Compact electric vehicle controller

Abstract

The utility model relates to a compact electric vehicle controller, which comprises a shell with an opening at the bottom and a bottom cover, and an installation space is formed between the shell and the bottom cover. A mounting space is formed in the bottom cover, a first PCB and a second PCB are sequentially mounted in the mounting space from top to bottom at intervals, the first PCB is electrically connected with the second PCB, the first PCB and the second PCB are separated through a plurality of supporting mechanisms, and the bottom end face of the second PCB is mounted in a manner of being tightly attached to the bottom cover; a binding post unit for inputting an external driving signal and outputting a three-phase driving signal, an outer lead unit for outputting a control signal and a plurality of capacitors are welded on the first PCB, and a conductive copper bar is also fixed on the first PCB beside the binding post unit; and a power chip is mounted on the second PCB. Through the arrangement of the supporting mechanism, the first PCB and the second PCB, the size of the electric vehicle controller can be effectively reduced under the condition that the working reliability of the electric vehicle controller is guaranteed, the needed installation space is reduced, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of electric vehicle controllers, in particular to a compact electric vehicle controller. Background Art

[0002] In recent years, electric bicycles have gradually become an important part of urban transportation. In order to facilitate people's standardized travel, electric bicycles are developing towards miniaturization, lightness and high performance. The electric bicycle controller is used to control the start, operation, advance and retreat, speed, stop and other electronic devices of the electric bicycle motor. It is the core control device on the electric bicycle and is responsible for coordinating the work of the entire electric bicycle system.

[0003] The electric vehicle controller in the prior art needs to integrate multiple capacitors, power tubes, wiring terminals and other devices. Due to the large number of devices and the need to ensure electrical isolation between the power devices and the signal processing devices, the internal space utilization rate is low, resulting in a large size of the electric vehicle controller and increased manufacturing costs. At the same time, the large-volume electric vehicle controller requires more installation space and is not suitable for small, lightweight, high-performance electric vehicles. Utility Model Content

[0004] In view of the shortcomings of the above-mentioned existing production technology, the applicant provides a compact electric vehicle controller. By setting a supporting mechanism, a first PCB board and a second PCB board, the volume of the electric vehicle controller can be effectively reduced while ensuring the working reliability of the electric vehicle controller, and the required installation space can be reduced, the manufacturing cost can be reduced, and it can adapt to the development trend of electric bicycles.

[0005] The technical solution adopted by the utility model is as follows:

[0006] A compact electric vehicle controller comprises a housing with an opening at the bottom, wherein a flat bottom cover is mounted on the opening of the housing so that an installation space is formed in the opening of the housing;

[0007] A first PCB board and a second PCB board are sequentially installed in the installation space from top to bottom, the first PCB board and the second PCB board are electrically connected, the first PCB board and the second PCB board are separated by a plurality of support mechanisms, the support mechanisms are electrically isolated from the first PCB board, the support mechanisms are electrically isolated from the second PCB board, and the bottom end surface of the second PCB board is installed close to the bottom cover;

[0008] The first PCB board is welded with a terminal unit for inputting external drive signals and outputting three-phase drive signals, an external lead unit for outputting control signals, and several capacitors, and a conductive copper bus is also fixed on the first PCB board next to the terminal unit;

[0009] A power chip is mounted on the second PCB board.

[0010] As a further improvement of the above technical solution:

[0011] The structure of the shell is as follows: it includes a shell, the bottom of the shell is hollowed out to form an opening, a wiring groove is arranged on the end face of the shell, a plurality of first mounting holes corresponding to the terminal unit are opened in the wiring groove, a wiring dividing protrusion is arranged on the end face of the shell between two adjacent first mounting holes, and a second mounting hole corresponding to the external lead unit is also opened on the end face of the shell.

[0012] The outer end surface of the shell is provided with a mark.

[0013] The structure of the single supporting mechanism is as follows: comprising a supporting bolt, the supporting bolt passes through the first PCB board and the second PCB board at the same time, and is fastened to the bottom cover, so as to position the first PCB board and the second PCB board; the conductive supporting ring is welded on the second PCB board and is located between the first PCB board and the second PCB board, so as to separate the first PCB board from the second PCB board;

[0014] An insulating ring for achieving electrical isolation is installed on the top of the supporting bolt.

[0015] The terminal unit includes several three-phase output terminals and several drive input terminals, the drive input terminals are connected to an external drive power supply, the three-phase output terminals are connected to the motor input terminal, a single three-phase output terminal is installed in conjunction with a Hall sensor, and a single Hall sensor is fixed on the top of the first PCB board and is electrically connected to the first PCB board.

[0016] The outer lead unit includes a first outer lead terminal and a second outer lead terminal.

[0017] The structure of the first external lead terminal is: comprising a first external lead post and a first base that are mutually clamped;

[0018] The side wall surface of the first base is provided with two convex strips arranged at intervals, a guide groove is formed between two adjacent convex strips, and a buckle is provided on the side wall surface of the first base between the two convex strips;

[0019] An inserting strip corresponding to the guide groove is arranged inside the first outer lead column, and a clamping groove corresponding to the buckle is arranged on the wall surface of the inserting strip.

[0020] The structure of the second outer lead terminal is as follows: it includes a second outer lead column and a second base, and a clamping protrusion is arranged on the outer wall surface of the second base, and the clamping protrusion is used to realize the clamping connection between the second outer lead column and the second base.

[0021] A top cover is installed on the external top of the shell, and the top cover covers the terminal unit extending to the outside of the shell. A ventilation hole is also provided on the shell, and a waterproof ventilation valve is installed in the ventilation hole, and a buckle cover is installed outside the ventilation hole.

[0022] The first PCB board and the second PCB board are electrically connected via a connector.

[0023] The beneficial effects of the utility model are as follows:

[0024] The utility model has a compact and reasonable structure and is easy to operate. By setting a supporting mechanism, the first PCB board and the second PCB board can be arranged at intervals from each other in the vertical direction, and electrical isolation between the two can be ensured, thereby effectively improving the utilization rate of the internal space of the electric vehicle controller and reducing the manufacturing cost. It is suitable for small and lightweight high-performance electric vehicles.

[0025] The utility model also has the following advantages:

[0026] (1) In the present invention, by providing a wiring groove on the housing and adjusting the installation layout of the electronic components in the housing opening, the structure of the electric vehicle controller is effectively compacted and its volume is reduced.

[0027] (2) In the present invention, by providing a wire splitting protrusion, it is possible to prevent the connecting wires from being entangled with each other during wiring, thereby achieving electrical isolation and improving the safety of the electric vehicle controller.

[0028] (3) In the present invention, a planar bottom cover is provided, and the bottom end surface of the second PCB board is directly attached to the bottom cover, so that the power chip on the second PCB board can be easily cooled, thereby effectively ensuring the working reliability of the electric vehicle controller.

[0029] (4) The internal structures of the first external lead terminal 8 and the second external lead terminal 9 of the external lead unit of the present invention are both installed by snap-fitting, which is convenient for assembly and disassembly, and can effectively improve the efficiency of subsequent maintenance and replacement. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a structural schematic diagram of the utility model.

[0031] Figure 2 for Figure 1 Bottom view of .

[0032] Figure 3 It is a schematic diagram of the internal structure of the utility model.

[0033] Figure 4 for Figure 3 main view.

[0034] Figure 5 This is an exploded view of the utility model (with a top cover).

[0035] Figure 6 It is an exploded view of the external lead unit in the utility model.

[0036] Figure 7 It is a schematic structural diagram of the first external lead column in the utility model.

[0037] Among them: 1. Shell; 2. Bottom cover; 3. Support mechanism; 4. Buckle cover; 5. First PCB board; 6. Second PCB board; 7. Conductive copper busbar; 8. First external lead terminal; 9. Second external lead terminal; 10. Capacitor; 11. Power chip; 12. Hall sensor; 13. Three-phase output terminal; 14. Drive input terminal; 15. Top cover; 16. Connector;

[0038] 101, housing; 102, first mounting hole; 103, second mounting hole; 104, wiring slot; 105, wiring bump;

[0039] 301, supporting bolt; 302, conductive support ring; 303, insulating ring;

[0040] 801, first external lead column; 802, first base; 803, guide groove; 804, buckle; 805, slot;

[0041] 901, second external lead column; 902, second base; 903, clamping protrusion. DETAILED DESCRIPTION

[0042] The specific implementation of the present utility model is described below in conjunction with the accompanying drawings.

[0043] The structure and functions of the utility model are as follows:

[0044] like Figure 1-Figure 7As shown, a compact electric vehicle controller comprises a housing 1 with an opening at the bottom, a flat bottom cover 2 is installed at the opening of the housing 1, so that an installation space is formed in the opening of the housing 1; a first PCB board 5 and a second PCB board 6 are installed in sequence from top to bottom in the installation space, the first PCB board 5 and the second PCB board 6 are electrically connected, the first PCB board 5 and the second PCB board 6 are separated by several support mechanisms 3, the support mechanism 3 is electrically isolated from the first PCB board 5, the support mechanism 3 is electrically isolated from the second PCB board 6, and the bottom end surface of the second PCB board 6 is installed close to the bottom cover 2; a terminal unit for external drive signal input and three-phase drive signal output, an external lead unit for control signal output and several capacitors 10 are welded on the first PCB board 5, and a conductive copper bus 7 is also fixed on the first PCB board 5 next to the terminal unit; a power chip 11 is mounted on the second PCB board 6. The compact electric vehicle controller of the utility model is installed inside an electric bicycle, has a compact structure, high heat dissipation efficiency, reliable performance, and is suitable for small and light electric bicycles.

[0045] like Figure 1 , Figure 5 As shown, the structure of the housing 1 is as follows: it includes a housing 101, the bottom of the housing 101 is hollowed out to form an opening, a wiring groove 104 is provided on the end surface of the housing 101, a plurality of first mounting holes 102 corresponding to the terminal units are provided in the wiring groove 104, a line separation bump 105 is provided on the end surface of the housing 101 between two adjacent first mounting holes 102, a second mounting hole 103 corresponding to the external lead unit is also provided on the end surface of the housing 101, and a mark is provided on the outer end surface of the housing 101; the wiring groove 104 is provided on the housing 101 A relatively low device is installed in the corresponding opening below the part, and a relatively high device is installed in the corresponding opening below the part without the wiring groove 104. At the same time, the first mounting hole 102 corresponding to the terminal unit is arranged in the wiring groove 104, so that after each terminal in the terminal unit extends from the corresponding first mounting hole 102, its height can be slightly lower than the height of the part of the shell 101 without the wiring groove 104, thereby reducing the height of the shell 1, facilitating the installation and application of the shell 1, and effectively reducing the volume of the electric vehicle controller;

[0046] In addition, a top cover 15 is installed on the external top of the shell 1, and the top cover 15 covers the terminal unit extending to the outside of the shell 1. A ventilation hole is also provided on the shell 1, and a waterproof ventilation valve is installed in the ventilation hole, and a buckle cover 4 is installed outside the ventilation hole; the top cover 15 is used to protect the terminal unit, the ventilation hole is used to increase the internal heat dissipation of the electric vehicle controller, and the buckle cover 4 prevents external dust from entering the electric vehicle controller.

[0047] like Figure 3-Figure 5As shown, the structure of a single supporting mechanism 3 is as follows: it includes a supporting bolt 301, which passes through the first PCB board 5 and the second PCB board 6 at the same time and is fastened to the bottom cover 2, so as to position the first PCB board 5 and the second PCB board 6; a conductive supporting ring 302 is welded on the second PCB board 6 and is located between the first PCB board 5 and the second PCB board 6, so as to separate the first PCB board 5 from the second PCB board 6; and an insulating ring 303 for achieving electrical isolation is installed on the top of the supporting bolt 301.

[0048] In the present invention, the first PCB board 5 and the capacitor 10, the terminal unit, and the external lead unit thereon are used to process input and output signals; wherein,

[0049] like Figure 3-Figure 5 As shown, the terminal unit includes several three-phase output terminals 13 and several drive input terminals 14, the drive input terminals 14 are connected to the external drive power supply, the three-phase output terminals 13 are connected to the motor input end, a single three-phase output terminal 13 is installed in conjunction with a Hall sensor 12, and a single Hall sensor 12 is fixed to the top of the first PCB board 5 and is electrically connected to the first PCB board 5; in the utility model, the drive input terminals 14 are arranged in two numbers for connecting the external drive voltage, and the three-phase output terminals 13 are arranged in three numbers for connecting the motor of the electric bicycle;

[0050] The external lead unit is used to connect the signal line to other actuators of the electric bicycle and output control signals to control the corresponding actuator actions, such as Figure 3-Figure 7 As shown, the external lead unit includes a first external lead terminal 8 and a second external lead terminal 9;

[0051] like Figure 6-Figure 7 As shown, the structure of the first external lead terminal 8 is as follows: it includes a first external lead column 801 and a first base 802 that are clamped together; two convex strips arranged at intervals are arranged on the side wall surface of the first base 802, a guide groove 803 is formed between two adjacent convex strips, and a buckle 804 is arranged on the side wall surface of the first base 802 between the two convex strips; an inserting strip corresponding to the guide groove 803 is arranged inside the first external lead column 801, and a clamping groove 805 corresponding to the buckle 804 is arranged on the wall surface of the inserting strip;

[0052] like Figure 6 As shown, the structure of the second external lead terminal 9 is as follows: it includes a second external lead column 901 and a second base 902, and a clamping protrusion 903 is provided on the outer wall surface of the second base 902, and the clamping protrusion 903 is used to realize the clamping connection between the second external lead column 901 and the second base 902;

[0053] In the present invention, the first base 802 and the second base 902 are respectively plugged into the first PCB board 5, so as to respectively realize the electrical connection between the first external lead terminal 8 and the first PCB board 5, and the electrical connection between the second external lead terminal 9 and the first PCB board 5;

[0054] The second PCB board 6 is a power board, on which a power chip 11 is mounted, and is used to convert an input signal introduced by a driving input terminal 14 into a three-phase AC signal, and output it through a three-phase output terminal 13;

[0055] The first PCB board 5 and the second PCB board 6 are electrically connected via a connector 16. The connector 16 includes a pin header and a female header. The female header is mounted on the first PCB board 5, and the pin header is mounted between the second PCB boards 6. The electrical connection between the first PCB board 5 and the second PCB board 6 is achieved by plugging the pin header and the female header.

[0056] In addition, the bottom end surface of the second PCB board 6 is directly attached to the bottom cover 2. The bottom cover 2 is made of metal and has a high specific heat capacity, which is convenient for dissipating heat for the power chip 11 on the second PCB board 6, thereby effectively ensuring the working reliability of the electric vehicle controller.

[0057] The working process of the utility model is as follows:

[0058] In the utility model, threaded holes are provided at the four corners of the bottom cover 2, through which the electric vehicle controller is fixed inside the electric bicycle;

[0059] According to the markings on the housing 101, the two drive input terminals 14 are connected to the positive and negative electrodes of the external drive power source (i.e., the battery of the electric bicycle) respectively;

[0060] According to the markings on the housing 101, the three three-phase output terminals 13 are respectively connected to the three-phase input terminals of the motor in the electric bicycle;

[0061] During wiring, the branching protrusion 105 can prevent the connection wires from getting entangled with each other, and can play a role in electrical isolation, thereby improving the safety of the electric vehicle controller;

[0062] The electric vehicle controller converts the direct current output by the external driving power supply into three-phase alternating current, thereby driving the motor of the electric bicycle to work and further controlling the movement of the electric bicycle.

[0063] The above description is an explanation of the utility model, not a limitation of the utility model. The scope of the utility model is defined by the claims. Any form of modification can be made within the protection scope of the utility model.

Claims

1. A compact electric vehicle controller, characterized in that: It comprises a housing (1) with an opening at the bottom, wherein a flat bottom cover (2) is mounted on the opening of the housing (1), thereby forming an installation space in the opening of the housing (1); A first PCB board (5) and a second PCB board (6) are sequentially installed in the installation space from top to bottom, the first PCB board (5) and the second PCB board (6) are electrically connected, the first PCB board (5) and the second PCB board (6) are separated by a plurality of support mechanisms (3), the support mechanisms (3) are electrically isolated from the first PCB board (5), the support mechanisms (3) are electrically isolated from the second PCB board (6), and the bottom end surface of the second PCB board (6) is installed in close contact with the bottom cover (2); A terminal unit for inputting external drive signals and outputting three-phase drive signals, an external lead unit for outputting control signals, and a plurality of capacitors (10) are welded on the first PCB board (5), and a conductive copper busbar (7) is also fixed on the first PCB board (5) next to the terminal unit; A power chip (11) is mounted on the second PCB board (6).

2. A compact electric vehicle controller as claimed in claim 1, characterized in that: The structure of the shell (1) is as follows: it comprises a shell (101), the bottom of the shell (101) is hollowed out to form an opening, a wiring groove (104) is arranged on the end surface of the shell (101), a plurality of first mounting holes (102) corresponding to the terminal units are opened in the wiring groove (104), a line dividing protrusion (105) is arranged on the end surface of the shell (101) between two adjacent first mounting holes (102), and a second mounting hole (103) corresponding to the external lead unit is also opened on the end surface of the shell (101).

3. A compact electric vehicle controller as claimed in claim 2, characterized in that: The outer end surface of the shell (101) is provided with a mark.

4. A compact electric vehicle controller as claimed in claim 1, characterized in that: The structure of the single supporting mechanism (3) is as follows: it comprises a supporting bolt (301), wherein the supporting bolt (301) passes through the first PCB board (5) and the second PCB board (6) at the same time, and is fastened to the bottom cover (2), thereby positioning the first PCB board (5) and the second PCB board (6); and a conductive support ring (302) welded on the second PCB board (6), wherein the conductive support ring (302) is located between the first PCB board (5) and the second PCB board (6), thereby separating the first PCB board (5) from the second PCB board (6); An insulating ring (303) for achieving electrical isolation is installed on the top of the supporting bolt (301).

5. A compact electric vehicle controller as claimed in claim 1, characterized in that: The terminal unit comprises a plurality of three-phase output terminals (13) and a plurality of drive input terminals (14), wherein the drive input terminals (14) are connected to an external drive power source, and the three-phase output terminals (13) are connected to a motor input terminal. A single three-phase output terminal (13) is installed in cooperation with a Hall sensor (12), and a single Hall sensor (12) is fixed to the top of a first PCB board (5) and is electrically connected to the first PCB board (5).

6. A compact electric vehicle controller as claimed in claim 1, characterized in that: The external lead unit comprises a first external lead terminal (8) and a second external lead terminal (9).

7. A compact electric vehicle controller as claimed in claim 6, characterized in that: The structure of the first external lead terminal (8) is as follows: comprising a first external lead post (801) and a first base (802) that are mutually clamped; The side wall surface of the first base (802) is provided with two convex strips arranged at intervals, a guide groove (803) is formed between two adjacent convex strips, and a buckle (804) is provided on the side wall surface of the first base (802) between the two convex strips; An inserting strip corresponding to the guide groove (803) is arranged inside the first external lead column (801), and a clamping groove (805) corresponding to the buckle (804) is arranged on the wall surface of the inserting strip.

8. A compact electric vehicle controller as claimed in claim 6, characterized in that: The structure of the second external lead terminal (9) is as follows: it comprises a second external lead column (901) and a second base (902); a clamping protrusion (903) is arranged on the outer wall surface of the second base (902); and the clamping protrusion (903) is used to realize the clamping connection between the second external lead column (901) and the second base (902).

9. A compact electric vehicle controller as claimed in claim 1, characterized in that: A top cover (15) is installed on the top of the outer surface of the housing (1), and the top cover (15) covers the terminal unit extending to the outside of the housing (1). The housing (1) is also provided with an air vent, and a waterproof air vent is installed in the air vent. A buckle cover (4) is installed outside the air vent.

10. A compact electric vehicle controller as claimed in claim 1, characterized in that: The first PCB board (5) and the second PCB board (6) are electrically connected via a connector (16).

Images