Integrated motor cover structure

Abstract

The utility model relates to a structure of a motor cover. An integrated motor cover structure comprises a cover body, an internal oil way pipeline is arranged in the cover body, the internal oil way pipeline is communicated with a cooling oil way of a motor, a temperature sensor is installed in the cover body, a sensitive unit of the temperature sensor is located in the internal oil way pipeline, the temperature sensor is fixed on a PCBA board through pins, and the PCBA board is connected with the internal oil way pipeline. The PCBA board is fixed on the cover body, and the PCBA board is provided with a motor rotation angle sensor at the same time. The integrated motor cover structure provided by the utility model has the advantages of simplified installation steps, low cost, simple structure and light weight. The technical problems of multiple installation steps, multiple installation auxiliary structures, multiple installation parts and high cost of various sensors in a motor structure in the prior art are solved.

Description

Technical Field

[0001] The utility model relates to a structure of a motor cover. Background Art

[0002] Currently, all-electric and hybrid vehicles on the market utilize a drivetrain with an electric motor. An electric motor typically consists of a stator, rotor, housing, and cover. The stator generates a rotating magnetic field, while the rotor's primary function is to be cut by magnetic lines of force within this rotating field, generating current. This design allows the stator and rotor to work together within the motor to convert and transmit electrical energy. The rotor, located within the stator, rotates freely. Permanent magnets or electromagnets are mounted on it, interacting with the magnetic field generated by the stator to generate rotational torque. This torque is transmitted to the vehicle's drivetrain, propelling the vehicle forward. Depending on the motor's structural requirements, various sensors are typically installed within the motor. These include a motor angle sensor, which detects the mechanical position of the drive motor rotor and transmits an electrical signal to the control system, which then calculates torque and determines power utilization. Temperature sensors also detect oil circuit temperature and transmit an electrical signal to the control system. Sensors are typically mounted on the motor housing, depending on the location of the sensor. Summary of the Invention

[0003] The utility model provides an integrated motor cover structure with simplified installation steps, low cost, simple and lightweight structure; it solves the technical problems existing in the prior art of the motor structure in that various sensors have many installation steps, many auxiliary installation structures, many installation components and high cost.

[0004] The above-mentioned technical problem is solved by the following technical solution: an integrated motor cover structure, comprising a cover body, an internal oil conduit disposed within the cover body, the internal oil conduit communicating with the motor's cooling oil circuit, a temperature sensor mounted within the cover body, a sensitive unit of the temperature sensor located within the internal oil conduit, the temperature sensor being pinned to a PCBA board, which is also mounted on the cover body, and a motor angle sensor mounted on the PCBA board. Integrating both the temperature sensor and the angle sensor within the housing simplifies the existing practice of separately mounting the temperature sensor and the motor angle sensor, which requires space and additional installation steps. While the functionality of the motor cover itself remains intact, the integration of the temperature sensor and angle sensor within the cover provides enhanced versatility and has no impact on the motor itself. The addition of the internal oil conduit within the cover body facilitates the placement of the temperature sensor and signal acquisition. The internal oil conduit only needs to be connected to the motor's cooling oil circuit, and coolant continues to enter through the center of the motor's rotor shaft, without affecting the motor's rotor cooling oil circuit. The integrated motor cover uses a plastic structure, making the product lighter and removing the sensor housing and sensor locking mechanism, reducing costs. It has little impact on the remaining internal structures of the motor and does not require changes to the internal structure of the motor, making it highly adaptable.

[0005] Preferably, the motor angle sensor includes a metal rotor fixed on a rotating shaft that rotates synchronously with the rotor shaft inside the motor. A winding structure is formed on the PCBA board, and a connecting end is provided at the center of the cover body. The rotating shaft and the connecting end are clearance-matched, and the connecting end is the oil outlet end of the internal oil pipeline. The rotating shaft rotates with the rotor shaft, and the metal rotor fixed on the rotating shaft rotates, thereby changing the magnetic field and the chip outputting the angle signal. The eddy current motor angle sensor is used for better accuracy. The PCBA board is divided into two functional module circuits and isolated by copper plating to ensure the accuracy of the eddy current sensor. At the same time, the cooling oil is input into the interior of the motor rotor through the rotating shaft. The oil outlet is connected to the rotating shaft, and the oil outlet directly inputs the cooling oil into the cooling pipeline inside the motor rotor for cooling, without changing the original cooling pipeline inside the motor rotor. The internal oil pipeline designed on the cover body facilitates data acquisition by the temperature sensor and does not delay the normal cooling process of the cooling oil circuit.

[0006] Preferably, the internal oil circuit is E-shaped, with two oil inlets on either side of the internal oil circuit and an oil outlet in the center. The oil inlets are connected to the motor's cooling oil inlet line, and the oil outlet is connected to the cooling pipe inside the motor rotor. The oil inlet and outlet are parallel to each other and are connected by a horizontal connecting pipe between the oil inlet and outlet, facilitating the arrangement of the temperature sensor's sensitive unit and improving the sensor's sensing accuracy.

[0007] Preferably, the installation direction of the temperature sensor is perpendicular to the PCBA board, and the sensitive unit of the temperature sensor is located in the horizontal connecting pipe of the internal oil pipeline, and the horizontal connecting pipe connects the oil inlet and the oil outlet.

[0008] Preferably, a sealing ring having the same shape as the end face of the cover body is installed on the end face of the cover body, and O-rings are provided at the oil inlet and the oil outlet.

[0009] Preferably, a connector is formed on the cover body, one end of the connector is connected to the PCBA board, and the other end of the connector is connected to an external controller.

[0010] Therefore, the integrated motor cover structure of this utility model has the following advantages: The temperature sensor and motor angle sensor are integrated into the motor end cover, which has minimal impact on the original motor structure, while simplifying the overall installation structure and streamlining the customer's system layout. The entire motor cover is made of plastic, making the product lighter and lowering the cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a three-dimensional diagram of an integrated motor cover structure.

[0012] Figure 2 yes Figure 1 A stereogram from another direction.

[0013] Figure 3 yes Figure 1 sectional view of . DETAILED DESCRIPTION

[0014] The technical solution of the utility model is further described in detail below through embodiments and in conjunction with the accompanying drawings.

[0015] Example:

[0016] like Figure 1 and 2 As shown in Figure 3, an integrated motor cover structure includes a cover body 1 made of plastic material, an E-shaped internal oil pipeline 2 is formed in the cover body 1, and the internal oil pipeline 2 includes two oil inlets 7 parallel to each other and an oil outlet 8 located between the two oil inlets 7, and the oil inlet 7 and the oil outlet 8 are connected by a horizontal connecting pipe 11. A PCBA board 10 is also installed in the middle of the cover body 1, and a connector 3 is molded on the outside of the cover body 1. The PCBA board 10 is connected to the connector 3 through a PIN needle 13, and the other end of the connector 3 can be connected to the controller. A special-shaped sealing ring 6 with the same shape as the end face of the cover body 1 is also installed on the lower end face of the cover body 1.

[0017] A temperature sensor 9 is also installed in the cover body 1. The sensitive unit of the temperature sensor 9 is located in the horizontal connecting pipe 11 of the internal oil pipeline. The temperature sensor 9 is installed vertically to the PCBA board 10, and one end of the temperature sensor 9 is fixed to the PCBA board 10 by a pin.

[0018] A coil is etched onto the PCBA board 10. An oil outlet 8 extends out of the cover body 1 and has a clearance fit with the rotating shaft 4. The shaft 4 has a through hole at its center. A metal rotor 5 is integrally formed on the shaft 4, its axial projection corresponding to the coil on the PCBA board 10. The other end of the shaft 4 has an interference fit with the motor's rotor shaft. Utilizing the principle of eddy currents, the metal rotor rotates as the rotor shaft rotates, thereby detecting the motor's rotor's rotation angle.

[0019] When the system is working, the cooling lubricating oil will enter the oil inlet 7 on the cover body 1 of the motor cover through the oil circuit on the motor housing. There is an oil circuit inside the cover body 1, and a temperature sensor 9 is arranged on the oil circuit pipeline. The temperature sensor 9 has an NTC thermistor inside, which senses the liquid temperature in the cavity and introduces its own resistance change through the sensor pin to the PCBA, and then guides it to the connector end through the PCBA circuit. Finally, it is transmitted to the controller through the external wiring harness system. In this way, the controller can always know the oil temperature inside the housing. Since the metal rotor of the eddy current sensor rotates synchronously with the motor rotor shaft, the rotor angle change can be tested at the same time by the eddy current principle angle sensor installed on the cover body. The coil is etched on the PCBA board 10 and guided to the connector end through the circuit of the PCBA board 10.

[0020] The exposed surface of the cover body 1 of the motor cover is provided with a male terminal feature, and the controller can be connected to it through a matching wiring harness structure to transmit electrical signals.

[0021] The pins of connector 3 are soldered to the PCBA inside the motor cover. The PCBA integrates a winding mechanism based on eddy current principles and circuitry for transmitting temperature sensors, resulting in a simpler structure. End-face sealing rings are located around the locking area of the motor cover and the oil inlet port. When the motor cover is locked to the motor housing, the contact area between the sealing rings creates a sealed environment, preventing internal oil leakage.

[0022] The above-mentioned integrated motor cover structure is manufactured by the following method:

[0023] The first step is to injection mold an internal oil pipeline body, which includes an internal oil pipeline body, a parallel oil inlet 7, an oil outlet 8, and a horizontal connecting pipe 11 connecting the oil inlet and the oil outlet. A temperature sensor installation cavity 16 is also reserved on the internal oil pipeline body.

[0024] In the second step, the temperature sensor 9 is installed in the sensor installation cavity of the pipe formed in the first step. The sensitive unit of the temperature sensor 9 is located in the horizontal connecting pipe 11, and the pins of the temperature sensor 9 are exposed outside the internal oil pipeline body. Then, the through holes of the internal oil pipeline body except the oil inlet and oil outlet are blocked with sealing plugs 12;

[0025] In the third step, the pin 13 and the embedded ring 14 are injection molded together with the internal oil pipe body formed in the second step to form the cover body 1 and the connector 3 on the cover body;

[0026] Step 4: Heat riveting or welding a PCBA board 10 on the cover body 1, welding the pins of the temperature sensor 9 to the PCBA board 10, and connecting the PCBA board 10 to the pins 13 of the connector. A winding structure is designed on the PCBA board 10;

[0027] Step 5: The joint 15 between the secondary injection molded part and the primary injection molded part is encapsulated with resin, and the PCBA board 10 is encapsulated at the same time;

[0028] In the sixth step, an end face sealing ring 6 is installed on the potting part completed in the fifth step, and a rotating shaft 4 for interference fit with the motor rotor shaft is installed at the end of the oil outlet 8. A metal rotor 5 is integrally formed on the rotating shaft 4, and the metal rotor 5 corresponds to the winding structure on the PCBA board 10.

[0029] The specific embodiments described herein are merely illustrative of the concepts of the present invention. Persons skilled in the art may make various modifications, additions, or substitutions to the described specific embodiments without departing from the spirit of the present invention or exceeding the scope defined by the appended claims.

Claims

1. An integrated motor cover structure, comprising a cover body, characterized in that: The cover body is provided with an internal oil pipeline, which is connected to the cooling oil pipeline of the motor. A temperature sensor is installed in the cover body. The sensitive unit of the temperature sensor is located in the internal oil pipeline. The temperature sensor is fixed to the PCBA board through pins. The PCBA board is fixed to the cover body. The PCBA board is also installed with a motor angle sensor.

2. The integrated motor cover structure according to claim 1, characterized in that: The motor angle sensor includes a metal rotor, which is fixed on a rotating shaft. The rotating shaft rotates synchronously with the rotor shaft inside the motor. A winding structure is formed on the PCBA board. A connecting end is provided at the center of the cover body. The rotating shaft and the connecting end are clearance-fitted. The connecting end is the oil outlet end of the internal oil pipeline.

3. The integrated motor cover structure according to claim 1, characterized in that: The internal oil circuit pipeline is E-shaped, with two oil inlets on both sides of the internal oil circuit and an oil outlet in the center. The oil inlet is connected to the cooling oil inlet pipeline of the motor, and the oil outlet is connected to the cooling pipe inside the motor rotor.

4. The integrated motor cover structure according to claim 1, 2 or 3, characterized in that: The installation direction of the temperature sensor is perpendicular to the PCBA board, and the sensitive unit of the temperature sensor is located in the horizontal connecting pipe of the internal oil pipeline, and the horizontal connecting pipe connects the oil inlet and the oil outlet.

5. The integrated motor cover structure according to claim 1, 2 or 3, characterized in that: The end face of the cover body is provided with a sealing ring with the same shape as the end face of the cover body, and O-shaped sealing rings are provided at the oil inlet and the oil outlet.

6. The integrated motor cover structure according to claim 1, 2 or 3, characterized in that: A connector is formed on the cover body, one end of the connector is connected to the PCBA board, and the other end of the connector is connected to an external controller.

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