Motor controller inlay assembly structure

Abstract

The application discloses a motor controller embedded assembly structure, and relates to the technical field of motor control, which comprises a motor body, a controller and a gear box, a reserved cavity is arranged at the connecting position of the gear box and the motor body, the controller comprises a PCB board, the PCB board is fixed on one side of the motor body close to the reserved cavity, the PCB board is located in the reserved cavity and suspends from the reserved cavity, power supply through holes connected with motor winding are arranged on the PCB board, and components are arranged on the two sides of the PCB board. The design enables the components to be arranged on the two sides of the PCB board, and the height integration design reduces the area of the PCB board, thereby reducing the volume of the whole controller, finally reducing the volume of the reserved cavity, reducing the overall size of the motor and saving the manufacturing cost. The power supply through holes connected with the motor winding are arranged on the PCB board, the power supply through holes simplify the power supply transmission path, and connectors are not needed, which reduces the volume of the controller and saves the manufacturing cost.

Description

Technical Field

[0001] This application relates to the technical field of motor control, and in particular to an embedded assembly structure for a motor controller. Background Technology

[0002] A drive motor is a device that converts electrical energy into mechanical energy and is a key component of an electric drive system. Its main function is to drive vehicles or various mechanical equipment by rotating the motor. Drive motors are typically used in conjunction with gearboxes to achieve functions such as speed change, torque change, and changing the direction of power. Drive motors are widely used in electric vehicles, electric bicycles, power tools, industrial automation equipment, and other fields. In drive motors, parameters such as speed and torque are controlled by a motor controller.

[0003] In related technologies, the assembly method between the controller and the drive motor is mainly a separate insertion type, that is, the motor and the controller are two independent components. An additional reserved cavity needs to be set in the motor body. The controller is inserted into the reserved cavity of the motor body. The controller's PCB board is equipped with components and position sensors. A power supply metal clip is set on the PCB board to contact the motor winding for power supply. A connector is set to connect the external power supply to the controller. Then, the controller's power is conducted to the motor winding through metal springs. Finally, the controller is sealed in the reserved cavity with screws to complete the assembly of the controller and the drive motor.

[0004] Regarding the aforementioned technologies, the controller needs to connect to external circuits via connectors, and the connector pins and power supply clips occupy specific positions on the PCB board. A single-sided PCB design allows the connector pins and power supply clips to be centrally located on one side of the PCB board, facilitating wiring and soldering. This single-sided layout simplifies the design and assembly process of the connectors and power supply clips, preventing the risk of poor contact due to double-sided soldering. However, a single-sided PCB design requires sufficient area to accommodate the connector pins and power supply clips, as well as various components, resulting in a larger PCB area and thus a larger controller size. This, in turn, affects the volume of the reserved cavity, leading to increased motor size, low space utilization, and increased manufacturing costs. To address these issues, this application proposes an embedded motor controller assembly structure. Utility Model Content

[0005] This application provides a motor controller embedded assembly structure.

[0006] This application provides a motor controller embedded assembly structure, which adopts the following technical solution:

[0007] An embedded assembly structure for a motor controller includes a motor body, a controller for controlling the operation of the motor, and a gearbox connected to the motor body and outputting torque. A reserved cavity is provided at the connection between the gearbox and the motor body. The controller includes a PCB board, which is fixed to the side of the motor body near the reserved cavity. The PCB board is located in and suspended within the reserved cavity. The PCB board has power through holes connected to the motor windings, and components are mounted on both sides of the PCB board.

[0008] By adopting the above technical solution, the controller's PCB board is placed and suspended in the reserved cavity at the connection between the gearbox and the motor body. Components can be installed on both sides of the PCB board. This double-sided layout significantly improves the integration of components and significantly reduces the PCB board area while ensuring functionality. This, in turn, reduces the overall size of the controller, thereby reducing the volume of the reserved cavity inside the motor body and ultimately lowering the overall size of the motor, thus improving space utilization. Power vias connected to the motor windings are provided on the PCB board. These vias simplify the power transmission path and eliminate the need for connectors, further reducing the controller's size and saving manufacturing costs.

[0009] Preferably, a fixing post is provided on the side of the motor body near the gearbox, the fixing post is set perpendicular to the PCB board, and the PCB board is fixed to the fixing post; the PCB board has a positioning hole for assisting the installation of the PCB board, and a positioning post is provided on the side of the motor body near the gearbox, the axis of the positioning post is perpendicular to the PCB board, and the positioning post is set through the positioning hole to assist the PCB board in being installed on the motor body through the fixing post.

[0010] By adopting the above technical solution, a fixing post perpendicular to the PCB board is set on the side of the motor body near the gearbox. The PCB board is fixed to the fixing post, providing stable mounting support for the PCB board and ensuring that the PCB board can be securely suspended in the reserved cavity, avoiding loosening of the PCB board due to motor vibration. The positioning holes on the PCB board cooperate with the positioning posts on the motor body, and the positioning posts pass through the positioning holes to pre-position the PCB board. This design helps the PCB board quickly find its installation position with the fixing post, reducing adjustment time during installation, improving assembly efficiency, and ensuring the positional accuracy of the PCB board in the reserved cavity, ensuring its accurate relative position with other motor components, which is beneficial for subsequent signal transmission and power connection.

[0011] Preferably, the reserved cavity has a slot on the side wall near the motor body, and the motor body has a protrusion that engages with the slot on the side near the reserved cavity.

[0012] By adopting the above technical solution, a slot is opened on the side wall of the reserved cavity near the motor body, and a protrusion is set at the corresponding position on the motor body, so that the two are engaged. This structure achieves the initial positioning of the motor body and the gearbox.

[0013] Preferably, the reserved cavity is further provided with a limiting platform on the side near the motor body. When the protrusion of the motor body engages with the slot on the inner wall of the reserved cavity, the motor body and the limiting platform abut against each other and are fixed together by fasteners.

[0014] By adopting the above technical solution, when the protrusion of the motor body engages with the slot of the reserved cavity, the motor body abuts against the limiting platform. The limiting platform further restricts the relative position of the motor body and the gearbox, ensuring that the two can achieve the preset positional accuracy during assembly, and avoiding the impact of assembly deviation on the overall performance of the motor. After the motor body abuts against the limiting platform, it is fixed by fasteners. Based on the engagement of the slot and the protrusion, the connection strength between the motor body and the gearbox is further strengthened, making the connection between the two more stable and reliable. It can withstand the vibration and impact during motor operation, and improve the stability and service life of the entire motor assembly structure.

[0015] Preferably, the inner wall of the reserved cavity is provided with a limiting protrusion, and the edge of the PCB board is provided with a mounting hole that matches the contour of the limiting protrusion. When the protrusion of the motor body is engaged with the slot of the inner wall of the reserved cavity, the limiting protrusion passes through the mounting hole on the PCB board.

[0016] By adopting the above technical solution, the limiting protrusion on the inner wall of the reserved cavity passes through the matching mounting hole on the edge of the PCB board. Based on the installation of the PCB board by the fixing post and positioning post, the displacement of the PCB board in the reserved cavity is further restricted. This effectively prevents the PCB board from shaking or shifting due to vibration, impact and other factors during motor operation, ensuring that the components on the PCB board maintain the correct relative position with other parts of the motor, and ensuring the stable operation of the controller.

[0017] Preferably, the motor body is provided with pins, the pins are connected to the motor windings, and the pins are fixed in contact with power vias.

[0018] By adopting the above technical solution, the pins of the motor body are connected to the motor windings, and the pins are fixed in contact with the power vias on the PCB board, forming a direct power transmission path from the motor windings to the PCB board. Compared with the traditional method of indirectly conducting power through metal springs, this design reduces contact resistance and loss during power transmission, improves the efficiency and reliability of power transmission, and simplifies the structure, which is beneficial for reducing the size of the controller.

[0019] Preferably, it also includes a motor output shaft, which is disposed through the PCB board, and a sensor for detecting the speed of the motor output shaft is provided at one end of the PCB board near the motor output shaft.

[0020] By adopting the above technical solution, the motor output shaft is set through the PCB board, making the layout of the motor output shaft and the controller more compact, reducing the space between the two, simplifying the overall structure of the motor, and helping to reduce the overall size of the motor; the sensor detects the output shaft speed and transmits the information to the system, which then adjusts the output shaft speed.

[0021] Preferably, the PCB board has a clearance hole at one end near the motor output shaft. The size of the clearance hole is designed to correspond to the diameter of the motor output shaft. The motor output shaft is perpendicular to the PCB board and passes through the clearance hole. The sensor is located on the periphery of the motor output shaft. The sensor is a Hall sensor.

[0022] By adopting the above technical solution, the size of the clearance hole on the PCB board matches the diameter of the motor output shaft, and the motor output shaft passes through the clearance hole perpendicularly to the PCB board, ensuring no mechanical interference between the motor output shaft and the PCB board, while guaranteeing the relative positional accuracy of the two, and providing reasonable space for the installation and operation of the sensor; the sensor is located on the periphery of the motor output shaft and adopts a Hall sensor. The Hall sensor has the characteristics of fast response speed and high detection accuracy, and can accurately detect the speed change of the motor output shaft.

[0023] In summary, this application includes at least one of the following beneficial technical effects:

[0024] 1. The controller's PCB board is placed and suspended in the reserved cavity at the connection between the gearbox and the motor body. Components can be installed on both sides of the PCB board. This double-sided layout significantly improves the integration of components and reduces the PCB board area significantly while ensuring functionality. This, in turn, reduces the overall size of the controller, allowing for a reduction in the volume of the reserved cavity inside the motor body. Ultimately, this reduces the overall size of the motor and improves space utilization. Power vias connected to the motor windings are provided on the PCB board. These vias simplify the power transmission path and eliminate the need for connectors, further reducing the controller's size and saving manufacturing costs.

[0025] 2. The pins of the motor body are connected to the motor windings, and the pins are fixed in contact with the power vias on the PCB board, forming a direct power transmission path from the motor windings to the PCB board. Compared with the traditional method of indirectly conducting power through metal springs, this design reduces contact resistance and loss during power transmission, improves the efficiency and reliability of power transmission, and simplifies the structure, which is beneficial for reducing the size of the controller;

[0026] 3. The motor output shaft is designed to run through the PCB board, making the layout of the motor output shaft and the controller more compact, reducing the space between them, simplifying the overall structure of the motor, and helping to reduce the overall size of the motor; the sensor detects the output shaft speed and transmits the information to the system, which then adjusts the output shaft speed. Attached Figure Description

[0027] Figure 1 This is an exploded view of the overall structure of an embodiment of this application;

[0028] Figure 2 This is a schematic diagram of the overall structure of the controller in an embodiment of this application;

[0029] Figure 3 This is a schematic diagram of the structure of the motor body and the motor output shaft in the embodiments of this application;

[0030] Figure 4 yes Figure 1 Enlarged view of section A.

[0031] Reference numerals in the attached diagram: 1. Motor body; 11. Pin; 12. Fixing post; 13. Positioning post; 14. Protrusion; 2. Motor output shaft; 3. Gearbox; 31. Reserved cavity; 32. Slot; 33. Limiting platform; 34. Limiting protrusion; 4. Controller; 41. PCB board; 42. Components; 43. Power supply via; 44. Clearance hole; 45. Positioning hole; 46. Mounting hole; 5. Sensor. Detailed Implementation

[0032] The following is in conjunction with the appendix Figure 1 - Appendix Figure 4 This application will be described in further detail.

[0033] This application discloses an embedded assembly structure for a motor controller.

[0034] refer to Figure 1 An embedded assembly structure for a motor controller includes a motor body 1, a motor output shaft 2, a gearbox 3, and a controller 4 for controlling the operation of the motor; wherein, a reserved cavity 31 is provided at the connection between the gearbox 3 and the motor body 1, and the motor output shaft 2 is installed in the reserved cavity 31; the motor output shaft 2 passes through the controller 4 and is rotatably connected to the gearbox 3.

[0035] refer to Figure 1 and Figure 2The controller 4 includes a rectangular PCB board 41, which is installed in and suspended within a reserved cavity 31. Components 42 are mounted on both sides of the PCB board 41. This double-sided layout significantly improves the integration of the components 42 and reduces the area of ​​the PCB board 41 while maintaining functionality. This, in turn, reduces the overall volume of the controller 4, thereby reducing the volume of the reserved cavity 31 within the motor body 1 and ultimately lowering the overall size of the motor and improving space utilization.

[0036] The PCB board 41 has multiple power vias 43 connected to the motor windings. The multiple power vias 43 are evenly spaced along the length of the PCB board 41. The power vias 43 simplify the power transmission path and eliminate the need for connectors, which reduces the size of the controller 4 and saves manufacturing costs.

[0037] A clearance hole 44 is provided at one end of the PCB board 41 near the motor output shaft 2. The size of the clearance hole 44 is designed to correspond to the diameter of the motor output shaft 2. The motor output shaft 2 is perpendicular to the PCB board 41 and passes through the clearance hole 44. A sensor 5 for detecting the rotational speed of the motor output shaft 2 is electrically connected to one end of the PCB board 41 near the motor output shaft 2. The sensor 5 is located around the motor output shaft 2. The sensor 5 detects the rotational speed of the output shaft and transmits the information to the system, which then adjusts the rotational speed of the output shaft. In this embodiment, the sensor 5 is a Hall sensor. Hall sensors have the characteristics of fast response speed and high detection accuracy, and can accurately detect changes in the rotational speed of the motor output shaft 2.

[0038] refer to Figure 1 and Figure 3 The motor body 1 is equipped with pins 11, which are connected to the motor windings. Pins 11 are in contact with and soldered to the power supply via 43. A fixing post 12 is integrally provided on the side of the motor body 1 near the gearbox 3. The fixing post 12 is set perpendicular to the PCB board 41, and the end of the fixing post 12 is bonded to the PCB board 41. A positioning post 13 is also integrally provided on the side of the motor body 1 near the gearbox 3. The PCB board 41 has positioning holes 45 for assisting the installation of the PCB board 41. The positioning post 13 passes through the positioning holes 45 to assist the PCB board 41 in positioning and installing on the motor body 1.

[0039] refer to Figure 1 and Figure 4The reserved cavity 31 has a slot 32 on the side wall near the motor body 1. The motor body 1 has a protrusion 14 integrally provided on the side near the reserved cavity 31, which engages with the slot 32. The reserved cavity 31 has a limiting platform 33 integrally provided on the side near the motor body 1. When the protrusion 14 of the motor body 1 engages with the slot 32 on the inner wall of the reserved cavity 31, the motor body 1 and the limiting platform 33 abut against each other and are fixed to each other by bolts.

[0040] The inner wall of the reserved cavity 31 is integrally formed with a limiting protrusion 34. The PCB board 41 has mounting holes 46 along its length on both edges that match the contour of the limiting protrusion 34. When the protrusion 14 of the motor body 1 engages with the slot 32 on the inner wall of the reserved cavity 31, the limiting protrusion 34 passes through the mounting holes 46 on the PCB board 41, further restricting the displacement of the PCB board 41 in the reserved cavity 31. This effectively prevents the PCB board 41 from shaking or shifting due to vibration, impact, or other factors during motor operation, ensuring that the components 42 on the PCB board 41 maintain the correct relative position with other parts of the motor, and ensuring the stable operation of the controller 4.

[0041] The implementation principle of this embodiment is as follows: First, components 42 are installed on both sides of the PCB board 41 of the controller 4. Then, the PCB board 41 is positioned by the positioning post 13 and fixed with the fixing post 12 of the motor body 1. The power through hole 43 on the PCB board 41 is soldered and fixed with the pin 11 on the motor body 1. Subsequently, the motor body 1 is installed and fixed by engaging with the slot 32 of the reserved cavity 31 of the gearbox 3 through the protrusion 14, so that the entire controller 4 is embedded in the motor body 1.

[0042] In summary, components 42 can be installed on both sides of the PCB board 41. The double-sided layout significantly improves the integration of components 42, and significantly reduces the area of ​​the PCB board 41 while ensuring functionality. This, in turn, reduces the overall size of the controller 4, allowing the volume of the reserved cavity 31 inside the motor body 1 to be reduced, ultimately lowering the overall size of the motor and improving space utilization. The PCB board 41 is provided with power vias 43 that connect to the motor windings. The power vias 43 simplify the power transmission path and eliminate the need for connectors, which reduces the size of the controller 4 and saves manufacturing costs.

[0043] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A motor controller embedded assembly structure, comprising a motor body (1), a controller (4) for controlling the operation of the motor, and a gearbox (3) connected to the motor body (1) and outputting torque, characterized in that, A reserved cavity (31) is provided at the connection between the gearbox (3) and the motor body (1). The controller (4) includes a PCB board (41). The PCB board (41) is fixed on the side of the motor body (1) near the reserved cavity (31). The PCB board (41) is located in the reserved cavity (31) and suspended in the reserved cavity (31). The PCB board (41) is provided with a power supply through hole (43) connected to the motor winding. Components (42) are installed on both sides of the PCB board (41).

2. An in-line motor controller assembly according to claim 1, wherein, The motor body (1) has a fixing post (12) on the side near the gearbox (3). The fixing post (12) is set perpendicular to the PCB board (41). The PCB board (41) is fixed to the fixing post (12). The PCB board (41) has a positioning hole (45) for assisting the installation of the PCB board (41). The motor body (1) has a positioning post (13) on the side near the gearbox (3). The axis of the positioning post (13) is perpendicular to the PCB board (41). The positioning post (13) passes through the positioning hole (45) to assist the PCB board (41) in being installed on the motor body (1) through the fixing post (12).

3. An in-line motor controller assembly according to claim 2, wherein: The reserved cavity (31) has a slot (32) on the side wall near the motor body (1), and the motor body (1) has a protrusion (14) that engages with the slot (32) on the side near the reserved cavity (31).

4. The in-line assembly structure of a motor controller according to claim 3, wherein The reserved cavity (31) is also provided with a limiting platform (33) on the side near the motor body (1). When the protrusion (14) of the motor body (1) is engaged with the slot (32) on the inner wall of the reserved cavity (31), the motor body (1) and the limiting platform (33) abut against each other and are fixed to each other by fasteners.

5. An in-line assembly structure for a motor controller according to claim 4, wherein The inner wall of the reserved cavity (31) is provided with a limiting protrusion (34), and the edge of the PCB board (41) is provided with a mounting hole (46) that matches the outline of the limiting protrusion (34). When the protrusion (14) of the motor body (1) is engaged with the slot (32) of the inner wall of the reserved cavity (31), the limiting protrusion (34) passes through the mounting hole (46) on the PCB board (41).

6. The in-line assembly structure of a motor controller according to claim 1, wherein The motor body (1) is provided with pins (11), which are connected to the motor windings and are fixed in contact with the power supply via (43).

7. The in-line motor controller assembly of claim 1, wherein: It also includes a motor output shaft (2), which is installed through the PCB board (41). The PCB board (41) is provided with a sensor (5) for detecting the rotational speed of the motor output shaft (2) at one end near the motor output shaft (2).

8. An in-line motor controller assembly according to claim 7, wherein, The PCB board (41) has a clearance hole (44) at one end near the motor output shaft (2). The size of the clearance hole (44) is designed to correspond to the diameter of the motor output shaft (2). The motor output shaft (2) is perpendicular to the PCB board (41) and passes through the clearance hole (44). The sensor (5) is located on the periphery of the motor output shaft (2). The sensor (5) is a Hall sensor (5).

Images