An eddy current sensor for new energy vehicles

Abstract

The utility model discloses a new energy automobile electric eddy current sensor in the field of new energy automobile sensor, including the casing and the wire harness, be provided with the briquetting and circuit board in the casing, the wire harness passes through briquetting and circuit board electricity is connected, briquetting inside along the length direction of itself is set up with a plurality of wire harness conductor passes through's through -hole structure, the through -hole structure includes the small through -hole and big through -hole of coaxial setting, the sealed cavity is formed between big through -hole inner wall and wire harness conductor outer wall, briquetting side surface corresponds small through -hole and forms the circular platform outwardly extending, the wire harness is equipped with the heat shrinkable sheath, and the heat shrinkable sheath end extends to the circular platform outside, the casing inner wall is seted up with the sealed recess, the casing is filled with the filling sealant, and the filling sealant forms the encapsulation layer in the sealed cavity, the sealed recess and above circuit board after solidification. The utility model has solved the sealed, insulation, anti -vibration problem between wire harness and sensor.

Description

Technical Field

[0001] This utility model belongs to the field of new energy vehicle sensor technology, and specifically relates to an eddy current sensor for new energy vehicles. Background Technology

[0002] Eddy current sensors, as a non-contact measurement device based on the principle of electromagnetic induction, are widely used in core scenarios such as wheel speed detection and motor rotor position sensing in new energy vehicles due to their high precision, strong anti-interference ability, and fast response speed.

[0003] At the connection point between the wiring harness and the sensor, which serves as the direct interface between the external environment and the sensor's internal circuitry, if the seal fails at the point where the wiring harness passes through the housing, moisture, oil, and other media can seep in along the gap between the wiring harness conductor and the housing, leading to problems such as short circuits on the circuit board, signal transmission interference, and decreased insulation resistance. This can cause anything from minor sensor false alarms or malfunctions to serious issues like high-voltage system breakdown, threatening passenger safety in existing technologies. Utility Model Content

[0004] The purpose of this invention is to provide an eddy current sensor for new energy vehicles, which solves the problems of sealing, insulation, and vibration resistance between the wiring harness and the sensor, protects the circuit board from environmental influences, and improves the reliability and service life of the sensor under the complex operating conditions of new energy vehicles.

[0005] The purpose of this utility model is achieved as follows: An eddy current sensor for new energy vehicles includes a housing and a wiring harness. A pressure block and a circuit board are disposed within the housing. The wiring harness passes through the pressure block and is electrically connected to the circuit board. The pressure block has several through-hole structures along its length to allow the wiring harness conductor to pass through. Each through-hole structure includes small and large through-holes arranged coaxially. A sealed cavity is formed between the inner wall of the large through-hole and the outer wall of the wiring harness conductor. A frustum extends outward from the side of the pressure block corresponding to the small through-holes. A heat-shrinkable sheath is fitted over the wiring harness, with its end extending to the outside of the frustum. A sealing groove is formed on the inner wall of the housing. The housing is filled with potting compound. After curing, the potting compound forms an encapsulation layer above the circuit board, inside the sealed cavity, and within the sealing groove.

[0006] During assembly, the circuit board is placed inside the housing, a heat-shrinkable sheath is applied to the wire harness, the ends of the wire harness are stripped, and the wire harness conductors are sequentially passed through the small and large through holes coaxially arranged inside the pressure block. Then, the pressure block is installed inside the housing, and the ends of the wire harness conductors are electrically connected to the circuit board pads. The heat-shrinkable sheath is heated to tightly wrap the wire harness and fit against the frustum to form an initial seal, preventing the medium from seeping in through the gap between the wire harness and the pressure block. Finally, potting compound is injected into the housing. The flowing potting compound fills the sealing groove, sealing cavity, and the area above and around the circuit board. After the compound cures, a continuous encapsulation layer is formed above the circuit board, inside the sealing cavity, and in the sealing groove, isolating external liquids, dust, and other media from intrusion. Compared with the prior art, the beneficial effects of this utility model are as follows: by using layered through holes in the pressure block, shrinking of the heat-shrinkable sheath, and full-area filling with potting compound, multiple sealing and fixing of the interface between the wire harness and the housing are achieved; after the potting compound cures, it wraps the wire harness conductor, pressure block, and circuit board, solidifying each component and the housing into a whole, avoiding problems such as wire harness loosening, poor contact, or circuit board solder joint detachment caused by vehicle vibration; the heat-shrinkable sheath itself has high insulation, and together with the insulating potting compound, it forms a double insulation barrier between the wire harness and the pressure block and housing, preventing leakage current or creepage of the high-voltage wire harness and ensuring the electrical safety of the sensor; the potting compound in the sealed cavity fills the gap between the wire harness conductor and the inner wall of the large through hole, preventing conductor exposure and reducing the risk of short circuit.

[0007] As a further improvement of this utility model, the two sides of the pressure block extend horizontally outward along their own length to form a pressure plate. A pressure hole is opened at the center of the pressure plate. An integrally formed mounting seat for accommodating the pressure plate is formed inside the housing. A rivet post is integrally formed on the upper side of the mounting seat. The rivet post passes through the pressure hole and forms a mushroom head on the upper side of the pressure plate using a hot riveting process.

[0008] As a further improvement of this utility model, the width of the pressing plate is smaller than the width of the pressing block.

[0009] As a further improvement of this utility model, a locking block is provided on the lower side of the pressure block along its own length direction, and a boss is integrally formed inside the housing to form a locking structure with the two sides of the locking block.

[0010] As a further improvement of this utility model, the housing includes a disc body portion, and a plurality of mounting portions are provided on the outer periphery of the disc body portion, and through-hole inserts are provided in the mounting portions.

[0011] As a further improvement of this utility model, the circuit board includes an annular electromagnetic induction area coaxially arranged with the disk body, the side of the electromagnetic induction area extends horizontally outward to form a rectangular connection area, and a conductive part for electrical connection with the wire harness conductor is provided on the upper side of the rectangular connection area.

[0012] As a further improvement of this utility model, the potting compound is one of epoxy resin, silicone and polyurethane materials. Attached Figure Description

[0013] Figure 1 This is a top view of the present invention.

[0014] Figure 2 for Figure 1 Sectional view at point AA.

[0015] Figure 3 This is a three-dimensional structural diagram of the pressure block of this utility model.

[0016] Figure 4 This is a three-dimensional structural diagram of the shell of this utility model.

[0017] The components include: 1. Housing; 101. Sealing groove; 102. Mounting base; 103. Rivet post; 104. Boss; 105. Disc body; 106. Mounting part; 2. Wire harness; 201. Conductor; 3. Pressing block; 301. Small through hole; 302. Large through hole; 303. Sealing cavity; 304. Frustum; 305. Press plate; 306. Press hole; 307. Locking block; 4. Circuit board; 401. Electromagnetic induction area; 402. Connection area; 403. Conductive part; 5. Heat shrink sleeve; 6. Encapsulation layer; 7. Through hole insert. Detailed Implementation

[0018] like Figure 1-2 As shown, an eddy current sensor for new energy vehicles includes a housing 1 and a wiring harness 2. A pressure block 3 and a circuit board 4 are disposed inside the housing 1. The wiring harness 2 passes through the pressure block 3 and is electrically connected to the circuit board 4. The pressure block 3 has six through-hole structures along its length, allowing the conductor 201 of the wiring harness 2 to pass through. Specifically, the through-hole structure includes a small through-hole 301 and a large through-hole 302 arranged coaxially. The annular gap between the inner wall of the large through-hole 302 and the outer wall of the conductor 201 of the wiring harness 2 forms a sealing cavity 303. The side of the pressure block 3 extends outward from the small through-hole 301 to form a frustum 304. A heat-shrinkable sheath 5 is fitted over the wiring harness 2, with its end extending to the outside of the frustum 304. A sealing groove 101 is formed on the inner wall of the housing 1. The housing 1 is filled with epoxy resin potting compound. After the potting compound cures, an encapsulation layer 6 is formed above the circuit board 4, inside the sealing cavity 303, and inside the sealing groove 101.

[0019] like Figure 3-4As shown, the pressure block 3 extends horizontally outward along its own length on both sides to form a pressing plate 305. The width of the pressing plate 305 is smaller than the width of the main body of the pressure block 3, and a pressing hole 306 is opened at the center. An integrally formed mounting base 102 for accommodating the pressing plate 305 is formed inside the housing 1. A rivet post 103 is integrally formed on the upper side of the mounting base 102. The rivet post 103 passes through the pressing hole 306 and forms a mushroom head on the upper side of the pressing plate 305 by hot riveting. A locking block 307 is provided on the lower side of the pressure block 3 along its own length. A boss 104 is integrally formed inside the housing 1 for forming a locking structure with the two sides of the locking block 307. The housing 1 includes a disc part 105. Three mounting parts 106 are provided on the outer periphery of the disc part 105. Through-hole inserts 7 are provided in the mounting parts 106.

[0020] The circuit board 4 includes an annular electromagnetic induction area 401 coaxially disposed with the disk body 105. The side of the electromagnetic induction area 401 extends horizontally outward to form a rectangular connection area 402. A conductive part 403 for electrically connecting with the conductor 201 of the wire harness 2 is disposed on the upper side of the rectangular connection area 402.

[0021] The advantages of this utility model are as follows: After the rivet 103 passes through the crimping hole 306, it is hot-riveted to form a mushroom head. This not only achieves a rigid connection between the pressure block 3 and the housing 1 through mechanical fitting, but the plastic deformation of the mushroom head can also fill the gap between the crimping hole 306 and the rivet 103, forming a micron-level seal and preventing the medium from intruding from the side of the pressure block 3. At the same time, the hot riveting process does not require additional fasteners, simplifying the assembly process and improving production efficiency. The locking block 307 on the lower side of the pressure block 3 forms a transverse locking with the two bosses 104, which, together with the hot riveting fixation, forms a double constraint in both the longitudinal and transverse directions. Even if high-frequency vibration occurs during vehicle operation, the pressure block 3 will not shift relative to the housing 1, avoiding the failure of the seal due to the breakage of the conductor 201 of the wire harness 2 and the solder joint of the circuit board 4 caused by pulling, or the loosening of the pressure block 3.

[0022] This utility model is not limited to the above embodiments. Based on the technical solutions disclosed in this utility model, those skilled in the art can make some substitutions and modifications to some of the technical features without creative labor, and these substitutions and modifications are all within the protection scope of this utility model.

Claims

1. An eddy current sensor for new energy vehicles, comprising a housing and a wiring harness, wherein a pressure block and a circuit board are disposed within the housing, and the wiring harness passes through the pressure block and is electrically connected to the circuit board, characterized in that, The pressure block has several through-hole structures along its length to allow wire harness conductors to pass through. The through-hole structures include small through-holes and large through-holes arranged coaxially. A sealed cavity is formed between the inner wall of the large through-hole and the outer wall of the wire harness conductor. The side of the pressure block extends outward to form a frustum corresponding to the small through-hole. The wire harness is covered with a heat-shrinkable sheath, the end of which extends to the outside of the frustum. A sealing groove is formed on the inner wall of the housing. The housing is filled with potting compound. After the potting compound cures, it forms an encapsulation layer above the circuit board, inside the sealed cavity, and inside the sealing groove.

2. The eddy current sensor for new energy vehicles according to claim 1, characterized in that, The two sides of the pressure block extend horizontally outward along their own length to form a pressure plate. A pressure hole is opened at the center of the pressure plate. An integrally formed mounting base for accommodating the pressure plate is formed inside the housing. A rivet post is integrally formed on the upper side of the mounting base. The rivet post passes through the pressure hole and forms a mushroom head on the upper side of the pressure plate using a hot riveting process.

3. The eddy current sensor for new energy vehicles according to claim 2, characterized in that, The width of the pressing plate is smaller than the width of the pressing block.

4. The eddy current sensor for new energy vehicles according to claim 2, characterized in that, A locking block is provided on the lower side of the pressure block along its own length direction, and a boss is integrally formed inside the housing to form a locking structure with the two sides of the locking block.

5. The eddy current sensor for new energy vehicles according to claim 1, characterized in that, The housing includes a disc portion, and a plurality of mounting portions are provided on the outer periphery of the disc portion, with through-hole inserts provided in the mounting portions.

6. The eddy current sensor for new energy vehicles according to claim 5, characterized in that, The circuit board includes an annular electromagnetic induction area coaxially arranged with the disk body. The side of the electromagnetic induction area extends horizontally outward to form a rectangular connection area. A conductive part for electrical connection with the wire harness conductor is provided on the upper side of the rectangular connection area.

7. The eddy current sensor for new energy vehicles according to claim 1, characterized in that, The potting compound is one of epoxy resin, silicone, and polyurethane materials.

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