Molded bracket for Hall sensor and printed circuit board (PCB) assembly

Abstract

The invention discloses a molded bracket of a Hall sensor and printed circuit board (PCB) assembly. The bracket (100) comprises an upper surface for accommodating a Hall sensor (101) and a printed circuit board (PCB) assembly (102), and a lower surface matched with a stator core (103) of a hub motor through a plurality of buckle structures (104), and a buckle structure (104) arranged on the bracket (100) is fastened on the stator iron core (103) through a screw (105), so that the Hall sensor (101) and the printed circuit board (PCB) assembly (102) are fixed. And the buckle structure (104) is tightly clamped with a corresponding thread groove on the hub motor stator iron core (103).

Description

Molded brackets for Hall sensors and printed circuit board (PCB) assemblies

[0001] The preceding description provides a detailed account of the present invention and its embodiments. Technical Field

[0002] This invention relates to a molded bracket for Hall sensor and printed circuit board (PCB) assembly, and more particularly to a molded bracket for housing a Hall sensor and PCB assembly on a motor stator core. Background Technology

[0003] In hub motors, the PCB (Printed Circuit Board) assembly serves as the integrated controller, housing various electronic components and circuits for controlling and monitoring the motor. These components may include microcontrollers, motor drivers, sensors, and other auxiliary circuits. Hub motors typically incorporate Hall effect sensors to detect the position of the rotor inside the motor. The Hall effect sensor then detects changes in the magnetic field generated by the rotor's permanent magnets, providing feedback on the rotor's position relative to the stator. The Hall effect sensor is usually positioned close to the stator core and facing the rotor magnets to detect changes in the magnetic field generated as the magnets pass by, thus sending a signal back to the motor controller for precise motor control.

[0004] There are various ways to fix the PCB assembly and Hall sensor, such as bracket mounting or using double-sided tape or adhesive pads to attach the PCB assembly to the inner surface of the motor housing. While this traditional method of fixing the PCB assembly and Hall sensor to the stator core of the hub motor has certain advantages, it also has many potential drawbacks. This is because hub motors are subjected to varying degrees of vibration and impact during operation, a problem that is particularly prominent in applications such as electric bicycles and electric vehicles.

[0005] Traditional mounting methods present significant challenges in disassembly and repair of PCB assemblies or Hall sensors, making maintenance and repair operations difficult. Furthermore, some traditional mounting methods require additional steps and components during assembly, such as brackets, screws, and adhesives, increasing production and assembly complexity and potentially raising costs. Similarly, maintenance and replacement of PCB assemblies or Hall sensors often require specialized tools and skills, further complicating the maintenance process. Moreover, traditional mounting methods lack sufficient shock and vibration resistance, making PCB assemblies or Hall sensors prone to loosening and damage over time, ultimately affecting the reliability and detection accuracy of the motor system.

[0006] Patent CN102341677A, entitled "Position Sensor Bracket," relates to a bracket for a motor position sensor. The bracket includes a receiving groove for accommodating the position sensor, an abutment portion, and a fixing portion for mounting on the motor. The device is provided with a biasing mechanism for biasing the abutment portion relative to the fixing portion. The motor also includes a stator, a position sensor, and a sensor bracket. The sensor bracket includes a receiving groove for fixing the position sensor, an abutment portion, and a biasing portion for biasing the abutment portion toward the stator.

[0007] Patent CN218388156U, entitled "PCB Board Support for SMT Printed Circuit Board Placement," relates to a PCB (printed circuit board) fixture suitable for surface mount technology (SMT) printed circuit board placement machines. This fixture includes a motor that drives a sector-shaped gear disk I to rotate. The sector-shaped gear disk I meshes with a sector-shaped gear disk II, which in turn drives a rocker arm to rotate. The rocker arm moves V-shaped clamping plates, and a limiting rod limits the rotation of the V-shaped clamping plates. This structure allows adjustment of the spacing between the V-shaped clamping plates according to the PCB specifications or required installation width, avoiding repeated bracket replacements, improving work efficiency, and increasing the usable area of ​​the PCB.

[0008] Patent number DE102020208113A1, entitled "Circuit Board Support with Cooling Element and System Including the Support and Circuit Board", relates to a printed circuit board support for fixing and mounting a printed circuit board to a base printed circuit board of a vehicle. The support includes an elongated fixing body, which is provided with a fixing clamp for accommodating the contact portion of the printed circuit board, and at least one cooling element is mounted on the elongated fixing body.

[0009] Patent CN206674330, entitled "PCB Board Clamping Component," relates to a PCB board clamping component. This component includes a base plate for placing a PCB board and a clamping component body that cooperates with the base plate. The clamping component body includes a base with an elongated groove. A fixing member is installed within the groove and is fixedly connected to the base plate. The base also has a through hole. A movable member, which can move on the base plate, passes through the through hole. A clamping plate is also connected to the base. The PCB board clamping component described in this application has a simple structure. The clamping plate and base plate cooperate to clamp the PCB board, preventing the PCB board from detaching from the base plate. The movable member moves the clamping component body, enabling the clamping and releasing of the PCB board. The operation is simple and the clamping effect is good.

[0010] Therefore, there is an urgent need for a suitable product that can securely fix the PCB assembly and Hall sensor, while providing additional support and shock absorption to facilitate maintenance and minimize the adverse effects of vibration on its performance. Summary of the Invention

[0011] To overcome the shortcomings of the prior art, the present invention discloses a molded bracket for a Hall sensor and a printed circuit board (PCB) assembly. The bracket includes an upper surface and a lower surface. The upper surface is used to accommodate the Hall sensor and the PCB assembly. The lower surface is adapted to the stator core of a hub motor by means of multiple clips. The clips on the bracket are fastened to the stator core by screws to fix the Hall sensor and the PCB assembly.

[0012] The purpose of this invention is to meet the requirements for additional support and vibration damping, reducing the impact of vibration and shock on PCB components and Hall sensors, thereby ensuring their long-term reliability and detection accuracy. Furthermore, this bracket can assist in the calibration process, ensuring accurate installation and debugging of the Hall sensor, enabling it to continuously provide stable and reliable signals to the motor controller. Simultaneously, the bracket simplifies the assembly process of PCB components and Hall sensors in hub motors, facilitating the positioning and fixation of various components through dedicated accommodating spaces and mounting points. Moreover, during maintenance or replacement work, the bracket allows for rapid disassembly and reassembly of PCB components and Hall sensors, minimizing equipment downtime. Attached Figure Description

[0013] Brief Description of the Drawings The above and other features of the embodiments of the present invention will become clearer when the following detailed description of the embodiments of the present invention is read in conjunction with the accompanying drawings. The same reference numerals in the drawings refer to the same parts.

[0014] Figure 1 is a three-dimensional structural schematic diagram of a molded bracket for a Hall sensor and printed circuit board (PCB) assembly according to an embodiment of the present invention.

[0015] Figure 2 is an exploded view of a molded bracket for a Hall sensor and printed circuit board (PCB) assembly according to an embodiment of the present invention.

[0016] Figure 3 is a schematic diagram of the structure of a molded bracket for a Hall sensor and printed circuit board (PCB) assembly according to an embodiment of the present invention. Detailed Implementation

[0017] The specific embodiments of the invention will be described in detail below. One or more embodiments of the invention are shown in the accompanying drawings. These embodiments are only used to illustrate the technical solutions of the invention and are not intended to limit the scope of protection of the invention. Various changes and modifications that can be readily made by those skilled in the art should be considered to fall within the spirit, scope of protection, and conceptual framework of the invention.

[0018] Figure 1 is a three-dimensional structural schematic diagram of a molded bracket for a Hall sensor and a printed circuit board (PCB) assembly according to an embodiment of the present invention. The bracket (100) includes an upper surface for accommodating the Hall sensor (101) and the printed circuit board (PCB) assembly (102), and a lower surface adapted to the stator core (103) of the hub motor by means of multiple clips (104); the clips (104) provided on the bracket (100) are fastened to the stator core (103) by screws (105), thereby realizing the fixation of the Hall sensor (101) and the printed circuit board (PCB) assembly (102).

[0019] In one embodiment of the present invention, the buckle (104) is tightly engaged with the corresponding threaded groove on the stator core (103) of the hub motor. At the same time, the screw (105) passes through the preset hole on the bracket (100) and is tightened into the corresponding threaded groove of the stator core (103) of the hub motor, so as to securely fix the Hall sensor (101) and the PCB assembly (102) in the preset position.

[0020] In one embodiment of the present invention, the bracket (100) has a cavity, which achieves lightweight design while ensuring the integrity of its own structure, and at the same time ensures that the PCB assembly (102) and the Hall sensor (101) can be firmly installed and effectively protected.

[0021] In one embodiment of the present invention, a stator winding is embedded inside the stator core (103) of the hub motor, which is used to generate the electromagnetic field required for the operation of the motor.

[0022] In one embodiment of the present invention, the Hall sensor (101) is a core component of the hub motor, playing a crucial role in position detection and motor control. Its main function is to detect the position of the rotor magnet during its rotation within the motor. The Hall sensor (101) senses changes in the magnetic field and feeds back signals to the motor controller, enabling precise control of the motor's operating state. The Hall sensor (101) is typically positioned close to the stator core (103) of the hub motor and facing the rotor magnet. This arrangement allows it to accurately detect and monitor changes in the magnetic field during rotor rotation. The Hall sensor (101) operates based on the Hall effect. When a conductor is simultaneously in a perpendicular magnetic field and current environment, a potential difference is generated across the conductor; this physical phenomenon is known as the Hall effect. In the hub motor, the Hall sensor (101) detects changes in the magnetic field caused by the rotating rotor magnet and generates an electrical signal corresponding to the rotor's position.

[0023] The output signal of the Hall sensor (101) is typically a digital signal, generally with three independent output channels: Hall A, Hall B, and Hall C. These three signals are used to transmit the position and direction information of the rotor magnet relative to the stator winding. After the output signal of the Hall sensor (101) is transmitted to the motor controller, the controller will synchronously regulate the current flow of the stator winding based on this information, thereby ensuring the efficient operation of the hub motor and achieving precise control of the motor speed, torque, and direction. To ensure the reliability and accuracy of the Hall sensor (101), its calibration and fixed installation within the hub motor are particularly critical. If the Hall sensor (101) malfunctions or is misaligned, it can easily lead to unstable motor operation, reduced efficiency, or even motor failure. Therefore, meticulous control over its calibration and fixed installation is essential.

[0024] In one embodiment of the present invention, the PCB (printed circuit board) assembly (102) integrates various electronic components and circuits for controlling and monitoring the hub motor, including microcontrollers, motor drivers, sensors and other auxiliary circuits; at the same time, the PCB board also has reserved connectors or soldering points adapted to the wiring of the Hall sensor (101).

[0025] The bracket (100) can securely position the Hall sensor (101) and PCB assembly (102) in the preset position of the hub motor, preventing them from shifting or shaking during motor operation and reducing the risk of component damage. At the same time, the bracket (100) optimizes the use of the internal space of the hub motor. Its structure can be adapted to the specific size and layout of the Hall sensor (101) and PCB assembly (102), making full use of the available space inside the motor without interfering with other components of the motor.

[0026] Figure 2 shows an exploded view of a molded bracket for a Hall sensor and a printed circuit board (PCB) assembly according to an embodiment of the present invention. In one embodiment of the present invention, the molded PCB bracket (100) is a component used to securely fix the Hall sensor (101) and the printed circuit board (PCB) assembly (102). It is made of plastic material, but is not limited thereto. The bracket is designed to provide mechanical support for the Hall sensor (101) and the PCB assembly (102) and ensure their installation stability. The shape and structure of the bracket (100) are specially designed according to the size and shape of the PCB assembly (102). It is provided with slots, hollow structures or snap-fit ​​parts that are adapted to the mounting holes or edges of the PCB board, so that the PCB assembly (102) can be securely embedded and fixed. In addition, the bracket (100) also has a wiring management function. It is provided with a wiring channel or wire clip structure for organizing and fixing the wires connected to the PCB assembly (102) and the Hall sensor (101), which not only achieves the neatness of the wiring, but also reduces the risk of interference or accidental detachment of the lines.

[0027] Meanwhile, the bracket (100) provides a dedicated mounting structure for the Hall sensor (101) and the PCB assembly (102), simplifying the assembly process and eliminating the need for additional brackets or fasteners. Its molded integrated design also provides excellent durability, protecting the components from external mechanical stress and impact.

[0028] Figure 3 is a schematic diagram of a molded bracket for a Hall sensor and a printed circuit board (PCB) assembly according to an embodiment of the present invention. In one embodiment of the present invention, the bracket (100) is provided with multiple buckles (104), which are locking mechanisms used to initially fix the Hall sensor (101) and the PCB assembly (102). The buckles (104) engage with the mating structures on the corresponding components to achieve tight fixation between the two. In addition to the buckles (104), the bracket (100) is also fixed by screws (105) to further improve the stability and firmness of the installation. The buckles (104) on the bracket (100) are fastened to the stator core (103) by screws (105) to form additional reinforcement and protection, so that the Hall sensor (101) and the PCB assembly (102) always maintain a stable installation state.

[0029] The molded bracket (100) of the present invention provides a reliable and efficient solution for fixing and protecting the Hall sensor (101) and PCB assembly (102) in the stator core assembly of the hub motor. It can ensure the installation alignment, stability and structural durability of the two, effectively prevent the Hall sensor (101) and PCB assembly (102) from becoming loose or falling off unexpectedly, thereby improving the overall operating performance of the motor system and extending its service life.

[0030] Reference number

Claims

1. A molded bracket for a Hall sensor and printed circuit board (PCB) assembly, the bracket (100) comprising: The bracket (100) is used to house the Hall sensor (101) and the upper surface of the printed circuit board (PCB) assembly (102), and to assemble the stator core (103) of the hub motor by means of multiple clips (104). The bracket (100) is characterized in that the clips (104) provided on the bracket (100) are fastened to the stator core (103) by one or more screws (105) to fix the Hall sensor (101) and the printed circuit board (PCB) assembly (102).

2. The bracket (100) as described in claim 1, characterized in that, The Hall sensor (101) detects changes in the magnetic field and converts the magnetic field into an electrical signal.

3. The bracket (100) as described in claim 1, characterized in that, The stator core (103) of the hub motor is provided with a stator winding, which is used to generate the electromagnetic field required for the operation of the motor.

4. The bracket (100) as described in claim 1, characterized in that, The buckle (104) engages tightly with the corresponding threaded groove on the stator core (103) of the hub motor.

5. The bracket (100) as described in claim 1, characterized in that, The screw (105) passes through the preset hole on the bracket (100) and is tightened into the corresponding threaded groove on the stator core (103) of the hub motor, thereby fixing the Hall sensor (101) and the PCB assembly (102) in place.

6. The bracket (100) as described in claim 1, wherein the bracket (100) has a cavity to reduce weight while ensuring structural integrity, and at the same time ensures the stable installation and protection of the PCB assembly (102) and the Hall sensor (101).

Images