A high performance controller device for electric vehicles

Abstract

The utility model relates to electric motor car controller technical field especially relates to a high performance controller device for electric motor car, including base, the upper portion of base has the open mouth, there is electrical element for controlling electric motor car motor in the base, be provided with the upper cover on the open mouth, the wiring post is integrally injection molded on the upper cover, and the wiring post is electrically connected with electrical element, and the base is fixedly connected with the upper cover through the wiring post, through above technical scheme, the utility model solves the problem that the current controller device structure is not enough simple, manual assembly is complicated and cost is high.

Description

Technical Field

[0001] This utility model relates to a controller, specifically a high-performance controller device for electric vehicles. Background Technology

[0002] As the central nervous system of the electric control system for new energy electric vehicles, the electric controller is facing a critical juncture for industrial upgrading.

[0003] When assembling the controller device, the existing controller device assembly process requires first installing the controller cover on the base, and then installing each terminal block on the cover in sequence. Each component is relatively independent and fragmented, lacking integration. Moreover, this installation method results in a large number of components to be installed, and the installation of each component requires separate operation steps, which makes the entire assembly process complex and cumbersome, thus greatly increasing the assembly time and labor intensity.

[0004] In addition, the assembly of the controller device currently relies mainly on manual operation, and the lack of streamlined components and too many installation steps result in high production costs.

[0005] Therefore, under the dual pressure of surging industry demand and cost control, the traditional labor-intensive manual assembly model can no longer meet the requirements of modern production.

[0006] The industry urgently needs to utilize modular assembly technology to build a simplified and cost-controllable controller structure, thereby achieving the dual benefits of improved process stability and consistent quality, while optimizing human resource allocation efficiency and reducing costs.

[0007] Therefore, there is an urgent need for a controller to solve the above-mentioned technical problems. Utility Model Content

[0008] In order to solve the problems in related technologies, this utility model provides a high-performance controller device for electric vehicles. This device solves the problems of existing controller devices having an insufficiently simplified structure, cumbersome manual assembly, and high cost.

[0009] To solve the above problems, the following technical solutions are provided:

[0010] A high-performance controller device for electric vehicles includes a base with an opening at the top. Electrical components for controlling the motor of the electric vehicle are located inside the base. A top cover is provided on the opening. The top cover is characterized in that a terminal block is integrally injection molded on it, and the terminal block is electrically connected to the electrical components. The base is fixedly connected to the top cover via the terminal block.

[0011] Through the above technical solution, the top cover is integrally injection molded with terminal blocks, and the top cover with integral injection molded terminal blocks makes the top cover a modular structure. This not only simplifies the structure of the top cover and reduces the number of structures and assembly steps that need to be installed during assembly, but also effectively reduces the manufacturing cost of the controller device, thereby improving production efficiency and reducing production costs.

[0012] In addition, the terminal block also functions as a fastening stud, eliminating the need for additional connectors to fix the top cover to the base, thereby improving assembly efficiency and reducing costs.

[0013] Furthermore, the upper outer circumferential surface of the terminal has a geometric knurled structure, which creates evenly distributed mechanical engagement points around the terminal.

[0014] Through the above technical solution, the knurled structure on the terminal block can improve the torsional torque resistance of the injection molding interface, thereby ensuring a more secure connection between the terminal block and the top cover, effectively preventing the terminal block from loosening or falling off during use, and thus improving the overall reliability of the product.

[0015] In addition, the terminal block and the top cover form an integrated injection molding structure, which reduces the number of parts that need to be assembled on the top cover during installation, simplifies the assembly steps and processes, and reduces the alignment and fixing steps during assembly, thereby improving production efficiency and reducing production costs.

[0016] Furthermore, the top cover corresponding to the terminal block has a recess, one end of which extends outward and penetrates the side wall of the top cover.

[0017] Through the above technical solution, the recessed design can protect the wires from external mechanical damage, thereby improving the reliability of the wiring. The recessed design also provides ample space for wiring operations, making it easier for operators to perform wiring, reducing the difficulty and time required, and thus improving wiring efficiency.

[0018] Furthermore, the terminal block includes a first terminal block and a second terminal block, wherein the first terminal block is used to connect an external DC power supply, and the second terminal block is used to connect the motor phase wire.

[0019] Furthermore, the electrical components include a power board and a control board that are electrically connected. The control board is used to drive the power board to control the motor to turn on or off. The bottom of the power board is attached to the inner bottom wall of the base, and the control board is fixedly mounted on the top of the power board.

[0020] Furthermore, the base has multiple countersunk holes on its outer bottom surface, each countersunk hole being a through hole; the power board has multiple first through holes, each first through hole corresponding to the position of a number of countersunk holes; and the diameter of the first through holes is smaller than the outer diameter of the second terminal; each terminal has a locking hole at its lower part, the locking hole being a threaded hole, and the multiple locking holes corresponding sequentially to the position of the countersunk holes.

[0021] Each countersunk hole contains a bolt, and each bolt passes through the corresponding countersunk hole and the first through hole in sequence before being installed in the corresponding locking hole; each bolt is fitted with an insulating ring, one end of each insulating ring is located in the corresponding countersunk hole, and the other end of each insulating ring extends through the corresponding through hole into the base.

[0022] Through the above technical solution, the bolts can be used to fasten the base, power board, control board and top cover, thereby ensuring the reliability of the entire equipment.

[0023] Furthermore, the control board has a second via hole corresponding to the position of the second terminal block. The second via hole is a through hole, and the diameter of the second via hole is the same as the outer diameter of the second terminal block.

[0024] The above technical solution, through the setting of the second through hole, can limit and fix the position of the control board in the vertical direction, thereby ensuring the stability of the control board in the vertical direction.

[0025] Furthermore, the base is arranged in a geometric bowl shape, and the base includes a base plate and a surrounding plate arranged around the top of the base plate. The bottom of the base plate has heat dissipation fins.

[0026] The base has a power fixing groove for placing the power board. The side walls of the enclosure and the top of the bottom plate on both sides of the power fixing groove have multiple support and limiting posts. There is a U-shaped positioning post on the enclosure between two support and limiting posts. The control plate has limiting holes corresponding to the positions of the support and limiting posts and the U-shaped positioning posts.

[0027] The above technical solution, through the setting of the power fixing slot, can limit the position of the power board and prevent the power board from shifting, thereby ensuring the installation stability of the power board; through the setting of the support limiting column and U-shaped positioning column, it can provide stable support and precise limiting for the control board, thereby ensuring the stability of the control board and significantly improving the reliability of the entire equipment.

[0028] The above solution has the following advantages:

[0029] 1. The top cover is made of one-piece injection molded terminal block, which makes the top cover a modular structure. This not only simplifies the structure of the top cover and reduces the number of structures and assembly steps that need to be installed during assembly, but also effectively reduces the manufacturing cost of the controller device, thereby improving production efficiency and reducing production costs.

[0030] In addition, the terminal block also functions as a fastening stud, meaning there is no need for additional connectors to fix the top cover and the base, thereby reducing the number of structures during product assembly, thus improving assembly efficiency and reducing costs.

[0031] 2. The knurled structure on the terminal block increases the torsional torque resistance of the injection molding interface, ensuring a more secure connection between the terminal block and the top cover. This effectively prevents the terminal block from loosening or falling off during use, thereby improving the overall reliability of the product. In addition, the terminal block and the top cover form an integrated injection molding structure, reducing the number of parts that need to be assembled on the top cover during installation. This simplifies the assembly steps and processes, thereby reducing alignment and fixing steps during assembly, which improves production efficiency and reduces production costs.

[0032] 3. The recessed design protects the wires from external mechanical damage, thereby improving the reliability of the wiring. The recessed design also provides ample space for wiring operations, making it easier for operators to perform wiring, reducing the difficulty and time required, and thus improving wiring efficiency.

[0033] 4. By using bolts, the base, power board, control board, and top cover can be fastened together, thereby ensuring the reliability of the entire device.

[0034] 5. The power fixing slots limit the position of the power board, preventing it from shifting and ensuring its installation stability. The support limit posts and U-shaped positioning posts provide stable support and precise positioning for the control board, ensuring its stability and significantly improving the overall reliability of the equipment. Attached Figure Description

[0035] To make the content of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein:

[0036] Figure 1 This is a schematic diagram of the structure of this utility model;

[0037] Figure 2 This is an exploded view of the present invention;

[0038] Figure 3This is a schematic diagram of the structure of the upper cover in this utility model;

[0039] Figure 4 This is a schematic diagram of the structure of the first terminal block in this utility model;

[0040] Figure 5 This is a structural schematic diagram of the base from one perspective in this utility model;

[0041] Figure 6 This is a schematic diagram of the base from a second perspective in this utility model;

[0042] Figure 7 This is a schematic diagram of the structure of the medium power board of this utility model;

[0043] Figure 8 This is a schematic diagram of the control board in this utility model;

[0044] Explanation of reference numerals in the attached drawings: 100, base; 101, bottom plate; 102, surrounding plate; 103, heat dissipation fins; 104, countersunk hole; 105, second anti-reverse mounting hole; 106, first anti-reverse mounting hole; 107, first through hole; 108, locking hole; 109, power fixing slot; 110, support limiting post; 111, U-shaped positioning post; 112, limiting hole; 113, second through hole;

[0045] 200. Top cover; 201. Vent hole; 202. Vent membrane; 203. First terminal; 204. Second terminal; 205. Knurled structure; 206. Recess;

[0046] 300, Power board; 301, First printed circuit board; 302, Power transistor; 303, First connector;

[0047] 400. Control board; 401. Second printed circuit board; 402. Control circuit; 403. Drive circuit; 404. Second connector;

[0048] 500, Bolt; 510, Insulating ring. Detailed Implementation

[0049] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0050] In a specific embodiment, such as Figure 1-8As shown, a high-performance controller device for electric vehicles includes a base 100 with an opening at the top. The base 100 contains electrical components for controlling the electric vehicle motor. In this specific embodiment, the electrical components are controllers for controlling the electric vehicle motor. A top cover 200 is provided on the opening, and a terminal block is integrally injection-molded on the top cover 200. The terminal block is electrically connected to the electrical components. The base 100 is fixedly connected to the top cover 200 via the terminal block. In this specific embodiment, the top cover 200 has mounting through holes, and both ends of the terminal block extend through these holes to the outside of the top cover 200. The terminal block and the top cover 200 are integrally injection-molded, and one end of the terminal block is electrically connected to the electrical components.

[0051] The one-piece injection-molded terminal block top cover makes the top cover 200 a modular structure. This not only simplifies the structure of the top cover 200 and reduces the number of structures and assembly steps that need to be installed during assembly, but also effectively reduces the manufacturing cost of the controller device, thereby improving production efficiency and reducing production costs.

[0052] In addition, the terminal block also functions as a fastening stud, eliminating the need for additional connectors to fix the top cover 200 and the base 100, thereby improving assembly efficiency and reducing costs.

[0053] like Figure 4 As shown, the upper outer circumferential surface of the terminal block has a geometrically knurled structure 205, which forms evenly distributed mechanical engagement points around the terminal block. In this specific embodiment, the geometric shape is triangular. The knurled structure 205 on the terminal block can increase the torsional torque resistance of the injection molding interface, thereby ensuring a more secure connection between the terminal block and the upper cover 200, effectively preventing the terminal block from loosening or falling off during use, thus improving the overall reliability of the product. The terminal block and the upper cover 200 form an integrated injection molding structure, reducing the number of parts that need to be assembled on the upper cover 200 during installation, simplifying the assembly steps and processes, thereby reducing the alignment and fixing steps during assembly, thus improving production efficiency and reducing production costs.

[0054] like Figure 3 and Figure 4 As shown, the upper cover 200 corresponding to the terminal block has a recess 206, one end of which extends outward and penetrates the side wall of the upper cover 200. The recess 206 facilitates wiring and connection of wires, and protects the wires from external mechanical damage, thereby improving the reliability of wiring. The recess 206 provides ample space for wiring operations, making it easier for operators to perform wiring, reducing the difficulty and time required for wiring, and thus improving wiring efficiency. In this specific embodiment, the recess 206 is a U-shaped recess 206.

[0055] like Figure 3As shown, the top cover 200 has a vent hole 201, and a breathable membrane 202 is attached to the vent hole 201.

[0056] The terminals include a first terminal 203 and a second terminal 204. The first terminal 203 is used to connect an external DC power supply, and the second terminal 204 is used to connect the motor phase wires. The terminals are metal terminals, which can be made of low-cost aluminum or high-conductivity copper, etc. The choice of metal terminals can be made according to actual needs. The outer circumference of the first terminal 203 and the second terminal 204 can be arbitrarily shaped. In this specific embodiment, both the first terminal 203 and the second terminal 204 are cylindrical. The cylindrical shape of the first terminal 203 and the second terminal 204 can reduce the processing difficulty and simplify the process, thereby reducing the production cost of the first terminal 203 and the second terminal 204. In this specific embodiment, there are two first terminals 203, which are used for the positive and negative terminals of the external power supply, respectively, and there are three second terminals 204, which are used to connect the U-phase wire, V-phase wire and W-phase wire of the motor, respectively.

[0057] like Figure 7-8 As shown, the electrical components include a power board 300 and a control board 400 that are electrically connected. The arrangement of the circuits on the power board 300 and the functions of each component are all existing technologies and will not be described in detail here. The control board 400 is used to drive the power board 300 to control the motor to turn on or off. The bottom of the power board 300 is attached to the inner bottom wall of the base 100, and the control board 400 is fixedly mounted on the top of the power board 300.

[0058] like Figure 7 As shown, the power board 300 includes a first printed circuit board 301. The bottom of the first printed circuit board 301 is attached to the inner bottom wall of the base 100. The first printed circuit board 301 has a second anti-reverse mounting hole 105 at three corners. The first printed circuit board 301 has a power transistor 302 and a first connector 303, and the power transistor 302 and the first connector 303 are electrically connected.

[0059] like Figure 8 As shown, the control board 400 includes a second printed circuit board 401. The second printed circuit board 401 has a control circuit 402, a drive circuit 403 and a second connector 404. The drive circuit 403 is electrically connected to the control circuit 402 and the second connector 404 respectively. The second connector 404 is electrically connected to the first connector 303.

[0060] The control board 400 has a second via 113 corresponding to the position of the second terminal 204. The second via 113 is a through hole, and the diameter of the second via 113 is the same as the outer diameter of the second terminal 204. The control board 400 has a notch, and the notch corresponds to the position of the first terminal 203.

[0061] like Figure 5-6 As shown, the base 100 has multiple countersunk holes 104 on its outer bottom surface, each of which is a through hole; the power board 300 has multiple first through holes 107, each of which corresponds to the countersunk hole 104; and the diameter of the first through hole 107 is smaller than the outer diameter of the second terminal 204; each terminal has a locking hole 108 at its lower part, which is a threaded hole, and the multiple locking holes 108 correspond to the countersunk holes 104 in sequence.

[0062] like Figure 2 As shown, each countersunk hole 104 contains a bolt 500. Each bolt 500 passes through the corresponding countersunk hole 104 and the first through hole 107 in sequence and is installed in the corresponding locking hole 108. The bolts 500 can fasten the base 100, power board 300, control board 400 and top cover 200, thereby ensuring the reliability of the entire device. Each bolt 500 has an insulating ring 510. The insulating rings 510 provide electrical isolation. One end of each insulating ring 510 is located in the corresponding countersunk hole 104, and the other end of each insulating ring 510 extends through the corresponding through hole 105 into the base 100.

[0063] like Figure 2 and Figure 5 As shown, the base 100 is arranged in a geometric bowl shape. The base 100 includes a base plate 101 and a surrounding plate 102 arranged around the top of the base plate 101. The bottom of the base plate 101 has heat dissipation fins 103. The base plate 101 has a first anti-reverse mounting hole 106 at three corners, and the three first anti-reverse mounting holes 106 correspond to the positions of three second anti-reverse mounting holes 105 respectively.

[0064] The base 100 has a power fixing groove 109 for placing the power board 300. The power fixing groove 109 can limit the position of the power board 300, preventing the power board 300 from shifting and thus ensuring the installation stability of the power board 300. There are multiple support limiting posts 110 on the side walls of the corresponding surrounding plates 102 and the top of the base plate 101 in the power fixing groove 109. There are U-shaped positioning posts 111 on the surrounding plates 102 between two support limiting posts 110. The control plate 400 has limiting holes 112 corresponding to the positions of the support limiting posts 110 and the U-shaped positioning posts 111. The support limiting posts 110 and the U-shaped positioning posts 111 can provide stable support and precise positioning for the control plate 400, thereby ensuring the stability of the control plate 400 and significantly improving the reliability of the entire device.

[0065] Operation process: Place the assembled power board in the base, aligning the first anti-reverse mounting hole on the first printed circuit board with the second anti-reverse mounting hole in the base. Electrically connect the first connector on the control board with the second connector on the power board. Place the top cover on the base, aligning the locking hole on the top cover with the locking hole on the first printed circuit board. Install each bolt into the corresponding locking hole by passing it through the countersunk hole and the first through hole in sequence. At this time, the bottom of each of the three second terminals passes through the second through hole and abuts against the top of the first printed circuit board, realizing the electrical connection between the second terminals and the first printed circuit board. The bottom of each of the two first terminals passes through the notch and abuts against the top of the first printed circuit board, realizing the electrical connection between the first terminals and the first printed circuit board. This completes the fixing of the base, electrical components, and top cover.

[0066] In the description of this utility model, it should be understood that the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," 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 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, and therefore should not be construed as a limitation of this utility model. In the description of this utility model, unless otherwise specified and limited, it should be noted that the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to mechanical or electrical connections, or internal connections between two components, and can be direct connections or indirect connections through an intermediate medium. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0067] Obviously, the above embodiments are merely examples for clear illustration and are not intended to limit the implementation. For those skilled in the art, other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all implementation methods here, and any obvious variations or modifications derived therefrom are still within the protection scope of this utility model.

Claims

1. A high-performance controller device for an electric vehicle, comprising a base, an opening at the top of the base, electrical components for controlling the electric vehicle motor located within the base, and a top cover provided on the opening, characterized in that, The upper cover is integrally injection molded with terminal blocks, which are electrically connected to the electrical components. The base is fixedly connected to the upper cover through the terminal blocks. The upper outer circumferential surface of the terminal has a geometric knurled structure, which creates evenly distributed mechanical engagement points around the terminal.

2. The high-performance controller device for electric vehicles as described in claim 1, characterized in that, The top cover corresponding to the terminal block has a recess, one end of which extends outward and penetrates the side wall of the top cover.

3. The high-performance controller device for electric vehicles as described in claim 1, characterized in that, The terminal block includes a first terminal block and a second terminal block. The first terminal block is used to connect an external DC power supply, and the second terminal block is used to connect the motor phase wire.

4. A high-performance controller device for electric vehicles as described in claim 3, characterized in that, The electrical components include a power board and a control board that are electrically connected. The control board is used to drive the power board to control the motor to turn on or off. The bottom of the power board is attached to the inner bottom wall of the base, and the control board is fixedly mounted on the top of the power board.

5. A high-performance controller device for electric vehicles as described in claim 4, characterized in that, The base has multiple countersunk holes on its outer bottom surface, each of which is a through hole; the power board has multiple first through holes, each of which corresponds to a position of a countersunk hole, and the diameter of the first through hole is smaller than the outer diameter of the second terminal; each terminal has a locking hole at its lower part, which is a threaded hole, and the locking holes correspond sequentially to the positions of the countersunk holes. Each countersunk hole contains a bolt, and each bolt passes through the corresponding countersunk hole and the first through hole in sequence before being installed in the corresponding locking hole; each bolt is fitted with an insulating ring, one end of each insulating ring is located in the corresponding countersunk hole, and the other end of each insulating ring extends through the corresponding through hole into the base.

6. A high-performance controller device for an electric vehicle as described in claim 5, characterized in that, The base includes a base plate and a surrounding plate arranged around the top of the base plate, and the bottom of the base plate has heat dissipation fins. The base has a power fixing groove for placing the power board. The side walls of the enclosure and the top of the bottom plate on both sides of the power fixing groove have multiple support and limiting posts. There is a U-shaped positioning post on the enclosure between two support and limiting posts. The control plate has limiting holes corresponding to the positions of the support and limiting posts and the U-shaped positioning posts.

7. A high-performance controller device for an electric vehicle as described in claim 5, characterized in that, The control board has a second via corresponding to the position of the second terminal. The second via is a through hole, and the diameter of the second via is the same as the outer diameter of the second terminal.

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