface and the connector.

[0009] As a further improvement to the above technical solution, the design of the housing interface shape includes the following steps: The housing interface is a proportionally enlarged version of the connector shape. Optimize and adjust the shape of the housing interface.

[0010] As a further improvement to the above technical solution, the gap between each end face of the housing interface and the corresponding end face of the connector is equal.

[0011] As a further improvement to the above technical solution, the design of the height and length of the water-retaining edge includes the following steps: The height of the water-retaining edge is designed based on ergonomic requirements; Obtain the tilt angle of the controller; Obtain the length of the connector protruding from the housing; Calculate the length of the water-retaining side.

[0012] As a further improvement to the above technical solution, the calculation of the length of the water-retaining side includes the following steps: The sum of the height of the water-retaining edge, the gap between the housing interface and the connector, and the height of the connector is the distance from the bottom of the connector to the water-retaining edge. The extension is calculated using the tangent function based on the distance from the bottom of the connector to the water-blocking edge and the tilt angle of the controller.

[0013] As a further improvement to the above technical solution, the calculation of the length of the water-retaining side also includes the following steps: The length of the connector protruding from the housing and the extension amount are calculated to be the length of the water-blocking edge.

[0014] This invention discloses a waterproof controller structure, using any of the waterproof controller structure design methods described above. The waterproof controller structure includes a housing and a water-blocking edge, and the housing is provided with a housing interface for installing a connector.

[0015] The present invention has at least the following beneficial effect: it satisfies the waterproof function of the connector.

[0016] This invention discloses a vehicle including the aforementioned controller waterproof structure. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a flowchart of the controller waterproof structure design method provided in the embodiment of the present invention; Figure 2 yes Figure 1 Detailed flowchart of steps S100 to S300; Figure 3 yes Figure 2 Detailed flowchart of step S310; Figure 4 yes Figure 1 Detailed flowchart of step S400; Figure 5 yes Figure 4 Detailed flowchart of step S440; Figure 6 This is a schematic diagram of the structure of the housing and connector provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the connector and water-blocking edge provided in an embodiment of the present invention; Figure 8 This is a schematic diagram of the waterproof controller structure provided in an embodiment of the present invention; Figure 9 yes Figure 8 Sectional view at point AA; Figure 10 yes Figure 8 A schematic diagram of the structure of the housing and connector.

[0018] The following labels are shown in the attached diagram: 500. Waterproof structure for the controller; 600. Shell; 610. First shell; 620. Second shell; 700, Housing interface; 710, First interface; 720, Second interface; 800 connector; 810 Ethernet connector; 820 video connector; 900, water-blocking edge. Detailed Implementation

[0019] This section will describe in detail specific embodiments of the present invention. Preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and overall technical solution of the present invention, but they should not be construed as limiting the scope of protection of the present invention.

[0020] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are 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 limiting this invention.

[0021] In the description of this invention, the use of terms such as "a number" means one or more, with "more than" meaning two or more. Terms like "greater than," "less than," and "exceeding" are understood to exclude the stated number, while terms like "above," "below," and "within" are understood to include the stated number. The use of terms like "first," "second," and "third" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, the number of indicated technical features, or the sequential relationship between indicated technical features.

[0022] Traditional waterproof structural designs have the following shortcomings: (1) Poor structural versatility, making it difficult to adapt to the needs of different vehicle models. The waterproof structure design method of traditional controllers is mainly to meet the waterproof level of a specific assembly position of a vehicle model. If adapted to other vehicle models or other assembly positions, its waterproof performance has great limitations for platform-based use, especially the low-level waterproof structure cannot be adapted to the high-level waterproof performance requirements.

[0023] (2) Long development cycle and high development cost. Due to the limitations of the performance design and universality of traditional controllers, they cannot be mass-produced on multiple vehicle models. This results in the drawback that multiple models need to be developed multiple times, which increases the development cycle and development cost.

[0024] (3) Relatively low reliability. Compared with the multi-vehicle verification of platform-based products, the design maturity of newly developed applications needs to be tested by the market over a long period of time, and the reliability of the products is relatively low.

[0025] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0026] Reference Figures 1 to 10 The following are several embodiments of a waterproof controller structure, design method, and vehicle based on the present invention.

[0027] like Figures 6 to 10As shown, the controller waterproof structure 500 of this embodiment uses a controller waterproof structure design method. The controller waterproof structure 500 includes a housing 600 and a water-blocking edge 900. The housing 600 is a controller housing 600, which facilitates the installation of various connectors 800. The housing 600 is provided with a housing interface 700 for installing the connectors 800. The water-blocking edge 900 is used to realize the water-blocking function of the connectors 800.

[0028] like Figure 1 As shown, the controller waterproof structure design method of this embodiment includes steps S100 to S400.

[0029] Step S100: Confirm the controller's waterproof rating.

[0030] Step S200: Select the model of connector 800.

[0031] Step S300: Design the housing interface 700.

[0032] Step S400: Design the height and length of the water-blocking edge 900.

[0033] Understandably, for controllers installed in locations prone to water ingress, a waterproof rating of IPX7 or higher is typically required. In this case, the controller's waterproof structure 500 needs to be completely sealed. For controllers installed in locations with a lower probability of water ingress, a waterproof rating of IPX2 or lower is typically required. In this case, the controller's waterproof structure 500 is not sealed.

[0034] The two types of controller waterproof structure design 500 are distinguished by the controller waterproof rating. Since there are essential differences in the design process, the controller waterproof rating is determined through step S100 to ensure that the controller waterproof structure design method corresponds to the controller waterproof rating.

[0035] In this embodiment, step S100 includes steps S110 to S120, such as... Figure 2 As shown.

[0036] Step S110: Obtain the installation location and working environment of the controller in the vehicle.

[0037] The waterproof rating of the controller is determined based on its installation location and operating environment within the vehicle.

[0038] Step S120: Determine whether the controller's waterproof rating exceeds IPX2.

[0039] If so, the controller's waterproof structure needs to be sealed, requiring a different, completely sealed design method.

[0040] If not, proceed to step S200. In this way, the waterproof rating is set to IPX2, enabling the controller waterproof structure design method to meet the waterproof requirements of controllers with IPX0 to IPX2 ratings at different installation locations. This ensures the controller waterproof structure design method is only designed for controllers with a waterproof rating not exceeding IPX2, making the controller waterproof structure design method platform-based and supporting multi-vehicle adaptation. By integrating the different design requirements of connector 800 for non-sealed controllers with low waterproof rating requirements, a compatible design is achieved, ensuring the designed controller waterproof structure 500 can meet the installation and usage needs of different vehicle models.

[0041] Understandably, the selection of connector 800 model is related to the product functions of the controller itself. For area controllers, connector 800 typically includes power, video, and Ethernet types. In step S200, a connector 800 model that meets the electrical performance requirements is selected.

[0042] In this embodiment, step S200 includes step S210, such as... Figure 2 As shown.

[0043] Step S210: Based on the product functions of the controller, select a model that meets the electrical performance requirements and determine the shape of connector 800.

[0044] Understandably, the housing interface 700 is used for partial embedding and partial exposure of the connector 800, facilitating waterproofing of the connector 800 and easy insertion and removal. By designing the housing interface 700 in step S300, a waterproof design for the connector 800 of the non-sealed controller is achieved.

[0045] Understandably, after the connector 800 is assembled with the housing 600, since the outer end face of the connector 800 protrudes from the side wall of the housing 600, vertically falling water droplets can easily affect the connector 800. Therefore, a protruding water-retaining edge 900 needs to be designed above the connector 800 to provide waterproof protection for the connector 800. In step S400, designing the water-retaining edge 900 includes designing the height and length of the water-retaining edge 900.

[0046] With this configuration, the controller waterproof structure design method of this embodiment integrates the connector 800 and the housing interface 700, the insertion and removal operation space of the connector 800, and the waterproof rating test requirements. It performs a platform-based compatible design for the controller waterproof structure 500 of non-sealed controllers, enabling the controller to not only meet the waterproof rating protection requirements but also adapt to the installation and usage needs of different vehicle models. This allows for simultaneous installation on multiple vehicle models, effectively shortening the development cycle of vehicle controllers and reducing development costs. Through platform-based design featuring standard design, product reuse, and unified change management, the controller waterproof structure design method can minimize failure risks and improve product stability and reliability.

[0047] In this embodiment, step S300 includes steps S310 and S320, as follows: Figure 2 As shown.

[0048] Step S310: Design the shape of the housing interface 700.

[0049] It is understood that the housing 600 is the existing conventional controller housing 600, that is, the housing 600 adopts a split design, including a first housing 610 and a second housing 620 connected to each other. The first housing 610 and the second housing 620 are assembled by means of fasteners, screws and other connection methods, which facilitates the installation and maintenance of the internal components of the housing 600.

[0050] Correspondingly, the housing interface 700 includes a first interface 710 located in the first housing 610 and a second interface 720 located in the second housing 620. When the first housing 610 and the second housing 620 are connected, the first interface 710 and the second interface 720 are combined to form a housing interface 700 for the connector 800 to be inserted and removed. Therefore, the shape of the housing interface 700 is a combination of the shape of the first interface 710 and the shape of the second interface 720.

[0051] It is understood that step S310 includes steps S311 and S312, such as... Figure 3 As shown.

[0052] Step S311: The housing interface 700 is enlarged proportionally based on the shape of the connector 800.

[0053] First, the initial shape of the housing interface 700 is designed as a proportionally enlarged shape corresponding to the outline shape of the connector 800, so that the shape of the housing interface 700 corresponds to that of the connector 800. This ensures that the housing interface 700 allows the connector 800 to be accurately positioned and guided for correct insertion, avoiding misalignment. It also enables the housing interface 700 to better achieve a waterproof effect for the connector 800.

[0054] Step S312: Optimize and adjust the shape of the housing interface 700.

[0055] Based on the manufacturability of the housing interface 700 shape, the interface shape is optimized and adjusted, and the final interface shape is determined.

[0056] In some embodiments, the profile at the corner of the housing interface 700 can be adjusted to a rounded curved surface with a smooth transition to reduce stress concentration and avoid local overload.

[0057] In other embodiments, the shape optimization of the housing interface 700 also needs to match the processing requirements such as die casting or welding, so that the subsequent mold adjustment and process modification costs of the housing 600 are reduced during the manufacturing process.

[0058] Step S320: Design the gap between the housing interface 700 and the connector 800.

[0059] Understandably, the gap design between the housing interface 700 and the connector 800 needs to balance installability and waterproof rating.

[0060] In this embodiment, the gaps between each end face of the housing interface 700 and the corresponding end face of the connector 800 are equal. Specifically, the gaps between the top surface of the housing interface 700 and the upper end face of the connector 800, the gaps between the bottom surface of the housing interface 700 and the lower end face of the connector 800, and the gaps between the side surface of the housing interface 700 and the corresponding connected side end face are all equal.

[0061] In this embodiment, step S400 includes steps S410 to S440, such as... Figure 4 As shown.

[0062] Step S410: Design the height of the water-retaining edge to be 900mm based on ergonomic requirements.

[0063] Thus, the main design principle is to facilitate the insertion and removal of the connector 800 pair of wire harnesses in a convenient and portable manner.

[0064] In some embodiments, if multiple different connectors 800 are involved, the water-blocking edge 900 can be designed with stepped structures of different heights above different connectors 800, or the water-blocking edge 900 corresponding to the connector 800 with the highest height can be made into a horizontal structure.

[0065] Step S420: Obtain the tilt angle of the controller.

[0066] In some embodiments, the IPX2 waterproof rating requires that when the controller is tilted at an angle less than a certain angle, vertically falling water droplets will not cause harmful effects on the controller and connector 800, thereby defining the tilt angle of the controller.

[0067] Step S430: Obtain the length of the connector 800 protruding from the housing 600.

[0068] In some embodiments, the length of the connector 800 protruding from the housing 600 can be measured manually or electronically.

[0069] Step S440: Calculate the length of the 900mm water-blocking edge.

[0070] The length of the water-blocking edge 900 is calculated based on the height of the water-blocking edge 900, the tilt angle of the controller, and the length of the connector 800 protruding from the housing 600.

[0071] It is understood that step S440 includes steps S441 to S443, such as... Figure 5 As shown.

[0072] Step S441: Calculate the sum of the height of the water-blocking edge 900, the gap between the housing interface 700 and the connector 800, and the height of the connector 800 as the distance from the bottom of the connector 800 to the water-blocking edge 900.

[0073]

[0074] Where b is the distance from the bottom of the connector to the water-blocking edge; b1 is the height of the water-retaining edge; 'a' represents the gap between the housing interface and the connector; b2 is the height of the connector.

[0075] Step S442: Based on the distance from the bottom of connector 800 to the water-blocking edge 900 and the tilt angle of the controller, calculate the extension using the tangent function.

[0076]

[0077] Where c2 is the extension amount, which is the length of the water-blocking edge 900 extending out of the connector 800; ɑ represents the tilt angle of the controller.

[0078] Step S443: Calculate the sum of the length of the connector 800 protruding from the housing 600 and the extension amount to get the length of the water-blocking edge 900.

[0079]

[0080] Where c is the length of the water-retaining side; c1 is the length of the connector protruding from the housing.

[0081] Thus, based on the data obtained above, the length of the 900-meter water-blocking edge can be derived.

[0082] In some embodiments, if multiple different connectors 800 are involved, the water-blocking edge 900 can be designed with step structures of different lengths above different connectors 800, or the water-blocking edge 900 corresponding to the longest connector 800 can be made into a horizontal structure.

[0083] Example 1 The design is based on the controller waterproof structure design method, such as Figures 8 to 10 As shown.

[0084] Step S100: Confirm the controller's waterproof rating. In this embodiment, the controller is a domain controller installed in the spare tire compartment of a car's trunk, where the risk of water ingress is low, and its waterproof rating requirement is IPX2.

[0085] Step S200: Select the model of connector 800. The controller includes functions such as cockpit, high-speed intelligent driving, and intelligent vehicle control. Connector 800 selection includes types such as main connector, video connector 820, and Ethernet connector 810, for example... Figure 8 As shown.

[0086] Step S300: Design the housing interface 700. The controller connector 800 and housing interface 700 are designed. Taking the video connector 820 as an example, the shape of the upper housing interface 700 is a proportionally enlarged version of the cross-sectional shape of the video connector 820. The upper housing interface 700 and the lower housing interface 700 are joined at the rounded corners below the cross-section of the connector 800, as shown below. Figure 10 As shown.

[0087] Step S320: Design the gap between the housing interface 700 and the connector 800. Based on the overall protection requirements, the distance between the shape of the housing interface 700 and the cross-section of the connector 800 is designed to be 0.5mm, i.e., a=0.5.

[0088] Step S400: Design the height and length of the 900mm water-retaining edge.

[0089] The height design of the water-blocking edge 900 of the controller is based on the Ethernet connector 810, which is the tallest among the multiple connectors 800, and is designed as a horizontal structure. The Ethernet connector 810 and its wiring harness require a height of ≥10mm for insertion and removal operations. Therefore, the height of the water-blocking edge 900 is 10mm, i.e., b1=10.

[0090] When the waterproof rating is IPX2, the tilt angle of the controller is 15°, i.e., α=15°, according to the test standard requirements. The length design of the controller's water-retaining edge 900 is based on the horizontal structure design of the video connector 820, which has the longest protrusion from the side of the housing among the multiple connectors 800. The length of the video connector 820 protruding from the housing 600 is 10mm, i.e., c1=10. The height of the connector 800 at the housing interface 700 is 13mm, i.e., b2=13.

[0091] Therefore, based on the controller's waterproof structure design method and the derived formula for the 900mm length of the water-blocking edge: c = c1 + (b1 + a + b2) From tanα, we can deduce that the length of the water-blocking edge 900 is c=16.4, that is, the length of the water-blocking edge 900 should be ≥16.4mm.

[0092] This invention also provides a vehicle including the controller waterproof structure 500 described above, wherein the controller waterproof structure 500 uses a controller waterproof structure design method.

[0093] The vehicle can be a private car, such as a sedan, SUV, MPV, or pickup truck. It can also be a commercial vehicle, such as a van, bus, small truck, or large semi-trailer. The vehicle must have an electric motor capable of outputting power or acting as a generator to store mechanical energy. When the vehicle is a new energy vehicle, it can be a hybrid or a pure electric vehicle.

[0094] Since the vehicle applies all the technical solutions of the above-mentioned controller waterproof structure 500 or controller waterproof structure design method, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0095] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the embodiments described. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of this application.

Claims

1. A method for designing a waterproof structure for a controller, characterized in that, Includes the following steps: Confirm the controller's waterproof rating; Select the connector model; Design the housing interface; Design the height and length of the water-retaining edge.

2. The controller waterproof structure design method according to claim 1, characterized in that, The selected connector model includes the following steps: Based on the product functions of the controller, select the model that meets the electrical performance requirements and determine the shape of the connector.

3. The controller waterproof structure design method according to claim 2, characterized in that, The design of the housing interface includes the following steps: Design the shape of the housing interface; Design the gap between the housing interface and the connector.

4. The controller waterproof structure design method according to claim 3, characterized in that, The design of the housing interface shape includes the following steps: The housing interface is a proportionally enlarged version of the connector shape. Optimize and adjust the shape of the housing interface.

5. The controller waterproof structure design method according to claim 4, characterized in that, The gap between each end face of the housing interface and the corresponding end face of the connector is equal.

6. The controller waterproof structure design method according to claim 5, characterized in that, The design of the water-retaining edge height and length includes the following steps: The height of the water-retaining edge is designed based on ergonomic requirements; Obtain the tilt angle of the controller; Obtain the length of the connector protruding from the housing; Calculate the length of the water-retaining side.

7. The controller waterproof structure design method according to claim 6, characterized in that, The calculation of the length of the water-retaining side includes the following steps: The sum of the height of the water-retaining edge, the gap between the housing interface and the connector, and the height of the connector is the distance from the bottom of the connector to the water-retaining edge. The extension is calculated using the tangent function based on the distance from the bottom of the connector to the water-blocking edge and the tilt angle of the controller.

8. The controller waterproof structure design method according to claim 7, characterized in that, The calculation of the length of the water-retaining side also includes the following steps: The length of the connector protruding from the housing and the extension amount are calculated to be the length of the water-blocking edge.

9. A waterproof structure for a controller, characterized in that, Using the controller waterproof structure design method according to any one of claims 1 to 8, the controller waterproof structure includes a housing and a water-retaining edge, and the housing is provided with a housing interface for installing a connector.

10. A vehicle, characterized in that, Includes the controller waterproof structure as described in claim 9.

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