Integrated motor cover structure and manufacturing method thereof

Abstract

The invention relates to a structure of a motor cover and a manufacturing method thereof. An integrated motor cover structure comprises a cover body, an internal oil way pipeline is arranged in the cover body, the internal oil way pipeline is communicated with a cooling oil way of a motor, a temperature sensor is installed in the cover body, a sensing unit of the temperature sensor is located in the internal oil way pipeline, and a PCBA board is provided with a motor rotation angle sensor at the same time. The motor cover structure is manufactured by completing the internal oil pipeline, the cover body and the connector assembly through twice injection molding, then welding the PCBA board and installing the rotating shaft part. The structure is simple, the universality is high, the process is simple, and the overall cost is low. The technical problems of multiple installation steps, multiple installation auxiliary structures, multiple installation parts and high cost of various sensors in a motor structure in the prior art are solved.

Description

Technical Field

[0001] The invention relates to a structure of a motor cover and a manufacturing method thereof. Background Art

[0002] At present, pure electric and hybrid vehicles on the market all use transmission systems with motors. The motor generally includes components such as the motor stator, motor rotor, motor housing and motor cover. The motor stator generates a rotating magnetic field, and the main function of the rotor is to be cut by the magnetic lines of force in this rotating magnetic field to generate current. This design allows the stator and rotor to work together in the motor to achieve the conversion and transmission of electrical energy. The rotor is located inside the stator and can rotate freely. It is equipped with permanent magnets or electromagnets, which interact with the magnetic field generated by the stator to generate a rotational torque. This rotational torque is transmitted to the transmission system of the car, thereby driving the vehicle forward. According to the needs of the motor structure, various sensors are generally installed in the motor, such as motor angle sensors, which are used to identify the mechanical position of the drive motor rotor and feed back electrical signals to the control system. The control system will calculate the torque to determine the power utilization rate. There is also a temperature sensor, which is used to identify the oil circuit temperature and feed back electrical signals to the control system. The installation position of the sensor is generally installed on the motor housing according to the detection position. Summary of the invention

[0003] The present invention provides an integrated motor cover structure and a manufacturing method thereof which simplifies the installation steps, has low cost, simple and lightweight structure, simple process and convenient molding; and solves the technical problems existing in the prior art that various sensors in the motor structure have many installation steps, many auxiliary installation structures, many installation components and high cost.

[0004] The above technical problem of the present invention is solved by the following technical solution: an integrated motor cover structure, including a cover body, an internal oil pipeline is arranged in the cover body, the internal oil pipeline is connected with the cooling oil circuit of the motor, a temperature sensor is installed in the cover body, the sensitive unit of the temperature sensor is located in the internal oil pipeline, the temperature sensor is fixed on the PCBA board through pins, the PCBA board is fixed on the cover body, and the PCBA board is also installed with a motor angle sensor. The temperature sensor and the angle sensor are integrated on the housing, which simplifies the original need to install the temperature sensor and the motor angle sensor separately, and needs to design the installation space and increase the installation steps. The function of the motor cover itself is still not affected. The temperature sensor and the angle sensor are integrated on the motor cover, which is more versatile and has no effect on the motor itself. The internal oil pipeline is added in the cover body, which facilitates the arrangement of the temperature sensor and the signal collection. It only needs to connect the internal oil pipeline with the cooling oil circuit of the motor itself. The coolant still enters from the center of the rotor shaft of the motor, and will not affect the cooling oil circuit of the motor rotor itself. The integrated motor cover uses a plastic structure, making the product lighter and removing the sensor housing and sensor locking mechanism, which reduces the cost. It has little impact on the rest of the motor structure, does not need to change the internal structure of the motor, and has strong adaptability.

[0005] Preferably, the motor angle sensor includes a metal rotor, which is fixed on a rotating shaft, and the rotating shaft rotates synchronously with the rotor shaft in the motor. A winding structure is formed on the PCBA board, and a connecting end is provided at the center of the cover body. The rotating shaft and the connecting end are clearance-matched, and the connecting end is the oil outlet end of the internal oil pipeline. The rotating shaft rotates with the rotor shaft, and the metal rotor fixed on the rotating shaft rotates, so that the magnetic field changes, and the chip outputs an angle signal. The eddy current motor angle sensor is used, and the accuracy is better. And it does not affect the structure of the rotor itself. The PCBA board is divided into 2 functional module circuits, which are isolated by copper plating to ensure the accuracy of the eddy current sensor. At the same time, the cooling oil is input into the motor rotor through the rotating shaft. The oil outlet is connected on the rotating shaft, and the oil outlet directly inputs the cooling oil into the cooling pipeline inside the motor rotor for cooling, without changing the original cooling pipeline in the motor rotor. The internal oil pipeline designed on the cover body facilitates data collection by the temperature sensor, and does not delay the normal cooling process of the cooling oil circuit.

[0006] Preferably, the internal oil pipeline is in an E shape, with two oil inlets on both sides of the internal oil pipeline, and an oil outlet at the center of the internal oil pipeline, the oil inlet is connected to the cooling oil inlet pipeline of the motor, and the oil outlet is connected to the cooling pipeline inside the motor rotor. The oil inlet and the oil outlet are parallel to each other, and are connected by a horizontal connecting pipeline between the oil inlet and the oil outlet, which facilitates the arrangement of the sensitive unit of the temperature sensor and improves the sensing accuracy of the sensor.

[0007] Preferably, the installation direction of the temperature sensor is perpendicular to the PCBA board, and the sensitive unit of the temperature sensor is located in a horizontal connecting pipe of the internal oil pipeline, and the horizontal connecting pipe connects the oil inlet and the oil outlet.

[0008] Preferably, a sealing ring having the same shape as the end face of the cover body is installed on the end face of the cover body, and O-rings are provided at the oil inlet and the oil outlet.

[0009] Preferably, a connector is formed on the cover body, one end of the connector is connected to the PCBA board, and the other end of the connector is connected to an external controller.

[0010] A method for manufacturing an integrated motor cover, comprising: In the first step, an internal oil pipeline body is injection molded, the internal oil pipeline body comprising an internal oil pipeline body, an oil inlet and an oil outlet parallel to each other, and a horizontal connecting pipeline connecting the oil inlet and the oil outlet, and a temperature sensor installation cavity is also reserved on the internal oil pipeline body; In the second step, a temperature sensor is installed in the sensor installation cavity of the pipe formed in the first step. The sensitive unit of the temperature sensor is located in the horizontal connecting pipe, and the pins of the temperature sensor are exposed outside the main body of the internal oil pipeline. Then, the through holes of the main body of the internal oil pipeline except the oil inlet and the oil outlet are blocked with sealing plugs; The third step is to perform a second injection molding of the pin needle and the embedded ring together with the internal oil pipeline body formed in the second step to form the cover body and the connector on the cover body; Step 4: A PCBA board is installed on the cover body, the pins of the temperature sensor are connected to the PCBA board, the PCBA board is connected to the pins of the connector, and the PCBA board is designed with a winding structure; The fifth step is to resin-fill the joint between the secondary injection molded part and the primary injection molded part, and at the same time complete the packaging of the PCBA; In the sixth step, an end face sealing ring is installed on the potting part completed in the fifth step, and a rotating shaft is installed at the end of the oil outlet. A metal rotor is integrally formed on the rotating shaft, and the metal rotor corresponds to the winding structure on the PCBA board.

[0011] Preferably, the PCBA board and the secondary injection molded part are fixed by hot riveting or soldering.

[0012] Therefore, an integrated motor cover structure and a manufacturing method thereof of the present invention have the following advantages: the temperature sensor and the motor angle sensor are integrated on the motor end cover, which has little impact on the original structure of the motor, but the overall installation structure is simpler, which simplifies the customer's system layout. The motor cover is made of a plastic structure as a whole, making the product lighter and lower in cost. The structure of the motor cover is completed by secondary injection molding, which has a simple process and can well integrate the temperature sensor and the motor angle sensor on the motor cover, thus simplifying the installation process of the sensor. There is no need to find a special installation space, and the impact on the structure of the motor itself is small, and the function of the motor cover itself is not affected. The integrated motor cover has strong versatility and can be adapted to motors of any model and function, greatly reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a stereogram of an integrated motor cover structure.

[0014] Figure 2 yes Figure 1 Another perspective view.

[0015] Figure 3 yes Figure 1 sectional view of .

[0016] Figure 4 It is the internal oil pipeline body formed after the first step of the manufacturing method is completed.

[0017] Figure 5 yes Figure 4 sectional view of .

[0018] Figure 6 It is the internal oil pipeline body formed after the second step of the manufacturing method is completed.

[0019] Figure 7 Schematic diagram of the motor end cover after the third step of the manufacturing method is completed.

[0020] Figure 8 Schematic diagram of the motor end cover after the fourth step of the manufacturing method is completed.

[0021] Fig. 9 It is a three-dimensional image after the fifth step of the manufacturing method is completed.

[0022] Fig.10 It is a cross-sectional view of the motor end cover after the fifth step of the manufacturing method is completed. DETAILED DESCRIPTION

[0023] The technical solution of the invention is further specifically described below through embodiments and in conjunction with the accompanying drawings.

[0024] Example: like Figure 1 and 2As shown in and 3, an integrated motor cover structure includes a cover body 1 made of plastic material, an E-shaped internal oil pipeline 2 is formed inside the cover body 1, and the internal oil pipeline 2 includes two oil inlets 7 parallel to each other and an oil outlet 8 located between the two oil inlets 7, and the oil inlet 7 and the oil outlet 8 are connected by a horizontal connecting pipeline 11. A PCBA board 10 is also installed in the middle of the cover body 1, and a connector 3 is molded outside the cover body 1. The PCBA board 10 is connected to the connector 3 through a PIN needle 13, and the other end of the connector 3 can be connected to the controller. A special-shaped sealing ring 6 with the same shape as the end face of the cover body 1 is also installed on the lower end face of the cover body 1.

[0025] A temperature sensor 9 is also installed in the cover body 1, and the sensitive unit of the temperature sensor 9 is located in the horizontal connecting pipe 11 of the internal oil pipeline. The temperature sensor 9 is installed vertically with the PCBA board 10, and one end of the temperature sensor 9 is fixed on the PCBA board 10 through a pin.

[0026] A coil is etched on the PCBA board 10, and the oil outlet 8 extends out of the cover body 1. The oil outlet 8 is clearance-matched with the rotating shaft 4. The center of the rotating shaft 4 is a through hole. A metal rotor 5 is integrally formed on the rotating shaft 4, and the axial projection of the metal rotor 5 corresponds to the coil on the PCBA board 10. The other end of the rotating shaft 4 is interference-fitted with the motor rotor shaft. By using the eddy current principle, the metal rotor is driven to rotate when the rotor shaft rotates, thereby detecting the rotation angle of the motor rotor.

[0027] When the system is working, the cooling lubricating oil will enter the oil inlet 7 on the cover body 1 of the motor cover through the oil circuit on the motor housing. There is an oil circuit inside the cover body 1, and a temperature sensor 9 is arranged on the oil circuit pipeline. The temperature sensor 9 has an NTC thermistor inside, which senses the liquid temperature in the cavity and introduces its own resistance change to the PCBA through the sensor pin, and then guides it to the connector end through the circuit of the PCBA. Finally, it is transmitted to the controller through the outer wiring harness system. In this way, the controller can always know the oil temperature inside the housing. Since the metal rotor of the eddy current sensor rotates synchronously with the motor rotor shaft, the angular change of the rotor can be tested by the eddy current principle angle sensor installed on the cover body at the same time. The coil is etched on the PCBA board 10 and guided to the connector end through the circuit of the PCBA board 10.

[0028] The exposed surface of the cover body 1 of the motor cover is provided with a male terminal feature, and the controller can be connected to it through a matching wiring harness structure to transmit electrical signals.

[0029] The pin of connector 3 will be soldered to the PCBA inside the motor cover. The PCBA will integrate the winding mechanism based on the eddy current principle and the circuit of the transmission temperature sensor, which has a simpler structure. The end face sealing ring will be arranged around the locking area of ​​the motor cover and the oil inlet port. When the motor cover is locked with the motor housing, the contact area of ​​the sealing ring will form a sealed environment to ensure that there will be no internal leakage in the oil circuit.

[0030] The above integrated motor cover structure is manufactured by the following method: like Figure 4 and 5 As shown, in the first step, an internal oil pipeline body is injection molded, and the internal oil pipeline body includes an internal oil pipeline body, an oil inlet 7 and an oil outlet 8 which are parallel to each other, and a horizontal connecting pipeline 11 connecting the oil inlet and the oil outlet, and a temperature sensor installation cavity 16 is also reserved on the internal oil pipeline body; like Figure 6 As shown, in the second step, the temperature sensor 9 is installed in the sensor installation cavity of the pipe formed in the first step, the sensitive unit of the temperature sensor 9 is located in the horizontal connecting pipe 11, the pins of the temperature sensor 9 are exposed outside the main body of the internal oil pipeline, and then the through holes of the main body of the internal oil pipeline except the oil inlet and the oil outlet are blocked by the sealing plug 12; like Figure 7 As shown, in the third step, the pin needle 13 and the embedded ring 14 are subjected to a second injection molding together with the internal oil pipeline body formed in the second step to form the cover body 1 and the connector 3 on the cover body; like Figure 8 As shown, in the fourth step, a PCBA board 10 is heat-riveted or welded on the cover body 1, the pins of the temperature sensor 9 are welded to the PCBA board 10, the PCBA board 10 is connected to the pin 13 of the connector, and a winding structure is designed on the PCBA board 10; like Fig. 9 and 10 As shown, in the fifth step, the joint 15 of the secondary injection molded part and the primary injection molded part is resin-encapsulated, and the packaging of the PCBA board 10 is completed at the same time; In the sixth step, the end face sealing ring 6 is installed on the potting part completed in the fifth step, and a rotating shaft 4 for interference fit with the motor rotor shaft is installed at the end of the oil outlet 8, and a metal rotor 5 is integrally formed on the rotating shaft 4, and the metal rotor 5 corresponds to the winding structure on the PCBA board 10.

[0031] The specific embodiments described herein are merely examples of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. An integrated motor cover structure, comprising a cover body, characterized in that: An internal oil pipeline is provided in the cover body, and the internal oil pipeline is connected to the cooling oil pipeline of the motor. A temperature sensor is installed in the cover body, and the sensitive unit of the temperature sensor is located in the internal oil pipeline. The temperature sensor is fixed to the PCBA board through pins, and the PCBA board is fixed on the cover body. The PCBA board is also installed with a motor angle sensor.

2. The integrated motor cover structure according to claim 1, characterized in that: The motor angle sensor includes a metal rotor, which is fixed on a rotating shaft. The rotating shaft rotates synchronously with the rotor shaft inside the motor. A winding structure is formed on the PCBA board. A connecting end is provided at the center of the cover body. The rotating shaft and the connecting end are clearance-matched. The connecting end is the oil outlet end of the internal oil pipeline.

3. The integrated motor cover structure according to claim 1, characterized in that: The internal oil circuit pipeline is in an E shape, with two oil inlets on both sides of the internal oil circuit and an oil outlet in the center of the internal oil circuit. The oil inlet is connected to the cooling oil inlet pipeline of the motor, and the oil outlet is connected to the cooling pipeline inside the motor rotor.

4. An integrated motor cover structure according to claim 1, 2 or 3, characterized in that: The installation direction of the temperature sensor is perpendicular to the PCBA board, and the sensitive unit of the temperature sensor is located in the horizontal connecting pipe of the internal oil pipeline, and the horizontal connecting pipe connects the oil inlet and the oil outlet.

5. An integrated motor cover structure according to claim 1, 2 or 3, characterized in that: The end surface of the cover body is provided with a sealing ring with the same shape as the end surface of the cover body, and O-shaped sealing rings are provided at the oil inlet and the oil outlet.

6. An integrated motor cover structure according to claim 1, 2 or 3, characterized in that: A connector is formed on the cover body, one end of the connector is connected to the PCBA board, and the other end of the connector is connected to an external controller.

7. A method for manufacturing an integrated motor cover, characterized in that: In the first step, an internal oil pipeline body is injection molded, the internal oil pipeline body comprising an internal oil pipeline body, an oil inlet and an oil outlet parallel to each other, and a horizontal connecting pipeline connecting the oil inlet and the oil outlet, and a temperature sensor installation cavity is also reserved on the internal oil pipeline body; In the second step, a temperature sensor is installed in the sensor installation cavity of the pipe formed in the first step. The sensitive unit of the temperature sensor is located in the horizontal connecting pipe, and the pins of the temperature sensor are exposed outside the main body of the internal oil pipeline. Then, the through holes of the main body of the internal oil pipeline except the oil inlet and the oil outlet are blocked with sealing plugs. The third step is to perform a second injection molding of the pin needle and the embedded ring together with the internal oil pipeline body formed in the second step to form the cover body and the connector on the cover body; Step 4: A PCBA board is installed on the cover body, the pins of the temperature sensor are connected to the PCBA board, the PCBA board is connected to the pins of the connector, and the PCBA board is designed with a winding structure; The fifth step is to resin-fill the joint between the secondary injection molded part and the primary injection molded part, and at the same time complete the packaging of the PCBA; In the sixth step, an end face sealing ring is installed on the potting component completed in the fifth step, and a rotating shaft is installed at the end of the oil outlet. A metal rotor is integrally formed on the rotating shaft, and the metal rotor corresponds to the winding structure on the PCBA board.

8. The method for manufacturing an integrated motor cover according to claim 7, characterized in that: The PCBA board and the secondary injection molded parts are fixed by hot riveting or soldering.

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