A rotation angle sensor device for an electromechanical hydraulic servo brake system and a method of manufacturing the same

Abstract

The application relates to a corner sensor device of an electromechanical hydraulic servo brake system and a manufacturing method thereof, and relates to the technical field of automobile chassis braking. The device comprises a motor assembly, a large valve block, a corner sensor, a serpentine spring PIN, a spring cover, an ECUPCBA and a shell assembly; the large valve block is assembled on the motor assembly, the corner sensor is assembled on the motor assembly and located between the motor assembly and the large valve block; the ECUPCBA is assembled on the shell assembly, the serpentine spring PIN is placed in a preset hole of the shell assembly, one end of the serpentine spring PIN is in abutment with the corner sensor, and the other end of the serpentine spring PIN is in abutment with the ECUPCBA; and the spring cover is sleeved on the serpentine spring PIN and buckled on the shell assembly. Whether from the structural connection reliability or the assembly process, the compact structure can realize good transmission of the corner signal, can greatly provide production efficiency, reduce manufacturing cost, and is more suitable for batch production or automatic production.

Description

Technical Field

[0001] This invention relates to the field of automotive chassis braking technology, specifically to an angle sensor device for an electromechanical-hydraulic servo braking system and its manufacturing method. Background Technology

[0002] With the continuous development of automotive electrification and intelligence, the demand for brake-by-wire systems is also increasing. As a core component, the steering angle sensor outputs a motor steering angle signal to the braking system. Based on this, the braking software control strategy realizes the braking pressure build-up, pressure holding, and pressure reduction, thereby achieving the basic braking, ABS, and ESC functions of the servo braking system. If the steering angle sensor signal fails, it can cause misjudgment or even direct failure of the braking control strategy, affecting vehicle driving safety, especially for intelligent assisted driving and autonomous driving, which require even higher safety and lower failure rates. Therefore, ensuring the reliable connection and stable signal transmission of the steering angle sensor has become a key technology in this field.

[0003] With the development of intelligent assisted driving and autonomous driving technologies, brake-by-wire systems such as Bosch's IPB and China's MC100 have emerged in the market. These brake-by-wire systems' steering sensors mainly suffer from two problems: complex assembly processes and the risk of signal loss.

[0004] Bosch's IPB corner sensor, with its flexible chip, results in a relatively long overall size. China's MC100 corner sensor uses a structure with multiple embedded gears, making the manufacturing and assembly of both corner sensors complex and less manufacturable. In addition, the connection between the corner sensor and the PCBA uses cylindrical springs, which have low stiffness and insufficient bending and vibration resistance. They are easily bent during production and assembly, or may lose signals due to violent vehicle driving. Summary of the Invention

[0005] The main objective of this invention is to provide an angle sensor device for an electromechanical-hydraulic servo braking system and its manufacturing method, so as to solve the above-mentioned problems.

[0006] To achieve the above objectives, the present invention provides a rotation angle sensor device for an electromechanical-hydraulic servo braking system, comprising: a motor assembly, a large valve block, a rotation angle sensor, a serpentine spring pin, a spring cover, an ECUPCBA, and a housing assembly; wherein,

[0007] The large valve block is mounted on the motor assembly, the angle sensor is mounted on the motor assembly and located between the motor assembly and the large valve block; the ECUPCBA is mounted on the housing assembly, the serpentine spring PIN is placed in a preset hole in the housing assembly, one end abuts against the angle sensor and the other end abuts against the ECUPCBA; the spring cover is sleeved on the serpentine spring PIN and snapped onto the housing assembly.

[0008] Furthermore, the angle sensor includes an angle sensor housing, an angle sensor PCBA, a connector, and an angle sensor PIN; the angle sensor PCBA is disposed inside the angle sensor housing, the connector is connected to one side of the angle sensor housing and passes through the large valve block; one end of the angle sensor PIN is connected to a fisheye terminal, the angle sensor PIN extends into the connector and is connected to the angle sensor PCBA through the fisheye terminal.

[0009] Furthermore, the end of the angle sensor PCBA furthest from the fisheye terminal is connected to an angle sensor PAD, and the angle sensor PAD is in contact with the serpentine spring PIN.

[0010] Furthermore, the angle sensor housing includes an angle sensor base and an angle sensor sealing cover, which are fixedly connected.

[0011] Furthermore, the angle sensor base is equipped with multiple elastic buckles and assembly positioning cylinders for assembly positioning and fixation with the motor assembly.

[0012] Furthermore, the ECUPCBA includes an ECUPCB ​​and an EUPAD, the EUPAD being connected to one side of the ECUPCBA and in contact with the serpentine spring PIN.

[0013] A method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system includes the following steps:

[0014] Step 1: Install the angle sensor onto the motor assembly, relying on multiple elastic clips at the angle and the assembly positioning cylinder to achieve assembly positioning and fixation with the motor assembly;

[0015] Step 2: Assemble the assembly from Step 1 with the large valve block;

[0016] Step 3: Place the serpentine spring pin into the pre-set hole of the housing assembly;

[0017] Step 4: Press the spring cover into the housing assembly and secure it to the housing assembly using the built-in snap-fit ​​mechanism to prevent the serpentine spring pin from falling off;

[0018] Step 5: Press the ECUPCBA onto the housing assembly to achieve contact between the ECUPCBA and the top of the serpentine spring PIN;

[0019] Step 6: Connect the assembly from Step 5 to the large valve block using threads.

[0020] Furthermore, the assembly method of the angle sensor is as follows:

[0021] S1, using a stamping process, electroplating and then bending, completes the processing of the corner sensor PIN;

[0022] S2, injection molding the corner sensor PIN and connector;

[0023] S3, the connector and the corner sensor base are injection molded together as one piece;

[0024] S4. Press the angle sensor PCBA to the fisheye terminal to complete the fixed assembly of the angle sensor PCBA;

[0025] S5. Weld the corner sensor sealing cover to the corner sensor base to complete the assembly of the entire corner sensor.

[0026] The beneficial effects of this invention are as follows:

[0027] The corner sensor device and its manufacturing and assembly method of the present invention have a compact structure, which can achieve good transmission of corner signals, greatly improve production efficiency, reduce manufacturing costs, and are more suitable for mass production or automated production, regardless of the reliability of structural connection or assembly process. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the structure of the present invention;

[0029] Figure 2 for Figure 1 A magnified view of a portion of the image;

[0030] Figure 3 This is an exploded view of the present invention;

[0031] Figure 4 This is a schematic diagram of the angle sensor of the present invention;

[0032] Figure 5 This is an exploded view of the angle sensor of the present invention;

[0033] Figure 6 This is a flowchart illustrating the assembly process of the angle sensor of the present invention.

[0034] Figure 7 This is a schematic diagram of the serpentine spring PIN of the present invention.

[0035] Among them, 100-motor assembly, 200-large valve block, 300-angle sensor, 400-serpentine spring PIN, 500-spring cover, 600-ECUPCBA, 700-housing assembly, 601-ECUPCB, 602-ECUPAD, 310-angle sensor PIN, 320-connector, 330-angle sensor base, 340-angle sensor PCBA, 350-angle sensor sealing cover, 311-angle sensor PAD, 312-fisheye terminal, 331-elastic buckle, 332-assembly positioning cylinder. Detailed Implementation

[0036] To achieve the above objectives and effects, the technical means and structure adopted by the present invention will be described in detail with reference to the accompanying drawings, focusing on the features and functions of the preferred embodiments of the present invention.

[0037] like Figure 1-7 As shown, the present invention provides a rotation angle sensor device for an electromechanical-hydraulic servo braking system, comprising: a motor assembly 100, a large valve block 200, a rotation angle sensor 300, a serpentine spring PIN 400, a spring cover 500, an ECUPCBA 600, and a housing assembly 700; wherein,

[0038] The large valve block 200 is mounted on the motor assembly 100, and the angle sensor 300 is mounted on the motor assembly 100 and located between the motor assembly 100 and the large valve block 200; the ECU PCBA 600 is mounted on the housing assembly 700, and the serpentine spring PIN 400 is placed in a preset hole in the housing assembly 700, with one end abutting against the angle sensor 300 and the other end abutting against the ECU PCBA 600; the spring cover 500 is sleeved on the serpentine spring PIN 400 and snapped onto the housing assembly 700.

[0039] The angle sensor 300 includes an angle sensor housing, an angle sensor PCBA 340, a connector 320, and an angle sensor PIN 310. The angle sensor PCBA 340 is disposed inside the angle sensor housing. The connector 320 is connected to one side of the angle sensor housing and passes through the large valve block 200. One end of the angle sensor PIN 310 is connected to a fisheye terminal 312. The angle sensor PIN 310 extends into the connector 320 and is connected to the angle sensor PCBA 340 through the fisheye terminal 312. The end of the angle sensor PCBA 340 away from the fisheye terminal 312 is connected to an angle sensor PAD 311, which contacts the serpentine spring PIN 400.

[0040] The housing of the angle sensor 300 includes an angle sensor base 330 and an angle sensor sealing cover 350, which are fixedly connected. The angle sensor base 330 is provided with multiple elastic buckles 331 and assembly positioning cylinders 332 for assembly, positioning and fixing with the motor assembly 100.

[0041] The ECUPCBA600 includes ECUPCB601 and EUPAD602. EUPAD602 is connected to one side of the ECUPCBA600 and contacts the serpentine spring PIN400. The ECU housing has guide and limiting grooves for assembling and fixing the serpentine spring PIN400. The serpentine spring PIN400 has two ends; one end contacts the angle sensor PAD311, and the other end contacts EUPAD602. Both ends are heavily gold-plated and have small protrusions on top to reduce the contact offset caused by machining and assembly errors, achieving a higher probability of contact with the PAD and ensuring good signal transmission with the angle sensor 300. Simultaneously, its serpentine structure, formed by stamping and bending, is more resistant to bending and vibration than a cylindrical spring, further ensuring reliable contact signals. The ECUPCBA600 has a circular EUPAD602 contacting the end of the serpentine spring PIN400, allowing the angle sensor 300 signal to be transmitted to the ECUPCBA600 for software control execution.

[0042] The angle sensor 300 of this invention is fixed to the inner hole of the motor assembly 100 by three elastic buckles 331 attached to the angle sensor base 330, and is assembled and positioned by the assembly positioning cylinder 332 attached to the angle sensor base 330. The mating surface of the motor assembly 100 is a circular hole, which is simple to manufacture. One end of the angle sensor PIN 310 is a circular angle sensor PAD 311, and the other end is a fisheye terminal 312. To achieve safety redundancy, two independent signals are used, with a total of 6 contact PADs, 3 PADs per signal path. The angle sensor PCBA 340 is connected to the fisheye terminal 312 by a crimping process. The angle sensor sealing cover 350 is welded to the angle sensor base 330 to protect the angle sensor PCBA 340 and prevent leakage of solenoid valves of electromechanical hydraulic servo devices or oil from pipelines from spilling into the angle sensor PCBA 340, which may cause failure, thus achieving greater safety redundancy. In summary, the angle sensor 300 has a reliable connection through injection molding of the angle sensor PIN 310 and connector 320, and the angle sensor PCBA 340 has a simple and reliable crimping process. The angle sensor sealing cover 350 provides sealing protection to ensure the reliable connection of the angle sensor 300. Moreover, the assembly with the motor assembly 100 is simple and reduces the processing difficulty of the motor assembly 100.

[0043] The present invention also provides a method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system, comprising the following steps:

[0044] Step 1: Install the corner sensor 300 onto the motor assembly 100, and achieve assembly, positioning and fixation with the motor assembly 100 by relying on multiple elastic buckles 331 at the corner and the assembly positioning cylinder 332.

[0045] Step 2: Assemble the assembly from Step 1 with the large valve block 200;

[0046] Step 3: Place the serpentine spring PIN400 into the preset hole of the housing assembly 700;

[0047] Step 4: Press the spring cover 500 into the housing assembly 700, and use its own snap-fit ​​mechanism to fix it to the housing assembly 700, thereby preventing the serpentine spring PIN 400 from falling off;

[0048] Step 5: Press the ECUPCBA600 to the housing assembly 700 to make contact between the top of the ECUPCBA602 and the serpentine spring PIN400;

[0049] Step 6: Connect the assembly from Step 5 to the large valve block 200 via threads.

[0050] In this embodiment, the assembly method of the angle sensor 300 is as follows:

[0051] S1, using a stamping process, electroplating, and then bending, completes the processing of the angle sensor PIN310, such as... Figure 6 As shown in (a);

[0052] S2, the corner sensor PIN310 and connector 320 are injection molded, as follows: Figure 6 As shown in (b);

[0053] S3, the connector 320 and the corner sensor base 330 are injection molded together as a single unit, such as... Figure 6 As shown in (c);

[0054] S4, crimp the angle sensor PCBA340 to the fisheye terminal 312 to complete the fixed assembly of the angle sensor PCBA340. Figure 6 As shown in (d);

[0055] S5, weld the corner sensor sealing cover 350 to the corner sensor base 330 to complete the assembly of the entire corner sensor 300, as follows. Figure 6 As shown in (e).

[0056] In terms of manufacturing method, the angle sensor PIN310 of the present invention is processed by stamping. One end of the angle sensor PIN310 is a circular PAD, and the other end is a fisheye terminal 312. It is then injection molded with the connector 320 of the angle sensor 300 to ensure reliable connection. Then, it is integrally injection molded with the angle sensor 300 housing to realize the sensor housing assembly. Then, the angle sensor PCBA340 is crimped to the fisheye terminal 312. Finally, the angle sensor sealing cover 350 is welded to the angle sensor base 330 to complete the manufacturing of the entire angle sensor 300. The serpentine spring PIN400 of the present invention has a stamped spring PIN body and gold-plated ends. Relying on its mold and strip processing technology, the production efficiency is greatly increased compared with the winding of cylindrical springs, and the cost is also greatly reduced, making it more suitable for mass production and automated production.

[0057] The corner sensor device and its manufacturing and assembly method of the present invention have a compact structure, which can achieve good transmission of corner signals, greatly improve production efficiency, reduce manufacturing costs, and are more suitable for mass production or automated production, regardless of the reliability of structural connection or assembly process.

[0058] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system, characterized in that, Includes the following steps: Step 1: Install the corner sensor onto the motor assembly, relying on multiple elastic clips at the corner and the assembly positioning cylinder to achieve assembly positioning and fixation with the motor assembly; Step 2: Assemble the assembly from Step 1 with the large valve block; Step 3: Place the serpentine spring pin into the pre-set hole of the housing assembly; Step 4: Press the spring cover into the housing assembly and secure it to the housing assembly using the built-in snap-fit ​​mechanism to prevent the serpentine spring pin from falling off; Step 5: Press the ECU PCBA to the housing assembly to achieve contact between the ECU PAD and the top of the serpentine spring PIN; Step 6: Connect the assembly from Step 5 to the large valve block using threads; The angle sensor device of the electromechanical-hydraulic servo braking system includes: a motor assembly, a large valve block, an angle sensor, a serpentine spring PIN, a spring cover, an ECU PCBA, and a housing assembly; among which, The large valve block is mounted on the motor assembly, the angle sensor is mounted on the motor assembly and located between the motor assembly and the large valve block; the ECU PCBA is mounted on the housing assembly, the serpentine spring PIN is placed in a preset hole in the housing assembly, one end abuts against the angle sensor and the other end abuts against the ECU PCBA; the spring cover is sleeved on the serpentine spring PIN and snapped onto the housing assembly.

2. The manufacturing method of the angle sensor device for an electromechanical-hydraulic servo braking system as described in claim 1, characterized in that, The angle sensor includes an angle sensor housing, an angle sensor PCBA, a connector, and an angle sensor PIN; the angle sensor PCBA is disposed inside the angle sensor housing, the connector is connected to one side of the angle sensor housing and passes through the large valve block; one end of the angle sensor PIN is connected to a fisheye terminal, the angle sensor PIN extends into the connector and is connected to the angle sensor PCBA through the fisheye terminal.

3. The manufacturing method of the angle sensor device for an electromechanical-hydraulic servo braking system as described in claim 2, characterized in that, The corner sensor PCBA is connected to a corner sensor PAD at the end away from the fisheye terminal, and the corner sensor PAD is in contact with the serpentine spring PIN.

4. A method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system as described in claim 2 or 3, characterized in that, The angle sensor housing includes an angle sensor base and an angle sensor sealing cover, which are fixedly connected.

5. A method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system as described in claim 4, characterized in that, The base of the corner sensor is equipped with multiple elastic buckles and assembly positioning cylinders to achieve assembly positioning and fixation with the motor assembly.

6. A method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system as described in claim 1, characterized in that, The ECU PCBA includes an ECU PCB and an ECU PAD. The ECU PAD is connected to one side of the ECU PCBA and is in contact with the serpentine spring PIN.

7. A method for manufacturing an angle sensor device for an electromechanical-hydraulic servo braking system as described in claim 6, characterized in that, The assembly method for the angle sensor is as follows: S1, using a stamping process, electroplating and then bending, completes the processing of the corner sensor PIN; S2, injection molding the corner sensor PIN and connector; S3, the connector and the corner sensor base are injection molded together as one piece; S4. Press the angle sensor PCBA to the fisheye terminal to complete the fixed assembly of the angle sensor PCBA; S5. Weld the corner sensor sealing cover to the corner sensor base to complete the assembly of the entire corner sensor.

Images