Electric power steering torque angle sensor

Abstract

The utility model belongs to the technical field of angle sensors, and discloses an electric power steering torque angle sensor which comprises a shell, a circuit board assembly, an output shaft rotor, an input shaft assembly and a driven gear, the output shaft rotor is connected with an output shaft, the input shaft assembly comprises a driving gear and a lining, and the lining is connected with the driving gear. The driving gear and the lining are integrally formed in an injection molding mode, namely, the input shaft assembly is an insert forming part, the complexity and cost of the technology can be reduced, the lining is connected with the input shaft and rotationally arranged on the lower cover, the driven gear is connected with the driving gear in a meshed mode, the driven gear is provided with a buckle, and the driven gear is connected with the lower cover in a buckled mode through the buckle. Therefore, the driven gear is more stable relative to the lower cover, the problem of axial movement of the driven gear is solved, the complexity of a mold caused by an elastic structure is simplified, and the cost is further reduced.

Description

Technical Field

[0001] This utility model relates to the field of angle sensor technology, and in particular to an electric power steering torque angle sensor. Background Technology

[0002] In the field of automotive steering, electric power steering systems comprise the five basic components of a traditional mechatronic system: sensing components (torque angle sensors, torsion bars, etc.), power components (motor), drive components (gear rack, worm gear, belt, and other transmission mechanisms), actuation components (ball joints, tie rods, etc.), and control and information components (electronic control unit).

[0003] By detecting the magnitude and direction of the torque and steering angle applied to the steering wheel, the signals are input to the electronic control unit (ECU). The ECU, after processing the vehicle's CAN signals, calculates a torque that matches the driving conditions and then sends a command to drive the motor. The motor's output torque, through the transmission mechanism, provides power steering assistance. Therefore, as a core component of the steering system, the accuracy of the torque angle sensor's signal directly affects the power steering performance, determining driving safety and the driver's feel.

[0004] In the torque angle sensor of automotive electric power steering, the mechanical structure is complex. Typically, the input shaft bushing and drive gear are laser-welded, a complex manufacturing process that increases cost. The driven gear is placed in a mounting hole in the housing, and a plastic cover is installed on top. An elastic structure within the plastic cover presses the top of the driven gear for fixation. However, this structure is complex, requiring specific molds for manufacturing and assembly, resulting in high costs. Furthermore, the driven gear can experience axial movement during transmission within the housing, affecting the sensor's detection capabilities.

[0005] Therefore, there is an urgent need for an electric power steering torque angle sensor to solve the above problems. Utility Model Content

[0006] The purpose of this invention is to provide an electric power steering torque angle sensor, in which the driving gear and bushing are integrally injection molded, which can reduce the complexity and cost of the process. Furthermore, it solves the problem of axial movement of the driven gear, simplifies the mold complexity, and further reduces costs.

[0007] To address the aforementioned problems in the existing technology, this utility model adopts the following technical solution:

[0008] Electric power steering torque angle sensor, including:

[0009] An outer casing having a receiving cavity, the outer casing including an upper cover and a lower cover, the upper cover being welded to the lower cover;

[0010] A circuit board assembly, the circuit board assembly being located within the receiving cavity and disposed between the upper cover and the lower cover;

[0011] An output shaft rotor, which is connected to an output shaft;

[0012] An input shaft assembly, comprising a drive gear and a bushing, wherein the drive gear and the bushing are integrally injection molded, the bushing is connected to the input shaft, and the bushing is rotatably mounted on the lower cover;

[0013] The driven gear is meshed with the driving gear. The driven gear is provided with a buckle, and the driven gear is fastened to the lower cover through the buckle.

[0014] Preferably, the lower cover is provided with a snap-fit ​​component, which has an eccentric asymmetrical structure and is used to prevent the sensor from rotating.

[0015] Preferably, the snap-fit ​​component includes a snap-fit ​​body and a plurality of snap-fit ​​parts, wherein the plurality of snap-fit ​​parts are disposed on the snap-fit ​​body and are arranged asymmetrically with respect to the center point of the snap-fit ​​body.

[0016] Preferably, the lower cover has a through hole and a snap-fit ​​groove, and the buckle passes through the through hole and is snapped into the snap-fit ​​groove.

[0017] Preferably, there are multiple buckles, which are spaced apart along the circumferential direction of the driven gear.

[0018] Preferably, the output shaft rotor is press-fitted with the output shaft.

[0019] Preferably, the input shaft assembly is press-fitted with the input shaft.

[0020] Preferably, the circuit board assembly includes a circuit board and a connector, the circuit board is disposed between the upper cover and the lower cover, the connector is surface-mounted on the circuit board, and the connector is connected to a signal harness.

[0021] Preferably, the electric power steering torque angle sensor further includes a gear housing, which is interference-fitted with the input shaft assembly.

[0022] Preferably, the gear housing is provided with a plurality of elastic elements, which are spaced apart along the circumferential direction of the gear housing. The drive gear is provided with a connecting hole, and the elastic elements elastically abut against the wall of the connecting hole.

[0023] The beneficial effects of this utility model are as follows:

[0024] The electric power steering torque angle sensor provided by this utility model has a housing with a receiving cavity. The housing includes an upper cover and a lower cover, with the upper cover welded to the lower cover. The circuit board assembly is located within the receiving cavity and positioned between the upper and lower covers. The output shaft rotor is connected to the output shaft. The input shaft assembly includes a drive gear and a bushing, which are integrally injection molded, meaning the input shaft assembly is an insert-molded component, reducing process complexity and cost. The bushing is connected to the input shaft and rotatably mounted on the lower cover. The driven gear meshes with the drive gear and has a snap-fit ​​mechanism, which engages with the lower cover. This makes the driven gear more stable relative to the lower cover, solving the problem of axial movement of the driven gear. Furthermore, it simplifies the mold complexity caused by the elastic structure, further reducing costs. Attached Figure Description

[0025] Figure 1 An exploded view of the electric power steering torque angle sensor provided in an embodiment of this utility model;

[0026] Figure 2 This is a structural schematic diagram of the lower cover and snap-fit ​​component provided in an embodiment of the present utility model.

[0027] Figure label:

[0028] 1. Top cover; 2. Bottom cover; 3. Output shaft rotor; 4. Drive gear; 5. Bushing; 6. Driven gear; 7. Snap-fit; 8. Snap-fit ​​component; 9. Snap-fit ​​part; 10. Circuit board; 11. Connector; 12. Gear housing; 13. Elastic component. Detailed Implementation

[0029] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0030] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0031] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0032] In the description of this embodiment, the terms "upper," "lower," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0033] like Figures 1-2 As shown, in this embodiment, the electric power steering torque angle sensor includes a housing, a circuit board assembly, an output shaft rotor 3, an input shaft assembly, and a driven gear 6. The housing has a receiving cavity and includes an upper cover 1 and a lower cover 2. The upper cover 1 is welded to the lower cover 2. The circuit board assembly is located within the receiving cavity and is positioned between the upper cover 1 and the lower cover 2. The output shaft rotor 3 is connected to the output shaft. The input shaft assembly includes a drive gear 4 and a bushing 5. The drive gear 4 and bushing 5 are integrally injection molded. The bushing 5 is connected to the input shaft and rotatably mounted on the lower cover 2. The driven gear 6 meshes with the drive gear 4 and is equipped with a latch 7, which engages with the lower cover 2.

[0034] The upper cover 1 is laser-welded to the lower cover 2 to form a receiving cavity. A circuit board assembly is housed within this cavity to provide torque signals to the sensor. The output shaft and input shaft are respectively assembled with the output shaft rotor 3 and bushing 5. The driving gear 4 and the bushing 5 assembled to the input shaft are integrally injection molded using inserts or other methods. This means the input shaft assembly is an insert-molded component, reducing process complexity and cost. The driven gear 6 has a snap-fit ​​structure 7, which engages with the lower cover 2, making the driven gear 6 more stable relative to the lower cover 2. This solves the problem of axial movement of the driven gear 6 and simplifies the mold complexity caused by the elastic structure, further reducing costs.

[0035] Continue to refer to Figures 1-2The lower cover 2 is equipped with a snap-fit ​​element 8, which has an eccentric asymmetrical structure and is used to prevent the sensor from rotating. The snap-fit ​​element 8 includes a snap-fit ​​body and multiple snap-fit ​​parts 9, which are disposed on the snap-fit ​​body and are asymmetrically arranged relative to the center point of the snap-fit ​​body. The anti-rotation structure on the lower cover 2 is designed as an eccentric asymmetrical double snap-fit ​​7, and the snap-fit ​​element 8 snaps onto the upper cover 1, effectively preventing the sensor from rotating and reducing the number of parts, thus lowering costs.

[0036] Continue to refer to Figures 1-2 The lower cover 2 has a through hole and a snap-fit ​​groove. A snap fastener 7 passes through the through hole and engages with the snap-fit ​​groove. Multiple snap fasteners 7 are spaced apart along the circumference of the driven gear 6. The driven gear 6 engages with the snap-fit ​​groove of the lower cover 2 via multiple snap fasteners 7, thus fixing the driven gear 6 to the lower cover 2 and resolving the problem of axial movement of the driven gear 6. Furthermore, this simplifies the mold complexity caused by the elastic structure and further reduces costs.

[0037] Preferably, the output shaft rotor 3 is press-fitted with the output shaft, and the input shaft assembly is press-fitted with the input shaft. It is necessary to consider designing the bushing 5 to have a thicker wall, for example, about 1mm, to avoid the deformation caused by the interference fit affecting the gear tooth profile. Traditional assembly methods often involve welding, requiring new welding equipment and increasing costs. In this embodiment, the input shaft rotor and input shaft assembly are press-fitted with the output shaft and input shaft respectively, reducing process complexity and manufacturing costs.

[0038] Continue to refer to Figures 1-2 The circuit board assembly includes a circuit board 10 and a connector 11. The circuit board 10 is disposed between the upper cover 1 and the lower cover 2. The connector 11 is surface-mounted on the circuit board 10 and is connected to the signal harness. The connector 11 of the wave soldering process of the circuit board 10 is designed as a label to reduce the process and thus reduce the manufacturing cost.

[0039] Continue to refer to Figures 1-2 The electric power steering torque angle sensor also includes a gear housing 12, which is interference-fitted with the input shaft assembly. The gear housing 12 is interference-fitted with the drive gear 4 and bushing 5 via snaps and ribs on either of its surfaces, and is supported in the height direction by the surface of the gear housing 12. The gear housing 12 has multiple protruding elastic elements 13, spaced apart along its circumference. The drive gear 4 has a connecting hole, and the elastic elements 13 elastically abut against the wall of the connecting hole, ensuring a secure connection that is not easily loosened.

[0040] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make various obvious changes, readjustments, and substitutions without departing from the protection scope of this utility model. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. An electric power steering torque angle sensor, characterized by, include: The outer casing has a receiving cavity, and the outer casing includes an upper cover (1) and a lower cover (2), wherein the upper cover (1) is welded to the lower cover (2); A circuit board assembly located within the receiving cavity and disposed between the upper cover (1) and the lower cover (2); Output shaft rotor (3), which is connected to the output shaft; An input shaft assembly, comprising a drive gear (4) and a bushing (5), wherein the drive gear (4) and the bushing (5) are integrally injection molded, the bushing (5) is connected to the input shaft, and the bushing (5) is rotatably mounted on the lower cover (2); Driven gear (6) meshes with driving gear (4). Driven gear (6) is provided with buckle (7). Driven gear (6) is fastened to lower cover (2) through buckle (7).

2. The electric power steering torque angle sensor according to claim 1, characterized in that, The lower cover (2) is provided with a snap-fit ​​member (8), which has an eccentric asymmetrical structure and is used to prevent the sensor from rotating.

3. The electric power steering torque angle sensor according to claim 2, characterized in that, The snap-fit ​​component (8) includes a snap-fit ​​body and a plurality of snap-fit ​​parts (9). The plurality of snap-fit ​​parts (9) are disposed on the snap-fit ​​body, and the plurality of snap-fit ​​parts (9) are asymmetrically arranged relative to the center point of the snap-fit ​​body.

4. The electric power steering torque angle sensor according to claim 1, characterized by The lower cover (2) has a through hole and a snap-fit ​​groove, and the buckle (7) passes through the through hole and is snap-fitted into the snap-fit ​​groove.

5. The electric power steering torque angle sensor according to claim 1, characterized by There are multiple buckles (7), and the multiple buckles (7) are spaced apart along the circumferential direction of the driven gear (6).

6. The electric power steering torque angle sensor of claim 1, wherein The output shaft rotor (3) is press-fitted with the output shaft.

7. The electric power steering torque angle sensor of claim 1, wherein The input shaft assembly is press-fitted with the input shaft.

8. The electric power steering torque angle sensor of claim 1, wherein, The circuit board assembly includes a circuit board (10) and a connector (11). The circuit board (10) is disposed between the upper cover (1) and the lower cover (2). The connector (11) is surface-mounted on the circuit board (10) and is connected to a signal harness.

9. The electric power steering torque angle sensor of claim 1, wherein, The electric power steering torque angle sensor also includes a gear housing (12), which is interference-fitted with the input shaft assembly.

10. The electric power steering torque angle sensor according to claim 9, characterized in that, The gear housing (12) is provided with a plurality of elastic elements (13). The plurality of elastic elements (13) are spaced apart along the circumferential direction of the gear housing (12). The drive gear (4) is provided with a connecting hole. The elastic elements (13) elastically abut against the hole wall of the connecting hole.

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