Sensor modules for installation in electric motors

Abstract

The present invention relates to a sensor module (1) for installation in an electric motor (2). The sensor module (1) comprises a holder (6) adapted to be installed in a wet chamber (8) of the electric motor (2) and a temperature sensor (7) adapted to be installed in a dry chamber (9) of the electric motor (2). A rotational position sensor (14) is mounted on the holder (6) and the temperature sensor (7) is spaced apart from the holder (6), wherein the rotational position sensor (14) and the temperature sensor (7) are connected to a connector interface (15) via a plurality of signal lines (13), the connector interface being adapted to be plugged into a corresponding connector. The sensor module (1) further comprises a sealing element (17) arranged between the rotational position sensor (14) and the temperature sensor (7), the sealing element being sealedly penetrated by a signal line (13) from one of the rotational position sensor (14) and the temperature sensor (7).

Description

Technical Field

[0001] The present invention relates to a sensor module for installation in an electric motor. Background Art

[0002] Ideally, electric motors (e.g., electric motors) should operate at their maximum design lifespan. Any defects in the motor could result in downtime. Therefore, sensors are used to analyze and predict the health of the motor. However, electric motors, especially those installed in vehicles, are preferably compact and lightweight to reduce the energy required to move the vehicle. However, the limited space within the motor makes installing sensors difficult, as operating the sensors within the motor compartment would be impaired.

[0003] It is therefore an object of the present invention to facilitate the installation of a sensor in an electric motor. Summary of the Invention

[0004] The present invention addresses the aforementioned issues by providing a sensor module for installation in an electric motor. The sensor module includes a holder adapted for installation in a wet compartment of the electric motor and a temperature sensor adapted for installation in a dry compartment of the electric motor. A rotational position sensor is mounted on the holder, and the temperature sensor is spaced apart from the holder, such that the rotational position sensor and the temperature sensor are connected to a connector interface via a plurality of signal lines, the connector interface being adapted to be plugged into a corresponding connector. The sensor module also includes a sealing element disposed between the rotational position sensor and the temperature sensor, the sealing element being penetrated by a signal line from one of the rotational position sensor and the temperature sensor.

[0005] This innovative solution allows the sensor module to be installed partially in the motor's wet compartment and partially in the dry compartment, allowing users to fully utilize the limited space within the motor. The sensor module's installation is no longer limited to either the wet or dry compartment, increasing installation space and thus improving the manageability of the sensor module within the motor. Furthermore, the rotational position sensor and temperature sensor are integrated into a single sensor module, reducing the margin for error during installation. This eliminates the need to purchase separate temperature and rotational position sensors and then integrate them into the motor's confined space during production.

[0006] The invention can be further developed by the following features, which are independent of one another in terms of their respective technical effects and can be combined in any desired manner.

[0007] For example, according to the first embodiment, the rotational position sensor can be a non-contact sensor, such as a resolver. Unlike encoders, resolvers lack electronic components, such as circuit boards. Therefore, resolvers are highly robust against contamination and vibration and can operate safely over a wide temperature range, resulting in high reliability. Rotary position sensors are particularly subject to harsh environments in electric motors; using a resolver as a rotational position sensor can therefore improve sensor reliability and life expectancy.

[0008] The holder can, in particular, be disc-shaped, having an outer circumference and an inner circumference. The rotational position sensor can be mounted at least partially around the inner circumference of the disc-shaped holder. If the rotational position sensor is a resolver, the stator can be fixedly mounted around the inner circumference of the disc-shaped holder. Providing a disc-shaped holder allows the sensor module, or at least the holder and the rotational position sensor, to be particularly compact, further facilitating installation in the electric motor.

[0009] The rotational position sensor can protrude from the disk-shaped holder beyond two opposite face sides. One face side can point toward the wet chamber of the motor and the other face side can point toward the dry chamber of the motor.

[0010] The sealing element can extend from one face side of the retainer to the other face side, forming a sealed passage between the wet chamber and the dry chamber when the sensor module is installed in the motor. The sealing element can be positioned adjacent to the retainer. Alternatively, the sealing element can at least partially enclose a portion of the retainer or penetrate the retainer.

[0011] Preferably, the connector interface is adapted to be arranged in a dry chamber of the electric motor. Thus, the sealing element can be penetrated by the signal line of the rotary position sensor to sealably lead the signal line of the rotary position sensor from the wet chamber to the connector interface in the dry chamber.

[0012] However, if the connector interface is to be arranged in a wet chamber of the electric motor, the sealing element can be penetrated by the signal line of the temperature sensor, which is sealedly led from the dry chamber to the connector interface in the wet chamber.

[0013] At least one of the two facing sides of the holder can be adapted to be arranged and / or facing the wet chamber of the motor. The terminals of the rotary position sensor can be arranged on the facing side and can be potted to seal the connection between the terminals of the rotary position sensor and the signal wires.

[0014] The rotary position sensor may include a sealing cover on at least one side adapted to face the wet chamber. The sealing cover may be potted against the rotary position sensor and may include potting of the terminals of the rotary position sensor. The sealing cover may extend around the edge of the retainer, guiding signal wires connected to the terminals to another sealing element that sealingly receives the signal wires. The sealing element may thus be formed from two sealing elements: the sealing cover and the sealing element, each disposed on opposite sides of the retainer.

[0015] The sealing element may be a potted sleeve, particularly a rubber sleeve, which is penetrated by a signal line of one of the rotational position sensor or the temperature sensor. The sealing element may also include a flange extending radially from the body of the sealing element. The flange may engage a frame of a passage formed between the wet and dry chambers of the motor, thereby securing the position of the sealing element within the chambers and sealing the passage.

[0016] In addition to its sealing function, the potting of the sealing element also provides a securing function. Signal wires penetrating the sealing element are held in place by the potting. This prevents relative movement between the signal wire and the sealing element, which could cause the signal wire to disconnect from its corresponding terminal.

[0017] According to another advantageous embodiment, the sensor module may further include a retaining bracket for holding the temperature sensor. The retaining bracket may further include a connector retainer for removably securing the connector interface to the connector retainer. Thus, the connector interface may be secured to the connector retainer during installation, reducing the risk of straining and / or tearing the signal cable during installation.

[0018] The connector interface can be fixed to the connector holder in a test position, such as for end-of-line testing. After installing the sensor module, the user can easily connect test equipment to the connector interface, regardless of the position of the complementary connector for the application. Preferably, the connector interface can be fixed to the connector holder from the manufacturing side, and after installing and testing the sensor module in the motor, the user can remove the connector interface from the connector holder and move it to the desired location.

[0019] The rotary position sensor and the temperature sensor can be connected to the same connector interface, in particular via multiple signal lines. Thus, the rotary position sensor and the temperature sensor can be tested simultaneously, requiring only one complementary connector in the application, thereby reducing the number of different components in the electric motor.

[0020] At least in the test position, a plurality of signal lines connecting the rotational position sensor and the temperature sensor to the connector interface can be at least partially wrapped around the holding bracket. Thus, the signal lines are neatly arranged in the sensor module and do not interfere during installation.

[0021] The retaining bracket may include a post having a free end, with the connector retainer disposed on the free end. At least in the test position, the signal line may be at least partially wrapped around the post. To position the plurality of signal lines around the retaining bracket, the retaining bracket may include positioning ribs projecting from an outer surface of the retaining bracket (particularly the post).

[0022] In an application position (in which the connector interface mates with a complementary connector arranged in the motor), the connector interface can be separated from the connector holder (in particular the holding bracket). Preferably, the connector interface can be mounted in a connector holder, which is spaced apart from the holding bracket in the application position.

[0023] When the connector interface is removed from the connector holder, the wrapped portion of the signal wire can be at least partially unwound, increasing the margin for positioning the connector interface. This further facilitates installation of the sensor module. Furthermore, the increased margin allows the sensor module to be adapted for various motors having different structures and / or different predetermined positions for the complementary connectors.

[0024] The retaining bracket may include a through-hole, wherein the temperature sensor extends through the through-hole. The through-hole may extend substantially parallel to the longitudinal axis, and the temperature sensor may include a sensor body extending substantially parallel to the longitudinal axis. The retaining bracket may be adapted to guide the temperature sensor along the through-hole to facilitate insertion of the temperature sensor into a predetermined sensing location in the motor.

[0025] The temperature sensor or at least the end of the sensing element carrying the temperature sensor can be adapted to be inserted into a hole, in particular a blind hole, which can be formed in the coil winding of the electric motor. The temperature sensor is surrounded by the coil winding, which improves the sensing accuracy of the temperature sensor.

[0026] The temperature sensor or at least the tip can preferably be rotationally symmetrical, so that the temperature sensor or at least the tip can be easily inserted into the hole, in particular a blind hole. Therefore, the relative rotational position of the temperature sensor and the hole is irrelevant for inserting the temperature sensor into the hole, in particular a blind hole.

[0027] However, if it is desired to arrange the temperature sensor in a predetermined rotational position relative to the hole (particularly the blind hole), the temperature sensor and / or the hole (particularly the blind hole) may comprise at least one coding feature. The temperature sensor may, for example, comprise a rotationally asymmetric shape that is complementary to the hole (particularly the blind hole).

[0028] The temperature sensor may preferably be a negative temperature coefficient thermistor sensor, also known as an NTC sensor. Such sensors are characterized by their fast response time and high accuracy.

[0029] The temperature sensor (particularly the end of the temperature sensor including the sensing element) can be encapsulated in an epoxy resin, for example. Encapsulation can protect the sensing element from the surrounding environment and prevent damage due to shock and / or vibration. Preferably, at least the end of the temperature sensor can be encapsulated in a fluoropolymer such as polytetrafluoroethylene (PTFA) and perfluoroalkoxy polymer (PFA). Fluoropolymers have high resistance to solvents, acids and bases. Therefore, encapsulating at least the end of the temperature sensor in a fluoropolymer can extend the service life of the temperature sensor, especially in harsh environments.

[0030] Depending on the application requirements, the shape of the temperature sensor can be adapted accordingly. Preferably, the tip, including the sensing element, and the remainder of the sensor body can have cross-sections, in a plane perpendicular to the longitudinal axis, that differ from one another in at least one of shape and size. The tip can, for example, have a circular cross-section, and the remainder of the sensor body can have a rectangular cross-section, with the wider side being approximately as wide as the diameter of the tip's cross-section. This allows for a clear distinction between the tip (which can be inserted into a hole, particularly a blind hole, for a winding of an electric motor) and the remainder of the sensor body.

[0031] To limit the insertion depth of the temperature sensor into a hole (particularly a blind hole) in a winding of an electric motor, the temperature sensor may include a limit stop that protrudes radially from the sensor body. The limit stop prevents the tip of the temperature sensor from being inserted too deeply into the winding and abutting the end of the hole, potentially damaging the tip.

[0032] The temperature sensor may be adapted to be movable relative to the holding bracket, adjusting the immersion depth of the temperature sensor in a hole, in particular a blind hole, of the winding of the electric motor, thereby further increasing flexibility and tolerance compensation during installation.

[0033] The retaining bracket can be formed as an integral component, for example by an injection molding process. The retaining bracket may include a center rod extending substantially parallel to the longitudinal axis. Other functional components may protrude from the periphery of the center rod. For example, a post comprising a connector retainer may protrude from the periphery of the center rod and may extend beyond the center rod substantially parallel to the longitudinal axis. Additionally, a second post may protrude from the other side of the periphery and extend beyond the center rod substantially parallel to the longitudinal axis. The second post may be characterized by a through hole for receiving a temperature sensor. Thus, the retaining features for retaining the connector interface and the temperature sensor are locally separated, reducing the risk of signal wire entanglement.

[0034] According to another advantageous aspect, a mounting protrusion may protrude from the central rod, the mounting protrusion being adapted to receive a bushing, in particular an annular bushing, which may engage a complementary formed mounting feature of the motor, thereby securing the retaining bracket in the motor.

[0035] In another advantageous embodiment, a position assurance member may be provided. The position assurance member may be adapted to be fixed to the holding bracket in at least two positions, wherein in a first of the at least two positions, the relative position between the temperature sensor and the holding bracket is movable, and in a second of the at least two positions, the relative position between the temperature sensor and the holding bracket is fixed. Thus, in the first position, the temperature sensor may be movable to enable height adjustment during use. In the second position, the temperature sensor is fixed at a desired height and secured against movement due to vibrations and / or shocks.

[0036] The temperature sensor can be secured in the through-hole by an interference fit. At least one locking fork can be provided, which presses against the outer contour of the temperature sensor in at least a second of at least two positions. Preferably, a plurality of locking forks can be provided, arranged around the periphery, wherein each locking fork presses against the temperature sensor in a second of the at least two positions. Thus, the locking forks retain the temperature sensor around its periphery in an interference fit.

[0037] The at least one locking fork may be formed in the through hole and elastically deflected by the position assurance member in a second position of the at least two positions. However, more preferably, the at least one locking fork may be formed as an integral component with the position assurance member, wherein the at least one locking fork is deflected toward the temperature sensor in the second position of the at least two positions.

[0038] The position assurance member can be adapted to guide movement of the temperature sensor, particularly movement substantially parallel to the longitudinal axis. At least one locking prong can abut a radial overhang of the sensor body parallel to the longitudinal axis. The at least one locking prong presses against the overhang while simultaneously moving parallel to the longitudinal axis from a first of at least two positions to a second of the at least two positions. Thus, due to the motion-transmitting coupling in at least one direction, the temperature sensor is caused to move parallel to the position assurance member. Consequently, the temperature sensor can be guided by the position assurance member into a bore of a winding of the electric motor.

[0039] A locking assembly can be provided to lock the position assurance member in one of the at least two positions, preferably the second of the at least two positions. The locking assembly can, for example, be formed by latches that engage with each other in a positive fit. This can prevent the position assurance member from shifting due to stresses (e.g., vibrations). Thus, securing the temperature sensor by the position assurance member is further improved.

[0040] The position assurance member can be fixed in two or more positions. For example, the position assurance member can include a plurality of teeth protruding from an outer surface of the position assurance member. Each tooth can correspond to one of at least two positions, in particular, at least two positions. The position assurance member can be actuated by moving it from one position to a subsequent position. In each subsequent position, the pressing force used to secure the temperature sensor via the interference fit can be increased.

[0041] An electric motor for a vehicle, in particular an electric motor, can be provided, comprising a wet chamber, a dry chamber and a channel connecting the wet chamber and the dry chamber, wherein a sensor module according to any of the aforementioned embodiments can be installed in the electric motor, a retainer is installed in the wet chamber and a temperature sensor is installed in the dry chamber, wherein a sealing element is sealingly fixed in the channel.

[0042] The connector interface may be arranged in the dry chamber, wherein a signal line from the rotational position sensor (which is fixed to the holder in the wet chamber) penetrates the sealing element to be sealingly guided through the channel to the dry chamber and connected to the connector interface.

[0043] In the figures, the same reference numerals are used for elements that correspond to one another in terms of function and / or structure.

[0044] According to the description of various aspects and embodiments, if the technical effect of the element is not required in a specific application, the element shown in the drawings may be omitted, and vice versa: that is, if the technical effect of a specific element is advantageous in a specific application, an element not shown or described with reference to the drawings but described above may be added. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0046] Figure 1 shows a schematic perspective view of an exemplary embodiment of a sensor module according to the present invention;

[0047] Figure 2 shows a schematic perspective view of an exemplary embodiment of a sensor module according to the invention installed in an electric motor;

[0048] Figure 3 A schematic perspective view showing an exemplary embodiment of a holder and a rotational position sensor of a sensor module according to the present invention;

[0049] Figure 4 shows another schematic perspective view of the rotational position sensor and the holder;

[0050] Figure 5 A schematic perspective view showing a holding bracket of an exemplary embodiment of a sensor die according to the present invention;

[0051] Figure 6 a schematic cross-sectional view showing a first exemplary embodiment of a position assurance member in a first position;

[0052] Figure 7 a schematic cross-sectional view showing a first exemplary embodiment of a position assurance member in a second position;

[0053] Figure 8 a schematic cross-sectional view showing a second exemplary embodiment of a position assurance member in a first position;

[0054] Figure 9 a schematic cross-sectional view showing a second exemplary embodiment of a position assurance member in a second position;

[0055] Figure 10 a schematic cross-sectional view showing a third exemplary embodiment of a position assurance member in a first position;

[0056] Figure 11 a schematic cross-sectional view showing a third exemplary embodiment of a position assurance member in a second position;

[0057] Figure 12 a schematic cross-sectional view showing a fourth exemplary embodiment of a position assurance member in a first position;

[0058] Figure 13 A schematic cross-sectional view of a fourth exemplary embodiment of a position assurance member is shown in a second position. DETAILED DESCRIPTION

[0059] First, refer to Figure 1 and Figure 2 An exemplary embodiment of the inventive sensor module 1 is explained in more detail.

[0060] Figure 1 The sensor element 1 is shown in a schematic perspective view and is Figure 2 In FIG. 1 , the sensor module 1 is shown installed in an electric motor 2 , in particular an electric motor 4 .

[0061] Sensor module 1 includes a holder 6 adapted to be mounted in wet chamber 8 of motor 2, and a temperature sensor 7 adapted to be mounted in dry chamber 9 of motor 2. A rotational position sensor 14 is mounted on holder 6, and a temperature sensor 7A is spaced apart from holder 6. Rotational position sensor 14 and temperature sensor 7 are connected to a connector interface 15, particularly a common connector interface 15, via a plurality of signal lines 13. Connector interface 15 is adapted to be connected to a corresponding connector. Furthermore, a sealing element 17 is provided between temperature sensor 7 and rotational position sensor 14, and a signal line from one of rotational position sensor 14 and temperature sensor 7 seals and penetrates sealingly therethrough.

[0062] In this case, connector interface 15 is arranged in dry chamber 9 of motor 2, and thus, sealing element 17 is penetrated by signal line 13 from rotational position sensor 14. Sealing element 17 can be sealingly fixed in passage 19 connecting wet chamber 8 and dry chamber 9 of motor 2. Thus, two sensors can be integrated into a single sensor module 1, whereby one sensor can be installed in wet chamber 8 and the other in dry chamber 9 of motor 2. Consequently, the space available for installing sensor module 1 within motor 2 is increased, allowing for improved manageability and ease of installation of sensor module 1 in motor 2.

[0063] Holder 6 (which is now referred to as Figure 3 and Figure 4 To clarify) comprises a disk-like shape, more particularly an annular shape, with an inner periphery 10 and an outer periphery 12. Around the inner periphery 10, a rotary position sensor 14 is mounted radially inwardly.

[0064] The rotary position sensor 14 may be a resolver 16, wherein a stator 18 of the resolver 16 is mounted around the inner periphery of the holder 6. The resolver 16 may also include a rotor 20, which may be attached to the shaft of the motor 2, wherein the angle is detected by means of an electrical signal generated due to a change in the reactance of the rotating rotor 20 and the fixed stator 18. Thus, the speed of the motor, in particular the rotational speed of the shaft, may be measured and then controlled by sending a signal to the motor.

[0065] In order to fix the holder 6 in the motor 2, the holder 6 is provided with a plurality of mounting holes 22, which extend from one face side 24 to an opposite face side 26. Thus, the holder can be fixed in the motor, for example, by means of screws, in order to fix the holder 6 and thus the rotational position sensor 14 against movement due to shock or vibration.

[0066] For space-saving assembly, the holder 6 may comprise recesses 28 along a circumferential portion in which terminals 30 of the rotary position sensor 14, in this case terminals of the stator 18, may be arranged. The terminals 30 may be connected to the signal lines 13 which are connected to the connector interface 15.

[0067] exist Figure 3 , the face side 24 of the retainer 6 is shown. In the installed state, in which the retainer 6 is installed in the motor 2, the face side 24 faces the wet chamber 8. The rotational position sensor 14 also includes at least one stabilizing rib 32, which protrudes from the outer edge of the rotational position sensor 14 into the recess 28. Preferably, the stabilizing rib 32 is provided on either side of the terminal 30. In the wet chamber 9, the rotational position sensor 14 may come into contact with a fluid such as oil. To further protect the rotational position sensor, a sealing cap 34 may be provided on the face side 24 of the rotational position sensor 14. The sealing cap 34 may preferably be potted to the rotational position sensor 14 to prevent the sealing cap 34 from loosening due to stress such as shock or vibration. The sealing cap 34 may preferably be embedded in the terminal 30, thereby protruding into the recess 28. The stabilizing rib 32 may also be embedded during potting, whereby the stabilizing rib 32 further stabilizes the potting in the recess 28. The signal line 13 of the rotary position sensor 14 (which may protrude from the sealing cover 34 on the opposite face side 26) penetrates the sealing element 17, which may be arranged on the opposite face side 26. The sealing element 17 may even abut the opposite face side 26 and / or the sealing cover 34, forming a closed, sealed path for the signal line 13 between the sealing cover 34 and the sealing element 17. However, depending on the design of the electric motor 26, the sealing element 17 may also be located away from the opposite face side 26 of the holder 6.

[0068] In this exemplary embodiment, the sealing element 17 is formed as a rubber sleeve that includes a flange portion 36 that radially protrudes from the remainder of the body of the sealing element. The flange portion 36 can be positioned adjacent to the frame of the passage 19 in the motor 2 to ensure that the sealing element 17 does not slip through the passage 19. The remainder of the body of the sealing element can be adapted to extend through the passage 19, sealing the passage between the wet chamber 8 and the dry chamber 9.

[0069] The temperature sensor 7 can be held by a holding bracket 38, see Figure 5 Describe it in more detail.

[0070] The retaining bracket 38 can preferably be formed as an integral component 40, such as an injection molded component. The retaining bracket 38 can include a connector retainer 42 for removably receiving the connector interface 15. The connector retainer 38 can include retaining arms 44 facing each other, each retaining arm 44 having a guide recess 46 into which a guide rail or protrusion of the connector interface 15 can be inserted to secure the interface to the retaining bracket 38. Of course, other means for removably securing the connector interface 15 to the retaining bracket 38O can be envisioned, such as a connector retainer 42 having a locking latch that can engage a locking protrusion of the connector interface 15.

[0071] exist Figure 1 and Figure 2 In the test position 46, connector interface 15 can be secured to retaining bracket 38. In test position 46, connector interface 15 can be easily connected to test equipment for end-of-line testing. Sensor module 1 is preferably positioned in test position 48 prior to installation, allowing for easy installation of sensor module 1 because connector interface 15 is secured to retaining bracket 38 and does not obstruct operation of sensor module 1. A user can focus on holding and positioning the rest of sensor module 1 without having to worry about connector interface 15.

[0072] In the second position, in particular the application position 48, in which the connector interface can be connected to a complementary connector for application purposes, the connector interface can be separated from the holding bracket 38, in particular the connector holder 38. The connector interface 15 in the application position 48 is in Figure 2 It is schematically shown by a dotted line.

[0073] The retaining bracket 38 may include a central rod 50 extending substantially parallel to the longitudinal axis L. Other functional components may protrude from the periphery of the central rod 50. For example, a post 52 having a free end 54 (on which the connector retainer 42 may be formed) may protrude from the periphery of the central rod 50 and may extend beyond the central rod 50 substantially parallel to the longitudinal axis L. Additionally, an additional post 56 may protrude from the other side of the periphery and extend beyond the central rod 50 substantially parallel to the longitudinal axis L. The additional post 56 may feature a through hole 57 for receiving the temperature sensor 7. Thus, the retaining features for retaining the connector interface 15 and the temperature sensor 7 are partially separated, reducing the risk of entanglement of the signal line 13.

[0074] According to another advantageous aspect, a mounting protrusion 58 may protrude from the central rod 50 , the mounting protrusion 58 being adapted to receive a bushing 60 , in particular an annular bushing, which may engage a complementary formed mounting feature of the motor 2 , thereby securing the retaining bracket 38 in the motor 2 .

[0075] At least in the test position 46, the signal line 13 can be at least partially wrapped around the post 52 to neatly arrange the signal line 13 during installation. Therefore, the signal line 13 will not interfere with the post 52 due to snagging, snagging, and / or tangling. In order to guide the signal line 13 around the post 52 and prevent the signal line 13 from shifting along the post 52, the post 52 can be provided with a protruding rib 62 protruding from the outer surface of the post 52.

[0076] As from Figure 2 It can be seen that in the application position 48, the signal line 13 can be unwound from the post 52. The unwound signal line 13 provides more room for positioning the connector interface 15. Therefore, the sensor module 1 can be applied to various motors that differ from each other in at least one of size and structure.

[0077] The temperature sensor 7 can be pin-shaped and comprises a body which extends parallel to the longitudinal axis L through a through hole 57 of the retaining bracket 38, in particular through a further upright 56 of the retaining bracket 38. The temperature sensor 7 can be inserted into the through hole 57 by means of a closing mouth 64 which is formed by circumferentially arranged, elastically deflectable latches 66 which press against the sensor body and stabilize the temperature sensor 7 in the retaining bracket 38. The relative position between the temperature sensor 7 and the retaining bracket 38, which is essentially parallel to the longitudinal axis L, can be adjusted to allow tolerance compensation. The temperature sensor 7 can be adapted to be inserted into a hole 68, in particular a blind hole 70 of a winding 72 of an electric motor, such as Figure 2 In particular, the end 74 of the temperature sensor 7 may be adapted to be inserted into the hole 68 , in particular the blind hole 70 .

[0078] At least the end 74 may comprise a cross section in a plane substantially parallel to the longitudinal axis L, which cross section corresponds to the cross section in the hole 68 of the winding 72 of the electric motor. Preferably, the cross section may be rotationally symmetrical, for example circular, so that the temperature sensor 7 can be inserted into the hole 68 regardless of the relative rotational position of the temperature sensor and the hole 68.

[0079] The tip 74 can have a different cross-section than the rest of the temperature sensor body. For example, the tip 74 can have a circular cross-section, while the rest of the sensor body can have a quadrilateral cross-section, particularly a rectangular cross-section. The width of the wider side of the quadrilateral cross-section and the diameter of the circular cross-section can be substantially equal.

[0080] The temperature sensor 7 can preferably be a negative temperature coefficient sensor, in which at least the distal end is encapsulated. The encapsulation can include a resin, such as epoxy resin. Epoxy resin has high thermal conductivity, which allows the sensor element encapsulated in the epoxy resin to sense temperature without high losses. Preferably, the encapsulation can be formed from a fluoropolymer such as PTFE and PFE, which, due to its good resistance to solvents, acids, and bases, can extend the life of the temperature sensor 7 in harsh environments. In addition, the high thermal conductivity and thermal diffusivity of the fluoropolymer allow heat to be quickly transferred to the distal end of the temperature sensor 7 without causing high losses.

[0081] The temperature sensor 7 may also be at least partially covered by a heat shrink sleeve to further protect the temperature sensor 7. In particular, the portion of the temperature sensor 7 arranged in the holding bracket 38 may be covered by the heat shrink sleeve.

[0082] At the end opposite the terminal end 74 , the temperature sensor 7 may be connected to a signal line 13 , which connects the sensing element of the temperature sensor 7 to the connector interface 15 .

[0083] A position assurance member 76 may be provided that can be fixed in at least two positions on the holding bracket 38. In a first of the at least two positions, the position of the temperature sensor 7 relative to the holding bracket 38, in particular, at least one of the rotational position and the position substantially parallel to the longitudinal axis L, may be movable. In a second of the at least two positions, the position of the temperature sensor 7 relative to the holding bracket 38, in particular, at least one of the rotational position and the position substantially parallel to the longitudinal axis L, may be fixed. Thus, the position of the temperature sensor 7 can be adjusted in the first of the at least two positions and then fixed in the second of the at least two positions.

[0084] Reference Figures 6 to 13 The interaction between the position assurance member 76 and the temperature sensor 7 is further clarified.

[0085] exist Figure 6 and Figure 7 A first exemplary embodiment of the position assurance member 76 is shown in FIG. Figure 6 In FIG. 1 , the position assurance member 76 is shown in a first position 78 of at least two positions, and in Figure 7 , the position assurance member 76 is shown in a second of at least two positions 80 .

[0086] In the first embodiment, the position assurance member 76 includes at least one locking prong 82 that nests within the periphery of the temperature sensor 7 . Thus, the temperature sensor 7 is retained by the locking prong 82 . Multiple locking prongs can be arranged around the periphery of the temperature sensor 7 . The locking prongs 82 extend into the through-hole 57 forming an opening 84 that is substantially concentric with the through-hole 57 . The at least one locking prong 82 includes circumferentially extending tabs that neatly nestle within the outer contour of the temperature sensor. In the first position, the at least one locking prong 82 only lightly presses against the outer contour of the temperature sensor 7 , thereby allowing the position of the temperature sensor 7 to be adjusted relative to the position assurance member 76 and the retaining bracket 38 .

[0087] To limit the movement of temperature sensor 7 and further prevent malfunction of sensor module 1, temperature sensor 7 can include a limit stop 86 that projects radially from the body of the temperature sensor. Limit stop 86 can be adapted to abut the frame of hole 68 in the motor winding. Thus, temperature sensor 7 is prevented from being inserted too deeply into hole 68 and then stopped, thereby preventing distal end 74 from striking the bottom of the hole and potentially causing damage. A heat shrink sleeve that at least partially surrounds temperature sensor 7 can form limit stop 86.

[0088] The limit stop 86 can also provide an abutment surface at an opposite end spaced a certain distance from the distal end 74 of the temperature sensor. At least one locking fork 82 can abut the abutment surface in a first position 78 of at least two positions and push the temperature sensor when the position assurance member 76 is moved from the first position 78 to the second position 80. Thus, a minimum insertion depth of the temperature sensor 7 into the hole 68 can be foreseen. Furthermore, the temperature sensor 7 can be guided into the hole 68 by the position assurance member.

[0089] exist Figure 7 In the second position shown, the position assurance member 76 can be fully inserted into the through-hole 57, wherein the front end of the position assurance member 76 engages the undercut 90 of the retaining bracket 38, locking the position assurance member 76 in the second position 80. At least one locking prong 82 is inserted into a groove 91 between the temperature sensor 7 and a rigid pressing protrusion 92 formed in the through-hole 57. The pressing protrusion 92 can prevent the pressing force of the at least one locking prong 82 against the temperature sensor from loosening. The groove 91 can be sized so that the inserted locking prong 82 is sandwiched between the pressing protrusion 92 and the temperature sensor 7, thereby increasing the pressing force of the at least one locking prong 82 against the temperature sensor 7, thereby securing the temperature sensor 7 in the retaining bracket 38 by an interference fit.

[0090] In the second exemplary embodiment (see Figure 8 and Figure 9), the position assurance member 76 can be arranged on the side of the through-hole 57 that points toward the end 74 of the temperature sensor 7. The position assurance member 76 is fitted around the other pillar 56 including the through-hole 57, wherein the position assurance member 76 tapers toward the end 74 and is then fitted around the temperature sensor 7. The taper of the position assurance member 76 forms a recess 94 in the interior of the position assurance member 76, wherein at least one locking fork 82 (which is integrally formed in the through-hole 57 of the retaining bracket 38) is received in the recess 94 in the second position 80 of the at least two positions. Thus, the locking fork 82 presses against the temperature sensor 7, securing it through an interference fit.

[0091] The front end 96 of the position assurance member 76 can be adapted to abut the top surface of the winding 72 of the motor so that when the temperature sensor 7 is further inserted into the hole 68, the position assurance member 76 is pushed upward away from the distal end 74 of the temperature sensor 7 into the second position 80 of the at least two positions, such as Figure 9 shown.

[0092] exist Figure 10 and Figure 11 , at least one locking fork 82 abuts against the limit stop 86 to simultaneously guide the distal end 74 of the temperature sensor into the hole 68 when the position assurance member 76 is moved from the first position to the second position. The position assurance member 76 also includes a locking latch 98 that positively engages a locking rib 100 formed on the outer surface of the retaining bracket 38 in the first and second positions. Thus, the position assurance member 38 can be securely fixed in the first and second positions.

[0093] exist Figure 12 and Figure 13 In another embodiment shown, a position assurance member 76 is arranged on the side of the temperature sensor 7 opposite the tapered wall 102 of the retaining bracket 38 to reduce the width of the through-hole 57. The position assurance member 76 includes locking prongs 82 formed as ribs that conform to the outer contour of the temperature sensor 7 parallel to the longitudinal axis L. In addition, a stabilizing clip is provided that extends partially around the periphery of the temperature sensor 7 to retain the temperature sensor 7. On the side facing away from the temperature sensor 7, the position assurance member 76 includes a plurality of protruding teeth 106 that can positively engage the locking latch 98 to block movement of the position assurance member 76 relative to the retaining bracket 38 away from the end 74 of the temperature sensor 7.

[0094] Each tooth 106 corresponds to a position at which the position securing member 76 can be secured. The temperature sensor 7 can be moved in the first position 78, allowing the position of the temperature sensor to be adjusted. With each incremental position, the distance between the locking fork 82 and the tapered wall 102 decreases, resulting in an increase in the pressing force of the locking fork 82 against the temperature sensor 7. Thus, the pressing force can be adapted to the application requirements.

[0095] Reference numerals

[0096] 1 sensor module

[0097] 2 Electric motors

[0098] 4 electric motors

[0099] 6 Retainer

[0100] 7 Temperature Sensor

[0101] 8 wet room

[0102] 9 Dry Room

[0103] 10 inner weeks

[0104] 12 Periphery

[0105] 13 signal lines

[0106] 14 Rotary position sensor

[0107] 15 Connector interface

[0108] 16 Resolver

[0109] 17 Sealing element

[0110] 18 stator

[0111] 19 channels

[0112] 20 rotors

[0113] 22 mounting holes

[0114] 24 side

[0115] 26 Opposite side

[0116] 28 notches

[0117] 30 terminals

[0118] 32 Stabilizing ribs

[0119] 34 Sealing cover

[0120] 36 flange part

[0121] 38 Holding bracket

[0122] 40 overall components

[0123] 42 Connector retainer

[0124] 44 Holding Arm

[0125] 46 test positions

[0126] 48 Application Locations

[0127] 50 center rod

[0128] 52 columns

[0129] 54 Free end

[0130] 56 Another pillar

[0131] 57 through holes

[0132] 58 Mounting protrusion

[0133] 60 Bushing

[0134] 62 protruding ribs

[0135] 64 Close Mouth

[0136] 66 Latch

[0137] 68 holes

[0138] 70 blind holes

[0139] 72 Motor windings

[0140] 74 End

[0141] 76 Position assurance component

[0142] 78 First Position

[0143] 80 Second position

[0144] 82 Locking Fork

[0145] 84 Opening

[0146] 86 limit stop

[0147] 90 Undercut

[0148] 91 slots

[0149] 92 Press the protrusion

[0150] 94 recess

[0151] 96 Frontend

[0152] 98 Locking Latch

[0153] 100 Locking ribs

[0154] 102 tapered wall

[0155] 104 Keep Rib

[0156] 106 teeth

[0157] L longitudinal axis

Claims

1. A sensor module (1) for installation in an electric motor (2), the sensor module (1) comprising a holder (6) adapted to be installed in a wet chamber (8) of the electric motor (2) and a temperature sensor (7) adapted to be installed in a dry chamber (9) of the electric motor (2), a rotational position sensor (14) being mounted on the holder (6) and the temperature sensor (7) being spaced apart from the holder (6), wherein the rotational position sensor (14) and the temperature sensor (7) are connected to a connector interface (15) via a plurality of signal lines (13), the connector interface being adapted to be plugged into a corresponding connector, and wherein the sensor module (1) further comprises a sealing element (17) arranged between the rotational position sensor (14) and the temperature sensor (7) and being sealedly penetrated by a signal line (13) from one of the rotational position sensor (14) and the temperature sensor (7); in, The sensor module (1) further comprises a holding bracket (38) for holding the temperature sensor (7), wherein the position ensuring member (76) is adapted to be fixed on the retaining bracket (38) in at least two positions, and wherein in a first position (78) of the at least two positions, the relative position between the temperature sensor (7) and the retaining bracket (38) is movable, and in a second position (80) of the at least two positions, the relative position between the temperature sensor (7) and the retaining bracket (38) is fixed.

2. The sensor module (1) as claimed in claim 1, wherein the sealing element (17) extends from one face side (24) to an opposite face side (26) of the holder (6).

3. The sensor module (1) according to claim 1, wherein the rotational position sensor (14) comprises a sealing cover (34) which closes the sealing element (17) from at least one side.

4. The sensor module (1) of claim 1, wherein the holding bracket (38) comprises a connector holder (42) for removably securing the connector interface (15) to the holding bracket (38) in a test position (46).

5. The sensor module (1) as claimed in claim 4, wherein at least in the test position (46), the plurality of signal lines (13) connecting the rotational position sensor (14) and / or the temperature sensor (7) to the connector interface (15) are at least partially wound around the holding bracket (38).

6. The sensor module (1) according to claim 4, wherein In an application position (48) for connecting the connector interface (15) to a complementary connector for a customer application, the connector interface (15) is spaced apart from the retaining bracket (38).

7. The sensor module (1) according to claim 4, wherein the holding bracket (38) comprises a through hole (57), and the temperature sensor (7) extends through the through hole (57).

8. The sensor module (1) according to claim 1, wherein the temperature sensor (7) comprises at least one limit stop (86) protruding radially from the body of the temperature sensor (7) for limiting the insertion depth of the temperature sensor (7).

9. The sensor module (1) as claimed in claim 1, wherein at least the end (74) of the temperature sensor (7) comprises a substantially rotationally symmetric cross section.

10. The sensor module (1) of claim 9, wherein the tip (74) of the temperature sensor (7) and the remainder of the temperature sensor (7) comprise cross-sections that differ from each other in at least one of size and shape.

11. The sensor module (1) as claimed in claim 1, wherein at least in a second position (80) of the at least two positions, at least one locking fork (82) presses against the temperature sensor (7).

12. The sensor module (1) according to claim 11, wherein the at least one locking fork (82) and the position assurance member (76) are formed integrally with each other as a one-piece component.

13. The sensor module (1) of claim 11, wherein the position assurance member (76) is adapted to guide the temperature sensor (7) parallel to a movement from a first position (78) of the at least two positions to another position of the at least two positions.

14. An electric motor (2) comprising a wet chamber (8), a dry chamber (9) and a passage (19) connecting the wet chamber (8) and the dry chamber (9), wherein the sensor module (1) according to any one of claims 1 to 13 is installed in the electric motor (2), the rotational position sensor (14) is installed in the wet chamber (8) and the temperature sensor (7) is installed in the dry chamber (9), and wherein the sealing element (17) is sealingly fixed in the passage (19).

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