An electrically controlled power device in which a motor and a controller are coaxially integrated

Abstract

This invention provides an electrically controlled power device with a motor and controller coaxially integrated, including a motor and an ECU assembly integrated on the motor. The motor includes a motor end, and the ECU assembly includes a drive PCB board, a support base, a main control PCB board, a power supply PCB board, and a connector assembly. The drive PCB board is mounted parallel to the motor end, the connector assembly is mounted parallel to the power supply PCB board, the main control PCB board is mounted parallel to the power supply PCB board, and the main control PCB board is mounted parallel to the drive PCB board. The support base is installed between the drive PCB board and the main control PCB board. The axes of the connector assembly, the power supply PCB board, the main control PCB board, the support base, and the drive PCB board are coaxial with the motor. This invention solves the problems of low space utilization, poor product versatility, poor electromagnetic compatibility (EMC) performance, and high installation cost.

Description

Technical Field

[0001] This utility model relates to the field of automotive electronic controller technology, and in particular to an electric power device in which the motor and controller are coaxially integrated. Background Technology

[0002] As automobiles enter the era of intelligentization, the requirements for the integration and spatial structure of automotive components are becoming increasingly stringent. Under current technology, the integration of motors and controllers mainly takes the following forms:

[0003] 1. The ECU (Electronic Control Unit / Controller) assembly is integrated on the side of the motor assembly, with the PCB board parallel to the motor axis and the connector assembly located at the tail of the motor.

[0004] 2. The ECU assembly is integrated at the rear of the motor assembly, the PCB board is coaxial with the motor, and the connector components protrude from the side of the motor.

[0005] 3. The ECU assembly and the motor assembly are coaxial. The PCB board inside the ECU is arranged perpendicular to the motor, and the control, power supply and drive are integrated on one board.

[0006] 4. The ECU assembly and the motor assembly are coaxial, with the PCB board arranged in sections and connected by PIN soldering.

[0007] The integration methods described above, particularly the first and second types, employ non-coaxial integration of the motor and controller, or screw-fastened integration. These methods result in a large space occupied by the controller in the radial or axial direction of the motor, leaving very little layout space for the product in the overall vehicle steering layout. This makes product placement on the main unit difficult, significantly impacting product development efficiency and, in severe cases, even preventing project implementation. Inefficient use of product space prevents the product from achieving multi-project versatility, leading to increased costs in product development, manufacturing, and management.

[0008] The third approach integrates all controller functions onto a single PCB board, resulting in poor module versatility and higher PCB board development and repair costs. Furthermore, the power supply and drive modules interfere with the control module, leading to poor EMC performance.

[0009] The fourth method involves soldering the pins between PCB boards. This method has high installation costs and low production efficiency. The soldering process can generate thermal stress on the circuit board, which can damage the circuit board. Furthermore, the soldering process is prone to problems such as short circuits and poor soldering, resulting in low reliability.

[0010] In addition, existing technologies also have drawbacks such as poor heat dissipation and poor waterproofing and dustproofing. Utility Model Content

[0011] This utility model provides an electric control power device with a motor and controller coaxially integrated, which solves the technical problem that the space size of the electric control power device in the prior art is not fully utilized, and it cannot be generalized to multiple projects, which leads to increased development, manufacturing and management costs.

[0012] One aspect of this utility model is to provide an electronically controlled power device with a motor and a controller coaxially integrated, the electronically controlled power device including a motor and an ECU assembly integrated on the motor;

[0013] The motor includes a motor end, and the ECU assembly includes a drive PCB board, a support base, a main control PCB board, a power supply PCB board, and a plug-in assembly.

[0014] The drive PCB board is mounted parallel to the motor end, the plug-in assembly is mounted parallel to the power supply PCB board, the main control PCB board is mounted parallel to the power supply PCB board, the main control PCB board is mounted parallel to the drive PCB board, and the support base is mounted between the drive PCB board and the main control PCB board.

[0015] The axes of the plug-in assembly, the power PCB board, the main control PCB board, the support base, and the drive PCB board are coaxial with the motor.

[0016] In a preferred embodiment, a first socket is formed on the drive PCB board, a phase wire connector is installed in the first socket, a phase wire extends from the end of the motor, and the phase wire connector contacts the phase wire.

[0017] In a preferred embodiment, a second socket is formed on the drive PCB board, and a first power connector is installed in the second socket. A third socket is formed on the power PCB board, and a second power connector is installed in the third socket. The first power connector is in contact with the second power connector.

[0018] In a preferred embodiment, a header is installed between the driving PCB board and the main control PCB board;

[0019] The pin header includes a top fisheye pin and a bottom fisheye pin. A fourth socket is provided on the driver PCB board, and a fifth socket is provided on the main control PCB board. The top fisheye pin is inserted into the fifth socket, and the bottom fisheye pin is inserted into the fourth socket.

[0020] In a preferred embodiment, the connector assembly is equipped with signal pins and power pins;

[0021] A sixth socket is provided on the main control PCB board, and a seventh socket is provided on the power supply PCB board. The signal pin is inserted into the sixth socket, and the power supply pin is inserted into the seventh socket.

[0022] In a preferred embodiment, the signal PIN pin is a fisheye pin.

[0023] In a preferred embodiment, the ECU assembly further includes a cover with a fastening ring, and a boss is provided at the end of the motor, with the fastening ring engaging with the boss.

[0024] In a preferred embodiment, the cover is further provided with an annular sealing strip, and the motor end is further provided with an annular groove, the annular sealing strip being embedded in the annular groove.

[0025] In a preferred embodiment, the support base is made of aluminum ADC12 material, and the support base includes:

[0026] A first mounting surface that contacts the main control PCB board and a second mounting surface that contacts the drive PCB board are coated with thermal adhesive.

[0027] In a preferred embodiment, the motor end is made of aluminum ADC12 material, and the end face of the motor end where the drive PCB board is mounted is coated with thermal adhesive.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] This utility model provides an electric power device with a motor and controller coaxially integrated, which makes full use of axial and radial space, greatly reduces the axial height of the product, makes it easier to arrange the overall machine scheme, improves the project completion rate and development efficiency, and also improves the versatility of the product in different projects, and reduces the product development, manufacturing and management costs.

[0030] This utility model provides an electric control power device with a motor and controller coaxially integrated. The PCB partitioning layout of the ECU assembly reduces the difficulty of design iteration and platform borrowing, production rework and material management, improves the EMC performance of the product, and makes the system more stable, safe and reliable.

[0031] This utility model provides an electric power device with a motor and controller coaxially integrated, which improves the heat dissipation performance of the product, allows the system performance to be fully utilized, and reduces the requirements and costs of components.

[0032] This utility model provides an electric power device with a motor and controller coaxially integrated, which improves the sealing performance of the product, gives the product good waterproof and dustproof capabilities, allows the system to meet the needs of use under some special working conditions, and expands the application range of the product.

[0033] This utility model provides an electric control power device with a motor and controller coaxially integrated, which improves the assembly efficiency of the product. The assembly of the PCB board inside the ECU assembly adopts the fisheye PIN press-fit method, which makes the product assembly cost low, efficient and reliable, and has a certain degree of versatility.

[0034] This utility model provides an electric power device with a motor and controller coaxially integrated, which solves the problems of low space utilization, poor product versatility, poor electromagnetic compatibility (EMC) performance, and high installation cost. Attached Figure Description

[0035] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the overall structure of an electric power device in which the motor and controller are coaxially integrated.

[0037] Figure 2 This is a schematic diagram of the structure of the ECU assembly of this utility model, in which the cover is separated from the electronically controlled power unit.

[0038] Figure 3 This is an exploded view from one perspective of an electric power device that integrates a motor and a controller coaxially according to this utility model.

[0039] Figure 4 This is an exploded view from another perspective of the electric power device that integrates a motor and a controller coaxially according to this utility model.

[0040] Figure 5 This is a schematic diagram of the structure of the plug-in assembly of this utility model.

[0041] Figure 6 This is a schematic diagram of the structure of the pin header of this utility model. Detailed Implementation

[0042] To make the above and other features and advantages of this utility model clearer, the utility model will be further described below with reference to the accompanying drawings. It should be understood that the specific embodiments given herein are for the purpose of explanation to those skilled in the art, and are exemplary only, not restrictive.

[0043] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0044] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0045] Combination Figures 1 to 6 According to an embodiment of the present invention, an electric power device with a motor and controller coaxially integrated is provided, including a motor 1 and an ECU assembly 2 integrated on the motor 1.

[0046] Motor 1 includes motor end 101. ECU assembly 2 includes cover 201, drive PCB board 202, support base 203, main control PCB board 204, power supply PCB board 205, and plug-in assembly 206.

[0047] The drive PCB board 202 is mounted parallel to the motor end 101. Specifically, the drive PCB board 202 is parallel to the end face of the motor end 101 and fits against the end face of the motor end 101. The drive PCB board 202 is mounted on the motor end 101 by the first bolt 3.

[0048] A first socket 2023 is opened on the drive PCB board 202. A phase wire connector 209 is installed in the first socket 2023. The end face of the motor end 101 extends out of the phase wire 1011, and the phase wire connector 209 contacts the phase wire 1011.

[0049] Furthermore, the motor end 101 is made of aluminum ADC12 material, and the end face of the motor end 101 on which the drive PCB board 202 is mounted is coated with thermal adhesive.

[0050] According to an embodiment of this utility model, the plug-in assembly 206 is installed parallel to the power PCB board 205. Specifically, the power PCB board 205 has a first mounting hole 2052, the plug-in assembly 206 has a first mounting post 2063, and a screw hole is formed on the first mounting post 2063. A second bolt 4 is inserted into the first mounting hole 2052 and screwed into the screw hole of the first mounting post 2063, thereby mounting the power PCB board 205 on the plug-in assembly 206 and making the plug-in assembly 206 parallel to the power PCB board 205.

[0051] According to an embodiment of the present invention, the main control PCB board 204 and the power supply PCB board 205 are installed in parallel, the main control PCB board 204 and the drive PCB board 202 are installed in parallel, and the support base 203 is installed between the drive PCB board 202 and the main control PCB board 204.

[0052] Specifically, the support base 203 includes a first mounting surface 2031 that contacts the main control PCB board 204, and a second mounting surface 2032 that contacts the drive PCB board 202. The main control PCB board 204 is attached to the first mounting surface 2031 of the support base 203, and the drive PCB board 202 is attached to the second mounting surface 2032 of the support base 203. The side of the main control PCB board 204 away from the support base 203 is attached to the power supply PCB board 205.

[0053] A second mounting hole 2064 is provided on the plug-in assembly 206, a third mounting hole 2044 is provided on the main control PCB board 204, a fourth mounting hole 2034 is provided on the support base 203, and a second mounting post 1013 is provided on the end face of the motor end 101, with screw holes provided on the second mounting post 1013. By inserting the third bolt 5 sequentially into the second mounting hole 2064, the third mounting hole 2044, the fourth mounting hole 2034, and the screw holes of the second mounting post 1013, the main control PCB board 204 and the power supply PCB board 205 are installed in parallel, and the main control PCB board 204 and the drive PCB board 202 are installed in parallel. The support base 203 is installed between the drive PCB board 202 and the main control PCB board 204.

[0054] Furthermore, the support base 203 is made of aluminum ADC12 material, and the first mounting surface 2031 and the second mounting surface 2032 are coated with heat dissipation adhesive.

[0055] According to an embodiment of this utility model, the plug-in component 206 is installed in parallel with the power PCB board 205, the main control PCB board 204 is installed in parallel with the power PCB board 205, the main control PCB board 204 is installed in parallel with the drive PCB board 202, the support base 203 is installed between the drive PCB board 202 and the main control PCB board 204, and the drive PCB board 202 is installed in parallel with the motor end 101. The axes of the plug-in component 206, the power PCB board 205, the main control PCB board 204, the support base 203, and the drive PCB board 202 are coaxial with the motor 1.

[0056] Furthermore, a limiting groove 2033 is provided on the support base 203, a first limiting post 2062 is provided on the plug-in assembly 206, and a second limiting post 1012 is provided on the end face of the motor end 101. The first limiting post 2062 and the second limiting post 1012 are embedded in the limiting groove 2033 of the support base 203.

[0057] According to an embodiment of the present invention, a second socket 2021 is provided on the drive PCB board 202, and a first power connector 207 is installed in the second socket 2021. A third socket 2051 is provided on the power PCB board 205, and a second power connector 210 is installed in the third socket 2051. The first power connector 207 is in contact with the second power connector 210.

[0058] In a preferred embodiment, the first power connector 207 and the second power connector 210 both employ fisheye double-ended pins. One end of the first power connector 207 is inserted into the second socket 2021 and mounted on the drive PCB board 202, while one end of the second power connector 210 is inserted into the third socket 2051 and mounted on the power PCB board 205. The other end of the first power connector 207 mates with the other end of the second power connector 210.

[0059] According to an embodiment of this utility model, a header pin 208 is installed between the driver PCB board 202 and the main control PCB board 204. The header pin 208 includes a top fisheye pin 2081 and a bottom fisheye pin 2082. A fourth socket 2022 is provided on the driver PCB board 202, and a fifth socket 2042 is provided on the main control PCB board 204. The top fisheye pin 2081 is inserted into the fifth socket 2042, and the bottom fisheye pin 2082 is inserted into the fourth socket 2022.

[0060] Furthermore, a first limiting hole 2024 is opened on the driving PCB board 202, a second limiting hole 2043 is opened on the main control PCB board 204, and a third limiting post 2083 is set on the pin header 208. The third limiting post 2083 is inserted into the first limiting hole 2024 and the second limiting hole 2043.

[0061] According to an embodiment of this utility model, a signal PIN pin 2061 and a power PIN pin 2065 are installed on the plug-in assembly 206. A sixth socket 2041 is provided on the main control PCB board 204, and a seventh socket 2053 is provided on the power PCB board 205. The signal PIN pin 2061 is inserted into the sixth socket 2041, and the power PIN pin 2065 is inserted into the seventh socket 2053.

[0062] Furthermore, signal pin 2061 is a fisheye pin.

[0063] According to an embodiment of the present invention, a fastening ring 2012 is provided on the cover 201, and a boss 1015 is provided on the motor end 101, with the fastening ring 2012 fastened to the boss 1015. Furthermore, an annular sealing strip 2011 is also provided on the cover 201, and an annular groove 1014 is also provided on the motor end 101, with the annular sealing strip 2011 embedded in the annular groove 1014.

[0064] Furthermore, the cover 201 has a vent 2013, and a vent plug 2014 is embedded in the vent 2013.

[0065] The axes of the plug-in assembly 206, the power PCB board 205, the main control PCB board 204, the support base 203, and the drive PCB board 202 of this utility model are coaxial with the motor 1 and parallel to each other. The main control PCB board 204 and the drive PCB board 202 are fixed together by a support base 203. The first limiting post 2062 and the second limiting post 1012 are embedded in the limiting groove 2033 of the support base 203 to limit the axial and radial directions.

[0066] The present invention features three circuit boards mounted in parallel and coaxial with motor 1, making full use of space, with a compact structure and small size. The internal structure of the ECU assembly 2 is also compact, with high space utilization.

[0067] The power PCB board 205, main control PCB board 204, and drive PCB board 202 of this utility model are arranged parallel to the end face of the motor end 101, which greatly saves the axial space inside the ECU assembly 2, thereby significantly reducing the overall axial height of the ECU assembly 2 and reducing the volume of the ECU assembly 2. This makes the ECU assembly 2 compact, with strong product versatility, and can greatly reduce the costs of product development, manufacturing, and management.

[0068] This utility model integrates the ECU assembly 2 at the end 101 of the motor (tail of the motor 1) and keeps it coaxial with the motor 1, so that the radial diameter of the electronic power device is basically consistent with the diameter of the motor assembly, making full use of the axial and radial space of the product, with high space utilization and good versatility for multiple projects.

[0069] The plug-in component 206 of this utility model is connected to the main control PCB board 204 via signal pin 2061, and to the power PCB board 205 via power pin 2065. The drive PCB board 202 is connected to the motor end 101 via phase wire connector 209-phase wire 1011. Inside the ECU assembly 2, the main control PCB board 204 and the drive PCB board 202 are connected by pin header 208, and the power PCB board 205 and the drive PCB board 202 are connected by contacting each other via first power connector 207 and second power connector 210. This achieves an independent partition design for the power PCB board 205, drive PCB board 202, and main control PCB board 204, reducing interference from the power PCB board 205 and drive PCB board 202 to the main control PCB board 204 and improving the overall EMC performance of the product.

[0070] This utility model features an independently partitioned design for the power supply PCB board 205, driver PCB board 202, and main control PCB board 204. If one area malfunctions, only the corresponding PCB board needs to be replaced, reducing rework material costs by an average of 33.4%. In the development of different product series, if some products cannot fully utilize existing ECUs, the independent arrangement of the three PCB boards allows for the development of only one or two module PCB boards, improving product development efficiency (by 33.4%–66.7%) and reducing material and management costs.

[0071] The end face of the motor end 101 of this utility model is coated with heat dissipation adhesive to dissipate heat from the drive PCB board 202 and the components on the drive PCB board 202. At the same time, the motor end 101 is made of aluminum (aluminum ADC12) housing to dissipate heat from the components, which effectively dissipates heat from the drive PCB board 202.

[0072] The support base 203 is installed between the drive PCB board 202 and the main control PCB board 204, keeping the main control PCB board 204 away from the heat source of the drive PCB board 202 and the motor 1. The support base 203 is made of aluminum (aluminum ADC12) material. The first mounting surface 2031 of the support base 203 in contact with the main control PCB board 204 and the second mounting surface 2032 in contact with the drive PCB board 202 are coated with thermal adhesive, which effectively dissipates heat from the main control PCB board 204.

[0073] In some preferred embodiments, there are spaces between the plug-in component 206 and the power PCB board 205, between the power PCB board 205 and the main control PCB board 204, and between the support base 203 and the drive PCB board 202. In addition to avoiding the components, the remaining gaps also play a certain role in heat dissipation.

[0074] The connection between the cover 201 and the motor end 101 of this utility model is achieved by an annular sealing strip 2011 and an annular groove 1014, and is fastened by a fastening ring 2012 and a boss 1015. This ensures that the cover 201 is axially and radially limited, while also providing excellent waterproof and dustproof effects. Furthermore, this structure improves the assembly efficiency of the product.

[0075] In a preferred embodiment, the annular groove 1014 is coated with sealant to further enhance the waterproof and dustproof effect inside the ECU assembly 2.

[0076] The cover 201 of this utility model has a vent hole 2013, and a vent plug 2014 is embedded in the vent hole 2013. This vent hole 2014 allows the heat generated by the PCB board inside the motor 1 and ECU assembly 2 to be vented, preventing the heat inside the ECU assembly 2 from being unable to escape, which would cause the cover 201 to expand and deform, thereby negatively affecting the sealing effect of the sealant.

[0077] The signal PIN pin 2061 of this invention uses a fisheye pin. A certain pressure is applied to the elastically deformed fisheye pin to insert it into the sixth socket 2041 of the main control PCB board 204, which has a metal plating. The top fisheye pin 2081 of the pin header 208 is also a fisheye pin. A certain pressure is applied to the elastically deformed fisheye pin to insert it into the fifth socket 2042 of the main control PCB board 204, which has a metal plating. The bottom fisheye pin 2082 of the pin header 208 is also a fisheye pin. A certain pressure is applied to the elastically deformed fisheye pin to insert it into the fourth socket 2022 of the drive PCB board 202, which has a metal plating. This invention uses fisheye pins for PCB connection, which, compared to soldering PIN pins, results in lower assembly costs, higher efficiency, and higher reliability.

[0078] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. An electrically controlled power device with a motor and controller coaxially integrated, characterized in that, The electronically controlled power unit includes a motor and an ECU assembly integrated on the motor; The motor includes a motor end, and the ECU assembly includes a drive PCB board, a support base, a main control PCB board, a power supply PCB board, and a plug-in assembly. The drive PCB board is mounted parallel to the motor end, the plug-in assembly is mounted parallel to the power supply PCB board, the main control PCB board is mounted parallel to the power supply PCB board, the main control PCB board is mounted parallel to the drive PCB board, and the support base is mounted between the drive PCB board and the main control PCB board. The axes of the plug-in assembly, the power PCB board, the main control PCB board, the support base, and the drive PCB board are coaxial with the motor.

2. The electrically controlled power device according to claim 1, characterized in that, A first socket is provided on the drive PCB board, a phase wire connector is installed in the first socket, a phase wire extends from the end of the motor, and the phase wire connector contacts the phase wire.

3. The electrically controlled power device according to claim 1, characterized in that, A second socket is provided on the drive PCB board, and a first power connector is installed in the second socket. A third socket is provided on the power PCB board, and a second power connector is installed in the third socket. The first power connector is in contact with the second power connector.

4. The electrically controlled power device according to claim 1, characterized in that, A header is installed between the driving PCB board and the main control PCB board; The pin header includes a top fisheye pin and a bottom fisheye pin. A fourth socket is provided on the driver PCB board, and a fifth socket is provided on the main control PCB board. The top fisheye pin is inserted into the fifth socket, and the bottom fisheye pin is inserted into the fourth socket.

5. The electrically controlled power device according to claim 1, characterized in that, The plug-in assembly is equipped with signal pins and power pins; A sixth socket is provided on the main control PCB board, and a seventh socket is provided on the power supply PCB board. The signal pin is inserted into the sixth socket, and the power supply pin is inserted into the seventh socket.

6. The electrically controlled power device according to claim 5, characterized in that, The signal PIN pin is a fisheye pin.

7. The electrically controlled power device according to claim 1, characterized in that, The ECU assembly also includes a cover, on which a fastening ring is provided, and at the end of the motor is a boss, to which the fastening ring is fastened.

8. The electrically controlled power device according to claim 7, characterized in that, The cover is also provided with an annular sealing strip, and the motor end is also provided with an annular groove, the annular sealing strip being embedded in the annular groove.

9. The electrically controlled power device according to claim 1, characterized in that, The support base is made of aluminum ADC12 material, and the support base includes: A first mounting surface that contacts the main control PCB board and a second mounting surface that contacts the drive PCB board are coated with thermal adhesive.

10. The electrically controlled power device according to claim 1, characterized in that, The motor end is made of aluminum ADC12 material, and the end face of the motor end where the drive PCB board is mounted is coated with thermal adhesive.

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