Controller and electric vehicle
By adopting a combination structure of stretched aluminum heat dissipation shell and aluminum substrate, the high cost and heat dissipation performance problems of electric motorcycle controllers are solved, achieving a low-cost and efficient heat dissipation effect.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-22
- Publication Date
- 2026-03-31
AI Technical Summary
Existing electric motorcycle controllers have high requirements for heat dissipation performance and high production costs, especially for die-cast aluminum products and terminal block structures. The terminal block structures require CNC machining, which also increases costs.
The structure combines a stretched aluminum heat sink shell, an aluminum substrate, a base, and conductive components. By incorporating both heat-conducting and insulating components, it reduces production costs while improving heat dissipation efficiency.
By using a combination structure of stretched aluminum parts and aluminum substrate, the processing cost of the controller is reduced, and the heat dissipation performance and current transmission stability are improved, making it suitable for mass production.
Smart Images
Figure CN224069019U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric vehicle technology, and in particular to a controller and an electric vehicle. Background Technology
[0002] Electric motorcycle controllers, due to their high power and heat generation, require extremely high heat dissipation performance. To improve this, die-cast aluminum heat sinks and aluminum substrate structures are commonly used. Furthermore, to meet overcurrent requirements, the positive and negative terminals and three-phase wiring terminals often employ a post-type structure. Die-cast aluminum is expensive to produce, and to meet corrosion resistance requirements, the surface needs passivation or painting, further increasing processing costs. The post-type structure requires CNC machining, which is also very costly. Therefore, a controller is needed to address these issues. Utility Model Content
[0003] The purpose of this invention is to provide a controller with low processing cost.
[0004] The purpose of this utility model is to provide an electric vehicle that reduces the processing cost of the electric vehicle by setting the above-mentioned controller.
[0005] To achieve this objective, the present invention adopts the following technical solution:
[0006] The controller includes:
[0007] A heat dissipation shell is provided with a receiving cavity, and the heat dissipation shell is a stretched aluminum part;
[0008] An aluminum substrate, wherein the aluminum substrate is disposed within the receiving cavity;
[0009] Two power terminals are provided, and the two power terminals are spaced apart along a first direction. Each power terminal includes a base and a conductive element. The base is disposed on the aluminum substrate. One end of the conductive element is connected to the aluminum substrate through the first fastener, and the other end of the conductive element is disposed on the base.
[0010] As an optional technical solution, a power transistor and a current guide are disposed on the aluminum substrate. The power transistor includes an upper bridge power transistor and a lower bridge power transistor, which are spaced apart along the first direction. The current guide is made of red copper. One end of the current guide is disposed between the upper bridge power transistor and the lower bridge power transistor, and the other end of the current guide crosses the lower bridge power transistor and is electrically connected to the conductive element of one of the power terminals. The other power terminal is electrically connected to the aluminum substrate.
[0011] As an optional technical solution, the conductive component is provided with a first mounting hole, the aluminum substrate is provided with a second mounting hole, and the heat dissipation shell is provided with a third mounting hole. The first fastener connects the conductive component, the aluminum substrate, and the heat dissipation shell through the first mounting hole, the second mounting hole, and the third mounting hole.
[0012] As an optional technical solution, an insulating element is provided between the conductive element and the first fastener.
[0013] As an optional technical solution, the size of the insulating component is larger than the inner diameter of the first mounting hole.
[0014] As an optional technical solution, the conductive component is a three-phase conductive component, and the insulating components corresponding to the three-phase conductive components are set independently or integrally.
[0015] As an optional technical solution, the controller further includes a control board, a support member is provided on the aluminum substrate, the control board is disposed on the support member and located above the aluminum substrate, and the control board is electrically connected to the aluminum substrate.
[0016] As an optional technical solution, the heat dissipation shell includes a heat dissipation shell body and two baffles. The two baffles are disposed opposite to each other on both sides of the heat dissipation shell body, and the two baffles and the heat dissipation shell body enclose the receiving cavity.
[0017] As an optional technical solution, a heat-conducting component is provided between the heat dissipation shell and the aluminum substrate.
[0018] An electric vehicle includes a vehicle body and a controller as described in any of the above embodiments, wherein the controller is mounted on the vehicle body.
[0019] The beneficial effects of this utility model are:
[0020] This invention provides a controller comprising a heat dissipation shell, an aluminum substrate, and power terminals. The heat dissipation shell has a receiving cavity and is made of stretched aluminum. The aluminum substrate is disposed within the receiving cavity. Two power terminals are provided, spaced apart along a first direction. Each power terminal includes a base and a conductive element. The base is disposed on the aluminum substrate, one end of the conductive element is connected to the aluminum substrate via a first fastener, and the other end of the conductive element is disposed on the base. By adopting a combined structure of stretched aluminum, aluminum substrate, and power terminals, costs can be effectively reduced. Furthermore, the power terminals employ a separate structure for the base and conductive element. The base can be injection molded, resulting in good dimensional consistency and suitability for mass production with low processing costs. The conductive element can be formed by stamping and bending, further reducing processing costs.
[0021] This utility model embodiment also provides an electric vehicle, including a vehicle body and the aforementioned controller. The controller is installed on the vehicle body. By setting up the controller, the processing cost of the electric vehicle is reduced. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of the controller provided in an embodiment of the present invention;
[0023] Figure 2 This is an exploded view of the controller provided in this embodiment of the utility model;
[0024] Figure 3 This is a schematic diagram of the power terminal provided in an embodiment of the present invention;
[0025] Figure 4 This is a schematic diagram of the first embodiment of the controller provided in this utility model, after the control board and the upper housing are hidden;
[0026] Figure 5 This is a schematic diagram of the second embodiment of the controller provided in this utility model, after the control board and the upper housing are hidden;
[0027] Figure 6 This is a schematic diagram of the structure of the first fastener and the insulating component involved in the embodiments of this utility model;
[0028] Figure 7 This is a schematic diagram of the controller provided in this embodiment of the present invention with the upper housing removed;
[0029] Figure 8 This is a schematic diagram of the structure of the heat dissipation shell provided in an embodiment of the present invention.
[0030] In the picture:
[0031] 1. Heat dissipation shell; 11. Heat dissipation shell body; 111. Third mounting hole; 12. Baffle; 121. Sixth mounting hole;
[0032] 2. Aluminum substrate; 21. Power transistor; 211. Upper bridge power transistor; 212. Lower bridge power transistor; 22. Current guide;
[0033] 3. Power terminal; 31. Base; 32. Conductive component; 321. First mounting hole;
[0034] 4. First fastener; 5. Insulating component; 6. Control board; 7. Support component; 8. Second fastener; 9. Upper housing;
[0035] 10. Signal connector; 20. Capacitor; 30. Signal terminal. Detailed Implementation
[0036] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0037] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0038] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0039] In the description of this utility model, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this utility model is in use. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," and "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.
[0040] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0041] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.
[0042] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.
[0043] The following is combined Figures 1-8 The technical solution of this utility model will be further illustrated through specific embodiments.
[0044] This utility model provides a controller, which includes a heat dissipation shell 1, an aluminum substrate 2, and power terminals 3. The heat dissipation shell 1 is made of stretched aluminum and has a receiving cavity. The aluminum substrate 2 is disposed within the receiving cavity. Two power terminals 3 are provided, spaced apart along a first direction. Each power terminal 3 includes a base 31 and three-phase conductive elements 32. The base 31 is disposed on the aluminum substrate 2, and the three-phase conductive elements 32 are spaced apart along a second direction. One end of each conductive element 32 is connected to the aluminum substrate 2 via a first fastener 4, and the other end is disposed on the base 31. The heat dissipation shell 1 in this controller is made of stretched aluminum, which has good strength and plasticity, and excellent heat dissipation performance. By adopting a combined structure of stretched aluminum, aluminum substrate 2, and power terminals 3, costs can be effectively reduced.
[0045] Furthermore, a heat-conducting component is provided between the heat dissipation housing 1 and the aluminum substrate 2. This component can quickly conduct heat, improving the controller's heat dissipation efficiency and ensuring stable operation. The heat-conducting component can be made of materials such as thermal grease or thermal gel; no specific limitations are specified here.
[0046] In this embodiment, two power terminals 3 are arranged opposite each other at both ends of the aluminum substrate 2 along a first direction. This arrangement facilitates the connection of the power terminals 3 to the outside world, thereby transmitting current. Furthermore, the base 31 of the power terminal 3 is made of plastic material and is formed by injection molding, resulting in good dimensional consistency and suitability for mass production, thus reducing processing costs. The conductive element 32 is made of copper, which has high conductivity, ensuring efficient and stable current transmission. Moreover, copper has relatively low processing costs, further reducing the production cost of the power terminal 3. The conductive element 32 is formed by stamping and bending, making processing convenient and cost-effective. The base 31 and the conductive element 32 are sealed together by adhesive dispensing, further achieving a sealed connection between them. Figures 3-4 as well as Figure 8 As shown, the conductive component 32 has a first mounting hole 321, the aluminum substrate 2 has a second mounting hole, and the heat dissipation shell 1 has a third mounting hole 111. The first fastener 4 connects the conductive component 32, the aluminum substrate 2, and the heat dissipation shell 1 through the first mounting hole 321, the second mounting hole, and the third mounting hole 111. Specifically, in this embodiment, the first fastener 4 is a first screw, and the third mounting hole 111 is a threaded hole. The first screw passes through the first mounting hole 321 and the second mounting hole and is screwed into the third mounting hole 111. This achieves the simultaneous pressing of the conductive component 32 onto the aluminum substrate 2 and fixing the aluminum substrate 2 onto the heat dissipation shell 1, thus fixing the three together and improving the reliability of the entire controller structure.
[0047] Furthermore, such as Figures 4 to 6 As shown, an insulating component 5 is provided between the conductive component 32 and the first fastener 4. In this embodiment, the insulating component 5 is an insulating gasket, which is disposed between the conductive component 32 and the first screw, realizing current transmission between the conductive component 32 and the aluminum substrate 2. In this embodiment, as... Figure 6 As shown, the size of the insulating member 5 is larger than the size of the first mounting hole 321. It should be noted that the aluminum substrate 2 has a second mounting hole, thus forming a restricted area around the second mounting hole. To avoid this restricted area, the first mounting hole 321 on the conductive member 32 needs to be larger, with its inner diameter greater than the diameter of the restricted area, to ensure electrical insulation. By setting the size of the insulating member 5 to be larger than the inner diameter of the first mounting hole 321, it is ensured that the first fastener 4 presses the insulating member 5 tightly onto the conductive member 32. Specifically, the insulating member 5 has a clamping portion and an insertion portion. The clamping portion is clamped between the head end of the first fastener 4 and the end face of the conductive member 32, and its size is larger than the inner diameter of the first mounting hole 321. The insertion portion is inserted into the first mounting hole 321 of the conductive member 32 and surrounds the first fastener 4.
[0048] In this embodiment, as Figure 4As shown, the insulating component corresponding to the conductive component 32 is independently provided. In other embodiments, such as Figure 5 As shown, the insulating component corresponding to the conductive component 32 can also be integrally formed.
[0049] Furthermore, such as Figure 4 As shown, a power transistor 21 and a three-phase current guide 22 are disposed on an aluminum substrate 2. The power transistor 21 includes an upper bridge power transistor 211 and a lower bridge power transistor 212, which are spaced apart along a first direction. The three-phase current guide 22 is spaced apart along a second direction. The current guide 22 is made of red copper. One end of the three-phase current guide 22 is disposed between the upper bridge power transistor 211 and the lower bridge power transistor 212, and the other end of the three-phase current guide 22 crosses the lower bridge power transistor and is electrically connected to the conductive part 32 of one of the power terminals 3. The other power terminal 3 is electrically connected to the aluminum substrate 2. Specifically, the upper bridge power transistor 211 and the lower bridge power transistor 212 are evenly arranged on the aluminum substrate 2 and located between the two power terminals 3. One end of the three-phase current guide 22 is located between the upper bridge power transistor 211 and the lower bridge power transistor 212. After the middle part of the three-phase current guide 22 crosses the lower bridge power transistor 212, the other end is electrically connected to the conductive part 32 of one of the power terminals 3. The current is conducted from the upper bridge power transistor 211 and the lower bridge power transistor 212 to the conductive part 32 through the current guide 22, so that the position of the power transistor 21 is not affected by the power terminals 3, and can be evenly distributed on the aluminum substrate 2, further improving the heat dissipation performance of the controller.
[0050] Optionally, the current guide 22 is made of copper, which has high conductivity, ensuring efficient and stable current transmission. Moreover, copper has relatively low processing costs, further reducing the production cost of the current guide 22.
[0051] In this embodiment, the power transistor 21 is welded to the aluminum substrate 2, which facilitates the welding process and makes the connection between the power transistor 21 and the aluminum substrate 2 firm and reliable.
[0052] In this embodiment, twelve power transistors 21 are provided, with each pair of power transistors 21 forming a group. Six upper-bridge power transistors 211 are divided into three groups, and six lower-bridge power transistors 212 are divided into three groups. The three groups of upper-bridge power transistors 211 and the three groups of lower-bridge power transistors 212 are arranged in a one-to-one correspondence to form a three-phase power supply. Correspondingly, three current guides 22 are provided, each positioned between an upper-bridge power transistor 211 and a lower-bridge power transistor 212. Three conductive elements 32 are provided in each of the two power terminals 3. One end of each conductive element 32 is spaced apart on the base 31. The other end of each conductive element 32 in one power terminal 3 is electrically connected to a current guide 22, and this end of the power terminal 3 is connected to the motor for motor control. The other end of each conductive element 32 in the other power terminal 3 is electrically connected to the aluminum substrate 2, and this end of the power terminal 3 is connected to the battery to provide the necessary power for the electric vehicle. The number of power transistors 21 can also be six, eighteen, etc., depending on the application requirements; no specific limitation is made here.
[0053] Furthermore, such as Figure 2 and Figure 7 As shown, the controller also includes a control board 6. A support member 7 is provided on the aluminum substrate 2. The control board 6 is disposed on the support member 7 and located above the aluminum substrate 2, and the control board 6 is electrically connected to the aluminum substrate 2. Specifically, the support member 7 is provided on the aluminum substrate 2, the control board 6 is provided with a fourth mounting hole, the support member 7 is provided with a first threaded hole, and a second fastener 8 passes through the fourth mounting hole and is screwed into the first threaded hole to connect the control board 6 to the aluminum substrate 2. In this embodiment, the support member 7 is a support column with a first threaded hole. The second fastener 8 is a second screw. The second screw passes through the fourth mounting hole and is screwed into the first threaded hole on the support member 7, locking the control board 6 onto the support column. This achieves a fixed connection between the control board 6 and the aluminum substrate 2, while also enabling current transmission between the control board 6 and the aluminum substrate 2 through the support column. A signal connector 10 is provided on the aluminum substrate 2 to realize signal transmission between the aluminum substrate 2 and the control board 6. The control board 6 is also equipped with control devices, such as capacitor 20, signal terminals and other electronic devices, so as to control the operating status of the controller.
[0054] Furthermore, such as Figure 8As shown, the heat dissipation housing 1 includes a heat dissipation housing body 11 and two baffles 12. The two baffles 12 are disposed opposite each other on both sides of the heat dissipation housing body 11, forming a receiving cavity with the heat dissipation housing body 11. A fifth mounting hole is provided on the baffle 12, and a second threaded hole is provided on the heat dissipation housing body 11. A third screw passes through the fifth mounting hole and is screwed into the second threaded hole to achieve a fixed connection between the baffle 12 and the heat dissipation housing body 11, thereby accommodating the aluminum substrate 2 and the control board 6 in the receiving cavity. A sealant is provided at the connection between the baffle 12 and the heat dissipation housing body 11 to further improve the sealing performance at the connection between the baffle 12 and the heat dissipation housing body 11. The controller can be connected to the vehicle body through the baffle 12. In this embodiment, the baffle 12 includes a connecting part and an extension part. The connecting part is connected to the heat dissipation housing body 11, and the extension part is disposed on one side of the connecting part. A plurality of sixth mounting holes 121 are provided at intervals on the extension part, and the controller can be connected to the vehicle body through the plurality of sixth mounting holes 121. Optionally, the sixth mounting hole 121 is a strip hole, and the extension direction of the strip hole is consistent with the extension direction of the baffle 12. This setting facilitates the installation of the controller.
[0055] Furthermore, the controller also includes an upper housing 9, which is mounted on the heat dissipation housing 1 and snaps into it. Specifically, the heat dissipation housing body 11 has a slot, and the upper housing 9 has a buckle. Pressing the buckle into the slot connects the upper housing 9 to the heat dissipation housing body 11, and applying adhesive at the connection point to further improve the sealing performance. The upper housing 9 effectively prevents dust and moisture from entering the controller, thus extending its service life.
[0056] Alternatively, the upper housing can be made of plastic, which is lightweight and can reduce the overall weight of the controller.
[0057] This utility model embodiment also provides an electric vehicle, including a vehicle body and the aforementioned controller. The controller is mounted on the vehicle body via a baffle 12. By setting up the controller, the processing cost of the electric vehicle is reduced.
[0058] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.
Claims
1. A controller characterized by, The application relates to a controller, which comprises the following parts: a heat-dissipating shell (1) provided with a containing cavity, wherein the heat-dissipating shell (1) is made of stretched aluminum; an aluminum base plate (2) arranged in the containing cavity; two power terminals (3) arranged at intervals along a first direction, wherein each power terminal (3) comprises a base (31) arranged on the aluminum base plate (2) and a conductive piece (32) having one end connected to the aluminum base plate (2) through a first fastener (4) and the other end arranged on the base (31).
2. The controller of claim 1, wherein, The aluminum base plate (2) is provided with power tubes (21) and a flow guide piece (22), wherein the power tubes (21) comprise upper bridge power tubes (211) and lower bridge power tubes (212), the upper bridge power tubes (211) and the lower bridge power tubes (212) are arranged at intervals along the first direction, the flow guide piece (22) is made of red copper, one end of the flow guide piece (22) is arranged between the upper bridge power tubes (211) and the lower bridge power tubes (212), the other end of the flow guide piece (22) crosses the lower bridge power tubes (212) and is electrically connected to the conductive piece (32) of one of the power terminals (3), and the other power terminal (3) is electrically connected to the aluminum base plate (2).
3. The controller of claim 1, wherein, The conductive piece (32) is provided with a first mounting hole (321), the aluminum base plate (2) is provided with a second mounting hole, and the heat-dissipating shell (1) is provided with a third mounting hole (111); the first fastener (4) connects the conductive piece (32), the aluminum base plate (2) and the heat-dissipating shell (1) through the first mounting hole (321), the second mounting hole and the third mounting hole (111).
4. The controller of claim 3, wherein, An insulating piece (5) is arranged between the conductive piece (32) and the first fastener (4).
5. The controller of claim 4, wherein, The size of the insulating piece (5) is larger than the inner diameter of the first mounting hole (321).
6. The controller of claim 4, wherein, The conductive piece (32) is a three-phase conductive piece (32), and the corresponding insulating pieces (5) are independently arranged or integrally arranged.
7. The controller of any one of claims 1-6, wherein, The controller further comprises a control board (6), the aluminum base plate (2) is provided with a supporting piece (7), the control board (6) is arranged on the supporting piece (7) and above the aluminum base plate (2), and the control board (6) is electrically connected to the aluminum base plate (2).
8. The controller of any one of claims 1-6, wherein, The heat-dissipating shell (1) comprises a heat-dissipating shell body (11) and two baffles (12) oppositely arranged on the two sides of the heat-dissipating shell body (11), and the two baffles (12) and the heat-dissipating shell body (11) form the containing cavity.
9. The controller of any one of claims 1-6, wherein, A heat-conducting piece is arranged between the heat-dissipating shell (1) and the aluminum base plate (2).
10. An electric vehicle, characterized by The application further relates to a vehicle body provided with the controller.