Three-in-one sensor for throttle valve

Abstract

According to the three-in-one sensor for the throttle valve provided by the utility model, the upper cover and the shell assembly are realized by adopting a plastic laser welding process, particulate matters are not generated in the welding process, harmful vibration is avoided, and damage to internal elements is avoided; the pressure sensor chip and the shell assembly are sealed through the sealing gasket, a dispensing mode is replaced, and poor sealing caused by incomplete curing or bubbles in the curing process of glue is avoided; the PCBA circuit board assembly is coated with three-proofing lacquer to protect a circuit board and related equipment from being corroded by the environment, the electric brush is formed by welding a platinum-palladium alloy wire brush and beryllium bronze through ultrasonic waves, and compared with a traditional scrubbing brush, the electric brush is small in noise, balanced in pressure, resistant to vibration, long in service life, small in abrasion to a resistive film and good in reliability; the rotor is provided with an inverted buckling structure, the rotor is prevented from being ejected out in the process that the three-in-one sensor is installed on the valve body, and meanwhile, the upper cover is provided with a profiling structure, so that inaccurate product position signal output caused by deviation of the rotor in the rotating process is avoided.

Description

Technical Field

[0001] The utility model belongs to the technical field of sensors, and in particular relates to a three-in-one sensor for a throttle valve. Background Art

[0002] The three-in-one sensor on the motorcycle throttle body integrates the throttle position sensor, intake pressure sensor, and intake temperature sensor into one. The motorcycle engine is small in size, and the three-in-one sensor is easy to install and use.

[0003] The throttle position sensor obtains the different position openings of the throttle through the different resistance values ​​or voltage values ​​of the variable resistor diaphragm in the body. Since the brush fixed on the rotor rotates with the throttle shaft, it needs to rub against the resistor diaphragm frequently. If the structural design and material selection are unreasonable, the product will be easily damaged after a period of use, and the measurement value will be inaccurate. The intake pressure sensor is similar to the air flow sensor. It can measure the change of absolute pressure (vacuum degree) in the intake manifold according to the load of the engine, and convert it into a voltage signal, which is transmitted to the electronic control unit together with the speed signal. However, the intake pressure sensor needs to be in a good airtight condition to work better and measure more accurate values. The three-in-one sensor currently on the market has poor airtightness and is easily damaged, resulting in inaccurate data measurement, which is not conducive to use. Utility Model Content

[0004] The utility model provides a three-in-one sensor for a throttle valve, aiming to solve the problems raised by the background technology.

[0005] The utility model is implemented as follows: a three-in-one sensor for a throttle valve comprises an upper cover and a housing assembly;

[0006] The upper cover and the outer shell assembly are connected by a plastic laser welding process;

[0007] A PCBA circuit board assembly and a rotor are arranged inside the shell assembly. The PCBA circuit board assembly is sprayed with three-proof paint. The PCBA circuit board assembly integrates a pressure sensor chip, a temperature sensor chip, a position sensor chip and a protection circuit. The pressure sensor chip and the shell assembly are sealed by a sealing gasket. An undercut structure is arranged on the rotor. A brush is fixed on the rotor by a positioning column pulse hot riveting process. The brush is made of a platinum-palladium alloy wire brush and beryllium bronze ultrasonically welded. A resistor diaphragm is arranged on the outside of the rotor. The resistor diaphragm contacts the pin inside the shell assembly through a spring sheet, thereby fixing the resistor diaphragm and conducting electrical signals.

[0008] Preferably, the temperature sensor chip is connected to a thermistor.

[0009] Preferably, the brush is a follow-wire brush.

[0010] Preferably, the rotor cooperates with the throttle flat shaft and is provided with guide ribs for controlling the matching clearance between the throttle flat shaft and the rotor to ensure a stable output signal.

[0011] Preferably, a contoured structure is provided on the upper cover to prevent the rotor from deviating during rotation, thereby preventing inaccurate output of product position signals.

[0012] Preferably, a special-shaped sealing ring is provided on the housing assembly.

[0013] Compared with the prior art, the beneficial effects of the utility model are:

[0014] 1. The upper cover and the outer shell assembly are realized by plastic laser welding process, which replaces the traditional ultrasonic welding and potting glue process. Laser welding uses a precise infrared laser beam, which is transmitted through the back cover transmission material and then absorbed by the shell material surface of the outer shell assembly. The two materials are in close contact. When the laser energy is absorbed, the connection between them heats up and melts, and finally forms a chemical connection. Laser welding is a non-friction heating method. The welding process does not produce particulate matter and no harmful vibration, avoiding damage to internal components;

[0015] 2. The pressure sensor chip and the housing assembly are sealed with a sealing gasket to replace the dispensing method to avoid incomplete curing of the glue or the presence of bubbles during the curing process, resulting in poor sealing. The sealing gasket needs to ensure a certain amount of compression. It uses hot riveting columns and pulse heating technology for fixation, and the pressure and stroke are controllable;

[0016] 3. The PCBA circuit board assembly is coated with conformal coating to protect the circuit board and related equipment from environmental corrosion. The brush (11 wires) is made of platinum-palladium alloy wire brush and high-elastic beryllium bronze by ultrasonic welding. The service life is ≥20 million times. The contact method is R0.13 arc contact point. Compared with the traditional plate brush (3 wires), it has low noise, balanced pressure, vibration resistance, long service life, less wear on the resistor film, and good reliability.

[0017] 4. The rotor is designed with an undercut structure to prevent the rotor from being pushed out during the installation of the three-in-one sensor on the valve body. At the same time, a contoured structure is provided on the upper cover to prevent the rotor from offset during rotation, which would cause inaccurate output of the product position signal. The rotor and the brush are fixed by a pulse hot riveting process with a positioning column. The pressure and stroke are controllable to ensure the contact force between the brush and the resistor diaphragm. The rotor cooperates with the throttle flat shaft and is designed with guide ribs to effectively control the matching clearance between the throttle flat shaft and the rotor to ensure stable output signals. The resistor diaphragm contacts the pin inside the housing assembly through a V-shaped stainless steel spring to simultaneously realize the functions of fixing the resistor diaphragm and conducting electrical signals. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is an exploded view of the overall structure of the utility model;

[0019] Figure 2 It is a three-dimensional diagram of the overall structure of the utility model;

[0020] Figure 3 It is a side view of the overall structure of the utility model;

[0021] Figure 4 It is a bottom view of the overall structure of the utility model;

[0022] Figure 5 This is a schematic diagram of the structure of the housing assembly and the PCBA circuit board assembly in the utility model;

[0023] Figure 6 It is a schematic diagram of the internal structure of the housing assembly in the utility model.

[0024] In the figure:

[0025] 1. Upper cover; 2. PCBA circuit board assembly; 3. Sealing gasket; 4. Rotor; 5. Brush; 6. Shrapnel; 7. Resistor diaphragm; 8. Housing assembly; 9. Thermistor; 10. Special-shaped sealing ring. DETAILED DESCRIPTION

[0026] The technical solution of the present utility model will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present utility model, rather than all of the embodiments.

[0027] The components of the embodiments of the present invention generally described and shown in the drawings herein can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention.

[0028] Based on the embodiments of the present utility model, all other embodiments obtained by ordinary technicians in the field without making any creative work shall fall within the scope of protection of the present utility model.

[0029] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0030] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installation", "connection" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0031] See also Figures 1 to 6 The utility model provides a technical solution: a three-in-one sensor for a throttle valve, comprising an upper cover 1 and a shell assembly 8; the upper cover 1 and the shell assembly 8 are connected by a plastic laser welding process; a PCBA circuit board assembly 2 and a rotor 4 are arranged inside the shell assembly 8, the PCBA circuit board assembly 2 is sprayed with a three-proof paint, the PCBA circuit board assembly 2 integrates a pressure sensor chip, a temperature sensor chip, a position sensor chip and a protection circuit, the pressure sensor chip and the shell assembly 8 are sealed by a sealing gasket 3, an undercut structure is arranged on the rotor 4, a brush 5 is fixedly arranged on the rotor 4 by a positioning column pulse hot riveting process, the brush 5 is made of a platinum-palladium alloy wire brush and beryllium bronze ultrasonically welded, a resistor diaphragm 7 is arranged on the outside of the rotor 4, the resistor diaphragm 7 is in contact with the pin inside the shell assembly 8 through a spring 6, and the resistor diaphragm 7 and the electrical signal conduction function are realized.

[0032] In this embodiment, the upper cover 1 and the housing assembly 8 are realized by a plastic laser welding process, which replaces the traditional ultrasonic welding and potting glue process. Laser welding uses a precise infrared laser beam, which is transmitted through the rear cover transmission material and then absorbed by the shell material surface of the housing assembly 8. The two materials are in close contact. When the laser energy is absorbed, the connection between them heats up and melts, and finally forms a chemical connection. Laser welding is a non-friction heating method. The welding process does not generate particulate matter and no harmful vibration, thereby avoiding damage to internal components.

[0033] The pressure sensor chip and the housing assembly 8 are sealed by a sealing gasket 3, which replaces the dispensing method to avoid incomplete curing of the glue or the presence of bubbles during the curing process, resulting in poor sealing. The sealing gasket 3 needs to ensure a certain amount of compression. It uses a hot riveting column and is fixed with a pulse heating process. The pressure and stroke are controllable. The sealing gasket 3 is a special-shaped design to seal the pressure sensor chamber;

[0034] The PCBA circuit board assembly 2 is coated with conformal coating to protect the circuit board and related equipment from environmental corrosion;

[0035] Brush 5 (11 wires) is made of platinum-palladium alloy wire brush and high-elastic beryllium bronze by ultrasonic welding, with a service life of ≥20 million times, and a contact method of R0.13 arc contact point. Compared with the traditional plate brush (3 wires), it has low noise, balanced pressure, vibration resistance, long service life, less wear on the resistor film, and good reliability;

[0036] The rotor 4 is designed with an undercut structure to prevent the three-in-one sensor from being pushed out during installation on the valve body. At the same time, a contoured structure is provided on the upper cover 1 to prevent the rotor 4 from being offset during rotation, resulting in inaccurate output of the product position signal. The rotor 4 and the brush 5 are fixed by a pulse hot riveting process of a positioning column. The pressure and stroke are controllable to ensure the contact force between the brush 5 and the resistor diaphragm 7. The rotor 4 cooperates with the throttle flat shaft and is designed with a guide rib position, which can effectively control the matching clearance between the throttle flat shaft and the rotor 4 to ensure the stability of the output signal.

[0037] The resistor diaphragm 7 contacts the pin inside the housing assembly 8 through the V-shaped stainless steel spring 6, and simultaneously realizes the functions of fixing the resistor diaphragm 7 and conducting the electrical signal. The spring 6 is provided with a convex point design, which can effectively ensure the transmission of the angle signal. The housing assembly 8 is combined with other devices to realize the basic functions of the sensor.

[0038] Furthermore, the temperature sensor chip is connected to the thermistor 9 .

[0039] In this embodiment, the temperature sensor chip is connected to the thermistor 9 for measuring temperature changes.

[0040] For further information, see Figure 1 , brush 5 is an 11-wire brush.

[0041] In this embodiment, the brush 5 (11 wires) is made of a platinum-palladium alloy wire brush and a high-elastic beryllium bronze by ultrasonic welding, with a service life of ≥20 million times and a contact method of an R0.13 arc contact point. Compared with the traditional plate brush (3 wires), it has low noise, balanced pressure, vibration resistance, long service life, low wear on the resistor film, and good reliability.

[0042] Furthermore, the rotor 4 cooperates with the throttle flat shaft and is provided with guide ribs for controlling the matching clearance between the throttle flat shaft and the rotor 4 to ensure the stability of the output signal.

[0043] In this embodiment, the rotor 4 and the brush 5 are fixed by a positioning column pulse hot riveting process, and the pressure and stroke are controllable to ensure the contact force between the brush 5 and the resistor diaphragm 7. The rotor 4 cooperates with the throttle flat shaft and is designed with guide ribs to effectively control the fitting clearance between the throttle flat shaft and the rotor 4 to ensure the stability of the output signal.

[0044] Furthermore, a contoured structure is provided on the upper cover 1 to prevent the rotor 4 from being offset during rotation, which would result in inaccurate output of the product position signal.

[0045] In this embodiment, the rotor 4 is designed with an undercut structure to prevent the rotor 4 from being pushed out when the three-in-one sensor is installed on the valve body. At the same time, a contoured structure is provided on the upper cover 1 to prevent the rotor 4 from offset during rotation, resulting in inaccurate output of the product position signal.

[0046] For further information, see Figure 1 A special-shaped sealing ring 10 is provided on the housing assembly 8.

[0047] In this embodiment, the housing assembly 8 is sealed by a special-shaped sealing ring 10 to ensure the sealing performance with the external throttle valve body.

[0048] The working principle and use process of the utility model: the three-in-one sensor integrates three sensors, namely, the throttle position sensor, the intake pressure sensor and the intake temperature sensor, into one. The product structure is divided into an upper cover 1, a PCBA circuit board assembly 2, a sealing gasket 3, a brush 5, a rotor 4, a spring 6, a resistor diaphragm 7, a shell assembly 8, an NTC thermistor 9 and a special-shaped sealing ring 10. The upper cover 1 is made of a light-transmitting material and is laser welded with the shell assembly 8 to ensure the protection of the product assembly. The PCBA circuit board assembly 2 integrates a pressure chip and a thermistor 9, which are fixed to the shell assembly 8 through a pulse hot riveting process. The sealing gasket 3 is a special-shaped design to play a role in the pressure sensor chamber. To achieve sealing effect, the brush 5 and the rotor 4 are also fixed by a pulse hot riveting process, and cooperate with the resistor diaphragm 7 to ensure reasonable design elasticity to ensure the angle detection of the three-in-one sensor. The spring piece 6 is provided with a convex point design, which can effectively ensure the transmission of the angle signal. The shell assembly 8 is combined with other devices to realize the basic functions of the sensor. The NTC thermistor 9 is welded to the circuit board of the PCBA circuit board assembly 2. A hollow strip column is arranged under the shell, and a circular hole for the thermistor 9 to pass through is arranged on the platform surface inside the shell. The circular hole is connected to the inside of the strip column, and the thermistor 9 passes through the circular hole into the inside of the strip column. The special-shaped sealing ring 10 realizes the sealing guarantee with the external throttle valve body.

[0049] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A three-in-one sensor for a throttle valve, characterized in that: It comprises an upper cover (1) and a housing assembly (8); The upper cover (1) and the outer shell assembly (8) are connected by using a plastic laser welding process; The housing assembly (8) is provided with a PCBA circuit board assembly (2) and a rotor (4). The PCBA circuit board assembly (2) is sprayed with a three-proof paint. The PCBA circuit board assembly (2) integrates a pressure sensor chip, a temperature sensor chip, a position sensor chip and a protection circuit. The pressure sensor chip and the housing assembly (8) are sealed by a sealing gasket (3). The rotor (4) is provided with an undercut structure. The rotor (4) is fixed with an electric brush (5) by a positioning column pulse hot riveting process. The electric brush (5) is made of a platinum-palladium alloy wire brush and beryllium bronze ultrasonically welded. A resistor diaphragm (7) is provided on the outside of the rotor (4). The resistor diaphragm (7) contacts with a pin inside the housing assembly (8) through a spring sheet (6), thereby fixing the resistor diaphragm (7) and realizing the function of conducting an electrical signal.

2. A three-in-one sensor for a throttle valve according to claim 1, characterized in that: The temperature sensor chip is connected to a thermistor (9).

3. A three-in-one sensor for a throttle valve according to claim 1, characterized in that: The brush (5) is an 11-wire brush.

4. A three-in-one sensor for a throttle valve according to claim 1, characterized in that: The rotor (4) cooperates with the throttle flat shaft and is provided with guide ribs for controlling the matching clearance between the throttle flat shaft and the rotor (4) to ensure the stability of the output signal.

5. The three-in-one sensor for throttle valve according to claim 1, characterized in that: The upper cover (1) is provided with a contoured structure for preventing the rotor (4) from deviating during rotation, thereby preventing the output of an inaccurate product position signal.

6. A three-in-one sensor for a throttle valve according to claim 1, characterized in that: The housing assembly (8) is provided with a special-shaped sealing ring (10).

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