A method for manufacturing a multi-channel current sensor for new energy vehicles

Abstract

The invention relates to the technical field of automotive current sensors, and discloses a method for manufacturing a multi-channel current sensor for new energy vehicles, including: S1, electrophoresis coating a layer of epoxy resin on the surface of the iron core, and the first injection molding to form an iron core The core prefabricated part has a positioning hole on the iron core prefabricated part; S2, the iron core prefabricated part is assembled in the mold for forming the shell, and the thimble of the mold is pierced in the positioning hole on the iron core prefabricated part; carry out the second Injection molding for the first time, and in the pressure-holding stage of the second injection molding, pull out the thimble to fill the positioning hole with plastic; form an integrated assembly of the iron core and the shell; S3, press-fit the pins and the circuit board on the On the shell; S4, press-fit the shell cover on the shell; the shell cover is arranged above the circuit board and the pins. The invention has the advantages that the current sensor has improved reliability in a high-temperature and humid environment, strong shock resistance and impact fatigue resistance, no need for welding, and simple process.

Description

technical field [0001] The invention relates to the technical field of automotive current sensors, in particular to a method for manufacturing a multi-channel current sensor for new energy vehicles. Background technique [0002] With the country's vigorous promotion of energy saving and environmental protection, new energy vehicles have gradually moved from a new technological product to the life of the general public. The battery management and motor drive control in new energy vehicles are inseparable from the application of current sensors, which can measure, detect and control measurement parameters such as current, voltage, and temperature. In the existing multi-connected current sensors (such as triple sensors), there are mainly two types. [0003] A structure of a current sensor, such as the integrated current sensor disclosed in "CN207007919U" for phase current detection of an automotive electronic control system. In this structure, the current sensor is composed o...

AI Technical Summary

Problems solved by technology

The current sensor with this structure mainly has the following problems: (1) The overall packaging of the product and the positioning of components are carried out in the way of glue filling, and the overall weight is heavy; (2) In order to meet the requirements of glue filling, an additional flow channel needs to be designed. This results in a larger product size; (3) The curing time of the potting glue is longer, prolonging the production cycle; (4) The debugging and other processes need to wait for the glue to be potted and cured. Process control and problem analysis; (5) Poor curing of potting glue can easily cause problems such as moisture absorption and stress, which will affect product accuracy and have certain risks

The current sensor with this structure mainly has the following problems: (1) The iron core is partially exposed after injection molding, which is prone to rust and rust, and the components have a short circuit risk under high temperature, humidity and vibration conditions; (2) The internal pins and the printed board The assembly method is welding, which is not easy to detect in mass production, and there are risks of missing soldering and false soldering; (3) The grounding method used in printed board assembly requires more materials for connection, which increases the cost

Images