A new energy automobile motor rotor position sensor

Abstract

The utility model discloses a kind of for new energy automobile motor rotor position sensor, belong to new energy automobile accessory technical field, including wire harness subassembly, wire harness subassembly wire side is fixedly connected with wire harness bracket assembly, wire harness subassembly wire end is fixedly connected with circuit board, wire harness bracket assembly and circuit board connection position and on circuit board respectively fixedly covered with several low-pressure injection-molding shell assemblies, several low-pressure injection-molding shell assemblies are provided with several metal embedding rings away from circuit board side, the circuit board, several low-pressure injection-molding shell assemblies and several metal embedding rings are fixedly covered with high-pressure injection-molding shell outside;The utility model uses low-pressure injection-molding material for structural member design, does not affect sensor output precision while reducing the number of parts and thickness to realize the double satisfaction of sealing and structural strength, and can solve the problem that product manufacturing cost is high due to epoxy resin sealing solidification working hours long.

Description

Technical Field

[0001] This utility model belongs to the field of new energy vehicle parts technology, specifically relating to a rotor position sensor for a new energy vehicle motor. Background Technology

[0002] The rotor position sensor of a new energy vehicle motor is a core sensing component installed inside the drive motor (or end cover) to detect the spatial position, rotation angle and speed signals of the rotor magnetic poles, providing accurate feedback to the motor controller (MCU) to realize the motor vector control or square wave control.

[0003] Current mainstream new energy vehicle motor rotor position sensors use high-pressure injection molding housings, PCB mounting and soldering, and finally epoxy resin potting to meet the installation and sealing requirements of new energy vehicle motor rotor position sensors. This technology has the following disadvantages: 1. The sensor structure design is complex, with many parts and processes, resulting in a long development time; 2. The epoxy resin needs to cover a sufficient thickness to achieve a complete seal, resulting in the overall thickness of the sensor not meeting customer requirements; 3. The long curing time of epoxy resin leads to low production line operating efficiency and high process costs; In view of this, a rotor position sensor for electric motors in new energy vehicles is designed to solve the above problems. Utility Model Content

[0004] To address the problems mentioned in the background section, this invention provides a rotor position sensor for new energy vehicle motors. It features the ability to use low-pressure injection molding materials in structural component design, reducing the number and thickness of parts without affecting sensor output accuracy, achieving both sealing and structural strength requirements. Furthermore, it solves the problem of high manufacturing costs caused by the long curing time of epoxy resin sealing.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a rotor position sensor for a new energy vehicle motor, comprising a wiring harness sub-assembly, a wiring harness bracket assembly fixedly connected to the wire side of the wiring harness sub-assembly, a circuit board fixedly connected to the wire end of the wiring harness sub-assembly, a plurality of low-pressure injection molded housing assemblies fixedly covering the connection position between the wiring harness bracket assembly and the circuit board, and a plurality of metal embedded rings disposed on the side of the plurality of low-pressure injection molded housing assemblies away from the circuit board, and a high-pressure injection molded housing fixedly covering the circuit board, the plurality of low-pressure injection molded housing assemblies and the plurality of metal embedded rings.

[0006] Furthermore, the wire harness bracket assembly includes two wire harness brackets fixedly and symmetrically attached to the upper and lower sides of the wire harness sub-assembly. The two wire harness brackets are provided with wire passage slots at equal intervals on their sidewalls, which are the same number as the wire harness sub-assembly wires. The two wire passage slots are merged to form wire holes for the wire harness sub-assembly wires to pass through. The wire harness brackets are alternately fixed with protruding ribs and grooves between two adjacent wire passage slots. The protruding ribs and grooves on the two wire harness brackets are correspondingly converted and matched with each other.

[0007] Furthermore, the low-pressure injection molded housing assembly includes several low-pressure injection molded housings fixedly covering the connection position between the wire harness support assembly and the circuit board, as well as the circuit board. The low-pressure injection molded housings are fixedly connected with sealing teeth, which are formed by several hollow frustum-shaped housings sleeved together, and the top of the hollow frustum-shaped housings has a pointed structure.

[0008] Furthermore, several of the aforementioned low-pressure injection molded housings are fixedly wrapped around the circuit board at equal intervals.

[0009] Furthermore, several of the metal embedded rings are equally spaced on the side of several low-pressure injection molded housing assemblies away from the circuit board and are alternately arranged with several low-pressure injection molded housing assemblies.

[0010] Compared with the prior art, the beneficial effects of this utility model are: 1. This utility model first wraps the electronic component area and part of the area with several low-pressure injection molded housing components to provide support for the high-pressure injection molded housing. Then the high-pressure injection molded housing completely wraps the components. Compared with the existing epoxy resin potting technology for product sealing, the use of low-pressure injection molding material in structural component design does not affect the sensor output accuracy while reducing the number and thickness of parts, achieving both sealing and structural strength. It can also solve the problem of high product manufacturing cost caused by the long curing time of epoxy resin sealing.

[0011] 2. The upper and lower wire harness brackets of this utility model are made of the same part, and are provided with matching grooves and ribs. This not only meets the structural strength requirements, but also effectively avoids the risk of material mixing and reduces the time required for manual identification.

[0012] 3. The sealing teeth of the low-pressure injection molded housing assembly of this utility model are composed of several hollow frustum-shaped housings connected together, and the top of the hollow frustum-shaped housings has a pointed structure, which can effectively reduce the entry of external moisture into the circuit board. At the same time, the pointed structure will be melted and integrated with the high-pressure injection molding material during high-pressure injection molding, which can greatly improve the sealing performance of the product. Attached Figure Description

[0013] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2This is a schematic diagram of the exploded structure of this utility model; Figure 3 This is a perspective structural diagram of the wire harness bracket assembly of this utility model; Figure 4 This is a schematic diagram of the low-pressure injection molded housing assembly structure of this utility model; In the diagram: 1. Wiring harness sub-assembly; 2. Wiring harness bracket assembly; 3. Low-pressure injection molded housing assembly; 4. Circuit board; 5. High-pressure injection molded housing; 6. Metal insert ring; 21. Wire harness bracket; 22. Wire channel; 23. Raised rib; 24. Groove; 31. Low-pressure injection molded housing; 32. Sealing teeth. Detailed Implementation

[0014] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0015] This utility model provides the following technical solution: A rotor position sensor for a new energy vehicle motor includes a wiring harness sub-assembly 1. A wiring harness bracket assembly 2 is fixedly connected to the wire side of the wiring harness sub-assembly 1. The wiring harness bracket assembly 2 is fixedly connected to the wire side of the wiring harness sub-assembly 1 by ultrasonic welding, assembling into a wiring harness sub-assembly. A circuit board 4 is fixedly connected to the wire end of the wiring harness sub-assembly 1. The circuit board 4 is fixedly connected to the wire end of the wiring harness sub-assembly 1 by pressure plate welding, so that the wiring harness sub-assembly and the circuit board 4 form an integral whole, assembling into a circuit board assembly. In this process, multiple products can be welded simultaneously through tooling design, which can greatly improve production efficiency. Several low-pressure injection molded housing assemblies 3 are fixedly covered at the connection position between the wiring harness bracket assembly 2 and the circuit board 4, and on the circuit board 4. The circuit board assembly is placed into a low-pressure injection mold, and several low-pressure injection molded housing assemblies 3 are filled into the wiring harness bracket assembly 2 by low-pressure injection molding. The components are connected to and assembled on the circuit board 4 to form a low-pressure injection molding sub-assembly, protecting the electronic components. In this process, multiple products can be simultaneously low-pressure injection molded using a multi-cavity mold, which greatly improves production efficiency. Several low-pressure injection molding housing components 3 are provided with several metal insert rings 6 on the side away from the circuit board 4. The circuit board 4, several low-pressure injection molding housing components 3 and several metal insert rings 6 are externally covered by a high-pressure injection molding housing 5. The low-pressure injection molding sub-assembly and several metal insert rings 6 are placed into the high-pressure injection molding mold, and the high-pressure injection molding housing 5 is filled between the circuit board 4, several low-pressure injection molding housing components 3 and several metal insert rings 6 through high-pressure injection molding. After assembly, several low-pressure injection molding housing components 3 first wrap around the electronic component area and part of the area, providing support for the high-pressure injection molding housing 5. Then the high-pressure injection molding housing 5 completely wraps around the electronic component area, which can achieve both sealing and structural strength.

[0016] Specifically, the wire harness bracket assembly 2 includes two wire harness brackets 21 that are fixedly connected vertically and symmetrically to the wire side of the wire harness sub-assembly 1. The two wire harness brackets 21 are fixedly connected vertically and symmetrically to the wire side of the wire harness sub-assembly 1 by ultrasonic welding. The two wire harness brackets 21 are provided with wire-passing grooves 22 at equal intervals on their side walls, which are close to each other. The two wire-passing grooves 22 are combined to form wire holes for the wires of the wire harness sub-assembly 1 to pass through. The wire harness brackets 21 are alternately fixed with protruding ribs 23 and grooves 24 between two adjacent wire-passing grooves 22. The protruding ribs 23 and grooves 24 on the two wire harness brackets 21 are correspondingly converted and matched with each other. The use of the same part for the upper and lower wire harness brackets 21 can not only meet the structural strength requirements, but also effectively avoid the risk of mixing materials and reduce the time required for manual identification.

[0017] Specifically, the low-pressure injection molded housing assembly 3 includes several low-pressure injection molded housings 31 fixedly covering the connection position between the wire harness bracket assembly 2 and the circuit board 4 and the circuit board 4. The several low-pressure injection molded housings 31 are filled into the connection position between the wire harness bracket assembly 2 and the circuit board 4 and the circuit board 4 by low-pressure injection molding. Sealing teeth 32 are fixedly connected to the low-pressure injection molded housings 31. The sealing teeth 32 are composed of several hollow frustum-shaped housings sleeved together, and the top of the hollow frustum-shaped housings has a pointed corner structure, which can effectively reduce the entry of external moisture into the circuit board 4. At the same time, the pointed corner structure will be melted and integrated with the high-pressure injection molding material during high-pressure injection molding, so as to greatly improve the sealing performance of the product.

[0018] Specifically, several low-pressure injection molded housings 31 are fixedly wrapped around the circuit board 4 at equal intervals.

[0019] Specifically, a number of metal embedded rings 6 are equally spaced on the side of a number of low-pressure injection molded housing assemblies 3 away from the circuit board 4 and are alternately arranged with the number of low-pressure injection molded housing assemblies 3.

[0020] The injection parameters for the low-pressure injection molding and high-pressure injection molding mentioned above are shown in the table below:

[0021] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A rotor position sensor for a new energy vehicle motor, characterized in that, The device includes a wire harness sub-assembly (1), a wire harness bracket assembly (2) is fixedly connected to the wire side of the wire harness sub-assembly (1), a circuit board (4) is fixedly connected to the wire end of the wire harness sub-assembly (1), a plurality of low-pressure injection molded housing assemblies (3) are fixedly covered at the connection position between the wire harness bracket assembly (2) and the circuit board (4) and on the circuit board (4), a plurality of metal embedded rings (6) are provided on the side of the plurality of low-pressure injection molded housing assemblies (3) away from the circuit board (4), and a high-pressure injection molded housing (5) is fixedly covered on the circuit board (4), the plurality of low-pressure injection molded housing assemblies (3) and the plurality of metal embedded rings (6).

2. The rotor position sensor for a new energy vehicle motor according to claim 1, characterized in that: The wire harness bracket assembly (2) includes two wire harness brackets (21) fixedly attached to the wire side of the wire harness sub-assembly (1) and symmetrically positioned above and below. The two wire harness brackets (21) are provided with wire passage slots (22) at equal intervals on their side walls, which are the same number of wires as the wire harness sub-assembly (1). The two wire passage slots (22) are combined to form wire holes for the wires of the wire harness sub-assembly (1) to pass through. The wire harness brackets (21) are provided with ribs (23) and grooves (24) alternately fixed between two adjacent wire passage slots (22). The ribs (23) and grooves (24) on the two wire harness brackets (21) are correspondingly converted and matched with each other.

3. A rotor position sensor for a new energy vehicle motor according to claim 2, characterized in that: The low-pressure injection molded housing assembly (3) includes several low-pressure injection molded housings (31) that are fixedly covered at the connection position between the wire harness bracket assembly (2) and the circuit board (4) and on the circuit board (4). The low-pressure injection molded housing (31) is fixedly connected with sealing teeth (32). The sealing teeth (32) are composed of several hollow frustum-shaped housings connected together, and the top of the hollow frustum-shaped housing is a pointed structure.

4. A rotor position sensor for a new energy vehicle motor according to claim 3, characterized in that: Several low-pressure injection molded housings (31) on the circuit board (4) are fixedly covered on the circuit board (4) at equal intervals.

5. A rotor position sensor for a new energy vehicle motor according to claim 4, characterized in that: Several metal embedded rings (6) are equally spaced on the side of several low-pressure injection molded housing assemblies (3) away from the circuit board (4) and are alternately arranged with several low-pressure injection molded housing assemblies (3).

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