Angle position sensor, angle measuring system, angle measuring method and electric driving system

Abstract

The invention provides an angle position sensor, an angle measuring system, an angle measuring method and an electric driving system.The sensor comprises a printed circuit board assembly, an exciting coil and a receiving coil, the exciting coil and the receiving coil are distributed in the printed circuit board assembly, the exciting coil and the receiving coil are concentrically designed, and the exciting coil is located on one side of the receiving coil; the printed circuit board assembly is integrated with a grounded conductive loop; the rotor sleeves the motor shaft and is arranged close to one end face of the excitation coil, and a gap is formed between the rotor and the excitation coil; the conductive device comprises two conductive parts, one conductive part is connected with the motor shaft, the other conductive part is connected with a conductive loop, and shaft current or / and shaft voltage is led out; the magnetic field formed by the excitation coil changes along with the rotation angle of the rotor, and the rotation angle of the rotor is determined according to the amplitude and phase output by the receiving coil. According to the integrated conductive device, the size of the sensor is effectively reduced, the cost is also reduced, and meanwhile, the influence of shaft electricity on the bearing is also reduced.

Description

Technical Field

[0001] This application relates to the field of mechatronic control technology, and particularly to an angular position sensor, an angular measurement system, a method, and an electric drive system. Background Art

[0002] In the field of mechatronic control technology, angular position sensors are used in many devices and systems to sense angular (e.g., rotational) positions. For example, the drive system of an electric drive new energy vehicle includes multiple components that rotate at high speeds and under high loads. After long-term use or passing durability tests, key rotating components, such as bearings and gears, may fail due to performance degradation.

[0003] However, in the related art, adding separate functional modules or components to achieve their respective functions has a high cost, which is not conducive to controlling the cost of the electric drive system; at the same time, this low-integration design scheme is also not conducive to the integration of the electric drive system. Summary of the Invention

[0004] In view of the above-mentioned disadvantages of the prior art, the purpose of this application is to provide an angular position sensor, an angular measurement system, a method, and an electric drive system, which are used to solve at least one of the above technical problems.

[0005] To achieve the above object and other related objects, the first aspect of this application provides an angular position sensor, including: a printed circuit board assembly, and an excitation coil and a receiving coil distributed inside the printed circuit board assembly, where the excitation coil and the receiving coil are concentrically designed and the excitation coil is located on one side of the receiving coil, and wherein the printed circuit board assembly is integrated with a grounded conductive loop; a rotor, sleeved on the motor shaft, disposed near one end face of the excitation coil, and having a gap with the excitation coil; a conductive device, including two conductive parts, one of the conductive parts is connected to the motor shaft, and the other conductive part is connected to the conductive loop to conduct the shaft current or / and shaft voltage; the magnetic field formed by the excitation coil changes with the rotation angle of the rotor, and the rotation angle of the rotor is determined according to the amplitude and phase output by the receiving coil.

[0006] In some embodiments of the first aspect of this application, it further includes: a vibration sensor, integrated in the printed circuit board assembly, for monitoring the vibration signal of the bearing sleeved on the motor shaft.

[0007] In some embodiments of the first aspect of this application, the conductive device includes a conductive bracket and a conductive mechanism, the conductive bracket is disposed on the printed circuit board assembly and connected to the conductive loop, the conductive mechanism is fixed on the conductive bracket and electrically connected to the motor shaft, or the conductive mechanism is indirectly electrically connected through the motor shaft and the bearing.

[0008] In some embodiments of the first aspect of the present application, the conductive part of the conductive mechanism electrically connected to the motor shaft includes any one of a conductive brush, a conductive ring or a slip ring.

[0009] In some embodiments of the first aspect of the present application, the conductive mechanism is fixed to the conductive support by conductive glue or bolts.

[0010] In some embodiments of the first aspect of the present application, the conductive support is fixed to the printed circuit board assembly by conductive glue or bolts.

[0011] In some embodiments of the first aspect of the present application, the conductive ring or the slip ring is integrated on the rotor and connected to the motor shaft.

[0012] In some embodiments of the first aspect of the present application, a sealant is provided between the conductive device and the printed circuit board assembly.

[0013] In some embodiments of the first aspect of the present application, the conductive device is bonded to the printed circuit board assembly.

[0014] In some embodiments of the first aspect of the present application, it further includes a housing assembly, and the printed circuit board assembly is assembled in the housing assembly.

[0015] In some embodiments of the first aspect of the present application, the shape of the housing assembly matches the shape of the printed circuit board assembly, and the printed circuit board assembly is fixed in the housing assembly by bolts.

[0016] In some embodiments of the first aspect of the present application, the printed circuit board assembly outputs externally by wires or connectors.

[0017] In some embodiments of the first aspect of the present application, the installation position of the vibration sensor on the printed circuit board assembly is close to the bearing.

[0018] The second aspect of the present application provides an angle measurement system, including the above-mentioned angle position sensor, motor controller, drive device and vehicle controller; the angle position sensor is used to collect the position signal and vibration signal of the motor; the motor controller is used to measure the rotation angle of the motor according to the position signal, generate a control current for the motor in response to the received control instruction and the current rotation angle; and is further used to judge the state of the drive device that drives the motor to operate according to the vibration signal; the vehicle controller is used to control the motor to enter a limp home state if the state of the drive device is abnormal.

[0019] The third aspect of the present application provides an angle measurement method, which uses the above-mentioned angle position sensor. The measurement method includes: obtaining the amplitude and phase of the output signal of the receiving coil in the angle position sensor; and determining the rotation angle of the rotor according to the amplitude and phase of the signal by using a quadrant recognition algorithm, a look-up table method or a sine-cosine change algorithm.

[0020] The fourth aspect of the present application provides an electric drive system, including the above-mentioned angle position sensor; or, the above-mentioned angle measurement system.

[0021] As described above, a technical solution of the angle position sensor, angle measurement system, method and electric drive system of the present application has the following beneficial effects:

[0022] In the present application, the printed circuit board assembly integrates a grounded conductive loop, an excitation coil and a receiving coil. Not only is the overall design compact, which greatly reduces the volume and has a high integration degree, but it is also easy to be integrated into various devices, reducing the installation space and the manufacturing cost at the same time; among them, the excitation coil is distributed outside or inside the receiving coil, and there is no contact between the rotor and the excitation coil, that is, there is no mechanical wear, improving the stability and reliability of the angle measurement system; through the cooperation of the conductive device and the conductive loop, the shaft voltage is derived, effectively reducing the risk of shaft electricity to the bearing, ensuring the service life of the bearing, and at the same time, avoiding the failure of the drive motor and the loss of vehicle power caused by shaft electricity. Description of the Drawings

[0023] Figure 1 It shows a schematic structural diagram of an angle position sensor provided by the present application;

[0024] Figure 2 It shows an assembly schematic diagram of an angle position sensor provided by the present application;

[0025] Figure 3 It shows an exploded view of the conductive device in an angle position sensor provided by the present application;

[0026] Figure 4 It shows a schematic diagram of the shaft electricity circuit of a motor provided by the present application;

[0027] Figure 5 It shows a schematic diagram of the printed circuit board assembly in an angle position sensor provided by the present application;

[0028] Figure 6 It shows a schematic flow diagram of an angle measurement method provided by the present application;

[0029] Figure 7 It shows a structural block diagram of an angle measurement system provided by the present application.

[0030] Description of the Reference Numerals:

[0031] 1. Rotor, 2. Housing assembly, 3. Printed circuit board assembly, 31. Control chip, 32. Vibration sensor, 33. Fixed power-on hole, 34. Angle signal output terminal, 35. Vibration signal output terminal, 36. Ground signal output terminal, 3. Housing assembly, 4. Sealant, 5. Conductive bracket, 6. Conductive mechanism, 7. Bolt. Specific embodiments

[0032] The following specific examples illustrate the implementation manners of the present application. Those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in this specification. The present application can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0033] It should be noted that the diagrams provided in the following embodiments only illustrate the basic concept of the present application in a schematic manner. Therefore, only the components related to the present application are shown in the diagrams, rather than being drawn according to the number, shape, and size of the components in actual implementation. The types, quantities, and proportions of the components in actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0034] An angular position sensor, also known as an angle sensor, is a component used to detect angles. The types of angle sensors include, but are not limited to, potentiometers, photoelectric, inductive, magnetosensitive, and resolver types. Angular position sensors are widely used in multiple fields and have advantages such as high precision, good repeatability, and good stability.

[0035] However, in the electric drive system of new energy vehicles, there are multiple high-speed rotating and high-load components. During the operation of the rotor of the electric drive system, the shaft voltage generated will cause serious harm to the life of the motor bearing (i.e., the bearing), and then cause the failure of the drive motor and the loss of vehicle power. Among them, the main reasons for the generation of shaft voltage are as follows: ① The uneven distribution of magnetic flux inside the motor forms a potential difference; ② The common-mode voltage generated by the electronic control; ③ The high-order harmonics of the power supply voltage generate electromagnetic induction in the stator and rotor. Once a loop is formed among the shaft, the motor bearing, and the housing after the shaft voltage is established, shaft current is generated.

[0036] In terms of related technologies, simply adding functional modules or components to reduce the shaft voltage itself has a high cost and is not conducive to controlling the cost of the electric drive system; at the same time, this low-integration design scheme is also not conducive to the integration of the electric drive system. Therefore, there is an urgent need for an integrated component to overcome the above technical defects.

[0037] Please refer toFigure 1 , which is a schematic structural diagram of an angular position sensor provided by this application, and is described in detail as follows:

[0038] A printed circuit board assembly 3, and an excitation coil and a receiving coil distributed inside the printed circuit board assembly. The excitation coil and the receiving coil are concentrically designed, and the excitation coil is located on one side of the receiving coil. Among them, the printed circuit board assembly is integrated with a grounded conductive loop;

[0039] Among them, the printed circuit board assembly installs and solders all necessary electronic components on the printed circuit board to form a complete functional circuit. With the high integration and reliability of the printed circuit board assembly 3, the performance and stability of the electronic device are greatly improved.

[0040] Among them, the excitation coil and the receiving coil are designed as concentric circular rings. The concentric design usually makes the mutual inductance between the coils symmetric. When the rotor rotates, the amplitude change of the output signal (such as sine and cosine signals) will be relatively smooth, and the phase relationship is also easy to control.

[0041] It should be noted that the excitation coil and the receiving coil are designed as concentric circular rings, and the excitation coil is located outside or inside the receiving coil. Among them, a magnetic field will be generated after the excitation coil is energized, and this magnetic field will change with the rotation of the rotor. The receiving coil receives the magnetic field through the induction principle and converts it into an electrical signal. The amplitude and phase of this electrical signal are related to the rotation angle of the rotor. The combined use of the excitation coil and the receiving coil realizes the precise measurement of the rotation angle of the rotor.

[0042] It should also be noted that the printed circuit board assembly is integrated with a grounded conductive loop, which is used to ensure the safe operation of the electronic device, prevent the influence of static electricity and electromagnetic interference on the device, and through the grounded conductive loop, the static electricity and electromagnetic interference in the electric drive system are introduced to the ground, thereby protecting the normal operation of the device. For example, different grounding methods, such as single-point grounding, multi-point grounding, etc., are adopted to meet different application requirements. Another example is to adaptively adjust the layout and shape of the grounded conductive loop according to the structure and function of the device, and the anti-interference ability and safety of the electronic device are improved through the conductive loop.

[0043] A rotor 1, sleeved on the motor shaft, is arranged close to one end face of the excitation coil, and there is a gap between it and the excitation coil;

[0044] Specifically, the rotor 1 is sleeved on the motor shaft, designed concentrically with the printed circuit board assembly 3, and disposed close to one end face of the excitation coil. There is a certain gap between the rotor 1 and the excitation coil to ensure non-contact measurement between them. The rotating rotor 1 changes the magnetic field distribution generated by the excitation coil, thereby affecting the electrical signal output by the receiving coil. By measuring the amplitude and phase of the electrical signal output by the receiving coil, precise measurement of the rotation angle of the rotor is achieved.

[0045] The conductive device includes two conductive parts. One of the conductive parts is connected to the motor shaft, and the other conductive part is connected to the conductive circuit to conduct out the shaft current and / or shaft voltage. Herein, the motor shaft in this application refers to the rotating shaft for transmitting torque inside the motor.

[0046] The magnetic field formed by the excitation coil varies with the rotation angle of the rotor. According to the amplitude and phase output by the receiving coil, the rotation angle of the rotor is determined.

[0047] Specifically, the conductive device includes two conductive parts. One conductive part (i.e., Figure 1 connected to Figure 2 the end of the conductive brush on the conductive mechanism 6 in Figure 1 is connected to the motor shaft, and the other conductive part (i.e., Figure 2 the bushing of the conductive bracket 5 connected to the ground connection in

[0048] connects the conductive circuit. The purpose of the conductive device is to conduct out the shaft current and / or shaft voltage to protect the normal operation of the electric drive system. During operation, shaft current or shaft voltage is generated due to the following reasons: ① The uneven distribution of magnetic flux inside the motor forms a potential difference; ② The common-mode voltage generated by the electronic control; ③ The high-order harmonics of the power supply voltage generate electromagnetic induction in the stator and rotor. Once a loop is formed between the shaft, the motor bearing, and the housing after the shaft voltage is established, shaft current is generated. By using the conductive device to connect the motor shaft and the conductive circuit, the current or voltage on the motor bearing (i.e., the bearing) is conducted out, thus avoiding damage to the motor bearing.

[0049] In other words, the conductive device can also adopt conductive wire, conductive line, brush-type conduction, slip-ring conduction, or liquid-metal conduction, etc., which will not be elaborated here.

[0050] The motor shaft refers to the rotating shaft inside the motor used to transmit torque, usually made of metal (such as steel), directly connecting the rotor and the load (such as gears, couplings). Figure 1 , Figure 2 As shown, the conductive device includes a conductive bracket 5, a conductive mechanism 6 and a bolt 7 made of a conductive metal material. In the design of the special-shaped PCBA structure, at least two welding substrates with through holes (PCS through-hole welding plates) are arranged on one side of the fan blade in the PCBA. The conductive bracket 5 has two bushings matched with the PCS through-hole welding plates, and the conductive mechanism 6 is vertically distributed along the motor shaft. The end of the conductive mechanism 6 is provided with a conductive brush. The through holes of the ears on both sides of the conductive mechanism 6 are matched with the PCS through-hole welding plate, so that the two bolts 7 pass through the through holes of the side ears and are fixed to the PCS through-hole welding plate, ensuring that the grounded conductive bracket 5 is connected through the conductive brush on the conductive mechanism 6 to solve the influence of electrical corrosion caused by shaft voltage or shaft current.

[0051] Through the above-mentioned method, the printed circuit board assembly in the present application integrates a grounded conductive loop, an excitation coil and a receiving coil. The overall design is compact, the volume is greatly reduced, the integration is high, and it is easy to be integrated into various devices, which reduces the installation space and reduces the manufacturing cost; wherein, the excitation coil is distributed on the outside or inside of the receiving coil, and there is no contact between the rotor and the excitation coil, that is, there is no mechanical wear, which improves the stability and reliability of the angle measurement system; through the cooperation of the conductive device and the conductive loop, the shaft voltage is derived, which effectively reduces the risk of shaft electricity to the motor bearings, ensures the service life of the motor bearings, and at the same time, avoids the failure of the drive motor and the loss of vehicle power caused by shaft electricity.

[0052] Optionally, based on the above embodiment, it further includes: a vibration sensor, integrated in the printed circuit board assembly, for monitoring the vibration signal of the bearing sleeved on the motor shaft.

[0053] It should be understood that vibration sensors usually select MEMS chips (i.e., vibration sensor chips) to convert vibration signals using the piezoelectric effect. On the PCB assembly, the vibration sensor chip is integrated into a specified position through SMT (surface mount technology) patch processing or DIP (dual in-line package) post-welding processing.

[0054] For example, since the vibration sensor chip is made of piezoelectric materials, such as piezoelectric ceramics or piezoelectric crystals, when the bearing or gear vibrates, the vibration signal will be transmitted to the sensor, and the piezoelectric material will deform under the action of the force, thereby generating changes in charge or potential, which are then converted into electrical signals.

[0055] In addition to the vibration sensor chip, piezoresistive, force balance, or resonant types can also be selected for replacement. Among them, the vibration sensor chip has the advantages of small size, light weight, and fast response speed. After being integrated on the PCB assembly, it is convenient to monitor vibration signals in real time.

[0056] The signal generated by the vibration sensor needs to be amplified by a preamplifier, and the amplified signal is then filtered by a filter to remove stray noise. For example, in addition to using a preamplifier and a filter, a signal conditioning circuit can also be considered. It integrates multiple functions such as amplification and filtering, simplifying the circuit design.

[0057] In this embodiment, abnormal conditions of the bearing (such as wear, looseness, pitting, poor lubrication, etc.) will cause non-stationary mechanical shocks or periodic vibrations during rotation. These vibrations are transmitted through the bearing to the equipment housing or shaft and captured by the vibration sensor. Amplify the amplitude of the weak signal (such as a charge amplifier) to ensure effective subsequent processing; remove noise (such as power interference, mechanical background noise) through low-pass, high-pass, or band-pass filters to improve the signal-to-noise ratio, convert it into a digital signal, and extract sensitive features reflecting the bearing state through time-domain, frequency-domain, or time-frequency domain methods. Detect abnormal conditions in the bearing vibration by comparing with a preset threshold (such as RMS, kurtosis) or a fault mode; for example, when the vibration signal exceeds the preset threshold or a specific frequency combination appears, an alarm is issued; identify abnormal vibrations, shocks, or periodic patterns by observing the waveform of the vibration signal. Determine the fault type by analyzing the spectrum of the vibration signal, such as ball friction, inner ring or outer ring damage, etc.; detect abnormal events, such as sudden increases or decreases in amplitude, changes in frequency, etc., and calculate statistical parameters such as the mean, standard deviation, and peak value of the signal to understand the average level and fluctuations of the signal. Through the above methods, abnormal conditions of the bearing, such as wear and looseness, can be detected in a timely manner, so as to predict faults in advance, perform maintenance or replacement in a timely manner, and prevent the faults from spreading to other components.

[0058] In other embodiments, see Figure 1 , this application proposes a design of an eddy current sensor integrated component integrating vibration monitoring and conductive mechanism functions. The multi-functional eddy current sensor adopts a highly integrated design scheme, integrating a MEMS chip with vibration acceleration testing function and a PCBA circuit board of the eddy current stator (i.e., printed circuit board assembly) for monitoring the vibration signals of the motor rotating components transmitted from the end cover. The conductive mechanism and its corresponding conductive circuit are integrated with the PCBA circuit board of the eddy current stator, and the conductive brush (i.e., conductive mechanism 6) is integrated with the eddy current stator PCBA through the conductive bracket 5 and the bolt 7.

[0059] Please refer to Figure 3, an exploded view of the conductive device in an angular position sensor provided by this application; wherein, the conductive device includes a conductive bracket 5 and a conductive mechanism 6, the conductive bracket is arranged on the printed circuit board assembly 3 and connected to the conductive loop, the conductive mechanism 6 is fixed on the conductive bracket 5 and electrically connected to the motor shaft, or the conductive mechanism 6 is indirectly electrically connected through the motor shaft and the bearing.

[0060] Among them, the conductive bracket uses its own conductive materials (such as copper, aluminum, etc.) and special connection methods to connect the conductive loop on the PCB to the conductive mechanism, forming a complete conductive path; for example, using other materials with good electrical conductivity to replace traditional copper, aluminum, etc., such as conductive polymers or composite conductive materials; in addition to welding and screw fixation, plug-in, snap-fit and other connection methods can also be considered to improve the assembly efficiency and reliability.

[0061] The motor shaft uses its own electrical conductivity and special contact design to effectively transfer the electrical signal on the motor bearing to the motor shaft, and uses the electrical conductivity of the conductive mechanism material to effectively transfer the electrical signal on the motor shaft to the conductive mechanism. The conductive mechanism ensures the timely derivation of shaft current or / and shaft voltage through the conductive loop.

[0062] For details, see Figure 4 , in the electric drive system, the blue part is the voltage and current generated along the axis due to uneven internal magnetic flux, or the common-mode voltage generated by the electronic control, or the electromagnetic induction generated by the high-order harmonics of the power supply voltage in the stator and rotor. Through the conductive device such as Figure 4 The red part in conducts the shaft voltage of the motor, which can effectively reduce the risk of shaft electricity to the motor bearing; it can conduct most of the shaft voltage, effectively reduce the impact of the shaft electricity problem, and ensure the service life of the motor bearing.

[0063] Through the above method, the conductive bracket ensures the electrical connection reliability between the conductive device and the PCB, and at the same time provides sufficient mechanical support; the conductive mechanism ensures the electrical connection reliability between the conductive device and the motor shaft, and at the same time provides good electrical conductivity and wear resistance, ensuring the stability and reliability of the conductive device's conductivity. In addition, the electrical connection between the end of the conductive bracket and the motor shaft ensures that the electrical signal can be transmitted stably and reliably, and also improves the overall performance and reliability.

[0064] Optionally, in some embodiments, the conductive part of the conductive mechanism electrically connected to the motor shaft includes any one of a conductive brush, a conductive ring or a slip ring.

[0065] Specifically, the conductive brush is in close contact with the contact surface of the motor shaft. Utilizing its own electrical conductivity and the contact pressure provided by pressure devices such as springs, it transfers the electrical signal from the motor shaft to the conductive mechanism; the conductive ring transfers the electrical signal from one end to the other through its own electrical conductivity and close contact with the contact surface, ensuring that it is not easily damaged during the long-term use of the motor bearing; the slip ring transfers the electrical signal from the rotating part to the stationary part through the internal conductive channel and the rotating contact surface, ensuring stable contact and electrical conductivity during rotation.

[0066] For example, the conductive brush has the advantages of simple structure, convenient installation, and reliable electrical conductivity; at the same time, by selecting appropriate materials and optimizing the structural design, its electrical conductivity and wear resistance are improved, and the service life is extended; for another example, the conductive ring has the advantages of stable electrical conductivity and high mechanical strength. By selecting appropriate materials and optimizing the structural design, its electrical conductivity and mechanical strength are improved to meet various complex application requirements. In addition, the slip ring has the advantages of stable electrical conductivity and flexible rotation. By selecting appropriate materials and optimizing the structural design, its electrical conductivity and rotational flexibility are improved to meet various rotational conductive application requirements.

[0067] Optionally, in some embodiments, the conductive mechanism 6 is fixed to the conductive bracket 5 by conductive adhesive or bolts 7.

[0068] Specifically, during the curing process of the conductive adhesive, the conductive particles are connected to each other through the bonding action of the resin matrix to form a conductive path; through the frictional force generated by the thread fit between the bolt and the nut, during the tightening process, the threads of the bolt and the nut are engaged with each other to generate sufficient frictional force to firmly connect the conductive mechanism and the conductive bracket together.

[0069] In this embodiment, the conductive adhesive can form a stable conductive path to ensure the electrical connection between the conductive mechanism and the conductive bracket; at the same time, the conductive adhesive has good bonding performance and can firmly adhere the conductive mechanism to the conductive bracket; the curing process of the conductive adhesive is simple and convenient, easy to operate and control. The bolt connection has high connection strength and anti-loosening performance, and can ensure the stable connection between the conductive mechanism and the conductive bracket; the bolt connection is applicable to conductive mechanisms and conductive brackets of various sizes, materials, and shapes; the bolt connection is easy to disassemble and reassemble, facilitating maintenance and replacement.

[0070] Optionally, in some embodiments, the conductive bracket 5 is fixed to the printed circuit board assembly 3 by conductive adhesive or bolts 7.

[0071] Specifically, after curing, the conductive adhesive forms a conductive path through the conductive particles inside it, realizing the electrical connection between the conductive bracket and the printed circuit board assembly; at the same time, the resin matrix of the conductive adhesive has good bonding performance and can firmly adhere the conductive bracket to the printed circuit board assembly. The conductive bracket is firmly fixed on the printed circuit board assembly through the frictional force between the bolt and the hole walls of the printed circuit board assembly and the conductive bracket; at the same time, the nut further enhances the tightness and reliability of the connection through the cooperation between its internal thread and the external thread of the bolt.

[0072] In this embodiment, the conductive adhesive can form a stable conductive path to ensure reliable electrical connection between the conductive bracket and the printed circuit board assembly; the conductive adhesive has good bonding performance and can firmly adhere the conductive bracket to the printed circuit board assembly without easy detachment; the conductive adhesive is applicable to conductive brackets and printed circuit board assemblies of various materials, shapes and sizes.

[0073] Optionally, in some embodiments, the conductive ring or the slip ring is integrated on the rotor and connected to the motor shaft.

[0074] Specifically, the conductive ring or the slip ring is integrated on the rotor and connected through the motor shaft, realizing the electrical connection between the rotating component and the stationary component; during rotation, the conductive ring or the slip ring can maintain stable electrical performance and transmit current or signal from the stationary component to the rotating component, or from the rotating component to the stationary component; for the slip ring, the connected grounded housing is led out through the slip ring to ensure continuous signal or energy transmission during rotation.

[0075] In this embodiment, the conductive ring or the slip ring can maintain stable electrical performance to ensure accurate transmission of current or signal; through the connection of the motor shaft, the rotor can maintain stable rotation and the friction and wear during rotation are small; the conductive ring or the slip ring is integrated on the rotor and can adapt to various complex rotation movements and working environments; the modular design of the conductive ring or the slip ring and the motor shaft makes it easy to disassemble and replace, facilitating the maintenance and repair of the equipment.

[0076] It should also be noted that in the structural design of the special-shaped PCBA (printed circuit board assembly), the conductive bracket in the power-on device is fixed in the printed circuit board assembly through bolts, the bolt holes in the printed circuit board assembly are connected to the conductive circuit, and the conductive mechanism is fixed to the conductive bracket through bolts. The conductive bracket is provided with a conductive brush connecting the motor shaft. In this way, a conductive circuit for guiding the voltage or current on the motor shaft is formed, avoiding the adverse effect of shaft electricity on the motor bearing.

[0077] Optionally, in some embodiments, a sealant is provided between the conductive device and the printed circuit board assembly.

[0078] Please refer to Figure 1and Figure 2 which is an assembly schematic diagram of an angular position sensor provided by this application, further including: a sealant for sealing the printed circuit board assembly within the housing assembly.

[0079] Among them, the sealant is an adhesive used for sealing, fixing, and protecting electronic components and circuits. During the manufacturing process of the angular position sensor, the sealant is used to firmly seal the printed circuit board assembly (including various electronic components and connection wires on the circuit board) inside the housing assembly. It should be noted that the sealant is an epoxy resin adhesive.

[0080] In the above embodiment, through different packaging designs, it can be applicable to oil-cooled / water-cooled electric drive design schemes; at the same time, it can also effectively reduce the cost of driving the electric drive.

[0081] Optionally, in some embodiments, the conductive device is bonded to the printed circuit board assembly.

[0082] Specifically, the bonding between the conductive device and the PCBA is achieved through a conductive adhesive, such as conductive glue, conductive tape, or conductive adhesive. The conductive adhesive has excellent conductive and bonding properties, can firmly bond the conductive device to the PCBA, and form a reliable electrical connection. During the bonding process, the conductive particles in the conductive adhesive are combined together through the bonding action of the matrix resin to form a conductive path, thereby realizing the electrical connection between the conductive device and the PCBA.

[0083] Through the above method, the bonding connection between the conductive device and the PCBA has excellent connection strength and stability, which can ensure that it will not loosen or fall off during long-term use; compared with welding, the bonding connection usually has a lower manufacturing cost, does not require high-temperature heating and complex welding equipment, reduces energy consumption and equipment investment; its excellent conductive properties also improve the electrical performance and stability of the entire circuit board.

[0084] Optionally, in some embodiments, it further includes a housing assembly, and the printed circuit board assembly is assembled within the housing assembly.

[0085] Specifically, the housing assembly protects the PCBA from damage by the external environment, such as dust, moisture, vibration, and shock, etc. By assembling the PCBA within the housing assembly, it ensures that it can still work normally in a harsh working environment. The design of the housing assembly usually takes into account characteristics such as heat dissipation, electromagnetic shielding, and waterproof and dustproof, to ensure the stability and reliability of the PCBA.

[0086] In the above manner, by assembling the PCBA inside a sturdy housing assembly, it can be protected from the external environment, thereby improving the stability and reliability of the device; by setting waterproof and dustproof structures on the housing assembly, such as sealing rings, waterproof coatings, etc., moisture and dust can be effectively prevented from entering the interior of the device, thereby extending the service life of the device; through reasonable design and optimization, the assembly process of the PCBA and the housing assembly is simplified, improving production efficiency and reducing costs.

[0087] Optionally, in some embodiments, the shape of the housing assembly matches the shape of the printed circuit board assembly, and the printed circuit board assembly is fixed in the housing assembly by bolts.

[0088] Among them, the shape of the housing assembly matching the shape of the printed circuit board assembly not only helps to protect the printed circuit board assembly from physical damage, but also ensures the precise alignment and fixation of the components inside the sensor; at the same time, by the matching of shapes, not only is the risk of internal components loosening or being damaged due to vibration or impact reduced, improving the reliability and durability of the sensor, but also the PCBA is stabilized by a thermal riveting process.

[0089] In addition, setting the output port at a closer end not only shortens the signal transmission path, reducing signal attenuation and interference; by connecting at the position of the output port to an external device or system, the wiring cost of the PCBA is also reduced. Among them, the output port of the angular position sensor is a connector, and the connector externally connects the wire harness assembly in a linked form. Using a connector as the output port in the angular position sensor facilitates connection and disconnection with the external wire harness assembly, without the need for soldering or special tools, reducing the difficulty and cost of installation and maintenance.

[0090] In addition, the connector also provides dual protection both electrically and mechanically, preventing signal interruption or device damage caused by poor connection or external force impact. Through the above interface design, it is conducive to wide replication and promotion on the existing product structure.

[0091] Optionally, in some embodiments, the printed circuit board assembly outputs externally using wires or connectors.

[0092] Specifically, the designed circuit diagram is printed through a laser printer or a photosensitive substrate to form a circuit pattern. The printed circuit board is manufactured through processes such as etching, drilling, and copper plating. Electronic components are installed on the circuit board according to the requirements of the circuit diagram, and wires are used to connect the components to each other and the circuit board to external devices. At the edge or designated position of the circuit board, wires are used to output the signals on the circuit board to external devices or interfaces, forming a wire-out interface solution.

[0093] In addition, the use of connectors provides a simple and reliable connection method. In the use of position angle sensors, connectors enable the connection between the sensor and the electronic device to be fast and accurate, without the need for complex soldering or fixing processes; not only does it save installation time, but it also reduces the installation difficulty, allowing non-professionals to perform basic device connections; at the same time, when the device needs to be repaired or components replaced, using connectors can conveniently disconnect the connection, reducing interference to the entire system and improving maintenance efficiency; in addition, the use of connectors can significantly reduce the production cost of electronic devices, as they adopt high-quality materials and advanced manufacturing processes to ensure the stability and reliability of the connection.

[0094] In this embodiment, through precise circuit design and manufacturing processes, the manufacturing accuracy of the circuit board and the reliability of component connections are ensured, reducing the failure rate; when a fault occurs, replacing or repairing a certain module reduces the repair cost and increases the service life.

[0095] Optionally, in some embodiments, the installation position of the vibration sensor on the printed circuit board assembly is close to the bearing.

[0096] Specifically, determine the installation position of the vibration sensor, that is, close to the bearing on the printed circuit board assembly, to ensure that the sensor can accurately capture the vibration signals generated by the rotation of the bearing or gear; when selecting the position, consider the relative position between the sensor and the bearing, as well as the transmission path of the vibration signal, to ensure that the sensor can receive clear vibration signals, and deploy the vibration sensor at the predetermined installation position. For example, fasten it to the printed circuit board assembly, and during the fastening process, apply an appropriate amount of thread locking agent to ensure that the sensor does not loosen during vibration. Another example is that a magnetic base can be used to install the vibration sensor, without the need to drill holes or tighten bolts, and the sensor can be quickly and conveniently deployed at the required position; another example is to use an adhesive to fix the sensor to the printed circuit board assembly, or when selecting the adhesive, consider factors such as its strength, temperature resistance, and corrosion resistance.

[0097] By the above method, the vibration sensor is installed close to the bearing to ensure that the sensor can receive clear vibration signals, thereby improving the measurement accuracy. In this way, the vibration state of the structure can be understood more accurately; by monitoring the vibration state of the bolt and the nearby structure, potential faults and damages can be detected in a timely manner, enhancing the structure monitoring ability and improving the safety and reliability of the equipment; installing the vibration sensor close to the bolt is simpler and more direct, ensuring accurate acquisition of vibration signals.

[0098] Optionally, in some embodiments, when preparing the printed circuit board assembly, the laminate design is changed from the original six-layer board to a four-layer board, thereby reducing the production cost of raw materials. Specifically, in the PCBA manufacturing process, parameters such as line width / line pitch are reduced to achieve the purpose of cost savings.

[0099] In this embodiment, by optimizing the laminate design and the PCBA manufacturing process, the manufacturing cost is further reduced.

[0100] Please refer to Figure 5 , which is a schematic diagram of the printed circuit board assembly in an angular position sensor provided by this application, and is described in detail as follows:

[0101] The design of the special-shaped PCBA structure realizes the integration of the vibration sensor MEMS chip (i.e., the vibration sensor 32) and the conductive mechanism. Through the selection of 8PIN (pins) or more plug-ins, the function assignment of the signal PIN pins is completed. By adding 2 PCS through holes (i.e., the fixed power-on holes 33) to the right fan blade to the solder plate 3, the metal hard connection with the conductive mechanism 6 is realized through the bushings of the bolts 7 and the conductive bracket 5. The conductive mechanism 6 realizes the connection with the shaft voltage circuit through the contact shaft, and realizes the connection with the corresponding GNDPin foot (i.e., the ground signal output terminal 36) through the circuit wiring between the laminates, guides the shaft voltage of the motor shaft to the conductive mechanism, and realizes the ground export through the GNDPin foot to solve the electro-corrosion effect of the shaft electricity on the motor bearing.

[0102] Through the circuit wiring between the left fan blade circuit boards, the connection between the MEMS signal and the corresponding PIN foot (i.e., the vibration signal output terminal 35) is realized. The multi-functional eddy current sensor is composed of a stator component installed on the end cover and a rotor installed on the motor shaft. Since the end cover itself has sufficient rigidity to effectively transmit the vibration signal, in order to enable the MEMS sensor on the circuit board to accurately detect the vibration signal on the end cover, the back of the sensor should be as closely attached to the end cover as possible and as close as possible to the installation position of the bolt. In this way, by measuring the vibration signal of the nearby bearing, the vibration signal of the gearbox of the drive unit equipped with the gearbox can also be monitored. The signal is connected through the circuit board loop and the signal is output to the controller through the corresponding Pin foot for further analysis and monitoring.

[0103] Among them, Figure 5 the control chip 31 in outputs through the angle signal output terminal 34 after determining the angle signal. Optionally, the control chip controls the excitation coil through the excitation circuit to excite a high-frequency oscillating magnetic field of 2 - 5Mhz, and the control chip demodulates the orthogonal high-frequency signal received by the receiving coil through the receiving circuit and outputs a sine-cosine envelope signal.

[0104] Specifically, the control chip is responsible for controlling the excitation circuit to generate a high-frequency oscillating magnetic field and processing the orthogonal high-frequency signals transmitted by the receiving circuit; the control chip integrates a complex digital signal processor or microcontroller and an analog front-end circuit for signal generation, reception, processing, and demodulation.

[0105] For example, under the control of the control chip, the excitation circuit supplies electrical energy to the excitation coil, enabling it to excite a high-frequency oscillating magnetic field of 2 - 5 MHz. When a metal conductor approaches the excitation coil, eddy currents will be generated on its surface, and these eddy currents will in turn change the impedance of the excitation coil or generate an induced voltage. This impedance change is used to detect the position, speed, or other relevant parameters of the metal conductor.

[0106] For example, the receiving circuit is connected to the receiving coil and is used to capture the orthogonal high-frequency signals caused by the induced voltage or impedance change generated by the metal conductor. This orthogonal high-frequency signal is usually very weak and superimposed on the high-frequency oscillating magnetic field. Therefore, processing means such as filtering and amplification are required to extract useful information.

[0107] In this embodiment, in the angular position sensor, in order to obtain higher measurement accuracy and stability, quadrature demodulation technology is used to process the received high-frequency signals. Quadrature demodulation is a method of decomposing high-frequency signals into two orthogonal components (usually sine and cosine components). By processing these two components separately, the noise and interference in the signal can be eliminated, and the signal-to-noise ratio of the signal can be improved. The control chip demodulates the orthogonal high-frequency signals received through the receiving circuit and finally outputs sine and cosine envelope signals. This envelope signal contains information such as the position and speed of the metal conductor and can be further processed or converted into digital signals for display, recording, or control, which will not be elaborated here.

[0108] Please refer to Figure 6 , the flowchart of an angle measurement method provided by this application. Using the above-mentioned angular position sensor, the measurement method includes:

[0109] Step S601, obtaining the amplitude and phase of the output signal of the receiving coil in the angular position sensor;

[0110] Step S602, determining the rotation angle of the rotor according to the amplitude and phase of the signal using a quadrant recognition algorithm, a look-up table method, or a sine-cosine change algorithm.

[0111] Specifically, a magnetic field is generated by the excitation coil in the angular position sensor. When the rotor rotates, it changes the magnetic flux in the receiving coil, thereby generating an induced electromotive force. The receiving coil converts the induced electromotive force into an electrical signal, which contains amplitude and phase information. Demodulation circuits, phase discrimination circuits, or correlation circuits (such as band-pass filter circuits, self-gain amplification circuits, etc.) are used to extract and process these electrical signals to obtain accurate amplitude and phase information. For example, the angular range is divided into multiple quadrants (such as four quadrants), and the quadrant where the rotor is located is determined according to the amplitude and phase information of the output signal of the receiving coil. The rotation angle of the rotor is further calculated based on the signal characteristics within the quadrant. For another example, a series of signal amplitudes and phase information corresponding to a series of angles are pre-calculated and stored.

[0112] In actual measurement, according to the amplitude and phase information of the output signal of the receiving coil, the closest matching item is searched in the stored table to determine the rotation angle of the rotor. For another example, using the properties of sine and cosine functions, the rotation angle of the rotor is calculated based on the amplitude and phase information of the output signal of the receiving coil. Trigonometric conversion formulas and phase difference calculation methods are required to obtain an accurate rotation angle.

[0113] Through the above methods, by accurately obtaining the amplitude and phase information of the output signal of the receiving coil, the accuracy and stability of angle measurement are improved; the approximate position of the rotor can be quickly determined; at the same time, it also has a certain robustness to signal noise and interference; through fast and accurate angle measurement, it is suitable for application scenarios with high real-time requirements; through high-precision angle measurement results, it is suitable for application scenarios with high precision requirements.

[0114] In addition, in order to accurately detect the angular position in a high-speed rotating motor, the magnetic field distribution of the coil is optimized to ensure that the magnetic field can evenly and stably cover the measured area. For example, an annular electromagnetic induction area is adopted. For example, the sine and cosine receiving coils arranged orthogonally at 90° generate high-frequency oscillating induced electromotive forces due to electromagnetic induction, which can improve their ability to receive eddy current signals. By optimizing the structure and materials of the coil, the sensitivity of the sensor is improved, enabling it to more accurately capture the changes in the motor angular position.

[0115] Furthermore, the coil design needs to consider how to reduce the influence of noise interference on the measurement results. For example, electromagnetic interference is reduced by adopting shielding technology or optimizing the circuit layout.

[0116] Please refer to Figure 7 for the structural block diagram of an angle measurement system provided by this application, which includes the above-mentioned angular position sensor 71, motor controller 72, drive device 74, and vehicle controller 73;

[0117] The angle position sensor 71 is used to collect the position signal and vibration signal of the motor;

[0118] The motor controller 72 is used to measure the rotation angle of the motor according to the position signal, generate a control current for the motor in response to the received control instruction and the current rotation angle; and is also used to judge the state of the driving device that drives the motor operation according to the vibration signal;

[0119] The vehicle controller 73 is used to control the motor to enter the limp home state if the state of the driving device 74 is abnormal.

[0120] Among them, when the motor rotates, it senses the magnetic field change and outputs an electrical signal related to the rotation angle. At the same time, it captures the vibration signal of the motor, and the vibration signal is usually associated with the operating state of the motor and the state of the driving device.

[0121] For example, by controlling the switching state of the power electronic device, the driving device can convert direct current into alternating current to drive the motor to operate; at the same time, the driving device also has protection functions such as overcurrent, overvoltage, and overheating to ensure the safe operation of the motor; the vehicle controller monitors the operating state of the system in real time and judges whether there is an abnormal situation according to the preset fault criterion; if an abnormal situation is detected, the vehicle controller will take corresponding protection measures, such as controlling the motor to enter the limp home state and issuing an alarm.

[0122] In the above way, the angle position sensor provides accurate motor position signals and vibration signals, providing inputs for the motor controller and the vehicle controller; the motor controller's precise control and fault detection of the motor improve the operating efficiency and reliability of the electric drive system; by adjusting the control current, the motor controller can achieve precise control of parameters such as the motor speed and torque to meet different application requirements. The motor controller realizes the precise control and fault detection of the motor, improving the operating efficiency and reliability of the electric drive system; the driving device realizes the conversion of electrical energy into mechanical energy, providing the necessary driving force for the motor; the driving device improves the operating efficiency and reliability of the motor; the vehicle controller improves the reliability and safety of the electric drive system through real-time monitoring and fault protection.

[0123] Among them, the angle measurement system or the electric drive system includes a memory, a processor, a communication interface, and a bus. Among them, the memory, the processor, and the communication interface are communicatively connected to each other through the bus.

[0124] The memory can be a read-only memory (ROM), a static storage device, and a random access memory (RAM). The memory can store a program. When the program stored in the memory is executed by the processor, the processor and the communication interface are used to execute the respective steps of the method for sensor detection according to the embodiments of the present application.

[0125] The processor can be a general-purpose central processing unit (CPU), a microprocessor, an application-specific integrated circuit (ASIC), a graphics processing unit (GPU), or one or more integrated circuits, and is used to execute relevant programs to implement the functions required by the units in the device according to the embodiments of the present application, or to execute the method for sensor detection according to the embodiments of the present application.

[0126] The processor can also be an integrated circuit chip with the ability to process signals. In the implementation process, the respective steps of the method for sensor detection according to the embodiments of the present application can be completed by the integrated logic circuit in the hardware of the processor or by instructions in software form.

[0127] The above-mentioned processor can also be a general-purpose processor, a digital signal processor (DSP), an ASIC, a field programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. It can implement or execute the various methods, steps, and logic block diagrams disclosed in the embodiments of the present application. The general-purpose processor can be a microprocessor, or the processor can also be any conventional processor, etc. The steps of the method disclosed in combination with the embodiments of the present application can be directly implemented by the execution of the hardware processor, or can be implemented by the combination of the hardware and software modules in the processor. The software module can be located in a mature storage medium in the art such as a random access memory, a flash memory, a read-only memory, a programmable read-only memory, or an electrically erasable programmable memory, a register, etc. This storage medium is located in the memory. The processor reads the information in the memory and combines its hardware to complete the functions required by the units included in the device for sensor detection according to the embodiments of the present application, or to execute the method for sensor detection according to the embodiments of the present application.

[0128] The communication interface uses a transceiver device such as, but not limited to, a transceiver to implement the communication between the device for sensor detection and other devices or communication networks.

[0129] The bus may include a path for transmitting information between various components of the device detected by the sensor (e.g., memory, processor, communication interface).

[0130] It should be noted that although the above-described device detected by the sensor only shows a memory, a processor, and a communication interface, in the specific implementation process, those skilled in the art should understand that the device detected by the sensor may also include other devices necessary for normal operation. At the same time, according to specific needs, those skilled in the art should understand that the device detected by the sensor also includes hardware devices for implementing other additional functions. In addition, those skilled in the art should understand that the device detected by the sensor may also only include the devices necessary for implementing the embodiments of the present application.

[0131] In some other embodiments, the third aspect of the present application provides an electric drive system, including the above-mentioned angular position sensor; or the above-mentioned angular measurement system, having the following technical effects:

[0132] First, the multifunctional eddy current sensor in the present application integrates the functions of vibration monitoring and shaft electrical conductivity mechanism, improving the overall reliability of the electric drive product.

[0133] Second, without changing the existing interface design, the present application not only reduces costs through the cable routing scheme, but also is more conducive to wide replication and promotion.

[0134] Third, through high integration on the printed circuit board assembly, the present application effectively reduces the cost of driving the electric drive.

[0135] The above embodiments are only illustrative of the principles and effects of the present application, and are not used to limit the present application. Any person familiar with this technology can modify or change the above embodiments without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes completed by those with ordinary knowledge in the technical field without departing from the spirit and technical idea disclosed by the present application should still be covered by the claims of the present application.

Claims

1. An angular position sensor, characterized in that: include: A printed circuit board assembly, and an excitation coil and a receiving coil distributed inside the printed circuit board assembly, wherein the excitation coil and the receiving coil are designed concentrically and the excitation coil is located on one side of the receiving coil, wherein the printed circuit board assembly is integrated with a grounded conductive loop; A rotor is sleeved on the motor shaft and is arranged close to one end surface of the excitation coil and has a gap between the rotor and the excitation coil; A conductive device, comprising at least two conductive parts, one of which is connected to the motor shaft, and the other of which is connected to the conductive loop to derive a shaft current and / or a shaft voltage; The magnetic field formed by the excitation coil varies with the rotation angle of the rotor, and the rotation angle of the rotor is determined according to the amplitude and phase output by the receiving coil.

2. The angular position sensor according to claim 1, characterized in that: Also includes: A vibration sensor is integrated in the printed circuit board assembly and is used to monitor the vibration signal of the bearing sleeved on the motor shaft.

3. The angular position sensor according to claim 2, characterized in that: The conductive device includes a conductive bracket and a conductive mechanism, wherein the conductive bracket is arranged on the printed circuit board assembly and connected to the conductive loop, and the conductive mechanism is fixed on the conductive bracket and electrically connected to the motor shaft, or the conductive mechanism is indirectly electrically connected to the bearing through the motor shaft.

4. The angular position sensor according to claim 3, characterized in that: The conductive part of the conductive mechanism electrically connected to the motor shaft includes any one of a conductive brush, a conductive ring or a slip ring.

5. The angular position sensor according to claim 4, characterized in that: The conductive mechanism is fixed on the conductive bracket by conductive glue or bolts.

6. The angular position sensor according to claim 4, characterized in that: The conductive bracket is fixed on the printed circuit board assembly by conductive glue or bolts.

7. The angular position sensor according to claim 4, characterized in that: The conductive ring or the slip ring is integrated on the rotor and connected to the motor shaft.

8. The angular position sensor according to claim 3, characterized in that: A sealant is arranged between the conductive device and the printed circuit board assembly.

9. The angular position sensor according to claim 1, characterized in that: The conductive device is bonded to the printed circuit board assembly.

10. The angular position sensor according to claim 2, characterized in that: A housing assembly is also included, in which the printed circuit board assembly is mounted.

11. The angular position sensor according to claim 10, characterized in that: The shape of the housing assembly matches the shape of the printed circuit board assembly, and the printed circuit board assembly is fixed in the housing assembly by bolts.

12. The angular position sensor according to claim 10, characterized in that: The printed circuit board assembly is output externally through a wire or a connector.

13. The angular position sensor according to claim 11, characterized in that: The vibration sensor is mounted on the printed circuit board assembly at a location close to the bearing.

14. An angle measurement system, characterized in that: It comprises the angle position sensor, motor controller, drive device and vehicle controller as claimed in any one of claims 1 to 13; The angle position sensor is used to collect the position signal and vibration signal of the motor; The motor controller is used to measure the rotation angle of the motor according to the position signal, generate a control current for the motor in response to a received control instruction and the current rotation angle; and is also used to determine the state of the driving device that drives the motor to operate according to the vibration signal; The vehicle controller is used to control the motor to enter a limp home state if the state of the driving device is abnormal.

15. An angle measurement method, characterized in that: Using the angle position sensor as described in any one of claims 1 to 13, the measurement method includes: obtaining the amplitude and phase of the output signal of the receiving coil in the angle position sensor; and determining the rotation angle of the rotor by a quadrant recognition algorithm, a table lookup method or a sine-cosine variation algorithm based on the amplitude and phase of the signal.

16. An electric drive system, characterized in that: Comprising the angular position sensor as claimed in any one of claims 1 to 13; or, the angle measurement system as claimed in claim 14.

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