Sensor rotor for rotating position sensor

Abstract

The invention relates to a sensor rotor for a rotational position sensor. The present invention provides a sensor rotor for a rotational position sensor, comprising: a circular ring portion having an axis of rotation and comprising a first axial side and a second axial side; and a plurality of lug portions, each of which is provided so as to extend radially outward from a radial outer peripheral side of the annular portion, each of which is provided so as to be inclined with respect to the radial direction toward a first axial side of the annular portion, and each of which is configured so as to be elastically deformable in the axial direction and the radial direction.

Description

Sensor rotors for rotary position sensors Technical Field

[0001] The present invention relates to the field of vehicles. More particularly, the present invention relates to a sensor rotor for a rotary position sensor. Background Art

[0002] Rotational position sensors can be used in many fields to measure the angular position of rotating components. In hybrid power modules, rotational position sensors are important components for motor control. The rotational position sensor includes a sensor stator and a sensor rotor. The rotational position sensor can be installed in the hybrid power module. In this case, the sensor rotor of the rotational position sensor needs to be fixed to the motor rotor bracket in the hybrid power module via a retaining ring. To do this, mounting grooves need to be machined on the motor rotor bracket for the sensor rotor and retaining ring, and the sensor rotor and retaining ring need to be installed separately. In addition, a circumferential limiting structure needs to be additionally designed and machined for the sensor rotor. Therefore, the existing sensor rotor processing and assembly processes are complex and costly.

[0003] For this purpose, a sensor rotor for a rotary position sensor is required that can be produced at low cost.

[0004] Summary of the Invention

[0005] One object of the present invention is to provide a sensor rotor for a rotary position sensor that can be manufactured at low cost. Another object of the present invention is to provide a sensor rotor for a rotary position sensor that can simplify the structure. Another object of the present invention is to provide a sensor rotor for a rotary position sensor that can simplify the manufacturing process. Another object of the present invention is to provide a sensor rotor for a rotary position sensor that can be easily assembled.

[0006] One aspect of the present invention provides a sensor rotor for a rotary position sensor, comprising: a circular ring portion having a rotation axis and including a first axial side and a second axial side; and a plurality of lug portions, wherein each lug portion is arranged to extend radially outward from a radially outer peripheral side of the circular ring portion, each lug portion is arranged to be inclined relative to the radial direction toward the first axial side of the circular ring portion, and each lug portion is configured to be able to elastically deform in the axial and radial directions.

[0007] According to an embodiment of the present invention, the plurality of lug portions have the same shape.

[0008] According to an embodiment of the present invention, the plurality of lug portions are arranged to be evenly spaced apart along the circumferential direction.

[0009] According to an embodiment of the present invention, the sensor rotor is integrally formed by a stamping process.

[0010] According to an embodiment of the present invention, the sensor rotor is made of stainless steel or aluminum alloy.

[0011] According to an embodiment of the present invention, the sensor rotor further includes: a plurality of sensing portions, wherein each sensing portion is arranged to extend radially inward from a radially inner circumferential side of the annular portion, and the plurality of sensing portions are arranged to be evenly spaced apart along the circumferential direction.

[0012] Another aspect of the present invention provides a rotational position sensor including: a sensor rotor according to an embodiment of the present invention; and a sensor stator.

[0013] Another aspect of the present invention provides a hybrid module, comprising: a housing; a motor, which is arranged in the housing and includes a motor rotor bracket; and a rotational position sensor, which includes a sensor rotor according to an embodiment of the present invention, wherein the motor rotor bracket includes an annular groove, the opening of the annular groove faces radially inward, wherein the protrusion portion of the sensor rotor is configured to be able to be embedded in the annular groove of the motor rotor bracket through elastic deformation to mount the sensor rotor to the motor rotor bracket.

[0014] According to an embodiment of the present invention, the motor rotor support includes a guide slope disposed adjacent to the annular groove, the guide slope being configured to extend obliquely from the annular groove toward the radially outer side with respect to the axial direction.

[0015] According to an embodiment of the present invention, the rotational position sensor further includes a sensor stator fixed to the housing.

[0016] According to an embodiment of the present invention, the sensor rotor includes a lug that is elastically deformable for mounting the sensor rotor and retaining the sensor rotor in position after installation. Thus, the sensor rotor according to an embodiment of the present invention incorporates the lug, which can function similarly to a retaining ring in existing designs, both for mounting and retaining the sensor rotor. This eliminates the need for a separate retaining ring to be manufactured and installed, simplifying the assembly process. According to an embodiment of the present invention, the multiple lugs of the sensor rotor can have the same shape and be evenly spaced along the circumference, simplifying the manufacturing and assembly process of the sensor rotor. According to an embodiment of the present invention, the sensor rotor can be integrally formed using a stamping process, reducing manufacturing costs. According to an embodiment of the present invention, the sensor rotor can be made of stainless steel or aluminum alloy, further reducing manufacturing costs and allowing the lug to have greater elastic deformation capabilities. According to an embodiment of the present invention, the motor rotor bracket can include an annular groove, which reduces manufacturing difficulty and cost compared to existing designs and improves assembly ease. According to an embodiment of the present invention, the motor rotor bracket can also include a guiding bevel, facilitating sensor rotor installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG1 is a schematic diagram of a hybrid module.

[0018] FIG2 is a partially enlarged schematic diagram of the hybrid power module shown in FIG1 .

[0019] FIG3 is a schematic diagram of a sensor rotor of a rotary position sensor.

[0020] FIG4 is a partial cross-sectional schematic diagram of the sensor rotor shown in FIG3 .

[0021] FIG5 is a schematic diagram of a retaining ring for fixing a sensor rotor.

[0022] FIG. 6 is a schematic diagram of a hybrid module according to an embodiment of the present invention.

[0023] FIG. 7 is a partially enlarged schematic diagram of the hybrid power module shown in FIG. 6 .

[0024] FIG8 is a schematic diagram of a sensor rotor of a rotary position sensor according to an embodiment of the present invention.

[0025] 9 is a partial cross-sectional schematic diagram of a sensor rotor of a rotary position sensor according to an embodiment of the present invention. DETAILED DESCRIPTION

[0026] Hereinafter, embodiments of the present invention are described with reference to the accompanying drawings. The following detailed description and the accompanying drawings are used to illustrate the principles of the present invention by way of example. The present invention is not limited to the preferred embodiments described, and the scope of the present invention is defined by the claims. The present invention will now be described in detail with reference to exemplary embodiments, some of which are illustrated in the accompanying drawings. The following description is made with reference to the accompanying drawings, and unless otherwise indicated, the same reference numerals in different drawings represent the same or similar elements. The schemes described in the following exemplary embodiments do not represent all schemes of the present invention. On the contrary, these schemes are merely examples of systems and methods of various aspects of the present invention involved in the appended claims.

[0027] Figure 1 is a schematic diagram of a hybrid power module. Figure 2 is a partially enlarged schematic diagram of the hybrid power module shown in Figure 1. The hybrid power module includes a motor, which includes a motor stator 1, a motor rotor 2, and a motor rotor bracket 3.

[0028] The hybrid module also includes a rotational position sensor for detecting the angular position of the motor stator 1. The rotational position sensor comprises a sensor stator and a sensor rotor 4. The sensor stator is secured to the hybrid module housing. The sensor rotor 4 is secured to the motor rotor bracket 3 via a retaining ring 5. Figure 3 is a schematic diagram of the sensor rotor of the rotational position sensor. Figure 4 is a partial cross-sectional schematic diagram of the sensor rotor shown in Figure 3. Figure 5 is a schematic diagram of the retaining ring used to secure the sensor rotor.

[0029] During installation, the sensor rotor 4 is first installed into one groove of the motor rotor support 3, and then the retaining ring 5 is installed into the other groove of the motor rotor support 3. This secures the sensor rotor 4 in the axial direction via the retaining ring 5. Furthermore, the sensor rotor 4 includes a recessed portion on its outer circumference, and the motor rotor support 3 includes a corresponding protrusion. After the sensor rotor 4 and retaining ring 5 are successively installed in the motor rotor support 3, the recessed portion of the sensor rotor 4 mates with the protrusion of the motor rotor support 3, thereby securing the sensor rotor 4 in the circumferential direction.

[0030] The motor rotor bracket 3 includes grooves for mounting the sensor rotor 4 and retaining ring 5, respectively. However, due to limited space, machining these grooves in the motor rotor bracket 3 is difficult. Currently, turning is used to machine these grooves in the motor rotor bracket 3, but this process is complex and expensive, with very low feed rates.

[0031] To address the above technical issues, the present invention provides a sensor rotor for a rotational position sensor and a rotational position sensor. The sensor rotor and rotational position sensor according to embodiments of the present invention can be installed in a vehicle, more specifically, in a hybrid vehicle module. Exemplary embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the drawings illustrate only certain embodiments of the present invention, and the scope of the present invention should be determined based on the claims.

[0032] Fig. 6 is a schematic diagram of a hybrid power module according to an embodiment of the present invention. Fig. 7 is a partially enlarged schematic diagram of the hybrid power module shown in Fig. 6 .

[0033] According to an embodiment of the present invention, a hybrid module includes a housing (not shown) and a motor. The motor is disposed and accommodated in the housing.

[0034] As shown in FIG6 , the motor includes a motor stator 11 fixed relative to the housing and a motor rotor 12 rotatable relative to the motor stator 11. The motor rotor 12 is located radially inward of the motor stator 11. The motor also includes a motor rotor support 13. The motor rotor support 13 is used to support the motor rotor 12 of the motor. In an exemplary embodiment, the motor rotor 12 is fixed to the radially outer side of the motor rotor support 13 and is non-rotatably connected to the motor rotor support 13, so that the motor rotor 12 and the motor rotor support 13 can rotate together.

[0035] According to an embodiment of the present invention, the hybrid module further includes a rotational position sensor. The rotational position sensor includes a sensor rotor 20 and a sensor stator (not shown in the figures). As shown in Figures 6 and 7, the sensor rotor 20 is mounted to the motor rotor bracket 13 of the motor so that it can rotate together with the motor rotor bracket 13. The sensor stator is fixed to the housing. When the motor rotor 12 and the motor rotor bracket 13 rotate, the rotational position sensor can be used to detect the rotational position, rotational speed, rotational direction, etc. of the motor rotor 12 through the interaction between the sensor rotor 20 and the sensor stator.

[0036] The sensor rotor of an exemplary embodiment of the present invention will be described below with reference to the accompanying drawings. FIG8 is a schematic diagram of a sensor rotor of a rotational position sensor according to an embodiment of the present invention. FIG9 is a partial cross-sectional schematic diagram of a sensor rotor of a rotational position sensor according to an embodiment of the present invention.

[0037] In an exemplary embodiment, as shown in FIG. 8 , the sensor rotor 20 includes a circular ring portion 21 , a plurality of lug portions 22 , and a plurality of sensing portions 23 .

[0038] The annular portion 21 is annular and has an axis of rotation. The annular portion 21 includes a first axial side A1 and a second axial side A2, as shown in FIG9 . Furthermore, the annular portion 21 has a radially inner circumferential side and a radially outer circumferential side. In some embodiments, the annular portion 21 has a generally Z-shaped axial cross-section, as shown in FIG9 .

[0039] The plurality of lugs 22 of the sensor rotor 20 are used to mount the sensor rotor 20 to the motor rotor bracket 13. The lugs 22 extend radially outward from the radially outer circumferential side of the annular portion 21. In an exemplary embodiment, the lugs 22 of the sensor rotor 20 have the same shape and are evenly spaced along the circumference.

[0040] The lug portion 22 is configured to be elastically deformable in the axial and radial directions. In an exemplary embodiment, as shown in FIG. 9 , the lug portion 22 extends obliquely relative to the radial direction, more specifically, toward the first axial side A1 of the sensor rotor 20 .

[0041] The plurality of sensing portions 23 of the sensor rotor 20 are configured to interact with the sensor stator to detect the relative position of the sensor rotor 20. The sensing portions 23 extend radially inward from the radially inner circumferential side of the annular portion 21. In an exemplary embodiment, the sensing portions 23 of the sensor rotor 20 have the same shape and are evenly spaced along the circumference.

[0042] In an exemplary embodiment, the sensor rotor 20 is integrally formed. The sensor rotor 20 may be made by a stamping process. Preferably, the sensor rotor 20 may be made of stainless steel or aluminum alloy.

[0043] According to an embodiment of the present invention, the motor rotor support 13 includes an annular groove 14 for mounting the sensor rotor 20. The opening of the annular groove 20 faces radially inward. The annular groove 20 can be formed on the motor rotor support 13 by a turning process or the like.

[0044] In an exemplary embodiment, the motor rotor support 13 further includes a guide slope 15, as shown in Figure 7. The guide slope 15 is provided adjacent to the annular groove 14. The guide slope 15 is provided to extend obliquely from the annular groove 14 toward the radial outside relative to the axial direction.

[0045] The following describes the installation process of the sensor rotor 20 according to an embodiment of the present invention with reference to the accompanying drawings. When installing the sensor rotor 20, the lugs 23 of the sensor rotor 20 are brought into contact with the guide ramps 15 of the motor rotor support 13. An axial force is then applied to the sensor rotor 20, causing the lugs 23 of the sensor rotor 20 to interact with the guide ramps 15 of the motor rotor support 13, elastically deforming in the axial and radial directions. Ultimately, the lugs 23 of the sensor rotor 20 are embedded in the annular grooves 14 of the motor rotor support 13. Once the lugs 23 of the sensor rotor 20 are in the annular grooves 14 of the motor rotor support 13, they elastically deform to restore their shape, allowing the sensor rotor 20 to be installed and positioned on the motor rotor support 13.

[0046] Although the present invention has been described with reference to exemplary embodiments, it should be understood that the present invention is not limited to the configurations and methods of the above-described embodiments. On the contrary, the present invention is intended to cover various modifications and equivalent configurations. In addition, although the various elements and method steps of the disclosed invention are shown in various exemplary combinations and configurations, other combinations including more or fewer elements or methods also fall within the scope of the present invention.

[0047] LIST OF REFERENCE NUMERALS 1 Motor stator; 2 Motor rotor; 3 Motor rotor bracket; 4 Sensor rotor; 5 Snap ring; 11 Motor stator; 12 Motor rotor; 13 Motor rotor bracket; 14 Annular groove; 15 Guide slope; 20 Sensor rotor; 21 Ring portion; 22 Lug portion; 23 Sensing portion; A1 First axial side; A2 Second axial side

Claims

1. A sensor rotor (20) for a rotary position sensor, comprising: a circular ring portion (21) having a rotation axis and including a first axial side (A1) and a second axial side (A2); and A plurality of lug portions (22), wherein each lug portion (22) is arranged to extend radially outward from the radial outer peripheral side of the annular portion (21), each lug portion (22) is arranged to be inclined relative to the radial direction toward the first axial side (A1) of the annular portion (21), and each lug portion (22) is configured to be elastically deformable in the axial direction and in the radial direction.

2. The sensor rotor (20) according to claim 1, wherein: The plurality of lug portions (22) have the same shape.

3. The sensor rotor (20) according to claim 1, wherein: The plurality of lug portions (22) are arranged to be evenly spaced and distributed along the circumferential direction.

4. The sensor rotor (20) according to claim 1, wherein: The sensor rotor (20) is integrally formed by a stamping process.

5. The sensor rotor (20) according to claim 1, wherein: The sensor rotor (20) is made of stainless steel or aluminum alloy.

6. The sensor rotor (20) according to any one of claims 1 to 4, further comprising: A plurality of sensing portions (23), wherein each sensing portion (23) is arranged to extend radially inward from the radial inner peripheral side of the annular portion (21), and the plurality of sensing portions (23) are arranged to be evenly spaced and distributed along the circumferential direction.

7. A rotation position sensor comprising: The sensor rotor (20) according to any one of claims 1 to 6; and Sensor stator.

8. A hybrid power module, comprising: case; A motor, which is arranged in the housing and includes a motor rotor support (13); and A rotary position sensor comprising a sensor rotor (20) according to any one of claims 1 to 6, The motor rotor support (13) comprises an annular groove (14), the opening of the annular groove (14) faces radially inwards. The lug portion (22) of the sensor rotor (20) is configured to be embedded in the annular groove (14) of the motor rotor bracket (13) through elastic deformation, so as to mount the sensor rotor (20) on the motor rotor bracket (13).

9. The hybrid power module according to claim 8, wherein: The motor rotor support (13) comprises a guide slope (15) arranged adjacent to the annular groove (14), wherein the guide slope (15) is configured to extend obliquely from the annular groove (14) toward the radial outside relative to the axial direction.

10. The hybrid power module according to claim 8 or 9, wherein: The rotational position sensor also includes a sensor stator fixed to the housing.

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