Double-outgoing-line waterproof controller convenient to assemble

Abstract

The utility model relates to the field of electric mopeds, in particular to a double-outgoing-line waterproof controller convenient to assemble. The controller comprises a controller shell, wire harness suites, sealing pieces, a mainboard and a wire core, the front end and the rear end of the controller shell are each provided with a wire harness open groove, the sealing pieces are connected to the wire harness open grooves in a sealed mode, each sealing piece is provided with at least one wire harness suite, one end of each wire harness suite is inwards communicated with an inner cavity of the controller shell, the other end of each wire harness suite extends outwards, and the wire core is arranged in the inner cavity of the controller shell. The main board is installed in an inner cavity of the controller shell, a plurality of wiring ports are formed in the main board, the wire core is connected into the wire harness external member, and one end of the wire core is in butt joint with the wiring ports. According to the double-side wire outlet controller, the installation problem of the controller is well improved, the damage risk caused by wire harness bending is reduced, and meanwhile the problem of using a complex deconcentrator is avoided.

Description

Technical Field

[0001] This utility model relates to the field of electric bicycles, and in particular to a dual-wire waterproof controller that is easy to assemble. Background Technology

[0002] Since the controller of an electric bicycle is generally installed at the bottom bracket of the vehicle, and the controller adopts a single-sided cable exit method due to the design requirements, this solution is not very user-friendly for the installation of the whole vehicle. If the controller is installed at the rear, the cable harness that needs to be routed upwards needs to be bent before it can be routed upwards. The bending of the cable harness will take up space inside the pipe and may cause damage to the cable harness. Even if the controller is not installed at the bottom bracket, it is still unavoidable to route the cable at both the front and rear.

[0003] The controller has the following problems with only one-sided outgoing wiring:

[0004] ①During controller installation, due to the need for front and rear wiring, when routing the wiring in the opposite direction, it is necessary to bend the wiring harness. The risk of damage to the wiring harness when bending it will be significantly increased, and the wiring harness will occupy the limited space inside the vehicle tube when bending it, making installation difficult.

[0005] ② Existing single-sided outgoing controllers have limited outgoing lines. When there are more functional requirements, a splitter is needed. Splitters are expensive and have the risk of incorrect welding of wire harnesses. At the same time, splitters are large in size and will occupy vehicle pipe space, making installation difficult. Utility Model Content

[0006] This invention provides a dual-outlet waterproof controller that is easy to assemble, aiming to solve the problem of single-sided outlet in existing controllers.

[0007] This utility model provides an easy-to-assemble dual-outlet waterproof controller, including a controller housing, a wiring harness kit, a sealing element, a main board, and wire cores. The controller housing has wiring harness slots at both its front and rear ends. The sealing element is sealed to the wiring harness slots. Each sealing element has at least one wiring harness kit. One end of the wiring harness kit communicates inwardly with the inner cavity of the controller housing, and the other end extends outward. The main board is installed in the inner cavity of the controller housing and has multiple wiring ports. The wire cores are connected inside the wiring harness kits, and one end of each wire core is connected to a wiring port.

[0008] As a further improvement of this utility model, the sealing element includes a front sealing plate, a rear sealing plate, and an intermediate sealing block. The intermediate sealing block is disposed between the front sealing plate and the rear sealing plate. The intermediate sealing block is interference-fitted with the groove edge of the wire harness slot. The rear sealing plate and the front sealing plate are respectively clamped on the inner and outer sides of the wire harness slot.

[0009] As a further improvement of this utility model, the controller housing includes an upper shell, a lower shell, and a sealing ring. The top edge of the lower shell is provided with a sealing boss, and the bottom edge of the upper shell is provided with a sealing groove. The upper shell and the lower shell are fastened together, and the sealing groove is aligned with the sealing boss. The sealing ring is squeezed and connected between the sealing groove and the sealing boss.

[0010] As a further improvement of this utility model, the edge of the sealing element is provided with a sealing protrusion, and after the sealing element is installed in the groove of the wire harness, the sealing protrusion is aligned with the sealing boss.

[0011] As a further improvement of this utility model, the sealing element and the wire harness kit are integrally injection molded.

[0012] As a further improvement of this utility model, the motherboard is divided into a front-end wiring section and a rear-end wiring section, and multiple wiring ports are respectively distributed in the front-end wiring section and the rear-end wiring section. The wire core located at the front end of the controller housing is connected to the wiring port of the front-end wiring section, and the wire core located at the rear end of the controller housing is connected to the wiring port of the rear-end wiring section.

[0013] As a further improvement of this utility model, a heat dissipation protrusion is provided at the bottom of the inner cavity of the controller housing, and a heat-generating electronic component is mounted on the motherboard, with the heat dissipation protrusion connecting to the heat-generating electronic component.

[0014] As a further improvement of this utility model, the bottom of the controller housing is provided with heat dissipation teeth.

[0015] The beneficial effects of this utility model are: the dual-sided cable controller improves the installation of the controller, reduces the risk of damage caused by wire harness bending, and avoids the problem of using a complicated splitter; the wire harness is connected to the controller housing through a seal, which improves the waterproof performance of the controller. Attached Figure Description

[0016] Figure 1 This is a schematic diagram showing the installation position of the controller of this utility model on an electric-assisted bicycle;

[0017] Figure 2 This is an overall structural diagram of the dual-line waterproof controller of this utility model;

[0018] Figure 3 This is an internal structural diagram of the dual-wire waterproof controller of this utility model;

[0019] Figure 4 This is a structural cross-sectional view of the dual-line waterproof controller of this utility model;

[0020] Figure 5 This is a connection structure diagram of the wire harness kit and seal of this utility model;

[0021] Figure 6 This is a top view of the lower shell structure of the controller of this utility model;

[0022] Figure 7 This is a bottom view of the lower shell structure of the controller of this utility model. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments.

[0024] like Figures 2 to 3 As shown, this utility model discloses a dual-outlet waterproof controller that is easy to assemble, comprising a controller housing 1, a wiring harness kit 3, a sealing element 2, a main board 4, and wire cores. The controller housing 1 has wiring harness slots 11 at both its front and rear ends. The sealing element 2 is sealed and connected to the wiring harness slots 11. Each sealing element 2 has at least one wiring harness kit 3. One end of the wiring harness kit 3 is internally connected to the inner cavity of the controller housing 1, and the other end of the wiring harness kit 3 extends outward. The main board 4 is installed in the inner cavity of the controller housing 1 and has multiple wiring ports 41. The wire cores are connected to the inside of the wiring harness kit 3, and one end of the wire core is connected to the wiring port 41.

[0025] like Figure 1 As shown, this easy-to-assemble dual-outlet waterproof controller can be installed at the bottom bracket position (point A) of an electric-assist bicycle (7), i.e., the position indicated by the symbol A in the diagram. The wiring harness at the front of the controller runs along the frame tube towards the front of the bicycle, connecting components such as the instrument panel, headlight, brake lever, and throttle. The wiring harness at the rear of the controller runs along the frame tube towards the rear wheel, connecting components such as the motor, taillight, buzzer, and torque sensor. Compared to traditional single-sided outlet controllers with limited wiring output, which require a splitter when there are many functional requirements, splitters are more expensive and carry the risk of incorrect soldering of the internal wiring harness. Furthermore, splitters are bulky and take up space in the frame tube. This controller has dual-sided outlet wiring, allowing for a larger number of wiring harnesses to be output at once, enabling one-to-one connections to multiple devices. Only the wiring harness and connectors are present in the frame tube, requiring less space and avoiding congestion of the wiring harness within the frame tube, thus preventing installation problems.

[0026] The wiring harness kit 3 is connected to the controller housing 1 via the sealing element 2, ensuring the overall waterproof performance of the controller. The wire core is encased within the wiring harness kit 3, which protects the wire core. One end of the wire core is connected to the wiring port 41 of the main board 4, and the other end is located at the end of the wiring harness kit 3, allowing the user to connect to various electronic components on the vehicle. The two wiring harness slots 11 on the front and rear of the controller housing 1 meet the assembly requirements of double-sided wiring.

[0027] like Figure 5As shown, the sealing element 2 includes a front sealing plate 21, a rear sealing plate 22, and an intermediate sealing block 23. The intermediate sealing block 23 is disposed between the front sealing plate 21 and the rear sealing plate 22. The intermediate sealing block 23 is interference-fitted with the edge of the wire harness slot 11. The rear sealing plate 22 and the front sealing plate 21 are respectively engaged on the inner and outer sides of the wire harness slot 11. The front sealing plate 21, the rear sealing plate 22, and the intermediate sealing block 23 form a groove on the side for engaging with the wire harness slot 11. The interference fit between the intermediate sealing block 23 and the edge of the wire harness slot 11 ensures the sealing performance on the side, while the front sealing plate 21 and the rear sealing plate 22 simultaneously seal the front and rear sides of the wire harness slot 11, further enhancing the sealing performance of the connection between the sealing element 2 and the controller housing 1 from both the front and rear.

[0028] like Figures 4 to 6 As shown, the controller housing 1 includes an upper shell 12, a lower shell 13, and a sealing ring 5. The top edge of the lower shell 13 has a sealing boss 14, and the bottom edge of the upper shell 12 has a sealing groove 15. The upper shell 12 and the lower shell 13 are tightly connected, and the sealing groove 15 mates with the sealing boss 14. The sealing ring 5 is compressed and connected between the sealing groove 15 and the sealing boss 14. The controller housing 1 is divided into two parts, the upper shell 12 and the lower shell 13, to facilitate the installation of internal components. Screw holes are provided at corresponding positions on the upper shell 12 and the lower shell 13, and the upper shell 12 and the lower shell 13 are fixed by fastening screws 6. After assembly, the sealing groove 15 and the sealing boss 14 compress the sealing ring 5, causing the sealing ring 5 to deform and fill the gap between the upper shell 12 and the lower shell 13, thereby achieving waterproofing.

[0029] The edge of the seal 2 is provided with a sealing protrusion 24. After the seal 2 is installed in the wire harness slot 11, the sealing protrusion 24 is aligned with the sealing boss 14. The sealing protrusion 24 is preferably located on the top of the middle sealing block 23. The seal 2 with the wire harness kit 3 is designed to have an interference fit with the lower shell 13 to achieve the sealing requirements. After the seal 2 is assembled into the lower shell 13, the sealing protrusion 24 and the sealing boss 14 of the lower shell 13 are at the same height. The sealing boss 14 of the lower shell 13 is tightened by screws to compress the sealing ring 5, thereby achieving the waterproof requirements.

[0030] The seal 2 and the wiring harness kit 3 are integrally injection molded. The controller has high waterproof requirements and has dual-sided wiring. The wiring harness kit 3 and the seal 2 (SR) are integrally injection molded. During the production of the wiring harness, the wiring harness is connected into a whole through mold injection molding. The waterproof effect of the whole wiring harness reaches IPX6 level.

[0031] like Figure 3As shown, the motherboard 4 is divided into a front-end wiring section 42 and a rear-end wiring section 43. Multiple wiring ports 41 are distributed in the front-end wiring section 42 and the rear-end wiring section 43 respectively. The wire core located at the front of the controller housing 1 is connected to the wiring port 41 of the front-end wiring section 42, and the wire core located at the rear of the controller housing 1 is connected to the wiring port 41 of the rear-end wiring section 43.

[0032] Due to the limited internal space of the vehicle tube, the controller's size can only be fixed within a certain range. Therefore, the internal space of the controller is also relatively limited. Under the same volume, the dual-sided outgoing controller requires the circuit board to use more connectors. More connectors mean that the layout of the main board 4 is more difficult. The components need to be laid out tightly and orderly while ensuring the integrity of the functions. Therefore, a structure of front-end wiring partition 42 and rear-end wiring partition 43 is adopted, so that the front-end wiring port 41 is close to the front-end wiring harness kit 3, and the rear-end wiring port 41 is close to the rear-end wiring harness kit 3. This reduces the wiring distance, avoids the crossing of internal wiring of the main board 4, and meets the wiring requirements of the compact main board 4.

[0033] like Figure 6 As shown, a heat dissipation bump 16 is provided at the bottom of the inner cavity of the controller housing 1. The motherboard 4 is equipped with heat-generating electronic components, and the heat dissipation bump 16 is connected to the heat-generating electronic components. The heat dissipation bump 16 is used to conduct heat dissipation to the key heat-generating electronic components on the motherboard 4, such as control chips. The heat dissipation bump 16 is in direct contact with these components, and the heat is quickly dissipated through the controller housing 1.

[0034] like Figure 7 As shown, the bottom of the controller housing 1 is provided with heat dissipation ridges 17. The structure of the heat dissipation ridges 17 can increase the heat dissipation area of ​​the controller housing 1 and improve the heat dissipation efficiency.

[0035] This utility model's controller employs a dual-sided cabling design, proactively controlling the front and rear cabling. Upward-facing cables are routed directly upwards, while rearward-facing cables are routed backwards, preventing cable bending. This protects the cabling during installation and reduces cabling costs. The dual-sided cabling also allows for efficient allocation of the wiring ports 41 on the motherboard 4, resolving the issue of limited space and difficult cable routing on the motherboard 4. Furthermore, the interference fit of the sealing element 2 and the compression structure of the sealing ring 5 enhance the overall waterproof performance.

[0036] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the protection scope of the present invention.

Claims

1. A dual-outlet waterproof controller that is easy to assemble, characterized in that, The device includes a controller housing, a wiring harness kit, a seal, a main board, and wire cores. The controller housing has wiring harness slots at both its front and rear ends. The seal is sealed to the wiring harness slots. Each seal has at least one wiring harness kit. One end of the wiring harness kit communicates inward with the inner cavity of the controller housing, and the other end extends outward. The main board is installed in the inner cavity of the controller housing and has multiple wiring ports. The wire cores are connected inside the wiring harness kits, and one end of each wire core is connected to a wiring port.

2. The easily assembled dual-outlet waterproof controller according to claim 1, characterized in that, The sealing element includes a front sealing plate, a rear sealing plate, and an intermediate sealing block. The intermediate sealing block is disposed between the front sealing plate and the rear sealing plate. The intermediate sealing block is interference-fitted with the groove edge of the wire harness slot. The rear sealing plate and the front sealing plate are respectively clamped on the inner and outer sides of the wire harness slot.

3. The easily assembled dual-outlet waterproof controller according to claim 1, characterized in that, The controller housing includes an upper shell, a lower shell, and a sealing ring. The top edge of the lower shell is provided with a sealing boss, and the bottom edge of the upper shell is provided with a sealing groove. The upper shell and the lower shell are fastened together, and the sealing groove is aligned with the sealing boss. The sealing ring is squeezed and connected between the sealing groove and the sealing boss.

4. The easily assembled dual-outlet waterproof controller according to claim 3, characterized in that, The edge of the seal is provided with a sealing protrusion. After the seal is installed in the groove of the wire harness, the sealing protrusion is aligned with the sealing boss.

5. The easily assembled dual-outlet waterproof controller according to claim 1, characterized in that, The seal and the wiring harness kit are integrally injection molded.

6. The easily assembled dual-outlet waterproof controller according to claim 1, characterized in that, The motherboard is divided into a front-end wiring section and a rear-end wiring section. Multiple wiring ports are distributed in the front-end wiring section and the rear-end wiring section respectively. The wire core located at the front of the controller housing is connected to the wiring port of the front-end wiring section, and the wire core located at the rear of the controller housing is connected to the wiring port of the rear-end wiring section.

7. The easily assembled dual-outlet waterproof controller according to claim 1, characterized in that, The bottom of the inner cavity of the controller housing is provided with a heat dissipation protrusion, and the motherboard is equipped with heat-generating electronic components, with the heat dissipation protrusion connecting to the heat-generating electronic components.

8. The easily assembled dual-outlet waterproof controller according to claim 1, characterized in that, The bottom of the controller housing is provided with heat dissipation fins.

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