Brushless motor controller cover plate and electric power steering unit

Abstract

This utility model discloses a brushless motor controller cover plate. The cover plate includes an upper cover body made of engineering plastic mixed with reinforced glass fiber. The upper cover body has multiple mounting holes, each containing a metal insert. The upper surface of the insert is flush with the surface of the upper cover body. Multiple bosses are provided in the middle of the upper cover body, some of which have height differences and form groove structures on the mating surfaces. The bosses and grooves are connected by reinforcing ribs. Reinforcing ribs are evenly distributed along the long and short sides of the edge area of ​​the upper cover body. The brushless motor controller cover plate of this utility model, with its upper cover body made of composite materials, can improve corrosion resistance, reduce corrosion risk, and reduce weight, achieving lightweight design. Furthermore, the inclusion of inserts and reinforcing ribs improves structural reliability. This utility model also discloses an integrated electric power steering system.

Description

Technical Field

[0001] This utility model belongs to the technical field of vehicle steering systems. Specifically, this utility model relates to a brushless motor controller cover and an integrated electric power steering system. Background Technology

[0002] The Electronic Control Unit (ECU) is the brain and command center of the Electric Power Steering (EPS). It receives information such as vehicle speed and driving mode, as well as the torque and angle information of the EPS. After calculation and processing, it provides the best assistance mode for vehicle steering. The current trend of electric vehicles becoming the mainstream models has also driven the rapid development of the EPS industry, which will also put forward requirements on the weight of EPS. As the chassis component of the whole vehicle, the ECU must have good impact resistance and dust and water resistance. Moreover, as the nerve center of EPS, the protection of the ECU is particularly important.

[0003] In existing technologies, there are two main solutions for ECU protection in brushless all-in-one machines. Solution 1: Using a steel cover for protection. This structure has strong impact resistance, but the disadvantage is that the material itself does not have anti-corrosion properties, requiring additional surface protection treatment, which increases the processing cost of the parts. Due to the inherent characteristics of steel, the weight of the parts is relatively high, which is not conducive to the lightweight design of the product. Solution 2: Using an aluminum alloy cover for protection. This structure has strong impact resistance, but the disadvantage is that the surface needs passivation treatment to meet anti-corrosion requirements, which increases processing costs. The weight of the parts is also relatively high, which is not conducive to the lightweight design.

[0004] Chinese Patent Application No. 202210729497.5 discloses an intelligent electric power steering system for all-terrain vehicles, including a housing assembly, a torque angle sensor, a power steering motor assembly, and a steering torsion bar mechanism mounted on the housing assembly. The power steering motor assembly includes a power steering motor body, a controller cover mounted on the power steering motor body, and a steering controller disposed between the power steering motor body and the controller cover. The steering controller is electrically connected to the torque angle sensor. However, the technical solution disclosed in this patent document also fails to solve the aforementioned technical problems.

[0005] This invention provides a cover for a brushless motor controller, specifically addressing how to improve corrosion resistance, reduce corrosion risk, and decrease weight. Utility Model Content

[0006] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention provides a brushless motor controller cover plate, which aims to improve corrosion resistance, reduce the risk of corrosion, and reduce weight.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a brushless motor controller cover plate, the cover plate comprising an upper cover body made of engineering plastic mixed with reinforced glass fiber, the upper cover body having multiple mounting holes, each mounting hole having a metal insert embedded therein; the upper surface of the insert is flush with the surface of the upper cover body; The upper cover body has multiple protrusions in the middle, some of which have a height difference and form a groove structure on the assembly and fitting surface. The protrusions and the grooves are connected by reinforcing ribs. The edge region of the upper cover body is provided with reinforcing ribs evenly distributed along the long and short sides.

[0008] The upper cover body is rectangular in shape.

[0009] There are six mounting holes, and the inner walls of the mounting holes are arc-shaped.

[0010] The outer arc of the six mounting holes is connected to the central boss by reinforcing ribs.

[0011] The upper cover body has several first reinforcing ribs on each of its long sides and several second reinforcing ribs on each of its short sides.

[0012] The upper cover body has a first protrusion and a second protrusion with different heights in the middle, wherein the second protrusion is higher than the first protrusion.

[0013] The end face of the first boss is provided with a rectangular groove, and the two ends of the first boss and the other boss have a 45° bevel structure.

[0014] At the edge between the first boss and the second boss, an arc-shaped cut is provided with the adjacent mounting hole as the center.

[0015] The upper cover body has an opening in the middle, and a vent valve is installed at the opening. The vent valve is pressed tightly against the opening by its own sealing ring. The middle opening is a conical hole, and the tail end of the conical hole is connected to a cylindrical hole. The vent valve has an inverted snap-fit ​​structure. The opening of the conical hole has several evenly distributed notches.

[0016] The assembly and fitting surface has multiple sub-grooves in the middle. The bottom surface of each sub-groove is lower than the assembly and fitting surface, and reinforcing ribs in different directions are provided in the sub-grooves.

[0017] The sub-groove includes multiple grooves that are parallel to each other or have different heights. One of the grooves has a rectangular boss in the middle, and the end face of the rectangular boss is lower than the assembly mating surface.

[0018] The metal insert is cylindrical, with a circumferential arc groove on the outer surface and a cylindrical hole inside.

[0019] This utility model also provides an integrated electric power steering system, including the brushless motor controller cover plate.

[0020] The brushless motor controller cover of this utility model is made of composite material, which can improve corrosion resistance, reduce corrosion risk, and reduce weight to achieve lightweight design. In addition, it is equipped with inserts and reinforcing ribs to improve structural reliability. Attached Figure Description

[0021] This manual includes the following figures, which illustrate the following: Figure 1 This is a schematic diagram of the convex surface of the top cover; Figure 2 This is a schematic diagram of the concave surface of the top cover; Figure 3 This is a schematic diagram of a metal insert structure; Figure 4 This is a schematic diagram of the top cover assembly; The markings in the diagram are as follows: 1. First plane; 2. Second plane; 3. First boss; 4. First groove; 5. Second boss; 6. Third boss; 7. Fourth boss; 8. Assembly mating surface; 9. Second groove; 10. Third groove; 11. Fourth groove; 12. Fifth boss; 13. Fifth groove; 14. Arc groove; 15. First sealing ring; 16. Second sealing ring; 17. Motor body; 18. Base; 19. Vent valve; 20. Bolt; 21. Top cover body; 22. ECU. Detailed Implementation

[0022] The specific embodiments of this utility model will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the concept and technical solution of this utility model, and to facilitate its implementation.

[0023] It should be noted that in the following embodiments, the terms "first", "second", "third", "fourth" and "fifth" do not represent an absolute distinction in structure and / or function, nor do they represent the order of execution, but are merely for the convenience of description.

[0024] Firstly, such as Figures 1 to 4 As shown, this utility model provides a brushless motor controller cover plate, including an upper cover body 21 made of engineering plastic mixed with reinforced glass fiber. The upper cover body 21 is provided with multiple mounting holes, and a metal insert is embedded in each mounting hole; the upper surface of the metal insert is flush with the surface of the upper cover body 21; multiple bosses are provided in the middle of the upper cover body 21, some of the bosses have a height difference and form a groove structure on the assembly and mating surface 8, and the bosses and grooves are connected by reinforcing ribs; reinforcing ribs are evenly distributed along the long and short sides of the edge area of ​​the upper cover body 21.

[0025] Specifically, such as Figure 1 and Figure 2 As shown, the upper cover body 21 is generally rectangular. There are six mounting holes, and the inner walls of the mounting holes are arc-shaped. The outer arc of the six mounting holes is connected to the central boss by a reinforcing rib. Metal inserts are embedded in the six mounting holes respectively. The central hole of the metal insert is for the bolt 20 to pass through. The upper cover body 21 is fixedly connected to the base 18 of the electric power steering unit by bolts 20.

[0026] Preferably, the upper cover body 21 has several first reinforcing ribs on each of its long sides and several second reinforcing ribs on each of its short sides.

[0027] like Figure 1 and Figure 2 As shown, in this embodiment, each of the two long sides of the upper cover body 21 is provided with 7 first reinforcing ribs, and each of the two short sides of the upper cover body 21 is provided with 5 second reinforcing ribs.

[0028] like Figure 1 and Figure 2 As shown, the upper cover body 21 has a first protrusion 3 and a second protrusion 5 of different heights in the middle, with the second protrusion 5 being higher than the first protrusion 3. The upper cover body 21 has a mounting surface 8, a first plane 1, and a second plane 2. The mounting surface 8 and the first plane 1 are located on opposite sides of the thickness direction of the upper cover body 21, and are parallel to each other. The mounting surface 8 is fitted to the base 18, and the mounting hole extends through the mounting surface 8 to the first plane 1. The first plane 1 and the second plane 2 are located in the same plane. The height direction of the first protrusion 3 and the second protrusion 5 is also the thickness direction of the upper cover body 21. The first protrusion 3 and the second protrusion 5 are rectangular protrusions. The upper cover body 21 also has a third protrusion 6, which is located in the same plane and has the same height. The first protrusion 3, the second protrusion 5, and the third protrusion 6 are arranged sequentially along the length direction of the upper cover body 21.

[0029] like Figure 1 and Figure 2 As shown, the end face of the first boss 3 is provided with a first groove 4, which is a rectangular groove, and the two ends of the first boss 3 and the third boss 6 have a 45° bevel structure. The two ends of the second plane 2 are also set with a 45° bevel structure. At the edge between the first boss 3 and the second boss 5, an arc-shaped cut is provided with the adjacent mounting hole as the center.

[0030] like Figure 1 and Figure 2As shown, on the upper cover body 21, a fourth protrusion 7 is provided in the middle position of the second plane 2. The first protrusion 3 is located between the fourth protrusion 7 and the second protrusion 5. The middle opening of the fourth protrusion 7 is a conical hole, and the tail end of the conical hole is connected to the cylindrical hole. The opening of the conical hole is provided with four evenly distributed notches.

[0031] like Figure 1 and Figure 2 As shown, an opening is provided in the middle of the upper cover body 21, and a vent valve 19 is installed at the opening. The vent valve 19 is pressed and fitted with the opening through its own second sealing ring 16. The vent valve 19 has an inverted snap-fit ​​structure.

[0032] like Figure 1 and Figure 2 As shown, the upper cover body 21 has multiple sub-grooves located in the middle of the mounting surface 8. The bottom surface of the sub-grooves is lower than the mounting surface 8, and reinforcing ribs in different directions are provided in the sub-grooves. The sub-grooves include multiple grooves that are parallel to each other or have different heights. One of the grooves has a rectangular boss in the middle, and the end face of the rectangular boss is lower than the mounting surface 8.

[0033] like Figure 1 and Figure 2 As shown, in this embodiment, the sub-groove includes a second groove 9, a third groove 10, a fourth groove 11, and a fifth groove 13. Multiple second grooves 9, 10, 11, and 13 are provided. The ends of the second groove 9 and 13 are set at a 45-degree bevel. At the connection between the third groove 10 and the fourth groove 11, with the mounting hole as the center, an arc-shaped outward protrusion is formed perpendicular to the end face. The second groove 9, 10, 11, and 13 are lower than the assembly contact surface 8. The second groove 9 and 13 are located in the same plane. The fourth groove 11 is lower than the second groove 9. A rectangular fifth protrusion 12 is provided in the middle of the 1. The fifth protrusion 12 is shorter than the fifth groove 13. The third groove 10 is shorter than the fourth groove 11. The second groove 9 is provided with three reinforcing ribs perpendicular to the short side and one reinforcing rib perpendicular to the long side. The third groove 10 is provided with one reinforcing rib perpendicular to the short side, one reinforcing rib perpendicular to the long side, and two irregular reinforcing ribs. One reinforcing rib is provided in the middle of the irregular reinforcing ribs. The fourth groove 11 and the fifth groove 13 are provided with three reinforcing ribs perpendicular to the short side of the upper cover body 21. The fourth groove 11 and the fifth groove 13 are each provided with one reinforcing rib perpendicular to the long side of the upper cover body 21.

[0034] The aforementioned protrusions and grooves are designed to provide clearance for the controller, ensuring a certain design gap between the controller and the cover plate after installation. This prevents the controller components from colliding with the controller cover plate due to vibration during vehicle operation. The grooves serve the following purposes: 1. Maintaining consistent material thickness across the cover plate; 2. Enhancing the cover plate's impact resistance; 3. The first groove 4 also provides a label placement area for product shipping, ensuring uniform label placement and improving product aesthetics.

[0035] Secondly, this utility model also provides an integrated electric power steering system, including a brushless motor controller cover plate with the above-described structure.

[0036] like Figure 4 As shown, the integrated electric power steering unit includes a motor body 17 and a base 18. The base 18 and the upper cover body 21 are fixedly mounted on the motor body 17 by bolts 20. The ECU 22 is installed inside the base 18. The upper cover body 21 closes the base 18. The upper cover body 21 and the base 18 are sealed by a first sealing ring 15.

[0037] like Figure 4 As shown, ECU22 is positioned on base 18. A rectangular groove is provided on the end face of base 18, and a first sealing ring 15 is placed in the groove. The cover plate is placed on the end face of base 18. After the six mounting holes are locked with bolts 20, the fitting surface 8 fits against the end face of base 18. The compression of the O-ring plays a role in dust and water protection. The tapered hole in the middle of the fourth boss 7 is fitted with an inverted vent valve 19. After the vent valve 19 and the tapered hole are engaged, the compression of the sealing ring on the vent valve 19 plays a role in dust and water protection. Thus, ECU22 is completely protected by the cover plate.

[0038] The brushless motor controller cover with the above structure has the following advantages: 1. Effectively protects ECU22 from dust and water, with a protection rating of IP68; 2. It has strong impact resistance, effectively preventing damage to the controller caused by the collision of stones during vehicle operation; 3. Simple manufacturing process and low price; 4. Strong corrosion resistance, no risk of corrosion; 5. Lightweight, with a weight reduction of about 10% compared to metal materials.

[0039] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A brushless motor controller cover, characterized in that: The cover plate includes an upper cover body made of engineering plastic mixed with reinforced glass fiber, and the upper cover body is provided with a plurality of mounting holes, each mounting hole being embedded with a metal insert; The upper cover body has multiple protrusions in the middle, some of which have a height difference and form a groove structure on the assembly and fitting surface. The protrusions and the grooves are connected by reinforcing ribs. The edge region of the upper cover body is provided with reinforcing ribs evenly distributed along the long and short sides.

2. The brushless motor controller cover plate according to claim 1, characterized in that: The upper cover body is rectangular in shape.

3. The brushless motor controller cover plate according to claim 1, characterized in that: There are six mounting holes, and the inner walls of the mounting holes are arc-shaped.

4. The brushless motor controller cover plate according to claim 3, characterized in that: The outer arc of the six mounting holes is connected to the central boss by reinforcing ribs.

5. The brushless motor controller cover plate according to any one of claims 1 to 4, characterized in that: The upper cover body has several first reinforcing ribs on each of its long sides and several second reinforcing ribs on each of its short sides.

6. The brushless motor controller cover plate according to any one of claims 1 to 4, characterized in that: The upper cover body has a first protrusion and a second protrusion with different heights in the middle, wherein the second protrusion is higher than the first protrusion.

7. The brushless motor controller cover plate according to claim 6, characterized in that: The end face of the first boss is provided with a rectangular groove, and the two ends of the first boss and the other boss have a 45° bevel structure.

8. The brushless motor controller cover plate according to claim 6, characterized in that: At the edge between the first boss and the second boss, an arc-shaped cut is provided with the adjacent mounting hole as the center.

9. The brushless motor controller cover plate according to any one of claims 1 to 4, characterized in that: An opening is provided in the middle of the upper cover body, and a vent valve is installed at the opening. The vent valve is pressed and fitted with the opening by its own sealing ring.

10. An integrated electric power steering system, characterized in that: Includes the brushless motor controller cover as described in any one of claims 1 to 9.

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