DE102020215978A1 - Sensor assembly for an electric drive device, electric drive device for a vehicle and method for manufacturing a sensor assembly - Google Patents

Abstract

A sensor assembly for an electric drive device of a vehicle comprises a carrier part for detachable attachment to a recess in a cover of the drive device, the cover being arranged on an axial end of an electric machine, a sensor device which has a speed sensor for detecting a speed of a rotor of the electric machine and is arranged on a first surface of the carrier part, and an electrical connection structure formed on a second surface of the carrier part.

Description

technical field

The present invention relates to a sensor assembly for an electric drive device for a vehicle, an electric drive device for a vehicle and a method for producing a sensor assembly.

State of the art

Electric drive devices for vehicles typically have an electric machine housed in a housing, which can often be operated as a motor and as a generator. In order to regulate the electric machine during operation, data about the current operating state of the electric machine, in particular its speed, is usually recorded. For this purpose, speed sensors are typically used, which are often installed inside the housing. In order to replace the speed sensor or other sensors, a relatively extensive dismantling of the drive device is usually required.

In the DE 10 2016 203 560 A1 a sensor module for an actuator with a displaceable armature is disclosed, which has a carrier plate with a plug arranged on an upper side and a sensor arranged on an underside for detecting an armature movement.

Disclosure of Invention

According to the invention, a sensor assembly having the features of claim 1, an electric drive device having the features of claim 9 and a method for producing a sensor assembly having the features of claim 11 are provided.

According to a first aspect of the invention, a sensor assembly for an electric drive device of a vehicle is provided. The sensor assembly according to the invention comprises a carrier part for detachable attachment to a recess of a cover of the drive device, the cover being arranged on one axial end of an electrical machine, a sensor device which has a speed sensor for detecting a speed of a rotor of the electrical machine and on a first Surface of the carrier part is arranged, and formed on a second surface of the carrier part electrical connection structure.

According to a second aspect of the invention, there is provided an electric drive device for a vehicle. The electric drive device according to the invention comprises an electric machine, which has a stator and a rotor mounted so as to be rotatable about an axis of rotation relative to the stator, a cover which is arranged at an axial end of the electric machine with respect to the axis of rotation and has a recess, and a sensor assembly according to the first aspect of the invention, wherein the support part is detachably connected to the cover and at least partially covers the recess, and wherein the first surface of the support part faces the rotor of the electrical machine.

According to a third aspect of the invention, there is provided a method of manufacturing a sensor assembly according to the first aspect of the invention. The method includes arranging the sensor device in a cavity of an injection mold and injection molding the carrier part and the connection structure by supplying molten casting material into the cavity, the carrier part being formed with a first connection structure which is formed into or around a second connection structure becomes.

One of the ideas on which the invention is based is to attach a sensor assembly in a simple, detachable manner to an axial cover of an electrical drive device for a vehicle, with an electrical machine, for example in the form of a three-phase synchronous machine, being arranged on a first side of the cover, and with the Sensor assembly mounted on an opposite thereto located second side of the cover, in particular is fixed. The cover has a recess extending between the first and the second side, through which a sensor device of the sensor assembly can be positioned on the electrical machine, in particular in the region of the rotor of the electrical machine. The sensor assembly comprises a flat, eg plate-shaped, carrier part with a first surface and a second surface located opposite to this. The sensor device, which has at least one speed sensor and optionally other sensors such as a temperature sensor, is arranged on the first surface of the carrier part. An electrical connection structure is formed on the second surface of the carrier part, which can in particular have a plurality of electrical contact structures which protrude from the first surface, extend through the carrier part and are electrically connected to the sensor device. When the sensor assembly is mounted on the cover, the first surface of the support part faces the electric machine and the sensor device is arranged in the recess of the cover. The support part can, for example as screwed to the cover or be releasably attached to it in some other way.

An advantage of this design of the sensor assembly and the drive device is that the sensor assembly can be installed in a simple manner. Furthermore, the entire sensor assembly can be easily replaced, e.g. in the event of service. The arrangement of the connection structure on the second surface of the carrier part of the sensor assembly makes it accessible from the outside, in particular from the second side of the cover. The electrical or signaling wiring of the drive device is thus simplified and a compact design of the drive device is possible. Furthermore, the production of the sensor assembly is particularly simple and economical in an injection molding process.

Advantageous refinements and developments result from the further dependent claims and from the description with reference to the figures of the drawing.

According to some embodiments, it can be provided that the carrier part and the sensor device are permanently connected to one another. “Inseparable” is to be understood here in particular as meaning that the sensor device and the carrier part cannot be separated from one another without being destroyed, e.g. without breaking a material bond. The carrier part and the sensor device thus form a firmly held assembly, which further facilitates the assembly of the sensor assembly.

According to some embodiments, it can be provided that the carrier part has at least one first connection structure on the first surface, which is connected to a second connection structure of the sensor device in a form-fitting and/or cohesive manner, the first connection structure being formed into and/or around the second connection structure . In particular, the first connection structure can be designed in the form of a projection, which can be configured, for example, in the form of a column. The second connection structure of the sensor device can be realized, for example, in the form of a recess. The material of the carrier part, which forms the first connection structure, encloses the second connection structure of the sensor device and/or fills it. In this way, the sensor device can be fastened to the carrier part in a simple and mechanically stable manner. In particular, the carrier part can be produced in a simple manner in an injection molding process, with the second connection structure of the sensor device being overmoulded.

According to some specific embodiments, it can be provided that the speed sensor is designed as a resolver or as a Hall sensor or as a TMR sensor. These speed sensors offer the advantage that they are inexpensive and work with high reliability. "TMR" is an abbreviation for the English expression "tunnel magnetoresistance". Thus, the sensor may be a tunneling magnetic resistance sensor.

According to some embodiments, it can be provided that the connection structure is designed as a socket for receiving a plug. The connection structure can thus have a frame which is designed to receive a plug mechanically, in particular in a form-fitting manner. Optionally, it can be provided that the socket or the frame forming it protrudes from the second surface of the carrier part and surrounds the electrical contact structures. The provision of a plug-in socket further simplifies connection of the sensor device.

According to some embodiments, it can be provided that the carrier part has a projection that protrudes from the first surface and is designed to be inserted into the recess in the cover and to rest on an inner circumference of the recess in the cover. For example, the extension can be designed as a closed frame, which has an outer circumference that corresponds to the inner circumference of the recess of the cover. For example, the approach can be implemented as a closed ring. The positioning of the carrier part on the recess of the cover is facilitated by the approach. In addition, sealing the first side of the cover relative to the second side of the cover is simplified.

According to some embodiments, it can be provided that the carrier part has at least one flange section with a through-opening for receiving a fastening pin, such as a screw or a bolt. The flange portion or flange portions may be formed on an outer periphery or generally in an edge area of the support part which overlaps an area of the cover surrounding the recess when the sensor assembly is arranged on the recess of the cover. The sensor assembly can be releasably attached to the cover through the through-openings, for example by means of screws.

According to some embodiments, it can be provided that a first centering structure in the form of a projection or a recess is formed on the first surface of the carrier part det, which is provided for engaging in a complementarily formed second centering structure of the cover. The optional centering structure further facilitates positioning of the sensor assembly on the cover, particularly with respect to a rotational position about the axis of rotation.

According to some specific embodiments, it can be provided that the cover is formed by a base of a stator pot, in which the stator of the electrical machine is accommodated. The stator pot can, for example, have a hollow-cylindrical section which is arranged coaxially to the axis of rotation and in which the stator is accommodated, the hollow-cylindrical section being closed at one axial end by a base. The stator pot can optionally be accommodated in a housing, with the base of the stator pot being arranged in an opening in the housing. This ensures particularly easy accessibility of the sensor assembly.

• 1 eine schematische Schnittansicht einer elektrischen Antriebsvorrichtung gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 2 eine perspektivische Ansicht einer elektrischen Antriebsvorrichtung gemäß einem Ausführungsbeispiel der vorliegenden Erfindung;
• 3 eine perspektivische Ansicht einer Sensorbaugruppe gemäß einem Ausführungsbeispiel der vorliegenden Erfindung mit Blickrichtung auf eine erste Oberfläche eines Trägerteils der Sensorbaugruppe;
• 4 eine perspektivische Ansicht der in 3 gezeigten Sensorbaugruppe mit Blickrichtung auf eine zweite Oberfläche des Trägerteils;
• 5 eine schematische Schnittansicht einer Spritzgussvorrichtung während eines Verfahrens zur Herstellung einer Sensorbaugruppe nach einem Ausführungsbeispiel der vorliegenden Erfindung; und
• 6 eine schematische Schnittansicht der in 5 gezeigten Spritzgussvorrichtung während eines weiteren Schritts des Verfahrens,

The invention is explained below with reference to the figures of the drawings. From the figures show:

• 1 a schematic sectional view of an electric drive device according to an embodiment of the present invention;
• 2 a perspective view of an electric drive device according to an embodiment of the present invention;
• 3 a perspective view of a sensor assembly according to an embodiment of the present invention looking towards a first surface of a carrier part of the sensor assembly;
• 4 a perspective view of in 3 sensor assembly shown looking towards a second surface of the support member;
• 5 a schematic sectional view of an injection molding device during a method for producing a sensor assembly according to an embodiment of the present invention; and
• 6 a schematic sectional view of in 5 shown injection molding device during a further step of the method,

In the figures, the same reference symbols designate identical or functionally identical components, unless otherwise stated.

1 1 shows a sectional view of an electric drive device 100 for a vehicle by way of example. In 2 the electric drive device 100 is shown in a perspective view.

As in the 1 and 2 As can be seen, drive device 100 has an electric machine 2 , a cover 3 and a sensor assembly 4 . Optionally, a housing 1 can also be provided. As in particular in 2 can be seen, a control device 7 can also optionally be provided.

The electric machine 2 is in 1 shown as an example in a sectional view and can be realized, for example, as a permanently excited synchronous machine. However, it is also conceivable that the electrical machine is implemented as an asynchronous machine. In general, the electrical machine 2 has a stator 20 and a rotor 21 . The rotor 21 is rotatably mounted relative to the stator 20 about an axis of rotation A20 and can be arranged, for example, inside the stator 20 with respect to a radial direction R20 extending transversely to the axis of rotation A20, as is shown in FIG 1 is shown as an example. The rotor 21 can, for example, be firmly connected to a rotor shaft 22, which in turn is rotatably mounted, as in 1 shown schematically. Furthermore, the rotor shaft 22 can be kinematically connected to a gearbox (in the 1 and 2 not shown) be coupled, e.g. via a gear wheel 23.

As in 1 shown schematically, the electric machine 2 can be accommodated in a stator pot 5 . In particular, the stator pot 5 can have a hollow cylinder 51 which is arranged coaxially to the axis of rotation A20. The stator pot 5 also has a base 50 which is arranged on an axial end of the hollow cylinder 51 and has a recess or opening 30 . The opening 30 can optionally also be arranged coaxially to the axis of rotation A20. As in 1 shown schematically, the stator 20 can bear against an inner peripheral surface 51a of the hollow cylinder 51 . A first surface 50a of the bottom 50 faces the electric machine 2, as shown in FIG 1 is shown as an example. Furthermore, the bottom 50 has a second surface 50b which is oriented opposite to the first surface 50a.

The optional housing 1 defines an interior space 10 in which the electric machine 2 is accommodated. Likewise, the transmission (not shown) can be accommodated in the housing 1 . As in particular in 1 As can be seen, the housing 1 can have an axial opening 11 in which the bottom 50 of the stator pot 5 can be arranged. As in particular in 2 As can be seen, the second surface 50b of the bottom 50 is therefore facing an outside or the environment.

The bottom 50 of the stator pot 5 thus forms a cover 3 which is arranged on an axial end 25 of the electrical machine 2 with respect to the axis of rotation A20. Alternatively, it would also be conceivable that instead of the base 50 an end wall of the housing 1 or a cover detachably connected to the housing 1 forms the cover 3 .

The optional control device 7 can, for example, have power electronics (not shown), which are accommodated in an electronics housing 70, with the electronics housing 70 being able to be arranged on the outside of the housing 1 in relation to the radial direction R20, as is shown in FIG 2 is shown as an example. The power electronics can have an inverter, for example, and is electrically connected to the electrical machine 2 . Furthermore, the power electronics can have an evaluation circuit (not shown) for evaluating sensor signals. As in 2 shown schematically, the control device 7 can have a sensor connection 71 via which an electrical connection to the evaluation circuit can be established.

The sensor assembly 4 is in the 3 and 4 shown in detail. As in the 3 and 4 shown by way of example, the sensor assembly 4 has a carrier part 40 , a sensor device 41 and a connection structure 42 .

As in the 3 and 4 is shown by way of example, the carrier part 40 can be designed, for example, as a circular plate or generally as a flat component with a first surface 40a and a second surface 40b oriented opposite to this. The carrier part 40 can in particular be formed from a plastic material, for example a thermoplastic material.

As in 3 As shown, the support member 40 may optionally include a tab 44 projecting from the first surface 40a. As in 3 shown by way of example, the projection 44 can be designed as a closed ring arranged in the edge area of the carrier part 40 . In general, the extension 44 can be implemented as a closed frame, which has a circumferential shape corresponding to the inner circumference 31 of the recess 30 of the cover 30 . The extension 44 can be formed in one piece with the carrier part 40, for example.

As in the 3 and 4 As can also be seen, the carrier part 40 can have one or more flange sections 45 . In the 3 and 4 three flange sections 45 are shown purely by way of example. The flange portions 45 may protrude, for example, from an outer periphery of the support member 40, as shown in FIGS 3 and 4 is shown. However, it is generally provided that the flange sections 45 are arranged in the area of a peripheral edge of the carrier part 40 . As in the 3 and 4 is also shown, each flange section 45 has a through opening 45A through which a fastening pin, for example in the form of a screw or a bolt, can be passed.

Furthermore optionally, the carrier part 40 can have a centering structure 46 which is formed on the first surface 40a. For example, the centering structure 46 can be a centering pin that protrudes from the first surface 40a of the support part 40, as is shown in FIG 3 is shown as an example. The centering structure 46 is preferably arranged between the projection 44 and the peripheral edge of the carrier part 40, as in FIG 3 shown as an example. Alternatively, it is also conceivable that a recess is provided as the centering structure 46 . In general, the centering structure 46 of the carrier part 40 is designed to engage in a complementary second centering structure (not shown) of the cover 3 .

The sensor device 41 can have one or more sensors for detecting various physical variables of the electrical machine 2 and/or for detecting ambient conditions prevailing in the housing 1 . In general, the sensor device 41 has at least one speed sensor 41A for detecting a speed of the rotor 21 of the electric machine 2 . In the 3 The sensor device 41 shown as an example has a speed sensor 41A implemented as a resolver. Alternatively, the speed sensor 41A could also be in the form of a Hall sensor or a TMR sensor.

As in 3 is shown, the sensor device 41 is arranged on the first surface 40a of the carrier part 40 . For example, the sensor device 41 can be arranged on the side of the first surface 40a but positioned at a distance from the first surface 40a. The sensor device 41 is also attached to the carrier part 40 . In particular, the sensor device 41 can be permanently connected to the carrier part 40 . This can include both a material connection and a form-fitting fixation. As in 3 Shown purely by way of example, the carrier part 40 can optionally have projections 43A on the first surface 40a, which can be realized, for example, in the form of a column and protrude from the first surface 40a. The sensor device 41 can have corresponding recesses 41C, into which the columns or projections 43A of the carrier part 40 protrude and fill them in such a way that the sensor device 41 is permanently fastened to the carrier part 40 . Thus, the Vor Cracks 43A, a first connection structure 43 of the carrier part 40 and the recesses 41C of the sensor device 41 form a second connection structure 41B, the first connection structure 43 being formed into the second connection structure 41B. Alternatively, it would also be conceivable for the projections 43A of the carrier part 40 to enclose an edge area of the sensor device 41 . In very general terms, it can therefore be provided that carrier part 40 has at least one first connection structure 43, which is connected in a form-fitting and/or cohesive manner to a second connection structure 41B of sensor device 41, with first connection structure 43 merging into and/or around second connection structure 41B this is shaped

The connection structure 42 is used for the electrical connection of the sensor device 41 , for example in order to transmit measurement data recorded by the sensor device 41 to the control device 7 . The connection structure 42 is formed on the second surface 40b of the carrier part 40 . In particular, the connection structure 42 can have a plurality of electrically conductive contact structures 42A, for example in the form of metal pins as shown in FIG 4 is shown by way of example, which protrude from the second surface 40b of the carrier part 40, extend through the carrier part 40 at least as far as the first surface 40a of the carrier part 40 and are electrically connected to the sensor device 41.

As in 4 shown purely by way of example, the connection structure 42 can be implemented as a socket 6 for receiving a plug (not shown). For example, the socket 6 can have a base plate 60 projecting transversely from the second surface 40b of the carrier part 40 and a frame 61 which extends from the base plate 60 . The frame 61 defines a plug opening 62 into which the plug is insertable. Contact structures 42A can, for example, protrude from the bottom plate 60 parallel to the second surface 40b of the carrier part 40 and be surrounded by the frame 61, as is shown in FIG 4 is shown purely as an example. Optionally, the socket 6 can be designed in one piece with the carrier part 40 .

The sensor assembly 4 described above can as in the 1 and 2 be mounted on the electric drive device 100 or on the cover 3 as shown by way of example. As in particular in 1 the sensor assembly 4 is arranged in the area of the recess 30 of the cover 3 . In particular, the carrier part 40 is detachably connected to the cover 3 . For example, the carrier part 40 can be screwed to the base 50 of the stator pot 5 by means of screws which are passed through the recesses 45A of the flange sections 45 . Furthermore, the recess 30 of the cover 30 is at least partially, preferably completely covered by the carrier part 40, as shown in FIGS 1 and 2 is recognizable. The first surface 40a of the carrier part 40 faces the rotor 21 of the electrical machine 2 . As in particular in 1 shown as an example, the sensor device 41 is accommodated in the recess 30 of the cover 3 . The optional projection 44, which is formed on the first surface 40a of the carrier part 40, rests on the inner circumference 31 of the recess 3, as shown in FIG 1 is shown as an example. As in 2 is shown schematically, a connecting cable 8 can be electrically connected to the connection structure 42 of the sensor assembly 4 and the sensor connection 71 of the optional control device 7 in order to electrically connect the sensor device 41 to the control device 7 for signal transmission.

In the 5 and 6 a method for producing a sensor assembly 4 is illustrated by way of example and purely schematically, which is explained below by way of example with reference to the sensor assembly 4 explained above.

As in 5 is shown schematically, the sensor device 41 is arranged in a cavity 203 of an injection mold 200 in a first step. In this case, the contact structures 42A can already be electrically and mechanically connected to the sensor device 41 . The injection mold 200 can have, for example, a first mold part 201 and a second mold part 202 that can be positioned opposite the first mold part 201, the cavity 203 being formed between the first and the second mold part 201, 202 when the first and the second mold part 201, 202 are arranged opposite one another, as in 5 is shown as an example. Sensor device 41 can in particular have at least one second connection structure 41B, e.g. in the form of a recess or opening 41C, as shown in 5 is shown schematically. Optionally, additional mold cores 204 can be arranged in the cavity 203, so that a cavity is formed in the cavity 203, the shape of which corresponds to the shape of the carrier part 40 to be formed and the connection structure 42 to be formed.

In a further step, the carrier part 40 and the connection structure 42 are injection molded 6 shown by way of example, molten casting material M40, e.g. a thermoplastic material, is fed into the cavity 203, e.g. through a recess 205 in the second mold part 202, as is shown in FIG 6 is shown purely schematically. This will make the hollow Space in the cavity 203 is filled by the material M40, which solidifies and thereby forms the carrier part 40 and the connection structure 42. As in 6 shown schematically, the material M40 also fills the recesses 41C of the sensor device 41 and thus forms a first connection structure 43 of the carrier part 40 . In general, the carrier part 40 is thus formed with a first connection structure 43 which is formed into or around a second connection structure 41C.

Although the present invention has been explained above by way of example using exemplary embodiments, it is not limited thereto but can be modified in many different ways. In particular, combinations of the above exemplary embodiments are also conceivable.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102016203560 A1 [0003]

Claims (11)

Sensor assembly (4) for an electric drive device (100) of a vehicle, with: a carrier part (40) for detachable attachment to a recess (30) of a cover (3) of the drive device (100), the cover (3) being arranged on an axial end (25) of an electrical machine (2); a sensor device (41) which has a speed sensor (41A) for detecting a speed of a rotor (21) of the electrical machine (2) and is arranged on a first surface (40a) of the carrier part (40); and an electrical connection structure (42) formed on a second surface (40b) of the carrier part (40). Drive device (100) after claim 1 , wherein the carrier part (40) and the sensor device (41) are permanently connected to each other. Drive device (100) after claim 2 , wherein the support part (40) has at least one first connection structure (43) on the first surface (40a), in particular in the form of a projection (43A), which is positively and/or materially connected to a second connection structure (41B), in particular in the form of a Recess (41C) to which the sensor device (41) is connected, the first connection structure (43) being formed into and/or around the second connection structure (41B). Drive device (100) according to one of the preceding claims, wherein the speed sensor (41A) is designed as a resolver or as a Hall sensor or as a TMR sensor. Drive device (100) according to one of the preceding claims, wherein the connection structure (42) is designed as a socket (6) for receiving a plug. Drive device (100) according to one of the preceding claims, wherein the carrier part (40) has a projection (44) projecting from the first surface (40a), in particular in the form of a closed frame, which is intended for insertion into the recess (30) of the cover (3) and is designed to rest on an inner circumference (31) of the recess (30) of the cover (3). Drive device (100) according to one of the preceding claims, wherein the support part (40) has at least one flange portion (45) with a through hole (45A) for receiving a fastening pin such as a screw or a bolt. Drive device (100) according to one of the preceding claims, wherein a first centering structure (46) in the form of a projection or a recess is formed on the first surface (40a) of the carrier part (40), which is designed to engage in a complementarily formed second centering structure of the cover (3) is provided. Electrical drive device (100) for a vehicle, comprising: an electrical machine (2) which has a stator (20) and a rotor (21) which is mounted such that it can rotate about an axis of rotation (A20) relative to the stator (20); a cover (3) which is arranged at an axial end (25) of the electric machine (2) with respect to the axis of rotation (A20) and has a recess (30); and a sensor assembly (4) according to one of the preceding claims, wherein the carrier part (40) is detachably connected to the cover (3) and the recess (30) at least partially covers, and wherein the first surface (40a) of the carrier part (40) faces the rotor (21) of the electrical machine (2). Electrical drive device (100) according to claim 9 , wherein the cover (3) is formed by a bottom (50) of a stator pot (5) in which the stator (20) of the electrical machine (2) is accommodated. Method for producing a sensor assembly (4) according to one of Claims 1 until 8th , comprising: arranging the sensor device (41) in a cavity (203) of an injection mold (200); and injection molding the support part (40) and the terminal structure (42) by supplying molten molding material (M40) into the cavity (203), wherein the support part (40) is formed with a first connection structure (43) which is divided into a second connection structure ( 41C) is molded into or around it.

Images