A current sensing unit and an inverter

Abstract

The utility model discloses an embodiment of current sensing unit and inverter relates to the technical field of vehicle -mounted electronic product. The current sensing unit includes insulating cover and sensor. Insulating cover includes insulating cover body and insulating cover pin, and the inside cavity is formed by the self enclosure of insulating cover body, and one end of insulating cover pin is fixedly connected with insulating cover body, and the other end is used for connecting control panel;Sensor includes sensor body and sensor pin;Among them, sensor body is fixedly arranged in the inside cavity, and sensor pin is connected with sensor body, and part is stretched out in the inside cavity, to be used for electric connection control panel, and insulating cover body is made of insulating material, to be used for high low voltage isolation. The insulating cover in the current sensing unit forms "isolation wall" through its own insulating property, plays the role of high low voltage insulation, need not to do insulating treatment on the current -carrying conductor additionally, and it reduces the manufacturing cost of current -carrying conductor while guaranteeing the sensing precision of sensor.

Description

Technical Field

[0001] This utility model relates to the field of automotive electronic products technology, and in particular to a current sensing unit and an inverter. Background Technology

[0002] Current sensors are used to sense the current on the phase lines of a motor and are a key parameter for realizing torque closed-loop control. Their non-contact measurement, high isolation, and fast response characteristics make them indispensable in complex power electronic systems.

[0003] In related technologies, the integration of current sensors and magnetic cores remains the mainstream design. For example... Figure 1 The diagram shows an integrated design of a pin-type current sensor and a C-shaped magnetic core. A energized copper busbar is placed in the center of the C-shaped magnetic core, which is made of grain-oriented silicon steel to block external interference and prevent external noise from affecting the current sensor's sensing accuracy. The current sensor body is connected to the control board via pins, sensing a magnetic field and converting it into a voltage signal output. Figure 2 The diagram shows an integrated design of a surface-mount current sensor and a U-shaped magnetic core. Similarly, a energized copper busbar is placed in the middle of the U-shaped magnetic core, which is made of oriented silicon steel sheet. This blocks external interference and prevents external noise from affecting the current sensor's sensing accuracy. The current sensor body is connected to the motherboard via pins, sensing a magnetic field and converting it into a voltage signal output.

[0004] However, with the miniaturization of product designs and the need to balance increasing power density with reducing size and weight, coreless current sensors have emerged as a novel miniaturized design solution for developers. Coreless current sensors acquire current information by directly measuring changes in the magnetic field generated by the current, without relying on traditional ferromagnetic cores. For example... Figure 3 The diagram illustrates an example of a coreless current sensor design. A slot is cut into the center of a current-carrying conductor, and the current sensor is embedded within this slot to sense changes in the magnetic field and convert them into a voltage signal output. The current sensor connects to a control board via its pins to transmit the acquired signal. The coreless design eliminates the need for a magnetic core, completely resolving the risk of magnetic saturation, and its simple structure enhances design flexibility.

[0005] Furthermore, since the coreless current sensor needs to be inserted into the slotted section of the energized conductor, which carries a high-voltage signal, while the current sensor is connected to the control board to transmit a low-voltage signal, it is necessary to ensure that the current sensor (including the pins) is insulated from the energized conductor. However, the current sensor in the relevant technology cannot solve the above technical problem. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the purpose of this utility model is to provide a current sensing unit and an inverter. In this current sensing unit, the insulating cover forms an "isolation wall" through its own insulating properties, which plays a role in high and low voltage insulation. There is no need to do additional insulation treatment on the current-carrying conductor. While ensuring the sensing accuracy of the sensor, it reduces the manufacturing cost of the current-carrying conductor. At the same time, the setting of the insulating cover pins can further enhance the structural stability of the connection between the sensor unit and the control board. Specifically, the insulating cover pins and the control board do not need to transmit signals, but only serve to mechanically connect and fix the two.

[0007] This utility model embodiment discloses a current sensing unit, including:

[0008] An insulating cover includes an insulating cover body and insulating cover pins. The insulating cover body itself encloses an internal cavity. One end of the insulating cover pins is fixedly connected to the insulating cover body, and the other end is used to connect to a control board.

[0009] The sensor includes the sensor body and the sensor pins;

[0010] The sensor body is fixedly arranged in the internal cavity, the sensor pins are connected to the sensor body and partially extend out of the internal cavity for electrical connection to the control board, the insulating cover body is made of insulating material for high and low voltage isolation, the sensor body is used to sample high voltage signals, and the sensor pins are used to transmit low voltage signals.

[0011] Furthermore, the internal cavity is filled with an adhesive, through which the sensor body is bonded to the internal cavity.

[0012] Furthermore, the adhesive includes adhesive glue or thermally conductive adhesive.

[0013] Furthermore, the internal cavity has an adhesive outlet and an electrical outlet at both ends along the axial direction, and a portion of the sensor pin extends out of the internal cavity through the electrical outlet. The adhesive is filled into the internal cavity through the adhesive outlet.

[0014] Furthermore, the insulating cover pins and the sensor pins are arranged in the same orientation.

[0015] Furthermore, the insulating cover pins are embedded in the insulating cover body.

[0016] Furthermore, the insulating cover pins are bonded to the insulating cover body.

[0017] Furthermore, the insulating cover body is made of polyhexamethylene terephthalate or polyphenylene sulfide.

[0018] This utility model embodiment also discloses an inverter, including:

[0019] Such as the current sensing unit mentioned above;

[0020] A current-carrying conductor, wherein an installation groove is formed in the current-carrying conductor;

[0021] The insulating cover is adapted to the mounting groove and is fixedly arranged in the mounting groove.

[0022] Furthermore, it also includes a control board, to which the sensor pins are soldered via reflow soldering.

[0023] Furthermore, the insulating cover pins are metal pins and are soldered to the control board by reflow soldering to fix the insulating cover body.

[0024] Furthermore, the insulating cover pins are bonded to the control board to secure the insulating cover body.

[0025] The current sensing unit and inverter provided by this utility model have the following beneficial effects, including but not limited to:

[0026] 1) The insulating cover in this current sensing unit forms an "isolation wall" through its own insulating properties, which plays the role of high and low voltage insulation. There is no need to do additional insulation treatment on the current-carrying conductor. While ensuring the sensing accuracy of the sensor, it reduces the manufacturing cost of the current-carrying conductor.

[0027] 2) This current sensing unit has a dispensing port. Dispensing adhesive through the dispensing port can make the sensor and the insulating cover body bond well, which increases the sensor's ability to resist external interference (such as mechanical shock and vibration) and solves the problem of sensing accuracy deviation caused by the displacement of the sensor relative to the current-carrying conductor during dynamic processes such as vehicle movement.

[0028] 3) The adhesive dispensing in this current sensing unit ensures good adhesion between the sensor and the insulating cover body, and the sensor is surrounded by the insulating cover body to form a safety protection sleeve, which solves the problem of sensor initial position displacement or even damage caused by transportation and human factors during the inverter product manufacturing process. Attached Figure Description

[0029] This specification will be further described by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting; in these embodiments, the same reference numerals denote the same structures, wherein:

[0030] Figure 1 A schematic diagram of the structure of a C-type sensor provided for related technologies;

[0031] Figure 2A schematic diagram of the structure of a U-shaped sensor provided for related technologies;

[0032] Figure 3 A schematic diagram of the structure of a coreless current sensor provided for related technologies;

[0033] Figure 4 One of the structural schematic diagrams of the current sensing unit provided in the embodiment of this utility model;

[0034] Figure 5 This is the second schematic diagram of the current sensing unit provided in the embodiment of this utility model.

[0035] Icon: 100 - Current sensing unit;

[0036] 101 - Internal cavity; 104 - Insulating cover body; 105 - Insulating cover pin;

[0037] 111 - Sensor body; 112 - Sensor pins

[0038] 20 - Current-carrying conductor; 201 - Mounting slot. Detailed Implementation

[0039] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0040] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Therefore, the illustrations only show the components related to the present invention and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0041] Please refer to Figures 4-5 ,in, Figure 4 This is one of the structural schematic diagrams of the current sensing unit 100 provided in this embodiment of the utility model; Figure 5This is a second structural schematic diagram of the current sensing unit 100 provided in this embodiment of the present invention. The present invention provides a current sensing unit 100, which includes an insulating cover and a sensor. The insulating cover includes an insulating cover body 104 and insulating cover pins 105. The insulating cover body 104 forms an internal cavity 101. One end of the insulating cover pins 105 is fixedly connected to the insulating cover body 104, and the other end is used to connect to a control board (not shown in the figure). The sensor includes a sensor body 111 and sensor pins 112. The sensor body 111 is fixedly arranged in the internal cavity 101, and the sensor pins 112 are connected to the sensor body 111 and partially extend out of the internal cavity 101 for electrical connection to the control board. The insulating cover body 111 is made of insulating material for high and low voltage isolation. The sensor body 111 is used to sample high-voltage signals, and the sensor pins are used to transmit low-voltage signals. The high-voltage signal refers to the magnetic field signal on the current-carrying conductor busbar.

[0042] It should be noted that, Figures 4-5 The illustration also includes a current-carrying conductor 20, which appears in the figure only to illustrate the relative positions of the current sensing unit 100 and the current-carrying conductor 20, and does not represent that the current sensing unit 100 in this application includes the current-carrying conductor 20. It is understood that the current-carrying conductor 20 can be the current-carrying conductor 20 output from the inverter to each phase of the motor, or it can be the current-carrying conductor 20 of other electrical components.

[0043] It is worth noting that the insulating cover in the current sensing unit 100 forms an "isolation wall" through its own insulating properties, serving as a high- and low-voltage insulation barrier. No additional insulation treatment is needed on the current-carrying conductor 20, which ensures the sensor's sensing accuracy while reducing the manufacturing cost of the current-carrying conductor 20. Furthermore, the placement of the insulating cover pins further enhances the structural stability of the connection between the sensor unit and the control board. Specifically, the insulating cover pins and the control board do not need to transmit signals; they only serve a mechanical connection and fixation function.

[0044] In some embodiments, the internal cavity 101 is filled with an adhesive, through which the sensor body 111 is bonded to the internal cavity 101.

[0045] Optionally, the adhesive may include adhesive glue or thermally conductive adhesive.

[0046] Specifically, by using adhesive to fill the internal cavity 101, the initial sway of the sensor caused by external factors can be prevented, ensuring good adhesion between the sensor and the insulating cover body 104. The sensor is also surrounded by the insulating cover body 104 (through adhesive) to form a safety protection sleeve, thus solving the problem of initial position displacement or even damage of the current sensor caused by transportation or human factors during the product manufacturing process.

[0047] It should be understood that the adhesive effectively fills the gap between the sensor body 111 and the insulating cover body 104, enhancing structural stability and preventing sensor displacement or loosening due to vibration, impact, or mechanical stress during transportation. Furthermore, replacing traditional clips or mechanical clamps with adhesive bonding reduces assembly errors and improves consistency and reliability in mass production. Simultaneously, the thermally conductive adhesive also possesses certain thermal conductivity properties, effectively transferring the heat generated during sensor operation to the insulating cover shell or heat dissipation structure, helping to reduce device temperature rise and extend sensor lifespan.

[0048] In some embodiments, the internal cavity 101 has an adhesive dispensing port and an electrical port at its two axial ends, respectively. A portion of the sensor pin 112 extends out of the internal cavity 101 through the electrical port, and adhesive is filled into the internal cavity 101 through the adhesive dispensing port. It is understood that the two axial ends here refer to the two ends in the axial direction of the internal cavity 101, and their specific locations can be referred to in Figure 6.

[0049] It is worth noting that the current sensing unit 100, by setting a dispensing port facing the opposite direction to the electrical port, allows for convenient injection of adhesive during the encapsulation stage. This ensures a good bond between the sensor and the insulating cover body 104, increasing the sensor's resistance to external interference (such as mechanical shock and vibration) and resolving the sensing accuracy deviation caused by displacement of the sensor relative to the current-carrying conductor 20 during dynamic processes such as vehicle movement. Specifically, without the dispensing port, adhesive would be difficult to distribute evenly and sufficiently between the sensor body 111 and the insulating cover from the electrical port, easily forming air bubbles and gaps, resulting in weak adhesion or off-center installation. This not only affects structural strength but also causes sensor displacement during long-term use, thus affecting its sensing accuracy and lifespan. The dispensing port not only optimizes the assembly process and improves manufacturing yield but also effectively enhances the reliability and adaptability of the sensor unit without increasing additional structural complexity, making it particularly suitable for automotive applications requiring strong resistance to environmental interference. It is also understandable that the adhesive or thermally conductive adhesive injected from the dispensing port has a certain degree of plasticity and viscosity, and is not a readily flowing liquid. Therefore, it will not leak or seep out from the electrical port due to excessive flow.

[0050] In some embodiments, the insulating cover pin 105 and the sensor pin 112 are arranged in the same orientation.

[0051] It is worth noting that the insulating cover pin 105 and the sensor pin 112 are arranged in the same direction, which facilitates the processing and forming of the current sensing unit 100 and is beneficial for industrial promotion.

[0052] In some embodiments, the insulating cover pins 105 are embedded in the insulating cover body 104.

[0053] It is worth noting that the insulating cover pins 105 are embedded in the insulating cover body 104, which can be achieved through injection molding, slot positioning, or in-mold inserts. In this case, the insulating cover pins 105 and the insulating cover body 104 are mechanically connected, which can withstand greater tensile force, insertion and extraction force, or bending stress, and is not easily loosened or displaced. The inserts are pre-placed in the mold and can be injection molded with the insulating material in one step, reducing subsequent processes and improving production consistency and automation.

[0054] In other embodiments, the insulating cover pins 105 are bonded to the insulating cover body 104.

[0055] It is worth noting that the insulating cover pins 105 are bonded to the insulating cover body 104 using conductive adhesive, structural adhesive, epoxy resin, or other methods. This eliminates the need for precision molds or slot designs, allowing for compatibility with pin assemblies of various sizes and shapes, facilitating versatility across multiple product categories. Simultaneously, the adhesive fills the gaps between the pins and the body, improving sealing and electrical insulation performance, and enhancing dustproof, moisture-proof, and oxidation-proof capabilities. Furthermore, this bonding method allows for easier fixation after sensor or connector assembly, facilitating on-site maintenance or replacement.

[0056] Alternatively, the insulating cover body 104 may be made of poly(hexamethylene terephthalate)diamine or polyphenylene sulfide (PPS).

[0057] Specifically, the insulating cover body 104 is made of PA6T or PPS material, both of which possess excellent high-temperature resistance, mechanical strength, and electrical insulation properties, meeting the requirements for long-term stable operation in complex environments such as high temperature, high humidity, and high voltage. Depending on the specific implementation environment, other insulating materials may also be used to manufacture the insulating cover body 104. This embodiment does not constitute a limitation on the specific materials used, but is merely an example illustrating preferred materials.

[0058] This utility model embodiment also discloses an inverter, including a current sensing unit 100 and a current-carrying conductor 20 as described above, wherein a mounting groove 201 is provided in the current-carrying conductor 20; wherein, an insulating cover is adapted to the mounting groove 201 and is fixedly arranged in the mounting groove 201.

[0059] It is worth noting that the current sensing unit 100 can also be applied to other existing electrical components, which will not be described in detail in this embodiment.

[0060] In some embodiments, a control board (not shown) is also included, to which sensor pin 112 is soldered via reflow soldering.

[0061] In some embodiments, the insulating cover pins 105 are metal pins and are soldered to the control board by reflow soldering to fix the insulating cover body 104.

[0062] In other embodiments, the insulating cover pins are glued to the control board to secure the insulating cover body.

[0063] It is worth noting that this embodiment does not constitute a limitation on the connection method between the insulating cover pins and the controller, as long as it can serve the purpose of mechanical fixation.

[0064] In some embodiments, the inverter assembly process involves first reflow soldering the sensor to the control board, and then reflow soldering the insulating cover to a designated position around the sensor. The slot dimensions of the insulating cover are designed using relevant dimensional chain calculations to ensure that the insulating cover body 104 and the sensor do not physically interfere with each other during the automated reflow soldering process.

[0065] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

[0066] Throughout this description, numerous specific details, such as examples of components and / or methods, are provided to provide a complete understanding of embodiments of the present invention. However, those skilled in the art will recognize that embodiments of the present invention may be practiced without one or more of these specific details or by other devices, systems, components, methods, parts, materials, components, etc. In other instances, well-known structures, materials, or operations have not been specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.

[0067] Throughout this specification, references to "an embodiment," "an embodiment," or "a specific embodiment" mean that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention, but not necessarily in all embodiments. Therefore, the various representations of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout the specification do not necessarily refer to the same embodiment. Furthermore, a particular feature, structure, or characteristic of any specific embodiment of the present invention can be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments of the present invention shown herein may be based on the teachings herein and will be considered part of the spirit and scope of the present invention.

[0068] It should also be understood that one or more of the elements shown in the figures may be implemented in a more separate or more integrated manner, or may even be removed because they are inoperable in certain circumstances or provided because they may be useful for a particular application.

[0069] Furthermore, unless otherwise expressly stated, any arrows in the accompanying drawings should be considered illustrative only and not limiting. Additionally, unless otherwise stated, the term "or" as used herein is generally intended to mean "and / or". Where a term is anticipated to provide a separation or combination capability that is unclear, a combination of components or steps will also be considered as indicated.

[0070] As used herein and throughout the claims below, unless otherwise specified, “a” and “the” include the plural references. Similarly, as used herein and throughout the claims below, unless otherwise specified, “in” means “in” and “on”.

[0071] The above description of the embodiments shown in this utility model (including the content in the abstract of the specification) is not intended to be an exhaustive enumeration or to limit the utility model to the precise forms disclosed herein. Although specific embodiments and examples of the utility model have been described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the utility model, as will be recognized and understood by those skilled in the art. As indicated, these modifications can be made to the utility model in accordance with the above description of the embodiments of the utility model, and such modifications will be within the spirit and scope of the utility model.

[0072] This document has generally described the systems and methods in detail to aid in understanding the present invention. Furthermore, various specific details have been set forth to provide a general understanding of embodiments of the present invention. However, those skilled in the art will recognize that embodiments of the present invention can be practiced without one or more specific details, or using other devices, systems, accessories, methods, components, materials, parts, etc. In other instances, well-known structures, materials, and / or operations have not been specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention.

Claims

1. A current sensing unit, characterized in that, include: An insulating cover includes an insulating cover body and insulating cover pins. The insulating cover body itself encloses an internal cavity. One end of the insulating cover pins is fixedly connected to the insulating cover body, and the other end is used to connect to a control board. The sensor includes the sensor body and the sensor pins; The sensor body is fixedly arranged in the internal cavity, the sensor pins are connected to the sensor body and partially extend out of the internal cavity for electrical connection to the control board, the insulating cover body is made of insulating material for high and low voltage isolation, the sensor body is used to sample high voltage signals, and the sensor pins are used to transmit low voltage signals.

2. The current sensing unit according to claim 1, characterized in that, The internal cavity is filled with adhesive, through which the sensor body is bonded to the internal cavity.

3. The current sensing unit according to claim 2, characterized in that, The adhesive includes adhesive glue or thermally conductive adhesive.

4. The current sensing unit according to claim 2, characterized in that, The internal cavity has an adhesive outlet and an electrical outlet at both ends along the axial direction. A portion of the sensor pin extends out of the internal cavity through the electrical outlet, and the adhesive fills the internal cavity through the adhesive outlet.

5. The current sensing unit according to claim 1, characterized in that, The insulating cover pins and the sensor pins are arranged in the same orientation.

6. The current sensing unit according to claim 5, characterized in that, The insulating cover pins are embedded in the insulating cover body.

7. The current sensing unit according to claim 5, characterized in that, The insulating cover pins are bonded to the insulating cover body.

8. The current sensing unit according to claim 5, characterized in that, The insulating cover body is made of polyhexamethylene terephthalate or polyphenylene sulfide.

9. An inverter, characterized in that, include: The current sensing unit as described in any one of claims 1-8; A current-carrying conductor, wherein an installation groove is formed in the current-carrying conductor; The insulating cover is adapted to the mounting groove and is fixedly arranged in the mounting groove.

10. The inverter according to claim 9, characterized in that, It also includes a control board, to which the sensor pins are soldered via reflow soldering.

11. The inverter according to claim 9, characterized in that, The insulating cover pins are metal pins and are soldered to the control board by reflow soldering to fix the insulating cover body.

12. The inverter according to claim 9, characterized in that, The insulating cover pins are bonded to the control board to fix the insulating cover body.

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