Sensor module for mounting inside the motor

Abstract

To provide a sensor module capable of facilitating mounting of a sensor in a motor.SOLUTION: A sensor module 1 comprises a holder 6 adapted to be mounted in a wet chamber of a motor and a temperature sensor 7 adapted to be mounted in a dry chamber of the motor. A rotational position sensor 14 is mounted on the holder, the temperature sensor is spaced apart from the holder, and the rotational position sensor and the temperature sensor are connected, via a plurality of signal lines 13, to a connector interface 15 adapted to be plugged into a corresponding connector. The sensor module further comprises a sealing element 17 arranged between the rotational position sensor and the temperature sensor, the sealing element being sealably penetrated by the signal lines 13 from one of the rotational position sensor and the temperature sensor.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a sensor module for mounting within a motor. [Background technology]

[0002] A motor, such as an electric motor, should theoretically operate up to its maximum design life. Any defect in the motor may lead to a shutdown. Therefore, sensors are utilized to analyze and predict the health of the motor. However, motors, especially those installed in vehicles, should preferably be small and lightweight to reduce the amount of energy required for the vehicle to move. However, it is extremely difficult to install sensors in the motor because the space in the motor is limited, compromising the handleability of the sensor in the motor chamber. Summary of the Invention [Problem to be solved by the invention]

[0003] SUMMARY OF THE PRESENT EMBODIMENT It is therefore an object of the present invention to facilitate mounting of sensors within a motor. [Means for solving the problem]

[0004] The present invention solves the above-mentioned problems by providing a sensor module for mounting in a motor, the sensor module comprising a holder adapted to be mounted in a wet chamber of the motor and a temperature sensor adapted to be mounted in a dry chamber of the motor. A rotational position sensor is mounted in the holder and the temperature sensor is spaced apart from the holder, whereby the rotational position sensor and the temperature sensor are connected via a number of signal lines to a connector interface adapted to be plugged into a corresponding connector. The sensor module further comprises a sealing element arranged between the rotational position sensor and the temperature sensor, the sealing element having a signal line passing through it from one of the rotational position sensor and the temperature sensor.

[0005] The solution of the present invention allows the sensor module to be installed partly in the wet chamber of the motor and partly in the dry chamber of the motor, which allows the user to make the most of the limited space in the motor. The installation of the sensor module is no longer limited to the wet chamber or the dry chamber, which increases the space for installation and therefore the manageability of the sensor module in the motor. Furthermore, the rotational position sensor and the temperature sensor are integrated into a single sensor module, which reduces the tolerance during installation. The user does not need to obtain the temperature sensor and the rotational position sensor separately and then integrate them in the closed space of the motor during the production line after installation.

[0006] The invention can be further improved by the following features, which are independent of one another with regard to their respective technical effect and can be combined in any combination:

[0007] For example, according to a first embodiment, the rotational position sensor can be a non-contact sensor such as a resolver. Unlike an encoder, a resolver does not have electronic components such as a circuit board. Thus, resolvers are robust against contamination, vibration, and function safely within a wide temperature range, making them very reliable, especially in motors, where the rotational position sensor is exposed to harsh environments. The use of a resolver as a rotational position sensor therefore increases the reliability and expected useful life of the sensor.

[0008] The holder may in particular be disk-shaped and may have an outer periphery and an inner periphery. The rotational position sensor may be at least partially mounted on the inner periphery of the disk-shaped holder. If the rotational position sensor is a resolver, the stator may be fixedly mounted on the inner periphery of the disk-shaped holder. By providing a disk-shaped holder, the sensor module or at least the holder and the rotational position sensor may be made particularly compact, which may further facilitate installation in the motor.

[0009] The rotational position sensor can protrude from the disc-shaped holder beyond two opposing surfaces: one surface can face towards the wet chamber of the motor and the other surface can face towards the dry chamber of the motor.

[0010] The sealing element can extend from one surface of the holder to the other surface and can form a sealed passage between the wet chamber and the dry chamber when the sensor module is mounted in the motor. The sealing element can be disposed adjacent to the holder. Alternatively, the sealing element can at least partially surround a portion of the holder or can penetrate the holder.

[0011] Preferably, the connector interface is adapted to be disposed within a dry chamber of the motor such that a signal wire of the rotational position sensor can pass through the sealing element to sealingly guide the signal wire from the wet chamber to the connector interface in the dry chamber.

[0012] However, if the connector interface is to be located within the wet chamber of the motor, the signal wire of the temperature sensor, which sealably guides the signal wire of the temperature sensor from the dry chamber to the connector interface in the wet chamber, can pass through the sealing element.

[0013] At least one of the two surfaces of the holder can be adapted to be disposed within and / or facing the wet chamber of the motor, and the terminals of the rotational position sensor can be disposed on said surface and can be potted to seal the connection between the terminals of the rotational position sensor and the signal wires.

[0014] The rotational position sensor may comprise a sealing cover at least on the side adapted to face the wet chamber. The sealing cover may be potted to the rotational position sensor and may include potting of the terminals of the rotational position sensor. The sealing cover may extend around the edge of the holder and may guide signal lines connected to the terminals to a further sealing element that sealably receives said signal lines. The sealing element may thus be formed by two sealing elements, the sealing cover and the sealing element, respectively arranged on opposite surfaces of the holder.

[0015] The sealing element may be a potted sleeve, in particular a rubber sleeve, through which a signal line of one of the rotational position sensor or the temperature sensor passes. The sealing element may further comprise a flange extending radially from a body of the sealing element. The flange may engage with a frame of a passage formed between the wet and dry chambers of the motor, thus fixing the position of the sealing element within the chamber and sealing the passage.

[0016] The potting of the sealing element can provide a fixing function in addition to the sealing function: the signal wire passing through the sealing element can be kept in place by the potting, thus preventing any relative movement of the signal wire and the sealing element that could lead to disconnection of the signal wire from the corresponding terminal.

[0017] According to a further advantageous embodiment, the sensor module may further comprise a holding bracket for holding the temperature sensor. The holding bracket may further comprise a connector holder for removably fixing the connector interface to the connector holder. Thus, the connector interface can be fixed to the connector holder during installation, which reduces the risk of distortion and / or tearing of the signal lines during installation.

[0018] The connector interface can be fixed in a test position in a connector holder, for example for termination testing. After a user installs the sensor module, the user can easily connect test equipment to the connector interface regardless of the position of the complementary connector for the application. Preferably, the connector interface can be fixed in the connector holder from the manufacturing side, and after installing and testing the sensor module in the motor, the user can remove the connector interface from the connector holder and move the connector holder to a desired position.

[0019] The rotational position sensor and the temperature sensor in particular can be connected to the same connector interface via multiple signal lines, so that the rotational position sensor and the temperature sensor can be tested simultaneously and only one complementary connector is required in the application, thereby further reducing the amount of different components in the motor.

[0020] A plurality of signal wires connecting the rotational position sensor and the temperature sensor to the connector interface, at least in the test position, can be at least partially wrapped around the retaining bracket, so that the signal wires are neatly arranged within the sensor module and do not interfere during installation.

[0021] The retainer bracket may include a post having a free end on which the connector holder is disposed. The signal wires may be at least partially wrapped around the post, at least in the test position. To position the plurality of signal wires about the retainer bracket, the retainer bracket may include positioning ribs projecting from an outer surface of the retainer bracket, and in particular from the post.

[0022] The connector interface can be removed from a connector holder, in particular a retaining bracket, at the application position, and the connector interface can be mated with a complementary connector arranged in the motor at the application position. Preferably, the connector interface can be mounted in a connector holder, the connector holder being spaced apart from the retaining bracket at the application position.

[0023] When the connector interface is removed from the connector holder, the signal wires can be at least partially unwrapped, providing additional slack for positioning the connector interface, which can make installation of the sensor module easier. Additionally, the additional slack allows the sensor module to be adapted to a variety of motors having different configurations and / or different predetermined positions for the complementary connector.

[0024] The retaining bracket can include a through hole whereby the temperature sensor extends through the through hole. The through hole can extend essentially parallel to the longitudinal axis and the temperature sensor can include a sensor body extending essentially parallel to the longitudinal axis. The retaining bracket can be adapted to guide the temperature sensor along the through hole, thereby facilitating insertion of the temperature sensor into a predetermined sensing location within the motor.

[0025] The temperature sensor, or at least the tip carrying the sensing element of the temperature sensor, can be adapted to be inserted into a hole, in particular a blind hole, that can be formed in the coil winding of the motor, so that the temperature sensor is surrounded by the coil winding, thereby improving the sensing accuracy of the temperature sensor.

[0026] The temperature sensor or at least the tip can preferably be rotationally symmetrical, thus facilitating insertion of the temperature sensor or at least the tip into a hole, in particular a blind hole, such that the relative rotational positions of the temperature sensor and the hole are not relevant for insertion of the temperature sensor into a hole, in particular a blind hole.

[0027] However, if it is desired that the temperature sensor be located at a predetermined rotational position relative to the hole, in particular the blind hole, the temperature sensor and / or the hole, in particular the blind hole, may be provided with at least one coding feature. The temperature sensor may, for example, be provided with a rotationally asymmetric shape that is complementary to the hole, in particular the blind hole.

[0028] The temperature sensor may preferably be a thermistor sensor with a negative temperature coefficient, also called an NTC sensor. Such sensors are characterized by a fast response time and high accuracy.

[0029] The temperature sensor, in particular the tip of the temperature sensor with the sensing element, can be encapsulated, for example, with an epoxy resin. The encapsulation can protect the sensing element from the surrounding environment and prevent damage due to shock and / or vibration. Preferably, at least the tip of the temperature sensor can be encapsulated with a fluoropolymer, such as polytetrafluoroethylene (PTFA) and perfluoroalkoxy polymer (PFA). Fluoropolymers have high resistance to solvents, acids and bases. Thus, encapsulating at least the tip of the temperature sensor with a fluoropolymer can increase the life cycle of the temperature sensor, especially in harsh environments.

[0030] Depending on the application requirements, the shape of the temperature sensor can be adapted accordingly. Preferably, the tip with the sensing element and the remainder of the sensor body can have cross sections in a plane perpendicular to the longitudinal axis that differ from each other in terms of at least one of shape and size. The tip can have, for example, a circular cross section and the remainder of the sensor body can have a rectangular cross section, the long side being as wide as the diameter of the tip cross section. This allows a clear distinction between the tip, which can be inserted into a hole in the motor winding, in particular a blind hole, and the remainder of the sensor body.

[0031] In order to limit the insertion depth of the temperature sensor into a bore, in particular a blind hole, in the motor windings, the temperature sensor can be provided with a limit stop projecting radially from the sensor body, which can prevent the tip of the temperature sensor from being inserted too deeply into the windings and coming into contact with the edge of the bore and possibly damaging the tip.

[0032] The temperature sensor can be adapted to move relative to the retaining bracket to adjust the penetration depth of the temperature sensor into the holes in the motor windings, particularly the blind holes, thereby providing additional flexibility and tolerance compensation during installation.

[0033] The retaining bracket can be formed as a unitary component, for example by an injection molding process. The retaining bracket can comprise a centre stem extending essentially parallel to the longitudinal axis. Further functional parts can also protrude from the periphery of the centre stem. For example, a post with a connector holder can protrude from the periphery of the centre stem and extend beyond the centre stem essentially parallel to the longitudinal axis. Furthermore, a second post can protrude from another side of the periphery and extend beyond the centre stem essentially parallel to the longitudinal axis. The second post can feature a through hole for receiving a temperature sensor. Thus, the connector interface and the retaining mechanism for holding the temperature sensor are locally separated, which reduces the risk of entanglement of the signal lines.

[0034] According to a further advantageous aspect, a mounting protrusion can protrude from the central stem, the mounting protrusion being adapted to receive a bushing, in particular a ring-shaped bushing, which can engage with a complementary formed mounting feature on the motor, thus fixing the retaining bracket within the motor.

[0035] In a further advantageous embodiment, a position assurance member may be provided. The position assurance member may be adapted to be fixed in at least two positions on the retainer bracket, where in a first of the at least two positions the relative position between the temperature sensor and the retainer bracket is movable, and in a second of the at least two positions the relative position between the temperature sensor and the retainer bracket is fixed. Thus, in the first position the temperature sensor may be movable to allow height adjustment during application. In the second position the temperature sensor is fixed at a desired height and secured against movement due to vibration and / or shock.

[0036] The temperature sensor can be fixed in the through hole by an interference fit. At least one locking prong can be provided, with the at least one locking prong pressing against an outer contour of the temperature sensor at at least a second of the at least two positions. Preferably, a plurality of circumferentially arranged locking prongs can be provided, with each locking prong pressing against the temperature sensor at a second of the at least two positions. Thus, the locking prongs hold the temperature sensor by interference at the periphery of the temperature sensor.

[0037] The at least one locking prong can be formed within the throughbore and is resiliently deflected by the position assurance member at a second of the at least two positions, but more preferably the at least one locking prong can form a unitary component with the position assurance member and the at least one locking prong is deflected toward the temperature sensor at a second of the at least two positions.

[0038] The position assurance member can be adapted to guide a movement of the temperature sensor, in particular a movement essentially parallel to the longitudinal axis. The at least one locking prong can abut a radial overhang of the sensor body parallel to the longitudinal axis. The at least one locking prong presses against said overhang while moving parallel to the longitudinal axis from a first of the at least two positions to a second of the at least two positions. The temperature sensor is thus moved parallel to the position assurance member by a motion transmission coupling in at least one direction. The temperature sensor can thus be guided by the position assurance member into a bore of the motor winding.

[0039] A locking assembly may be provided for locking the position assurance member in at least one of the at least two positions, preferably at least a second of the at least two positions. The locking assembly may be formed, for example, by latches that engage with each other with a positive fit. This prevents the position assurance member from shifting position due to stresses such as vibration. Thus, the fixation of the temperature sensor by the position assurance member is further improved.

[0040] The position assurance member may also be fixed in more than two positions. For example, the position assurance member may include a number of teeth projecting from an outer surface of the position assurance member. Each tooth may correspond to one of at least two positions, particularly three or more positions. The position assurance member may be actuated by moving the position assurance member from one position to the next. With each subsequent position, the compression force with which the temperature sensor is held by the interference fit may be increased.

[0041] It is possible to provide a motor for a vehicle, in particular an electric motor, comprising a wet chamber, a dry chamber and a passage connecting the wet chamber and the dry chamber, whereby a sensor module according to any one of the previous embodiments can be mounted in said motor, the holder being mounted in the wet chamber, the temperature sensor being mounted in the dry chamber and the sealing element being sealably fixed in the passage.

[0042] The connector interface can be disposed within the dry chamber, and a signal line from a rotational position sensor fixed to a holder in the wet chamber is sealably guided through the sealing element, through a passageway to the dry chamber, and connected to the connector interface.

[0043] In these figures, the same reference numbers are used for elements that correspond to one another in terms of function and / or structure.

[0044] In accordance with the description of the various aspects and embodiments, elements shown in the drawings may be omitted if the technical effect of those elements is not required for a particular application, and vice versa, i.e. elements not shown or described with reference to these figures but discussed above may be added if the technical effect of those particular elements is advantageous in a particular application.

[0045] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0046] [Figure 1] 1 is a schematic perspective view of an exemplary embodiment of a sensor module according to the present invention; [Diagram 2] 1 is a schematic perspective view of an exemplary embodiment of a sensor module according to the present invention mounted within a motor; [Diagram 3] 1 is a schematic perspective view of an exemplary embodiment of a holder and a rotational position sensor of a sensor module according to the present invention; [Figure 4]FIG. 13 is a further schematic perspective view of the rotational position sensor and holder; [Diagram 5] 1 is a schematic perspective view of a retaining bracket of an exemplary embodiment of a sensor module according to the present invention; [Figure 6] 1 is a schematic cutaway view of a first exemplary embodiment of a position assurance member in a first position; [Figure 7] 1 is a schematic cutaway view of a first exemplary embodiment of a position assurance member in a second position; [Figure 8] 11 is a schematic cutaway view of a second exemplary embodiment of a position assurance member in a first position; [Figure 9] 11 is a schematic cutaway view of a second exemplary embodiment of a position assurance member in a second position; [Figure 10] 11 is a schematic cutaway view of a third exemplary embodiment of a position assurance member in a first position; FIG. [Figure 11] 11 is a schematic cutaway view of a third exemplary embodiment of a position assurance member in a second position. [Figure 12] 13 is a schematic cutaway view of a fourth exemplary embodiment of a position assurance member in a first position. [Figure 13] 13 is a schematic cutaway view of a fourth exemplary embodiment of a position assurance member in a second position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] First, an exemplary embodiment of a sensor module 1 of the present invention will be described in more detail with reference to FIGS.

[0048] FIG. 1 shows a sensor element 1 in a schematic perspective view, and in FIG. 2 the sensor module 1 is shown mounted in a motor 2, in particular an electric motor 4.

[0049] The sensor module 1 comprises a holder 6 adapted to be mounted in a wet chamber 8 of the motor 2 and a temperature sensor 7 adapted to be mounted in a dry chamber 9 of the motor 2. A rotational position sensor 14 mounted on the holder 6 and a temperature sensor 7 are spaced apart from the holder 6. The rotational position sensor 14 and the temperature sensor 7 are connected via a number of signal lines 13 to a connector interface 15, in particular a common connector interface 15. The connector interface 15 is adapted to be connected to a corresponding connector. Furthermore, a sealing element 17 is provided between the temperature sensor 7 and the rotational position sensor 14, through which a signal line 13 from one of the rotational position sensor 14 and the temperature sensor 7 sealably passes.

[0050] In this case, the connector interface 15 is arranged in the dry chamber 9 of the motor 2 and thus the sealing element 17, through which the signal line 13 from the rotational position sensor 14 passes. The sealing element 17 can be sealably fixed in a passage 19 of the motor 2 connecting the wet chamber 8 and the dry chamber 9. Two sensors can thus be integrated in a single sensor module 1, whereby one sensor can be mounted in the wet chamber 8 of the motor 2 and the other sensor can be mounted in the dry chamber 9. The space for mounting the sensor module 1 in the motor 2 is thus increased, allowing improved manageability and thus easier installation of the sensor module 1 in the motor 2.

[0051] The holder 6 will now be described with reference to Figures 3 and 4. The holder 6 has a disk-like shape, more specifically a ring-like shape, and has an inner circumference 10 and an outer circumference 12. The rotational position sensor 14 is attached to the inner circumference 10 so as to face radially inward.

[0052] The rotational position sensor 14 may be a resolver 16, the stator 18 of which is mounted on the inner circumference of the holder 6. The resolver 16 may also comprise a rotor 20, which may be mounted on the shaft of the motor 2, whereby the angle is detected by means of electrical signals generated by the changing reaction of the rotating rotor 20 and the fixed stator 18. Thus, the speed of the motor, in particular the rotational speed of the shaft, may be measured and then controlled by sending a signal to the motor.

[0053] To secure the holder 6 within the motor 2, the holder 6 is provided with a number of mounting holes 22 which extend from one surface 24 to an opposing surface 26. The holder can thus be secured, for example by bolts within the motor, to secure the holder 6, and thus the rotational position sensor 14, against movement due to shock or vibration.

[0054] For space-saving assembly, the holder 6 can be provided with notches 28 along its outer periphery in which terminals 30 of the rotational position sensor 14, in this case the terminals of the stator 18, can be located. The terminals 30 can be connected to the signal lines 13, which in turn are connected to the connector interface 15.

[0055] In FIG. 3, the surface 24 of the holder 6 is shown. In the mounted state, when the holder 6 is mounted in the motor 2, said surface 24 faces the wet chamber 8. The rotational position sensor 14 further comprises at least one stabilizing rib 32 protruding from the outer edge of the rotational position sensor 14 into the notch 28. Preferably, the stabilizing rib 32 is provided on both sides of the terminal 30. In the wet chamber 8, the rotational position sensor 14 can be in contact with a fluid such as oil. To further protect the rotational position sensor, a sealing cover 34 can be provided on the surface 24 of the rotational position sensor 14. The sealing cover 34 can preferably be potted on the rotational position sensor 14 to prevent loosening of the sealing cover 34 due to stress such as shock or vibration. The sealing cover 34 can preferably embed the terminal 30 and thus protrude into the notch 28. The stabilizing rib 32 may also be embedded in the potting, whereby the stabilizing rib 32 further stabilizes the potting in the notch 28. The signal line 13 of the rotational position sensor 14 may protrude from the sealing cover 34 at the opposite surface 26 and pass through a sealing element 17 which may be arranged on the opposite surface 26. The sealing element 17 may further abut against the opposite surface 26 and / or the sealing cover 34 to form a closed sealed path for the signal line 13 between the sealing cover 34 and the sealing element 17. However, depending on the structure of the motor 2, the sealing element 17 may also be spaced from the opposite surface 26 of the holder 6.

[0056] The sealing element 17 in this exemplary embodiment is formed as a rubber sleeve and comprises a flange portion 36 which projects radially from the remainder of the body of the sealing element. The flange portion 36 can abut against the frame of the passage 19 in the motor 2 to fix the sealing element 17 against sliding through the passage 19. The remainder of the body of the sealing element can extend through the passage 19 and be adapted to seal said passage between the wet chamber 8 and the dry chamber 9.

[0057] The temperature sensor 7 may be held by a retaining bracket 38. The retaining bracket 38 is discussed in more detail with reference to FIG.

[0058] The retaining bracket 38 may preferably be formed as a unitary component 40, for example as an injection molded component. The retaining bracket 38 may comprise a connector holder 42 for removably receiving the connector interface 15. The connector holder 42 may comprise opposing retaining arms 44, each having a guide notch 46 into which a guide rail or protrusion of the connector interface 15 may be inserted to secure the interface to the retaining bracket 38. Of course, other means for removably securing the connector interface 15 to the retaining bracket 38 may be envisaged, such as the connector holder 42 having a locking latch that may engage a locking protrusion of the connector interface 15.

[0059] The connector interface 15 can be secured to the retaining bracket 38 in a test position 46 shown in Figures 1 and 2. In the test position 46, the connector interface 15 can be easily connected to test equipment for termination testing. The sensor module 1 can preferably be provided in the test position 48 prior to installation, allowing for easier installation of the sensor module 1 since the connector interface 15 is secured to the retaining bracket 38 and does not get in the way during handling of the sensor module 1. The user can concentrate on holding and positioning the remainder of the sensor module 1 without unnecessary consideration of the connector interface 15.

[0060] In a second position, particularly an application position 48 where the connector interface can be connected to a complementary connector for application purposes, the connector interface can be removed from the holding bracket 38, particularly the connector holder 42. The connector interface 15 in the application position 48 is shown diagrammatically in FIG. 2 by dashed lines.

[0061] The retaining bracket 38 may comprise a central stem 50 extending essentially parallel to the longitudinal axis L. Further functional parts may also protrude from the outer periphery of the central stem 50. For example, a post 52 having a free end 54, which may form the connector holder 42, may protrude from the outer periphery of the central stem 50 and extend beyond the central stem 50 essentially parallel to the longitudinal axis L. Furthermore, a further post 56 may protrude from another side of the outer periphery and extend beyond the central stem 50 essentially parallel to the longitudinal axis L. The further post 56 may feature a through hole 57 for receiving the temperature sensor 7. The connector interface 15 and the retaining mechanism for holding the temperature sensor 7 are thus locally separated, which reduces the risk of entanglement of the signal line 13.

[0062] According to a further advantageous embodiment, a mounting projection 58 can project from the central stem 50, the mounting projection 58 being adapted to receive a bushing 60, in particular a ring-shaped bushing, which can engage with a complementary formed mounting feature on the motor 2, thus fixing the retaining bracket 38 within the motor 2.

[0063] At least at test position 46, signal wire 13 may be at least partially wrapped around post 52 to neatly position signal wire 13 during installation. Thus, signal wire 13 does not interfere by getting in the way, tangling, and / or entangling. Post 52 may be provided with protruding ribs 62 that protrude from an outer surface of post 52 to guide signal wire 13 around post 52 and prevent movement of signal wire 13 along post 52.

[0064] 2, the signal wire 13 can be unwound from the post 52 at the application location 48. Unwounding the signal wire 13 provides additional room in positioning the connector interface 15. Thus, the sensor module 1 can be applied to a variety of motors that differ from each other in terms of at least one of size and structure.

[0065] The temperature sensor 7 can be pin-shaped and can have a body that extends parallel to the longitudinal axis L through a through-hole 57 in the retaining bracket 38, in particular through a further strut 56 in the retaining bracket 38. The temperature sensor 7 can be inserted into the through-hole 57 through a closing opening 64 formed by a circumferentially arranged elastically deflectable latch 66, which presses against the sensor body and stabilizes the temperature sensor 7 in the retaining bracket 38. The relative position between the temperature sensor 7 and the retaining bracket 38 can be adjusted essentially parallel to the longitudinal axis L, which allows for tolerance compensation. The temperature sensor 7 can be adapted to be inserted into a hole 68, in particular a blind hole 70, in the motor winding 72, as shown in FIG. 2. In particular, a tip 74 of the temperature sensor 7 can be adapted to be inserted into the hole 68, in particular the blind hole 70.

[0066] At least the tip 74 may have a cross-section, in a plane essentially orthogonal to the longitudinal axis L, that corresponds to the cross-section of the hole 68 in the motor winding 72. Preferably, this cross-section may be rotationally symmetric, e.g. circular, thus allowing insertion of the temperature sensor 7 into the hole 68 regardless of the relative rotational position of the temperature sensor with respect to the hole 68.

[0067] The tip 74 may have a different cross-section than the remainder of the body of the temperature sensor. For example, the tip 74 may have a circular cross-section and the remainder of the body of the sensor may have a square, particularly rectangular, cross-section. The width of the long side of the square cross-section and the diameter of the circular cross-section may be essentially equal.

[0068] The temperature sensor 7 may preferably be a sensor with a negative temperature coefficient, and at least the tip is encapsulated. The encapsulation may be made of a resin, such as an epoxy resin. Epoxy resin has a high thermal conductivity, which allows the sensor element encapsulated in the epoxy resin to sense temperature without significant losses. Preferably, the encapsulation may be formed by a fluoropolymer, such as PTFE and PFE, which allows a long life cycle of the temperature sensor 7 in harsh environments due to its good resistance to solvents, acids, and bases. Furthermore, the high thermal conductivity and thermal diffusivity of the fluoropolymer allows fast heat transfer to the tip of the temperature sensor 7 without significant losses.

[0069] The temperature sensor 7 may further be at least partially sleeved by a heat sink sleeve to further protect the temperature sensor 7. In particular, the portion of the temperature sensor 7 that is disposed within the retaining bracket 38 may be sleeved by a heat sink sleeve.

[0070] At the end opposite tip 74 , temperature sensor 7 may be connected to signal line 13 , which connects the sensing element of temperature sensor 7 to connector interface 15 .

[0071] A position assurance member 76 may be provided, which may be fixable in at least two positions on the holding bracket 38. In a first of the at least two positions, at least one of the positions of the temperature sensor 7 relative to the holding bracket 38, in particular the rotational position and the position essentially parallel to the longitudinal axis L, may be movable. In a second of the at least two positions, at least one of the positions of the temperature sensor 7 relative to the holding bracket 38, in particular the rotational position and the position essentially parallel to the longitudinal axis L, may be fixed. Thus, the position of the temperature sensor 7 may be adjusted in the first of the at least two positions and then fixed in the second of the at least two positions.

[0072] The interaction of position assurance member 76 and temperature sensor 7 will now be further described with reference to FIGS.

[0073] A first exemplary embodiment of a position assurance member 76 is shown in Figures 6 and 7. In Figure 6, the position assurance member 76 is shown in a first position 78 of at least two positions, and in Figure 7, the position assurance member 76 is shown in a second position 80 of the at least two positions.

[0074] In the first embodiment, the position assurance member 76 comprises at least one locking prong 82 that fits around the periphery of the temperature sensor 7. The temperature sensor 7 is thus held by the locking prong 82. A number of locking prongs can be arranged around the periphery of the temperature sensor 7. The locking prong 82 extends into the through hole 57 that forms an opening 84 that is essentially concentric with the through hole 57. The at least one locking prong 82 comprises a flap extending in the periphery direction so as to fit neatly around the outer contour of the temperature sensor. In the first position, the at least one locking prong 82 presses slightly against the outer contour of the temperature sensor 7, thus allowing the position of the temperature sensor 7 to be adjusted relative to the position assurance member 76 and the retaining bracket 38.

[0075] To limit the movement of the temperature sensor 7 and to make the sensor module 1 even more foolproof, the temperature sensor 7 can be provided with a limit stop 86 projecting radially from the body of the temperature sensor. The limit stop 86 can be adapted to abut against the rim of the hole 68 in the motor winding. The temperature sensor 7 is thus stopped from being inserted too deeply into the hole 68, thereby preventing the tip 74 from hitting the bottom of the hole and possibly being damaged. A heat sink sleeve fitted at least partially around the temperature sensor 7 can form the limit stop 86.

[0076] The limit stop 86 may also provide an abutment surface at an opposite end of the temperature sensor remote from the tip 74. The at least one locking prong 82 may abut against the abutment surface at a first position 78 of the at least two positions to press against the temperature sensor while moving the position assurance member 76 from the first position 78 to the second position 80. Thus, a minimum depth to which the temperature sensor 7 may be inserted into the bore 68 may be considered. Additionally, the position assurance member may guide the temperature sensor 7 into the bore 68.

[0077] In the second position shown in FIG. 7 , the position assurance member 76 can be fully inserted into the through hole 57, whereby a front end of the position assurance member 76 engages an undercut 90 in the retaining bracket 38, locking the position assurance member 76 in the second position 80. The at least one locking prong 82 is inserted into a slot 91 between the temperature sensor 7 and a rigid pressing projection 92 formed in the through hole 57. The pressing projection 92 can prevent loosening of the pressing force pressing the at least one locking prong 82 against the temperature sensor. The slot 91 can be dimensioned such that the inserted locking prong 82 is clamped between the pressing projection 92 and the temperature sensor 7, thus increasing the pressing force of the at least one locking prong 82 against the temperature sensor 7, resulting in the temperature sensor 7 being secured in the retaining bracket 38 by an interference fit.

[0078] In a second exemplary embodiment (see FIGS. 8 and 9 ), the position assurance member 76 can be arranged on the side of the through-hole 57 facing the tip 74 of the temperature sensor 7. The position assurance member 76 fits around the further post 56 that defines the through-hole 57, whereby the position assurance member 76 tapers towards the tip 74 and then fits around the temperature sensor 7. The tapering of the position assurance member 76 forms a pocket 94 therein, in which at least one locking prong 82 integrally formed in the through-hole 57 of the retainer bracket 38 is received in the second position 80 of the at least two positions. The locking prong 82 is thus pressed against the temperature sensor 7 and secures the temperature sensor 7 by an interference fit.

[0079] The front end 96 of the position assurance member 76 may be adapted to abut the top surface of the motor windings 72 such that further insertion of the temperature sensor 7 into the hole 68 pushes the position assurance member 76 upwardly, away from the tip 74 of the temperature sensor 7, into a second of the at least two positions 80, as shown in FIG. 9.

[0080] 10 and 11, the at least one locking prong 82 abuts against the limit stop 86 to move the position assurance member 76 from the first position to the second position while simultaneously guiding the temperature sensor tip 74 into the bore 68. The position assurance member 76 further includes a locking latch 98 which is engaged with a locking rib 100 formed on an outer surface of the retaining bracket 38 with a positive fit in the first and second positions. Thus, the position assurance member 76 can be securely fixed in the first and second positions.

[0081] In a further embodiment shown in Figs. 12 and 13, the position assurance member 76 is disposed on the side of the temperature sensor 7 opposite the tapered wall 102 of the retaining bracket 38, thereby reducing the width of the through-hole 57. The position assurance member 76 comprises a locking prong 82 formed as a rib that fits against the outer contour of the temperature sensor 7 parallel to the longitudinal axis L. Furthermore, a stabilizing clamp is provided, which extends partially around the circumference of the temperature sensor 7 to hold the temperature sensor 7. On the side facing away from the temperature sensor 7, the position assurance member 76 comprises a plurality of protruding teeth 106 that can engage with the locking latch 98 with a positive fit to prevent movement of the position assurance member 76 relative to the retaining bracket 38 away from the tip 74 of the temperature sensor 7.

[0082] Each tooth 106 corresponds to a position at which the position assurance member 76 can be secured. At the first position 78, the temperature sensor 7 can be moved, thereby allowing the position of the temperature sensor to be adjusted. With each position increment, the distance between the locking prongs 82 and the tapered wall 102 decreases and the pressing force of the locking prongs 82 against the temperature sensor 7 increases. Thus, the pressing force can be adapted depending on the application requirements. [Explanation of symbols]

[0083] 1 Sensor module 2 Motors 4 Electric motor 6 Holder 7 Temperature Sensor 8. Wet Chamber 9 Dry Chamber 10 Inner Circumference 12 Outer circumference 13 Signal Line 14 Rotational Position Sensor 15 Connector Interface 16 Resolver 17 Sealing elements 18 Stator Aisle 19 20 Rotor 22 Mounting hole 24 Surface 26 Opposite surface 28 Notch 30 Terminals 32 Stabilizing rib 34 Sealing cover 36 Flange part 38 Retaining bracket 40 Single Component 42 Connector holder 44 Holding Arm 46 Test Position 48 Application position 50 central stem 52 Pillar 54 Free end 56 More Support 57 Through hole 58 Mounting protrusion 60 Bushing 62 Protruding rib 64 Closed mouth 66 Latch 68 holes 70 Blind Hole 72 Motor Windings 74 Tip 76 Position Assurance Materials 78 1st position 80 2nd position 82 Locking Prongs 84 Aperture 86 Limit Stop 90 Undercut 91 Slots 92 Pressing protrusion 94 Pockets 96 Front end 98 Locking Latch 100 Rocking Rib 102 Tapered Wall 104 Retaining rib 106 teeth L Longitudinal axis

Claims

1. a sensor module (1) for mounting in a motor (2) having a wet chamber (8) and a dry chamber (9), comprising: a holder (6) adapted to be mounted in the wet chamber (8) of the motor (2); and a temperature sensor (7) adapted to be mounted in the dry chamber (9) of the motor (2), a rotational position sensor (14) mounted in the holder (6), the temperature sensor (7) being spaced apart from the holder (6), the rotational position sensor (14) and the temperature sensor (7) being connected via a plurality of signal lines (13) to a connector interface (15) adapted to be plugged into corresponding connectors, the sensor module (1) further comprising a sealing element (17) arranged between the rotational position sensor (14) and the temperature sensor (7) and through which a signal line (13) from one of the rotational position sensor (14) and the temperature sensor (7) sealably passes, The sensor module (1), wherein the connector interface (15) is adapted to be disposed within the dry chamber (9) of the motor (2), and the sealing element (17) is adapted to be fixed within a passage (19) of the motor (2) connecting the wet chamber (8) of the motor (2) and the dry chamber (9) of the motor (2) so as to be able to seal the passage (19).

2. The rotational position sensor (14) is a resolver (16); The resolver (16) comprises a stator (18) attached to the holder (6) and a rotor (20) adapted to be attached to a shaft of the motor (2); The sensor module (1) according to claim 1, wherein the temperature sensor (7) is spaced apart from the holder (6) and the stator (18) of the resolver (16).

3. The sealing element (17) is inserted from one surface (24) of the holder (6) to the opposite surface ( 26)。 The sensor module (1) according to claim 1, further comprising a first connecting member (26).

4. 2. The sensor module (1) according to claim 1, wherein the rotational position sensor (14) comprises a sealing cover (34) which closes the sealing element (17) from at least one side.

5. The sensor module (1) of claim 1, further comprising a retaining bracket (38) for retaining the temperature sensor (7), the retaining bracket (38) comprising a connector holder (42) for removably securing the connector interface (15) to the retaining bracket (38) in a test position (46).

6. 6. The sensor module (1) of claim 5, wherein at least at the test position (46), the plurality of signal lines (13) connecting the rotational position sensor (14) and / or the temperature sensor (7) to the connector interface (15) are at least partially wrapped around the retaining bracket (38).

7. 6. The sensor module (1) of claim 5, wherein the connector interface (15) is spaced from the retaining bracket (38) at an application location (48) for connecting the connector interface (15) to a complementary connector for a customer application.

8. 6. The sensor module (1) according to claim 5, wherein the retaining bracket (38) comprises a through hole (57), and the temperature sensor (7) extends through the through hole (57).

9. The sensor module (1) of claim 1, wherein the temperature sensor (7) is provided with at least one limit stop (86) protruding radially from a body of the temperature sensor (7) to limit an insertion depth of the temperature sensor (7).

10. 2. The sensor module (1) according to claim 1, wherein at least a tip (74) of the temperature sensor (7) has an essentially rotationally symmetric cross section.

11. The sensor module (1) according to claim 10, wherein the tip (74) of the temperature sensor (7) and the remaining part of the temperature sensor (7) have cross sections which differ from each other in terms of at least one of size and shape.

12. The sensor module (1) of claim 11 further comprises a retaining bracket (38) for retaining the temperature sensor (7), and a position assurance member (76) is adapted to be fixed in at least two positions on the retaining bracket (38), and at a first position (78) of the at least two positions, the relative position between the temperature sensor (7) and the retaining bracket (38) is movable, and at a second position (80) of the at least two positions, the relative position between the temperature sensor (7) and the retaining bracket (38) is fixed.

13. 13. The sensor module (1) according to claim 12, wherein at least one locking prong (82) is pressed against the temperature sensor (7) in at least the second position (80) of the at least two positions.

14. The sensor module (1) of claim 13, wherein the at least one locking prong (82) and the position assurance member (76) are integrally formed with one another as a unitary component.

15. 14. The sensor module (1) of claim 13, wherein the position assurance member (76) is adapted to guide the temperature sensor (7) parallel to movement from the first position (78) of the at least two positions to the other position of the at least two positions.

16. a sensor module (1) for mounting in a motor (2), comprising: a holder (6) adapted to be mounted in a wet chamber (8) of the motor (2); and a temperature sensor (7) adapted to be mounted in a dry chamber (9) of the motor (2), a rotational position sensor (14) mounted in the holder (6), the temperature sensor (7) being spaced apart from the holder (6), the rotational position sensor (14) and the temperature sensor (7) being connected via a plurality of signal lines (13) to a connector interface (15) adapted to be plugged into corresponding connectors, the sensor module (1) further comprising a sealing element (17) arranged between the rotational position sensor (14) and the temperature sensor (7) and through which a signal line (13) from one of the rotational position sensor (14) and the temperature sensor (7) sealably passes, the sensor module (1) further comprising a retaining bracket (38) for retaining the temperature sensor (7), the retaining bracket (38) comprising a connector holder (42) for removably securing the connector interface (15) to the retaining bracket (38) in a test position (46); The connector interface (15) is spaced from the retainer bracket (38) at an application location (48) for connecting the connector interface (15) to a complementary connector for a customer application.

17. a sensor module (1) for mounting in a motor (2), comprising: a holder (6) adapted to be mounted in a wet chamber (8) of the motor (2); and a temperature sensor (7) adapted to be mounted in a dry chamber (9) of the motor (2), a rotational position sensor (14) mounted in the holder (6), the temperature sensor (7) being spaced apart from the holder (6), the rotational position sensor (14) and the temperature sensor (7) being connected via a plurality of signal lines (13) to a connector interface (15) adapted to be plugged into corresponding connectors, the sensor module (1) further comprising a sealing element (17) arranged between the rotational position sensor (14) and the temperature sensor (7) and through which a signal line (13) from one of the rotational position sensor (14) and the temperature sensor (7) sealably passes, At least a tip (74) of the temperature sensor (7) has an essentially rotationally symmetric cross section, The tip (74) of the temperature sensor (7) and the remainder of the temperature sensor (7) are having cross sections that differ from one another with respect to at least one of size and shape; The sensor module (1) further comprises a retaining bracket (38) for retaining the temperature sensor (7), and a position assurance member (76) is adapted to be fixed in at least two positions on the retaining bracket (38), wherein at a first position (78) of the at least two positions, the relative position between the temperature sensor (7) and the retaining bracket (38) is movable, and at a second position (80) of the at least two positions, the relative position between the temperature sensor (7) and the retaining bracket (38) is fixed.

18. a sensor module (1) for mounting in a motor (2) having a wet chamber (8) and a dry chamber (9), comprising: a holder (6) adapted to be mounted in the wet chamber (8) of the motor (2); and a temperature sensor (7) adapted to be mounted in the dry chamber (9) of the motor (2), a rotational position sensor (14) mounted in the holder (6), the temperature sensor (7) being spaced apart from the holder (6), the rotational position sensor (14) and the temperature sensor (7) being connected via a plurality of signal lines (13) to a connector interface (15) adapted to be plugged into corresponding connectors, the sensor module (1) further comprising a sealing element (17) arranged between the rotational position sensor (14) and the temperature sensor (7) and through which a signal line (13) from one of the rotational position sensor (14) and the temperature sensor (7) sealably passes, The sensor module (1) further comprises a retaining bracket (38) for retaining the temperature sensor (7), the retaining bracket (38) comprising a connector holder (42) for removably securing the connector interface (15) to the retaining bracket (38) at a test position (46).

19. 19. A motor (2) comprising a wet chamber (8), a dry chamber (9) and a passage (19) connecting the wet chamber (8) and the dry chamber (9), wherein a sensor module (1) according to any one of claims 1 to 18 is mounted in the motor (2), the rotational position sensor (14) is mounted in the wet chamber (8), the temperature sensor (7) is mounted in the dry chamber (9) and the sealing element (17) is sealably fixed in the passage (19).

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