A starting power generation all-in-one machine

Abstract

The application discloses a starting and power generation integrated machine and belongs to the technical field of motors. The starting and power generation integrated machine comprises a motor assembly and an inverter assembly. The inverter assembly comprises a PCBA shell, a shell body and a cover plate arranged above the shell body, a PCBA arranged in the shell body, a heat dissipation structure comprising a heat dissipation plate and a water pipe, the heat dissipation plate has a first side and a second side arranged in the up-down direction, the first side of the heat dissipation plate is used for being attached to the shell body and a power module, the second side of the heat dissipation plate is provided with a containing groove, the water pipe is in interference fit in the containing groove, and at least part of the outer wall of the water pipe is attached to the groove wall of the containing groove. The starting and power generation integrated machine can sufficiently dissipate heat of the PCBA and the power module, and the reliability and stability of the whole machine are improved.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and in particular to an integrated starter-generator. Background Technology

[0002] The starter generator can provide torque assistance during cold / hot starts of a car, reducing fuel consumption, and recover energy during braking to charge the 48V battery. Therefore, cars equipped with starter generators can effectively save fuel.

[0003] However, the installation space of starter generators in vehicles is mostly small, and the working environment is characterized by high temperature, high humidity, and a lot of dust. The entire unit needs to operate in a vibrating and high-temperature environment for a long time. At the same time, the PCBA and power module on the starter generator generate a lot of heat during operation. Due to the limitations of the existing heat dissipation structure design of starter generators, which is often not reasonable enough, the stability and heat dissipation efficiency of the heat dissipation structure are low, which affects the normal operation of the starter generator and results in poor reliability and stability of the entire unit. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated starter generator with a highly stable heat dissipation structure that can achieve sufficient heat dissipation, thereby improving the reliability and stability of the entire machine.

[0005] To achieve the above objectives, the following technical solution is provided:

[0006] A starter generator includes a motor assembly and an inverter assembly, wherein the inverter assembly includes:

[0007] PCBA housing includes a housing body and a cover plate disposed on the top of the housing body; a PCBA is disposed inside the housing body;

[0008] A heat dissipation structure includes a heat dissipation plate and a water pipe. The heat dissipation plate has a first side and a second side arranged in a vertical direction. The first side of the heat dissipation plate is used to fit against the housing body and the power module. The second side of the heat dissipation plate is provided with a receiving groove. The water pipe is interference-fitted into the receiving groove, and at least a portion of the outer wall of the water pipe is in contact with the groove wall of the receiving groove.

[0009] As an optional solution for the above-mentioned integrated generator starter, the receiving slot is a strip structure and includes multiple sub-slots arranged sequentially along the extension direction, with two adjacent sub-slots arranged at an included angle.

[0010] A transition groove is provided between two adjacent sub-grooves, and the width of the opening of the transition groove is greater than the outer diameter of the water pipe placed therein.

[0011] As an optional solution for the aforementioned integrated generator start-up unit, a chamfer is provided between the wall of the transition trough and the wall of the adjacent sub-trough, and the angle of the chamfer is greater than 90 degrees.

[0012] As an optional solution for the aforementioned integrated starter generator, the motor assembly includes a motor, and the inverter assembly further includes a sensor assembly, which includes:

[0013] A magnetic ring having an outer ring body and an inner ring body arranged coaxially at intervals, with an upwardly opening accommodating space formed between the outer ring body and the inner ring body; the inner ring body is coaxially connected to the rotating shaft of the motor;

[0014] A sensor assembly, comprising a connecting bracket and a sensor body disposed below the connecting bracket, the connecting bracket being connected to the heat sink, and the sensor body being suspended within the accommodating space.

[0015] As an optional solution for the aforementioned integrated generator start-up system, the sensor assembly further includes:

[0016] A sensor bracket is detachably connected to the connecting bracket, and the sensor body is mounted on the sensor bracket;

[0017] A protective cover is provided below the connecting bracket, the protective cover covers the periphery of the sensor bracket, and the protective cover is filled with potting compound.

[0018] As an alternative solution for the aforementioned integrated generator set, the inverter assembly further includes a signal connector, which is riveted to the top of the cover plate.

[0019] As an optional solution for starting the aforementioned integrated generator, the signal connector includes:

[0020] A connector body is connected to the cover plate; a sealed cavity is formed between the connector body and the PCB connector on the PCBA.

[0021] The first retaining wall is integrated into the top of the connector body;

[0022] A vent hole connects the sealed chamber to the outside; the vent hole includes a first opening, a second opening, and a flow channel between the first opening and the second opening; the first opening is located on the circumferential side wall of the first retaining wall, and the second opening is located on the connector body;

[0023] A breathable membrane is located on the gas flow path of the breathable holes.

[0024] As an alternative solution for the aforementioned integrated generator, the first retaining wall and the connector body are integrally formed; the vent hole is an L-shaped structure or a T-shaped structure.

[0025] As an alternative solution for the aforementioned integrated generator starter, a portion of the bottom surface of the cover plate is recessed upwards to form a drainage hole between it and the upper end surface of the housing body; the drainage hole is located on the outer periphery of the PCBA housing and communicates with the interior of the housing body.

[0026] As an optional solution for the aforementioned integrated generator, the inverter assembly further includes power terminals. The power terminals include an insulating substrate and a first terminal and a second terminal embedded in the insulating substrate. The insulating substrate has a second retaining wall formed at the first terminal and around the second terminal, and a drainage groove is provided on the second retaining wall.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] The integrated starter generator provided by this invention features a heat dissipation structure located beneath the PCBA housing. The heat dissipation plate of this structure is in close contact with the PCBA housing and power module, ensuring sufficient heat dissipation for both the PCBA and power module. This prevents overheating from affecting the normal operation of the integrated starter generator, thus improving the overall reliability and stability. The heat dissipation structure directly integrates water pipes into the receiving groove without the need for thermally conductive adhesive. This not only ensures a stable connection between the water pipes and the heat dissipation plate, preventing the water pipes from detaching during frequent vibrations, but also allows for maximum contact between the outer wall of the water pipes and the wall of the receiving groove. The heat from the heat dissipation plate is directly transferred to the coolant through the outer wall of the water pipes, eliminating the need for indirect thermal adhesive and improving heat dissipation efficiency. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of an integrated start-up generator according to an embodiment of the present invention;

[0030] Figure 2 This is an exploded structural diagram of the inverter assembly in an embodiment of the present invention;

[0031] Figure 3 This is a schematic diagram of the assembly of the signal connector and the PCBA housing in an embodiment of the present invention;

[0032] Figure 4 This is a cross-sectional view of the signal connector assembled with the PCBA housing in an embodiment of the present invention;

[0033] Figure 5 This is a schematic diagram of the heat dissipation structure in an embodiment of the present invention from a first perspective;

[0034] Figure 6 This is a schematic diagram of the heat dissipation structure in an embodiment of the present invention from a second perspective;

[0035] Figure 7 This is a schematic diagram of the water pipe structure in an embodiment of the present invention;

[0036] Figure 8 This is a schematic diagram of the heat dissipation structure after the water pipe is removed in an embodiment of the present invention;

[0037] Figure 9 for Figure 8 A magnified view of a portion of point A in the middle;

[0038] Figure 10 for Figure 6 Sectional view of BB;

[0039] Figure 11 This is a schematic diagram of the sensor assembly and the motor shaft assembly in an embodiment of the present invention;

[0040] Figure 12 This is a partial cross-sectional view of the sensor assembly and the motor shaft assembled in an embodiment of the present invention;

[0041] Figure 13 This is a schematic diagram of the assembly of the sensor assembly and the bearing in an embodiment of the present invention;

[0042] Figure 14 This is a schematic diagram of the assembly of the magnetic ring and some sensor components in an embodiment of the present invention;

[0043] Figure 15 This is a partial structural diagram of the sensor assembly in an embodiment of the present invention;

[0044] Figure 16 This is a top view of the sensor assembly in an embodiment of the present invention;

[0045] Figure 17 This is a schematic diagram of the structure of a signal connector in an embodiment of the present invention. Figure 1 ;

[0046] Figure 18 This is a schematic diagram of the cover plate in an embodiment of the present invention;

[0047] Figure 19 This is a schematic diagram of the structure of a signal connector in an embodiment of the present invention. Figure 2 ;

[0048] Figure 20 This is a top view of a signal connector according to an embodiment of the present invention;

[0049] Figure 21 This is a cross-sectional view of a signal connector according to an embodiment of the present invention;

[0050] Figure 22 This is a cross-sectional view of another signal connector in an embodiment of the present invention;

[0051] Figure 23 This is a schematic diagram of the power supply terminal structure in an embodiment of the present invention.

[0052] Figure label:

[0053] 100. Motor assembly; 200. Shaft; 300. Inverter assembly; 400. Bearing; 500. Cooling fan;

[0054] 10. PCBA housing; 11. Cover plate; 111. Hot riveting hole; 112. Mounting hole; 12. Housing body; 13. Drain hole; 14. Protective chamber; 15. PCBA; 16. Power module; 17. Sealed chamber;

[0055] 20. Heat dissipation structure; 21. Heat dissipation plate; 211. Receiving groove; 2111. Dividing groove; 2112. Transition groove; 212. Mounting base; 2121. First through hole; 22. Water pipe; 221. Boss; 222. Sealing groove; 23. Water pipe connector; 231. Second through hole; 232. Limiting step; 24. Sealing element;

[0056] 30. Sensor assembly; 31. Magnetic ring; 311. Outer ring body; 312. Inner ring body; 32. Sensor assembly; 321. Connecting bracket; 3211. Encapsulation hole; 3212. Vent hole; 3213. Metal cable; 322. Sensor body; 323. Sensor bracket; 324. Protective cover; 325. Encapsulating adhesive;

[0057] 40. Signal connector; 41. Connector body; 411. Hot-riveted post; 42. First retaining wall; 43. Vent hole; 431. First opening; 432. Second opening; 44. Breathable membrane;

[0058] 50. Power terminal; 51. Insulating substrate; 511. Second retaining wall; 512. Drainage channel; 52. First terminal; 53. Second terminal. Detailed Implementation

[0059] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0060] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0061] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0062] In the description of this invention, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0063] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0064] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0065] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0066] Figure 1 This is a schematic diagram of the structure of an integrated start-up generator according to an embodiment of the present invention; Figure 2 This is an exploded structural diagram of the inverter assembly in an embodiment of the present invention; Figure 3 This is a schematic diagram of the assembly of the signal connector and the PCBA housing in an embodiment of the present invention; Figure 4 This is a cross-sectional view of the signal connector assembled with the PCBA housing in an embodiment of the present invention; Figure 5 This is a schematic diagram of the heat dissipation structure in an embodiment of the present invention from a first perspective;

[0067] Figure 6 This is a schematic diagram of the heat dissipation structure in an embodiment of the present invention from a second perspective; Figure 7 This is a schematic diagram of the water pipe structure in an embodiment of the present invention; Figure 8 This is a schematic diagram of the heat dissipation structure after the water pipe is removed in an embodiment of the present invention; Figure 9 for Figure 8 A magnified view of a portion of point A in the middle; Figure 10 for Figure 6 Sectional view at point B;

[0068] Figure 11 This is a schematic diagram of the sensor assembly and the motor shaft assembly in an embodiment of the present invention; Figure 12 This is a partial cross-sectional view of the sensor assembly and the motor shaft assembled in an embodiment of the present invention; Figure 13 This is a schematic diagram of the assembly of the sensor assembly and the bearing in an embodiment of the present invention; Figure 14 This is a schematic diagram of the assembly of the magnetic ring and some sensor components in an embodiment of the present invention; Figure 15 This is a partial structural diagram of the sensor assembly in an embodiment of the present invention; Figure 16 This is a top view of the sensor assembly in an embodiment of the present invention; Figure 17 This is a schematic diagram of the structure of a signal connector in an embodiment of the present invention. Figure 1 ; Figure 18 This is a schematic diagram of the cover plate in an embodiment of the present invention; Figure 19 This is a schematic diagram of the structure of a signal connector in an embodiment of the present invention. Figure 2 ; Figure 20 This is a top view of a signal connector according to an embodiment of the present invention; Figure 21 This is a cross-sectional view of a signal connector according to an embodiment of the present invention;

[0069] Figure 22 This is a cross-sectional view of another signal connector in an embodiment of the present invention; Figure 23 This is a schematic diagram of the power supply terminal structure in an embodiment of the present invention.

[0070] like Figure 1 As shown, this embodiment provides an integrated starter generator, which includes a motor assembly 100 and an inverter assembly 300. The inverter assembly 300 and the motor assembly 100 are arranged one above the other. Further, a cover is provided on the outside of the inverter assembly 300 to provide protection for it. Specifically, refer to... Figure 2 The inverter assembly 300 includes a PCBA housing 10 and a heat dissipation structure 20. The PCBA housing 10 and the heat dissipation structure 20 are also arranged in a top-bottom configuration. (Reference) Figure 2-4 The PCBA housing 10 includes a housing body 12 and a cover plate 11 covering the housing body 12; a PCBA 15 is disposed inside the housing body 12. The PCBA housing 10 ensures that the product is protected from direct impact by water, dust, and impurities on the circuit board under harsh working environments such as vibration and shock, thus protecting the PCBA 15. (Reference) Figure 5-8 The heat dissipation structure 20 includes a heat sink 21 and a water pipe 22. The heat sink 21 has a first side and a second side arranged along the thickness direction (i.e., the vertical direction). The first side of the heat sink 21 is used to fit against the housing body 12 and the power module 16. The second side of the heat sink 21 is provided with a receiving groove 211. The water pipe 22 is interference-fitted into the receiving groove 211, and at least a portion of the outer wall of the water pipe 22 is in contact with the groove wall of the receiving groove 211. In a specific implementation, the inverter assembly 300 also includes a power module 16. Since the power module 16 generates much more heat than the PCBA 15, the power module 16 is directly attached to the heat sink 21 to achieve direct and rapid heat dissipation of the power module 16. Since the heat generated by PCBA15 is relatively small, PCBA15 is bonded to the housing body 12 with thermally conductive adhesive, and the housing body 12 is also bonded to the heat sink 21 with thermally conductive adhesive. The heat generated by PCBA15 can be gradually transferred to the heat sink 21, so that the heat dissipation structure 20 can dissipate heat from PCBA15.

[0071] This embodiment provides sufficient heat dissipation for the PCBA 15 and power module 16 by setting a heat dissipation structure 20 below the PCBA housing 10 and attaching the heat dissipation plate 21 of the heat dissipation structure 20 to the PCBA housing 10 and power module 16. This ensures that the integrated generator will not be affected by overheating during startup, thus improving the reliability and stability of the entire machine. The heat dissipation structure 20 directly inserts the water pipe 22 into the receiving groove 211 without the need for thermally conductive adhesive. This not only ensures a stable connection between the water pipe 22 and the heat dissipation plate 21, preventing the water pipe 22 from falling off during frequent vibrations of the entire machine, but also allows the outer wall of the water pipe 22 to fit as closely as possible to the wall of the receiving groove 211. The heat from the heat dissipation plate 21 is directly transferred to the coolant through the outer wall of the water pipe 22, without the need for thermally conductive adhesive, thus improving heat dissipation efficiency. Optionally, the power module 16 is directly attached to the first side of the heat dissipation plate 21, facilitating direct heat transfer to the heat dissipation plate 21 for heat dissipation.

[0072] Specifically, refer to Figure 4 A protective chamber 14 is formed inside the PCBA housing 10, and a PCBA 15 is disposed inside the protective chamber 14. In the operating environment of the integrated generator, moisture inevitably forms inside the device. Therefore, the top surface of the existing cover plate 11 is usually provided with openings to facilitate the evaporation of moisture. However, this opening design allows dust and impurities to fall directly into the PCBA housing 10 through the openings. Although sealant can be potted inside the PCBA housing 10 to protect the PCBA 15, the sealant itself has a certain fluidity, and impurities will gradually sink into the sealant and reach the PCBA 15. Since there are many electronic components on the PCBA 15, metallic impurities can cause short circuits between components, affecting the performance of the PCBA 15. In this embodiment, reference... Figure 3 and Figure 4 A portion of the bottom surface of the cover plate 11 is recessed upwards to form a drainage hole 13 between it and the upper end face of the housing body 12. The drainage hole 13 is located on the outer periphery of the PCBA housing 10 and communicates with the interior of the housing body 12. That is, by partially thinning the thickness of the cover plate 11, a drainage hole 13 is formed between it and the upper end face of the housing body 12, which serves the purpose of drainage while helping to minimize the opening area and reduce the risk of foreign object intrusion.

[0073] In specific implementation, the water pipe 22 has a circular cross-section, and the receiving groove 211 has an arc-shaped cross-section. Furthermore, the inner diameter of the receiving groove 211 is larger than the outer diameter of the water pipe 22, the cross-section of the receiving groove 211 is an arc-shaped structure, and the width of the opening of the receiving groove 211 is smaller than the outer diameter of the water pipe 22. During press fitting, the water pipe 22 needs to be squeezed into the receiving groove 211 through the small opening using extrusion pressure to achieve an interference fit. Then, the water pipe 22 is further squeezed to deform it and finally fit against the wall of the receiving groove 211, maximizing the contact area and improving heat dissipation. In this embodiment, both the water pipe 22 and the heat sink 21 are made of metal materials with good thermal conductivity, which not only improves the overall strength of the heat dissipation structure 20 but also ensures sufficient heat dissipation.

[0074] The receiving groove 211 has a strip-shaped structure, and the water pipe 22 conforms to the shape of the receiving groove 211, also having a strip-shaped structure. After the water pipe 22 is embedded in the receiving groove 211, its inlet and outlet are respectively led out from the two free ends of the receiving groove 211. In specific implementation, since multiple power modules 16 are usually set in different locations, in order to ensure that each power module 16 receives sufficient heat dissipation, the water pipe 22 needs to extend to each power module 16. That is, both the water pipe 22 and the receiving groove 211 that accommodates the water pipe 22 need to be adapted to bend. Specifically, refer to Figure 8 and Figure 9 The receiving groove 211 includes a plurality of sub-grooves 2111 arranged sequentially along the extending direction, with adjacent sub-grooves 2111 arranged at an included angle; in this embodiment, reference Figure 6 and Figure 8 The included angle β between any two adjacent slots 2111 is obtuse to avoid stress concentration caused by excessive bending angle. Furthermore, a transition slot 2112 is provided between any two adjacent slots 2111, with the width of the opening of the transition slot 2112 greater than the outer diameter of the water pipe 22 placed therein. Since the shape of the bend in the water pipe 22 is less controllable than that of the straight section during manufacturing, and the wall thickness itself thins at the bend, making stress concentration more likely, the width of the opening of the transition slot 2112 is set larger than the outer diameter of the water pipe 22. This prevents excessive compression between the water pipe 22 and the wall of the receiving slot 211 at the bend during press fitting, thus avoiding excessive external force causing the bend of the water pipe 22 to crack. In practice, to facilitate production, the outer diameter of the water pipe 22 is generally kept consistent. Therefore, in this embodiment, the size of the receiving groove 211 is improved so that the width of the opening of the transition groove 2112 is greater than the inner diameter of the adjacent dividing groove 2111, leaving enough space for the water pipe 22 here to avoid excessive compression of the water pipe 22.

[0075] Furthermore, since the dimensions of the transition groove 2112 and the dividing groove 2111 are inconsistent, and the forming of the receiving groove 211 is usually done by mechanical cutting, sharp steps will be formed at the bends of the receiving groove 211. This can easily cause localized stress concentration during the pressing of the water pipe 22, leading to cutting of the water pipe 22 and leakage. Therefore, in this embodiment, referring to... Figure 9 A chamfer C is provided between the wall of the transition groove 2112 and the wall of the adjacent sub-groove 2111, and the angle of chamfer C is greater than 90 degrees to avoid sharp transition edges as much as possible. Specifically, the angle of chamfer C can be 100 degrees, 125 degrees, or 160 degrees. Furthermore, the wall of the transition groove 2112 and the wall of the sub-groove 2111 have a smooth transition to further avoid stress concentration between them and the water pipe 22.

[0076] refer to Figure 5 and Figure 10 The receiving groove 211 has mounting bases 212 at both free ends, and water pipe connectors 23 are provided on the mounting bases 212. The inlet and outlet of the water pipe 22 are connected to the outside through the water pipe connectors 23 to realize the flow of coolant. Specifically, the water pipe connectors 23 are located on the first side of the heat dissipation plate 21; optionally, the mounting base 212 is a protruding structure protruding from the first side of the heat dissipation plate 21, and the water pipe connectors 23 are installed on the free end of the protruding structure. Optionally, the water pipe connectors 23 are fixed to the mounting base 212 by fasteners; in this embodiment, the fasteners are screws. Further, refer to Figure 10 The mounting base 212 has a first through hole 2121 along the thickness direction of the heat sink 21. When the water pipe 22 is pressed into the receiving groove 211, the free end of the water pipe 22 passes through the first through hole 2121 and extends out of the first through hole 2121, which facilitates subsequent assembly with the water pipe connector 23. Furthermore, the diameter of the first through hole 2121 gradually decreases along the second side away from the heat sink 21. Since the water pipe 22 is made of a material with high hardness such as metal, for this kind of irregular pipe fitting that needs to be bent many times in this embodiment, the tolerance at its inlet and outlet cannot be very small. In order to avoid the water pipe 22 getting stuck at the free end of the receiving groove 211 during interference fit, which would lead to assembly failure or damage to the press fit equipment, it is necessary to ensure the accurate positioning of the inlet and outlet of the water pipe 22 during press fit. The first through hole 2121 is designed with a cone-like structure, which allows the water pipe 22 to have a large range of motion at the free end of the receiving groove 211, preventing it from getting stuck. At the same time, the cone-shaped structure also provides better guidance for the water pipe 22 as it passes through the first through hole 2121, preventing the water pipe 22 from shifting position. Further, refer to... Figure 8 The receiving groove 211 and the first through hole 2121 are smoothly connected, which further ensures that the water pipe 22 can be smoothly inserted into the mounting base 212.

[0077] In one embodiment, the first through-hole 2121 may be a smooth tapered structure, meaning its diameter gradually decreases along the direction away from the second side of the heat sink 21, until it reaches its minimum at the free end of the mounting base 212. In other embodiments, refer to... Figure 10 The first through hole 2121 includes a first section and a second section connected in sequence. The first section is closer to the second side of the heat sink 21 than the second section. The first section has a smooth conical structure, while the second section has a cylindrical structure. That is, the diameter of the second section is consistent and equal to or slightly larger than the outer diameter of the water pipe 22 at this point. This arrangement allows the water pipe 22 to be roughly guided through the first section and then the water pipe 22 to be fully limited through the second section, ensuring that the axis of the water pipe 22 coincides with the axis of the first through hole 2121 as much as possible. Of course, in specific implementation, in order to facilitate the demolding operation during the molding process of the second section, the second section should have a certain demolding taper, but this taper is often small and does not affect the full limitation of the water pipe 22 by the entire second section.

[0078] Still referencing Figure 10 Furthermore, the water pipe connector 23 has a second through hole 231, which is coaxially arranged with and communicates with the first through hole 2121 to facilitate the flow of coolant from the water pipe connector 23 into the water pipe 22 or from the water pipe 22 into the water pipe connector 23. The diameter of the second through hole 231 is slightly larger than the outer diameter of the water pipe 22, ensuring that the water pipe 22 can be smoothly fitted into the water pipe connector 23. Further, the diameter of the second through hole 231 at the connection between the first through hole 2121 and the second through hole 231 is even larger than the outer diameter of the water pipe 22. That is, a guide slope is provided on the wall of the hole at the end where the second through hole 231 connects to the first through hole 2121. The purpose is to allow the water pipe 22 to be quickly assembled with the water pipe connector 23 via the guide slope and smoothly inserted into the water pipe connector 23 without getting stuck at the junction.

[0079] Specifically, refer to Figure 7 and Figure 10At least two protrusions 221 are provided on the outer circumferential surface of both the inlet and outlet of the water pipe 22. Two adjacent protrusions 221 are spaced apart along the axial direction of the water pipe 22 to form a sealing groove 222. A sealing element 24 is installed within the sealing groove 222. The sealing element 24 is confined between the two protrusions 221 and cannot move freely, ensuring the stability of the sealing element 24's position. The sealing element 24 is pressed between the outer wall of the water pipe 22 and the inner wall of the water pipe connector 23 to seal the circumferential gap between the water pipe 22 and the water pipe connector 23. In specific implementations, the sealing groove 222 can also be directly cut on the outer wall of the water pipe 22 using mechanical cutting. In this embodiment, the sealing groove 222 is formed using a rolling grooving process, that is, by using a rotating roller to roll on the water pipe 22, at least two protrusions 221 are rolled out, and a sealing groove 222 is naturally formed between the two protrusions 221. This simplifies the forming process of the sealing groove 222 and avoids stress concentration caused by mechanical cutting. Further, as... Figure 10 As shown, a limiting step 232 is also provided on the wall of the second through hole 231. The limiting step 232 restricts the length of the water pipe 22 extending into the water pipe joint 23 by abutting against the boss 221 on the water pipe 22, thereby realizing the installation and positioning of the water pipe 22 and the water pipe joint 23.

[0080] The motor assembly 100 includes a motor, and the inverter assembly 300 includes a sensor assembly 30. The sensor assembly 30 includes a magnetic ring 31 and a sensor component 32. The magnetic ring 31 is connected to the motor shaft 200. The sensor component 32 and the magnetic ring 31 directly cooperate through the Hall effect to obtain an electrical signal, which is then transmitted to the processing unit of the PCBA 15 to obtain rotational information such as the motor speed, forming a closed-loop control. To improve detection accuracy, high requirements are placed on the accuracy and stability of the sensor's placement. However, in existing starter generators, the sensor is generally placed separately outside the magnetic ring 31. The airflow generated by the motor's built-in cooling fan 500 causes significant disturbance to the sensor, reducing the accuracy of sensor detection. In this embodiment, reference... Figure 11-14The magnetic ring 31 has an outer ring body 311 and an inner ring body 312 arranged coaxially at intervals, with an upwardly opening accommodating space between the outer ring body 311 and the inner ring body 312; the inner ring body 312 is coaxially connected to the motor shaft 200; the sensor assembly 32 includes a connecting bracket 321 and a sensor body 322 disposed below the connecting bracket 321, the connecting bracket 321 is connected to the heat sink 21, and the sensor body 322 is suspended in the accommodating space. By forming an accommodating space between the outer ring body 311 and the inner ring body 312 of the magnetic ring 31, the sensor body 322 can be suspended in the accommodating space, thereby realizing the magnetic field sensing of the magnetic ring 31 and thus completing the detection of motor rotation information. The outer ring body 311 of the magnetic ring 31 also blocks the airflow generated by the cooling fan 500 of the motor assembly 100, avoiding interference with the sensor, playing a role in fully protecting the sensor, and improving the accuracy of sensor detection.

[0081] Further, refer to Figure 14 Since the magnetic ring 31 has a circular structure, the accommodating space it forms is also circular. The sensor assembly 30 comprises multiple sensor bodies 322, all located on the same virtual circle centered on the axis of the magnetic ring 31, to fit the circular magnetic ring 31 and facilitate accurate detection. The multiple sensor bodies 322 include Hall effect sensors and temperature sensors. The Hall effect sensors primarily detect motor rotation information, while the temperature sensors are selectively installed as needed. The temperature sensors have temperature detection capabilities, allowing the system to react promptly when the motor overheats.

[0082] Specifically, refer to Figure 12 , 14 In addition to 15, the sensor assembly 30 also includes a sensor bracket 323 and a protective cover 324. The sensor bracket 323 is connected to the connecting bracket 321, the sensor body 322 is mounted on the sensor bracket 323, and the protective cover 324 is located below the connecting bracket 321 and covers the periphery of the sensor bracket 323. The protective cover 324 is filled with potting compound 325. Since the sensor body 322 is a sensitive device, a protective cover 324 is needed to cover the periphery of the sensor bracket 323 and to fill it with potting compound 325 to encapsulate and protect the sensor body 322, thus isolating it from external vibrations or contaminants. Optionally, refer to... Figure 16A potting hole 3211 is provided on the connecting bracket 321, which connects to the protective cover 324. The colloid can enter the protective cover 324 through the potting hole 3211. During colloid filling within the protective cover 324, air entrapment may occur. Air bubbles trapped in the colloid will expand at high temperatures, compressing the entire colloid or the sensor body 322, causing damage. Therefore, an venting hole 3212 connected to the protective cover 324 is also provided on the connecting bracket 321 to assist in venting and prevent air entrapment. In this embodiment, multiple sensor bodies 322 are located on the same virtual circle, so the protective cover 324 is approximately arc-shaped. Furthermore, the portion of the connecting bracket 321 connecting to the protective cover 324 is also approximately arc-shaped. Optionally, two venting holes 3212 are provided, located on both sides of the potting hole 3211 along the circumference of the connecting bracket 321.

[0083] refer to Figure 14 and Figure 15 A metal ribbon cable 3213 is provided on the connecting bracket 321. Both ends of the metal ribbon cable 3213 are led out from the connecting bracket 321. One end is connected to the PCBA15 in the PCBA housing 10, and the other end is connected to the sensor body 322, thereby realizing the transmission of electrical signals from the sensor to the PCBA15. Optionally, a sensor bracket 323 is inserted into the connecting bracket 321. In a specific implementation, a socket is provided on the sensor bracket 323, and the end of the metal ribbon cable 3213 connected to the sensor body 322 can be inserted into the socket, thereby realizing the insertion connection between the sensor bracket 323 and the connecting bracket 321. Then, the pins of the sensor body 322 on the sensor bracket 323 are soldered to the metal ribbon cable 3213 to realize the transmission of electrical signals. Optionally, the connecting bracket 321 covers the metal ribbon cable 3213, providing mechanical and electrical protection for the metal ribbon cable 3213. For a given motor, the placement and arrangement of the sensor body 322 are specific, thus requiring high precision in placement. However, positional misalignment can easily occur when welding the sensor body 322 to the corresponding metal cable 3213. Therefore, using a sensor bracket 323 to mount the sensor body 322 effectively secures it and prevents misalignment during welding. Optionally, the sensor bracket 323 has a slot in which the sensor body 322 is secured.

[0084] Further reference Figure 15In this embodiment, the sensor bracket 323 and the connecting bracket 321 are separate structures and are detachably connected. That is, the sensor bracket 323 and the connecting bracket 321 are two independent parts. This arrangement is because the motor structure used in the generator is different and the placement position of the sensor body 322 is different. During assembly, only the appropriate sensor bracket 323 needs to be selected to achieve quick and accurate positioning of the sensor body 322, which improves the applicability of the entire sensor assembly 30.

[0085] refer to Figure 11 and Figure 12 The cooling fan 500 of the integrated generator is located below the magnetic ring 31. In this embodiment, an opening is provided above the accommodating space of the magnetic ring 31 so that the sensor body 322 can be placed inside the accommodating space from top to bottom. At the same time, the bottom of the accommodating space is closed to prevent air from entering the accommodating space from the bottom and interfering with the sensor body 322 placed inside. Further, a layer of magnetic material is provided on the inner surface of the outer ring 311 of the magnetic ring 31. After being magnetized, the magnetic material forms multiple magnetic poles. When the magnetic ring 31 rotates with the motor shaft 200, the Hall sensor senses the change in magnetic field and generates an electrical signal. In specific implementations, the number of magnetic poles can be adapted to different motor structures, and the placement position of the sensor body 322 will also be different. Optionally, refer to Figure 12 The bottom surface of the magnetic ring 31 is recessed upward to form a relief groove. The cooling fan 500 is partially accommodated in the relief groove, and the blades of the cooling fan 500 surround the outer ring body 311 of the magnetic ring 31 to prevent airflow into the accommodating space.

[0086] Continue to refer to Figure 11 and Figure 12 A bearing 400 is also provided inside the motor assembly 100. The inner ring 312 and the motor shaft 200 are both connected to the inner ring of the bearing 400 so that the motor can synchronously drive the magnetic ring 31 to rotate. In a specific implementation, the outer ring of the bearing 400 is fixed to the housing of the motor assembly 100.

[0087] refer to Figure 2 The inverter assembly 300 also includes a signal connector 40 for connecting the PCBA15 to the vehicle controller to enable signal transmission between the PCBA15 and the vehicle controller; specifically, refer to... Figure 3 and Figure 4The signal connector 40 is riveted to the top of the cover plate 11 so that the cover plate 11 supports the signal connector 40. In traditional manufacturing methods, the signal connector 40 and the cover plate 11 are integrally injection molded. Due to the large size of the injection molded part, and the presence of a signal cable within the signal connector 40, the thermal shock resistance and mechanical shock resistance of the injection molded part are poor, making it prone to cracking. Therefore, designing the signal connector 40 and the cover plate 11 as two separate parts allows the cover plate 11 to be made of metal, which not only improves its own protective performance and provides better protection, but also improves the product's EMC (electromagnetic compatibility) performance. For specific implementation, refer to... Figure 17 and Figure 18 The signal connector 40 has several hot riveting posts 411, and the cover plate 11 has a corresponding number of hot riveting holes 111. During installation, the hot riveting posts 411 pass through the hot riveting holes 111, and the hot riveting posts 411 are melted at the other end by a hot riveting device, and then cooled to form a cap-shaped buckle, thereby fixing the signal connector 40 to the cover plate 11.

[0088] Further, refer to Figure 18 Mounting holes 112 are provided on the cover plate 11. After the signal connector 40 is hot-riveted to the cover plate 11, the signal cable on it enters the protective chamber 14 through the mounting holes 112, and then connects to the PCBA 15. Specifically, the signal connector 40 is connected to the PCB connector on the PCBA 15. Furthermore, since the transmission of electrical signals needs to meet dustproof and waterproof requirements, a sealed chamber 17 is formed between the signal connector 40 and the PCB connector on the PCBA 15 with sealant to prevent external impurities from entering. However, due to the high and low temperature changes in the environment in the vehicle, in order to prevent the temperature change from causing changes in the internal air pressure of the sealed chamber 17, which may lead to sealant cracking and other failure risks, a vent 43 is designed to connect the outside to the sealed chamber 17 to balance the air pressure inside the chamber. A vent membrane 44 is provided on the vent 43 to allow gas to pass through, but to prevent water, oil, dust and other impurities from entering. Because the transmission of electrical signals needs to meet dust and water resistance requirements, all products must undergo dust and water resistance testing after manufacturing. The existing vents are linear in design, protruding directly from the top of the signal connector 40. Therefore, during the IPX9K dust and water resistance test, high-pressure water jets spraying directly onto the breathable membrane 44 can damage it, causing the product's dust and water resistance to fail. Water entering the chamber can lead to internal short circuits or series connections, ultimately rendering the product unusable. Current technology typically requires additional protective covers or shields for protection, but this undoubtedly increases costs.

[0089] In this embodiment, reference Figure 19-22The signal connector 40 includes a connector body 41, which is connected to the cover plate 11; a hot riveting post 411 is disposed on the connector body 41. The signal connector 40 also includes: a first baffle 42, integrated into the top of the connector body 41; a vent 43, connecting the sealed chamber 17 to the outside, ensuring that gas flows through the vent 43 and the air pressure in the sealed chamber 17 remains stable; the vent 43 includes a first opening 431, a second opening 432, and a flow channel disposed between the first opening 431 and the second opening 432; the first opening 431 is disposed on the circumferential side wall of the first baffle 42, and the second opening 432 is disposed on the connector body 41; and a breathable membrane 44, which is located on the gas flow path of the vent 43, allowing gas to flow while preventing water and dust from entering the sealed chamber 17, ensuring the smooth conduct of the dustproof and waterproof test.

[0090] During the IPX9K dust and water resistance test, a high-pressure water gun is sprayed towards the top of the connector body 41. In this embodiment, a first baffle 42 is integrated into the top of the connector body 41. Therefore, when the high-pressure water gun is sprayed towards the connector body 41 during the dust and water resistance test, the high-pressure water first directly impacts the first baffle 42 and does not directly spray onto the vent 43. The obstruction of the first baffle 42 can effectively reduce the water flow velocity and water pressure. The water then enters the vent 43 through the first opening 431 on the circumferential side wall of the first baffle 42, thus avoiding direct impact on the breathable membrane 44 on the vent 43. This ensures the successful completion of the relevant dust and water resistance test and effectively prevents product failure.

[0091] Optionally, the first retaining wall 42 has a cylindrical structure, and the first opening 431 is located on the outer circumferential surface of the first retaining wall 42 to facilitate molding. In some other embodiments, the first retaining wall 42 can be a frustum structure. Optionally, the first retaining wall 42 is a plastic retaining wall, that is, the first retaining wall 42 is made of plastic material, which helps the first retaining wall 42 and the connector body 41 to be integrally molded using injection molding.

[0092] Further, in one embodiment, the breathable membrane 44 is disposed at the second opening 432 of the vent 43, that is, at the connection between the vent 43 and the sealed chamber 17; of course, in some other embodiments, the breathable membrane 44 may also be disposed between the first opening 431 and the second opening 432 of the vent 43; in short, the farther the breathable membrane 44 is disposed from the first opening 431, the lower the water pressure it bears, the less likely it is to be damaged, and the better it can ensure the smooth progress of the dustproof and waterproof test. Optionally, the breathable membrane 44 is disposed on the inner wall of the flow channel at the second opening 432; or alternatively, refer to Figure 21The connector body 41 has a receiving groove at the bottom of the second opening 432. The breathable membrane 44 is installed in the receiving groove, that is, the breathable membrane 44 is placed on the outside of the vent 43, which is also on the gas flow path. While ensuring dust and water protection, the receiving groove also facilitates the installation of the breathable membrane 44.

[0093] In this embodiment, reference Figure 21 When the breathable membrane 44 is located at or near the second opening 432, the vent 43 can be L-shaped. The L-shaped structure lengthens the water flow path, further helping to slow down the water velocity and reduce water pressure. Therefore, even if a small amount of high-pressure water is reflected and directly enters the vent 43, it will not cause excessive impact on the breathable membrane 44. Specifically, the L-shaped vent 43 includes a third portion and a fourth portion that are perpendicularly connected to each other. The third portion forms a first opening 431 on the first baffle 42, and the fourth portion forms a second opening 432 on the connector body 41. Furthermore, the third portion can be appropriately extended at the connection with the fourth portion to facilitate the formation of a vortex in the water flow, still serving to slow down the water velocity. Further optionally, refer to... Figure 22 The vent 43 can also be a T-shaped structure. The T-shaped vent 43 also includes a third and a fourth section that are perpendicularly connected to each other. The third section forms two first openings 431 on the first baffle 42, and the fourth section forms a second opening 432 on the connector body 41. Water flows in through the two first openings 431 and can collide with each other to form a vortex, which also serves to slow down the water flow. Further, optionally, whether it is an L-shaped or T-shaped structure, the cross-section of the third section is rectangular, circular, or other shapes; the cross-section of the fourth section is also rectangular, circular, or other shapes. Of course, in specific implementations, there are no specific limitations on the shape and cross-sectional shape of the vent 43, as long as the first opening 431 and the second opening 432 of the vent 43 can respectively connect to the outside and the sealed chamber 17. There are no specific limitations on the bending angle and number of bends of the vent 43 in the gas flow path.

[0094] Furthermore, multiple vent holes 43 are provided to improve air permeability. Specifically, in one embodiment, each vent hole 43 is provided with a first opening 431 and a second opening 432. Alternatively, the second openings 432 of multiple vent holes 43 can be set in the same position, that is, the first openings 431 of multiple vent holes 43 are set separately, but air is ultimately discharged through the same second opening 432. In this way, only a breathable membrane 44 needs to be set at the second opening 432 to save costs. Optionally, when multiple vent holes 43 are used, the multiple vent holes 43 are evenly distributed along the outer periphery of the first retaining wall 42.

[0095] refer to Figure 1 and Figure 2The inverter assembly 300 also includes power terminals 50 for supplying power to the inverter assembly 300; optionally, the power terminals 50 are mounted on the heat sink 21. (Reference) Figure 23 The power terminal 50 includes an insulating substrate 51 and a first terminal 52 and a second terminal 53 embedded in the insulating substrate 51. A second baffle 511 is formed around both the first terminal 52 and the second terminal 53 on the insulating substrate 51. A drainage groove 512 is provided on the second baffle 511. Existing power terminals 50 lack a drainage design, making it easy for water to accumulate in the second baffle 511 at the terminal, corroding the copper busbar and studs, and posing a risk of short circuit or open circuit failure. Figure 23 The diagram shows the placement of the power terminal 50 after the generator is installed on the vehicle. A drainage channel 512 is located below the corresponding terminal, allowing water entering the power terminal 50 to flow directly out through the drainage channel 512, thus preventing water accumulation and corrosion of the wiring.

[0096] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A starter generator integrated unit, characterized in that, It includes a motor assembly (100) and an inverter assembly (300), the inverter assembly (300) comprising: PCBA housing (10) includes housing body (12) and cover plate (11) covering the housing body (12); PCBA (15) is disposed inside the housing body (12). The heat dissipation structure (20) includes a heat dissipation plate (21) and a water pipe (22). The heat dissipation plate (21) has a first side and a second side arranged in the vertical direction. The first side of the heat dissipation plate (21) is used to fit against the housing body (12) and the power module (16). The second side of the heat dissipation plate (21) is provided with a receiving groove (211). The water pipe (22) is interference-fitted into the receiving groove (211). At least a portion of the outer wall of the water pipe (22) fits against the groove wall of the receiving groove (211). A portion of the bottom surface of the cover plate (11) is recessed upward to form a drainage hole (13) between it and the upper end face of the housing body (12); the drainage hole (13) is located on the outer periphery of the PCBA housing (10) and communicates with the interior of the housing body (12); The inverter assembly (300) further includes a power terminal (50), the power terminal (50) includes an insulating substrate (51) and a first terminal (52) and a second terminal (53) embedded in the insulating substrate (51). The insulating substrate (51) has a second barrier wall (511) formed at the first terminal (52) and around the second terminal (53). A drainage groove (512) is provided on the second barrier wall (511).

2. The integrated start-up generator according to claim 1, characterized in that, The receiving groove (211) is a strip structure and includes a plurality of sub-grooves (2111) arranged sequentially along the extension direction, with two adjacent sub-grooves (2111) arranged at an included angle; A transition groove (2112) is provided between two adjacent sub-grooves (2111), and the width of the opening of the transition groove (2112) is greater than the outer diameter of the water pipe (22) placed therein.

3. The integrated start-up generator according to claim 2, characterized in that, The wall of the transition groove (2112) is chamfered with respect to the wall of the adjacent sub-groove (2111), and the angle of the chamfer is greater than 90 degrees.

4. The integrated starter generator according to any one of claims 1-3, characterized in that, The motor assembly (100) includes a motor, and the inverter assembly (300) further includes a sensor assembly (30), the sensor assembly (30) including: A magnetic ring (31) has an outer ring body (311) and an inner ring body (312) arranged coaxially at intervals, and an upwardly opening accommodating space is formed between the outer ring body (311) and the inner ring body (312); the inner ring body (312) is coaxially connected to the rotating shaft (200) of the motor. The sensor assembly (32) includes a connecting bracket (321) and a sensor body (322) disposed below the connecting bracket (321). The connecting bracket (321) is connected to the heat sink (21), and the sensor body (322) is suspended in the accommodating space.

5. The integrated start-up generator according to claim 4, characterized in that, The sensor assembly (30) also includes: The sensor bracket (323) is detachably connected to the connecting bracket (321), and the sensor body (322) is mounted on the sensor bracket (323); A protective cover (324) is provided below the connecting bracket (321). The protective cover (324) covers the periphery of the sensor bracket (323), and the protective cover (324) is filled with potting compound (325).

6. The integrated start-up generator according to any one of claims 1-3, characterized in that, The inverter assembly (300) also includes a signal connector (40) which is riveted to the top of the cover plate (11).

7. The integrated start-up generator according to claim 6, characterized in that, The signal connector (40) includes: A connector body (41) is connected to the cover plate (11); a sealed chamber (17) is formed between the connector body (41) and the PCB connector on the PCBA (15). The first retaining wall (42) is integrated on the top of the connector body (41); A vent (43) connects the sealed chamber (17) to the outside; the vent (43) includes a first opening (431), a second opening (432) and a flow channel between the first opening (431) and the second opening (432); the first opening (431) is located on the circumferential sidewall of the first retaining wall (42), and the second opening (432) is located on the connector body (41); The breathable membrane (44) is located on the gas flow path of the breathable hole (43).

8. The integrated start-up generator according to claim 7, characterized in that, The first retaining wall (42) is integrally formed with the connector body (41); the vent (43) is an L-shaped structure or a T-shaped structure.

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