Molding holder for Hall sensors and printed circuit board (PCB) assemblies

Abstract

The present invention discloses a molded holder for a Hall sensor and a printed circuit board (PCB) assembly, the holder (100) comprising an upper surface for housing a Hall sensor (101) and a printed circuit board (PCB) assembly (102), and a lower surface that is attached to a stator core (103) of a hub motor using a plurality of snap locks (104), the snap locks (104) provided on the holder (100) being fastened to the stator core (103) using screws (105) to secure the Hall sensor (101) and the printed circuit board (PCB) assembly (102), the snap locks (104) stably engage with corresponding screw grooves on the stator core (103) of the hub motor.

Description

Technical Field

[0001] (Preface of the Description) In the following description, in particular, the present invention and its embodiments will be described.

[0002] (Description of the Present Invention) The present invention relates to a molded holder for a hall sensor and a printed circuit board (PCB) assembly. In particular, the present invention relates to a molded holder for accommodating a hall sensor and a PCB assembly on a stator core of a motor.

Background Art

[0003] In a hub motor, a PCB (printed circuit board) assembly functions as an integrated controller of the motor. The PCB assembly includes various electronic components and circuits designed to control and monitor the hub motor. The PCB assembly may include components such as a microcontroller, a motor driver, a sensor, and other auxiliary circuits. A hall sensor is often incorporated into the hub motor to determine the position of the rotor within the motor. However, by detecting the magnetic field changes generated by the permanent magnet of the rotor, the hall sensor can provide feedback regarding the position of the rotor relative to the stator. The hall sensor is typically placed in close proximity to the stator core and is positioned to face the rotor magnet, enabling it to detect the magnetic field changes as the magnet passes by. Further, the hall sensor provides feedback to the motor controller, enabling precise control of the operation of the motor.

[0004] Conventional methods for holding PCB assemblies and Hall sensors in place in hub motors include bracket mounting and attachment of the PCB assembly to the inner surface of the motor housing using double-sided tape or adhesive pads. While conventional methods of holding PCB assemblies and Hall sensors on the stator core of a hub motor have their own advantages, they also have some potential drawbacks, particularly in applications such as electric bicycles or vehicles, where the hub motor is subjected to varying levels of vibration and shock during operation.

[0005] In conventional methods, accessing and removing PCB assemblies or Hall sensors for maintenance or repair is extremely difficult. Furthermore, some conventional mounting methods require additional steps and components such as brackets, screws, or adhesives during assembly. This can increase the complexity of the manufacturing and assembly process, potentially adding to production costs. Similarly, maintenance or replacement of PCB assemblies or Hall sensors may require specialized tools or skills, leading to increased maintenance complexity. Additionally, conventional mounting methods may not provide sufficient shock and vibration resistance, potentially causing loosening or damage to PCB assemblies or Hall sensors over time. This can affect the reliability and precision of the motor system.

[0006] Chinese Patent Application Publication No. 102341677, titled "Position Sensor Holder," relates to a holder for a motor position sensor, the holder comprising a pocket for holding the position sensor, a contact portion, and a fixing portion attachable to a motor biasing means on the device for biasing the contact portion toward a fixing means. Furthermore, the motor includes a stator, a position sensor, and a sensor holder. The sensor holder comprises a pocket portion for holding the position sensor internally, a contact portion, and a biasing portion for biasing the contact portion toward the stator.

[0007] Chinese Utility Model No. 218388156, titled "PCB board holder suitable for paste-embedded SMT printed circuit boards," relates to a PCB (printed circuit board) clamp holder suitable for an SMT (surface mount technology) printed circuit board chip mounter. The holder comprises a motor and a limiting rod. The motor rotates a fan-shaped grooved disk I, which meshes with a fan-shaped grooved disk II to rotate a oscillating rod. The oscillating rod moves a V-shaped clamp plate, and the limiting rod restricts the rotation of the V-shaped clamp plate. This structure allows for adjustment of the width between the V-shaped clamp plates according to the PCB specifications or required mounting width, thereby preventing the holder from being replaced again, improving work efficiency, and increasing the usable area of ​​the PCB.

[0008] German Patent Application Publication No. 102020208113, titled "Circuit board holder with cooling element, and system comprising circuit board holder and circuit board," relates to a printed circuit board holder for holding a printed circuit board and fixing the printed circuit board to a base printed circuit board in a vehicle, wherein the holder comprises an elongated holding body, the elongated holding body having a holding jig for positioning the contact portion of the printed circuit board inside, and at least one cooling element disposed on the elongated holding body.

[0009] Chinese Utility Model No. 206674330, titled "PCB Board Holder Piece," relates to a PCB board holder piece. The clamp piece includes a base plate on which the PCB board is placed, and the clamp piece is used in cooperation with the base plate. The clamp piece includes a base, the base is provided with an elongated slot, and a mounting portion is provided within the elongated slot, and the mounting portion is fixedly connected to the base plate. Furthermore, the base is provided with a through hole, and a movable member is provided on the base plate that is movable on the base plate, and the movable member passes through the through hole. The base is further connected to the clamp plate. This utility model discloses a PCB board holder piece that, with a simple structure, centrally grips the PCB board with the clamp plate and base plate, the clamp plate prevents the PCB board from flying off the base plate, the clamp piece can be moved and removed by the movable member, and central gripping and release of the PCB board can be performed, the operation is easy, and the central gripping is effective.

[0010] Therefore, there is a demand for suitable products that can stably hold PCB assemblies and Hall sensors, provide additional support, damping capabilities, and easy maintenance, and minimize the adverse effects of vibration on their performance. [Overview of the project]

[0011] The present invention overcomes the shortcomings of the prior art by disclosing a molded holder for a Hall sensor and a printed circuit board (PCB) assembly, the holder comprising an upper surface for housing the Hall sensor and the printed circuit board (PCB) assembly and a lower surface that is attached to the stator core of a hub motor using a plurality of snap locks, the snap locks provided on the holder being fastened to the stator core using screws to secure the Hall sensor and the printed circuit board (PCB) assembly.

[0012] The present invention aims to address the demand for maintaining reliability and accuracy over time by providing additional support and damping, thereby reducing the effects of shock and vibration on the PCB assembly and Hall sensor. In addition, the holder assists the calibration process, ensuring that the Hall sensor is properly set up and provides consistent and reliable feedback to the motor controller. Furthermore, the holder simplifies the process of integrating the PCB assembly and Hall sensor into the hub motor, thereby providing dedicated space or mounting points and facilitating the positioning and securing of the components. Moreover, during maintenance or replacement, the holder facilitates the quick and easy removal and reinstallation of the PCB assembly and Hall sensor, minimizing downtime. [Brief explanation of the drawing]

[0013] The features of the aforementioned and other embodiments will become clearer when the following detailed description of embodiments is read in conjunction with the accompanying drawings. In the drawings, similar reference numerals refer to similar elements.

[0014] [Figure 1] Figure 1 shows a perspective view of a molded holder for a Hall sensor and printed circuit board (PCB) assembly according to one embodiment of the present invention.

[0015] [Figure 2] Figure 2 shows an exploded view of a molded holder for a Hall sensor and printed circuit board (PCB) assembly according to one embodiment of the present invention.

[0016] [Figure 3] Figure 3 shows a schematic diagram of a molded holder for a Hall sensor and printed circuit board (PCB) assembly according to one embodiment of the present invention. Detailed description of the invention

[0017] The following description of the subject matter is detailed, and one or more embodiments are shown in the drawings. Each embodiment is provided for illustrative purposes only and is not limiting. Various changes and modifications that are obvious to those skilled in the art to which the invention pertains are considered to be within the spirit, scope and assumptions of the invention.

[0018] Figure 1 shows a perspective view of a molded holder for a Hall sensor and a printed circuit board (PCB) assembly according to one embodiment of the present invention. The holder (100) has an upper surface for housing the Hall sensor (101) and the printed circuit board (PCB) assembly (102), and a lower surface which is attached to the stator core (103) of a hub motor using a plurality of snap locks (104). The snap locks (104) provided on the holder (100) are fastened to the stator core (103) using screws (105) to secure the Hall sensor (101) and the printed circuit board (PCB) assembly (102).

[0019] In one embodiment of the present invention, the snap lock (104) stably engages with a corresponding thread groove on the stator core (103) of the hub motor. Furthermore, a screw (105) is inserted through a specific hole in the holder (100) and fastened to the corresponding thread groove on the stator core (103) of the hub motor, thereby securing the Hall sensor (101) and PCB assembly (102) in place.

[0020] In one embodiment of the present invention, the holder (100) is provided with a cavity to achieve weight reduction while maintaining structural integrity, and to ensure stable mounting and protection of the PCB assembly (102) and the Hall sensor (101).

[0021] In one embodiment of the present invention, the stator core (103) of the hub motor houses the stator windings, which are responsible for generating the electromagnetic field necessary for motor operation.

[0022] In one embodiment of the present invention, the Hall sensor (101) is a critical component within the hub motor, performing important functions related to position detection and motor control. Its primary role is to detect the position of the rotor magnets rotating within the motor. By detecting changes in the magnetic field, the Hall sensor (101) provides feedback to the motor controller, enabling precise control of the motor's operation. Typically, the Hall sensor (101) is positioned in close proximity to the stator core (103) of the hub motor, facing the rotor magnets. This strategic placement allows for accurate detection and monitoring of fluctuations in the magnetic field associated with the rotor's rotation. The Hall sensor (101) operates based on the Hall effect, which involves the generation of a voltage difference in a conductor when it is exposed to orthogonal magnetic fields and a current flow. In the context of a hub motor, the Hall sensor (101) detects changes in the magnetic field caused by the rotating magnets and generates an electrical signal corresponding to the rotor position.

[0023] Typically, the Hall sensor (101) provides a digital output signal, often in the form of three separate channels or signals known as Hall A, Hall B, and Hall C. These signals transmit information about the position and orientation of the rotor magnets relative to the stator windings. The signals from the Hall sensor (101) are then supplied to the motor controller, which uses this information to synchronize the current flow in the stator windings. This synchronization ensures efficient operation and precise control of the hub motor's speed, torque, and direction. To ensure reliable and accurate performance, it is crucial that the Hall sensor (101) is properly calibrated and stably mounted within the hub motor. Any failure or misplacement of the Hall sensor (101) can lead to motor instability, reduced efficiency, or even motor failure. Therefore, attention to detail in its calibration and stably mounted is of paramount importance.

[0024] In one embodiment of the present invention, the PCB (Printed Circuit Board) assembly (102) includes various electronic components and circuits designed to control and monitor a hub motor. The PCB assembly (102) may include components such as a microcontroller, a motor driver, sensors, and other auxiliary circuits. Further, the PCB has predetermined connectors or soldering points for the wiring of the Hall sensor (101).

[0025] The holder (100) ensures that the Hall sensor (101) and the PCB assembly (102) are securely positioned within the hub motor. This helps prevent any movement or displacement during operation and minimizes the risk of component damage. Further, the holder (100) optimizes the space utilization within the hub motor. The holder (100) can accommodate Hall sensors (101) and PCB assemblies (102) of specific dimensions and arrangements, ensuring efficient use of the available area without interfering with other motor components.

[0026] Figure 2 shows an exploded view of a molded holder for a Hall sensor and a printed circuit board (PCB) assembly according to an embodiment of the present invention. In one embodiment of the present invention, the molded PCB holder (100) is a component used to stably hold a Hall sensor (101) and a printed circuit board (PCB) assembly (102) in a predetermined position. The holder (100) is made of plastic, but is not limited thereto, and is designed to provide mechanical support and stability to the Hall sensor (101) and the PCB assembly (102). The holder (100) is specially molded and manufactured to accommodate the dimensions and shape of the PCB assembly (102). The holder (100) includes slots, cutouts, or clips that are aligned with the mounting holes or edges of the PCB to enable the PCB assembly (102) to be securely inserted and held in a predetermined position. In addition, the holder (100) includes features for cable management, such as channels or clips for routing and fixing the wiring or cables connected to the PCB assembly (102) and the Hall sensor (101). This helps to organize the wiring and reduce the risk of interference or accidental cutting.

[0027] Furthermore, the holder (100) simplifies the assembly process by providing a dedicated mounting solution for the Hall sensor (101) and the PCB assembly (102), eliminating the need for separate brackets or fasteners. The molded structure also provides durability and protection to the assembly, guarding it against mechanical stress or shock.

[0028] Figure 3 shows a schematic diagram of a molded holder for a Hall sensor and printed circuit board (PCB) assembly according to one embodiment of the present invention. In one embodiment of the present invention, the holder (100) incorporates a number of snap locks (104), which are fastening mechanisms used to secure the Hall sensor (101) and PCB assembly (102) in place. The snap locks (104) engage with corresponding features on the components to ensure a tight and stable mating. In addition to the snap locks (104), the holder (100) also utilizes screws (105) for further stability and security. The snap locks (104) provided on the holder (100) are fastened to the stator core (103) using screws (105), providing an additional layer of reinforcement for firmly holding the Hall sensor (101) and PCB assembly (102) in place.

[0029] The molded holder (100) provides a reliable and efficient solution for securing and protecting the Hall sensor (101) and PCB assembly (102) within the stator core (103) pack of the hub motor, ensuring proper positioning, stability, and durability, thereby preventing unintended loosening or detachment of the Hall sensor (101) and PCB assembly (102), and contributing to the overall performance and extended lifespan of the motor system. [Explanation of Symbols]

[0030] 100... Holder 101...Hall sensor 102... PCB Assembly 103... Stator core 104...Snap Lock 105... screw

Claims

1. A molded holder for Hall sensors and printed circuit board (PCB) assemblies, wherein the holder (100) is a. A holder (100) comprising an upper surface for housing a Hall sensor (101) and a printed circuit board (PCB) assembly (102), and a lower surface that is attached to the stator core (103) of a hub motor using a plurality of snap locks (104), wherein the snap locks (104) provided on the holder (100) are fastened to the stator core (103) using one or more screws (105) to secure the Hall sensor (101) and the printed circuit board (PCB) assembly (102).

2. The Hall sensor (101) detects a change in the magnetic field and converts the magnetic field into an electrical signal, as described in claim 1, the holder (100).

3. The stator core (103) of the hub motor is a holder (100) according to claim 1, which houses the stator windings responsible for generating the electromagnetic field necessary for motor operation.

4. The holder (100) according to claim 1, wherein the snap lock (104) stably engages with a corresponding screw groove on the stator core (103) of the hub motor.

5. The holder (100) according to claim 1, wherein the screw (105) is inserted through a specific hole in the holder (100) and fastened to a corresponding screw groove on the stator core (103) of the hub motor, thereby fixing the Hall sensor (101) and the PCB assembly (102) in a predetermined position.

6. The holder (100) according to claim 1, wherein the holder (100) is provided with a cavity to achieve weight reduction while maintaining structural integrity and to ensure stable mounting and protection of the PCB assembly (102) and the Hall sensor (101).

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