A highly protected sensor for a vehicle

Abstract

The utility model relates to sensor technical field, concretely to a kind of high protective vehicle sensor, including upper shell, lower shell, circuit board and limit ring, the upper shell is the cylindrical shell of section being "T" shape, annular groove is set up in the bottom of the upper shell outer edge, the lower shell is the cylindrical shell of section being convex, the inside of the lower shell integrally formed has baffle, the inside space of the lower shell is divided into upper cavity and lower cavity by the baffle, the circuit board is welded with wire;The utility model passes through the baffle integrally formed in the inside of lower shell and divides shell space into independent upper and lower cavities, lower cavity is used to accommodate circuit board, a small amount of lubricating oil breaks through outside sealing and enters upper cavity under extreme working condition, baffle can also form physical barrier, avoid oil and circuit board direct contact, completely solve the problem of oil intrusion damage electrical components in existing single cavity structure.

Description

Technical Field

[0001] This utility model relates to the field of sensor technology, specifically a highly protective vehicle sensor. Background Technology

[0002] The gear position sensor is a core sensing component in a vehicle's automatic transmission system. Its main function is to collect the vehicle's gear position status in real time (such as parking, reverse, forward, neutral, etc.) and accurately transmit the gear position signal to the vehicle controller. This provides crucial information for the controller to execute shift control, power output adjustment, and driving safety warnings. The operational stability of the gear position sensor directly determines the shift response accuracy of the automatic transmission, thus affecting the vehicle's ride smoothness, power performance, and driving safety. Therefore, under complex vehicle operating conditions, the sensor must possess reliable structural strength and sealing protection performance. Currently, the industry generally uses a one-piece injection molding process to manufacture the outer shell of the gear position sensor. This process has advantages such as high processing efficiency, low production cost, and good overall shell structure, which can meet the structural support requirements of the sensor foundation, thus effectively solving existing technical problems. However, its structure still needs improvement, specifically as follows: In this solution, during the one-piece injection molding process, a parting line is formed on the surface of the outer shell when the mold separates after injection molding. This parting line usually directly covers the mounting sealing surface of the O-ring. Due to the mold fitting clearance and material shrinkage characteristics of the injection molding process, protrusions, burrs, or micro-gaps are easily formed at the parting line, resulting in damage to the flatness of the sealing surface. When the O-ring is assembled on this sealing surface, the defects of the parting line will cause a local gap between the sealing ring and the sealing surface, making it impossible to achieve a tight fit, which in turn leads to the failure of the sealing structure. Contaminants such as transmission lubricating oil and mud can easily enter the sensor through this gap. In addition, the internal space of the existing one-piece injection molded outer shell is a single cavity structure, and the core electrical components such as the circuit board and signal acquisition module are directly connected to the sealing area. When the seal fails, the transmission lubricating oil will directly enter the internal cavity of the sensor and contact the circuit board. Since the oil is conductive and corrosive, it will cause short circuits, solder joint corrosion, or circuit aging on the electronic components on the circuit board, affecting the use of the sensor. Therefore, a highly protective vehicle sensor is needed to improve the above problems. Utility Model Content

[0003] To address the problem that existing integrated injection-molded housings have a single-cavity internal structure, with core electrical components such as circuit boards and signal acquisition modules directly connected to the sealed area, allowing transmission lubricating oil to directly enter the sensor's internal cavity and contact the circuit board when the seal fails, this invention provides a highly protective vehicle sensor to solve the aforementioned problems.

[0004] To achieve the above objectives, this utility model provides the following technical solution: A highly protective vehicle sensor includes an upper housing, a lower housing, a circuit board, and a limiting ring. The upper housing is a cylindrical housing with a "T"-shaped cross-section, and an annular groove is formed at the bottom of the outer edge of the upper housing.

[0005] The lower shell is a cylindrical shell with a convex cross-section. The interior of the lower shell is integrally formed with a partition, which divides the internal space of the lower shell into an upper cavity and a lower cavity.

[0006] The circuit board has wires soldered on it. When the circuit board is installed in the lower cavity, the lower cavity is filled with resin glue to seal the circuit board and the wires.

[0007] When the bottom of the upper housing is inserted into the upper cavity, the narrow end of the lower housing is inserted into the annular groove, forming an installation groove between the upper and lower housings, and an O-ring is fitted onto the installation groove.

[0008] As a preferred embodiment of this utility model, the top of the upper housing is provided with an upper assembly hole that communicates with the upper cavity. An upper bushing 111 is embedded in the assembly hole 11. A Hall effect trigger slider assembly 12 is provided inside the upper bushing 111. One end of the Hall effect trigger slider assembly 12 extends into the upper cavity 22.

[0009] As a preferred embodiment of this utility model, the bottom of the partition is fixed with a rod, and there are three rods arranged in a triangle in the lower cavity.

[0010] As a preferred embodiment of this utility model, the outer wall of the circuit board is triangularly perforated with a through hole, and when the circuit board is installed in the lower cavity, the through hole cooperates with the insertion rod.

[0011] As a preferred embodiment of this utility model, the outer wall of the lower housing is integrally formed with a positioning plate, and the positioning plate 24 has a through-hole 241. A lower bushing 242 is embedded in the mounting hole 241, and a positioning ring 25 is fixedly connected inside the lower bushing 242.

[0012] As a preferred embodiment of this utility model, a stop block is integrally formed on the side wall of the insertion rod, an internal thread is provided on the inner wall of the lower cavity, and guide grooves are distributed in a triangular pattern on the inner wall of the lower cavity. When the circuit board is installed in the lower cavity, the circuit board overlaps the stop block.

[0013] As a preferred embodiment of this utility model, the outer wall of the circuit board is integrally formed with three guide blocks arranged in a triangular pattern. When the circuit board is installed on the lower cavity, the guide blocks slide in conjunction with the guide grooves.

[0014] As a preferred embodiment of this utility model, the outer wall of the limiting ring is provided with an L-shaped rod, and the bottom of the limiting ring is fixed with an L-shaped rod. There are two L-shaped rods, and a knob is fixedly connected to one end of the two L-shaped rods that are connected to each other. After the circuit board is installed in the lower cavity, the limiting ring is threaded into the lower cavity, and the top of the limiting ring contacts the bottom of the circuit board.

[0015] Compared with the prior art, this utility model adopts a split molding process for the upper and lower shells. Since the mold parting line can avoid the preset area of ​​the sealing surface when the single shell is formed, the problem of the parting line directly covering the sealing surface in the prior art is completely eliminated, ensuring that the sealing surface is flat and smooth, without protruding burrs or gaps. When the O-ring is assembled into the sealing groove, it can achieve full-area tight fit with the flat sealing surface. With the precise docking of the upper and lower shells, a leak-free sealing structure is formed.

[0016] Compared with existing technologies, the integrated partition inside the lower housing of this invention divides the housing space into independent upper and lower cavities. The lower cavity is used to accommodate the circuit board. Under extreme operating conditions, even if a small amount of lubricating oil breaks through the external seal and enters the upper cavity, the partition can still form a physical barrier to prevent the oil from directly contacting the circuit board. This completely solves the problem of oil intrusion damaging electrical components in existing single-cavity structures. At the same time, the integrated design of the partition and the lower housing eliminates the need for additional assembly, avoiding the risk of secondary leakage that may occur with spliced ​​structures. This improves the protection of the circuit board and ensures that the sensor can still work stably in harsh environments such as oil immersion, high temperature and high humidity.

[0017] Compared with existing technologies, this utility model, through the structural design of guide grooves and guide blocks, can guide the circuit board into the lower cavity during installation, thereby ensuring that the through holes can achieve stable engagement with the insertion rods, reducing assembly difficulty and improving installation efficiency. In addition, the design of the stop block supports the circuit board, preventing the electronic components on the top of the circuit board from colliding with the partition and causing damage to the electronic components. At the same time, the structural design of the limiting ring can limit the circuit board after initial installation, thereby facilitating subsequent glue filling operations and ensuring the stability of the circuit board during the filling process. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the internal structure of the present invention; Figure 3 This is a schematic diagram of the internal structure of the lower shell of this utility model; Figure 4 This is a schematic diagram of the assembly structure of the upper and lower shells of this utility model; Figure 5This is a schematic diagram of the circuit board assembly structure of this utility model.

[0019] In the diagram: 1. Upper housing; 10. Annular groove; 11. Upper mounting hole; 111. Upper bushing; 12. Hall effect trigger slider assembly; 2. Lower housing; 21. Partition plate; 22. Upper cavity; 23. Lower cavity; 231. Insert rod; 232. Stop block; 233. Guide groove; 234. Internal thread; 24. Positioning plate; 241. Mounting hole; 242. Lower bushing; 25. Positioning ring; 3. Circuit board; 31. Wire; 32. Through hole; 33. Guide block; 4. Limiting ring; 41. L-shaped rod; 42. Knob; 5. Mounting groove; 6. O-ring seal. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0021] Example 1: Please refer to Figures 1-4 The vehicle sensor shown includes an upper housing 1, a lower housing 2, and a circuit board 3. The upper housing 1 is a cylindrical housing with a "T" shaped cross-section, and an annular groove 10 is provided at the bottom of the outer edge of the upper housing 1.

[0022] The lower shell 2 is a cylindrical shell with a convex cross-section. The interior of the lower shell 2 is integrally formed with a partition 21, which divides the internal space of the lower shell 2 into an upper cavity 22 and a lower cavity 23.

[0023] The circuit board 3 is soldered with wires 31. When the circuit board 3 is installed in the lower cavity 23, the lower cavity 23 is filled with resin glue to seal the circuit board 3 and the wires 31.

[0024] The resin adhesive is epoxy resin, which is filled into the lower cavity 23 to completely seal the circuit board 3 and the wire 31.

[0025] When the bottom of the upper housing 1 is inserted into the upper cavity 22, the narrow end of the lower housing 2 is inserted into the annular groove 10, and an installation groove 5 is formed between the upper housing 1 and the lower housing 2. An O-ring seal 6 is fitted on the installation groove 5.

[0026] Among them, the O-ring 6 is made of nitrile rubber and is fitted into the mounting groove 5 formed by the mating of the upper and lower shells.

[0027] To ensure a stable connection between the upper housing 1 and the lower housing 2, laser welding technology is used to weld the upper housing 1 and the lower housing 2 together.

[0028] In this embodiment, the top of the upper housing 1 is provided with an upper assembly hole 11 that communicates with the upper cavity 22. An upper bushing 111 is embedded in the assembly hole 11. A Hall effect trigger slider assembly 12 is provided inside the upper bushing 111. One end of the Hall effect trigger slider assembly 12 extends into the upper cavity 22.

[0029] The Hall effect trigger slider assembly 12 and the circuit board 3 transmit signals via electromagnetic means.

[0030] The Hall effect trigger slider assembly 12 is a standard industry design and mainly includes: Sliding push rod: It can reciprocate along the upper mounting hole 11 of the sensor housing. The end of the push rod is usually integrated with a magnetic core (or permanent magnet), which is a key component for realizing electromagnetic signal transmission.

[0031] Return spring: Surrounding the outside of the sliding push rod, it is used to push the sliding push rod back to the initial position after the external force disappears, ensuring the mechanism resets after gear shifting.

[0032] In this embodiment, the bottom of the partition 21 is fixed with a rod 231, and there are three rods 231, which are distributed in a triangle in the lower cavity 23.

[0033] In this embodiment, the outer wall of the circuit board 3 has a through hole 32 in the shape of a triangle. When the circuit board 3 is installed in the lower cavity 23, the through hole 32 cooperates with the insertion rod 231.

[0034] Among them, circuit board 3 is a circular PCB board, which has components such as signal acquisition chip and wire 31 soldered on it.

[0035] In this embodiment, the outer wall of the lower housing 2 is integrally formed with a positioning plate 24, and a mounting hole 241 is provided through the positioning plate 24. A lower bushing 242 is embedded in the mounting hole 241, and a positioning ring 25 is fixedly connected inside the lower bushing 242.

[0036] The positioning plate 24 is a flat plate integrally formed on the outer wall of the lower housing 2. A mounting hole is opened through the plate, and a metal positioning ring 25 is fixed in the hole. The positioning plate 24 provides a mounting support for the sensor as a whole and is compatible with mounting surfaces such as vehicle gearboxes. The metal positioning ring 25 can enhance the wear resistance of the mounting hole, avoid wear and deformation of the hole wall caused by long-term disassembly and assembly, and improve the stability and service life of the sensor installation.

[0037] Example 2: Please refer to Figure 5The illustrated high-protection vehicle sensor includes all the structures of Embodiment 1 and the limiting ring 4.

[0038] The insert 231 has an integrally formed stop 232 on its side wall, the lower cavity 23 has an internal thread 234 on its inner wall, and the lower cavity 23 has guide grooves 233 distributed in a triangular pattern on its inner wall. When the circuit board 3 is installed in the lower cavity 23, the circuit board 3 overlaps the stop 232.

[0039] Among them, the stop block 232 provides stable support for the circuit board, defines the installation height, and reserves space for resin glue filling.

[0040] The outer wall of the circuit board 3 is integrally formed with three guide blocks 33, which are arranged in a triangle. When the circuit board 3 is installed on the lower cavity 23, the guide blocks 33 slide with the guide grooves 233.

[0041] The guide block 33 works in conjunction with the guide groove 233 to ensure that the circuit board is installed quickly and accurately, avoiding reverse installation or misalignment.

[0042] The outer wall of the limiting ring 4 is provided with an L-shaped rod 41. The bottom of the limiting ring 4 is fixed with an L-shaped rod 41. There are two L-shaped rods 41. A knob 42 is fixedly connected to one end of the two L-shaped rods 41 that are connected to each other. After the circuit board 3 is installed in the lower cavity 23, the limiting ring 4 is threaded in the lower cavity 23. The top of the limiting ring 4 contacts the bottom of the circuit board 3.

[0043] The knob 42 has anti-slip texture on its surface. The threaded fixing method can be quickly operated by the knob without special tools, which improves the ease of assembly. The top of the limiting ring 4 can be in contact with the bottom of the circuit board 3 or not, as long as the circuit board 3 is inside the lower cavity 23, which prepares for the subsequent sealing process. The design of the L-shaped rod 41 makes the knob located on the outside of the lower housing, which makes it easier for the operator to exert force with their hands and reduces the difficulty of assembly.

[0044] When the limiting ring 4 and the internal thread 234 are designed and processed, it can be ensured that the limiting ring 4 can just support the bottom of the circuit board 3 after installation, so as to limit the movement and avoid excessive compression of the circuit board 3. During assembly, one of the L-shaped rods 41 is placed against the rubber protective sleeve on the outer wall of the wire 31, and then rotated clockwise until the other L-shaped rod 41 contacts the rubber protective sleeve to complete the installation.

[0045] A highly protective vehicle sensor operates as follows: The operator first aligns the guide block 33 of the circuit board 3 with the guide groove 233 on the inner wall of the lower housing 23, and slowly pushes it into the lower cavity 23 along the guide groove 233. During the pushing process, the through hole 32 of the circuit board 3 is simultaneously fitted into the insertion rod 231 at the bottom of the partition 21 until the bottom of the circuit board 3 is attached to the stop block 232 of the insertion rod 231, completing the initial positioning. During this process, the cooperation between the guide block 33 and the guide groove 233 ensures that the circuit board 3 does not shift, and the cooperation between the through hole 32 and the insertion rod 231 further restricts the circumferential rotation of the circuit board 3.

[0046] Insert the limiting ring 4 from the bottom of the lower cavity, so that the external thread on the outer wall of the limiting ring aligns with the internal thread 234 of the lower cavity. Rotate the knob 42 to drive the L-shaped rod 41 and the limiting ring 4 to rotate until the top of the limiting ring 4 contacts the bottom of the circuit board 3.

[0047] Liquid epoxy resin is injected into the lower cavity 23. The resin fills all the gaps between the circuit board 3 and the lower cavity 23, completely covering the soldering parts of the circuit board and the wires 31. After the resin cures, a rigid sealing layer is formed, which completely isolates the circuit board 3 from the external environment and further enhances the fixation stability of the circuit board 3.

[0048] The O-ring 6 is fitted into the annular groove 10 at the bottom of the upper housing 1, ensuring that the sealing ring is fully embedded in the groove without any deviation. Then, the bottom of the upper housing 1 is aligned with the narrow end of the lower housing 2, so that the narrow end of the lower housing 2 is inserted into the annular groove 10. At this time, the mating surfaces of the upper housing 1 and the lower housing 2 form a closed mounting groove 5. The O-ring 6 is squeezed and deformed in the groove, filling all the tiny gaps and forming the first line of sealing. Then, laser welding technology is used to weld the upper housing 1 and the lower housing 2 together.

[0049] After the upper and lower housings are connected, the upper mounting hole 11 of the upper housing is connected to the upper cavity 22 of the lower housing. The Hall effect trigger slider assembly 12 is then inserted through the upper mounting hole, so that one end of the rod extends into the upper cavity 22.

[0050] The sensor is fixed to the vehicle gearbox's preset mounting position using bolts through the mounting holes on the lower housing positioning plate 24 and the positioning ring 25. The positioning ring 25 ensures that the bolts and mounting holes are precisely matched to avoid installation misalignment.

[0051] All standard parts used in this application can be purchased from the market. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art and are also general components, which are common knowledge in this field.

[0052] 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 highly protective vehicle sensor, characterized in that, include: The upper shell (1) is a cylindrical shell with a "T" shaped cross-section, and an annular groove (10) is provided at the bottom of the outer edge of the upper shell (1). The lower shell (2) is a cylindrical shell with a convex cross section. The interior of the lower shell (2) is integrally formed with a partition (21), which divides the interior space of the lower shell (2) into an upper cavity (22) and a lower cavity (23). Circuit board (3), on which wires (31) are soldered, and when the circuit board (3) is installed in the lower cavity (23), the lower cavity (23) is filled with resin glue to seal the circuit board (3) and the wires (31); When the bottom of the upper housing (1) is inserted into the upper cavity (22), the narrow end of the lower housing (2) is inserted into the annular groove (10), and an installation groove (5) is formed between the upper housing (1) and the lower housing (2), and an O-ring (6) is fitted on the installation groove (5).

2. The highly protective vehicle sensor according to claim 1, characterized in that: The top of the upper housing (1) is provided with an upper assembly hole (11) that connects to the upper cavity (22). An upper bushing (111) is embedded in the assembly hole (11). A Hall effect trigger slider assembly (12) is provided inside the upper bushing (111). One end of the Hall effect trigger slider assembly (12) extends into the upper cavity (22).

3. The highly protective vehicle sensor according to claim 1, characterized in that: The bottom of the partition (21) is fixed with a rod (231), and there are three rods (231) arranged in a triangle in the lower cavity (23).

4. A highly protective vehicle sensor according to claim 1 or 3, characterized in that: The outer wall of the circuit board (3) is triangular and has a through hole (32). When the circuit board (3) is installed in the lower cavity (23), the through hole (32) cooperates with the plug (231).

5. A highly protective vehicle sensor according to claim 1, characterized in that: The outer wall of the lower housing (2) is integrally formed with a positioning plate (24), and a mounting hole (241) is provided through the positioning plate (24). A lower bushing (242) is embedded in the mounting hole (241), and a positioning ring (25) is fixedly connected in the lower bushing (242).

6. A highly protective vehicle sensor according to claim 3, characterized in that: The insert (231) has a stop block (232) integrally formed on its side wall. The inner wall of the lower cavity (23) has an internal thread (234). The inner wall of the lower cavity (23) has guide grooves (233) distributed in a triangular pattern. When the circuit board (3) is installed in the lower cavity (23), the circuit board (3) overlaps the stop block (232).

7. A highly protective vehicle sensor according to claim 1, characterized in that: The outer wall of the circuit board (3) is integrally formed with guide blocks (33), there are three of them, which are distributed in a triangle. When the circuit board (3) is installed on the lower cavity (23), the guide blocks (33) slide with the guide groove (233).

8. A highly protective vehicle sensor according to claim 1, characterized in that: It also includes a limiting ring (4), the outer wall of which is provided with an L-shaped rod (41), the bottom of which is fixed with an L-shaped rod (41), there are two L-shaped rods (41), and a knob (42) is fixedly connected to one end of the two L-shaped rods (41) that are connected to each other. The circuit board (3) is installed in the lower cavity (23), the limiting ring (4) is threaded in the lower cavity (23), and the top of the limiting ring (4) contacts the bottom of the circuit board (3).

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