Pedal displacement sensor
Through the injection molding and hot melting process of the T-type PTS bracket and the Busbar insert, combined with the press-fit connection between the fish-eye terminal and the PCBA, the problems of high welding cost and poor connection reliability of the pedal displacement sensor are solved, and environmentally friendly, low-cost and reliable connection are achieved.
Patent Information
- Application Number
- CN202422240979.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-12
- Publication Date
- 2025-08-05
- Estimated Expiration
- 2034-09-12
AI Technical Summary
The welding process of existing pedal displacement sensors is high, environmentally friendly and has poor connection reliability. PCBA is prone to shake during use and affects electrical connection reliability.
The T-type PTS bracket is used to inject molded connection with Busbar inserts. Through hot melting process and press-matching connection, the welding-free connection between Busbar and printed circuit board components is achieved, and the elastic interference coordination between the fish-eye terminal and the PCBA is used to achieve a tight connection.
Reduces production costs, simplifies assembly processes, improves connection reliability and product life, and reduces the risk of shaking of electrical connections.
Smart Images
Figure CN223192327U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of sensor technology, and in particular to a pedal displacement sensor. Background Art
[0002] As vehicles increasingly electrify, traditional internal combustion engines are being replaced by electric motors and batteries. This lacks a vacuum source for the vehicle, making it impossible to use a vacuum booster to build pressure in the hydraulic lines. Vacuum booster pumps, however, have not been widely adopted due to their high noise levels and short service life. Brake-by-wire technology effectively addresses this vacuum source issue by replacing the vacuum booster with an electric motor to build pressure in the brake hydraulic lines.
[0003] According to the different implementation forms of the wire control brake system of passenger cars, the wire control brake system can be divided into two categories: electronic hydraulic brake (EHB, Electro-Hydraulic Brake) system and electronic mechanical brake (EMB, Electro-Mechanical Brake) system.
[0004] EHB is based on the traditional hydraulic brake system, replacing some mechanical components with electronic devices, using brake fluid as the power transmission medium, and also has a hydraulic backup brake system. It is the current mainstream technical solution. According to the level of integration, EHB is divided into two technical solutions: Two-box and One-box.
[0005] The current pedal travel sensor (PTS) usually uses a busbar that is inserted into the connection hole of the printed circuit board assembly (PCBA) at one end and then connected by soldering, or uses elastic pins (Pogo pins) to solder and fix the PCBA, and the PCBA is then assembled with the PTS bracket. However, the soldering connection requires an additional welding process after the PCBA and PTS bracket are assembled, which is costly and not environmentally friendly. In addition, the solder has poor environmental resistance and is easily oxidized, with a short lifespan. After long-term use, stress is released and the connection strength is poor. Pogo pins are also expensive. In addition, in the existing PCBA and PTS bracket assembly process, the PCBA cannot be fixed firmly in the PTS bracket as a whole, and will shake slightly during use, affecting the reliability of the electrical connection. Utility Model Content
[0006] In view of this, the embodiments of the present application hope to provide a pedal displacement sensor that does not require welding technology, is easy to assemble, and has a reliable connection relationship.
[0007] To achieve the above objectives, the technical solution of this application is implemented as follows:
[0008] The embodiment of the present application provides a pedal displacement sensor, comprising: a pedal displacement sensor PTS bracket, a busbar, and a printed circuit board assembly; wherein,
[0009] The PTS bracket is a T-shaped structure, and multiple Busbar inserts are injection-molded into the PTS bracket. The top of the PTS bracket is provided with a corresponding number of plug-in slots for the Busbars, and the first end of the Busbar is located in the plug-in slot.
[0010] The PTS bracket has a receiving slot in the middle, the shape of which matches the printed circuit board assembly; the printed circuit board assembly is installed in the receiving slot; a raised hot melt column is provided in the receiving slot, and a through hole matching the size of the hot melt column is provided at the position corresponding to the hot melt column of the printed circuit board assembly. After the hot melt column passes through the through hole, the printed circuit board assembly and the PTS bracket are connected by a hot melt process;
[0011] The second end of the busbar is connected to the printed circuit board assembly through a press-fit connection.
[0012] In some optional implementations, the second end of the busbar is a fisheye terminal, the printed circuit board assembly is provided with a connection hole corresponding to the fisheye terminal of the busbar, and the printed circuit board assembly is connected to the fisheye terminal of the busbar through the connection hole.
[0013] In some optional implementations, the width of the fisheye terminal is slightly larger than the diameter of the connection hole of the printed circuit board assembly, and the fisheye terminal is tightly connected to the connection hole through an elastic interference fit.
[0014] In some optional implementations, the plug-in slot and the first end of the busbar disposed therein together constitute an external interface of the pedal displacement sensor.
[0015] In some optional implementations, there are 6 busbars and 6 plug-in slots.
[0016] In some optional implementations, after the printed circuit board assembly is installed in the receiving groove, the height of the groove walls on the four sides of the receiving groove is higher than the height of the components on the adjacent printed circuit board assembly, protecting the printed circuit board assembly from collision and friction during use.
[0017] In some optional implementations, after the printed circuit board assembly is connected to the PTS bracket through a hot melt process, the height of the hot melt column after connection is at least lower than the height of the highest side wall among the four side walls of the accommodating groove.
[0018] In some optional implementations, both shoulders of the PTS bracket are provided with weight-reducing grooves for reducing the weight of the pedal displacement sensor. The weight-reducing grooves adopt a stable structure and their shape matches the arrangement of the busbars insert-molded in the PTS bracket.
[0019] In some optional implementations, a connection structure for stabilizing the connection relationship of the pedal displacement sensor is provided under the shoulder of at least one side of the PTS bracket.
[0020] In some optional implementations, the connection structure is provided with a snap groove that matches the external connection component; the connection structure is a cylinder and is integrally formed with the PTS bracket.
[0021] The pedal displacement sensor in the embodiment of the present application is composed of a PTS bracket, a busbar, and a PCBA assembly. Six busbar inserts are injection-molded into the PTS bracket, and the busbar and PTS bracket are firmly assembled. The six busbar small ends adopt a fisheye pin structure. The fisheye pin structure of the busbar and the PCBA are press-fitted to the PCB board through the Press-Fit process. The PCBA is press-fitted to the PTS bracket and then fixed to the PCBA through a hot melt process. The pedal displacement sensor described in the present application does not require a welding process, has a simple structure, is easy to assemble, shortens the product assembly process cycle time, reduces manufacturing costs, is more environmentally friendly, and the fisheye pin is reliably connected to the PCBA, has a large holding force, and increases the life of the product. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 This is a schematic diagram of an optional structure of a pedal displacement sensor in an embodiment of the present application;
[0023] Figure 2 This is a perspective structural diagram of a pedal displacement sensor in an embodiment of the present application;
[0024] Figure 3 This is a schematic diagram of the connection relationship between the fisheye terminal and the PCBA in an embodiment of the present application. DETAILED DESCRIPTION
[0025] The technical solution of the present application is further elaborated in detail below with reference to the accompanying drawings and specific embodiments.
[0026] In the description of the embodiments of this application, it should be noted that, unless otherwise specified and limited, the term "connection" should be understood in a broad sense. For example, it can be an electrical connection, or it can be the internal connection between two components. It can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meaning of the above terms can be understood according to the specific circumstances.
[0027] Figure 1This is a schematic diagram of an optional structure of a pedal displacement sensor in an embodiment of the present application; Figure 2 This is a perspective structural diagram of the pedal displacement sensor in the embodiment of the present application. Figure 1 and Figure 2 The pedal displacement sensor described in the embodiments of the present application is described in detail.
[0028] like Figure 1 and Figure 2 As shown, the pedal displacement sensor described in the embodiment of the present application includes: a PTS bracket 1, a busbar 2, and a printed circuit board assembly 3;
[0029] The PTS bracket 1 is a T-shaped structure, with multiple Busbars 2 inserts and injection molded into it. The top of the PTS bracket 1 is equipped with a corresponding number of slots 4 for the number of Busbars 2, with the first ends of the Busbars 2 located within these slots. Together, the slots 4 and the first ends of the Busbars within them form the external interface of the pedal displacement sensor. In this embodiment, there are six Busbars 2 and six slots 4.
[0030] A receiving groove 5 is provided in the middle of the PTS bracket 1. The shape of the receiving groove 5 matches that of the printed circuit board assembly 3. The printed circuit board assembly 3 is installed in the receiving groove 5. A raised hot melt column 6 is provided in the receiving groove 5. A through hole matching the size of the hot melt column 6 is provided at the position corresponding to the hot melt column 6 of the printed circuit board assembly 3. After the hot melt column 6 passes through the through hole, the printed circuit board assembly 3 and the PTS bracket 1 are connected through a hot melt process. After the printed circuit board assembly 3 is installed in the receiving groove 5, the height of the groove walls on the four sides of the receiving groove 5 is higher than the height of the components on the adjacent printed circuit board assembly 3 to protect the printed circuit board assembly 3 from collision and friction during use. After the printed circuit board assembly 3 and the PTS bracket 1 are connected through the hot melt process, the height of the connected hot melt column 6 must be at least lower than the height of the highest side of the four side walls of the receiving groove 5 to prevent the hot melt column from becoming an obstacle during use of the pedal displacement sensor.
[0031] The second end of busbar 2 is press-fitted to printed circuit board assembly 3. Specifically, the second end of busbar 2 is a fisheye terminal 7, and printed circuit board assembly 3 is provided with a connection hole corresponding to the fisheye terminal 7 of busbar 2. Through the connection hole, printed circuit board assembly 3 and fisheye terminal 7 of busbar 2 are connected to each other through a supercooling connection, achieving a reliable electrical contact without soldering. Figure 2 This is a schematic diagram of the connection relationship between the fisheye terminal and the PCBA in the embodiment of the present application. Figure 2As shown, the width of the fisheye terminal 7 is slightly larger than the diameter of the connection hole of the printed circuit board assembly 3. When pressed into the connection hole of the PCBA, the fisheye terminal 7 elastically deforms during the insertion process, achieving a high clamping force with a small pressing force. The fisheye terminal 7 and the connection hole are tightly connected through an elastic interference fit, providing a tight connection with low contact impedance and high reliability. Without soldering between the fisheye terminal 7 and the PCBA, the Busbar 2 can be quickly connected to the PCBA, reducing connection impedance and thus lowering production costs and assembly time. Furthermore, the Busbar 2 and PCBA can be easily disassembled. If the PCBA fails, it can be replaced separately without discarding the entire sensor.
[0032] In the embodiment of the present application, the fisheye terminal can be set to different shapes for PCBAs of different board thicknesses to match the corresponding insertion force and withdrawal force to meet the use requirements in different environments.
[0033] In one embodiment, both shoulders of the PTS bracket 1 are provided with weight-reducing grooves 8 for reducing the weight of the pedal displacement sensor. Figure 2 As shown, the shape of the weight-reducing groove 8 matches the arrangement of the Busbars insert-molded in the PTS bracket. While reducing the material consumption of the PTS bracket 1, the arrangement of the multiple Busbars insert-molded in the PTS bracket 1 is not affected. The weight-reducing groove 8 adopts a stable structure. While reducing the material consumption of the PTS bracket 1, the stability of the PTS bracket 1 is not affected.
[0034] In one embodiment, a connection structure 9 for stabilizing the connection relationship of the pedal displacement sensor is provided under the shoulder of at least one side of the PTS bracket 1. The connection structure 9 is provided with a snap groove 10 that matches the external connection component. In one embodiment, the connection structure 9 is a cylinder and is integrally formed with the PTS bracket 1. In actual application, the shape of the connection structure 9 is not limited to Figure 1 Any structure that can connect the pedal displacement sensor to other components falls within the scope of protection of the present invention.
[0035] The pedal displacement sensor in the embodiment of the present application is composed of a PTS bracket, a busbar, and a PCBA assembly. Six busbar inserts are injection-molded into the PTS bracket, and the busbar and PTS bracket are firmly assembled. The six busbar small ends adopt a fisheye pin structure. The fisheye pin structure of the busbar and the PCBA are press-fitted to the PCB board through the Press-Fit process. The PCBA is press-fitted to the PTS bracket and then fixed to the PCBA through a hot melt process. The pedal displacement sensor described in the present application does not require a welding process, has a simple structure, is easy to assemble, shortens the product assembly process cycle time, reduces manufacturing costs, is more environmentally friendly, and the fisheye pin is reliably connected to the PCBA, has a large holding force, and increases the life of the product.
[0036] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of this application. Therefore, the scope of protection of this application should be based on the scope of protection of the claims.
Claims
1. A pedal displacement sensor, characterized in that: The pedal displacement sensor includes: a pedal displacement sensor PTS bracket, a busbar, and a printed circuit board assembly; wherein, The PTS bracket is a T-shaped structure, and multiple Busbar inserts are injection-molded into the PTS bracket. The top of the PTS bracket is provided with a corresponding number of plug-in slots for the Busbars, and the first end of the Busbar is located in the plug-in slot. The PTS bracket has a receiving slot in the middle, the shape of which matches the printed circuit board assembly; the printed circuit board assembly is installed in the receiving slot; a raised hot melt column is provided in the receiving slot, and a through hole matching the size of the hot melt column is provided at the position corresponding to the hot melt column of the printed circuit board assembly. After the hot melt column passes through the through hole, the printed circuit board assembly and the PTS bracket are connected by a hot melt process; The second end of the busbar is connected to the printed circuit board assembly through a press-fit connection.
2. The pedal displacement sensor according to claim 1, characterized in that: The second end of the busbar is a fisheye terminal. The printed circuit board assembly is provided with a connection hole corresponding to the fisheye terminal of the busbar. The printed circuit board assembly is connected to the fisheye terminal of the busbar through the connection hole.
3. The pedal displacement sensor according to claim 2, characterized in that: The width of the fisheye terminal is slightly larger than the diameter of the connection hole of the printed circuit board assembly, and the fisheye terminal is tightly connected to the connection hole through elastic interference fit.
4. The pedal displacement sensor according to claim 1, characterized in that: The plug-in slot and the first end of the busbar arranged therein together form an external interface of the pedal displacement sensor.
5. The pedal displacement sensor according to claim 1, characterized in that: There are 6 busbars and 6 plug-in slots.
6. The pedal displacement sensor according to claim 1, characterized in that: After the printed circuit board assembly is installed in the receiving groove, the height of the groove walls on the four sides of the receiving groove is higher than the height of the components on the adjacent printed circuit board assembly, protecting the printed circuit board assembly from collision and friction during use.
7. The pedal displacement sensor according to claim 6, characterized in that: After the printed circuit board assembly is connected to the PTS bracket through the hot melt process, the height of the hot melt column after connection is at least lower than the height of the highest side wall among the four side walls of the accommodating groove.
8. The pedal displacement sensor according to claim 1, characterized in that: Both shoulders of the PTS bracket are provided with weight-reducing grooves for reducing the weight of the pedal displacement sensor. The weight-reducing grooves adopt a stable structure, and the shape matches the arrangement of the busbars insert-molded in the PTS bracket.
9. The pedal displacement sensor according to claim 1, characterized in that: A connection structure for stabilizing the connection relationship of the pedal displacement sensor is provided under the shoulder of at least one side of the PTS bracket.
10. The pedal displacement sensor according to claim 9, characterized in that: The connection structure is provided with a snap groove that matches the external connection component; the connection structure is a cylinder and is integrally formed with the PTS bracket.