WO2024082678A1 - 一种小尺寸双冗余电动助力转向电机控制器结构 - Google Patents

一种小尺寸双冗余电动助力转向电机控制器结构 Download PDF

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Publication number
WO2024082678A1
WO2024082678A1 PCT/CN2023/102298 CN2023102298W WO2024082678A1 WO 2024082678 A1 WO2024082678 A1 WO 2024082678A1 CN 2023102298 W CN2023102298 W CN 2023102298W WO 2024082678 A1 WO2024082678 A1 WO 2024082678A1
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WO
WIPO (PCT)
Prior art keywords
board
connector
power
control board
motor controller
Prior art date
Application number
PCT/CN2023/102298
Other languages
English (en)
French (fr)
Inventor
王焘
陈海明
吴夏青
钱结苗
管金炜
刘兰保
张磊
李山
邢锦鹏
陆劲锋
汪兵兵
Original Assignee
博世华域转向系统有限公司
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Application filed by 博世华域转向系统有限公司 filed Critical 博世华域转向系统有限公司
Publication of WO2024082678A1 publication Critical patent/WO2024082678A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D5/00—Power-assisted or power-driven steering
    • B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
    • B62D5/0403—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by constructional features, e.g. common housing for motor and gear box
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D5/00—Power-assisted or power-driven steering
    • B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00—Printed circuits
    • H05K1/02—Details
    • H05K1/14—Structural association of two or more printed circuits
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
    • H05K7/209—Heat transfer by conduction from internal heat source to heat radiating structure

Definitions

  • the invention relates to the technical field of electric power steering systems, in particular to a small-size dual-redundancy electric power steering motor controller structure.
  • the electric power steering system EPS is an automotive power steering system that relies on an electric motor to provide auxiliary torque. Compared with traditional hydraulic steering, the electric power steering system has many advantages such as low fuel consumption, good steering feel, adjustable power software, small size, simple production and assembly, and short development cycle. It is currently the first choice for automotive steering solutions.
  • the electric power steering system EPS is mainly composed of several parts such as torque sensor, electronic control unit ECU, motor and reducer.
  • the electronic control unit ECU is the brain of the whole system. All signals are calculated and processed by the electronic control unit ECU and then sent to the corresponding unit to control the steering of the whole vehicle.
  • the ECU and the motor are assembled together to form the motor controller of the entire electric power steering system.
  • the conventional motor controller is mainly composed of a sealed cover, a 12V power connector, a vehicle communication connector, a torque sensor connector, a hardware circuit of a set of components, and a three-phase motor.
  • Such a steering system configuration has a low functional safety level and a failure rate of about 500 fits, that is, 1,000 steering systems will experience about 500 sudden power failures in one hour of operation. It is only suitable for L0 and L1 intelligent driving, and cannot meet the needs of L2 and higher levels of intelligent driving.
  • L3 smart driving is currently a hot topic and trend in the entire automotive industry.
  • the failure rate of L3 smart driving vehicles is 10%.
  • L4 and higher levels are currently only in the research stage. Due to the safety driving policies of various countries, they cannot be commercialized in large quantities even if they are launched in a short period of time. Therefore, L3 smart driving vehicles will be the future. This is the golden track that all OEMs are competing for.
  • the motor controller In order to meet the requirements of low failure rate for L3 intelligent driving, the motor controller needs to be designed with redundant backup.
  • the redundant motor controller is mainly composed of a sealed cover, 2 12V power connectors, 2 vehicle communication connectors, 1 torque sensor connector, 2 sets of hardware circuits of components and a six-phase motor.
  • the dual redundant motor controller design contains almost twice as many components as the conventional single system design, and the corresponding volume is basically doubled.
  • smart driving vehicles that meet L3 and above levels are often mid-to-high-end vehicles.
  • Their electric power steering systems are placed on the car chassis rather than the cockpit.
  • the space available for chassis layout is relatively small, and it is difficult to put the motor controller in if the size is doubled. This is also the difficulty of the current industry's redundant electric power steering system design.
  • Many EPS manufacturers have the ability to design redundant steering systems, but they are often too large to be used on the entire vehicle.
  • the purpose of the present invention is to overcome the deficiencies of the prior art and provide a small-size dual-redundant electric power steering motor controller structure to reduce the size of the motor controller and facilitate its application in a vehicle.
  • the present invention provides a small-size dual-redundant electric power steering motor controller structure, including a sealing cover, a breathable valve, a connector, a power connector connector, a bendable PCBA board, screws, stud screws, magnets, a radiator, and a six-phase motor.
  • a coupling is installed at the bottom of the six-phase motor, and a radiator, a motor Pin, a magnet and a stud screw mounting hole are provided on the top of the six-phase motor.
  • the bendable PCBA board includes a power board, a control board, and a bendable PCB.
  • the power board is fixed on the radiator, the power board and the six-phase motor are fixed by stud screws, the six-phase motor and the power board are connected by motor Pins, the control board is placed parallel to the power board, the control board is fixed on the top of the stud screws by screws, the control board and the power board are connected by a bendable PCB, the power board and the control board are connected by a power connector connector, the control board is installed with a connector, and the sealing cover covers the power board.
  • the board, the control board, and the bendable PCB, the connector passes through the through hole on the surface of the sealing cover, and the air valve is installed on the sealing cover.
  • a small-size dual-redundant electric power steering motor controller structure comprises a sealing cover, a connector, a power connector connector, a bendable PCBA board, a radiator, and a six-phase motor.
  • the top of the six-phase motor (14) is provided with a radiator (12) and a motor pin (13).
  • the bendable PCBA board comprises a power board (8), a control board (6), and a bendable PCB (7).
  • the power board (8) is fixed on the radiator (12).
  • the power board (8) is fixed to the six-phase motor (14).
  • the six-phase motor (14) and the power board (7) are connected to the power board (7).
  • the power boards (8) are connected by motor pins (13); the control board (6) and the power board (8) are placed in parallel; the control board (6) and the power board (8) are connected by a bendable PCB (7); the power board (8) and the control board (6) are connected by a power connector (9); a connector (5) is installed on the control board (6); a sealing cover (2) covers the power board (8), the control board (6) and the bendable PCB (7); and the connector (5) passes through a through hole on the surface of the sealing cover (2).
  • a stud screw mounting hole is also provided on the top of the six-phase motor (14), and the electric power steering motor controller structure also includes a screw (3) and a stud screw (4), the power board (8) and the six-phase motor (14) are fixed by the stud screw (4), and the control board (6) is fixed on the top of the stud screw (4) by the screw (3).
  • the electric power steering motor controller structure further comprises a magnet (11), wherein the magnet (11) corresponds to the position of the sensor chip of the power board (8).
  • the connector includes three connector bodies, and the three connector bodies are an integrated structure.
  • the three connector bodies are integrated via a base, and the base is welded to the control board via a plurality of PIN needles, so that an accommodating space is formed between the base and the control board.
  • the magnet corresponds to the position of the sensor chip of the power board.
  • the bendable PCB is a semi-flexible circuit board or a bendable PCB hard board.
  • the surface of the radiator is provided with heat dissipation glue, and the heat dissipation glue is in contact with the power components of the power board. Metal parts in contact.
  • a step is provided between the heat dissipation adhesive coating surface of the heat sink and the power board fixing surface.
  • a guide block is provided at the bottom of the power board, a hollow structure is provided at the bottom of the guide block, and a triangular support structure is provided at the top.
  • one end of the stud screw is provided with an external thread, and the other end is provided with an internal thread.
  • the upper end of the power joint connector is provided with two guide pins of different lengths.
  • the sealing cover and the connector are interference-connected via fixing pins, and the connection surfaces between the sealing cover and the radiator and between the sealing cover and the connector are filled with sealant.
  • the present invention designs a small-size dual-redundant electric power steering motor controller structure.
  • the power board and the control board are separated and installed in parallel in the controller, which not only reduces the size of the motor controller, but also facilitates heat dissipation and is convenient for application on the whole vehicle.
  • FIG. 1 is an axonometric view of the present invention.
  • FIG. 2 is an exploded view of the present invention.
  • FIG. 3 is a flat front view of the bendable PCBA board of the present invention.
  • FIG. 4 is a cross-sectional view of the present invention.
  • the present invention provides a small-size dual-redundant electric power steering motor controller structure, including a sealing cover 2, a breathable valve 1, a connector 5, a power connector connector 9, a bendable PCBA board, screws 3, stud screws 4, a magnet 11, a heat sink 12, and a six-phase motor 14.
  • a coupling 15 is installed at the bottom of the six-phase motor 14, and a heat sink 12, a motor pin 13, a magnet 11, and a stud screw mounting hole are provided at the top of the six-phase motor 14.
  • the magnet 11 and the gear hub are assembled on the motor shaft 16.
  • the bendable PCBA board includes a power board 8, a control board 6, and a bendable PCB7.
  • the power board 8 is fixed to the heat sink.
  • the power board 8 and the six-phase motor 14 are fixed with stud screws 4, the six-phase motor 14 and the power board 8 are connected with motor Pin 13, the 12V power supply on the power board 8 is filtered and processed by MOS switch, and then the current is output to the six-phase motor 14 through the motor Pin 13, the control board 6 is placed parallel to the power board 8, the control board 6 is fixed on the top of the stud screw 4 with screws 3, the control board 6 and the power board 8 are connected with a bendable PCB7, the power board 8 and the control board 6 are connected with a power connector connector 9, a connector 5 is installed on the control board 6, the sealing cover 2 covers the power board 8, the control board 6, and the bendable PCB7, the connector 5 passes through the through hole on the surface of the sealing cover 2, and the air valve 1 is installed on the sealing cover 2.
  • connection surface between the sealing cover 2 and the connector 5 is filled with sealant.
  • the sealing cover 2 and the connector 5 are interference-connected by a fixing pin, ensuring that the sealing cover 2 and other components do not move relative to each other when the product circulates on the production line before the sealant is cured; on the other hand, the stress on the sealant caused by vibration and external force during the operation of the automobile can be reduced to the greatest extent, which is beneficial to improving the reliability of the seal.
  • control board 6 and the power board 8 are placed in parallel and connected through the bendable PCB 7.
  • the bendable PCB 7 it is helpful to reduce the space occupied by the PCBA, and it is helpful to reduce the size of the electric power steering motor controller structure and realize its miniaturization.
  • the sealing cover 2 plays a sealing and protective role, and the material can be plastic or metal aluminum. If metal aluminum is selected, the EMC performance of the entire system can be improved.
  • the sealing cover 2 and the connector 5 are split structures, which is convenient for mold opening, and the production cost and defect rate are relatively low.
  • a lip structure is provided between the sealing cover 2 and the radiator 12. Similar to the connection between the sealing cover 2 and the connector 5, the connection surface between the sealing cover 2 and the radiator 12 is also filled with sealant.
  • the air valve 1 ensures air connectivity between the inside and outside of the ECU, while meeting waterproof requirements, avoiding additional stress in the sealing area caused by the pressure difference with the external environment due to temperature rise and fall during operation, and improving the reliability of the seal.
  • the connector 5 includes three connector bodies 51, which are an integrated structure with low production cost.
  • the three connector bodies 51 are: the 12V power input and vehicle communication connector of the A-side system circuit; the 12V power input and vehicle communication connector of the B-side system circuit; and the internal communication connector, which is connected to the torque sensor through a wiring harness.
  • the connector body combines the vehicle communication connector and the power connector into one, and a sufficient electrical insulation distance is reserved between the two PIN pins, which can not only greatly reduce the area occupied by the connector in the sealing cover, reduce the number of connectors and the manufacturing mold opening cost, but also ensure safety in use.
  • the three connector bodies 51 of the connector 5 are set as one body through a common base 52, and the base 52 is set on the control board 6 through a plurality of PIN pins 53 arranged at intervals.
  • the base 52 is welded to the control board 6 through a plurality of PIN pins 53, so that a accommodating space is formed between the base 52 and the control board 6.
  • the three connector bodies 51 are connected to the control board 6 only through the PIN pins 53.
  • the three connector bodies 51 are elevated by the base 52.
  • the control board 6 is a logic control circuit PCBA, which includes a microprocessor chip, a vehicle communication chip, a power MOS tube control chip, and a chip power supply chip module, etc.
  • the 12V power PIN needle of the connector 5 passes through the slotted hole at the projection of this board.
  • the power board 8 is equipped with high current and high power consumption components, which generate a lot of heat.
  • the 12V power PIN of the connector 5 has a corresponding docking connector at the projection of this board.
  • the power components are arranged on the motor side to dissipate heat.
  • the bendable PCB 7 is a semi-flexible circuit board or a bendable PCB hard board.
  • the PCB material is the same as that of the control board 6 and the power board 8, generally a FR4 board, which can be bent 0-180 degrees and is formed during PCB processing and production.
  • the magnet 11 corresponds to the position of the sensor chip of the power board 8.
  • the magnet 11 is a speed regulating magnet.
  • the sensor chip on the power board 8 senses the speed and direction of the magnet 11 and feeds back to the microprocessor to control how the motor rotates.
  • the heat sink 12 is an integrated design, which not only provides support for the motor rotor bearing, but also provides heat dissipation for the power device.
  • the surface of the heat sink 12 is provided with heat dissipation glue, which contacts the metal part of the power component of the power board 8.
  • the heat sink 12 is used to heat the high-power power components of the power board 8.
  • the surface of the heat sink 12 is provided with heat dissipation glue, and the heat dissipation glue is in contact with the metal part of the power components of the power board 8.
  • the power components used in the present invention are top heat dissipation, and the heat dissipation glue is in contact with the top of the power components to directly dissipate heat, so that there is more layout space on the back of the power components, which is conducive to miniaturization design.
  • a step is provided between the heat dissipation adhesive coating surface of the heat sink 12 and the power board fixing surface to ensure the thickness of the heat dissipation adhesive after the power board is assembled, thereby ensuring good heat dissipation performance.
  • the six-phase motor 14 the microprocessor controls the motor to rotate and drive the steering gear to rotate the steering wheel of the car.
  • the six-phase motor 14 extends six motor pins 13, and the motor pins 13 are connected to the power board 8 by soldering. In order to ensure the welding quality, it is necessary to ensure the gap between the corresponding pinholes of the power board 8 and the motor pins 13.
  • a guide block 10 is provided at the bottom of the power board 8.
  • the lower cylinder of the power connector connector 9 guides and positions the assembly of the power board 8 and the radiator 12, and the guide block 10 guides the assembly of the motor pins 13 to ensure that the motor pins 13 can be correctly assembled into the corresponding pinholes of the power board 8, while avoiding the risk of excessive stress on the circuit board due to poor positioning of the motor pins 13.
  • a hollow structure is provided at the bottom of the guide block 10 to facilitate the inspection of the welding quality after welding, and a triangular support structure is provided at the top to maximize the camera angle of AI image recognition after welding, while also avoiding the influence of molten tin on plastic parts during tin penetration.
  • One end of the stud screw 4 is provided with an external thread, and the other end is provided with an internal thread.
  • the external thread cooperates with the stud screw mounting hole to fix the power board 8.
  • the internal thread is connected with the screw 3 that fixes the control board 6, thereby achieving good fixation of the bendable PCBA board.
  • the upper end of the power connector 9 is provided with two guide pins of different lengths to achieve the connection between the control board 6 and the The guiding, correction and alignment of the power board 8.
  • two guide pins of different lengths are provided is to achieve the rapid positioning and installation of the power joint connector 9 and the control board 6.
  • the power connector 9 it should be noted that its main function is to achieve the transmission of power or current.
  • the system power is transmitted to the control board 6 through the connector 5, and then transmitted to the power board 8 through the power connector 9.
  • the present invention designs a small-size dual-redundant electric power steering motor controller structure.
  • the power board and the control board are separated and installed in parallel in the controller, which not only reduces the size of the motor controller, but also facilitates heat dissipation and is convenient for application on the whole vehicle.
  • the overall size of the motor controller of the present invention is only 10%-15% larger than that of the non-redundant motor controller, which is about 60% of the overall size of the conventional dual-redundant motor controller, which can meet the chassis space size requirements of most complete machine factories and has market application prospects.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
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  • Power Steering Mechanism (AREA)

Abstract

一种小尺寸双冗余电动助力转向电机控制器结构，包括密封罩盖、透气阀、接插件、功率接头接插件、可弯折PCBA板、螺钉、双头螺钉、磁铁、散热器、六相电机，六相电机的底部安装有联轴器，六相电机的顶部设有散热器、电机Pin针、磁铁和双头螺钉安装孔，可弯折PCBA板包括功率板、控制板、可弯折PCB，功率板固定在散热器上，功率板与六相电机间采用双头螺钉固定，六相电机与功率板之间采用电机Pin针连接，控制板与功率板平行放置，控制板采用螺钉固定在双头螺钉的顶部，控制板与功率板之间采用可弯折PCB连接，控制板上安装有接插件。该电机控制器结构既减小了电机控制器尺寸，也易于散热，便于在整车上应用。

Description

一种小尺寸双冗余电动助力转向电机控制器结构
本申请要求申请日为2022/10/20的中国专利申请202211285988.1的优先权。本申请引用上述中国专利申请的全文。
技术领域
本发明涉及电动助力转向系统技术领域，具体地说是一种小尺寸双冗余电动助力转向电机控制器结构。
背景技术
电动助力转向系统EPS是一种依靠电机提供辅助扭矩的汽车动力转向系统，相比较传统液压转向，电动助力转向系统具有油耗低、转向手感好、助力软件可调、尺寸小、生产装配简单和开发周期短等诸多优点，是目前汽车转向方案的首选。
电动助力转向系统EPS主要由扭矩传感器、电控单元ECU、电机和减速器等几个部分构成，其中，电控单元ECU是整个系统的大脑，所有信号通过电控单元ECU计算处理后再发送到相应单元从而控制整车的转向。
电控单元ECU和电机组装在一起成为整个电动助力转向系统的电机控制器部分，常规的电机控制器主要由密封罩盖、1个12V电源接插件、1个整车通信接插件、1个扭矩传感器接插件、1组元器件的硬件电路和三相电机等组成。这样的转向系统配置功能安全等级低，失效率会达到500fit左右，即1000套转向系统运行1小时出现500次左右的突然失去助力失效，只适用于L0以及L1级智能驾驶，无法满足L2以及更高级别智能驾驶的需求。
目前智能驾驶是整个汽车行业的热点和趋势，L3级智能驾驶车辆的失效率为10fit。L4以及更高等级目前只是在研究阶段，受限于各国安全驾驶政策，短时间即使推出也无法大量商用。所以，L3级智能驾驶车辆将会是未 来各主机厂争夺的黄金赛道。
为了满足L3级智能驾驶低失效率的要求，电机控制器需要进行冗余备份设计，冗余后的电机控制器主要由密封罩盖、2个12V电源接插件、2个整车通信接插件、1个扭矩传感器接插件、2组元器件的硬件电路和六相电机等组成。
可见，双冗余电机控制器设计所包含的部件几乎是常规单套系统设计的两倍，相应的体积也基本变大了1倍。通常，满足L3及以上等级的智能驾驶车辆往往是中高端车，其电动助力转向系统是放在汽车底盘而非驾驶舱，底盘可布置空间比较小，电机控制器尺寸变大1倍很难能放进去，这也是当前行业冗余电动助力转向系统设计的难点。很多EPS生产厂商有能力设计出冗余转向系统，但往往尺寸太大导致无法在整车上应用。
因此，需要设计一种小尺寸双冗余电动助力转向电机控制器结构，以减小电机控制器尺寸，便于在整车上应用。
发明内容
本发明的目的是克服现有技术的不足，提供了一种小尺寸双冗余电动助力转向电机控制器结构，以减小电机控制器尺寸，便于在整车上应用。
为了达到上述目的，本发明提供一种小尺寸双冗余电动助力转向电机控制器结构，包括密封罩盖、透气阀、接插件、功率接头接插件、可弯折PCBA板、螺钉、双头螺钉、磁铁、散热器、六相电机，六相电机的底部安装有联轴器，六相电机的顶部设有散热器、电机Pin针、磁铁和双头螺钉安装孔，可弯折PCBA板包括功率板、控制板、可弯折PCB，功率板固定在散热器上，功率板与六相电机之间采用双头螺钉固定，六相电机与功率板之间采用电机Pin针连接，控制板与功率板平行放置，控制板采用螺钉固定在双头螺钉的顶部，控制板与功率板之间采用可弯折PCB连接，功率板与控制板之间采用功率接头接插件连接，控制板上安装有接插件，密封罩盖覆盖在功率 板、控制板、可弯折PCB外，接插件穿过密封罩盖表面的通孔，透气阀安装在密封罩盖上。
一种小尺寸双冗余电动助力转向电机控制器结构，包括密封罩盖、接插件、功率接头接插件、可弯折PCBA板、散热器、六相电机，六相电机(14)的顶部设有散热器(12)和电机Pin针(13)，可弯折PCBA板包括功率板(8)、控制板(6)、可弯折PCB(7)，功率板(8)固定在散热器(12)上，功率板(8)固定于六相电机(14)，六相电机(14)与功率板(8)之间采用电机Pin针(13)连接，控制板(6)与功率板(8)平行放置，控制板(6)与功率板(8)之间采用可弯折PCB(7)连接，功率板(8)与控制板(6)之间采用功率接头接插件(9)连接，控制板(6)上安装有接插件(5)，密封罩盖(2)覆盖在功率板(8)、控制板(6)、可弯折PCB(7)外，接插件(5)穿过密封罩盖(2)表面的通孔。
优选地，六相电机(14)的顶部还设有双头螺钉安装孔，电动助力转向电机控制器结构还包括螺钉(3)和双头螺钉(4)，功率板(8)与六相电机(14)之间采用双头螺钉(4)固定，控制板(6)采用螺钉(3)固定在双头螺钉(4)的顶部。
优选地，电动助力转向电机控制器结构还包括磁铁(11)，所述的磁铁(11)与所述的功率板(8)的传感器芯片位置对应。
优选地，所述的接插件包括三个接插件本体，三个接插件本体为一体式结构。
优选地，三个所述的接插件本体通过基座设置为一体，所述的基座通过多个PIN针与所述的控制板焊接连接，以使所述的基座与所述的控制板之间形成有容纳空间。
优选地，所述的磁铁与功率板的传感器芯片位置对应。
优选地，所述的可弯折PCB为半柔性线路板或可折弯PCB硬板。
优选地，所述的散热器表面设有散热胶，散热胶与功率板的功率元件的 金属部分接触。
优选地，所述的散热器的散热胶涂覆面与功率板固定面之间设有台阶。
优选地，所述的功率板的底部设有导向块，导向块的底部设有镂空结构，顶部设有三角支撑结构。
优选地，所述的双头螺钉的一端设有外螺纹，另一端设有内螺纹。
优选地，所述的功率接头接插件的上端设有两个不同长度的导向销。
优选地，所述的密封罩盖与接插件通过固定销过盈连接，密封罩盖与散热器之间、密封罩盖与接插件之间的连接面上填充有密封胶。
本发明同现有技术相比，设计了小尺寸双冗余电动助力转向电机控制器结构，通过可弯折PCBA板的设置，将功率板与控制板分离并平行安装在控制器内，既减小了电机控制器尺寸，也易于散热，便于在整车上应用。
附图说明
图1为本发明的轴测图。
图2为本发明的爆炸图。
图3为本发明可弯折PCBA板的平铺正视图。
图4为本发明的剖视图。
具体实施方式
现结合附图对本发明做进一步描述。
参见图1～图4，本发明提供一种小尺寸双冗余电动助力转向电机控制器结构，包括密封罩盖2、透气阀1、接插件5、功率接头接插件9、可弯折PCBA板、螺钉3、双头螺钉4、磁铁11、散热器12、六相电机14，六相电机14的底部安装有联轴器15，六相电机14的顶部设有散热器12、电机Pin针13、磁铁11和双头螺钉安装孔，磁铁11和齿毂装配在电机轴16上。可弯折PCBA板包括功率板8、控制板6、可弯折PCB7，功率板8固定在散热 器12上，功率板8与六相电机14之间采用双头螺钉4固定，六相电机14与功率板8之间采用电机Pin针13连接，功率板8上的12V电源经过滤波和MOS开关处理后，通过电机Pin针13输出电流到六相电机14，控制板6与功率板8平行放置，控制板6采用螺钉3固定在双头螺钉4的顶部，控制板6与功率板8之间采用可弯折PCB7连接，功率板8与控制板6之间采用功率接头接插件9连接，控制板6上安装有接插件5，密封罩盖2覆盖在功率板8、控制板6、可弯折PCB7外，接插件5穿过密封罩盖2表面的通孔，透气阀1安装在密封罩盖2上。
本发明中，密封罩盖2与接插件5之间的连接面上填充有密封胶，一方面，密封罩盖2与接插件5通过固定销过盈连接，保证密封胶固化前产品在生产线流转时密封罩盖2与其他器件不发生相对移动；另一方面在汽车运行过程中能够最大程度上减少由于振动和外力导致密封胶受到的应力，有利于提升密封的可靠性。
需要说明的是，控制板6与功率板8平行放置，并通过可弯折PCB7连接，相较于现有技术中一个平面的单板，有利于减少PCBA占用的空间，有利于减少电动助力转向电机控制器结构的尺寸，实现其的小型化。另外，相较于现有技术中在高度方向叠设的多个板而言，有利于简化电动助力转向电机控制器结构的整体结构。
密封罩盖2起到密封保护作用，材质可为塑料或金属铝，若选用金属铝材可以改善整个系统EMC性能。且密封罩盖2与接插件5为分体结构，开模方便，生产成本和不良率均比较低。密封罩盖2与散热器12之间设有唇形结构，与密封罩盖2与接插件5之间的连接类似，密封罩盖2与散热器12之间的连接面上也填充有密封胶。
透气阀1确保ECU内部与外部的空气连通，同时实现防水要求，避免产品在工作过程中由于温度升降从与外部环境的压差在密封区域产生的额外应力，提高密封的可靠性。
接插件5包括三个接插件本体51，三个接插件本体51为一体式结构，生产成本低。三个接插件本体51分别为：A边系统电路的12V电源输入和整车通信接插件；B边系统电路的12V电源输入和整车通信接插件；内部通信接插件，通过线束连接到扭矩传感器。接插件本体将整车通信接插件和电源接插件合二为一，两种PIN针之间预留足够电气绝缘距离，这样不仅可以大大缩小接插件占用密封罩盖的面积，减少接插件数量和制造开模成本，也可以保证使用上的安全。结合图2予以理解，接插件5的三个接插件本体51通过一个共同的基座52设置为一体，基座52通过间隔设置的多个PIN针53设置在控制板6上，基座52通过多个PIN针53与控制板6焊接连接，以使基座52与控制板6之间形成有容纳空间。其中，一方面，三个接插件本体51仅通过PIN针53与控制板6连接，三个接插件本体51通过基座52被架高，除了PIN针53外，接插件本体51的其他部分与控制板6不直接接触，使得接插件5与控制板6的接触面积较小；另一方面，基座52与控制板6之间形成的空间可以用来容纳其他结构件，空间利用率高，也有利于实现电动助力转向电机控制器结构的小型化。
控制板6为逻辑控制电路PCBA，包含微处理器芯片、整车通信芯片、功率MOS管控制芯片以及芯片供电电源芯片模块等，接插件5的12V电源PIN针在此板投影处开槽孔穿过。
功率板8设置的是大电流和高功耗元件，发热大，接插件5的12V电源PIN针在此板投影处有相应对接接插件。功率元件布置在电机侧散热。
可弯折PCB7为半柔性线路板或可折弯PCB硬板，PCB材质与控制板6、功率板8相同，一般为FR4板材，可折弯0-180度，PCB加工生产时形成。
磁铁11与功率板8的传感器芯片位置对应。磁铁11为调速磁铁，功率板8上的传感器芯片感应磁铁11的转速和方向，反馈给微处理器从而控制电机如何转动。
散热器12为集成式设计，既为电机转子轴承提供支撑，也为功率器件提供散热功能。散热器12表面设有散热胶，散热胶与功率板8的功率元件的金属部分接触。
散热器12用于功率板8的大功耗的功率元件发热，散热器12表面设有散热胶，散热胶与功率板8的功率元件的金属部分接触。本发明中采用的功率元件为顶部散热，散热胶与功率元件顶部接触直接散热，这样功率元件背面有了更多的布局空间，利于小型化设计。
散热器12的散热胶涂覆面与功率板固定面之间设有台阶，以确保功率板装配后散热胶的厚度，保证良好的散热性能。
六相电机14，微处理器控制电机转动驱动转向齿轮从而使汽车方向盘发生转动。六相电机14伸出六根电机Pin针13，电机Pin针13与功率板8通过锡焊连接，为了保证焊接质量，需要保证功率板8的对应针孔与电机Pin针13的间隙。功率板8的底部设有导向块10。在自动化装配过程中，功率接头接插件9下部圆柱实现功率板8与散热器12装配的导向和定位，导向块10实现电机Pin针13装配的导向，以确保电机Pin针13能正确装配到功率板8的对应针孔内，同时避免因为电机Pin针13位置度不好导致电路板上应力过大的风险。
导向块10的底部设有镂空结构，以便于焊接后焊接质量的检查，顶部设有三角支撑结构，最大程度保证焊接后AI图像识别的拍照角度，同时也避免透锡时熔融状态的锡对塑料件的影响。
双头螺钉4的一端设有外螺纹，另一端设有内螺纹。外螺纹与双头螺钉安装孔配合，以固定功率板8。内螺纹与固定控制板6的螺钉3连接，从而实现可弯折PCBA板的良好固定。与两块板都固定在散热器上的方案相比，减少了功率板8避让控制板6支撑而削减的区域，最大程度上提高了PCB板的空间利用率。
功率接头接插件9的上端设有两个不同长度的导向销，实现控制板6与 率板8的导向、校正以及对齐。其中，之所以设置两个不同长度的导向销，是为了实现功率接头接插件9与控制板6的快速定位和安装。
关于功率接头接插件9，需要说明的是，其主要作用是实现电源或电流的传递。系统电源通过接插件5传递到控制板6上，接着通过功率接头接插件9传递到功率板8上。
本发明设计了小尺寸双冗余电动助力转向电机控制器结构，通过可弯折PCBA板的设置，将功率板与控制板分离并平行安装在控制器内，既减小了电机控制器尺寸，也易于散热，便于在整车上应用。经测算，本发明电机控制器整体尺寸仅比非冗余的电机控制器尺寸大10％-15％，是常规双冗余电机控制器整体尺寸的60％左右，可以满足大多数整机厂底盘空间尺寸的要求，具有市场应用前景。
虽然以上描述了本发明的具体实施方式，但是本领域的技术人员应当理解，这些仅是举例说明，在不背离本发明的原理和实质的前提下，可以对这些实施方式做出多种变更或修改。因此，本发明的保护范围由所附权利要求书限定。

Claims (14)

  1. 一种小尺寸双冗余电动助力转向电机控制器结构，包括密封罩盖、透气阀、接插件、功率接头接插件、可弯折PCBA板、螺钉、双头螺钉、磁铁、散热器、六相电机，其特征在于：六相电机(14)的底部安装有联轴器(15)，六相电机(14)的顶部设有散热器(12)、电机Pin针(13)、磁铁(11)和双头螺钉安装孔，可弯折PCBA板包括功率板(8)、控制板(6)、可弯折PCB(7)，功率板(8)固定在散热器(12)上，功率板(8)与六相电机(14)之间采用双头螺钉(4)固定，六相电机(14)与功率板(8)之间采用电机Pin针(13)连接，控制板(6)与功率板(8)平行放置，控制板(6)采用螺钉(3)固定在双头螺钉(4)的顶部，控制板(6)与功率板(8)之间采用可弯折PCB(7)连接，功率板(8)与控制板(6)之间采用功率接头接插件(9)连接，控制板(6)上安装有接插件(5)，密封罩盖(2)覆盖在功率板(8)、控制板(6)、可弯折PCB(7)外，接插件(5)穿过密封罩盖(2)表面的通孔，透气阀(1)安装在密封罩盖(2)上。
  2. 一种小尺寸双冗余电动助力转向电机控制器结构，包括密封罩盖、接插件、功率接头接插件、可弯折PCBA板、散热器、六相电机，其特征在于：六相电机(14)的顶部设有散热器(12)和电机Pin针(13)，可弯折PCBA板包括功率板(8)、控制板(6)、可弯折PCB(7)，功率板(8)固定在散热器(12)上，功率板(8)固定于六相电机(14)，六相电机(14)与功率板(8)之间采用电机Pin针(13)连接，控制板(6)与功率板(8)平行放置，控制板(6)与功率板(8)之间采用可弯折PCB(7)连接，功率板(8)与控制板(6)之间采用功率接头接插件(9)连接，控制板(6)上安装有接插件(5)，密封罩盖(2)覆盖在功率板(8)、控制板(6)、可弯折PCB(7)外，接插件(5)穿过密封罩盖(2)表面的通孔。
  3. 根据权利要求2所述的小尺寸双冗余电动助力转向电机控制器结构，其特征在于：六相电机(14)的顶部还设有双头螺钉安装孔，电动助力转向电机控制器结构还包括螺钉(3)和双头螺钉(4)，功率板(8)与六相电机(14)之间采用双头螺钉(4)固定，控制板(6)采用螺钉(3)固定在双头螺钉(4)的顶部。
  4. 根据权利要求2所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：电动助力转向电机控制器结构还包括磁铁(11)，所述的磁铁(11)与所述的功率板(8)的传感器芯片位置对应。
  5. 根据权利要求1-4中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的接插件(5)包括三个接插件本体(51)，三个接插件本体(51)为一体式结构。
  6. 根据权利要求5所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：三个所述的接插件本体(51)通过基座(52)设置为一体，所述的基座(52)通过多个PIN针(53)与所述的控制板(6)焊接连接，以使所述的基座(52)与所述的控制板(6)之间形成有容纳空间。
  7. 根据权利要求1或4所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的磁铁(11)与功率板(8)的传感器芯片位置对应。
  8. 根据权利要求1-7中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的可弯折PCB(7)为半柔性线路板或可折弯PCB硬板。
  9. 根据权利要求1-8中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的散热器(12)表面设有散热胶，散热胶与功率板(8)的功率元件的金属部分接触。
  10. 根据权利要求9所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的散热器(12)的散热胶涂覆面与功率板固定面之 间设有台阶。
  11. 根据权利要求1-10中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的功率板(8)的底部设有导向块(10)，导向块(10)的底部设有镂空结构，顶部设有三角支撑结构。
  12. 根据权利要求1、3、5-11中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的双头螺钉(4)的一端设有外螺纹，另一端设有内螺纹。
  13. 根据权利要求1-12中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的功率接头接插件(9)的上端设有两个不同长度的导向销。
  14. 根据权利要求1-13中任一项所述的一种小尺寸双冗余电动助力转向电机控制器结构，其特征在于：所述的密封罩盖(2)与接插件(5)通过固定销过盈连接，密封罩盖(2)与散热器(12)之间、密封罩盖(2)与接插件(5)之间的连接面上填充有密封胶。
PCT/CN2023/102298 2022-10-20 2023-06-26 一种小尺寸双冗余电动助力转向电机控制器结构 WO2024082678A1 (zh)

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