Torque angle sensor of electric power steering system

Abstract

The invention relates to the technical field of torque angle sensors, in particular to a torque angle sensor of an electric power steering system, which comprises a shell, a magnet driven gear assembly, an input rotor, a PCB (printed circuit board), a cover plate and an output rotor, rotor blades, a driving gear and a rotor sleeve are integrally arranged; the rotor blade is used for generating an induced magnetic field, and the driving gear and the magnet driven gear set rotate in a meshed mode; the magnet driven gear set is formed by magnet insert injection molding, and the magnet driven gear set is provided with a magnet used for generating a magnetic field so as to influence sensing of the angle chip. The input rotor is integrally formed through insert injection molding, the magnet driven gear set is formed through magnet insert injection molding, and the follow-up installation technology and installation steps are simplified. The technical problems that in the prior art, friction noise between the input shaft and the upper shell is large, the technology is complex, and the number of installation steps is large are solved.

Description

Technical Field

[0001] The invention relates to the technical field of torque angle sensors, and in particular relates to a torque angle sensor for an electric power steering system. Background Art

[0002] The electric power steering system is a system used to assist the driver in adjusting the direction to reduce the force required when operating the steering wheel. The torque and angle sensor is a type of electric power steering system.

[0003] A common torque angle sensor can refer to the patent document with authorization announcement number CN218496025U, which discloses a torque angle sensor for an automotive electric power steering system. The torque angle sensor includes an input rotor, the upper part of which is sleeved with a driving gear and a housing, and one side of the driving gear is connected to a magnet gear assembly; the lower part of the input rotor is sleeved with a PCB board, a cover plate and an output rotor; the housing is cooperatively connected to the cover plate, and the PCB board, the middle part of the input rotor, the driving gear and the magnet gear assembly are located in a connecting cavity between the housing and the cover plate.

[0004] The advantages of the torque angle sensor are: compared with the existing technology, the input rotor, PCB board, and magnet gear assembly are all placed inside the housing to achieve unidirectional installation, thereby simplifying the process flow; at the same time, the connector frame is directly integrated into the housing, the top cover plate is eliminated, and the metal springs on the anti-rotation structure are eliminated, thereby reducing the number of parts and reducing costs. However, it still has certain shortcomings: 1) The friction noise between the input shaft rotor and the upper housing is large, and there is wear and tear during the life cycle that affects the driver's feel; 2) There are problems with the air gap between the input shaft rotor and the PCB, and the air gap between the output shaft rotor and the PCB that are difficult to control; 3) The number of overall components is still large, and there are problems with complex processes and many installation steps. Summary of the invention

[0005] The invention provides a torque angle sensor for an electric power steering system, so as to solve the technical problems in the prior art of large friction noise between an input shaft and an upper housing, complex process and many installation steps.

[0006] In order to solve the above problems, the torque angle sensor of the electric power steering system provided by the present invention adopts the following technical solutions:

[0007] A torque angle sensor for an electric power steering system comprises a housing, a magnet driven gear assembly, an input rotor, a PCB board, a cover plate and an output rotor, wherein the input rotor is formed by insert injection molding and is integrated with rotor blades, a driving gear and a rotor sleeve; the rotor blades are used to generate an induced magnetic field, and the driving gear meshes and rotates with the magnet driven gear assembly;

[0008] The magnet driven gear assembly is formed by injection molding of magnet inserts, and the magnet driven gear assembly has a magnet for generating a magnetic field to affect the perception of the angle chip.

[0009] The torque angle sensor of the electric power steering system provided by the present invention has the following beneficial effects: 1) the input rotor is formed by insert injection molding, and the magnet driven gear set is formed by magnet insert injection molding, which simplifies the subsequent installation process and installation steps. The input rotor and the magnet driven gear set form a prefabricated part, which can be quickly installed in place during assembly; 2) the upper shell of the entire sensor is eliminated, and since there is no friction between the shell and the input shaft, the noise problem of the sensor is avoided;

[0010] Through the above arrangement, the present invention improves and upgrades the existing torque angle sensor, and effectively solves the technical problems in the prior art of large friction noise between the input shaft and the upper shell, complex process and many installation steps.

[0011] Furthermore, the cover plate is connected to the shell by ultrasonic or laser welding, and simultaneously presses the PCB board to limit the PCB board in the shell.

[0012] Furthermore, a gear elastic arm is installed in the shell, and the gear elastic arm is used to limit and support the PCB board and provide tight meshing tension.

[0013] Furthermore, the surface of the PCB board has an induction coil, an excitation coil and an angle chip. The PCB board is used to cooperate with the input rotor and the output rotor to generate a first angle signal, and is used to cooperate with the magnet driven gear set to generate a second angle signal.

[0014] Furthermore, the PCB board has a mounting hole for fixing the PCB board on the housing.

[0015] Furthermore, the magnet driven gear set is rotatably mounted in the housing, and a mounting seat for rotatably mounting the magnet driven gear set is provided in the housing, so that the magnet driven gear set can rotate 360° in the housing.

[0016] Furthermore, the housing also has a connector assembly, and the connector assembly has a connector interface for connecting to a main control end to transmit torque and angle signals to the main control end.

[0017] Furthermore, the housing is provided with a flexible connector, which is located between the housing and the main control end so that the housing and the main control end are tightly combined to avoid displacement and rotation.

[0018] Furthermore, the flexible connector includes a flexible plate and two through holes formed on the flexible plate. The flexible connector can be deformed when subjected to external force and can return to its original shape after the external force disappears, thereby alleviating or eliminating stress concentration caused by the external force and improving the durability and earthquake resistance of the structure.

[0019] Furthermore, the output rotor and the output shaft are fixedly connected by welding, riveting or interference fit to achieve coaxial and equal-speed rotation. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] By reading the following detailed description with reference to the accompanying drawings, the above and other objects, features and advantages of the exemplary embodiments of the present invention will become readily understood. In the accompanying drawings, several embodiments of the present invention are shown in an exemplary and non-limiting manner, and the same or corresponding reference numerals represent the same or corresponding parts, wherein:

[0021] Figure 1 An exploded schematic diagram of a torque angle sensor of an electric power steering system provided by the present invention;

[0022] Figure 2 for Figure 1 Partial diagram of the middle shell Figure 1 ;

[0023] Figure 3 for Figure 1 Partial diagram of the middle shell Figure 2 ;

[0024] Figure 4 for Figure 1 Partial diagram of the middle shell Figure 3 ;

[0025] Figure 5 for Figure 1 Schematic diagram of the PCB board;

[0026] Figure 6 for Figure 1 Schematic diagram of the input rotor;

[0027] Figure 7 for Figure 1 Schematic diagram of the magnet driven gear set;

[0028] Figure 8 This is an overall schematic diagram of the torque angle sensor of the electric power steering system provided by the present invention.

[0029] Description of reference numerals:

[0030] 1. Housing; 2. Magnet driven gear set; 3. Input rotor; 4. PCB board; 5. Cover plate; 6. Output rotor; 7. Gear elastic arm; 8. Connector PIN pin; 9. Flexible connector; 10. Connector assembly; 11. PIN pin hole; 12. Angle chip; 13. Induction coil; 14. Excitation coil; 15. Rotor blade; 16. Driving gear; 17. Rotor sleeve; 18. Magnet. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Those skilled in the art should know that the embodiments described below are part of the embodiments of the present disclosure, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0032] It should be noted that the main concept of the present invention is that the input rotor 3 is formed by insert injection molding, and the magnet driven gear set 2 is formed by magnet insert injection molding, which simplifies the subsequent installation process and installation steps. The input rotor 3 and the magnet driven gear set 2 form a prefabricated part, which can be quickly installed in place during assembly; the entire sensor eliminates the upper shell, and since there is no friction between the shell and the input shaft, the noise problem of the sensor is avoided; so as to solve the technical problems in the prior art of high friction noise between the input shaft and the upper shell, complex process and many installation steps.

[0033] After introducing the basic principle of the present invention, various non-limiting embodiments of the present invention are described in detail below. The number of any element in the drawings is for illustration and not for limitation, and any naming is only for distinction and does not have any limiting meaning.

[0034] The principle and spirit of the present invention are explained in detail below with reference to several representative embodiments of the present invention.

[0035] Embodiment 1 of the torque angle sensor of the electric power steering system provided by the present invention:

[0036] like Figures 1 to 8 As shown, the torque angle sensor of the electric power steering system includes a housing 1, a magnet driven gear set 2, an input rotor 3, a PCB board 4, a cover plate 5 and an output rotor 6. The input rotor 3 is formed by insert injection molding, and is integrated with rotor blades 15, a driving gear 16 and a rotor sleeve 17; the rotor blades 15 are used to generate an induced magnetic field, and the driving gear 16 meshes and rotates with the magnet driven gear set 2; the magnet driven gear set 2 is formed by magnet insert injection molding, and the magnet driven gear set 2 has a magnet 18 for generating a magnetic field to affect the perception of the angle chip 12.

[0037] The output rotor 6 is fixedly connected to the output shaft by welding, riveting or interference fitting to achieve coaxial and equal-speed rotation.

[0038] Specifically, the cover plate 5 is connected to the housing 1 by ultrasonic or laser welding, and simultaneously presses the PCB board 4 to limit the PCB board 4 in the housing 1 .

[0039] Regarding the arrangement of the PCB board 4. A gear elastic arm 7 is installed in the housing 1, which is used to limit and support the PCB board 4 and provide tension for tight meshing. The surface of the PCB board 4 has an induction coil 13, an excitation coil 14 and an angle chip 12. The PCB board 4 is used to cooperate with the input rotor 3 and the output rotor 6 to generate a first angle signal, and is used to cooperate with the magnet driven gear set 2 to generate a second angle signal. The PCB board 4 has a mounting hole for fixing the PCB board 4 on the housing 1.

[0040] In addition, the housing 1 is provided with a connector PIN pin 8, and the PCB board 4 is provided with a PIN pin hole 11 to facilitate the installation of the connector PIN pin 8 to complete the conductive transmission of the electrical signal.

[0041] Regarding the installation of the magnet driven gear set 2. The magnet driven gear set 2 is rotatably installed in the housing 1, and the housing 1 has a mounting seat for rotatably installing the magnet driven gear set 2, so that the magnet driven gear set 2 can rotate 360 ​​degrees in the housing 1.

[0042] The entire torque angle sensor is connected to an external main control end through a connector assembly 10. Specifically, the housing 1 also has a connector assembly 10, and the connector assembly 10 has a connector interface for connecting to the main control end to transmit torque and angle signals to the main control end.

[0043] Finally, the housing 1 also has a flexible connector 9, which is located between the housing 1 and the main control end so that the housing 1 and the main control end are tightly combined to avoid displacement and rotation. The flexible connector 9 includes a flexible plate and two through holes opened on the flexible plate. The flexible connector 9 can deform when subjected to external force and can return to its original state after the external force disappears, which can reduce or eliminate the stress concentration caused by the external force and improve the durability and earthquake resistance of the structure.

[0044] When the torque angle sensor of the electric power steering system provided by the present invention is actually working: the input rotor 3 is formed by insert injection molding, and the magnet driven gear set 2 is formed by magnet insert injection molding, which simplifies the subsequent installation process and installation steps. The input rotor 3 and the magnet driven gear set 2 form a prefabricated part and can be quickly installed in place during assembly; the entire sensor eliminates the upper shell, and since there is no friction between the shell and the input shaft, the noise problem of the sensor is avoided.

[0045] Embodiment 2 of the torque angle sensor of the electric power steering system provided by the present invention:

[0046] The main difference between it and Example 1 is:

[0047] In Example 1, the PCB board has a mounting hole for fixing the PCB board on the housing.

[0048] In this embodiment, a card slot and a buckle structure are provided between the PCB board and the housing to achieve mutual connection.

[0049] According to the above description of this specification, those skilled in the art may also understand that the terms used below, such as "up", "down", "front", "back", "left", "right", "width", "horizontal", "top", "bottom", "inside", "outside" and the like, which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the drawings of this specification, and are only for the purpose of facilitating the explanation of the scheme of the present invention and simplifying the description, rather than explicitly or implicitly indicating that the devices or elements involved must have the specific orientation, be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms cannot be understood or interpreted as limitations on the scheme of the present invention.

[0050] In addition, in the description of this specification, “plurality” means at least two, for example, two, three or more, etc., unless otherwise clearly and specifically defined.

Claims

1. A torque angle sensor for an electric power steering system, comprising a housing, a magnet driven gear assembly, an input rotor, a PCB board, a cover plate and an output rotor, characterized in that: The input rotor is formed by insert injection molding, and is integrated with rotor blades, drive gears and rotor sleeves; the rotor blades are used to generate an induced magnetic field, and the drive gear meshes and rotates with the magnet driven gear set; the magnet driven gear set is formed by magnet insert injection molding, and the magnet driven gear assembly has a magnet for generating a magnetic field to affect the perception of the angle chip.

2. The torque angle sensor of the electric power steering system according to claim 1, characterized in that: The cover plate is connected to the shell by ultrasonic or laser welding, and simultaneously presses the PCB board to limit the PCB board in the shell.

3. The torque angle sensor of the electric power steering system according to claim 2, characterized in that: A gear elastic arm is installed in the shell, and the gear elastic arm is used to limit and support the PCB board and provide tight meshing tension.

4. The torque angle sensor of the electric power steering system according to claim 3, characterized in that: The surface of the PCB board has an induction coil, an excitation coil and an angle chip. The PCB board is used to cooperate with the input rotor and the output rotor to generate a first angle signal, and is used to cooperate with the magnet driven gear set to generate a second angle signal.

5. The torque angle sensor of the electric power steering system according to claim 4, characterized in that: The PCB board is provided with a mounting hole for fixing the PCB board on the housing.

6. The torque angle sensor of the electric power steering system according to any one of claims 1 to 5, characterized in that: The magnet driven gear set is rotatably mounted in the housing, and a mounting seat for rotatably mounting the magnet driven gear set is provided in the housing so that the magnet driven gear set can rotate 360 ​​degrees in the housing.

7. The torque angle sensor of the electric power steering system according to any one of claims 1 to 5, characterized in that: The housing also has a connector assembly having a connector interface for connecting to a main control end so as to transmit torque and angle signals to the main control end.

8. The torque angle sensor of the electric power steering system according to any one of claims 1 to 5, characterized in that: The shell is also provided with a flexible connection piece, which is located between the shell and the main control end so as to make the shell and the main control end tightly combined to avoid displacement and rotation.

9. The torque angle sensor of the electric power steering system according to claim 8, characterized in that: The flexible connecting piece includes a flexible board and two through holes opened on the flexible board.

10. The torque angle sensor of the electric power steering system according to any one of claims 1 to 5, characterized in that: The output rotor is fixedly connected to the output shaft by welding, riveting or interference fitting to achieve coaxial and uniform rotation.

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