CN112291952A

CN112291952A - Controller of electric vehicle

Info

Publication number: CN112291952A
Application number: CN202011074464.9A
Authority: CN
Inventors: 钟治平; 郭胤杰; 杨永昌; 黄威; 蒲道勇
Original assignee: Wenling Jiuzhou Electromechanical Co ltd
Current assignee: Zhejiang Jiuzhou New Energy Technology Co Ltd
Priority date: 2020-10-09
Filing date: 2020-10-09
Publication date: 2021-01-29
Anticipated expiration: 2040-10-09
Also published as: CN112291952B

Abstract

The invention provides an electric vehicle controller, which comprises a shell, a wire holder, a pin header socket, a circuit board and an end cover, wherein the shell is provided with a plurality of through holes; the shell is made of a tensile section, the outer surface of the shell is divided into a flat surface and a radiating rib surface, wiring seat notches are respectively formed in two ends of the upper portion of the shell on the flat surface of the shell, wiring seats are installed in the wiring seat notches, and control wire pin arranging socket holes are formed in the side edge of the shell and are used for installing pin arranging sockets; a cavity for accommodating the circuit board is arranged in the shell, a through convex rib for positioning the wiring seat is arranged in the upper part of the shell corresponding to the notch side of the wiring seat, and a through channel for installing a positioning piece of the circuit board is arranged in the bottom or two sides of the shell; the shell is provided with a heat conducting surface which is jointed with the power tube; the structure design solves the contradiction of the two prior arts, and has the advantages of simple and ingenious structure, good manufacturability, high heat dissipation performance, low cost, water resistance, reliability and electromagnetic shielding function; the quality and the standardization of the electric vehicle are improved, the manufacturing process cost of the whole vehicle is reduced, and the future maintenance is convenient.

Description

Controller of electric vehicle

Technical Field

The invention relates to the technical field of electric vehicles, in particular to a controller of an electric vehicle.

Background

The controller of the electric vehicle is one of four important parts of the electric vehicle, is the brain of the electric vehicle, controls the starting, running, advancing and retreating, speed and stopping of the electric vehicle, and the electric vehicle can go a long time and is difficult to run if the controller fails.

The annual output of two-wheeled bicycles used as common people transportation tools in electric vehicles reaches nearly five million orders of magnitude, and the quantity of the two-wheeled bicycles, leisure electric vehicles, electric tricycles and the like is very large in addition to take-out/express electric two-wheeled vehicles, leisure electric vehicles, electric tricycles and the like, and the performance of controllers used as main parts seriously affects the product quality, the production process and the cost of the electric vehicles.

Chinese patent No. 201220565888.X, granted publication No. CN202931712U discloses a waterproof controller, which comprises a case in which a circuit device is installed, a wire harness connected to the circuit device in the case and mainly composed of a plurality of wires, and a cover plate installed on the case and through which the wire harness can pass; the wire bundle penetrates out of the hole of the cover plate and is electrically connected with the outside.

201120455341.X discloses a structure of a three-gear shunt controller of an electric vehicle, wherein a circuit board is arranged in a controller shell, and one end of the controller is led in and led out a pile of conducting wires.

Along with the development of electronic technology, particularly chip technology, circuits are simpler and smaller, but on the other hand, along with the higher and higher requirements on the driving force of an electric vehicle, the service power of a controller is higher and higher, the two high powers mean that the sectional area of a lead is greatly increased, meanwhile, the upgrading and upgrading of the electric vehicle enable the controller to continuously increase the content of services besides high-power input and output, including the functions of speed selection, instrument communication, theft prevention and the like which are greatly increased in recent years besides the existing electric door lock and speed control, and manufacturers reserve interfaces for the convenience of function expansion in the future; these requirements make the input and output power lines of the controller continuously thicker, and the number of other control lines greatly increased;

under the condition, the structural modes reflected by the two patents seriously affect the volume limitation of the controller, and in addition, as more flexible leads are led out, firstly, the manual insertion of the leads in the production process is low in efficiency, and the process cost is multiplied; secondly, the sealing of a plurality of soft leads is difficult to process, and the waterproof effect is poor; and each wire needs to be connected with a connecting terminal and a whole vehicle cable, and various wires are different in length, so that the cost is increased, including the production cost of the controller and the assembly process cost of the electric vehicle, the connection reliability is low, the overall quality is not guaranteed, and the future maintenance is also inconvenient.

Chinese patent application No. 201720022395.4, No. CN206323688U discloses an electric vehicle controller, the controller adopts a structure of upper and lower shells with end covers, the upper shell adopts insulating plastic material, the upper and lower shells are connected by extrusion buckles, sealing strips and insulating sealing gaskets are respectively used between the upper and lower shells and the left and right end covers to seal, and input and output interfaces and data interfaces are all arranged on the upper shell.

This structure has several disadvantages: firstly, the plastic shell material has poor heat dissipation effect, and the combined structure of half plastic shell and half aluminum alloy shell makes the whole heat dissipation surface area of the controller smaller because the plastic is difficult to conduct heat compared with metal; secondly, the sealing rubber gasket arranged at the positions of the controller structure, the split joint part and the like can keep sealing only by continuous pressing force, the mechanical strength of the plastic structure shell is low, and plastic is easy to generate irreversible deformation under high temperature and loses the continuous pressing force required by sealing; thirdly, the plastic shell is not beneficial to the controller to shield electromagnetic interference; fourthly, the split type structure of plastic housing and aluminum alloy heat dissipation casing complex, sealed point is more, and the sealed degree of difficulty is great, and water-proof effects is not good.

Disclosure of Invention

Aiming at the problems in all aspects of the prior art, the controller which is reasonable in structure, high in heat dissipation efficiency and small in size and adopts an integral metal structure capable of effectively shielding electromagnetic interference is designed to serve the electric vehicle output with the magnitude order of magnitude, the cost of the controller is low, the controller can be well used for the installation/maintenance of the electric vehicle, the quality of the electric vehicle product and the connection convenience and reliability of an electric control system are improved, and the controller is required to have good waterproof performance, heat dissipation performance and mechanical strength/rigidity.

The invention mainly adopts the following technical scheme:

an electric vehicle controller comprises a shell, a wire holder, a pin header socket, a circuit board and end covers arranged at two ends of the shell; the casing adopts tensile section bar to make, and the casing surface divide into levelling surface and heat dissipation muscle face, its characterized in that: on the flat surface of the shell, wiring seat gaps, which are respectively provided with power supply input and output, at two ends of the upper part of the shell are provided with input and output wiring seats, and control wire pin arranging socket holes are arranged on the side edge of the shell to install pin arranging sockets; a cavity for accommodating the circuit board is arranged in the shell, a through convex rib for positioning the wiring seat is arranged in the upper part of the shell corresponding to the notch side of the wiring seat, and a through channel for installing a positioning piece of the circuit board is arranged in the bottom or two sides of the shell; a heat conducting surface attached to the power tube on the circuit board is arranged in the shell; the length of the peripheral projection of the whole cross section of the shell is 50-80% of the total length of the shell.

Furthermore, the heat conducting surface attached to the power tube on the circuit board in the shell is positioned at the angular position in the shell, and the preferable scheme is that the heat conducting surface is an inclined surface which forms an included angle with the horizontal plane, and the preferable included angle range is 15-45 degrees. In order to attach the power tube, the MOS tube which is widely applied to the electric vehicle controller at ordinary times is arranged on the heat-conducting surface, so that the heat-radiating effect meets the design requirement, and an elastic part for pressing and holding the power tube on the heat-conducting surface is arranged beside the heat-conducting surface of the shell.

The upper part of the shell is step-shaped, the pin header is arranged at the lower part of the step, namely the part with low height, and the wire holder is arranged at the upper part of the step. The arrangement ensures that the final controller product is tidy and highly consistent, the pin header socket with the low step is connected with the plug of the electric vehicle, and the socket is high, so that the controller socket is as short as possible, the final plug cannot be too high after being mounted, and the consistency and the harmony of the product are high.

The heat dissipation ribs are arranged on the periphery of the shell, so that the heat dissipation efficiency of the controller can be improved, the influence on the performance caused by overhigh temperature in the controller is prevented, most area of the periphery of the shell is used for arranging the heat dissipation ribs, the volume of the whole shell can be smaller, the material and the cost are saved, in addition, the strength and the rigidity of the whole shell are greatly improved by the heat dissipation ribs, and the post machining workload of the whole shell is greatly reduced, so that the best design is that the heat dissipation ribs are arranged on 60-80% of the projection length of the periphery of the whole shell, besides the above flat surface, a flat surface for sticking a product label is generally needed, and in addition, the heat dissipation ribs are arranged as the heat dissipation surface as far as possible;

the convex ribs for positioning the upper surface in the shell are used for positioning the power supply input and output wire holders left and right, the whole shell is communicated with at least one convex rib, the side edge of the step design on the upper part of the shell plays a role in installing and positioning one side of the wire holder, the preferred scheme is two convex ribs, because even if the side wall of the step formed on the upper part of the shell plays a role in positioning one side of the wire holder, the wire holders on two ends of the shell respectively correspond to two input and output wires and three wires, the width of the wire holder can be different due to the optimal cost design of a common wire holder, the two convex ribs can be used for positioning the other sides of the two wire holders with different widths respectively, and according to the requirements, the design of the convex ribs can;

the positioning piece for positioning the circuit board can be arranged on the side wall of the shell and also can be arranged below the circuit board, namely the mounting channel of the positioning piece for positioning the circuit board penetrates through the whole shell, can be arranged on two sides of the shell and also can be arranged at the lower part of the shell seat body, and can be arranged to better position the circuit board;

the wire holder of power input and output comprises pedestal and metallic conductor connecting piece, and the metallic conductor connecting piece passes the pedestal, and pedestal lower part system has the erection column with circuit board complex, and the pedestal outward flange system has the gluey groove turn-ups, and the first turn-ups height that corresponds the end cover position is minimum, and the second turn-ups height that the pedestal both sides and protruding muscle complex is next, and the third turn-ups height that cooperates with casing cavity top plane department is the highest. The flanging is designed to form a groove with the seat body structure for a glue-pouring sealing structure, and the heights of the flanging are different, including the first flanging, the second flanging and the third flanging, so that the flanging is matched with the integral metal shell, and arrangement of a matching structure and a sealing waterproof structure is better solved;

for the pin header, the basic structure is similar to that of the wire holder, but the height of the flanging is consistent, because the metal shell for installing the pin header is a plane through hole.

The metal conductor connecting piece and the base body need to be sealed to prevent water from entering the base body, the sealing method includes gluing and sealing, and sealing can be achieved through interference fit of the base body and the metal conductor.

In the field of electric vehicles, the aforementioned power input connector base is also called a power cord socket, which is a circuit cable connector for a controller and a power supply storage battery, and generally comprises two electric wires; in addition, the power output connector base, also called a phase wire connector base, is a connector of a circuit cable between the controller and the driving motor, generally three wires, and the pin header is a connector of the controller and a vehicle control or communication cable.

The shell is provided with three gaps which are respectively used for installing an input power supply connection socket, an output phase line connection socket and a control pin header socket to form a power supply connection socket gap, a phase line connection socket gap and a pin header gap, wherein the power supply connection socket gap and the phase line connection socket gap are respectively communicated with the left end and the right end of the shell; however, the manufacturing and installation convenience and low cost of the controller must be considered, the mentioned two-end wire holder and pin header socket must be firstly installed and welded on the circuit board, because the wire holder and socket are installed on the metal shell and have waterproof structural requirements, when the two-end wire holder and pin header socket are installed on the controller, the wire holder and pin header socket should be exposed out of the shell, i.e. a structure of a wire holder with two tilted ends and a pin header socket with a raised middle is formed, at this time, the whole circuit board with the wire holder, the pin header socket and the circuit component installed must be inserted into the shell of the integral structure, the inside of the shell must have a certain cavity in the height direction, after the whole circuit board is inserted, the whole circuit board is lifted upwards to the notch of the wire holder and the shell to be installed in place, and finally, the groove channels arranged at the two sides or the bottom edge in the shell are used for positioning the positioning structure of the circuit board, can install in the channel, realize the installation of circuit board fixed with spacing.

By adopting the stretching section bar, particularly the aluminum section bar, various structural arrangement can be completed at one time, the processing cost and the process cost brought by the convenience of shell installation are greatly saved, the product consistency is good, the quality can be effectively ensured, and the manufactured and assembled controller can effectively solve all the technical problems to be solved in the prior art.

The casing is tensile aluminium alloy, is provided with a plurality of heat dissipation muscle at the casing periphery, and the outward appearance of seting up jagged casing position is planar, does not establish the heat dissipation muscle, is convenient for reduce the blanking power when processing the breach and provides the plane that controller product label pasted.

Compared with the prior art, the invention has the following innovation points and advantages:

1. the problem of in the past just need draw forth the pencil from the end cover with whole aluminium alloy shell and make binding post and connect with whole car cable harness as the connector, but do not have the pencil connector and can only adopt two split type upper and lower casing integrated configuration's contradiction is solved. The problems that cost is increased by using a lead-out wire harness, connection reliability is not high, the wire harness is difficult to waterproof and the like are solved, too many sealing points of a split type combined structure are also solved, in addition, the combined structure of a plastic upper shell and an aluminum alloy lower shell is basically adopted in the prior art, the upper shell made of a plastic material is easy to deform at high temperature to cause sealing failure, and meanwhile, the plastic shell does not have the electromagnetic shielding effect and the like are solved.

2. The shell surface of the stretching aluminum profile is only provided with the notch for installing the wiring seat, sealing points are reduced, the waterproof reliability is high, the aluminum profile processing consistency is good, the structure is simple, the manufacturability is good, and the manufacturing cost is low.

3. The integral aluminum profile shell is provided with the end metal end cover, the whole peripheral structure of the controller is made of metal materials, the heat dissipation surface area of the controller is large, the heat dissipation effect is good, the metal shielding cover is formed by the whole metal shell, and the electromagnetic interference shielding effect of the controller is greatly improved.

4. The sealing position of the wire holder and the aluminum profile shell can be sealed by adopting an injection type or a sealing rubber gasket, and the wire holder and the shell do not need continuous pressing force when the injection sealing mode is adopted, so that the bearing pressure on the circuit board is eliminated. The aluminum alloy shell is sealed by adopting the sealing gasket for water proofing, cannot be deformed at high temperature, and can stably maintain continuous tension required by sealing.

5. The ingenious design of overall structure has solved the problem that the production quality can be guaranteed, has also improved the efficiency of production processing, and the standardization level improves greatly, simultaneously, provides the contribution of controller for the improvement of the technological cost reduction and the whole car quality of whole car production.

Drawings

FIG. 1 is a schematic perspective view of the entire controller;

FIG. 2 is a schematic perspective view of the controller housing;

FIG. 3 is an exploded view of one embodiment reflecting the composition of the controller;

FIG. 4 is a top view of a part of the controller corresponding to FIG. 1;

FIG. 5 is a schematic diagram showing a cross-sectional configuration of the controller housing;

FIG. 6 is a cross-sectional schematic view of the power input terminal mounted in the housing;

FIG. 7 is a cross-sectional schematic view of the power outlet terminal mounted in the housing;

FIG. 8 is a longitudinal cross-sectional view of the entire controller reflecting the two-terminal block and housing mounting structure;

FIG. 9 is a schematic perspective view of a wire holder;

FIG. 10 is a schematic diagram showing the perspective structure of the pin header socket;

FIG. 11 is a cross-sectional view of one embodiment of a thermally conductive surface reflecting a planar form;

FIG. 12 is a cross-sectional view of an embodiment of a thermally conductive surface reflecting an elevational form;

FIG. 13 is a schematic cross-sectional view of an embodiment of a circuit board mounted by means of positioning members in guide slots provided on both sides of a housing;

FIG. 14 is a schematic cross-sectional view of another embodiment of a circuit board mounted by means of positioning members in guide slots provided on both sides of a housing;

FIG. 15 is a schematic cross-sectional view of a circuit board mounted by locating elements in channels provided on the sides and bottom of the housing;

fig. 16 is a perspective view of the structural relationship between the circuit board and the support post corresponding to fig. 15.

100 casing, 200 input wire holder, 300 output wire holder, 400 row pin socket, 500 circuit board, 600 end cover, 108 flat surface, 109 heat dissipation rib surface, 101 input wire holder notch, 102 output wire holder notch, 103 control wire row pin socket hole, 104 heat conduction surface, 105 circuit board positioning piece channel, 106 convex rib, 107 cavity, 110 heat dissipation rib, 111 step, 112 power tube holding elastic piece channel, 113 screw hole channel, 114 waterproof pad positioning channel, 700 waterproof pad, 800 fastener, 900 circuit board positioning piece, 1000 power tube, 1100 elastic piece, 1200 wiring terminal, 1300 protective cover, 1400 glue, 301 base/401 row pin base, 302/402 metal conductor connector, mounting column 503/403, 304 first flanging, 305 second flanging, 306 third flanging, 307 notch, 308U-shaped groove, 309 surrounding wall, 7 limit protrusion.

Detailed Description

The invention will be further elucidated with reference to the drawings in which:

referring particularly to fig. 1 to 6, an electric vehicle controller includes a housing 100, an input wire holder 200, an output wire holder 300, a pin header socket 400, a circuit board 500, and end caps 600 disposed at both ends of the housing 100; the shell 100 is made of an extension section, the outer surface of the shell 100 is divided into a flat surface 108 and a radiating rib surface 109, two ends of the upper part of the shell 100 are respectively provided with a power supply input wire holder notch 101 and an output wire holder notch 102 on the flat surface 108 of the shell for installing the input wire holder 200 and the output wire holder 300, and the side edge of the shell 100 is provided with a control wire pin row socket hole 103 for installing a pin row socket 400; a cavity 107 for accommodating a circuit board is arranged in the shell 100, a through convex rib 106 for positioning the wiring base is arranged in the upper part of the shell 100 corresponding to the notch side of the wiring base, and a through circuit board positioning piece channel 105 for installing a circuit board positioning piece 900 of the circuit board 500 is arranged in the bottom or two sides of the shell 100; a heat conducting surface 104 attached to the power tube 1000 on the circuit board 500 is formed in the housing 100; the length of the heat dissipation ribs 110 on the projection length around the whole cross section of the casing 100 accounts for 50-80% of the total length.

Further, the heat conducting surface 104 attached to the power tube 1000 on the circuit board 500 in the housing 100 is located at an inner angle position of the housing 100, and preferably, the heat conducting surface 104 is an inclined surface having an included angle with a horizontal plane, and the included angle is preferably in a range of 15-45 degrees. In order to attach the power tube 1000, including the MOS tube widely used in the general electric vehicle controller to the heat conducting surface 104, so that the heat dissipation effect meets the design requirement, an elastic member 1100 for pressing and holding the power tube 1000 to the heat conducting surface is installed beside the heat conducting surface 104 of the housing 100, the elastic member 1100 adopts a comb-shaped spring plate bent in a comb handle portion, and the elastic member 1100 presses and holds the power tube 1000 to the heat conducting surface 104 through the power tube pressing elastic plate channel 112.

Referring to fig. 1 to 7 and 11 to 15, the upper portion of the housing 100 is stepped, the pin header 400 is mounted at a lower portion, i.e., a lower portion, of the step 111, and the wire holder is mounted at an upper portion of the step 111. Such arrangement makes final controller product neat and level, because the row's of step 111 low pin socket 400 can be connected with the corresponding plug of electric motor car at last, highly be unlikely to too high after the plug connection, reduces the risk that plug and other parts interfere, has improved the holistic uniformity and the harmony of product, and the outward appearance is clean and tidy, the installation operation of being convenient for.

Referring to fig. 1 to 7, the heat dissipating ribs 110 disposed on the periphery of the housing 100 can improve the heat dissipating efficiency of the controller, and prevent the performance of the controller from being affected by an excessive temperature inside the controller, and most of the area of the periphery of the housing 100 is used for disposing the heat dissipating ribs 110, so that the volume of the entire housing 100 can be made smaller, and the material and cost can be saved, and in addition, the strength and rigidity of the entire housing 100 are greatly improved by the heat dissipating ribs 110, and the post-machining workload of the entire housing 100 is greatly reduced, so the best design is to dispose the heat dissipating ribs 110 on 60-80% of the projection length of the periphery of the entire housing, and in addition to the above-mentioned flat surface 108, a flat surface for attaching a product label is generally required, and in addition, the heat dissipating ribs 109 are disposed as far.

The rib 106 for positioning the inner upper surface of the shell 100 serves for left and right positioning of the power supply input wire holder 200 and the output wire holder 300, at least one rib penetrates through the whole shell 100, the side edge of the step 111 on the upper portion of the shell 100 plays a role in installing and positioning one side of the wire holder, the preferred scheme is two ribs, because even though the side wall of the step 111 formed on the upper portion of the shell 100 plays a role in positioning one side of the side wall, the wire holders on two ends of the shell 100 respectively correspond to two wires for input and output and three wires, the optimal cost design of the general wire holder can lead the widths of the wire holder to be different, the two ribs 106 serve for positioning the other sides of the two wire holders with different widths respectively, and according to the requirements, the design of the rib 106 can be three or four.

Referring to fig. 13 to 15, the positioning element 900 for positioning the circuit board 500 may be disposed on a side wall of the housing 100, or below the circuit board 500, that is, the circuit board positioning element channel 105 of the positioning element 900 for mounting the circuit board 500 penetrates through the entire housing 100, and may be disposed on both sides of the housing 100, or may be disposed at a lower portion of an inner cavity of the housing 100, or may be disposed at both sides, so as to better position the circuit board 500. Preferably, in various embodiments as shown in fig. 13-16, the locating member 900 may be as shown by

reference numerals

9001, 9002, 9003. Preferably, the circuit board locator channels 105 may be as shown by

reference numerals

1051, 1052.

Referring to fig. 9, the power input and output connector base is composed of a base body 301/pin header socket, a pin header body 401 and a metal conductor connector 302/402, the metal conductor connector 302/402 penetrates through the base body 301/pin header body 401, the lower portion of the base body 301/pin header body 401 is provided with a mounting post 503/403 matched with the circuit board 500, the outer edge of the base body 301 is provided with a rubber groove flange, the height of the first flange 304 corresponding to the position of the end cover 600 is the lowest, the height of the second flange 305 matched with the convex rib 106 on both sides of the base body 301 is the second, and the height of the third flange 306 matched with the top plane of the cavity 107 of the housing 100 is the highest. The flanges are designed to form grooves with the auxiliary structures of the seat body 301/the pin header seat body 401 for glue-pouring sealing structures, and in addition, the heights of the flanges are different, including the first flange 304, the second flange 305 and the third flange 306 mentioned above, so as to be matched with the integral metal shell, and better solve the arrangement of a matching structure and a sealing waterproof structure.

Referring to fig. 10, the basic structure of the pin header 400 is similar to that of a wire holder, but the height of the flange is the same because the metal shell 100 where the pin header is installed is a planar through hole.

Referring to fig. 9 and 10, in which a seal is required between the metal conductor connector 302/402 and the housing 301/pin header 401 to prevent water from entering, the seal may be a glue seal or a seal may be achieved by interference fit between the housing and the metal conductor.

In the field of electric vehicles, the above-mentioned input connection terminal 200, also called a power line socket, is a connection port for a circuit cable between a controller and a power supply battery, and generally comprises two electric wires; in addition, the output connector base 300, also referred to as a phase wire connector base, is a connector for a circuit cable of the controller and the driving motor, and generally includes three wires, and the pin header base 400 is a connector for a control cable or a communication cable of the controller and the vehicle. The top of 100 cavities 107 of casing is protruding downward and is formed the spacing boss of phase line connection seat, and the boss is the step form, and 100 marginal correspondence positions of casing are equipped with the spacing arch of connection seat, and the spacing breach of phase line connection seat is located between spacing boss and the spacing arch, has linked firmly the phase line connection seat on the circuit board 500, and the spacing boss of phase line connection seat and the spacing arch of phase line connection seat control lateral shifting through restriction phase line connection seat to reach the purpose of lateral shifting about the restriction circuit board. The top of the cavity 107 of the housing 100 is raised downward to form a power connection base sealing boss, and the height of the raised downward is equal to the first step height of the phase connection base limiting boss. The power supply wire holder sealing boss is located in front of the phase line wire holder boss and the wire holder limiting protrusion and close to one side of the phase line wire holder boss, and the power supply wire holder gap is located between the power supply wire holder sealing boss and the wire holder limiting protrusion. Two circuit board positioning piece channels 105 for placing circuit board 500 supporting strips are arranged at the bottom of the cavity 107 of the shell 100, the circuit board 500 supporting strips upwards support the circuit board 500 to press the wiring bases on the circuit board 500 to the top of the cavity 107 of the shell 100, and therefore the up-and-down displacement of the circuit board 500 is limited.

Be provided with erection column 503 and metallic conductor connecting piece 302 on phase line connection terminal and the power connection terminal, for example the metallic conductor connecting piece is the copper pin, and the copper pin is with circuit welding intercommunication on the circuit board 500, and erection column 503 is fixed on circuit board 500 with the mode of joint to increase the tie point of connection terminal and circuit board 500, improve the stability of linking firmly. In order to separate each wiring terminal 1200, limiting protrusions 7 extending towards the wire outlet end are arranged on the phase wire connection base and the power supply connection base, a limiting groove is formed between the two limiting protrusions 7, and the wiring terminals 1200 are installed and fixed in the limiting grooves, so that the wiring terminals are separated in pairs, and the safety of the circuit is guaranteed. For preventing binding post 1200 from exposing outside, all be provided with protecting cover 1300 on phase line connection terminal and the power connection terminal, it is corresponding with it to be provided with protecting cover buckle muscle on phase line connection terminal and power connection terminal, and protecting cover buckle muscle sets up on connection terminal both sides and the spacing arch 7 of going out the line side.

The housing 100 at the matching position with the pin header socket 400 is planar, so the flanging height of the pin header is set to be equal to the surrounding height, and the flanging height is matched with the notch of the pin header to form a glue accommodating groove for injecting glue 1400.

The waterproof pads 700 are adhered to the end covers 600 on the two sides, and the waterproof pads 700 at the end covers 600 and the glue injection mode at the wire holder ensure the integral protection of the controller. Preferably, the end cap 600 is coupled to the case 100 by a fastener 800, more preferably, a screw, and the waterproof pad 700 and the end cap 600 are mounted to the case 100 through the screw hole channel 113 and the waterproof pad positioning channel 114.

One corner of the bottom of the cavity 107 of the housing 100 is provided with an inclined boss for fixing and dissipating the power transistor 1000, such as a MOS transistor, and after the circuit board 500 is fixed and mounted in place, the pin of the MOS transistor is bent, the MOS transistor is attached to the inclined boss, and then the MOS transistor is pressed on the inclined boss by using an elastic member 1100, such as a pressing spring piece.

The edges of the power wire holder, the phase wire holder and the pin header are all provided with upward raised flanges, and the flanges and the surrounding wall 309 on the wire holder form a U-shaped groove 308 for injecting glue. The power connection base is for matching power connection base breach department shape, set up its gluey groove turn-ups to co-altitude not, it is highly minimum to correspond the first turn-ups 304 that end cover 600 goes out the line breach position, with the second turn-ups 305 height of the spacing arch of connection base and the sealed boss cooperation department of power connection base secondly, with casing 100 cavity 107 top plane department complex third turn-ups 306 height-height highest, after the assembly is accomplished, turn-ups that the height differs mutually support with casing 100 and end cover 600 and have formed the appearance gluey groove that is used for the injecting glue. Similarly, the phase line wire holder is the shape of matching phase line wire holder breach department, also set up its glue groove turn-ups to co-altitude not, it is minimum that the first turn-ups 304 that corresponds end cover 600 goes out the line breach position is high, with the second turn-ups 305 height of the spacing boss of phase line wire holder and the spacing protruding cooperation department of phase line, it is highest with the third turn-ups 306 height of the 100 cavity 107 top plane department complex of casing, be equipped with breach 307 in third turn-ups 306 department, in order to dodge the sealed boss of power connection holder, after the assembly is accomplished, turn-ups that the height differs mutually support with casing 100 and end cover 600 and have formed the glue groove that holds that is used for injecting glue 1400.

The shell is provided with three gaps which are respectively used for installing an input power supply connection socket, an output phase line connection socket and a control pin header socket to form a power supply connection socket gap, a phase line connection socket gap and a pin header gap, wherein the power supply connection socket gap and the phase line connection socket gap are respectively communicated with the left end and the right end of the shell; however, the manufacturing and installation convenience of the controller must be considered, the mentioned two-end wire holder and pin header socket must be firstly installed and welded on the circuit board, because the wire holder and the socket are installed on the metal shell and have waterproof structural requirements, when the two-end wire holder and pin header socket are installed on the controller, the wire holder and the pin header socket should be exposed out of the shell, i.e. a structure of the wire holder with two tilted ends and the pin header socket with a raised middle is formed, at this time, the whole circuit board with the wire holder, the pin header socket and the circuit components installed therein must be inserted into the shell of the integral structure, a certain cavity must be formed in the height direction inside the shell, after the whole circuit board is inserted, the whole circuit board is lifted upwards to the notch of the wire holder and the shell to be installed in place, and finally, the groove channel arranged at the two side edges or the bottom edge inside the shell is used for positioning the positioning structure component, can be installed into the channel.

The shell 100 is a tensile aluminum profile, a plurality of heat dissipation ribs 110 are arranged on the periphery of the shell 100, and the outer surface of the part of the shell 100 with the notch is planar and is not provided with the heat dissipation ribs, so that the blanking force during notch processing is reduced, and a plane for sticking labels of controller products is provided.

Claims

1. An electric vehicle controller comprises a shell, a wire holder, a pin header socket, a circuit board and end covers arranged at two ends of the shell; the casing adopts tensile section bar to make, and the casing surface divide into levelling surface and heat dissipation muscle face, its characterized in that: on the flat surface of the shell, wiring seat gaps, which are respectively provided with power supply input and output, at two ends of the upper part of the shell are provided with input and output wiring seats, and control wire pin arranging socket holes are arranged on the side edge of the shell to install pin arranging sockets; a cavity for accommodating the circuit board is arranged in the shell, a through convex rib for positioning the wiring seat is arranged in the upper part of the shell corresponding to the notch side of the wiring seat, and a through channel for installing a positioning piece of the circuit board is arranged in the bottom or two sides of the shell; a heat conducting surface attached to the power tube on the circuit board is arranged in the shell; the length of the peripheral projection of the whole cross section of the shell is 50-80% of the total length of the shell.

2. The controller according to claim 1, wherein: the heat conducting surface is positioned at the angular position in the shell and is an inclined surface with an included angle with the horizontal plane.

3. The controller according to claim 1, wherein: the upper portion of the shell is step-shaped, the pin header is installed at the lower portion of the step, and the wire holder is installed at the upper portion of the step.

4. The controller according to claim 1, wherein: and heat dissipation ribs are arranged on 60-80% of the projection length of the outer periphery of the whole shell.

5. The controller according to claim 1, wherein: two or three convex ribs of the positioning wire holder on the inner upper surface of the shell are communicated in the whole shell.

6. A controller according to claim 1, wherein the mounting channel of the positioning member of the circuit board extends through the whole housing, and the channel is located on both sides of the housing and/or on the lower portion of the housing.

7. The controller according to claim 1, wherein: the wire holder of power input and output comprises pedestal and metallic conductor connecting piece, and the metallic conductor connecting piece passes the pedestal, and pedestal lower part system has the erection column with circuit board complex, and the pedestal outward flange system has the gluey groove turn-ups, and the first turn-ups height that corresponds the end cover position is minimum, and the second turn-ups height that the pedestal both sides and protruding muscle complex is next, and the third turn-ups height that cooperates with casing cavity top plane department is highest.

8. The controller according to claim 1, wherein: an elastic part for pressing the power tube to the heat-conducting surface is arranged beside the heat-conducting surface of the shell.

9. The controller of claim 7, wherein: the top of pedestal is provided with the joining region, the metallic conductor connecting piece sets up in the joining region, be formed with the leg around the joining region, the leg with the gluey groove turn-ups form U type groove.

10. The controller according to claim 8, wherein: the elastic piece is in a bent comb shape.