An external air-cooled controller structure

Abstract

The utility model discloses an external air -cooled controller structure, including motor, controller and the heat dissipation seat with sealed storehouse, heat dissipation seat detachable mode setting in motor front side and with stator end part is pasted, the lower end of controller is inserted to sealed storehouse and will sealed storehouse close, and the controller is fixed on the heat dissipation seat through screw, and the heat dissipation seat is set up and is taken out the hole for motor shaft, motor wire, and the wiring harness on the controller is electrically connected with motor wire, external wiring harness. Install the controller through the heat dissipation seat in the front side of motor, make the controller separate from the closed environment, can take away the heat of controller surface through the natural wind produced when riding the electric vehicle, and cooperate heat dissipation seat and promptly spread out the heat produced when the controller works to the outside, prevent the controller overheating, have promoted the controller efficiency, have prolonged the service life of controller, because the controller is installed in the front side of motor, can greatly shorten motor wire, has saved the production cost.

Description

Technical Field

[0001] This utility model relates to the technical field of electric vehicle controllers, and in particular to an external air-cooled controller structure. Background Technology

[0002] As electric two-wheelers become increasingly popular, the lifespan of electric vehicles has become a concern. Traditional electric vehicle controllers are fixed at the bottom of the seat and located inside the plastic parts of the vehicle, which puts the controller in a relatively enclosed environment. This makes it difficult for the controller to dissipate heat, causing problems such as unstable power output and performance degradation. Therefore, improvements are needed. Summary of the Invention

[0003] This invention addresses the shortcomings of existing technologies where the controller is installed at the bottom of the electric vehicle seat bucket and inside the vehicle's plastic components, which hinders heat dissipation and affects controller performance. It provides a new external air-cooled controller structure.

[0004] To solve the above-mentioned technical problems, this utility model is achieved through the following technical solution:

[0005] An external air-cooled controller structure includes a motor and a controller, and a heat sink with a sealed chamber. The heat sink is detachably installed on the front side of the motor and attached to the stator end. The lower end of the controller is inserted into the sealed chamber and seals the chamber. The controller is fixed to the heat sink with screws. The heat sink has through holes for the motor shaft and motor wires to pass through. The wiring harness on the controller is electrically connected to the motor wires and external wiring harness.

[0006] By mounting the controller on the front of the motor via a heat sink, the controller is no longer in a confined environment. The heat generated during electric vehicle riding can carry away the heat from the controller's surface, and the heat sink can also dissipate the heat generated during operation, preventing overheating, improving controller efficiency, and extending the controller's lifespan. Since the controller's position has been moved from inside the vehicle's plastic components to the front of the motor, the original motor cable, which was more than one meter long, can be shortened, saving production costs.

[0007] Preferably, in the above-described external air-cooled controller structure, the upper surface of the heat sink is provided with a first wiring groove and a second wiring groove. The two ends of the first wiring groove are respectively connected to the through hole and the sealing chamber. The first wiring groove is for the motor wire to pass through, and the second wiring groove is for the wiring harness on the controller to pass through.

[0008] The first and second wiring channels can separate and limit the wiring harnesses of the motor wires and the controller, which facilitates wiring, connection and subsequent maintenance.

[0009] Preferably, the external air-cooled controller structure described above also includes a cable sleeve with a through-hole. The cable sleeve is detachably mounted on the heat sink and covers the first and second cable routing channels. The through-hole is directly opposite the through-hole.

[0010] The cable cover covers the first and second cable trays, thus neatly confining the motor wires and controller wiring harnesses on the heat sink, improving the neatness of the wiring and protecting the motor wires and controller wiring harnesses.

[0011] Preferably, in the above-described external air-cooled controller structure, the heat sink is provided with a mating tube surrounding the outside of the through hole, and the cable sheath is sleeved on the mating tube.

[0012] The fitting tube provides an installation position for the cable sheath, making it easy to press and fix the cable sheath onto the heat sink, and to cover the first and second cable routing channels.

[0013] Preferably, in the above-described external air-cooled controller structure, the upper surface of the controller is provided with a first heat dissipation fin plate, the outer surface of the heat sink is provided with a second heat dissipation fin plate, the inner surface of the heat sink is provided with a positioning groove, the positioning groove is for the stator end to be inserted and engaged, and the top inner wall of the positioning groove is flat and in contact with the stator end.

[0014] The positioning groove and the stator are connected to achieve pre-positioning of the heat sink, which makes it easy to fix the heat sink to the front side of the motor. The top inner wall of the positioning groove is in contact with the end of the stator, which allows the heat sink to be directly attached to the end of the stator, which facilitates heat dissipation of the stator. The first heat dissipation fin and the second heat dissipation fin achieve heat dissipation of the controller itself and the heat sink, thereby enabling more effective heat dissipation of the controller.

[0015] As a preferred embodiment, in the aforementioned external air-cooled controller structure, the second heat dissipation fin plate includes an upper plate and a lower plate distributed on the upper and lower surfaces of the heat dissipation base, and the top of the upper plate is wavy.

[0016] The second heat dissipation fins are distributed on the upper and lower surfaces of the heat sink, further increasing the heat conduction performance of the heat sink. The top of the upper plate is wavy, which can more effectively guide the air to the surface of the controller, thereby further promoting heat dissipation on the surface of the controller.

[0017] Preferably, the aforementioned external air-cooled controller structure further includes a rear horizontal fork, on which a through hole and a locking hole are provided. The through hole and the mating hole are aligned and the motor shaft passes through. The heat sink is provided with a hollow locking post aligned with the locking hole. The locking post has a flexible sleeve inside. The heat sink and the rear horizontal fork are fixed by the locking post, the locking hole, and bolts. The inner wall of the rear horizontal fork has a limiting protrusion for pressing against the front end of the cable sleeve.

[0018] The limiting protrusion on the rear horizontal fork presses against the cable protection sleeve, improving the stability of the cable protection sleeve covering the first and second cable routing grooves. The rear horizontal fork can cover, protect, and limit the front side of the heat sink. The flexible sleeve can act as a buffer between the bolts and locking pins, improving the stability of the connection between the rear horizontal fork and the heat sink. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of this utility model;

[0020] Figure 2 This is a schematic diagram of the controller, heat sink, and cable sleeve of this utility model;

[0021] Figure 3 This is an exploded view of the heat sink and cable sheath of this utility model.

[0022] Figure 4 This is an exploded view of the controller, heat sink, and cable sheath of this utility model;

[0023] Figure 5 This is a schematic diagram of the structure of the rear flat fork of this utility model.

[0024] Explanation of reference numerals in the attached drawings: Motor 1; Controller 2; First heat dissipation fin 21; Heat dissipation base 3; Sealing chamber 30; Through hole 31; First wiring groove 32; Second wiring groove 33; Matching pipe 34; Second heat dissipation fin 35; Upper plate 351; Lower plate 352; Positioning groove 36; Locking post 37; Flexible sleeve 371; Cable protection sleeve 4; Matching hole 41; Rear horizontal fork 5; Through hole 51; Locking hole 52; Limiting protrusion 53. Detailed Implementation

[0025] The following is in conjunction with the appendix Figure 1-5 The present invention will be further described in detail with reference to specific embodiments, but these are not intended to limit the present invention: Example

[0026] like Figures 1-5As shown, an external air-cooled controller structure includes a motor 1 and a controller 2, and a heat sink 3 with a sealed chamber 30. The heat sink 3 is detachably installed on the front side of the motor 1 and attached to the stator end. The lower end of the controller 2 is inserted into the sealed chamber 30 and seals the sealed chamber 30. The controller 2 is fixed to the heat sink 3 with screws. The heat sink 3 has a through hole 31 for the motor shaft and motor wires to pass through. The wiring harness on the controller 2 is electrically connected to the motor wires and the external wiring harness.

[0027] Preferably, the upper surface of the heat sink 3 is provided with a first wiring groove 32 and a second wiring groove 33. The two ends of the first wiring groove 32 are connected to the through hole 31 and the sealing chamber 30 respectively. The first wiring groove 32 is used for the motor wire to pass through, and the second wiring groove 33 is used for the wiring harness on the controller 2 to pass through.

[0028] Preferably, a cable protector 4 is also included, with a through-hole 41 on the cable protector 4. The cable protector 4 is detachably mounted on the heat sink 3 and covers the first cable routing groove 32 and the second cable routing groove 33. The through-hole 41 is directly opposite to the through-hole 31.

[0029] Preferably, the heat sink 3 is provided with a mating tube 34 surrounding the outside of the through hole 31, and the wire sheath 4 is sleeved on the mating tube 34.

[0030] Preferably, the upper surface of the controller 2 is provided with a first heat dissipation fin plate 21, the outer surface of the heat dissipation base 3 is provided with a second heat dissipation fin plate 35, and the inner surface of the heat dissipation base 3 is provided with a positioning groove 36 for the stator end to be inserted and engaged. The top inner wall of the positioning groove 36 is flat and is in contact with the stator end.

[0031] Preferably, the second heat dissipation fin plate 35 includes an upper plate 351 and a lower plate 352 distributed on the upper and lower surfaces of the heat dissipation base 3, and the top of the upper plate 351 is wavy.

[0032] Preferably, it also includes a rear horizontal fork 5, which has a through hole 51 and a locking hole 52. The through hole 51 is aligned with the mating hole 41 and the motor shaft passes through it. The heat sink 3 is provided with a hollow locking post 37 that is aligned with the locking hole 52. The locking post 37 has a flexible sleeve 371 inside. The heat sink 3 and the rear horizontal fork 5 are fixed by the locking post 37, the locking hole 52 and bolts. The inner wall of the rear horizontal fork 5 has a limiting protrusion 53 for pressing against the front end of the cable sleeve 4.

[0033] Specifically, such as Figures 1-4As shown, a rectangular limiting notch is formed at the bottom edge of the controller 2, and an extension plate extending outward in the horizontal direction is integrally formed on the top of the sealing chamber 30. The extension plate is inserted into the limiting notch for mating. The outer side wall of the controller 2 is flush with the outer side wall of the extension plate, and the inner side wall of the limiting notch is in contact with the inner wall of the sealing chamber 30. Thus, the sealing chamber 30 can be sealed by the controller 2.

[0034] The heat sink 3 has three fixed posts integrally formed on the side of the sealed chamber 30. The fixed posts have a first hole for engaging with screws. The three fixed posts are connected in sequence to form a triangle. The controller 2 is fixed to the heat sink 3 by the mutual engagement of screws, the first hole and the second hole.

[0035] The bottom of the controller 2 has terminals and connectors. Power and signal wires extend from the side of the controller 2. The power and signal wires are laid in the second wiring trough 33 and electrically connected to the external wiring harness. The motor wires emerge from the through hole 31 along with the motor shaft. The motor wires are laid in the first wiring trough 32 and pass into the sealed chamber 30. The motor wires are electrically connected to the terminals and connectors on the controller 2. At the same time, the cable sleeve 4 can be pressed together at the first wiring trough 32 and the second wiring trough 33, which further improves the neatness and stability of the motor wires, signal wires and power wires laid on the heat sink 3, and facilitates the subsequent maintenance of the controller 2.

[0036] Because the wiring terminals and connectors at the bottom of the controller 2 are located inside the sealed chamber 30, by pouring insulating thermally conductive adhesive into the sealed chamber 30, not only can the heat of the controller 2 be better dissipated, but the motor wire can also be stably connected to the wiring terminals and connectors, further improving the stability of the connection between the controller 2 and the motor wire, and the stability of the controller 2 fixed on the heat sink 3.

[0037] When a user is using the electric vehicle, the controller 2, mounted on the front of the motor 1 via the heat sink 3, is no longer in a confined environment. The natural wind generated during riding carries away the heat from the controller 2's surface, and the heat sink 3 further dissipates the heat generated during operation, preventing overheating, improving efficiency, and extending the controller 2's lifespan. Because the controller 2's location has been moved from inside the vehicle's plastic components to the front of the motor 1, the original motor wiring, which was over a meter long, can be shortened, saving production costs.

[0038] More specifically, such as Figures 1-5As shown, the top inner wall of the positioning groove 36 is flat and has three third holes spaced apart. The heat sink 3 is fitted onto the stator end through the positioning groove 36 and fixed to the front side of the motor 1 through the third holes and screws. Because the top inner wall of the positioning groove 36 is flat and directly contacts the stator end, the thermally conductive coating applied to the top inner wall of the positioning groove 36 can effectively dissipate heat from the stator end.

[0039] The rear horizontal fork 5 is U-shaped. One side of the rear horizontal fork 5 is connected and fixed to the heat sink 3 by bolts, locking pins 37, and locking holes 52. This, together with the motor 1, can limit the forward and backward movement of the heat sink 3, improving the stability of the heat sink 3. Because the rear horizontal fork 5 has a limiting protrusion 53 that presses against the front side of the cable guard 4, it can press the cable guard 4 tightly against the mating tube 34, further improving the stability of the cable guard 4 pressing against the first cable routing groove 32 and the second cable routing groove 33.

[0040] In summary, the above description is only a preferred embodiment of the present utility model. All equivalent changes and modifications made within the scope of the patent application of the present utility model shall be covered by the present utility model.

Claims

1. An external air-cooled controller structure, comprising a motor (1) and a controller (2), characterized in that: It also includes a heat sink (3) with a sealed chamber (30), the heat sink (3) is detachably installed on the front side of the motor (1) and attached to the stator end, the lower end of the controller (2) is inserted into the sealed chamber (30) and the sealed chamber (30) is sealed, the controller (2) is fixed on the heat sink (3) by screws, the heat sink (3) has a through hole (31) for the power supply shaft and motor wires to pass through, and the wiring harness on the controller (2) is electrically connected to the motor wires and external wiring harness.

2. The external air-cooled controller structure according to claim 1, characterized in that: The upper surface of the heat sink (3) is provided with a first wiring groove (32) and a second wiring groove (33). The two ends of the first wiring groove (32) are connected to the through hole (31) and the sealing chamber (30) respectively. The first wiring groove (32) allows the motor wire to pass through, and the second wiring groove (33) allows the wiring harness on the controller (2) to pass through.

3. The structure of an external air-cooled controller according to claim 2, characterized in that: It also includes a cable sleeve (4), on which a mating hole (41) is provided. The cable sleeve (4) is detachably mounted on the heat sink (3) and covers the first cable routing groove (32) and the second cable routing groove (33). The mating hole (41) is directly opposite to the through hole (31).

4. The external air-cooled controller structure according to claim 3, characterized in that: The heat sink (3) is provided with a fitting tube (34) surrounding the outside of the through hole (31), and the wire sheath (4) is fitted on the fitting tube (34).

5. The structure of an external air-cooled controller according to claim 1, characterized in that: The controller (2) is provided with a first heat dissipation fin plate (21) on its upper surface, and the heat dissipation base (3) is provided with a second heat dissipation fin plate (35) on its outer surface. The heat dissipation base (3) is provided with a positioning groove (36) on its inner surface. The positioning groove (36) is for the stator end to be inserted and connected. The top inner wall of the positioning groove (36) is flat and is attached to the stator end.

6. The structure of an external air-cooled controller according to claim 5, characterized in that: The second heat dissipation fin plate (35) includes an upper plate (351) and a lower plate (352) distributed on the upper and lower surfaces of the heat dissipation base (3), and the top of the upper plate (351) is wavy.

7. The structure of an external air-cooled controller according to claim 3, characterized in that: It also includes a rear flat fork (5), on which a through hole (51) and a locking hole (52) are passed through. The through hole (51) and the mating hole (41) are aligned and the motor shaft passes through. The heat sink (3) is provided with a hollow locking post (37) aligned with the locking hole (52). The locking post (37) has a flexible sleeve (371) inside. The heat sink (3) and the rear flat fork (5) are fixed by the locking post (37), the locking hole (52) and the bolt. The inner wall of the rear flat fork (5) has a limiting protrusion (53) for pressing against the front end of the cable sleeve (4).

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