Preparation method of vehicle-mounted sensor and vehicle-mounted sensor

Abstract

The invention discloses a preparation method of a vehicle-mounted sensor and the vehicle-mounted sensor, and belongs to the technical field of vehicle part preparation. The vehicle-mounted sensor comprises a sensor support and a sensing device, and the preparation method of the vehicle-mounted sensor comprises the steps that molten powder is provided, the molten powder comprises raw material powder and doped powder of the sensor support, and the doped powder is selected from at least one of rare earth element powder and organic metal powder; carrying out one-time forming treatment on the molten powder through a powder bed melting process to obtain a sensor bracket precursor which is provided with an inner cavity with an opening; a sensor device is placed in the inner cavity, a cover body is prepared on the sensor support precursor through a powder bed melting technology and molten powder, the cover body is used for sealing the opening, and the vehicle-mounted sensor is obtained. By doping the rare earth elements in the raw material powder and adopting an integrated preparation mode, the preparation method provided by the invention can effectively improve the reliability and stability of the vehicle-mounted sensor.

Description

Technical Field

[0001] This application relates to the field of automotive parts manufacturing technology, and in particular to a method for manufacturing an automotive sensor and the automotive sensor itself. Background Technology

[0002] With the development of intelligent and electric vehicles, a large number of onboard sensors are integrated into various electronic control systems such as the vehicle's power system, chassis system, body control system, and environmental perception system. Examples include engine temperature and pressure sensors, chassis acceleration and displacement sensors, and vehicle body collision and rain sensors.

[0003] Building upon this foundation, to ensure vehicle safety, stability, and energy economy, higher requirements are placed on the precision, lightweight design, environmental adaptability, and integration of sensor brackets for onboard sensors. In related technologies, the manufacturing processes for sensor brackets typically include two types: stamping, which uses a punch press and molds to process and shape the material; and casting, which involves pouring molten material into a mold and then allowing it to cool and solidify.

[0004] However, among the above methods, the stamping process is difficult to control in terms of precision during the preparation process, while the casting process involves multiple steps such as mold design and mold casting, which requires a long production cycle. Summary of the Invention

[0005] This application provides a method for fabricating an on-board sensor and an on-board sensor itself, to solve the technical problems existing in related technologies. It includes the following technical solutions: In a first aspect, this application provides a method for fabricating an on-board sensor, the on-board sensor including a sensor bracket and a sensor element, the fabrication method comprising: providing molten powder, the molten powder including raw material powder of the sensor bracket and doped powder, the doped powder being selected from at least one of rare earth element powder and organometallic powder; performing a one-time molding process on the molten powder to obtain a sensor bracket precursor, the sensor bracket precursor having an open inner cavity; placing the sensor element in the inner cavity; and fabricating a cover on the sensor bracket precursor using the powder bed melting process and the molten powder, the cover being used to seal the opening, thereby obtaining the on-board sensor.

[0006] In some possible embodiments, the mass ratio of the raw material powder to the doped powder in the molten powder is 99:1-199:1; the raw material powder includes at least one of magnesium-aluminum alloy powder, stainless steel powder, and titanium alloy powder; the rare earth element powder includes at least one of lanthanum powder, cerium powder, yttrium powder, lanthanum oxide powder, and cerium oxide powder; and the organometallic powder includes at least one of zinc stearate powder and magnesium stearate powder.

[0007] In some possible embodiments, when the raw material powder is the magnesium-aluminum alloy powder, the doping powder is the yttrium powder, and the mass ratio of the magnesium-aluminum alloy powder to the yttrium powder is 169:1-199:1; when the raw material powder is the stainless steel powder, the doping powder is the zinc stearate powder, and the mass ratio of the stainless steel powder to the zinc stearate powder is 99:1-129:1; when the raw material powder is the titanium alloy powder, the doping powder is the lanthanum oxide powder, and the mass ratio of the titanium alloy powder to the lanthanum oxide powder is 129:1-169:1.

[0008] In some possible implementations, the particle size of the raw material powder is 20 μm-50 μm.

[0009] In some possible implementations, the temperature of the powder bed in the powder bed melting process is 180°C-200°C.

[0010] In some possible implementations, the thickness of the powder layer formed by the molten powder in the powder bed is 20 μm-40 μm.

[0011] In some possible implementations, before the molten powder is formed in a single step by a powder bed melting process, the preparation method further includes: passivating the molten powder to form an oxide film on the surface of the molten powder.

[0012] In some possible implementations, the thickness of the oxide film is 0.3 μm to 0.7 μm.

[0013] In some possible implementations, the method further includes post-processing the vehicle-mounted sensor by at least one of hot isostatic pressing, surface shot peening, and electrophoretic coating.

[0014] Secondly, this application provides an on-board sensor, which is prepared using any of the preparation methods described in the first aspect of this application.

[0015] Thirdly, this application provides a vehicle equipped with an on-board sensor, which is the on-board sensor described in the second aspect of this application, or an on-board sensor prepared using the preparation method described in the first aspect of this application.

[0016] The beneficial effects of the technical solution provided in this application include at least the following: The technical solution provided in this application utilizes the high-precision preparation characteristics of powder bed melting technology, which can process molten powder at the micron level using a high-precision energy source, thereby improving the accuracy of vehicle-mounted sensors and their adaptability to complex scenarios.

[0017] Furthermore, the vehicle-mounted sensor fabrication method provided in this application has two advantages. Firstly, by adding one or more dopant powders selected from rare earth element powders and organometallic powders to the raw material powder of the vehicle-mounted sensor, the processing performance of the molten powder during processing can be improved. For example, this improves the mechanical properties of the molten powder, enhances the microstructure of the raw material powder, and strengthens the corrosion resistance and oxidation resistance of the molten powder, thereby enhancing the reliability and stability of the vehicle-mounted sensor. Secondly, the vehicle-mounted sensor fabrication method provided in this application employs an integrated fabrication method. After placing the sensor element in the inner cavity of the main body of the sensor bracket, a sealing cap can be directly fabricated in the main body, allowing the sensor bracket and sensor element to be tightly combined and forming a stable specific environment during processing. This avoids performance degradation due to loosening or interference, thereby improving the electrical stability of the vehicle-mounted sensor. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a flowchart of the manufacturing method of the vehicle-mounted sensor provided in the embodiments of this application. Detailed Implementation

[0020] Vehicle-mounted sensors are sensors installed in vehicles to monitor and control various operating parameters of the vehicle, and are an important component of the vehicle's electronic control system. Because vehicles may encounter extreme operating scenarios during operation, such as vibration, impact, and extreme temperatures, vehicle-mounted sensors not only need high detection accuracy but also good environmental adaptability and extremely high reliability to ensure the stability of the vehicle's electronic control system and the safety of vehicle operation.

[0021] In response to the technical problems of poor control precision in the stamping process and long production cycle in the casting process, which fail to meet the requirements of vehicles for on-board sensors, this application provides a method for preparing on-board sensors. This method can not only greatly shorten the production cycle of on-board sensors and reduce production costs and energy consumption by using powder bed melting technology, but also ensure the reliability and stability of on-board sensors through integrated preparation and special design of the molten powder.

[0022] Figure 1 This is a flowchart illustrating the fabrication method of an on-board sensor provided in this application embodiment. The on-board sensor provided in this application embodiment includes a sensor bracket and a sensor component, as shown in the reference diagram. Figure 1 The method for preparing the vehicle-mounted sensor provided in this application includes steps S110-S130.

[0023] Step S110: Provide molten powder, which includes raw material powder for the sensor holder and doped powder, wherein the doped powder is selected from at least one of rare earth element powder and organometallic powder.

[0024] For example, raw material powder, as the main material of automotive sensors, can be used, but is not limited to, determining the basic mechanical properties, weight, corrosion resistance, and cost of automotive sensors. Doped powder can be used, but is not limited to, optimizing for problems such as high temperature, corrosion, and molding defects that may occur during the manufacturing process of automotive sensors without significantly changing the density of the automotive sensors, thereby improving the performance of the automotive sensors.

[0025] Considering the complexity of automotive sensor usage scenarios, to ensure the stability and reliability of automotive sensors under extreme usage conditions, high-strength, high-temperature resistant, vibration-resistant, and corrosion-resistant raw material powders, as well as appropriate doped powders, can be selected. In some embodiments, the raw material powder includes, but is not limited to, at least one of magnesium-aluminum alloy powder, stainless steel powder, and titanium alloy powder; rare earth element powders include at least one of lanthanum powder, cerium powder, yttrium powder, lanthanum oxide powder, and cerium oxide powder; and organometallic powders include at least one of zinc stearate powder and magnesium stearate powder.

[0026] When the mass ratio of doped powder in molten powder is low, it may not be able to effectively optimize potential problems in the fabrication process of vehicle sensors. When the mass ratio of doped powder in molten powder is high, it may increase the fabrication cost of vehicle sensors and significantly change the basic mechanical properties of vehicle sensors, causing the basic mechanical properties of vehicle sensors to deviate from the expected target. In view of this, in order to improve the microstructure of the molten powder, enhance its processing properties such as oxidation resistance and corrosion resistance, and ensure the consistency of material properties in the molten powder, in some embodiments, the mass ratio of raw material powder to doped powder in the molten powder is 99:1-199:1, for example, 99:1, 100:1, 105:1, 110:1, 115:1, 120:1, 125:1, 130:1, 135:1, 140:1, 145:1, 150:1, 155:1, 160:1, 165:1, 170:1, 175:1, 180:1, 185:1, 190:1, 195:1, 199:1, etc., or other values ​​within the above range. This application does not impose any limitations in this regard.

[0027] Furthermore, considering the varying compatibility between different raw material powders and different dopant powders in practical applications, in order to ensure the controllability of the vehicle sensor manufacturing process, in some embodiments, when the raw material powder is magnesium-aluminum alloy powder, the dopant powder is yttrium powder, and the mass ratio of magnesium-aluminum alloy powder to yttrium powder is 169:1-199:1, for example, 170:1, 175:1, 180:1, 185:1, 190:1, 195:1, 199:1, etc.

[0028] In some other embodiments, when the raw material powder is stainless steel powder, the doping powder is zinc stearate powder, and the mass ratio of stainless steel powder to zinc stearate powder is 99:1-129:1, for example, 99:1, 100:1, 105:1, 110:1, 115:1, 120:1, 125:1, etc.

[0029] In some other embodiments, when the raw material powder is titanium alloy powder, the doping powder is lanthanum oxide powder, and the mass ratio of titanium alloy powder to lanthanum oxide powder is 129:1-169:1, for example 130:1, 135:1, 140:1, 145:1, 150:1, 155:1, 160:1, 165:1, etc.

[0030] In some possible implementations, in order to ensure the flowability and bulk density of the raw material powder, the particle size of the raw material powder is 20μm-50μm, such as 20μm, 22μm, 24μm, 26μm, 28μm, 30μm, 32μm, 34μm, 36μm, 38μm, 40μm, 42μm, 44μm, 46μm, 48μm, 50μm, etc., or other values ​​within the above range. This application does not impose any limitations in this regard.

[0031] In some embodiments, to improve the stability of the processing performance of the raw material powder during processing, thereby ensuring the performance of the vehicle-mounted sensor, the method for preparing the vehicle-mounted sensor provided in this application further includes, before performing a one-time molding process on the molten powder using a powder bed melting process, a passivation treatment on the molten powder to form an oxide film on the surface of the molten powder. For example, chemical passivation treatment is used to form a dense oxide film on the surface of the molten powder, enhancing its oxidation resistance and corrosion resistance.

[0032] In some possible embodiments, the thickness of the oxide film is 0.3 μm-0.7 μm, for example, 0.3 μm, 0.32 μm, 0.34 μm, 0.36 μm, 0.38 μm, 0.40 μm, 0.42 μm, 0.44 μm, 0.46 μm, 0.48 μm, 0.50 μm, 0.52 μm, 0.54 μm, 0.56 μm, 0.58 μm, 0.60 μm, 0.62 μm, 0.64 μm, 0.66 μm, 0.68 μm, 0.7 μm, or other values ​​within the above range. This application does not impose any limitations in this regard.

[0033] Step S120: The molten powder is formed in one step by a powder bed melting process to obtain the sensor bracket precursor, which has an inner cavity with an opening.

[0034] Optionally, the sensor bracket for the vehicle-mounted sensor may include, for example, a sensor bracket front body and a cover. The sensor bracket front body can be used, but is not limited to, as the main structure within the sensor bracket for providing fixation, support, and protection. The cover is a portion of the sensor bracket used to seal the inner cavity of the sensor bracket front body, allowing the inner cavity to form a specific, stable space distinct from the external environment. The sensor bracket front body has an open inner cavity, which can be used, but is not limited to, to provide a space for accommodating the sensor component.

[0035] In some embodiments, the sensor bracket front body may further include at least one of the following: mounting holes for fixing the vehicle-mounted sensor; wire channels and / or electrical connection sockets for providing support for the electrical connection of the sensor; and support structures for providing support and ensuring the mechanical strength of the vehicle-mounted sensor.

[0036] For example, the design of sensor brackets needs to be closely integrated with the type, installation location, and operating requirements of the vehicle sensors. For instance, for temperature and pressure sensors in the engine compartment, heat insulation grooves can be designed inside the sensor bracket and filled with high-temperature resistant materials, and a sealed cavity can be provided with rubber sealing rings.

[0037] Optionally, the energy source in the powder bed melting process can be, for example, a laser or an electron beam. The process parameters of the powder bed process, such as the scanning strategy, scanning path, and related parameters of the energy source, can be determined through simulation and actual testing based on the structure and usage requirements of the on-board sensor. For example, the power and speed of the laser can be adjusted according to the thickness of the support wall in the on-board sensor and the structural precision of the on-board sensor. When the thickness of the support wall in the vehicle sensor is small, and / or the structural precision of the vehicle sensor is high, the power of the energy source and the scanning speed can be reduced. A laser with a power of 150W-180W can be used, such as 150W, 155W, 160W, 165W, 170W, 175W, 180W, etc., and / or the laser scanning speed can be adjusted to 800mm / s-1200mm / s, such as 800mm / s, 900mm / s, 1000mm / s, 1100mm / s, 1200mm / s, etc., to ensure the forming accuracy and structural integrity of the vehicle sensor.

[0038] In some embodiments, in order to avoid reducing stress concentration, improve vibration resistance, and further enhance the performance of vehicle-mounted sensors, a regional and variable-direction scanning control strategy can be adopted for the energy source in the powder bed melting process, adjusting the scanning direction and path according to the force and function of different parts of the support.

[0039] To ensure the quality of the vehicle-mounted sensors, an infrared thermal imager or other type of temperature sensor can be used to monitor the temperature field of the powder bed during the powder bed melting process, controlling the powder bed temperature within a reasonable range. Simultaneously, a high-speed camera or other imaging device can be used to observe the dynamics of the molten pool, adjusting parameters promptly in case of anomalies to ensure the stability of the preparation process. In some possible implementations, the temperature of the powder bed temperature field in the powder bed melting process is 180℃-200℃, for example, 180℃, 182℃, 184℃, 186℃, 188℃, 190℃, 192℃, 194℃, 196℃, 198℃, 200℃, or other values ​​within the aforementioned range. This application makes no limitations in this regard.

[0040] In some possible implementations, in order to ensure the consistency and uniformity of the properties of the molten powder, the thickness of the powder layer formed by the molten powder in the powder bed is 20μm-40μm, for example, 20μm, 22μm, 24μm, 26μm, 28μm, 30μm, 32μm, 34μm, 36μm, 38μm, 40μm, or other values ​​within the above range. This application does not impose any limitations in this regard.

[0041] In step S130, the sensor is placed in the inner cavity, and a cover is prepared on the front of the sensor bracket by powder bed melting process and molten powder to obtain the vehicle sensor. The cover is used to seal the opening.

[0042] Considering that vehicle-mounted sensors may encounter extreme environments such as vibration, impact, and high / low temperatures during use, integrated fabrication can be used to tightly combine the sensor bracket and sensor element, forming a specific stable space distinct from the external environment to ensure the electrical stability of the sensor element. Therefore, the vehicle-mounted sensor fabrication method provided in this application adopts a staged fabrication approach. First, a sensor bracket precursor is fabricated. After the sensor element is embedded in the inner cavity of the sensor bracket precursor, a sealing cap is directly fabricated on the sensor bracket precursor to complete the remaining fabrication, achieving a robust physical and reliable electrical connection and enhancing vibration and impact resistance.

[0043] In some embodiments, to further improve the performance of the vehicle-mounted sensor, the manufacturing method of the vehicle-mounted sensor provided in this application further includes: post-processing the vehicle-mounted sensor by at least one of hot isostatic pressing, surface shot peening, and electrophoretic coating. The hot isostatic pressing process can be used, but is not limited to, to eliminate pores and defects inside the vehicle-mounted sensor, improving density and mechanical properties; the surface shot peening process can be used, but is not limited to, to create a residual compressive stress layer on the surface of the vehicle-mounted sensor by performing surface shot peening treatment, thereby improving fatigue resistance and vibration resistance; the electrophoretic coating process can be used, but is not limited to, to electrophoretically coat easily corroded parts of the vehicle-mounted sensor, forming a paint film on the surface of the easily corroded parts, thereby enhancing the corrosion resistance of the vehicle-mounted sensor.

[0044] Optionally, the integration of the sensor element and the sensor bracket can be a magnetic integration structure, with magnetic components set on both the sensor bracket and the sensor element, using magnetic force to achieve quick installation and removal of the sensor element; or, the integration of the sensor element and the sensor bracket can be a snap-on slot-type glue-free connection method, using a specially designed snap-on and slot structure to achieve a tight connection between the sensor element and the sensor bracket, thereby improving the convenience of later sensor element maintenance and replacement.

[0045] In some embodiments, when post-processing the vehicle-mounted sensor using hot isostatic pressing (HIP), the HIP temperature is 400℃-500℃, for example, 400℃, 410℃, 420℃, 430℃, 440℃, 450℃, 460℃, 470℃, 480℃, 490℃, 500℃, etc.; the HIP pressure is 100MPa-200MPa, for example, 100 MPa, 110 MPa, 120 MPa, 130 MPa, 140 MPa, 150 MPa, 160 MPa, 170 MPa, 180 MPa, 190 MPa, 200 MPa, etc.; the HIP processing time is 1.8h-2.2h, for example, 1.8h, 1.9h, 2h, 2.1h, 2.2h, etc., or other values ​​within the above ranges. This application does not impose any limitations in this regard.

[0046] In some embodiments, when post-processing the vehicle sensor using an electrophoretic coating process, the thickness of the paint film formed on the vehicle sensor is 20μm-30μm, for example, 20μm, 21μm, 22μm, 23μm, 24μm, 25μm, 26μm, 27μm, 28μm, 29μm, 30μm, or other values ​​within the above range.

[0047] In some embodiments, when post-processing the vehicle-mounted sensor by surface shot peening, the shot particle size is 0.28 mm - 0.32 mm, for example, 0.28 mm, 0.29 mm, 0.30 mm, 0.31 mm, or 0.32 mm; the shot peening velocity is 45 m / s - 55 m / s, for example, 45 m / s, 46 m / s, 47 m / s, 48 ​​m / s, 49 m / s, 50 m / s, 51 m / s, 52 m / s, 53 m / s, 54 m / s, or 55 m / s, or other values ​​within the above range.

[0048] The technical solution provided in this application utilizes the high-precision preparation characteristics of powder bed melting technology, which can process molten powder at the micron level using a high-precision energy source, thereby improving the accuracy of vehicle-mounted sensors and their adaptability to complex scenarios.

[0049] Furthermore, the vehicle-mounted sensor fabrication method provided in this application has two advantages. Firstly, by adding one or more dopant powders selected from rare earth element powders and organometallic powders to the raw material powder of the vehicle-mounted sensor, the processing performance of the molten powder during processing can be improved. For example, this improves the mechanical properties of the molten powder, enhances the microstructure of the raw material powder, and strengthens the corrosion resistance and oxidation resistance of the molten powder, thereby enhancing the reliability and stability of the vehicle-mounted sensor. Secondly, the vehicle-mounted sensor fabrication method provided in this application employs an integrated fabrication method. After placing the sensor element in the inner cavity of the main body of the sensor bracket, a sealing cap can be directly fabricated in the main body, allowing the sensor bracket and sensor element to be tightly combined and forming a stable specific environment during processing. This avoids performance degradation due to loosening or interference, thereby improving the electrical stability of the vehicle-mounted sensor.

[0050] In another possible implementation, this application also provides an on-board sensor. The on-board sensor is fabricated using the aforementioned method. By adding one or more dopant powders selected from rare earth element powders and organometallic powders to the raw material powder of the on-board sensor, the corrosion resistance and oxidation resistance of the molten powder are enhanced, thereby improving the reliability and stability of the on-board sensor. Furthermore, the on-board sensor provided in this application employs an integrated fabrication method, which is beneficial for improving the electrical stability of the on-board sensor.

[0051] In another possible implementation, this application also provides a vehicle equipped with an on-board sensor manufactured using the aforementioned on-board sensor or the aforementioned manufacturing method. The on-board sensor employs an integrated manufacturing method, which can create a stable specific environment during processing, avoiding performance degradation due to loosening or interference. This makes it suitable for various extreme operating environments during vehicle operation, helping to ensure data reliability requirements during vehicle operation and thus improving vehicle safety.

[0052] Exemplary embodiments of the present invention will now be described in more detail. While exemplary embodiments of the present invention are described below, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Where specific techniques or conditions are not specified in the embodiments, they are performed in accordance with techniques or conditions described in the literature in the art or according to product instructions. Reagents or instruments used, unless otherwise specified, are all commercially available conventional products.

[0053] Example 1 The molten powder used in Example 1 has a particle size of 30 μm. The molten powder is formed by ball milling and mixing magnesium-aluminum alloy powder and yttrium powder. The mass ratio of magnesium-aluminum alloy powder to yttrium element powder in the molten powder is 199:1.

[0054] Step 1: Immerse the molten powder in chromate for 10 minutes to form a 0.5 μm oxide film on the surface of the molten powder.

[0055] Step 2: A molten powder layer with a thickness of 25μm is formed in a powder bed. A 1064nm fiber laser is used, with the laser power adjusted to 160W. The scanning speed of the laser in the low-temperature region of the powder bed is adjusted to 1000mm / s, and the scanning speed in the high-temperature region is adjusted to 800mm / s. The molten powder is then subjected to a one-time molding process to obtain the sensor support precursor. During the one-time molding process, an infrared thermal imager is used to monitor the temperature of the powder bed, ensuring that the temperature in the low-temperature region is 200°C and the temperature in the high-temperature region is 250°C. A high-speed camera is used to monitor the powder bed, and the laser power is reduced to 150W in case of abnormalities. The top of the sensor precursor has a groove-shaped inner cavity with a depth of 4mm. The opening diameter of the inner cavity is 0.08mm larger than the maximum diameter of the sensor element. Four pressure transmission holes with a diameter of 0.15mm are opened at the bottom of the groove. A wire channel with a diameter of 0.4mm is provided inside the groove to the waterproof socket on the side of the sensor precursor.

[0056] Step 3: Place the sensor component in the inner cavity of the sensor front body, and prepare the cover body on the sensor bracket front body through the powder bed melting process in Step 3 and the molten powder to obtain the vehicle sensor.

[0057] Step 4: Set the temperature of hot isostatic pressing (HIP) to 450°C and the pressure to 150MPa for 2 hours. Then, use stainless steel shot peening with a diameter of 0.3mm at a speed of 50m / s to perform surface shot peening on the HIP-treated vehicle sensor. Finally, form a 25μm thick paint film on the surface of the shot-peened vehicle sensor using an electrophoretic coating process.

[0058] Example 2 The molten powder used in Example 2 has a particle size of 30 μm. The molten powder is formed by mechanically mixing stainless steel powder and zinc stearate powder, and the mass ratio of stainless steel powder to zinc stearate powder in the molten powder is 99:1.

[0059] Step 1: A 30μm thick molten powder layer is formed in a powder bed. A 1064nm fiber laser is used, with the laser power adjusted to 170W and the laser scanning speed adjusted to 1100mm / s. Rotation scanning is performed, rotating each layer of molten powder by 45°. The molten powder is then subjected to a one-time molding process to obtain the sensor support precursor. During the one-time molding process, temperature and humidity sensors are used to monitor the temperature and humidity of the powder bed, ensuring the temperature is 250±2°C and the humidity is 40%-60%. A high-speed camera is used to monitor the powder bed, reducing the laser power to 150W in case of abnormalities. The top of the sensor precursor has a 4mm deep groove-shaped cavity, the opening diameter of which is 0.08mm larger than the maximum diameter of the sensor element. Mounting holes are provided at the bottom of the groove, and electrical interfaces and wire channels are provided on the sides of the groove.

[0060] Step 2: Install a rubber buffer layer at the point where the inner wall of the groove is not connected to the outside. The thickness of the rubber buffer layer is [missing information].

[0061] Step 3: Place the sensor component in the inner cavity of the sensor front body, and prepare the cover body on the sensor bracket front body through the powder bed melting process in Step 1 and the molten powder, so as to obtain the vehicle sensor.

[0062] Step 4: Set the temperature of hot isostatic pressing (HIP) to 450°C and the pressure to 150MPa for 2 hours. Then, use stainless steel shot peening with a diameter of 0.3mm at a speed of 50m / s to perform surface shot peening on the HIP-treated vehicle sensor. Finally, form a 25μm thick paint film on the surface of the shot-peened vehicle sensor using an electrophoretic coating process.

[0063] In the embodiments of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The term "multiple" refers to two or more unless otherwise expressly defined.

[0064] The above description is only for the purpose of enabling those skilled in the art to understand the technical solution of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the principles of this application should be included within the scope of protection of this application.

Claims

1. A method for manufacturing an on-board sensor, characterized in that, The vehicle-mounted sensor includes a sensor bracket and a sensor component, and the manufacturing method includes: A molten powder is provided, the molten powder comprising the raw material powder and doping powder of the sensor holder, wherein the doping powder is selected from at least one of rare earth element powder and organometallic powder; The molten powder is subjected to a one-time molding process using a powder bed melting process to obtain a sensor bracket precursor, which has an inner cavity with an opening. The sensor is placed in the inner cavity, and a cover is prepared on the front of the sensor bracket by the powder bed melting process and the molten powder to obtain the vehicle sensor. The cover is used to seal the opening.

2. The preparation method according to claim 1, characterized in that, The mass ratio of the raw material powder to the doped powder in the molten powder is 99:1-199:1; The raw material powder includes at least one of magnesium-aluminum alloy powder, stainless steel powder, and titanium alloy powder. The rare earth element powder includes at least one of lanthanum powder, cerium powder, yttrium powder, lanthanum oxide powder, and cerium oxide powder, and the organometallic powder includes at least one of zinc stearate powder and magnesium stearate powder.

3. The preparation method according to claim 2, characterized in that, When the raw material powder is the magnesium-aluminum alloy powder, the doping powder is the yttrium powder, and the mass ratio of the magnesium-aluminum alloy powder to the yttrium powder is 169:1-199:1; When the raw material powder is the stainless steel powder, the doped powder is the zinc stearate powder, and the mass ratio of the stainless steel powder to the zinc stearate powder is 99:1-129:1; When the raw material powder is the titanium alloy powder, the doping powder is the lanthanum oxide powder, and the mass ratio of the titanium alloy powder to the lanthanum oxide powder is 129:1-169:

1.

4. The preparation method according to claim 1, characterized in that, The particle size of the raw material powder is 20μm-50μm.

5. The preparation method according to claim 1, characterized in that, The temperature of the powder bed in the powder bed melting process is 180℃-200℃.

6. The preparation method according to claim 1, characterized in that, The thickness of the powder layer formed by the molten powder in the powder bed is 20μm-40μm.

7. The preparation method according to any one of claims 1-6, characterized in that, Before performing a one-time molding process on the molten powder using a powder bed melting process, the preparation method further includes: The molten powder is passivated to form an oxide film on its surface.

8. The method according to claim 7, characterized in that, The thickness of the oxide film is 0.3 μm-0.7 μm.

9. The preparation method according to any one of claims 1-6, characterized in that, The method further includes: The vehicle-mounted sensor is post-processed using at least one of the following processes: hot isostatic pressing, surface shot peening, and electrophoretic coating.

10. A vehicle-mounted sensor, characterized in that, The vehicle-mounted sensor is prepared using the preparation method described in any one of claims 1-9.

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