Description:TECHNICAL FIELD
[001] The present subject matter relates to a controller, more particularly, a bus bar of the controller.
BACKGROUND
[002] In general, conventional controllers are connected to an electric motor for controlling the functioning of the electric motor. The controller is connected to a battery for receiving power and the controller utilizes this power to run the electric motor.
[003] The conventional controller generally comprises of a power board, a MOSFET or converter board and a signal board. The power board, MOSFET board and the signal board are made of PCB. The power board receives a positive and a negative supply power line from the battery. The power received from the battery is converted from DC power to AC power in the MOSFET board.
[004] The MOSFET board has three power lines receiving ports for the line, neutral and phase wires. These three power lines are further connected to the electric motor to control the electric motor.
[005] Conventionally, the signal to switch on or switch off the electric motor is sent to the electric motor from the signal board of the controller. The signal board of the controller comprises of individual current sensing units disposed on the signal board to measure the current flowing in a bus bar connecting the power board, the MOSFET board and the signal board.
[006] In the above configuration, each of the current sensing units have an opening to receive corresponding bus bars from the battery and the electric motor. However, individual current sensing units are heavy and occupies entire space of the signal board.
[007] Furthermore, in the above configuration the overall weight, part count and volume of the controller increases due to the plurality of current sensing units and this in turn increases the difficulty in packaging the current sensing units on the signal board.
[008] Thus, the conventional configuration of the controller is bulky and also includes additional parts which becomes difficult to package inside the controller. Therefore, an improved and compact design of the controller is required.
SUMMARY
[009] The present subject matter provides a bus bar for a controller comprising a first part and a second part. The first part including a current sensing circuit for sending a current signal to a signal board of the controller. The split design of the bus bar reduces material used to manufacture the bus bar and also the bus bar design with the current sensing circuit reduces the overall part count and weight of the controller.
[010] As per an aspect of the present invention, a bus bar for a controller comprising a first part and a second part. The first part and the second part being attached using one or more mounting provisions. The first part comprising one or more electronic circuits for sensing current to be supplied to the controller.
[011] As per an embodiment, the first part includes a first end, second end and a third end. The first end including a receiving portion for receiving a wire terminal, and the wire terminal is mounted using a fastener. The first end including a plurality of neck portions disposed at a peripheral edge of the first end. The first end having a cylindrical profile.
[012] As per another embodiment, the second end including a first surface and a second surface. Further a circuit board is disposed on the first surface of the second end, and one or more electronic circuits is disposed on the circuit board.
[013] As per another embodiment, the second surface of the second end is configured to have a notch portion. The notch portion is configured to conform and align parallel to a current sensing circuit of the one or more electronic circuits. The one or more electronic circuits being disposed on the first surface of the second end.
[014] As per another embodiment, the circuit board is mounted on the first surface of the second end using a plurality of fasteners.
[015] As per another aspect of the present invention, the second part being configured to receive the first part in a securing portion. The second part being fastened to a power board using one or more fastening means. The one or more fastening means being disposed on one end of the second part.
[016] As per another embodiment, the third being disposed inside the securing portion of the second part of the bus bar.
[017] As per another aspect of the present invention, a controller comprising a power board, a converter board, and a signal board. A bus bar of the controller comprising a first part and a second part. The first part and the second part of the bus bar being disposed on the converter board. The second part being mounted on the power board. The bus bar being disposed on the signal board for receiving current signals for controlling an electric motor by the controller.
[018] As per an embodiment, the controller being covered using a cover. The cover being configured to have one or more openings for receiving the first part of the bus bar. The one or more openings conforming and aligning shape of a plurality of neck portions of the first part of the bus bar.
[019] As per another embodiment, the first part being configured to have a first end, a second end, and a third end. The first end including a receiving portion for receiving a wire terminal. The wire terminal being mounted using a fastener. The first end including the plurality of neck portions disposed at a peripheral edge of the first end. The first end having a cylindrical profile.
[020] As per another embodiment, the second end including a first surface and a second surface. Further a circuit board being disposed on the first surface of the second end. The one or more electronic circuits being disposed on the circuit board.
[021] As per another embodiment, the second surface of the second end being configured to have a notch portion. The notch portion being configured to conform and align parallel to a current sensing circuit of the one or more electronic circuits being disposed on the first surface of the second end. The circuit board being mounted on the first surface of the second end using a plurality of fasteners.
[022] As per another embodiment, the second part being configured to receive the first part in a securing portion. The second part being fastened to the power board using one or more fastening means. The one or more fastening means being disposed on one end of the second part. The third end being disposed inside the securing portion of the second part of the bus bar.
[023] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPT ION OF THE DRAWINGS
[024] The present invention is described with reference to figures. This invention is implementable in two-wheeled, three wheeled and four wheeled vehicles and other electronic gadgets being run by an electric motor. The same numbers are used throughout the drawings to reference like features and components. Further, the inventive features of the invention are outlined in the appended claims.
[025] Figure 1 illustrates a perspective view of a bus bar of a controller, in accordance with an embodiment of the present subject matter.
[026] Figure 2 illustrates an exploded view of the bus bar of the controller, in accordance with an embodiment of the present subject matter.
[027] Figure 3a illustrates a left side view of the bus bar of the controller, in accordance with an embodiment of the present subject matter.
[028] Figure 3b illustrates a front side view of the bus bar of the controller, in accordance with an embodiment of the present subject matter.
[029] Figure 4 illustrates a cross section view of the bus bar of the controller along an axis A-A’, in accordance with an embodiment of the present subject matter.
[030] Figure 5 illustrates a perspective view of a cover of the controller, in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION OF THE DRAWINGS

[031] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations, and other implementations are possible without departing from the scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope being indicated by the following claims.
[032] The present subject matter is further described with reference to accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to encompass equivalents thereof.
[033] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims.
[034] Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification.
[035] Hence it is an object of the present invention to provide a bus bar configuration and design to improve packaging of components inside the controller and also overcome other related problems known in the art.
[036] It is also an object of the present invention to reduce overall part count and weight of the controller.
[037] It is also an object of the present invention to provide a design of the bus bar which utilizes less material and is not bulky.
[038] It is also an object of the present invention to provide ease of assembly and ease of handling of the controller by reducing overall weight of the controller.
[039] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
[040] Figure 1 illustrates a perspective view of a bus bar (100) of a controller, in accordance with an embodiment of the present subject matter. A controller (not shown) comprising a power board (not shown), a converter board (not shown) and a signal board (not shown). The power board, converter board and the signal board is connected to each other electrically by a bus bar (100). The power board, converter board and the signal board is made of printed circuit boards (PCB), hereinafter called as circuit board. The bus bar (100) is configured to include a first part (102) and a second part (104). In one embodiment, the bus bar (100) is a split type of bus bar. The split type of bus bar reduces the machining cost in manufacturing an integrated bus bar and thereby reduces overall weight of the controller.
[041] The first part (102) is affixed with a circuit board (108). The circuit board (108) is configured to control the current signal being passed through the controller to an electric motor. The second part (104) is affixed on the power board at a fixing portion (106) for rigid mounting of the bus bar (100) in the controller.
[042] Figure 2 illustrates an exploded view of the bus bar (100) of the controller, in accordance with an embodiment of the present subject matter. The bus (100) is divided into the first part (102) and the second part (104). The first part (102) is divided into a first end (200), a second end (202) and a third end (204). The first end (200) including a receiving portion (208) for receiving wire terminals (not shown). The wire terminals are connected to the electric motor (not shown) and the battery (not shown). The wire terminals are disposed on the signal board for giving current signals to the electric motor. The receiving portion (208) is having a circular profile. The receiving portion (208) is concentric to the first end (200) of the first part (102). The wire terminal is mounted using a metal fastener such as a bolt or a screw. The first end (200) is configured to have plurality of neck portions (210). The plurality of neck portions (210) are disposed along peripheral edges of the first end (200). The plurality of neck portions (210) is extending rearwardly along the peripheral edges of the first end (200). The plurality of neck portions (210) prevents misalignment and bending of the bus bar (100) by locking the bus bar (100) to the signal board. Thus, while mounting the wire terminals the bus bar (100) are rigid and intact in the controller.
[043] The second end (202) is configured to have an asymmetrical profile. The second end (202) includes a flat surface extending downwardly to a notch portion (216). The notch portion (216) extends downwardly to descend into a third end (204). The third end (204) is disposed in the second part (104) to affix and fasten the first part (102) in the second part (104).
[044] The second end (202) is configured to receive a circuit board (108) on one or more mounting points (206a, 206b). The circuit board (102) comprising one or more electronic circuits (400, 402) (as shown in figure 3b). The circuit board (108) is attached and fastened to the second end using a plurality of fasteners (220a, 220b). The plurality of fasteners (220a, 220b) is disposed on opposite ends of the circuit board (108) on the one or more mounting points (206a, 206b). The profile and shape of the circuit board (108) conforms with the profile and shape of the second end (202). The third end (204) is received in a securing portion (304) of the second part (104). The first part (102) is secured in the securing portion (304) by one or more mounting provisions (300b, 302b). The one or more mounting provisions (300b, 302b) is fastened from a bottom region of the second part (104) when viewed along a longitudinal axis (Y-Y’) of the bus bar (100).
[045] Another end of the second part (104) of the bus bar (100) fixedly attaches the bus bar (100) to the power board (not shown) of the controller using one or more fastening means (300a, 302a). The one or more fastening means (300a, 302a) is fastened from a top region of the second part (104) when viewed along the longitudinal axis (Y-Y’) of the bus bar (100).
[046] Figure 3a illustrates a left side view of the bus bar (100) of the controller, in accordance with an embodiment of the present subject matter. Figure 3b illustrates a front side view of the bus bar (100) of the controller, in accordance with an embodiment of the present subject matter. For brevity, figures 3a and 3b will be discussed together. The second end (202) is configured to have a first surface (330a) and a second surface (330b). The first surface (330a) receives the circuit board (108). The second surface (330b) includes the notch portion (216) of the second end (202). The notch portion (216) is disposed behind the circuit board (108).
[047] The circuit board (108) comprising the one or more electronic circuits (400, 402). The one or more electronic circuits (400, 402) includes a current sensing circuit (402) and a connector (400). The current sensing circuit (402) is configured to sense the current flowing across the controller and limit the current value to be supplied the electric motor through the connector (402). The profile and shape of the notch portion (216) corresponds to the profile and shape of the current sensing circuit (402). This configuration enhances the conductivity of current signal from the current sensing circuit (402) to the electric motor and prevents additional signal loss surrounding the notch portion (216).
[048] In another embodiment, the current sensing circuit (402) receives signal from the battery and converts the DC power from the battery into AC power without the use of multiple converters. Therefore, this configuration reduces the overall part count, overall volume, and overall size of the bus bar (100).
[049] Figure 4 illustrates a cross section view of the bus bar (100) of the controller along an axis A-A’, in accordance with an embodiment of the present subject matter. The cross section view of the bus bar (100) along an axis A-A’ provides mounting details of the split type bus bar (100) into the first part (102) and the second part (104). This configuration of the bus bar (100) saves material for manufacturing the bus bar (100). This configuration also affixes the bus bar (100) rigidly on the power board and the signal board of the controller without use of any complex tools.
[050] Figure 5 illustrates a perspective view of a cover (500) of the controller, in accordance with an embodiment of the present subject matter. The controller is covered by a cover (500) for protecting and securing the power board, the signal board, the converter board and the bus bar (100). In one embodiment, the controller comprises of five bus bard supplying current from the battery and supplying current to phase, live and neutral wire of the electric motor. The cover (500) comprising one or more openings (502) for receiving the bus bars (100). The one or more openings (502) has a profile and shape aligning with the shape and profile of the plurality of neck portions (210) of the first end (200) of the first part (102) of the bus bar (100). This configuration prevents turning and twisting of the bus bar (100) while attaching and fixing the bus bar (100) inside the controller. Therefore, the present configuration prevents bending and damage of the bus bar (100) and also prevents damage of the one or more electronic circuits (400, 402) disposed on the bus bar (100).
[051] Various embodiments of the invention provides a bus bar for a controller comprising a first part and a second part. The first part including a current sensing circuit for sending a current signal to a signal board of the controller. The split design of the bus bar reduces material used to manufacture the bus bar and also the bus bar design with the current sensing circuit reduces the overall part count and weight of the controller.
[052] The present invention is a bus bar for a controller comprising a first part and a second part. The first part and the second part being attached using one or more mounting provisions. The first part comprising one or more electronic circuits for sensing current to be supplied to the controller.
[053] The present claimed invention solves the technical problem of use of plurality of current sensing units on a signal board of a controller and inadvertently increasing the overall volume of the controller and reducing the packaging space of the signal board of the controller.
[054] Specifically, the claimed controller having a split type of bus bar comprising a circuit board with a current sensing circuit for reducing the size and packaging space of the controller and also enhances handling capability of the controller.
[055] Additionally, the configuration of the split type of bus bar rigidly affixes the bus bar in position and also reduces material cost in manufacturing the bus bar.
[056] The present invention also provides technical advantages of an improved bus bar comprising provisions to accommodate one or more electronic circuits and in turn reduces the packaging space and electronic circuits conventionally required to function a controller.
[057] In light of the above-mentioned advantages and the technical advancements provided by the disclosed bus bar and the controller, the claimed steps as discussed above are not routine, conventional, or well understood in the art, as the claimed steps enable the following solutions to the existing problems in conventional technologies. Further, the claimed steps clearly bring an improvement in the design and configuration of a bus bar for a controller comprising one or more electronic circuits and a split type configuration for enhanced handling and reducing overall volume of the controller as the claimed steps provide a technical solution to a technical problem.
[058] While the present invention has been shown and described with reference to the foregoing preferred embodiments, it will be apparent to those skilled in the art that changes in form, connection, and detail may be made therein without departing from the spirit and scope of the invention. 

Reference Numerals:



100 bus bar
102 first part
104 second part
106 fixing portion
108 circuit board
200 first end
202 second end
204 third end
206a, 206b one or more mounting points
208 receiving portion
210 plurality of neck portions
216 notch portion
220a, 220b plurality of fasteners
300a, 302a one or more fastening means
300b, 302b one or more mounting provisions
330a first surface
330b second surface
400 connector
402 current sensing circuit
500 cover
502 one or more openings
, Claims:I/We claim:
1. A bus bar (100) for a controller, said bus bar (100) comprising:
a first part (102); and
a second part (104);
wherein said first part (102) and said second part (104) being attached using one or more mounting provisions (300b, 302b);
wherein said first part (102) comprising one or more electronic circuits (400, 402) for sensing current to be supplied to said controller.
2. The bus bar (100) as claimed in claim 1, wherein said first part (102) being configured to have a first end (200), second end (202) and a third end (204).
3. The bus bar (100) as claimed in claim 2, wherein said first end (200) including a receiving portion (208) for receiving a wire terminal, said wire terminal being mounted using a fastener, and wherein said first end (200) including a plurality of neck portions (210) disposed at a peripheral edge of said first end (200).
4. The bus bar (100) as claimed in claim 3, wherein said first end (200) having a cylindrical profile.
5. The bus bar (100) as claimed in claim 2, wherein said second end (202) including a first surface (330a) and a second surface (330b), and a circuit board (108) being disposed on said first surface (330a) of said second end (202), wherein said one or more electronic circuits (400, 402) being disposed on said circuit board (108).
6. The bus bar (100) as claimed in claim 5, wherein said second surface (330b) of said second end (202) being configured to have a notch portion (216), said notch portion (216) being configured to conform and align parallel to a current sensing circuit (402) of said one or more electronic circuits (400, 402) being disposed on said first surface (330a) of said second end (202).
7. The bus bar (100) as claimed in claim 5, wherein said circuit board (108) being mounted on said first surface (330a) of said second end (202) using a plurality of fasteners (220a, 220b).
8. The bus bar (100) as claimed in claim 1, wherein said second part (104) being configured to receive said first part (102) in a securing portion (304) and said second part (104) being fastened to a power board using one or more fastening means (300a, 302a), wherein said one or more fastening means (300a, 302a) being disposed on one end of said second part (104).
9. The bus bar (100) as claimed in claim 2, wherein said third end (204) being disposed inside said securing portion (304) of said second part (104) of said bus bar (100).
10. A controller comprising:
a power board;
a converter board; and
a signal board;
wherein a bus bar (100) comprising a first part (102) and a second part (104) being disposed on said converter board, and wherein said second part (104) being mounted on said power board;
wherein said bus bar (100) being disposed on said signal board for receiving current signals for controlling an electric motor by said controller.
11. The controller as claimed in claim 10, wherein said controller being covered using a cover (500), said cover (500) being configured to have one or more openings (502) for receiving said first part (102) of said bus bar (100).
12. The controller as claimed in claim 11, wherein said one or more openings (502) conforming and aligning a shape of a plurality of neck portions (210) of said first part (102) of said bus bar (100).
13. The controller as claimed in claim 10, wherein said first part (102) being configured to have a first end (200), a second end (202), and a third end (204).
14. The controller as claimed in claim 13, wherein said first end (200) including a receiving portion (208) for receiving a wire terminal, said wire terminal being mounted using a fastener, and wherein said first end (200) including said plurality of neck portions (210) disposed at a peripheral edge of said first end (200).
15. The controller as claimed in claim 14, wherein said first end (200) having a cylindrical profile.
16. The controller as claimed in claim 13, wherein said second end (202) including a first surface (330a) and a second surface (330b), and a circuit board (108) being disposed on said first surface (330a) of said second end (202), wherein said one or more electronic circuits (400, 402) being disposed on said circuit board (108).
17. The controller as claimed in claim 16, wherein said second surface (330b) of said second end (202) being configured to have a notch portion (216), said notch portion (216) being configured to conform and align parallel to a current sensing circuit (402) of said one or more electronic circuits (400, 402) being disposed on said first surface (330a) of said second end (202).
18. The controller as claimed in claim 16, wherein said circuit board (108) being mounted on said first surface (330a) of said second end (202) using a plurality of fasteners (220a, 220b).
19. The controller as claimed in claim 10, wherein said second part (104) being configured to receive said first part (102) in a securing portion (304) and said second part (104) being fastened to said power board using one or more fastening means (300a, 302a), wherein said one or more fastening means (300a, 302a) being disposed on one end of said second part (104).
20. The controller as claimed in claim 13, wherein said third end (204) being disposed inside said securing portion (304) of said second part (104) of said bus bar (100).