Height sensor with wire harness assembly

Abstract

The utility model discloses a height sensor with a wire harness assembly, which comprises a shell, a rotating shaft, an electric brush carrier, a rocker arm, a circuit board, a bottom cover and a wiring assembly, and the wiring assembly comprises an inner framework, a pin piece, a wire harness and a sensor head. The wiring harness, the pin piece and the circuit board are fixed in the plastic shell, a quick-plug structure of a traditional sensor is abandoned, an assembly gap generated at a hanging position due to the quick-plug structure is eliminated, the problem of hardening failure of a sealing ring or sealant does not need to be worried about, and the possibility of short circuit caused by external rainwater and slurry permeation is fundamentally eradicated; and the joint of the inner framework and the shell is coated with the sensor head, so that the structural strength of the joint is improved, and the service life of the sensor in a severe working environment for a long time is prolonged.

Description

Technical Field

[0001] This utility model relates to the technical field of Hall sensors, and in particular to a height sensor with a wiring harness assembly. Background Technology

[0002] Most existing height sensors use quick-connect terminals, which connect the wiring harness to the housing via a separate plug and socket. However, quick-connect terminals inevitably have assembly gaps. Although sealing rings or sealants are added to the terminals, they are prone to losing elasticity due to aging and hardening during long-term use. This can lead to cracks that allow rainwater and mud to enter the terminals, causing problems such as short circuits and signal distortion, which seriously affect the lifespan of the sensor. Utility Model Content

[0003] To overcome the shortcomings of the prior art, the technical solution adopted by this utility model is as follows: a height sensor with a wiring harness assembly, including a housing, a rotating shaft, a brush holder, a rocker arm, a circuit board, a bottom cover, and a wiring assembly. The housing is rotatably connected to the rotating shaft, and the upper and lower ends of the rotating shaft are respectively connected to the brush holder and the rocker arm. The housing is provided with a circuit board corresponding to the brush holder, and a wiring assembly for connecting to an external vehicle ECU. The brush holder is provided with brushes electrically connected to the circuit board. The bottom of the housing is sealed with a bottom cover. The wiring assembly includes an inner frame, pins, a wiring harness, and a sensor head. The two ends of the inner frame are respectively embedded with pins and the wiring harness. The pins are electrically connected to the wiring harness. The inner frame is sequentially connected to the housing and the sensor head through secondary injection molding, and the sensor head is located at the connection between the inner frame and the housing.

[0004] By adopting the above technical solution, the inner frame is used as an installation insert. A secondary injection molding process is used to fix the wire harness, pins, and circuit board inside the plastic shell. This eliminates the quick-connect structure of traditional sensors, thus eliminating the assembly gaps caused by the quick-connect structure at the suspension point. There is no need to worry about the sealing ring or sealant hardening and failure. This fundamentally eliminates the possibility of short circuits caused by external rainwater or mud seeping in. Furthermore, the sensor head is covered at the connection between the inner frame and the outer shell to improve the structural strength of the connection and extend the service life of the sensor in harsh working environments.

[0005] The present invention is further configured such that the outer shell has a mounting cavity for mounting the circuit board, a rectangular portion is provided on one side of the outer shell, the inner skeleton is provided inside the rectangular portion, and the pin extends through the rectangular portion into the mounting cavity.

[0006] Furthermore, the inner skeleton includes a positioning part, a transition part, and a cylindrical part connected in sequence. The pin and the wire harness are respectively disposed in the positioning part and the cylindrical part, and the connection between the pin and the wire harness is disposed in the transition part. The positioning part is embedded in the rectangular part, and the transition part is provided with a limiting protrusion corresponding to the rectangular part.

[0007] By adopting the above technical solution, the plug structure of the traditional sensor housing is changed to a rectangular part for installing the inner skeleton. The adapter is embedded in the rectangular part by a limiting protrusion to prevent the inner skeleton from being pulled out of the housing when the wire harness is pulled by external force, thus maintaining the stability of the structure.

[0008] The present invention is further configured such that a process groove is provided at the positioning part of the rectangular part, and the positioning part is provided with a positioning post extending to the process groove.

[0009] By adopting the above technical solution, when the inner skeleton is formed into the outer shell by secondary injection molding, the design of the process groove not only optimizes the material flow path in one part of the rectangular part, but also provides space for the positioning post of the mold to clamp the inner skeleton, effectively reducing the length required for the positioning post and avoiding the positioning post from breaking due to excessive length, making the structural design compact and reasonable.

[0010] The present invention is further configured such that the inner skeleton is provided with a positioning groove and a side pressure groove for fixing the wire harness, the positioning groove is distributed on the upper and lower sides of the connection of the adapter, and the side pressure groove is provided on the left and right sides of the cylindrical part.

[0011] Using the above technical solution, the positioning groove and the side pressure groove are distributed in a cross shape around the inner skeleton. The positioning groove and the side pressure groove provide space for the injection mold to clamp the wire harness, and prevent the wire harness from being displaced by the impact of the molten material during injection.

[0012] The present invention is further configured such that the sensor head is provided with a rectangular portion two and a cylindrical portion two for covering the rectangular portion one and the inner skeleton.

[0013] Using the above technical solution, after the outer shell is injection molded, the sensor head is injection molded again at the connection between the outer shell and the inner frame, and the positioning groove and side pressure groove are covered, which improves the aesthetics of the sensor and improves the structural strength of the wire harness bending point, effectively preventing damage to the internal core wire caused by bending the wire harness.

[0014] The present invention is further configured such that the pin component has a bending portion and a riveting portion, the circuit board is electrically connected to the bending portion, and the wire core of the wire harness is electrically connected to the pin component through the riveting portion.

[0015] Furthermore, the insert member is provided with two or more sets of inserts, and a connecting tube is provided between the inserts. The positioning part is provided with a punching groove for punching the connecting tube.

[0016] Using the above technical solution, when making the inner skeleton through mold opening, the pins are connected to the wire core of the wire harness through the riveting part, which avoids the pins and wire cores being broken by the impact of the molten material during injection molding, ensuring that each pin is connected to the wire core. After the inner skeleton is injection molded, the connecting tube between adjacent pins is cut through the punching groove, so that each pin is independently distributed to meet the power connection requirements of the circuit board.

[0017] The embodiments of this utility model will be further described below with reference to the accompanying drawings. Attached Figure Description

[0018] Figure 1 This is a perspective view of the present invention;

[0019] Figure 2 This is a cross-sectional view of the present invention;

[0020] Figure 3 This is a structural schematic diagram of the pin assembly riveting harness of this utility model;

[0021] Figure 4 This is a schematic diagram of the internal skeleton formed by injection molding according to this utility model;

[0022] Figure 5 This is a schematic diagram of the injection-molded shell structure of this utility model;

[0023] Figure 6 This is a schematic diagram of the injection-molded sensor head of this utility model;

[0024] Figure 7 This is the utility model Figure 5 A magnified view of a section at point A in the middle;

[0025] The components are: 1-outer shell, 2-rotating shaft, 3-brush holder, 4-rocker arm, 5-circuit board, 6-bottom cover, 7-wiring assembly, 8-brush component, 11-inner frame, 12-pin component, 13-wire harness, 14-sensor head, 101-mounting cavity, 102-rectangular section one, 103-process groove, 111-positioning section, 112-transfer section, 113-cylindrical section one, 114-positioning post, 115-positioning groove, 116-side pressure groove, 117-punching groove, 118-limiting protrusion, 121-bending section, 122-riveting section, 123-pin, 124-connecting tube, 141-rectangular section two, 142-cylindrical section two; Detailed Implementation

[0026] The embodiments of this utility model will now be described with reference to the accompanying drawings. In this process, to ensure clarity and convenience, we may exaggerate the width of lines or the size of constituent elements in the drawings.

[0027] Furthermore, the terms used below are defined based on the functions of this utility model and may vary depending on the intentions or conventions of the user or operator. Therefore, these terms are defined based on the entire contents of this specification.

[0028] like Figure 1 , 2 As shown, this utility model provides a height sensor with a wiring harness assembly, including a housing 1, a rotating shaft 2, a brush holder 3, a rocker arm 4, a circuit board 5, a bottom cover 6, and a wiring assembly 7. The housing 1 is rotatably connected to the rotating shaft 2, and the upper and lower ends of the rotating shaft 2 are respectively connected to the brush holder 3 and the rocker arm 4. The housing 1 is provided with a circuit board 5 corresponding to the brush holder 3, and a wiring assembly 7 for connecting to an external vehicle ECU. The brush holder 3 is provided with brushes 8 electrically connected to the circuit board 5. The bottom of the housing 1 is sealed with the bottom cover 6. The wiring assembly 7 includes an inner frame 11, a pin 12, a wiring harness 13, and a sensor head 14. The two ends of the inner frame 11 are respectively embedded with the pin 12 and the wiring harness 13. The pin 12 is electrically connected to the wiring harness 13. The inner frame 11 is sequentially connected to the housing 1 and the sensor head 14 by secondary injection molding, and the sensor head 14 is located at the connection between the inner frame 11 and the housing 1.

[0029] Combination Figure 4 , 5 As shown, in this embodiment, the outer casing 1 has a mounting cavity 101 for mounting the circuit board 5. A rectangular portion 102 is provided on one side of the outer casing 1. An inner frame 11 is disposed within the rectangular portion 102. A pin 12 extends through the rectangular portion 102 into the mounting cavity 101. The inner frame 11 includes a positioning portion 111, a transition portion 112, and a cylindrical portion 113 connected in sequence. The pin 12 and the wire harness 13 are respectively disposed within the positioning portion 111 and the cylindrical portion 113, and the pin 12 and the wire harness 13... The connection is located inside the adapter 112, and the positioning part 111 is embedded in the rectangular part 102. The adapter 112 is provided with a limiting protrusion 118 corresponding to the rectangular part 102. The plug structure of the traditional sensor housing 1 is changed to the rectangular part 102 for installing the inner skeleton 11. The adapter 112 is embedded between the rectangular part 102 and the sensor head 14 through the limiting protrusion 118, which prevents the inner skeleton 11 from being pulled out of the housing 1 when the wire harness 13 is pulled by external force, thus maintaining the stability of the structure.

[0030] Combination Figure 7As shown, in this embodiment, the rectangular part 102 is provided with a process groove 103 at the positioning part 111, and the positioning part 111 is provided with a positioning post 114 extending to the process groove 103. When the inner skeleton 11 is injection molded to form the outer shell 1, the design of the process groove 103 optimizes the material flow path at the rectangular part 102 and also provides space for the positioning post 114 of the inner skeleton 11 to be clamped by the mold, effectively reducing the length required for the positioning post 114 and avoiding the positioning post 114 from being too long and breaking, so that the structure is designed to be compact and reasonable.

[0031] Combination Figure 4 , 5 As shown, in this embodiment, the inner frame 11 is provided with a positioning groove 115 and a side pressure groove 116 for fixing the wire harness 13. The positioning groove 115 is distributed on the upper and lower sides of the connection of the adapter 112, and the side pressure groove 116 is provided on the left and right sides of the cylindrical part 113. The positioning groove 115 and the side pressure groove 116 are arranged in a cross shape around the inner frame 11. The positioning groove 115 and the side pressure groove 116 provide space for the injection mold to clamp the wire harness 13, and prevent the wire harness 13 from being offset by the impact of the molten material during injection molding. The sensor head 14 is provided with a rectangular part 141 and a cylindrical part 142 for covering the rectangular part 102 and the inner frame 11. After the outer shell 1 is injection molded, the sensor head 14 is injection molded again at the connection between the outer shell 1 and the inner frame 11, and the positioning groove 115 and the side pressure groove 116 are covered, which improves the aesthetics of the sensor and improves the structural strength of the bending point of the wire harness 13, effectively preventing damage to the internal core wire caused by bending the wire harness 13.

[0032] Combination Figure 3 As shown, in this embodiment, the pin assembly 12 is provided with a bending portion 121 and a riveting portion 122. The circuit board 5 is electrically connected to the bending portion 121. The wire core of the wire harness 13 is electrically connected to the pin assembly 12 through the riveting portion 122. The pin assembly 12 is provided with two or more sets of pins 123. A connecting tube 124 is provided between the pins 123. The positioning portion 111 is provided with a punching groove 117 for punching the connecting tube 124. When the inner skeleton 11 is made by mold opening, the pins 123 are connected to the wire core of the wire harness 13 through the riveting portion 122 to avoid the pins 123 and the wire core being broken by the impact of the molten material during injection molding. This ensures that each pin 123 is connected to the wire core. After the inner skeleton 11 is injection molded, the connecting tube 124 between adjacent pins 123 is cut through the punching groove 117 so that each pin 123 is independently distributed to meet the power connection requirements of the circuit board 5.

[0033] In this invention, the inner frame 11 is used as an installation insert. A secondary injection molding process is adopted to fix the wire harness 13, the pin 12, and the circuit board 5 inside the plastic shell. This eliminates the quick-connect structure of traditional sensors, thus eliminating the assembly gap caused by the quick-connect structure at the suspension point. There is no need to worry about the sealing ring or sealant hardening and failure. This fundamentally eliminates the possibility of short circuits caused by external rainwater or mud seeping in. Furthermore, the sensor head 14 is covered at the connection between the inner frame 11 and the outer shell 1 to improve the structural strength of the connection and extend the service life of the sensor in harsh working environments.

[0034] The assembly process of this utility model is as follows: First, the wire harness 13 is stripped and fixed with the corresponding colored wire core by riveting the riveting part 122 of the pin 12; second, the fixed pin 12 and wire harness 13 are injection molded to form the inner skeleton 11 through the inner skeleton 11 mold; then, the connecting tube 124 of the pin 12 is cut and injection molded on the basis of the inner skeleton 11 through the outer shell 1 mold to form the outer shell 1; next, the sensor head 14 is injection molded on the basis of the outer shell 1 through the sensor head 14 mold to form the sensor head 14; then, the brush holder 3 and rocker arm 4 are installed on the outer shell 1 through the rotating shaft 2, and the circuit board 5 is placed in the mounting cavity 101 and electrically connected to the brush 8 and pin 12; finally, the bottom cover 6 is closed on the bottom of the mounting cavity 101 and welded and sealed by laser welding process, thereby completing the assembly.

[0035] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A height sensor with a wiring harness assembly, comprising a housing (1), a rotating shaft (2), a brush holder (3), a rocker arm (4), a circuit board (5), a bottom cover (6), and a wiring assembly (7), wherein the housing (1) is rotatably connected to the rotating shaft (2), the upper and lower ends of the rotating shaft (2) are respectively connected to the brush holder (3) and the rocker arm (4), the housing (1) is provided with a circuit board (5) corresponding to the brush holder (3), and a wiring assembly (7) for connecting to an external vehicle ECU, the brush holder (3) is provided with brushes (8) electrically connected to the circuit board (5), and the bottom of the housing (1) is sealed with the bottom cover (6), characterized in that, The wiring assembly (7) includes an inner frame (11), a pin (12), a wire harness (13), and a sensor head (14). The two ends of the inner frame (11) are respectively embedded with the pin (12) and the wire harness (13). The pin (12) is electrically connected to the wire harness (13). The inner frame (11) is connected to the outer shell (1) and the sensor head (14) in sequence by secondary injection molding. The sensor head (14) is located at the connection between the inner frame (11) and the outer shell (1).

2. A height sensor with a wiring harness assembly according to claim 1, characterized in that: The outer casing (1) is provided with a mounting cavity (101) for mounting the circuit board (5). A rectangular part (102) is provided on one side of the outer casing (1). The inner frame (11) is located in the rectangular part (102). The pin (12) extends through the rectangular part (102) into the mounting cavity (101).

3. A height sensor with a wiring harness assembly according to claim 2, characterized in that: The inner frame (11) includes a positioning part (111), a transition part (112) and a cylindrical part (113) connected in sequence. The pin (12) and the wire harness (13) are respectively located in the positioning part (111) and the cylindrical part (113), and the connection between the pin (12) and the wire harness (13) is located in the transition part (112). The positioning part (111) is embedded in the rectangular part (102), and the transition part (112) is provided with a limiting protrusion (118) corresponding to the rectangular part (102).

4. A height sensor with a wiring harness assembly according to claim 3, characterized in that: The rectangular part (102) is provided with a process groove (103) at the positioning part (111), and the positioning part (111) is provided with a positioning post (114) extending to the process groove (103).

5. A height sensor with a wiring harness assembly according to claim 4, characterized in that: The inner frame (11) is provided with a positioning groove (115) and a side pressure groove (116) for fixing the wire harness (13). The positioning groove (115) is distributed on the upper and lower sides of the connection of the adapter (112), and the side pressure groove (116) is provided on the left and right sides of the cylindrical part (113).

6. A height sensor with a wiring harness assembly according to claim 5, characterized in that: The sensor head (14) is provided with a rectangular part (141) and a cylindrical part (142) for covering the rectangular part (102) and the inner frame (11).

7. A height sensor with a wiring harness assembly according to claim 3, characterized in that: The pin assembly (12) is provided with a bending part (121) and a riveting part (122). The circuit board (5) is electrically connected to the bending part (121), and the wire core of the wire harness (13) is electrically connected to the pin assembly (12) through the riveting part (122).

8. A height sensor with a wiring harness assembly according to claim 7, characterized in that: The pin component (12) is provided with two or more sets of pins (123), and a connecting tube (124) is provided between the pins (123). The positioning part (111) is provided with a punching groove (117) for punching the connecting tube (124).

Images