Electromagnetic shielding engine ECU case

Abstract

The utility model relates to the field of aero-engines, in particular to an electromagnetic shielding engine ECU case which comprises a case body installed on an engine, an equipment cavity used for containing a starting motor driving module, a fuel pump driving module and an engine controller is formed in the case body, and the equipment cavity is open upwards. The upper part of the box body is provided with a box cover for sealing the upper part opening of the equipment cavity, the box body is made of a metal material or a non-metal material, the inner wall of the box body is sprayed with a shielding coating, the upper side of the box cover is provided with radiating fins, and the box cover and the shielding coating jointly define the equipment cavity capable of shielding electromagnetism; the bottom plate is in a sector ring shape smaller than a half of a circular ring, the upper side of the bottom plate is provided with an outer ring plate and an inner ring plate, the outer ring plate and the inner ring plate are spaced front and back, the upper side of the bottom plate is further provided with an end plate, external wiring harnesses and independent modules are eliminated, the size of an air inlet casing is reduced, the overall compactness of an engine is improved, and the engine case is suitable for engine working conditions with high vibration and strong electromagnetic interference.

Description

Technical Field

[0001] This utility model relates to the field of aero-engines, specifically to an electromagnetically shielded engine ECU chassis. Background Technology

[0002] Traditional small aircraft turbojet engine control systems generally adopt a distributed architecture, which has the following drawbacks: large space occupation, with the starter motor, fuel pump drive module and controller installed independently and connected by wiring harnesses, resulting in a complex layout around the intake casing and an increase in external parts (such as electronic speed governors, sensors, etc.), occupying limited space in the engine nacelle; low heat dissipation efficiency, with the electronic control unit (ECU) relying on active cooling (low-temperature airflow during flight), which not only increases weight and energy consumption, but is also prone to system failure due to insufficient heat dissipation in high-temperature environments; and the need for precise docking of multiple modules due to their dispersed installation leads to complex assembly and maintenance, increasing assembly difficulty and failure risk, and often requiring the disassembly of multiple components during maintenance, resulting in high maintenance costs, which need to be improved. Utility Model Content

[0003] The purpose of this invention is to provide an electromagnetically shielded engine ECU housing to address the above problems, thereby solving the issues of existing engine control systems occupying limited space in the engine compartment, having many external parts, and relying on active cooling.

[0004] To achieve the above objectives, this utility model discloses an electromagnetically shielded engine ECU housing, characterized by the following features: a housing mounted on the engine, the housing being fan-shaped, containing a device cavity for accommodating a starter motor drive module, a fuel pump drive module, and an engine controller, the device cavity being open upwards, and a cover sealing the upper opening of the device cavity installed on the top of the housing, the housing being made of metal or non-metal materials, and the inner wall of the housing being coated with a shielding coating, and heat dissipation fins on the upper side of the cover, the cover and the shielding coating together forming a device cavity capable of shielding electromagnetic fields.

[0005] The motor drive module, fuel pump drive module, and engine controller are installed within the chassis, resulting in a more compact, integrated, and smaller engine accessory package that is easier to disassemble and maintain. The chassis is 3D printed. While 3D-printed non-metallic chassis do not offer superior electromagnetic shielding, their processing cycle is short, typically only a few hours. Furthermore, 3D printing technology is highly automated, eliminating traditional machining processes such as tool setting and clamping, thus reducing costs and ensuring better product consistency. The metal chassis cover not only enhances heat dissipation but, combined with the internal shielding coating, achieves excellent shielding. Different shielding effects can be achieved by adjusting the type and thickness of the coating material.

[0006] The housing includes a base plate, which is a fan-shaped annulus less than half the length of a circle. An outer ring plate and an inner ring plate are located on the upper side of the base plate, spaced apart front to back. Two end plates are also located on the upper side of the base plate, spaced apart laterally. These two end plates connect to the outer and inner ring plates. The outer ring plate, inner ring plate, and two end plates together form an upward-opening housing. The overall fan-shaped housing design ensures sufficient space for the starter motor drive module, fuel pump drive module, and engine controller while conforming to the existing engine's spatial layout.

[0007] The side of the enclosure has a first slot located at the top, where an assembly nut is installed. A second screw hole is located on the top of the enclosure, extending into the first slot. The cover also has a first screw hole, with the first and second screw holes positioned vertically. A screw, passing through both the first and second screw holes and threaded into the assembly nut, is installed on the cover. The cover is installed on the top of the enclosure, and then the first screw holes are installed, sequentially passing through the first and second screw holes. Finally, the first screw is tightened onto the assembly nut, ensuring the integrity of the electromagnetic shielding within the equipment cavity. Furthermore, compared to designs that directly tap the second screw hole, the nut in this design is replaceable; if the threads are damaged, the assembly nut can be directly replaced.

[0008] There are six slots in total. Two slots are provided on each of the two end plates, and one slot is provided on each of the outer and inner ring plates. Each slot has a corresponding assembly nut, a second screw hole, a first screw hole, and a screw. By setting up six sets of screws and nuts to work together, and distributing the six sets of screws and nuts, the stability of the connection between the box body and the box cover is ensured.

[0009] The bottom of the base plate has a second slot that extends upwards and into the end plate. A positioning nut for connecting the engine is installed in the second slot. The end plate has a positioning hole that extends into the second slot. The engine has a corresponding connecting hole. Bolts pass through the connecting hole and the positioning hole and then engage with the positioning nut threadedly, thereby mounting the housing onto the engine.

[0010] A plug is provided on the lower side of the cover, and a positioning groove is provided in the equipment cavity. The shape and size of the positioning groove match the plug. The positioning groove is located at the upper edge of the equipment cavity, and the plug is inserted into the positioning groove. The plug is shaped like a boss, and the plug and positioning groove are inserted to reduce the connection gap between the box body and the cover, thus blocking the electromagnetic wave leakage path.

[0011] The end plate has a wiring harness hole, and a wiring harness nut is fixedly installed on the end plate. The wiring harness nut is located in front of the wiring harness hole, and a waterproof gland is threaded onto the wiring harness nut. The connection lines of the starter motor drive module, fuel pump drive module, and engine controller pass through the wiring harness hole and connect to the engine. The waterproof gland protects the wiring harness from corrosion by dust, oil, or water.

[0012] The chassis is manufactured using 3D printing, with the base plate, outer ring plate, inner ring plate, and end plates forming a single integrated structure. FDM or DIW materials can be selected for 3D printing. 3D printing is a material extrusion additive manufacturing process that can directly print complex chassis structures, eliminating the need for mold development and shortening the manufacturing cycle to several hours to several days. Layered manufacturing characteristics support the integrated generation of cavities, slots, and internal support structures, reducing assembly gaps and mitigating the risk of electromagnetic leakage from the outset.

[0013] The cover is shaped like a fan ring that matches the housing. Multiple cooling fins extend radially along the fan ring, arranged in a fan-ring pattern. The densely packed cooling fins on the cover increase the heat dissipation surface area. Combined with airflow within the housing, this ensures stable core temperature of the ECU under high-temperature conditions, preventing the risk of overheating and shutdown.

[0014] The shielding coating can be a silver / copper-nickel composite coating or a graphene-doped polymer. Graphene-doped polymers are polymers of graphene dopants. The shielding coating can form a continuous metallized shielding layer. The spraying process is adaptable to complex geometric surfaces, covers the gaps between printed layers, and improves the overall shielding effectiveness. At the same time, a high-frequency shielding effect of >60dB can be achieved by adjusting the coating composition, compensating for the low conductivity of non-metallic substrates.

[0015] In summary, the beneficial effects of this utility model are as follows: The motor drive module, fuel pump drive module, and engine controller are installed within the chassis, protected by a single housing, eliminating external wiring harnesses and independent modules, reducing the intake casing volume, and improving the overall compactness of the engine. The metal chassis cover not only enhances heat dissipation, but also, in conjunction with the internal shielding coating, achieves excellent shielding. Furthermore, different shielding effects can be achieved by adjusting the type and thickness of the coating material. This optimizes electromagnetic compatibility, environmental protection, and thermal management within a limited space, making it particularly suitable for engine operating conditions characterized by high vibration and strong electromagnetic interference. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the exploded structure of this utility model;

[0018] Figure 3 This is a disassembled structural diagram of the box body and lid;

[0019] Figure 4 This is a cross-sectional structural diagram of the box body and the box lid;

[0020] Figure 5 This is a schematic diagram of the mating structure of the positioning nut and the second slot;

[0021] Figure 6 This is a schematic diagram of the chassis in its assembled state.

[0022] In the diagram: 1. Box body; 2. Box cover; 3. Waterproof gland; 4. Wire harness nut; 5. Screw; 6. Assembly nut; 7. Positioning nut; 8. Shielding coating; 9. Equipment cavity; 10. Plug; 11. Positioning groove; 12. Heat dissipation fins; 13. First slot; 14. Second slot; 15. First screw hole; 16. Second screw hole; 17. Inner ring plate; 18. Outer ring plate; 19. End plate; 20. Base plate; 21. Positioning hole; 22. Wire harness hole. Detailed Implementation

[0023] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0024] The following is a description of preferred embodiments of the present invention in conjunction with the accompanying drawings.

[0025] An electromagnetically shielded engine ECU housing includes a housing 1 mounted on the engine. The housing 1 is fan-shaped and contains a cavity 9 for accommodating a starter motor drive module, a fuel pump drive module, and an engine controller. The cavity 9 is open upwards. A cover 2 is installed on the upper part of the housing 1 to close the upper opening of the cavity 9. The housing 1 is made of metal or non-metal, and its inner wall is coated with a shielding coating 8. Heat dissipation fins 12 are provided on the upper side of the cover 2. The cover 2 and the shielding coating 8 together form the cavity 9, which is capable of shielding electromagnetic fields. (See attached diagram.) Figure 1 The enclosure 1 is made using 3D printing. While 3D-printed non-metallic materials do not offer superior electromagnetic shielding, they boast a shorter processing cycle, typically only a few hours. Furthermore, 3D printing technology is highly automated, eliminating traditional machining processes such as tool setting and clamping, resulting in lower costs and better product consistency. The metal enclosure cover 2 not only enhances heat dissipation but, in conjunction with the shielding coating 8 inside the enclosure 1, achieves excellent shielding. Moreover, different shielding effects can be achieved by adjusting the type and thickness of the coating material.

[0026] See attached document Figure 2 The housing 1 includes a base plate 20, which is a fan-shaped ring less than half the length of a circle, as shown in the attached diagram. Figure 3The upper side of the base plate 20 is provided with an outer ring plate 18 and an inner ring plate 17, which are spaced apart front to back. The upper side of the base plate 20 is also provided with end plates 19, two of which are spaced apart left to right. The two end plates 19 are connected to the outer ring plate 18 and the inner ring plate 17. The outer ring plate 18, the inner ring plate 17, and the two end plates 19 together form an upwardly open box 1. The box 1 is fan-shaped, which ensures that it can accommodate the starter motor drive module, the fuel pump drive module, and the engine controller while conforming to the existing engine space layout.

[0027] See attached document Figure 3 The side of the housing 1 has a first slot 13, which is located at the top of the housing 1. An assembly nut 6 is installed in the first slot 13. A second screw hole 16 is provided on the upper side of the housing 1, which extends into the first slot 13. The cover 2 has a first screw hole 15, which is vertically aligned with the second screw hole 16. A screw 5 is installed on the cover 2, which passes through the first screw hole 15 and the second screw hole 16 and is threaded into the assembly nut 6. The cover 2 is installed on the upper side of the housing 1, and then the first screw hole 15 is installed, so that the first screw hole 15 passes through the first screw hole 15 and the second screw hole 16 in sequence. The first screw hole 15 is then tightened onto the assembly nut 6 to ensure the integrity of the electromagnetic shielding inside the equipment cavity 9. There are six first slots 13: two on each of the two end plates 19, and one on each of the outer ring plate 18 and inner ring plate 17. Each first slot 13 has a corresponding assembly nut 6, a second screw hole 16, a first screw hole 15, and a screw 5. By setting six sets of screws 5 and nuts to cooperate, the stability of the connection between the box body 1 and the box cover 2 is ensured.

[0028] See attached document Figure 5 The bottom of the base plate 20 has a second slot 14 that extends upward and into the end plate 19. A positioning nut 7 for connecting the engine is installed in the second slot 14. The end plate 19 has a positioning hole 21 that extends into the second slot 14. The engine has a corresponding connecting hole 21. Bolts pass through the connecting hole and the positioning hole 21 and then engage with the positioning nut 7 through threads, thereby mounting the housing 1 onto the engine.

[0029] See attached document Figure 3 A plug 10 is provided on the lower side of the cover 2, and a positioning groove 11 is provided in the equipment cavity 9. The shape and size of the positioning groove 11 match the plug 10. The positioning groove 11 is located at the upper edge of the equipment cavity 9, and the plug 10 is inserted into the positioning groove 11. The plug 10 is in the shape of a boss, and the plug 10 and the positioning groove 11 are inserted and matched to reduce the connection gap between the box body 1 and the cover 2, thus blocking the electromagnetic wave leakage path.

[0030] The end plate 19 has a wiring harness hole 22, and a wiring harness nut 4 is fixedly installed on the end plate 19. The wiring harness nut 4 is located in front of the wiring harness hole 22, and a waterproof gland 3 is threaded onto the wiring harness nut 4. The connection lines of the starter motor drive module, the fuel pump drive module and the engine controller pass through the wiring harness hole 22 and are connected to the engine. The waterproof gland 3 can protect the wiring harness from corrosion by dust, oil stains or water stains.

[0031] The chassis 1 is manufactured using 3D printing. The base plate 20, outer ring plate 18, inner ring plate 17, and end plate 19 are a single integrated structure. FDM or DIW can be selected as the 3D printing material. 3D printing is a material extrusion additive manufacturing process that can directly print complex chassis structures, eliminating the mold development stage and shortening the manufacturing cycle to several hours to several days. Layered manufacturing characteristics support the integrated generation of cavities, slots, and internal support structures, reducing assembly gaps and mitigating the risk of electromagnetic leakage from the outset. (See attached diagram.) Figure 6 The cover 2 is shaped like a fan ring matching the body 1. Multiple heat dissipation fins 12 extend radially along the fan ring and are arranged in a fan-ring pattern. The densely packed heat dissipation fins 12 on the cover 2 achieve efficient heat exchange through natural convection of the low-temperature airflow within the chamber, eliminating the need for additional cooling devices, reducing system weight, and lowering energy consumption. (See attached diagram.) Figure 4 The shielding coating 8 is a composite coating such as silver / copper-nickel or graphene-doped polymer. The graphene-doped polymer is a polymer of graphene dopants. The shielding coating 8 can form a continuous metallized shielding layer. The spraying process is adapted to complex geometric surfaces, covers the gaps between printed layers, and improves the overall shielding effectiveness. At the same time, the high-frequency shielding effect of >60dB can be achieved by adjusting the coating composition, which can compensate for the low conductivity of non-metallic substrates.

[0032] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and substitutions can be made without departing from the technical principles of the present utility model, and these improvements and substitutions should also be considered within the protection scope of the present utility model.

Claims

1. An electromagnetically shielded engine ECU housing, comprising a housing (1) mounted on an engine, characterized in that, The housing (1) is fan-shaped. The housing (1) has a device cavity (9) for accommodating the starter motor drive module, the fuel pump drive module and the engine controller. The device cavity (9) is open to the top. The upper part of the housing (1) is fitted with a cover (2) that closes the upper opening of the device cavity (9). The housing (1) is made of metal or non-metal and the inner wall of the housing (1) is coated with a shielding coating (8). The cover (2) is made of metal and has heat dissipation fins (12) on the upper side. The cover (2) and the shielding coating (8) together form a device cavity (9) that can shield electromagnetic fields.

2. The electromagnetically shielded engine ECU chassis as described in claim 1, characterized in that, The box (1) includes a bottom plate (20), which is a fan-shaped ring less than half the size of a circle. The bottom plate (20) has an outer ring plate (18) and an inner ring plate (17) on its upper side. The outer ring plate (18) and the inner ring plate (17) are spaced apart front and back. The bottom plate (20) also has an end plate (19) on its upper side. There are two end plates (19), which are spaced apart left and right. The two end plates (19) are connected to the outer ring plate (18) and the inner ring plate (17). The outer ring plate (18), the inner ring plate (17) and the two end plates (19) together form an upward-opening box (1).

3. The electromagnetically shielded engine ECU chassis as described in claim 2, characterized in that, The side of the box (1) is provided with a first slot (13), which is located at the top of the box (1). An assembly nut (6) is installed in the first slot (13). A second screw hole (16) is provided on the upper side of the box (1). The second screw hole (16) extends into the first slot (13). A first screw hole (15) is provided on the box cover (2). The positions of the first screw hole (15) and the second screw hole (16) are corresponding vertically. A screw (5) is installed on the box cover (2) that passes through the first screw hole (15) and the second screw hole (16) and is threadedly engaged with the assembly nut (6).

4. The electromagnetically shielded engine ECU chassis as described in claim 3, characterized in that, The first slot (13) is provided in six places. Two first slots (13) are provided on each of the two end plates (19). The two first slots (13) on the end plates (19) are spaced apart from each other and located on the upper part of the end plates (19). A first slot (13) is provided on the upper part of the middle part of the outer ring plate (18) and a first slot (13) is provided on the upper part of the middle part of the inner ring plate (17).

5. The electromagnetically shielded engine ECU chassis as described in claim 2, characterized in that, The bottom of the base plate (20) is provided with a second slot (14), which extends upward and into the end plate (19). A positioning nut (7) for connecting the engine is installed in the second slot (14). A positioning hole (21) is provided on the end plate (19), which extends into the second slot (14).

6. The electromagnetically shielded engine ECU chassis as described in claim 1, characterized in that, The lower side of the cover (2) is provided with a plug (10), and the equipment cavity (9) is provided with a positioning groove (11). The shape and size of the positioning groove (11) match the plug (10). The positioning groove (11) is located at the upper edge of the equipment cavity (9), and the plug (10) is inserted into the positioning groove (11).

7. The electromagnetically shielded engine ECU chassis as described in claim 2, characterized in that, The end plate (19) has a wire harness hole (22) and a wire harness nut (4) is fixedly installed on the end plate (19). The wire harness nut (4) is located in front of the wire harness hole (22) and a waterproof gland (3) is threaded onto the wire harness nut (4).

8. The electromagnetically shielded engine ECU chassis as described in claim 2, characterized in that, The box body (1) is made by 3D printing, and the bottom plate (20), outer ring plate (18), inner ring plate (17) and end plate (19) are an integral structure.

9. The electromagnetically shielded engine ECU chassis as described in claim 2, characterized in that, The cover (2) is in the shape of a fan ring that matches the body (1). The heat dissipation fins (12) extend radially along the fan ring. There are multiple heat dissipation fins (12), and the multiple heat dissipation fins (12) are arranged in a fan ring shape at intervals.

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