Motor controller assembly, steering system, and vehicle therefor

Abstract

The application relates to a motor controller assembly, a steering system and a vehicle thereof, which comprise a motor assembly, a controller upper cover, a PCBA board, a connector and a conductive piece. The motor assembly comprises a motor and a shell, the motor is located in the shell and connected with the shell, and the motor comprises a first three-phase winding and a second three-phase winding. The controller upper cover is connected with the shell, and a cavity is arranged between the controller upper cover and the shell. The PCBA board is located in the cavity and connected with the shell, and the PCBA board comprises a first control module and a second control module, the first control module is connected with the first three-phase winding, and the second control module is connected with the second three-phase winding. The connector is arranged in the shell and connected with the shell and the PCBA board. The conductive piece is located in the cavity and connected between the shell and the PCBA board. The motor controller assembly, the steering system and the vehicle thereof can improve the safety of intelligent driving.

Description

Technical Field

[0001] This application belongs to the technical field of automotive steering systems, specifically relating to a motor controller assembly, a steering system, and a vehicle thereof. Background Technology

[0002] Electric power steering (EPS) is a type of automotive power steering system that relies on an electric motor to provide auxiliary torque. Its main components include: steering mechanism, controller, motor, etc.

[0003] Since most existing electric power steering systems are single control systems, and the electric power steering system requires a large current to operate, the heat generated by the large current will shorten the service life of the components or even cause damage to the components. Therefore, the safety of the electric power steering system cannot be guaranteed, and it is difficult to meet the safety requirements of intelligent driving. Utility Model Content

[0004] The purpose of this application is to provide a motor controller assembly, a steering system, and a vehicle thereof that can improve the safety of intelligent driving.

[0005] The first aspect of this application discloses a motor controller assembly, comprising: a motor assembly, a controller cover, a PCBA board, a connector, and a conductive component. The motor assembly includes a motor and a housing. The motor is located inside and connected to the housing, and includes a first three-phase winding and a second three-phase winding. The controller cover is connected to the housing, and a cavity is provided between the controller cover and the housing. The PCBA board is located inside the cavity and connected to the housing. The PCBA board includes a first control module and a second control module. The first control module is connected to the first three-phase winding, and the second control module is connected to the second three-phase winding. The connector passes through the housing and is connected to both the housing and the PCBA board. The conductive component is located inside the cavity and is connected between the housing and the PCBA board.

[0006] In one exemplary embodiment of this application, the conductive component includes a conductive portion and a plastic-coated portion. The conductive portion is disposed within the plastic-coated portion and is connected to the PCBA board. The plastic-coated portion is connected to the outer shell. The conductive portion includes a first conductive portion and a second conductive portion. The first conductive portion includes a first current inlet terminal and a first current outlet terminal. The second conductive portion includes a second current inlet terminal and a second current outlet terminal. The first current inlet terminal, the second current inlet terminal, the first current outlet terminal, and the second current outlet terminal are all connected to the PCBA board.

[0007] In one exemplary embodiment of this application, the connector includes a 2P pin header connector and two 10P pin header connectors. The two 10P pin header connectors are integrally formed. The 2P pin header connector and the two 10P pin header connectors are spaced apart. The 2P pin header connector and the two 10P pin header connectors are all disposed within the housing and are connected to the housing and the PCBA board. The 2P pin header connector is used to connect to a power source. One 10P pin header connector is used to transmit a signal, and the other 10P pin header connector is used to connect to a sensor.

[0008] In one exemplary embodiment of this application, the PCBA board is provided with a first mounting hole, the connector is provided with a second mounting hole, and the conductive component is provided with a third mounting hole; the motor controller assembly further includes a fastener, the fastener passing through the first mounting hole and connected to the housing; the fastener passing through the second mounting hole and connected to the housing; and the fastener passing through the third mounting hole and connected to the housing.

[0009] In one exemplary embodiment of this application, the outer shell is provided with a plurality of slots, which are spaced apart from each other; the controller cover is provided with a plurality of buckles, which are spaced apart from each other, and the plurality of buckles are riveted into the plurality of slots one by one.

[0010] In one exemplary embodiment of this application, the motor assembly further includes six pins, all of which pass through the housing. Three of the pins are connected between the first three-phase winding and the first control module, and the other three pins are connected between the second three-phase winding and the second control module.

[0011] In one exemplary embodiment of this application, the housing is provided with a heat dissipation area, and the motor controller assembly further includes a heat dissipation adhesive, which is disposed in the heat dissipation area of ​​the housing.

[0012] In one exemplary embodiment of this application, the motor assembly further includes a magnet located inside the housing and connected to one end of the motor shaft near the PCBA board; the PCBA board is provided with a sensing chip, which is correspondingly arranged with the magnet.

[0013] A second aspect of this application discloses a steering system including the aforementioned motor controller assembly.

[0014] A third aspect of this application discloses a vehicle including the aforementioned steering system.

[0015] The proposed solution has the following beneficial effects: In this embodiment, since the first control module of the PCBA board is connected to the first three-phase winding of the motor, and the second control module of the PCBA board is connected to the second three-phase winding of the motor, under normal operation, both the first control module and the first three-phase winding, as well as the second control module and the second three-phase winding, work simultaneously, providing 100% power assist. Even if a fault occurs in either the first control module and the first three-phase winding (or the second control module and the second three-phase winding), the second control module and the second three-phase winding (or the first control module and the first three-phase winding) can still function normally, providing 50% power assist. Therefore, the electric power steering system is a dual control system to improve the safety of intelligent driving. Furthermore, the PCBA board can achieve high-current over-the-air connection through conductive components, which helps reduce the impact of high current on the PCBA board, thereby extending its service life and reducing the probability of damage, thus improving the safety of intelligent driving.

[0016] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort. The drawings herein are for illustrating the inventive concept of this application and are not entirely equivalent to the structure of the actual product protected by this application.

[0018] Figure 1 A three-dimensional structural schematic diagram of the motor controller assembly in an embodiment of this application is shown.

[0019] Figure 2 A schematic diagram of the disassembled structure of the motor controller assembly in an embodiment of this application is shown.

[0020] Figure 3 A front view of the motor controller assembly in an embodiment of this application is shown.

[0021] Figure 4 A schematic diagram of the motor controller assembly without a controller cover is shown in an embodiment of this application.

[0022] Figure 5 An embodiment of this application is shown. Figure 4 The diagram shows the structure of the motor controller assembly without a PCBA board.

[0023] Explanation of reference numerals in the attached figures: 1. Motor assembly; 101. Slot; 102. Heat dissipation area; 102a. First heat dissipation area; 102b. Second heat dissipation area; 11. Housing; 12. Pin; 13. Magnet; 2. Controller top cover; 201. Cavity; 3. PCBA board; 4. Connector; 41. 2P pin header connector; 42. 10P pin header connector; 5. Conductive component; 511. First current inlet terminal; 512. First current outlet terminal; 521. Second current inlet terminal; 522. Second current outlet terminal; a. First connection point; b. Second connection point; c. Fastener; d. Buckle; e. Axis of symmetry. Detailed Implementation

[0024] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided to make this application more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art.

[0025] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0026] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments. It should be noted that the technical features involved in the various embodiments described below can be combined with each other as long as they do not conflict with each other. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present application, and should not be construed as limiting the present application.

[0027] like Figures 1 to 5As shown, this embodiment provides a motor controller assembly, including: a motor assembly 1, a controller cover 2, a PCBA board 3, a connector 4, and a conductive component 5. The motor assembly 1 includes a motor and a housing 11. The motor is located inside the housing 11 and connected to the housing 11. The motor includes a first three-phase winding and a second three-phase winding. The controller cover 2 is connected to the housing 11, and a cavity 201 is provided between the controller cover 2 and the housing 11. The PCBA board 3 is located inside the cavity 201 and connected to the housing 11. The PCBA board 3 includes a first control module and a second control module. The first control module is connected to the first three-phase winding, and the second control module is connected to the second three-phase winding. The connector 4 passes through the housing 11 and is connected to the housing 11 and the PCBA board 3. The conductive component 5 is located inside the cavity 201 and is connected between the housing 11 and the PCBA board 3.

[0028] In this embodiment, combined with Figure 4 As shown, the first control module and the second control module are symmetrically arranged on two opposite sides of the axis of symmetry e. The first control module has three first connection points a, which are connected one-to-one with the first three-phase winding; the second control module has three second connection points b, which are connected one-to-one with the second three-phase winding.

[0029] In this embodiment, since the first control module of PCBA board 3 is connected to the first three-phase winding of the motor, and the second control module of PCBA board 3 is connected to the second three-phase winding of the motor, under normal operation, the first control module and the first three-phase winding, as well as the second control module and the second three-phase winding, work simultaneously, providing 100% power assist. When a fault occurs in the first control module and the first three-phase winding (or the second control module and the second three-phase winding), the second control module and the second three-phase winding (or the first control module and the first three-phase winding) can still work normally, providing 50% power assist. Therefore, the electric power steering system is a dual control system to improve the safety of intelligent driving. Furthermore, PCBA board 3 can achieve high-current over-the-air connection through conductive element 5, which helps reduce the impact of high current on PCBA board 3, thereby extending the service life of PCBA board 3 and reducing the probability of PCBA board 3 damage, thus improving the safety of intelligent driving.

[0030] In this embodiment, combined with Figure 5 As shown, the conductive component 5 includes a conductive part and a plastic-coated part. The conductive part is disposed inside the plastic-coated part and is connected to the PCBA board 3. The plastic-coated part is connected to the outer shell 11. The plastic-coated part not only isolates the conductive part, preventing direct contact between the conductive part and the outer shell 11, but also protects the conductive part and prevents oxidation.

[0031] For example, the conductive part can be a copper busbar.

[0032] Combination Figure 4 and Figure 5 As shown, the conductive part includes a first conductive part and a second conductive part. The first conductive part includes a first current inlet terminal 511 and a first current outlet terminal 512. The second conductive part includes a second current inlet terminal 521 and a second current outlet terminal 522. The first current inlet terminal 511, the second current inlet terminal 521, the first current outlet terminal 512, and the second current outlet terminal 522 are all connected to the PCBA board 3 by soldering.

[0033] In this embodiment, the first conductive part includes two first current inlet terminals 511 and two first current outlet terminals 512, both of which are positive electrodes; the second conductive part includes two second current inlet terminals 521 and two second current outlet terminals 522, both of which are negative electrodes.

[0034] In this embodiment, when the PCBA board 3 is connected to the power supply, the current flows out from the positive terminal and first flows into the conductive component 5 through the two first current inlet terminals 511, then flows back to the PCBA board 3 through the conductive component 5 through the two first current outlet terminals 512, then flows into the motor, and then returns to the PCBA board 3. The current then flows into the conductive component 5 through the two second current inlet terminals 521, and then flows back to the PCBA board 3 through the two second current outlet terminals 522. Changing the current flow path through the conductive component 5 helps to reduce the impact of large currents on the components on the PCBA board.

[0035] It should be understood that since the motor includes a first three-phase winding and a second three-phase winding, there are two current inlet terminals 511, 521, 512, and 522.

[0036] Combination Figure 3 As shown, connector 4 includes a 2P pin header connector 41 and two 10P pin header connectors 42. The two 10P pin header connectors 42 are an integral structure. The 2P pin header connector 41 and the two 10P pin header connectors 42 are spaced apart. The 2P pin header connector 41 and the two 10P pin header connectors 42 are all inserted through the housing 11 and are connected to the housing 11 and the PCBA board 3. The 2P pin header connector 41 is used to connect to the power supply. One 10P pin header connector 42 is used to transmit signals, and the other 10P pin header connector 42 is used to connect to the sensor.

[0037] In this embodiment, the 2P pin header connector 41 and the two 10P pin header connectors 42 are all connected to the PCBA board 3 by soldering. The two 10P pin header connectors 42 are an integral structure for easy installation in the housing 11. The PCBA board 3 is connected to the power supply through the 2P pin header connector 41 to ensure the normal operation of the motor controller assembly. The PCBA board 3 transmits control signals through one 10P pin header connector 42, and the PCBA board 3 is connected to the sensor through the other 10P pin header connector 42 to receive feedback signals from the sensor.

[0038] Combination Figures 3 to 5 As shown, PCBA board 3 has a first mounting hole, connector 4 has a second mounting hole, and conductive component 5 has a third mounting hole; the motor controller assembly also includes fastener c, which passes through the first mounting hole and is connected to housing 11; fastener c passes through the second mounting hole and is connected to housing 11; and fastener c passes through the third mounting hole and is connected to housing 11.

[0039] In this embodiment, the fastener c is a screw. The PCBA board 3 has four spaced-apart first mounting holes. Four screws pass through each of the four first mounting holes and connect to the housing 11 to achieve the connection between the PCBA board 3 and the housing 11. The 2P pin header connector 41 has two spaced-apart second mounting holes. Two screws pass through each of the two second mounting holes and connect to the housing 11 to achieve the connection between the 2P pin header connector 41 and the housing 11. The two 10P pin header connectors 42 have two spaced-apart second mounting holes. Two screws pass through each of the two second mounting holes and connect to the housing 11 to achieve the connection between the two 10P pin header connectors 42 and the housing 11. The plastic-coated part has two spaced-apart third mounting holes. Two screws pass through each of the two third mounting holes and connect to the housing 11 to achieve the connection between the plastic-coated part and the housing 11.

[0040] In this embodiment, the PCBA board 3, connector 4, and conductive component 5 are all connected to the housing 11 by screws, so that the PCBA board 3, connector 4, and conductive component 5 are all fixed to the motor assembly 1, which helps to improve the stability and reliability of the motor controller assembly.

[0041] Combination Figure 1 and Figure 2 As shown, the outer casing 11 is provided with multiple slots 101, which are spaced apart from each other; the controller cover 2 is provided with multiple buckles d, which are spaced apart from each other, and each buckle d is riveted into the multiple slots 101.

[0042] It should be understood that "multiple" includes two or more quantities.

[0043] In this embodiment, the outer casing 11 has four slots 101, and the controller cover 2 has four clips d. The four clips d are riveted into the four slots 101 to connect the outer casing 11 and the controller cover 2. Compared with screw connections, the clips d being riveted into the slots 101 reduces the space occupied by the chassis and saves BOM costs. Connecting the outer casing 11 and the controller cover 2 by riveting improves the connection strength between the outer casing 11 and the controller cover 2, thereby protecting the PCBA board 3.

[0044] Combination Figure 1 , Figure 2 and Figure 5 As shown, the motor assembly 1 also includes six pins 12, all of which pass through the housing 11. Three pins 12 are connected between the first three-phase winding and the first connection point a of the first control module, and the other three pins 12 are connected between the second three-phase winding and the second connection point b of the second control module.

[0045] In this embodiment, three PIN pins 12 are connected between the first three-phase winding and the first connection point a of the first control module to realize the connection between the first three-phase winding and the first control module; the other three PIN pins 12 are connected between the second three-phase winding and the second connection point b of the second control module to realize the connection between the second three-phase winding and the second control module.

[0046] Combination Figure 5 As shown, the housing 11 is provided with a heat dissipation area 102, and the motor controller assembly also includes thermal adhesive, which is disposed in the heat dissipation area 102 of the housing 11.

[0047] In this embodiment, the heat dissipation area 102 includes a first heat dissipation area 102a and a second heat dissipation area 102b symmetrically arranged. Both the first heat dissipation area 102a and the second heat dissipation area 102b are provided with thermal adhesive. The thermal adhesive is disposed between the outer casing 11 and the PCBA board 3, and is in contact with both the outer casing 11 and the PCBA board 3. The thermal adhesive can establish an efficient heat dissipation path between the outer casing 11 and the PCBA board 3, thereby transferring the heat generated by the PCBA board 3 to the outer casing 11, and dissipating the heat through the outer casing 11. This ensures the performance stability of the PCBA board 3, extends its service life, and reduces the probability of damage to the PCBA board 3.

[0048] Combination Figure 2 As shown, the motor assembly 1 also includes a magnet 13, which is located inside the housing 11 and connected to one end of the motor shaft near the PCBA board 3; the PCBA board 3 is provided with a sensing chip, which is correspondingly set with the magnet 13.

[0049] In this embodiment, the magnet 13 is press-fitted onto the end of the motor shaft near the PCBA board 3 to achieve synchronous rotation between the magnet 13 and the motor shaft. A sensing chip is correspondingly positioned to the magnet 13 to ensure that the sensing chip can detect the changing magnetic field generated by the magnet 13 in real time.

[0050] This embodiment also provides a steering system, including the motor controller assembly described above.

[0051] For other aspects of the steering system, please refer to existing technologies; they will not be elaborated upon here.

[0052] This embodiment also provides a vehicle including the steering system described above.

[0053] For other aspects of the vehicle's structure, please refer to existing technology; details will not be elaborated here.

[0054] In this application, unless otherwise expressly specified and limited, the terms "assembly," "connection," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0055] 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. "A plurality of" means two or more, unless otherwise explicitly specified. The terms "some embodiments," "exemplarily," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application.

[0056] The illustrative expressions of the terms used above do not necessarily refer to the same embodiments or examples. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, those skilled in the art can combine and integrate the different embodiments or examples described herein, as well as the features of those different embodiments or examples, without contradiction.

[0057] Although embodiments of this application have been shown and described above, it should be understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application. Therefore, any changes or modifications made in accordance with the claims and description of this application should fall within the scope of the patent coverage of this application.

Claims

1. A motor controller assembly, characterized in that, include: A motor assembly, comprising a motor and a housing, wherein the motor is located inside and connected to the housing, and the motor includes a first three-phase winding and a second three-phase winding; A controller cover is provided, which is connected to the outer shell, and a cavity is provided between the controller cover and the outer shell; PCBA board, the PCBA board is located in the cavity and connected to the outer shell, the PCBA board includes a first control module and a second control module, the first control module is connected to the first three-phase winding, and the second control module is connected to the second three-phase winding; A connector that passes through the housing and connects to the housing and the PCBA board; A conductive component is located within the cavity and is connected between the outer casing and the PCBA board.

2. The motor controller assembly according to claim 1, characterized in that, The conductive component includes a conductive part and a plastic-coated part. The conductive part is disposed inside the plastic-coated part and is connected to the PCBA board. The plastic-coated part is connected to the outer shell. The conductive part includes a first conductive part and a second conductive part. The first conductive part includes a first current inlet end and a first current outlet end. The second conductive part includes a second current inlet end and a second current outlet end. The first current inlet end, the second current inlet end, the first current outlet end, and the second current outlet end are all connected to the PCBA board.

3. The motor controller assembly according to claim 1, characterized in that, The connector includes a 2P pin header connector and two 10P pin header connectors. The two 10P pin header connectors are an integral structure. The 2P pin header connector and the two 10P pin header connectors are spaced apart. The 2P pin header connector and the two 10P pin header connectors are all inserted through the housing and are all connected to the housing and the PCBA board. The 2P pin header connector is used to connect to the power supply; One of the 10P pin header connectors is used for transmitting signals, and the other of the 10P pin header connectors is used for connecting a sensor.

4. The motor controller assembly according to claim 1, characterized in that, The PCBA board is provided with a first mounting hole, the connector is provided with a second mounting hole, and the conductive component is provided with a third mounting hole; The motor controller assembly further includes fasteners, which pass through the first mounting hole and are connected to the housing; the fasteners pass through the second mounting hole and are connected to the housing; and the fasteners pass through the third mounting hole and are connected to the housing.

5. The motor controller assembly according to claim 1, characterized in that, The outer casing is provided with multiple slots, and the multiple slots are spaced apart from each other; The controller cover is provided with multiple buckles, which are spaced apart from each other and are riveted into the slots one by one.

6. The motor controller assembly according to claim 1, characterized in that, The motor assembly also includes six pins, all of which pass through the housing. Three of the pins are connected between the first three-phase winding and the first control module, and the other three pins are connected between the second three-phase winding and the second control module.

7. The motor controller assembly according to claim 1, characterized in that, The outer casing is provided with heat dissipation areas. The motor controller assembly also includes thermal adhesive, which is disposed in the heat dissipation area of ​​the housing.

8. The motor controller assembly according to claim 1, characterized in that, The motor assembly also includes a magnet located inside the housing and connected to one end of the motor shaft near the PCBA board; The PCBA board is equipped with a sensing chip, which is configured to correspond to the magnet.

9. A steering system, characterized in that, Includes the motor controller assembly as described in any one of claims 1-8.

10. A vehicle, characterized in that, Includes the steering system as described in claim 9.

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