Terminal sensor holder

Abstract

A terminal sensor holder (1000) for coupling a stator (400) to a PCB (500) is provided. The terminal sensor holder (1000) comprises: a housing (100) comprising a protruding portion (101) adapted to receive a magnetic sensor (200) and at least four terminal seats (103A; 103A, 103B), wherein each terminal block (103A; 103B) is configured to receive a magnetic terminal (300A; 300B) for connecting the magnetic wire (202, 402) to the PCB (500); 300B) for a motor vehicle.

Description

Technical Field

[0001] The present invention relates to the field of terminal sensor holders. More specifically, the present invention relates to the field of insulating holders capable of holding magnetic sensors and magnetic terminals and adapted to allow a connection between a stator, such as a stator of an electric motor, and a PCB. Background Art

[0002] In modern technology, there is often a need to be able to connect magnetic coils. For example, it is desirable to connect magnetic sensors and stators of electric motors to PCBs. These connections are usually achieved by means of a soldering process. However, the soldering process presents more than one disadvantage. For example, soldering can be challenging under high vibration conditions. Furthermore, the soldering process can be difficult due to the need to pre-strip the magnet wire, which can result in damage to the magnet wire. In addition, during the soldering process, there are always problems such as smoke generation and burn hazards. These problems are amplified if the magnet wires to be connected are thin, i.e. their thickness is less than 0.13 mm. Finally, the cost of the soldering process is high and the overall production time is usually prolonged.

[0003] In view of the above, it would be advantageous to find a solution that enables solderless connection of the stator, sensor and PCB.

[0004] The present invention faces this problem. Summary of the invention

[0005] The present invention is based on the concept of providing a terminal sensor holder for connecting a stator to a PCB, the terminal sensor holder comprising: a shell including a protruding portion suitable for accommodating a magnetic sensor and at least four terminal seats, wherein each terminal seat is configured to accommodate a magnetic terminal for connecting a magnetic wire to the PCB.

[0006] Within the scope of the present disclosure, magnet wire is an electrically conductive wire covered by a cover insulating material. An example of a suitable electrically conductive material is copper. An example of a suitable cover insulating material is a polymer film material such as Formvar, polyurethane, polyamide, polyester, polyester-polyimide, polyamide-polyimide (or amide-imide), and polyimide. Magnet wire is typically used in applications requiring a tight coil of insulated wire.

[0007] The magnetic terminal according to the present invention can be any type of magnetic terminal known to those skilled in the art. For example, the magnetic terminals that can be used according to the present invention are described in the following prior art documents:

[0008] D1: “Contact Systems for the Automotive Market” by Tyco Electronics, 9-2008 revision, available for download at the link: https: / / www.te.com / content / dam / te-com / documents / automotive / global / 889780-2-contact-systems.pdf (see, e.g., Section 26, pages 26-1 to 26-18); and

[0009] D2: US 4,026,013.

[0010] The teachings of each of these documents are incorporated herein by reference in their entirety. In particular, the structural and functional characteristics of the magnetic terminals and methods of use described in each of these documents are incorporated herein by reference.

[0011] The magnetic terminals described in these documents are also called MAG-MATE terminals.

[0012] The teachings of D1 regarding MAG-MATE terminals are incorporated herein by reference in their entirety. In particular, all structural and functional characteristics of the MAG-MATE terminals described on pages 26-1 to 26-18 of D1 are incorporated herein by reference. All possible sizes and functions of the MAG-MATE terminals described on pages 26-1 to 26-18 of D1 are incorporated herein by reference. According to an embodiment of the present invention, a method of operating the system as described on page 26-3 may also be adopted and is incorporated herein by reference in its entirety. According to an embodiment of the present invention, a termination sequence as described on page 26-16 may also be adopted and is incorporated herein by reference in its entirety.

[0013] As can be seen from D1, there are "standard MAG-MATE terminals" (see pages 26-1 to 26-14) and "micro MAG-MATE terminals" (see pages 26-15 to 26-18). The micro MAG-MATE terminals are similar to those also described in document D2.

[0014] According to the present invention, standard MAG-MATE terminals and micro MAG-MATE terminals as described in D1 and D2 can be used. For example, according to an embodiment of the present invention, all four terminal blocks of the housing are configured to accommodate standard MAG-MATE terminals as described in D1. According to another embodiment of the present invention, all four terminal blocks of the housing are configured to accommodate micro MAG-MATE terminals as described in D1 and D2. According to still another embodiment of the present invention, two terminal blocks of the housing are configured to accommodate standard MAG-MATE terminals as described in D1, and the other two terminal blocks are configured to accommodate micro MAG-MATE terminals as described in D1 and D2.

[0015] By using the terminal sensor holder according to the present invention, no soldering process and no pre-stripping of the magnetic wire are required. Therefore, the time and cost of the assembly process are significantly reduced. The problems associated with smoke generation and combustion hazards are completely overcome. In addition, the production process can be fully automated. Finally, due to the use of magnetic terminals, the electrical connection between the magnetic wire and the PCB is greatly simplified.

[0016] For example, two ends of the stator are coupled to two magnetic terminals housed in two terminal blocks of the housing, and two ends of the sensor are coupled to two other magnetic terminals housed in two other terminal blocks of the housing. Easy and solderless connection of the four magnetic terminals to the PCB allows coupling the stator to the PCB and terminating the magnetic wires from the magnetic coils wound on the stator at the same time.

[0017] According to the present invention, the housing can be made of any suitable insulating material. For example, the housing can be made of nylon, such as nylon with improved insulation resistance. Alternatively, it can be nylon with different glass fiber percentages.

[0018] According to an embodiment of the present invention, each terminal block also includes a slit for receiving and / or holding a magnetic wire. In this way, the magnetic wire is mechanically connected to the magnetic terminal and effectively held in place. No welding process is required. The slit can be advantageously used to hold the magnetic wire in place before and during the insertion of the magnetic terminal into the corresponding terminal block, thereby ensuring that the magnetic terminal is correctly connected to the magnetic wire, such as described in documents D1 and D2.

[0019] According to an embodiment of the present invention, each terminal seat also includes support elements for holding the magnetic wires. These support elements allow the magnetic wires to be maintained under a predetermined tension. For example, the support elements protrude from the housing so as to allow the magnetic wires to be wound around the support elements. Preferably, each support element is positioned corresponding to each slit, for example at one end of the slit. The support elements can be advantageously used to hold the magnetic wires in place before and during the insertion of the magnetic terminals into the corresponding terminal seats, thereby ensuring that the magnetic terminals are correctly connected to the magnetic wires, such as described in documents D1 and D2.

[0020] According to an embodiment of the present invention, the protruding portion includes a body including a groove suitable for accommodating a magnetic sensor. Therefore, the terminal sensor holder allows a simple solution for adding a magnetic sensor that can be connected to a PCB to an assembly. In fact, no additional parts and / or space are required because the sensor can be mounted directly on the terminal sensor holder. For example, the magnetic sensor may include a coil formed by a magnetic wire, and the coil is advantageously wound around the groove of the protruding portion. The two ends of the magnetic wire forming the coil can be connected to two magnetic terminals accommodated in two terminal seats of the housing in a solderless manner.

[0021] According to an embodiment of the present invention, four terminal blocks form two pairs of equal terminal blocks to accommodate two different types of magnetic terminals. The first type of magnetic terminal can be used, for example, to connect to the end of a magnetic wire of a sensor, while the second type of magnetic terminal can be used to connect to the end of a magnetic wire of a stator. In this way, the magnetic wires of the stator and the sensor can be different magnetic wires, such as magnetic wires with different diameters. For example, two pairs of terminal blocks can be implemented to accommodate two standard MAG-MATE terminals as described in D1 and two miniature MAG-MATE terminals as described in D1 or D2. However, the present invention is not limited to this embodiment, and the terminal block can be suitable for accommodating any kind of required magnetic terminals.

[0022] According to an embodiment of the present invention, the first type of magnetic terminal is suitable for connecting a magnetic wire having a diameter smaller than that of the magnetic wire connected to the second type of magnetic terminal. In fact, the first magnetic terminal can, for example, be suitable for connecting a thin magnetic wire, the thickness of which is, for example, included between 0.05 mm and 0.13 mm. For example, the first magnetic terminal can be a miniature MAG-MATE terminal such as those described in document D1, pages 26-15 to 26-18 or D2. The second magnetic terminal can, for example, be suitable for connecting a thicker magnetic wire, the thickness of which is, for example, included between 0.18 mm and 0.23 mm. For example, the second magnetic terminal can be a standard MAG-MATE terminal such as those described in D1, pages 26-1 to 26-14. This increases the versatility of possible options for magnetic wiring for sensors and stators.

[0023] According to an embodiment of the present invention, the housing further comprises a PCB holder portion for accommodating a PCB. The PCB holder portion may comprise a pair of parallel tracks to hold the PCB. The PCB holder portion may be configured to allow connection between the PCB and magnetic terminals accommodated in a terminal block of the housing. This facilitates the process of mounting the PCB on the terminal sensor holder. For example, the PCB holder portion is located directly above the terminal block. Preferably, the PCB holder portion is located on a side of the housing opposite to the side from which the protruding portion protrudes.

[0024] According to another embodiment of the present invention, a terminal sensor holder assembly is provided, which includes a terminal sensor holder according to any embodiment of the present invention described above and at least four magnetic terminals to be inserted into four terminal seats. The four magnetic terminals allow the magnetic wires of both the stator and the sensor to be easily mechanically connected to the PCB. Soldering is no longer required. The four magnetic terminals can be any magnetic terminals described in documents D1 and D2.

[0025] According to an embodiment of the present invention, four magnetic terminals form two pairs of equal terminals to connect two different types of magnetic wires. The two types of magnetic wires can be magnetic wires with different thicknesses. Thin magnetic wires, such as the magnetic wires of magnetic sensors, can have a thickness included, for example, between 0.05 mm and 0.13 mm. Thicker magnetic wires, such as the magnetic wires of stator coils, can have a thickness included, for example, between 0.18 mm and 0.23 mm. For example, the magnetic terminals for thin magnetic wires can be miniature MAG-MATE terminals as described in D1 pages 26-15 to 16-18 or D2. The magnetic terminals for thicker wires can be, for example, standard MAG-MATE terminals as described in D1 pages 26-1 to 26-14.

[0026] According to an embodiment of the present invention, the magnetic terminal is a MAG-MATE terminal. Descriptions of these known magnetic terminals can be found in documents D1 and D2. The structural and functional characteristics of the magnetic terminals and methods of use described in each of these documents are incorporated herein by reference.

[0027] According to an embodiment of the present invention, the terminal sensor holder assembly also includes a magnetic sensor placed on the protruding portion. No additional parts or space are required to add the magnetic sensor. The magnetic sensor may include a coil formed by a magnetic wire. The two ends of the magnetic wire forming the coil may be connected to two magnetic terminals to be accommodated in two terminal seats in the terminal seat of the housing.

[0028] According to an embodiment of the invention, the magnetic sensor comprises a coil wound around a groove.The design of the terminal sensor holder allows a simple solution to add a magnetic sensor connectable to a PCB to an assembly.

[0029] According to an embodiment of the present invention, the terminal sensor holder assembly also includes a PCB. The connection with the PCB is achieved by inserting a PCB pin into the magnetic terminal. The process is easy and completely avoids welding. The structure and size of the PCB can be designed to be accommodated by the housing of the terminal sensor holder. For example, the structure and size of the PCB can be designed to be accommodated by the PCB holder portion of the housing.

[0030] According to another embodiment of the present invention, a sensor system is provided, which includes a terminal sensor holder according to any embodiment of the present invention described above, a magnetic sensor placed on a protruding portion, and a stator, wherein the protruding portion is inserted into the stator so that the magnetic sensor can detect a current flowing in the stator. The terminal sensor holder is compact in design, easy to install, and avoids welding processes.

[0031] According to an embodiment of the present invention, the magnetic sensor includes a sensor coil, and the stator includes a stator coil, wherein the ends of the sensor coil and the ends of the stator coil are each connected to one of four magnetic terminals. The magnetic terminals allow the connection of magnetic wires with different thicknesses without resorting to welding processes.

[0032] According to an embodiment of the invention, the sensor system further comprises a PCB connected to at least two of the magnetic terminals, preferably four of the magnetic terminals.Connection to the PCB is easy and simply requires mechanical insertion of the PCB pins into the magnetic terminals.

[0033] According to another embodiment of the present invention, a method for assembling a sensor system is provided, comprising: providing a terminal sensor holder according to any embodiment of the present invention described above; providing a sensor on a protruding portion, whereby ends of the sensor are inserted into two of four terminal seats; inserting the protruding portion into a stator; inserting ends of the stator into the other two of the four terminal seats, and inserting a magnetic terminal into the terminal seat.

[0034] According to an embodiment of the present invention, the method further comprises: providing a PCB and connecting the PCB to at least two of the magnetic terminals, preferably four magnetic terminals.

[0035] The method according to the invention, by using the terminal sensor holder according to the invention, allows a simple, fast and cheap solution to connect, for example, a stator of an electric motor and a magnetic sensor to a PCB without soldering. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The present invention will be described with reference to the accompanying drawings, wherein like reference numerals and / or symbols designate like parts and / or similar and / or corresponding parts of the machine.

[0037] Figure 1 A 3D view of a terminal sensor holder according to the present invention is schematically shown.

[0038] Figure 2A Shows Figure 1 The terminal sensor holder is shown rotated 90° clockwise from above in the XY plane with a pair of magnetic terminals ready to be inserted therein.

[0039] Figure 2B Shows Figure 2A The terminal sensor holder is shown with a pair of magnetic terminals inserted therein and another pair of magnetic terminals ready for insertion.

[0040] Figure 2C Shows Figure 2A The terminal sensor holder shown in FIG. 1 with all four magnetic terminals inserted into it.

[0041] Figure 3A A 3D view of a terminal block according to an embodiment of the present invention is schematically shown. Figure 2C Rotate 90° clockwise on the XY plane, with the wire inserted.

[0042] Figure 3B Shows Figure 3A The terminal base shown is a cross section along the AA direction at the moment when the magnetic terminal is inserted therein.

[0043] Figure 4 Schematically shown is a 3D view of a stator coil wrapped around an insulating stator coil holder with a stator coil cover in place to be mounted thereon.

[0044] Figure 5A A 3D view of the outer part of the metal stator housing is schematically shown.

[0045] Figure 5B A 3D view of the inner part of the metal stator housing is schematically shown.

[0046] Figure 6 Schematically shows the terminal sensor holder according to an embodiment of the present invention relative to Figure 1 An inverted view of a terminal sensor holder having a sensor coil wound around a groove in a protruding portion thereof.

[0047] Figure 7 Schematically shows the Figure 6 The terminal sensor holder shown is mounted on Figure 5A and 5B Inside the metal stator housing shown.

[0048] Figure 8 It shows that Figure 7 The terminal sensor holder is shown with a PCB mounted thereon.

[0049] Fig. 9 This is Figure 3 on page 26-3 of document D1.

[0050] Fig.10 It is from document D2 Figure 1 . DETAILED DESCRIPTION

[0051] In the following, the present invention is described with reference to specific embodiments as shown in the accompanying drawings. However, the present invention is not limited to the specific embodiments described in the following detailed description and shown in the accompanying drawings, but the described embodiments simply illustrate several aspects of the invention, and the scope of the invention is defined by the appended claims.

[0052] Further modifications and variations of the present invention will be apparent to those skilled in the art. Therefore, this specification must be considered to include all modifications and / or variations of the present invention, the scope of the present invention being defined by the appended claims.

[0053] For simplicity, the same reference numerals are used in the drawings to indicate the same or corresponding components.

[0054] Figure 1 A 3D view of a terminal sensor holder 1000 according to an embodiment of the present invention is shown.

[0055] For ease of description, refer to Figure 1 , an orthogonal reference system XYZ is defined. More specifically, the vertical direction Z is defined as the direction along which the magnetic terminals 300A and 300B can be inserted into the terminal sensor holder 100, the horizontal direction Y is defined as the direction in which the support element 105A suitable for holding the sensor magnetic wire 202 extends from the terminal sensor holder 1000, and the direction X is defined as a direction perpendicular to the first two directions.

[0056] The terminal sensor holder 1000 includes a housing 100 made of an insulating material (e.g., hard plastic). The housing 100 includes at least four terminal seats, namely two terminal seats 103A and two terminal seats 103B. The at least four terminal seats 103A, 103B are equal in pairs. In fact, two of them are suitable for accommodating a first type of magnetic terminal 300A, while the other two are suitable for accommodating a second type of magnetic terminal 300B. More specifically, according to a preferred embodiment of the present invention, the first pair of terminal seats 103A are suitable for accommodating the first type of magnetic terminal 300A and the end of the sensor magnetic wire 202 of the sensor coil 201 of the magnetic sensor 200, reference Figure 6 The other two terminal blocks 103B are adapted to accommodate the second type of magnetic terminals 300B and the ends of the stator magnetic wires 202 of the stator coils 201 of the stator 200, as shown in FIG. Figure 4 , Figure 5A and Figure 5B Examples of these magnetic terminals 300A and 300B are described in references D1 and D2. A description of a magnetic sensor 200 having a sensor magnetic wire 202 and a stator 400 having a stator magnetic wire 402 can be found in Figure 4 , Figure 5A , Figure 5B and Figure 6can be found in the description.

[0057] Each terminal block 103A, 103B includes a V-shaped opening 109A, 109B, through which the magnetic wire 202, 402 can be guided into the slit 104A, 104B of the terminal block 103A, 103B, and the slit 104A, 104B and the support element 105A, 105B are suitable for holding the magnetic wire 202, 402 inserted into the slit 104A, 104B in place. More specifically, the first support element 105A of the first type of terminal block 103A extends out of the housing 100 along the X direction, and the second support element 105B of the second type of terminal block 103B extends out of the housing 100 along the Y direction in opposite directions relative to each other.

[0058] The body 100 also includes a protruding portion 102, which includes a groove 107 at its end. The protruding portion is suitable for insertion into the stator 400, as shown in FIG. Figure 7 The groove 107 is suitable for accommodating the magnetic sensor 200, as shown in FIG. Figure 6 The housing 100 further comprises a PCB holder 101 . The PCB holder 101 comprises a track structure that facilitates the insertion of the PCB 500 into the housing 100 of the terminal sensor holder 1000 .

[0059] The body 100 further includes a guide portion 108 to guide an end of the sensor magnetic wire 202 of the sensor coil 201 of the magnetic sensor 200 from the groove 107 to the first terminal base 103A.

[0060] Figure 2A Shows Figure 1 The terminal sensor holder 1000 is shown rotated 90° clockwise on the XY plane from above, with a pair of magnetic terminals 300A ready to be inserted therein.

[0061] The magnetic terminals 300A may be magnetic terminals of the type described in documents D1, pp. 26-15 to 26-18 and D2. The magnetic terminals 300A may be inserted into corresponding terminal blocks 103A along the Z direction. These magnetic terminals 300A may be, for example, miniature MAG-MATE terminals.

[0062] like Figure 2A As shown, and as Figure 6As better shown in FIG. 1 , the terminal sensor holder 1000 already has a magnetic sensor 200 mounted on the groove 107 of the protruding portion 102 of the housing 100. The magnetic sensor 200 comprises a sensor coil 201 comprising a sensor magnetic wire 202 wound around the groove 107. The sensor magnetic wire 202 may have a diameter comprised between 0.05 mm and 0.13 mm. The two free ends of the sensor magnetic wire 202 are inserted into the housing 100 and, through the guide 108, they enter into the terminal seat 103A and pass through the slit 104A to be wound around the support element 105A. The fact that the sensor magnetic wire 202 is wound around the support element 105A allows the sensor magnetic wire 202 to be kept appropriately tensioned, for example before or during insertion into the magnetic terminal 300A. Winding such a low thickness of magnetic wire around the support element 105A allows the wire to be easily and safely kept at the desired tension and position. Without support element 105A, it would be difficult to maintain the wire at a desired tension and position by simply holding the wire within slot 104A.

[0063] Figure 2B Shows Figure 2A The terminal sensor holder shown in FIG. 1 , in which a pair of magnetic terminals 300A have been inserted, and another pair of magnetic terminals 300B are ready to be inserted.

[0064] The magnetic terminal that has been inserted is a first type of magnetic terminal 300A, such as described in document D1, pages 26-15 to 26-18 or D2. The pair of magnetic terminals 300B to be inserted can be, for example, magnetic terminals of the type described in document D1, pages 26-1 to 26-14. The magnetic terminals 300B can be inserted into the corresponding terminal seat 103B along the Z direction. These magnetic terminals 300B can be, for example, standard MAG-MATE terminals.

[0065] Advantageously, when the first magnetic terminal 300A is inserted into the first type of terminal block 103A, the ends of the support element 105A and the sensor magnetic coil 202 are cut, as shown in FIG. Figure 2B and Figure 2A As can be seen. For example, the machine for placing the first magnetic terminal 300A in the first type terminal seat 103A uses a blade MB to cut the portion of the support element 105A and the sensor magnetic coil 202 extending from the terminal sensor holder 1000 while inserting the magnetic terminal 300A. In fact, the sensor magnetic wire 202 is now held in place by the first type of magnetic terminal 300A and electrically connected to the first type of magnetic terminal 300A. The insertion and termination of the magnetic terminal 300A can be performed as described in pages 26-15 to 26-18 of D1 (especially page 26-16) or D2. The teachings of each of these documents in this regard are incorporated herein by reference.

[0066] For example, reference D2, in particular, is reproduced as Fig.10 of this document Figure 1 , the first type magnetic terminal of D2, indicated by numeral 120 in FIG. 2, actually includes a grinding blade element indicated by numeral 126 in D2, which partially grinds the covering insulating material of the sensor magnetic wire 202 while being inserted into the corresponding terminal seat 103A. In this way, this portion of the conductive wire is no longer covered by the covering insulating material, contacts the magnetic terminal 300A, and is therefore electrically connected to the magnetic terminal 300A.

[0067] like Figure 2B As shown, for the terminal sensor holder 1000, the stator magnetic wire 402 of the stator coil 401 of the stator 400 has been installed inside the housing 100. In order for this to be the case, the terminal sensor holder must have been inserted into the stator 400, such as Figure 7 However, for simplicity, Figure 2B Only the terminal sensor holder 1000 is shown in the figure, where the stator magnetic wire 402 is in place in the housing 100. The thickness of the stator sensor coil 402 can be included between 0.18mm and 0.23mm. The stator magnetic wire 402 passes through the second type of terminal block 300B and is inserted into the slit 104B. The stator magnetic wire 402 is located on the support element 105B, which holds the stator magnetic wire 402 in place.

[0068] Figure 2C Shows Figure 2A The terminal sensor holder shown in FIG. 1 with all four magnetic terminals inserted into it.

[0069] Advantageously, when the second magnetic terminal 300A is inserted into the second type terminal block 103B, the end of the support element 105B and the stator magnetic coil 402 are cut, as shown in FIG. Figure 2C and Figure 2B For example, the machine for placing the second magnetic terminal 300B in the second type of terminal seat 103B inserts the magnetic terminal 300B and also uses the blade MB to cut the portion of the support element 105B and the stator magnetic coil 402 extending from the terminal sensor holder 1000, as shown in FIG. Figure 3B shown.

[0070] The stator magnet wire 402 is now held in place by and electrically connected to the second type of magnet terminal 300B.

[0071] Insertion and termination of the magnetic terminal 300B may be performed as described in D1, pages 26-1 to 26-14, in particular page 26-3. The teachings of this document in this regard are incorporated herein by reference.

[0072] For example, reference D1, in particular reference is reproduced herein as Fig. 9 3 on page 26-3 of the document of D1, the second type of magnetic terminal includes parallel slits (indicated by number 4 in FIG. 3 on page 26-3 of D1), the magnetic wire is inserted into the parallel slits, and the cutting blade element (indicated by number 4 in the same figure) laterally cuts the covering insulation material of the stator magnetic wire 402 without damaging the conductive wire covered by it. In this way, the portion of the conductive wire no longer covered by the covering insulation material contacts the magnetic terminal 300B and is therefore electrically connected to the magnetic terminal 300B.

[0073] Figure 3A A 3D view of a second type of terminal block 103B according to an embodiment of the present invention is shown, which is relative to Figure 2C Rotated 90° clockwise in the XY plane with the wire inserted. This figure shows the terminal block 103B into which the stator magnet wire 402 has been inserted, held in place by the support element 105B. The support element 105B includes a slot adapted to hold the magnet wire 402.

[0074] Figure 3B Shows Figure 3A The terminal block is shown in cross section along the AA direction at the moment when the machine inserts the magnetic terminal 300B therein. The figure shows the blade MB of the machine for inserting the magnetic terminal 300B, which cuts the stator magnetic coil 402 and the support element 105B extending from the terminal block 103B.

[0075] Figure 4 A 3D view of a stator coil 401 is shown wound around an insulating stator coil holder 403 with a stator coil cover 404 in place to be mounted thereon.

[0076] The stator magnetic wire 402 is wound around the stator coil holder 403 to form the stator coil 401. The number of windings may be, for example, 750. The stator coil holder 403 and the stator coil 401 are then inserted into the stator coil cover 404, which serves as a first protective element for the stator coil 401. Both the stator coil holder 403 and the stator coil cover 404 have a cylindrical form and are made of an insulating material such as hard plastic.

[0077] Figure 5A A 3D view of the outer portion of the metal stator housing 405 is shown.

[0078] Figure 5B A 3D view of the inner portion of the metal stator housing 405 is shown.

[0079] The stator housing 405 includes an inner portion 407 made of a metal material and an outer portion 406 made of a metal material. The inner portion 407 is in the form of a cylinder suitable for insertion into the stator coil holder 403. The outer portion 406 is in the form of a cylinder suitable for surrounding the stator coil holder 403. The inner portion 407 and the outer portion 406 are made to be coupled to each other and, when in place, form a stator housing 405 that completely surrounds the stator coil cover 404 containing the stator coil 401.

[0080] Figure 6 An inverted view of the terminal sensor holder 1000 is shown with the sensor coil 201 wound around the groove 107 of the protruding portion 102 thereof.

[0081] The sensor magnetic wire 202 having a thickness between 0.05 mm and 0.23 mm is wound around the groove 107 of the protruding portion 102 of the sensor terminal holder 1000. The number of windings may be, for example, 183. The end of the sensor magnetic wire is inserted into the slit 104A of the terminal base 103A, as shown in FIG. Figure 2A The sensor terminal holder 1000 now holds the magnetic sensor 200 .

[0082] Figure 7 It shows that Figure 6 The terminal sensor holder 1000 is shown mounted within the metal stator housing 405 .

[0083] The sensor terminal holder 1000 with the magnetic sensor 200 mounted thereon is now inserted into the stator case 405 so that the sensor coil 201 is positioned inside the stator case 405 with the terminal bases 103A and 103B facing upward.

[0084] In this position, the magnetic sensor 200 can detect the current flowing in the stator 400 .

[0085] At this time, the end of the stator magnetic wire 402 can also be inserted into the corresponding terminal block 103B, such as Figure 2A shown.

[0086] Finally, the magnetic terminals 300A and 300B can be inserted into the corresponding terminal blocks 103A and 103B. They also automatically make electrical contact with the corresponding magnetic wires 202 and 402, as shown in FIG. Figure 2A and 2C Explained.

[0087] Figure 8 It shows that Figure 7The terminal sensor holder 1000 is shown mounted on the stator 400 and has a PCB mounted thereon.

[0088] The assembly consisting of the terminal sensor holder 1000 is now ready to be connected to the PCB 500, wherein the magnetic sensor 200 is mounted on the terminal sensor holder 1000, inserted into the stator 400, and the magnetic terminals 300A and 300B are in place in the corresponding terminal seats 103A and 103B. This can be achieved very easily because the connecting pins 501 of the PCB 500 can be directly inserted into the magnetic terminals 300A and 300B. The PCB 500 can be connected to at least two, preferably four, of the magnetic terminals 300A and 300B. The PCB holder 101 of the housing 100 ensures that the PCB 500 is correctly positioned on the terminal sensor holder 1000.

[0089] The present invention also relates to a method for assembling a terminal sensor system. The method comprises the following steps:

[0090] -Providing a terminal sensor holder according to the invention, see e.g. Figure 1 ;

[0091] - providing the sensor on the protruding portion, whereby the ends of the sensor are inserted into two of the four terminal blocks, see e.g. Figure 6 and Figure 2A ;

[0092] - Insert the protrusion into the stator, see e.g. Figure 7 ;

[0093] - Insert the ends of the stator into two of the four terminal blocks, see for example Figure 2B ;

[0094] - Insert the magnetic terminal into the terminal holder, see e.g. FIG. 2A to FIG. 2C ;

[0095] - providing a PCB and connecting the PCB to at least two, preferably four, of the magnetic terminals, see e.g. Figure 8 .

[0096] By using the terminal sensor holder 1000 according to the invention, the method according to the invention allows a simple, fast and cheap solution for connecting the stator 400 and the sensor 200 to the PCB 500. No soldering is required.

[0097] Although the present invention has been described with reference to the above embodiments, it will be apparent to those skilled in the art that various modifications may be made to the present invention in accordance with the teachings above and in the appended claims without departing from the scope of the present invention.

[0098] For example, the thickness and number of magnet wires to be connected can vary depending on the type and number of components to be connected to the PCB. For example, a standard MAGMATE can terminate up to 2 wires each, so the number of coils can be increased to 6.

[0099] Thus, the number and type of terminal blocks in the housing can vary depending on the magnet wire to be connected and therefore the magnet terminals they need to accommodate. In fact, the type of magnet terminals required is a function of the thickness of the magnet wire and can vary as needed.

[0100] Finally, in order to avoid unduly obscuring the description of the present invention, those aspects that are considered known by those skilled in the art have not been described.

[0101] Therefore, the present invention is not limited to the above-described embodiments, but is only limited by the scope of protection of the accompanying claims.

[0102] Reference numerals

[0103] 1000 Terminal Sensor Holder

[0104] 2000 Terminal Sensor Holder Assembly

[0105] 3000 Sensor System

[0106] 100 Shell

[0107] 101 PCB Holder

[0108] 102 Protrusion

[0109] 103A, 103B terminal block

[0110] 104A, 104B slits

[0111] 105A, 105B support element

[0112] 106 Main Body

[0113] 107 Grooves

[0114] 109 V-shaped opening

[0115] 200 Magnetic Sensor

[0116] 201 Sensor coil

[0117] 202 Sensor magnetic wire

[0118] 300A, 300B magnetic terminals

[0119] 400 Stator

[0120] 401 stator coil

[0121] 402 stator magnetic wire

[0122] 403 Stator Coil Retainer

[0123] 404 stator coil cover

[0124] 405 stator housing

[0125] 406 External part

[0126] 407 Internal Section

[0127] 500 PCB

[0128] 501 Connection Pins

Claims

1. A terminal sensor holder (1000) for coupling a stator (400) to a PCB (500), the terminal sensor holder comprising: A housing (100) comprising a protruding portion (101) adapted to accommodate a magnetic sensor (200) and at least four terminal seats (103A; 103B), wherein each terminal block (103A; 103B) is configured to receive magnetic terminals (300A; 300B) for connecting magnetic wires (202, 402) to the PCB (500).

2. The terminal sensor holder (1000) according to claim 1, wherein: Each terminal block (103A; 103B) also includes a slot (104A; 104B) to receive and / or retain the magnet wire (202, 402).

3. The terminal sensor holder (1000) according to any one of the preceding claims, wherein: Each terminal block (103A; 103B) also includes a support element (105A; 105B) for holding the magnet wire (202, 402).

4. The terminal sensor holder (1000) according to any one of the preceding claims, wherein: The protruding portion (101) comprises a body (106) comprising a recess (107) adapted to receive the magnetic sensor (200).

5. The terminal sensor holder (1000) according to any one of the preceding claims, wherein: The four terminal blocks (103A; 103B) forms two pairs of equal terminal blocks to accommodate two different types of magnetic terminals (300A; 300B).

6. The terminal sensor holder (1000) according to claim 5, wherein: A first type of magnetic terminal (300A) is adapted to connect to a magnet wire (202) having a diameter that is smaller than a diameter of a magnet wire (402) connected to a second type of magnetic terminal (300B).

7. The terminal sensor holder (1000) according to any one of the preceding claims, wherein: The housing (100) further comprises a PCB holder portion (101) for accommodating the PCB (500).

8. A terminal sensor holder assembly (2000), comprising a terminal sensor holder (1000) according to any one of the preceding claims and at least four magnetic terminals (300A; 300B) to be inserted into the four terminal seats (103A; 103B).

9. The terminal sensor holder assembly (2000) according to claim 8 as appended to claim 5 or 6, wherein: The four magnetic terminals (300A; 300B) form two pairs of equal terminals for connecting two different types of magnetic wires (202, 402).

10. The terminal sensor holder assembly (2000) according to claim 8 or 9, wherein: The magnetic terminal (103A; 103B) is the MAG-MATE terminal.

11. The terminal sensor holder assembly (2000) according to any one of claims 8 to 10, further comprising a magnetic sensor (200) placed on the protruding portion (101).

12. The terminal sensor holder assembly (2000) according to claim 11 as appended to claim 4, wherein: The magnetic sensor (200) includes a coil (201), and the coil (201) is wound around the groove (107).

13. The terminal sensor holder assembly (2000) according to any one of claims 8 to 12, further comprising a PCB (500).

14. A sensor system (3000), comprising a terminal sensor holder (1000) according to any one of claims 1 to 7, a magnetic sensor (200) placed on the protruding portion (101), and a stator (400), wherein: The protruding portion (101) is inserted into the stator (400) so that the magnetic sensor (200) can detect the current flowing in the stator (400).

15. The sensor system (3000) according to claim 14, wherein: The magnetic sensor (200) includes a sensor coil (201), and the stator (400) includes a stator coil (401), wherein an end of the sensor coil (201) and an end of the stator coil (401) are each connected to one of the four magnetic terminals (300A; 300B).

16. The sensor system (3000) according to claim 14 or 15, further comprising a PCB (500), wherein the PCB (500) is connected to at least two of the magnetic terminals (300A; 300B), preferably to four of the magnetic terminals (300A; 300B).

17. A method of assembling a sensor system (3000), comprising: - providing a terminal sensor holder (1000) according to any one of claims 1 to 7; - providing a sensor (200) on the protruding portion (101), whereby the ends of the sensor (200) are inserted into the four terminal blocks (103A; 103B) in two terminal blocks; - inserting the protruding portion (101) into the stator (400); - inserting the ends of the stator (400) into the four terminal blocks (103A; 103B) in the other two terminal blocks; - Inserting the magnetic terminal (300A; 300B) into the terminal block.

18. The method according to claim 17, further comprising: - providing a PCB (500) and connecting the PCB (500) to at least two of the magnetic terminals (300A; 300B), preferably to four of the magnetic terminals (300A; 300B).

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