WO2022188880A1 - 一种启动发电一体机 - Google Patents

一种启动发电一体机 Download PDF

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Publication number
WO2022188880A1
WO2022188880A1 PCT/CN2022/080449 CN2022080449W WO2022188880A1 WO 2022188880 A1 WO2022188880 A1 WO 2022188880A1 CN 2022080449 W CN2022080449 W CN 2022080449W WO 2022188880 A1 WO2022188880 A1 WO 2022188880A1
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WO
WIPO (PCT)
Prior art keywords
water pipe
sensor
heat dissipation
assembly
integrated starter
Prior art date
Application number
PCT/CN2022/080449
Other languages
English (en)
French (fr)
Inventor
金英
董天源
白玉峰
Original Assignee
上海法雷奥汽车电器系统有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN202120524796.6U external-priority patent/CN214384879U/zh
Priority claimed from CN202110269112.7A external-priority patent/CN112865440A/zh
Application filed by 上海法雷奥汽车电器系统有限公司 filed Critical 上海法雷奥汽车电器系统有限公司
Priority to DE112022001452.0T priority Critical patent/DE112022001452T5/de
Publication of WO2022188880A1 publication Critical patent/WO2022188880A1/zh

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
    • H02K11/21—Devices for sensing speed or position, or actuated thereby
    • H02K11/215—Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/06—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices
    • H02K29/08—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with position sensing devices using magnetic effect devices, e.g. Hall-plates, magneto-resistors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/20—Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
    • H02K5/225—Terminal boxes or connection arrangements
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/20218—Modifications to facilitate cooling, ventilating, or heating using a liquid coolant without phase change in electronic enclosures
    • H05K7/20272—Accessories for moving fluid, for expanding fluid, for connecting fluid conduits, for distributing fluid, for removing gas or for preventing leakage, e.g. pumps, tanks or manifolds
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
    • H05K7/20927—Liquid coolant without phase change

Definitions

  • the invention relates to the technical field of electric motors, in particular to a starter-generator integrated machine.
  • the starter-generator can provide torque boost during the cold/hot start of the car, reduce fuel consumption, and recover energy to charge the 48V battery during the car braking process. Therefore, the application of the starter-generator can effectively save fuel.
  • the installation space of the integrated starter and generator in the vehicle is mostly small, and the working environment has high temperature, high humidity, and a lot of dust.
  • the whole machine needs to run in a vibration and high temperature environment for a long time, and at the same time, the PCBA and power module on the starter generator are integrated
  • the heating phenomenon during operation is relatively serious, and the heat dissipation structure design of the existing starter-generator unit is often unreasonable, and the stability and heat dissipation efficiency of the heat dissipation structure are low, which will affect the normal operation of the starter-generator unit. Poor reliability and stability.
  • the purpose of the present invention is to provide a starter-generator integrated machine, the heat dissipation structure of which has high stability, can achieve sufficient heat dissipation, and improves the reliability and stability of the whole machine.
  • An integrated starter and generator including a motor assembly and an inverter assembly, the inverter assembly including:
  • the PCBA casing includes a casing body and a cover plate arranged above the casing body; the casing body is provided with a PCBA;
  • the heat dissipation structure includes a heat dissipation plate and a water pipe, the heat dissipation plate has a first side and a second side arranged in an up-down direction, and the first side of the heat dissipation plate is used to be attached to the housing body and the power module
  • the second side of the heat dissipation plate is provided with an accommodating groove; the water pipe is interference fit in the accommodating groove, and at least part of the outer wall of the water pipe is in contact with the groove wall of the accommodating groove combine.
  • the accommodating slot is a strip-shaped structure, and includes a plurality of sub-slots arranged in sequence along the extending direction, and two adjacent sub-slots form an included angle set up;
  • a transition slot is arranged between two adjacent sub-slots, and the width of the opening of the transition slot is larger than the outer diameter of the water pipe placed there.
  • a chamfer is set between the groove wall of the transition groove and the adjacent groove wall of the sub-groove, and the angle of the chamfer is greater than 90 degrees.
  • the motor assembly includes a motor
  • the inverter assembly further includes a sensor assembly
  • the sensor assembly includes:
  • the magnetic ring has an outer ring body and an inner ring body spaced coaxially, a accommodating space opening upward is formed between the outer ring body and the inner ring body; the inner ring body coaxially connected with the rotating shaft of the motor;
  • the sensor assembly includes a connection bracket and a sensor body disposed below the connection bracket, the connection bracket is connected to the heat dissipation plate, and the sensor body is suspended in the accommodating space.
  • the sensor assembly further includes:
  • a sensor bracket which is detachably connected to the connection bracket, and the sensor body is mounted on the sensor bracket;
  • the protective cover is arranged below the connecting bracket, the protective cover is arranged on the periphery of the sensor bracket, and the protective cover is filled with potting glue.
  • the inverter assembly further includes a signal connector, and the signal connector is riveted above the cover plate.
  • the signal connector includes:
  • a connector body the connector body is connected to the cover plate; a sealed chamber is formed between the connector body and the PCB connector on the PCBA;
  • a first retaining wall integrated on the top of the connector body
  • the ventilation hole which communicates the sealed chamber and the outside world;
  • the ventilation hole includes a first opening, a second opening and a circulation channel arranged between the first opening and the second opening;
  • the first opening is provided with On the circumferential side wall of the first retaining wall, the second opening is arranged on the connector body;
  • the gas permeable membrane is located on the gas flow path of the gas permeable hole.
  • the first retaining wall and the connector body are integrally formed; the ventilation hole is an L-shaped structure or a T-shaped structure.
  • a part of the bottom surface of the cover plate is recessed upward to form a drainage hole with the upper end surface of the housing body; the drainage hole is provided in the The outer circumference of the PCBA shell is communicated with the inside of the shell body.
  • the inverter assembly further includes a power terminal, and the power terminal includes an insulating base and first terminals and second terminals embedded on the insulating base.
  • a terminal, the insulating base body is formed with a second blocking wall at the first terminal and the periphery of the second terminal, and a drainage groove is provided on the second blocking wall.
  • a heat dissipation structure is arranged under the PCBA shell, and the heat dissipation plate of the heat dissipation structure is attached to the PCBA shell and the power module, so as to fully dissipate heat from the PCBA and the power module, and ensure the start-up power generation.
  • the all-in-one machine will not affect the normal operation due to overheating, which improves the reliability and stability of the whole machine;
  • the heat dissipation structure directly fits the water pipe into the accommodating groove, and does not need to use thermal adhesive for bonding, which not only ensures the water pipe and the heat dissipation plate
  • the stable connection between them can prevent the water pipes from falling off when the whole machine vibrates frequently, and can also make the outer wall of the water pipe and the groove wall of the accommodating tank fit as closely as possible. It is indirectly realized by using thermal conductive glue, which improves the heat dissipation efficiency.
  • FIG. 1 is a schematic structural diagram of a starter-generator integrated machine in an embodiment of the present invention
  • FIG. 2 is a schematic diagram of an exploded structure of an inverter assembly in an embodiment of the present invention
  • FIG. 3 is a schematic diagram of the assembly of a signal connector and a PCBA housing in an embodiment of the present invention
  • FIG. 4 is a cross-sectional view of a signal connector and a PCBA housing after assembly in an embodiment of the present invention
  • FIG. 5 is a schematic structural diagram of a heat dissipation structure in a first viewing angle according to an embodiment of the present invention
  • FIG. 6 is a schematic structural diagram of a heat dissipation structure in a second viewing angle according to an embodiment of the present invention
  • FIG. 7 is a schematic structural diagram of a water pipe in an embodiment of the present invention.
  • FIG. 8 is a schematic structural diagram of the heat dissipation structure after removing the water pipe according to the embodiment of the present invention.
  • Fig. 9 is the partial enlarged schematic diagram of A place in Fig. 8.
  • Figure 10 is a sectional view of B-B in Figure 6;
  • FIG. 11 is a schematic diagram of the assembly of the sensor assembly and the rotating shaft of the motor in the embodiment of the present invention.
  • 13 is a schematic diagram of the assembly of the sensor assembly and the bearing in the embodiment of the present invention.
  • FIG. 14 is a schematic diagram of the assembly of the magnetic ring and part of the sensor assembly in the embodiment of the present invention.
  • FIG. 15 is a partial structural schematic diagram of a sensor assembly in an embodiment of the present invention.
  • FIG. 16 is a schematic top view of a sensor assembly in an embodiment of the present invention.
  • 17 is a schematic structural diagram 1 of a signal connector according to an embodiment of the present invention.
  • FIG. 18 is a schematic structural diagram of a cover plate in an embodiment of the present invention.
  • 19 is a second structural schematic diagram of a signal connector in an embodiment of the present invention.
  • FIG. 20 is a top view of a signal connector in an embodiment of the present invention.
  • 21 is a cross-sectional view of a signal connector according to an embodiment of the present invention.
  • FIG. 22 is a cross-sectional view of another signal connector according to an embodiment of the present invention.
  • FIG. 23 is a schematic structural diagram of a power terminal in an embodiment of the present invention.
  • PCBA shell 11. Cover plate; 111. Hot riveting hole; 112. Mounting hole; 12. Shell body; 13. Drain hole; 14. Protection chamber; 15. PCBA; 16. Power module; 17. sealed chamber;
  • heat dissipation structure 21, heat dissipation plate; 211, accommodating groove; 2111, sub-slot; 2112, transition groove; 212, mounting seat; 2121, first through hole; 22, water pipe; 221, boss; 222, seal groove; 23, water pipe joint; 231, second through hole; 232, limit step; 24, seal;
  • sensor assembly 31, magnetic ring; 311, outer ring body; 312, inner ring body; 32, sensor assembly; 321, connecting bracket; 3211, potting hole; 3212, exhaust hole; 3213, metal cable ; 322, sensor body; 323, sensor bracket; 324, protective cover; 325, potting glue;
  • Power terminal 51. Insulation base; 511, Second retaining wall; 512, Drainage groove; 52, First terminal; 53, Second terminal.
  • the terms “upper”, “lower”, “left”, “right”, “vertical”, “horizontal”, “inner”, “outer”, etc. indicate the orientation or The positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the product of the invention is usually placed when it is used. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying the device referred to. Or elements must have a particular orientation, be constructed and operate in a particular orientation, and therefore should not be construed as limiting the invention. Furthermore, the terms “first”, “second”, “third”, etc.
  • first position and “second position” are two different positions.
  • plural means two or more.
  • connection should be understood in a broad sense, for example, it may be a fixed connection or a detachable connection, or It can be connected in one piece; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be internal communication between two components.
  • a first feature "on” or “under” a second feature may include the first and second features in direct contact, or may include the first and second features Not directly but through additional features between them.
  • the first feature being “above”, “over” and “above” the second feature includes the first feature being directly above and obliquely above the second feature, or simply means that the first feature is level higher than the second feature.
  • the first feature is “below”, “below” and “below” the second feature includes the first feature being directly below and diagonally below the second feature, or simply means that the first feature has a lower level than the second feature.
  • FIG. 1 is a schematic structural diagram of an integrated starter and generator in an embodiment of the present invention
  • FIG. 2 is a schematic diagram of an exploded structure of an inverter assembly in an embodiment of the present invention
  • FIG. 3 is a signal connector and a PCBA shell in an embodiment of the present invention
  • Figure 4 is a cross-sectional view of the signal connector and the PCBA housing after assembly in the embodiment of the present invention
  • Figure 5 is a schematic structural diagram of the heat dissipation structure in the embodiment of the present invention from a first perspective
  • Figure 6 is an embodiment of the present invention.
  • FIG. 7 is a schematic structural diagram of a water pipe in the embodiment of the present invention
  • Figure 8 is a schematic structural diagram of the heat dissipation structure in the embodiment of the present invention after removing the water pipe
  • Figure 9 is A in Figure 8
  • Figure 10 is a sectional view at B in Figure 6
  • Figure 11 is a schematic diagram of the assembly of the rotating shaft of the sensor assembly and the motor in the embodiment of the present invention
  • Figure 12 is the rotating shaft of the sensor assembly and the motor in the embodiment of the present invention Partial cross-sectional view after assembly
  • FIG. 13 is an assembly schematic diagram of a sensor assembly and a bearing in an embodiment of the present invention
  • FIG. 14 is an assembly schematic diagram of a magnetic ring and part of the sensor assembly in an embodiment of the present invention
  • this embodiment provides an integrated starter-generator machine, which includes a motor assembly 100 and an inverter assembly 300 .
  • the inverter assembly 300 and the motor assembly 100 are set up and down.
  • a cover is provided outside the inverter assembly 300 , and the cover is used to provide protection for the inverter assembly 300 .
  • the inverter assembly 300 includes a PCBA housing 10 and a heat dissipation structure 20 .
  • the PCBA housing 10 and the heat dissipation structure 20 are also arranged one above the other. Referring to FIGS.
  • the PCBA housing 10 includes a housing body 12 and a cover plate 11 disposed above the housing body 12 ; the housing body 12 is provided with a PCBA 15 .
  • the PCBA shell 10 ensures that the product is protected from direct impact on the circuit board by water, dust and impurities under harsh working environments such as vibration and shock, and plays a protective role on the PCBA 15.
  • the heat dissipation structure 20 includes a heat dissipation plate 21 and a water pipe 22, the heat dissipation plate 21 has a first side and a second side arranged along the thickness direction (ie, the upper and lower direction), and the first side of the heat dissipation plate 21 is used for connecting with the shell
  • the body 12 and the power module 16 are attached together, and the second side of the heat dissipation plate 21 is provided with an accommodating groove 211; Wall fit.
  • the inverter assembly 300 further includes the power module 16. Since the heat generation of the power module 16 is much larger than that of the PCBA 15, the power module 16 is directly attached to the heat sink 21, so that the power module 16 can be directly and quickly of heat dissipation.
  • the PCBA15 and the housing body 12 are bonded by thermally conductive adhesive, and the housing body 12 and the heat sink 21 are also bonded by the thermally conductive adhesive, so that the heat generated by the PCBA15 can be gradually transferred to the heat dissipation
  • the board 21 realizes the heat dissipation of the heat dissipation structure 20 to the PCBA 15 .
  • the heat dissipation structure 20 is arranged under the PCBA casing 10, and the heat dissipation plate 21 of the heat dissipation structure 20 is attached to the PCBA casing 10 and the power module 16 to fully dissipate heat from the PCBA 15 and the power module 16 to ensure the integration of starting and power generation.
  • the normal operation of the machine will not be affected due to overheating, which improves the reliability and stability of the whole machine;
  • the stable connection with the cooling plate 21 prevents the water pipe 22 from falling off when the whole machine vibrates frequently, and also enables the outer wall of the water pipe 22 and the groove wall of the accommodating groove 211 to fit as closely as possible, and the heat of the cooling plate 21 directly passes through the water pipe.
  • the outer wall is transferred to the cooling liquid, which does not need to be indirectly realized by thermal conductive glue, which improves the heat dissipation efficiency.
  • the power module 16 is directly attached to the first side of the heat dissipation plate 21, so that heat can be directly transferred to the heat dissipation plate 21 for heat dissipation.
  • a protection chamber 14 is formed inside the PCBA housing 10 , and a PCBA 15 is provided in the protection chamber 14 .
  • a PCBA 15 is provided in the protection chamber 14 .
  • the top surface of the existing cover plate 11 is usually provided with openings to facilitate the volatilization of water vapor, but the design of such openings will cause dust and impurities can directly drop into the PCBA shell 10 through the opening.
  • the sealant can be potted inside the PCBA shell 10 to protect the PCBA 15, the sealant itself has a certain fluidity, and the impurities will gradually sink in.
  • a part of the bottom surface of the cover plate 11 is recessed upward to form a drainage hole 13 between the cover plate 11 and the upper end surface of the housing body 12 , and the drainage hole 13 is provided on the outer periphery of the PCBA housing 10 . , and communicates with the interior of the housing body 12 . That is, by partially reducing the thickness of the cover plate 11, a drainage hole 13 is formed with the upper end surface of the housing body 12, which not only plays a role in drainage, but also helps to minimize the opening area and reduce the risk of foreign matter intrusion.
  • the cross-section of the water pipe 22 is a circular structure, and the cross-section of the accommodating groove 211 is an arc structure; further, the inner diameter of the accommodating groove 211 is larger than the outer diameter of the water pipe 22, and the cross-section of the accommodating groove 211 is a superior arc structure , and the width of the opening of the accommodating groove 211 is smaller than the outer diameter of the water pipe 22; when the water pipe 22 is pressed, the water pipe 22 needs to be squeezed into the accommodating groove 211 from the small opening of the accommodating groove 211 by the pressing force, so as to realize the two Then continue to squeeze the water pipe 22 to deform it and finally fit with the groove wall of the accommodating groove 211, so as to increase the contact area as much as possible and improve the heat dissipation effect.
  • the water pipes 22 and the heat dissipation plate 21 are made of metal materials with better thermal conductivity, which can not only improve the overall strength of the heat dissipation structure 20 but also ensure sufficient heat dissipation.
  • the accommodating groove 211 is a strip-shaped structure, and the water pipe 22 follows the accommodating groove 211 , which is also a strip-shaped structure. terminal lead out.
  • the water pipes 22 need to extend to each power module 16, that is, the water pipes 22 and the water pipes 22.
  • the grooves 211 all need to be bent adaptively.
  • the accommodating slot 211 includes a plurality of sub-slots 2111 arranged in sequence along the extending direction, and two adjacent sub-slots 2111 are arranged at an angle; in this embodiment, refer to FIG. 6 and FIG. 8.
  • the included angle ⁇ between the two adjacent sub-slots 2111 is an obtuse angle, so as to avoid stress concentration caused by excessive bending angle.
  • a transition groove 2112 is provided between two adjacent sub-grooves 2111, and the width of the opening of the transition groove 2112 is larger than the outer diameter of the water pipe 22 placed there.
  • the width of the opening of the transition groove 2112 is set to a ratio of The outer diameter of the water pipe 22 is large to avoid excessive extrusion between the water pipe 22 and the groove wall of the accommodating groove 211 at the bend during press-fitting, so that the bend of the water pipe 22 is ruptured by a large external force.
  • the outer diameter of the water pipe 22 is generally kept the same.
  • the size of the accommodating groove 211 is selected to be improved, so that the width of the opening of the transition groove 2112 is larger than that of the adjacent sub-grooves 2111
  • the inner diameter of the water pipe 22 should be sufficient, so as to avoid excessive extrusion of the water pipe 22.
  • a chamfer C is set between the groove wall of the transition groove 2112 and the groove wall of the adjacent sub-groove 2111 , and the angle of the chamfer C is greater than 90 degrees to avoid as much as possible. Produces sharp transition edges.
  • the angle of the chamfer C may be 100 degrees, 125 degrees or 160 degrees. Further, a smooth transition is formed between the groove wall of the transition groove 2112 and the groove wall of the sub-groove 2111 to further avoid stress concentration with the water pipe 22 .
  • both free ends of the accommodating groove 211 are provided with mounting seats 212, and the mounting seats 212 are provided with water pipe joints 23, and the water inlet and the water outlet of the water pipe 22 are communicated with the outside world through the water pipe joints 23, Realize the circulation of coolant.
  • the water pipe joint 23 is provided on the first side of the heat dissipation plate 21; specifically, optionally, the mounting seat 212 is a convex structure protruding from the first side of the heat dissipation plate 21, and the water pipe joint 23 is installed on the free side of the convex structure. end.
  • the water pipe joint 23 is fixed on the mounting seat 212 by a fastener; in this embodiment, the fastener is a screw. Further, referring to FIG.
  • a first through hole 2121 is formed on the mounting seat 212 along the thickness direction of the heat dissipation plate 21 .
  • the free end of the water pipe 22 passes through the first through hole 2121 . It extends from the first through hole 2121 to facilitate subsequent assembly with the water pipe joint 23 ; further, the diameter of the first through hole 2121 gradually decreases along the direction away from the second side of the heat dissipation plate 21 .
  • the first through hole 2121 is designed to be similar to a conical structure, so that the water pipe 22 has a larger space for movement at the free end of the accommodating groove 211 to avoid jamming, and the conical structure can also prevent the water pipe 22 in the first through hole.
  • the piercing in the 2121 plays a better guiding role and avoids the position deviation of the water pipe 22 . Further, referring to FIG. 8 , the accommodating groove 211 and the first through hole 2121 have a smooth transition, which further ensures that the water pipe 22 enters the mounting seat 212 smoothly.
  • the first through hole 2121 may be a smooth tapered structure, that is, the diameter of the first through hole 2121 gradually decreases along the direction away from the second side of the heat dissipation plate 21 until it reaches the minimum at the free end of the mounting seat 212 .
  • the first through hole 2121 includes a first subsection and a second subsection connected in sequence, wherein the first subsection is closer to the second subsection of the heat dissipation plate 21 than the second subsection
  • the first sub-section is a smooth conical structure; while the second sub-section is a cylindrical structure, that is, the aperture of the second sub-section remains the same, and is equal to or slightly larger than the outer diameter of the water pipe 22 here.
  • the water pipe 22 is roughly guided through the first subsection, and then the second subsection is used to limit the position of the water pipe 22 as much as possible, so as to ensure that the axes of the water pipe 22 and the first through hole 2121 overlap as much as possible;
  • the second subsection should have a certain draft taper, but this taper is often small and does not affect the sufficient limit of the entire second subsection to the water pipe 22 .
  • the water pipe joint 23 is provided with a second through hole 231 , and the second through hole 231 and the first through hole 2121 are coaxially arranged and communicated with each other, so as to facilitate the flow of the cooling liquid from the water pipe joint 23 into the water pipe 22 or It flows out from the water pipe 22 to the water pipe joint 23 .
  • the diameter of the second through hole 231 is slightly larger than the outer diameter of the water pipe 22 , so as to ensure that the water pipe 22 can be smoothly inserted into the water pipe joint 23 .
  • the diameter of the second through hole 231 at the connection between the first through hole 2121 and the second through hole 231 is larger than the outer diameter of the water pipe 22 , that is, the hole at one end of the second through hole 231 and the first through hole 2121 is connected
  • the wall is provided with a guide slope, the purpose is that when the water pipe joint 23 is subsequently assembled, the water pipe 22 can be quickly assembled with the water pipe joint 23 through the guide slope, and the water pipe joint 23 can be smoothly inserted without jamming at the junction.
  • At least two bosses 221 are provided on the outer circumferential surfaces of the water inlet and the water outlet of the water pipe 22 , and the two adjacent bosses 221 are spaced apart along the axial direction of the water pipe 22 .
  • the sealing member 24 is arranged in the sealing groove 222 to form a sealing groove 222.
  • the sealing member 24 is limited between the two bosses 221 and cannot move at will, so as to ensure the stability of the position of the sealing member 24; the sealing member 24 is squeezed Between the outer wall of the water pipe 22 and the inner wall of the water pipe joint 23 , the annular gap between the water pipe 22 and the water pipe joint 23 is sealed.
  • the sealing groove 222 may also be formed directly on the outer wall of the water pipe 22 by mechanical cutting.
  • the sealing groove 222 is formed by a rolling groove process, that is, a rotating roller is used to roll on the water pipe 22 to roll out at least two bosses 221, and a sealing groove 222 is naturally formed between the two bosses 221. This not only simplifies the forming process of the sealing groove 222, but also avoids stress concentration caused by mechanical cutting.
  • a limit step 232 is also provided on the hole wall of the second through hole 231 , and the limit step 232 restricts the water pipe 22 from extending into the water pipe joint 23 through abutment with the boss 221 on the water pipe 22 . The length of the water pipe 22 and the water pipe joint 23 is realized.
  • the motor assembly 100 includes a motor
  • the inverter assembly 300 further includes a sensor assembly 30,
  • the sensor assembly 30 includes a magnetic ring 31 and a sensor assembly 32,
  • the magnetic ring 31 is connected to the rotating shaft 200 of the motor, and the sensor assembly 32 and the magnetic ring 31 directly cooperates with each other to obtain electrical signals through the Hall effect, and transmits the electrical signals to the processing unit of PCBA15 to obtain rotational information such as the rotational speed of the motor to form closed-loop control.
  • the processing unit of PCBA15 to obtain rotational information such as the rotational speed of the motor to form closed-loop control.
  • the sensor is generally placed outside the magnetic ring 31 alone, and the motor comes with a cooling fan.
  • the magnetic ring 31 has an outer ring body 311 and an inner ring body 312 that are coaxially spaced apart, and an upwardly-opening accommodation is formed between the outer ring body 311 and the inner ring body 312 space; the inner ring body 312 is coaxially connected with the rotating shaft 200 of the motor; the sensor assembly 32 includes a connection bracket 321 and a sensor body 322 arranged below the connection bracket 321, the connection bracket 321 is connected to the heat sink 21, and the sensor body 322 is suspended on within the accommodation space.
  • the sensor body 322 can be suspended in the accommodating space, so that the magnetic field induction of the magnetic ring 31 can be realized, thereby completing the motor
  • the outer ring body 311 of the magnetic ring 31 will also block the wind generated by the operation of the cooling fan 500 of the motor assembly 100, so as to avoid interference to the sensor, play a role in fully protecting the sensor, and improve the detection accuracy of the sensor. Accuracy.
  • the magnetic ring 31 is a circular ring structure, so the accommodating space formed by it is a circular ring; the number of the sensor bodies 322 of the sensor assembly 30 is set to a plurality, and the plurality of sensor bodies 322 are located in the magnetic
  • the axis of the ring 31 is on the same virtual circle with the center of the circle, so as to fit with the magnetic ring 31 of the ring structure, so as to facilitate accurate detection.
  • the plurality of sensor bodies 322 include Hall sensors and temperature sensors, among which the Hall sensors are mainly used to complete the detection of motor rotation information, and the temperature sensors are selectively installed according to needs; React.
  • the sensor assembly 30 further includes a sensor bracket 323 and a protective cover 324, wherein the sensor bracket 323 is connected to the connection bracket 321, the sensor body 322 is mounted on the sensor bracket 323, and the protective cover 324 It is arranged below the connection bracket 321 and covered on the periphery of the sensor bracket 323 , and a potting glue 325 is encapsulated in the protective cover 324 . Since the sensor body 322 is a sensitive device, it is necessary to use a protective cover 324 to cover the periphery of the sensor bracket 323, and encapsulate the potting glue 325 inside to wrap and protect the sensor body 322 to isolate external vibration or pollutants, etc. .
  • a protective cover 324 to cover the periphery of the sensor bracket 323, and encapsulate the potting glue 325 inside to wrap and protect the sensor body 322 to isolate external vibration or pollutants, etc.
  • a potting hole 3211 is provided on the connecting bracket 321 , the potting hole 3211 communicates with the protective cover 324 , and the colloid can enter the protective cover 324 through the potting hole 3211 .
  • glue is poured into the protective cover 324, air trapping may occur, and the air bubbles remaining in the colloid will expand at high temperature, squeezing the entire colloid or the sensor body 322, causing damage. Therefore, the connecting bracket 321 is also provided with a protection
  • the exhaust hole 3212 communicated with the cover 324 is used to assist in realizing exhaust and avoid the occurrence of trapped air.
  • the plurality of sensor bodies 322 are located on the same virtual circle, so the protective cover 324 is roughly arc-shaped; further, the part of the connecting bracket 321 connected to the protective cover 324 is also roughly arc-shaped; optionally, There are two exhaust holes 3212 , and they are respectively located on both sides of the potting hole 3211 along the circumferential direction of the connecting bracket 321 .
  • a metal cable 3213 is provided on the connection bracket 321. Both ends of the metal cable 3213 are drawn out from the connection bracket 321. One end of the metal cable 3213 is connected to the PCBA 15 in the PCBA housing 10, and the other end is connected to the sensor body. 322 connection, thereby realizing the transmission of electrical signals from the sensor to the PCBA15. Further optionally, the sensor bracket 323 is inserted on the connection bracket 321 .
  • a jack is provided on the sensor bracket 323, and one end of the metal cable 3213 connected to the sensor body 322 can be inserted into the jack, so as to realize the plug connection between the sensor bracket 323 and the connection bracket 321, and then connect the sensor bracket
  • the pins of the sensor body 322 on the 323 are welded and connected to the metal cable 3213 to realize electrical signal transmission.
  • the connection bracket 321 is wrapped around the metal cable 3213 to protect the mechanical and electrical properties of the metal cable 3213 .
  • the installation position and arrangement position of the sensor body 322 are specific, so the accuracy of placement is high, but the position deviation is likely to occur when welding the sensor body 322 and the corresponding metal cable 3213.
  • the sensor bracket 323 can effectively realize the fixing of the sensor body 322 and avoid the displacement of the sensor body 322 during the welding process.
  • the sensor bracket 323 is provided with a card slot, and the sensor body 322 is locked in the card slot.
  • the sensor bracket 323 and the connection bracket 321 are in a split structure, and the two are detachably connected, that is, the sensor bracket 323 and the connection bracket 321 are two independent structures.
  • This arrangement is due to the different motor structures used in the starter-generator integrated machine and the different placement positions of the sensor body 322.
  • only a suitable sensor bracket 323 can be selected to realize the fast and accurate positioning of the sensor body 322. , which improves the applicability of the entire sensor assembly 30 .
  • the cooling fan 500 of the integrated starter and generator is arranged below the magnetic ring 31 .
  • an opening is arranged above the accommodating space of the magnetic ring 31 , so that the sensor body 322 is placed in the upper part of the magnetic ring 31 from top to bottom.
  • the bottom of the accommodating space is closed to prevent wind from entering the accommodating space from the bottom and causing interference to the sensor body 322 placed in the accommodating space.
  • a layer of magnetic material is provided on the inner surface of the outer ring body 311 of the magnetic ring 31, and the magnetic material is magnetized to form a plurality of magnetic poles.
  • the number of magnetic poles can also be adaptively changed due to different motor structures, and the corresponding placement positions of the sensor body 322 are also different.
  • the bottom surface of the magnetic ring 31 is recessed upward to form a vacant groove, the cooling fan 500 is partially accommodated in the vacated groove, and the blades of the cooling fan 500 surround the outer circumference of the outer ring body 311 of the magnetic ring 31 . , to avoid wind flow into the accommodation space.
  • the motor assembly 100 is also provided with a bearing 400, the inner ring body 312 and the motor shaft 200 are connected to the inner ring of the bearing 400, so that the motor can synchronously drive the magnetic ring 31 to rotate.
  • the outer ring of the bearing 400 is fixed on the housing of the motor assembly 100 .
  • the inverter assembly 300 further includes a signal connector 40 for connecting the PCBA 15 and the vehicle controller to realize signal transmission between the PCBA 15 and the vehicle controller; specifically, refer to FIG. 3 and FIG. 4.
  • the signal connector 40 is riveted above the cover plate 11 so that the cover plate 11 supports the signal connector 40 .
  • the signal connector 40 and the cover plate 11 are made of one-piece injection molding. Due to the large size of the injection molded part and the signal cable in the signal connector 40, the thermal shock performance and mechanical shock resistance of the injection molded part are improved. The performance is poor and it is easy to crack.
  • the signal connector 40 and the cover plate 11 are designed as two separate parts, so that the cover plate 11 can be made of metal material, which not only helps to improve its own protection performance, but also plays a better role in protecting itself. It can also improve the EMC (ie electromagnetic compatibility) performance of the product. 17 and 18, there are several hot riveting posts 411 on the signal connector 40, and a corresponding number of hot riveting holes 111 are provided on the cover plate 11. During installation, after the hot riveting posts 411 pass through the hot riveting holes 111, At the other end, the hot riveting column 411 is melted by the hot riveting equipment, and then cooled to form a cap-shaped snap, thereby fixing the signal connector 40 on the cover plate 11 .
  • a mounting hole 112 is provided on the cover plate 11 .
  • the signal connector 40 is thermally riveted on the cover plate 11 , the signal cable on the cover plate 112 enters the protection chamber 14 through the mounting hole 112 , and then Connection with the PCBA15 is possible; specifically, the signal connector 40 is connected with the PCB connector on the PCBA15.
  • a sealed chamber 17 is formed between the signal connector 40 and the PCB connector on the PCBA 15 through a sealant to prevent the entry of external impurities.
  • the ventilation hole 43 is designed to connect the outside world and the sealed chamber.
  • the chamber 17 is used to balance the air pressure in the chamber; the ventilation hole 43 is provided with a breathable membrane 44 to allow gas to pass through, but can prevent water, oil, dust and other impurities from entering. Since the transmission of electrical signals needs to meet the requirements of dust and water resistance, the product needs to be tested for dust and water resistance after manufacturing.
  • the existing ventilation holes are designed in a straight line and are directly exposed from the top of the signal connector 40, and then the IPX9K protection is carried out.
  • the high-pressure water gun spraying directly on the breathable membrane 44 will cause its damage, thereby making the product's dust-proof and waterproof function ineffective.
  • an additional protective cover or protective cover is usually required to achieve protection, but this undoubtedly increases the cost.
  • the signal connector 40 includes a connector body 41 , and the connector body 41 is connected to the cover plate 11 ;
  • the signal connector 40 also includes: a first blocking wall 42 integrated on the top of the connector body 41; a ventilation hole 43, which communicates the sealing chamber 17 with the outside world, ensuring that the gas circulates through the ventilation hole 43, and the air in the sealing chamber 17.
  • the air pressure can be kept stable;
  • the ventilation hole 43 includes a first opening 431 , a second opening 432 and a circulation channel arranged between the first opening 431 and the second opening 432 ;
  • the first opening 431 is arranged in the circumferential direction of the first blocking wall 42
  • the second opening 432 is provided on the connector body 41;
  • the breathable film 44, the breathable film 44 is located on the gas flow path of the breathable hole 43, which can allow the gas to flow, prevent water and dust from entering the sealed chamber 17, and ensure the prevention of The dust and water resistance test was carried out smoothly.
  • the high-pressure water gun is sprayed toward the top of the connector body 41.
  • a first blocking wall 42 is integrated on the top of the connector body 41, and then the dust-proof and waterproof test is performed.
  • the high-pressure water first directly hits the first retaining wall 42 instead of directly spraying to the ventilation holes 43.
  • the blocking of the first retaining wall 42 can effectively reduce the water flow velocity and water pressure.
  • the first opening 431 of the circumferential side wall of a retaining wall 42 enters the ventilation hole 43, and thus will not directly impact the ventilation film 44 on the ventilation hole 43, so as to successfully complete the relevant dustproof and waterproof detection and effectively avoid product failure.
  • the first blocking wall 42 has a cylindrical structure, and the first opening 431 is provided on the outer circumferential surface of the first blocking wall 42 to facilitate molding.
  • the first retaining wall 42 may be a truncated cone structure.
  • the first retaining wall 42 is a plastic retaining wall, that is, the first retaining wall 42 is made of a plastic material, so that the first retaining wall 42 and the connector body 41 can be integrally formed by an injection molding process.
  • the breathable film 44 is provided at the second opening 432 of the breathable hole 43, that is, at the connection between the breathable hole 43 and the sealing chamber 17; of course, in some other embodiments, The breathable film 44 can also be arranged between the first opening 431 and the second opening 432 of the breathable hole 43; in short, the farther the breathable film 44 is set from the first opening 431, the smaller the water pressure it bears, and the less likely it will be damaged. If it is destroyed, the more it can ensure the smooth progress of the dustproof and waterproof test.
  • the breathable membrane 44 is provided on the inner wall of the circulation channel at the second opening 432; or alternatively, referring to FIG.
  • the connector body 41 is provided with a receiving groove at the bottom of the second opening 432, and the breathable membrane 44 is installed In the accommodating groove, the air-permeable membrane 44 is arranged on the outside of the air-permeable hole 43 , which is also on the gas flow path, so as to ensure dustproof and waterproof, and the accommodating groove also facilitates the installation of the air-permeable membrane 44 .
  • the air-permeable hole 43 can be an L-shaped structure, and the L-shaped structure makes the water flow path longer, which is more helpful for slowing down The water speed and water pressure are reduced, so even if a small part of high-pressure water will directly enter the ventilation hole 43 through reflection, it will not cause excessive impact on the ventilation membrane 44 .
  • the L-shaped ventilation hole 43 includes a third subsection and a fourth subsection that communicate with each other vertically, the third subsection is formed with a first opening 431 on the first retaining wall 42, and the fourth subsection is in the connector body.
  • a second opening 432 is formed on the 41; further, the third subsection can be appropriately extended at the connection with the fourth subsection, so that the water flow can form a vortex here, and still play the role of slowing down the water speed.
  • the ventilation hole 43 can also be a T-shaped structure, and the T-shaped ventilation hole 43 also includes a third subsection and a fourth subsection that communicate with each other vertically, and the third subsection is in the first block. Two first openings 431 are formed on the wall 42, and a second opening 432 is formed on the connector body 41 in the fourth subsection. purpose of water speed.
  • the cross-section of the third subsection is rectangular, circular or other shapes; the cross-section of the fourth subsection is also rectangular, circular or other shapes.
  • the shape, structure and cross-sectional shape of the ventilation hole 43 are not specifically limited, as long as the first opening 431 and the second opening 432 of the ventilation hole 43 can communicate with the outside world and the sealed chamber 17, respectively.
  • the bending angle and frequency of the ventilation holes 43 on the flow path are not specifically limited.
  • each ventilation hole 43 is correspondingly provided with a first opening 431 and a second opening 432 .
  • the second openings 432 of the plurality of ventilation holes 43 can be arranged at the same position, that is, the first openings 431 of the plurality of ventilation holes 43 are respectively arranged, but the air is eventually exhausted from the same second opening 432.
  • the second A breathable membrane 44 may be provided at the opening 432 to save costs.
  • the multiple ventilation holes 43 are evenly distributed along the outer circumference of the first blocking wall 42 .
  • the inverter assembly 300 further includes a power terminal 50 for supplying power to the inverter assembly 300 ; optionally, the power terminal 50 is mounted on the heat dissipation plate 21 .
  • the power terminal 50 includes an insulating base 51 and a first terminal 52 and a second terminal 53 embedded on the insulating base 51 , and the insulating base 51 is formed with a second The retaining wall 511 and the second retaining wall 511 are provided with drainage grooves 512 .
  • the existing power terminals 50 do not have a drainage design, which is easy to generate water in the second retaining wall 511 at the terminals, corrode the copper busbars and studs, and have the risk of short circuit or open circuit failure.
  • 23 shows the placement position of the power terminals 50 after the starter-generator is installed on the vehicle, wherein the drainage grooves 512 are arranged below the corresponding terminals, and the water entering the power terminals 50 can flow out directly from the drainage grooves 512 , to avoid the occurrence of stagnant water to corrode the cable.

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  • Thermal Sciences (AREA)
  • Motor Or Generator Frames (AREA)

Abstract

提供了一种启动发电一体机，属于电机技术领域。启动发电一体机包括电机总成（100）和逆变器总成（300），逆变器总成（300）包括：PCBA壳体（10），包括壳体本体（12）和盖设于壳体本体（12）上方的盖板（11）；壳体本体（12）内设置有PCBA（15）；散热结构(20)，包括散热板(21)和水管(22)，散热板(21)具有沿上下方向设置的第一侧和第二侧，散热板(21)的第一侧用于与壳体本体(12)和功率模块(16)相贴合，散热板(21)的第二侧设置有容置槽(211)；水管(22)过盈配合于容置槽(211)内，水管(22)的至少部分外壁与容置槽(211)的槽壁相贴合。启动发电一体机可以对PCBA和功率模块进行充分散热，提升整机的可靠性和稳定性。

Description

一种启动发电一体机 技术领域
本发明涉及电机技术领域，尤其涉及一种启动发电一体机。
背景技术
启动发电一体机在汽车冷/热启动过程中可以提供扭矩助力，减少燃油消耗，并在汽车制动过程中回收能量为48V电池充电，因此应用有启动发电一体机的汽车能够有效节省燃油。
但是启动发电一体机在车辆内的安装空间大多狭小，工作环境的温度高、湿度大、灰尘多，整机需要长时间在振动及高温的环境中运行，同时启动发电一体机上的PCBA和功率模块运行时发热现象较为严重，受制于现有的启动发电一体机的散热结构设计往往不够合理，散热结构的稳固性和散热效率均较低，给启动发电一体机的正常运行造成影响，整机的可靠性和稳定性较差。
发明内容
本发明的目的在于提供一种启动发电一体机，其散热结构的稳固性高，且能够实现充分散热，提升了整机的可靠性和稳定性。
为实现上述目的，提供以下技术方案：
一种启动发电一体机，包括电机总成和逆变器总成，所述逆变器总成包括：
PCBA壳体，包括壳体本体和盖设于所述壳体本体上方的盖板；所述壳体本体内设置有PCBA；
散热结构，包括散热板和水管，所述散热板具有沿上下方向设置的第一侧和第二侧，所述散热板的所述第一侧用于与所述壳体本体和功率模块相贴合，所述散热板的所述第二侧设置有容置槽；所述水管过盈配合于所述容置槽内， 所述水管的至少部分外壁与所述容置槽的槽壁相贴合。
作为上述一种启动发电一体机的一种可选方案，所述容置槽为条形结构，且包括沿延伸方向依次设置的多个分槽，相邻的两个所述分槽呈夹角设置；
相邻的两个所述分槽之间设置过渡槽，所述过渡槽开口处的宽度大于置于此处的所述水管的外径。
作为上述一种启动发电一体机的一种可选方案，所述过渡槽的槽壁与相邻的所述分槽的槽壁之间设置倒角，所述倒角的角度大于90度。
作为上述一种启动发电一体机的一种可选方案，所述电机总成包括电机，所述逆变器总成还包括传感器总成，所述传感器总成包括：
磁环，所述磁环具有同轴心间隔设置的外环体和内环体，所述外环体和所述内环体之间的形成有向上开口的容置空间；所述内环体与所述电机的转轴同轴连接；
传感器组件，所述传感器组件包括连接支架和设于所述连接支架下方的传感器本体，所述连接支架连接于所述散热板上，所述传感器本体悬置于所述容置空间内。
作为上述一种启动发电一体机的一种可选方案，所述传感器总成还包括：
传感器支架，可拆卸地连接于所述连接支架上，所述传感器本体安装于所述传感器支架上；
保护罩，设于所述连接支架下方，所述保护罩罩设于所述传感器支架外围，且所述保护罩内灌封有灌封胶。
作为上述一种启动发电一体机的一种可选方案，所述逆变器总成还包括信号接插件，所述信号接插件铆接于所述盖板上方。
作为上述一种启动发电一体机的一种可选方案，所述信号接插件包括：
接插件本体，所述接插件本体连接于所述盖板上；所述接插件本体与所述PCBA上的PCB接插件之间形成有一密封腔室；
第一挡墙，集成于所述接插件本体的顶部；
透气孔，连通所述密封腔室与外界；所述透气孔包括第一开口、第二开口和设于所述第一开口与所述第二开口之间的流通通道；所述第一开口设于所述第一挡墙的周向侧壁上，所述第二开口设于所述接插件本体上；
透气膜，位于所述透气孔的气体流通路径上。
作为上述一种启动发电一体机的一种可选方案，所述第一挡墙与所述接插件本体一体成型；所述透气孔为L型结构或T型结构。
作为上述一种启动发电一体机的一种可选方案，所述盖板的底面的部分区域向上凹陷，以与所述壳体本体的上端面之间形成排水孔；所述排水孔设于所述PCBA壳体的外周，并与所述壳体本体内部相连通。
作为上述一种启动发电一体机的一种可选方案，所述逆变器总成还包括电源端子，所述电源端子包括绝缘基体和嵌设于所述绝缘基体上的第一端子和第二端子，所述绝缘基体在所述第一端子处和所述第二端子外围均形成有第二挡墙，所述第二挡墙上设置有排水槽。
与现有技术相比，本发明的有益效果：
本发明所提供的启动发电一体机，通过在PCBA壳体下方设置散热结构，并使散热结构的散热板与PCBA壳体及功率模块贴合，以对PCBA和功率模块进行充分散热，确保启动发电一体机不会由于过热影响正常运行，提升了整机的可靠性和稳定性；散热结构直接将水管过盈配合于容置槽内，无需采用导热胶进 行粘接，不仅能够保证水管与散热板之间的稳固连接，避免水管在整机频繁振动时发生脱落，还能够实现水管外壁与容置槽的槽壁尽可能的贴合，散热板的热量直接通过水管外壁传递至冷却液中，无需采用导热胶间接实现，提高了散热效率。
附图说明
图1为本发明实施例中一种启动发电一体机的结构示意图；
图2为本发明实施例中逆变器总成的分解结构示意图；
图3为本发明实施例中信号接插件与PCBA壳体的装配示意图；
图4为本发明实施例中信号接插件与PCBA壳体装配后的剖视图；
图5为本发明实施例中散热结构在第一视角下的结构示意图；
图6为本发明实施例中散热结构在第二视角下的结构示意图；
图7为本发明实施例中水管的结构示意图；
图8为本发明实施例中散热结构去除水管后的结构示意图；
图9为图8中A处的局部放大示意图；
图10为图6中B-B的剖视图；
图11为本发明实施例中传感器总成与电机的转轴装配示意图；
图12为本发明实施例中传感器总成与电机的转轴装配后的部分剖视图；
图13为本发明实施例中传感器总成与轴承的装配示意图；
图14为本发明实施例中磁环与部分传感器组件的装配示意图；
图15为本发明实施例中传感器组件的部分结构示意图；
图16为本发明实施例中传感器组件的俯视示意图；
图17为本发明实施例中一种信号接插件的结构示意图一；
图18为本发明实施例中盖板的结构示意图；
图19为本发明实施例中一种信号接插件的结构示意图二；
图20为本发明实施例中一种信号接插件的俯视图；
图21为本发明实施例中一种信号接插件的剖视图；
图22为本发明实施例中另一种信号接插件的剖视图；
图23为本发明实施例中电源端子的结构示意图。
附图标记：
100、电机总成；200、转轴；300、逆变器总成；400、轴承；500、散热风扇；
10、PCBA壳体；11、盖板；111、热铆孔；112、安装孔；12、壳体本体；13、排水孔；14、保护腔室；15、PCBA；16、功率模块；17、密封腔室；
20、散热结构；21、散热板；211、容置槽；2111、分槽；2112、过渡槽；212、安装座；2121、第一通孔；22、水管；221、凸台；222、密封槽；23、水管接头；231、第二通孔；232、限位台阶；24、密封件；
30、传感器总成；31、磁环；311、外环体；312、内环体；32、传感器组件；321、连接支架；3211、灌封孔；3212、排气孔；3213、金属排线；322、传感器本体；323、传感器支架；324、保护罩；325、灌封胶；
40、信号接插件；41、接插件本体；411、热铆柱；42、第一挡墙；43、透气孔；431、第一开口；432、第二开口；44、透气膜；
50、电源端子；51、绝缘基体；511、第二挡墙；512、排水槽；52、第一端子；53、第二端子。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。通常在此处附图中描述和示出的本发明实施例的组件可以以各种不同的配置来布置和设计。
因此，以下对在附图中提供的本发明的实施例的详细描述并非旨在限制要求保护的本发明的范围，而是仅仅表示本发明的选定实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步定义和解释。
在本发明的描述中，需要说明的是，术语“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，或者是该发明产品使用时惯常摆放的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。此外，术语“第一”、“第二”、“第三”等仅用于区分描述，而不能理解为指示或暗示相对重要性。其中，术语“第一位置”和“第二位置”为两个不同的位置。在本发明的描述中，除非另有说明，“多个”的含义是两个或两个以上。
在本发明的描述中，还需要说明的是，除非另有明确的规定和限定，术语“设置”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也 可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本发明中的具体含义。
在本发明中，除非另有明确的规定和限定，第一特征在第二特征之“上”或之“下”可以包括第一和第二特征直接接触，也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且，第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方，或仅仅表示第一特征水平高度小于第二特征。
下面详细描述本发明的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本发明，而不能理解为对本发明的限制。
图1为本发明实施例中一种启动发电一体机的结构示意图；图2为本发明实施例中逆变器总成的分解结构示意图；图3为本发明实施例中信号接插件与PCBA壳体的装配示意图；图4为本发明实施例中信号接插件与PCBA壳体装配后的剖视图；图5为本发明实施例中散热结构在第一视角下的结构示意图；图6为本发明实施例中散热结构在第二视角下的结构示意图；图7为本发明实施例中水管的结构示意图；图8为本发明实施例中散热结构去除水管后的结构示意图；图9为图8中A处的局部放大示意图；图10为图6中B处的剖视图；图11为本发明实施例中传感器总成与电机的转轴装配示意图；图12为本发明实施例中传感器总成与电机的转轴装配后的部分剖视图；图13为本发明实施例 中传感器总成与轴承的装配示意图；图14为本发明实施例中磁环与部分传感器组件的装配示意图；图15为本发明实施例中传感器组件的部分结构示意图；图16为本发明实施例中传感器组件的俯视示意图；图17为本发明实施例中一种信号接插件的结构示意图一；图18为本发明实施例中盖板的结构示意图；图19为本发明实施例中一种信号接插件的结构示意图二；图20为本发明实施例中一种信号接插件的俯视图；图21为本发明实施例中一种信号接插件的剖视图；图22为本发明实施例中另一种信号接插件的剖视图；图23为本发明实施例中电源端子的结构示意图。
如图1所示，本实施例在于提供一种启动发电一体机，该启动发电一体机包括电机总成100和逆变器总成300。逆变器总成300和电机总成100一上一下设置。进一步地，逆变器总成300外设置有罩盖，罩盖用于为逆变器总成300提供防护。具体地，参考图2，逆变器总成300包括PCBA壳体10和散热结构20。PCBA壳体10和散热结构20也为一上一下设置。参考图2-4，PCBA壳体10包括壳体本体12和盖设于壳体本体12上方的盖板11；壳体本体12内设置有PCBA15。PCBA壳体10保证产品在振动、冲击等恶劣工作环境下，防止水、灰尘杂质等直接冲击到电路板，对PCBA15起到保护作用。参考图5-8，散热结构20包括散热板21和水管22，散热板21具有沿厚度方向(即上下方向)设置的第一侧和第二侧，散热板21的第一侧用于与壳体本体12和功率模块16相贴合，散热板21的第二侧设置有容置槽211；水管22过盈配合于容置槽211内，水管22的至少部分外壁与容置槽211的槽壁相贴合。具体实施时，逆变器总成300还包括有功率模块16，由于功率模块16的发热较PCBA15大得多，功率模块16便直接贴设于散热板21上，以实现功率模块16直接且快速的散热。而由 于PCBA15产生的热量较小，PCBA15与壳体本体12之间通过导热胶贴合，壳体本体12与散热板21之间也通过导热胶贴合，PCBA15产生的热量便可以逐渐传递至散热板21，实现散热结构20对PCBA15的散热。
本实施例通过在PCBA壳体10下方设置散热结构20，并使散热结构20的散热板21与PCBA壳体10及功率模块16贴合，对PCBA15和功率模块16进行充分散热，确保启动发电一体机不会由于过热影响正常运行，提升了整机的可靠性和稳定性；散热结构20直接将水管22过盈配合于容置槽211内，无需采用导热胶进行粘接，不仅能够保证水管22与散热板21之间的稳固连接，避免水管22在整机频繁振动时发生脱落，还能够实现水管22外壁与容置槽211的槽壁尽可能的贴合，散热板21的热量直接通过水管22外壁传递至冷却液中，无需采用导热胶间接实现，提高了散热效率。进一步可选地，功率模块16直接贴设于散热板21的第一侧，方便热量直接传递至散热板21上进行散热。
具体地，参考图4，PCBA壳体10内部形成一保护腔室14，保护腔室14内设置有PCBA15。启动发电一体机的工作环境下，不可避免地会在装置内部形成水汽，因此现有的盖板11的顶面上通常设置开孔，方便水汽的挥发，但这种开孔的设计会使得灰尘和杂质可以通过开孔直接掉落到PCBA壳体10内，虽然可以在PCBA壳体10内部灌封密封胶起到保护PCBA15的作用，但密封胶本身有一定的流动性，杂质会逐渐沉入胶体内，并到达PCBA15，由于PCBA15上有大量的电子元器件，金属杂质会导致元器件相互短路等问题，影响PCBA15性能。本实施例中，参考图3和图4，盖板11的底面的部分区域向上凹陷，以与壳体本体12的上端面之间形成排水孔13，排水孔13设于PCBA壳体10的外周，并与壳体本体12内部相连通。即通过局部减薄盖板11的厚度，与壳体本体12的上 端面形成了排水孔13，起到排水作用的同时，有助于实现开口面积最小化，降低异物侵入的风险。
具体实施时，水管22的截面为圆形结构，容置槽211的截面为弧形结构；进一步地，容置槽211的内径大于水管22的外径，容置槽211的截面为优弧结构，且使容置槽211开口处的宽度小于水管22的外径；压装时，水管22需要依靠挤压力由容置槽211的小尺寸开口处挤入容置槽211内，实现二者的过盈配合，然后继续挤压水管22，使其变形并最终与容置槽211的槽壁相贴合，尽可能增大接触面积，提升散热效果。本实施例中，水管22及散热板21均采用导热性能较佳的金属材料制成，既能提高散热结构20的整体强度，还能保证热量的充分散发。
容置槽211为条状结构，水管22随形于容置槽211，也为条状结构，且水管22嵌入容置槽211后，其进水口和出水口分别由容置槽211的两自由端引出。具体实施时，由于功率模块16通常设置多个且设置位置不同，为了保证每个功率模块16都得到充分散热，水管22需要延伸到各个功率模块16处，即水管22和容纳水管22的容置槽211均需要适应性地弯折。具体地，参考图8和图9，容置槽211包括沿延伸方向依次设置的多个分槽2111，相邻的两个分槽2111呈夹角设置；本实施例中，参考图6和图8，相邻的两个分槽2111之间的夹角β均为钝角，以避免弯折角度过大造成应力集中。进一步地，相邻的两个分槽2111之间设置有过渡槽2112，过渡槽2112开口处的宽度大于置于此处的水管22的外径。由于水管22制造时弯折处的形状相对于直线段来说可控性差，且在弯折处本身壁厚会减薄，进而容易发生应力集中，因此将过渡槽2112开口处的宽度设置的比水管22的外径大，避免压装时水管22与容置槽211的槽壁在 弯折处发生过度挤压，使水管22的弯折处受到较大的外力发生破裂。具体实施时，为方便生产，水管22的外径一般都保持一致，因此，本实施例中选择将容置槽211的尺寸进行改进，使得过渡槽2112开口处的宽度大于相邻的分槽2111的内径，给此处的水管22留有足够的空隙，避免发生水管22的过度挤压。
进一步地，由于过渡槽2112与分槽2111的尺寸不一致，容置槽211的成型通常采用机械切割，因此在容置槽211的弯折处会形成锋利的台阶，压装水管22时极易造成局部应力集中，发生切割水管22并造成水管22泄漏的现象。因此，本实施例中，参考图9，在过渡槽2112的槽壁与相邻的分槽2111的槽壁之间设置倒角C，且倒角C的角度大于90度，以尽可能地避免产生锋利的过渡边缘。具体地，倒角C的角度可以为100度、125度或者160度。进一步地，过渡槽2112的槽壁与分槽2111的槽壁之间圆滑过渡，以进一步避免与水管22之间发生应力集中现象。
参考图5和图10，容置槽211的两自由端处均设置有安装座212，安装座212上设置有水管接头23，水管22的进水口和出水口均通过水管接头23与外界连通，实现冷却液的流通。具体地，水管接头23设于散热板21的第一侧；具体可选地，安装座212为凸设于散热板21的第一侧的凸起结构，水管接头23安装于凸起结构的自由端。可选地，水管接头23通过紧固件固定在安装座212上；本实施例中，紧固件为螺钉。进一步地，参考图10，安装座212上沿散热板21的厚度方向开设有第一通孔2121，水管22压入容置槽211的同时，水管22的自由端穿过第一通孔2121，并由第一通孔2121伸出，方便后续与水管接头23的装配；进一步地，第一通孔2121的孔径沿着远离散热板21的第二侧的方向逐渐减小。由于水管22采用金属等硬度较高的材料制造，对于本实施 例中这种需要弯折多次的异形管件来说，其进水口和出水口处的公差并不能达到很小，为避免过盈压装时，水管22在容置槽211的自由端发生卡死现象，导致装配失败或损坏压装设备，需要在压装时保证水管22的进水口和出水口定位的准确。将第一通孔2121设计为类似锥形的结构，使得水管22在容置槽211的自由端具有较大的活动空间，避免卡死，同时锥形结构还能对水管22在第一通孔2121内的穿设起到更好地导向作用，避免水管22发生位置偏移。进一步地，参考图8，容置槽211与第一通孔2121圆滑过渡，进一步保证水管22顺利进入安装座212内。
一种实施方式中，第一通孔2121可以是光滑的锥形结构，即其孔径沿着远离散热板21的第二侧的方向逐渐减小，直至在安装座212的自由端达到最小。在其他的实施例中，参考图10，第一通孔2121包括依次连接的第一分部和第二分部，其中，第一分部相对于第二分部更加靠近散热板21的第二侧，第一分部为圆滑的锥形结构；而第二分部为圆柱形结构，即第二分部的孔径保持一致，且等于或略大于水管22在此处的外径，这样设置能够先通过第一分部实现水管22的大致导向，再通过第二分部实现水管22尽可能充分的限位，保证水管22与第一通孔2121轴线的尽可能地重合；当然具体实施时，为了方便第二分部成型过程中的拔模操作，第二分部应当具有一定的拔模锥度，但这个锥度往往较小，并不影响整个第二分部对水管22的充分限位。
仍然参考图10，进一步地，水管接头23开设有第二通孔231，第二通孔231与第一通孔2121同轴设置且相互连通，以方便冷却液由水管接头23流入水管22内或由水管22流出至水管接头23。第二通孔231的孔径略大于水管22的外径，能保证水管22能顺利套入水管接头23内即可。进一步地，第二通孔 231在第一通孔2121与第二通孔231连接处的孔径要更加大于水管22的外径，即第二通孔231与第一通孔2121连接的一端的孔壁上设置有导向斜面，目的是在后续装配水管接头23时，水管22能够通过导向斜面与水管接头23快速装配，顺利插入水管接头23，而不会在交界处发生卡顿。
具体地，参考图7和图10，水管22的进水口和出水口处的外圆周面上均设置有至少两个凸台221，相邻的两个凸台221沿着水管22的轴线方向间隔设置，以形成密封槽222，密封槽222内设置密封件24，密封件24被限位于两个凸台221之间不能随意移动，保证了密封件24位置的稳定性；密封件24被挤压在水管22的外壁与水管接头23的内壁之间，用于密封水管22与水管接头23之间的环向间隙。具体实施时，也可以直接在水管22外壁上采用机械切割的方式来开设密封槽222。本实施例中，密封槽222采用滚槽工艺成型，即利用旋转的滚轮在水管22上滚压，滚出至少两个凸台221，两个凸台221之间自然形成了一个密封槽222，既简化了密封槽222的成型工艺，还能避免机械切割造成的应力集中。进一步地，如图10所示，在第二通孔231的孔壁上还设置限位台阶232，限位台阶232通过与水管22上的凸台221的抵接限制水管22伸入水管接头23的长度，即实现水管22与水管接头23的安装定位。
电机总成100包括电机，逆变器总成300还包括传感器总成30，传感器总成30包括磁环31和传感器组件32，磁环31连接于电机的转轴200上，传感器组件32与磁环31直接通过霍尔效应相互配合获得电信号，并将电信号传递至PCBA15的处理单元，以获得电机的转速等转动信息，形成闭环控制。为提高检测的精准性，对于传感器的放置位置精度、放置的稳定性都有较高要求，但现有的启动发电机中，传感器一般是单独放置在磁环31外，电机自带的散热风 扇500所形成的风，对传感器产生较大扰动，降低了传感器检测的精准性。本实施例中，参考图11-14，磁环31具有同轴心间隔设置的外环体311和内环体312，外环体311和内环体312之间的形成有向上开口的容置空间；内环体312与电机的转轴200同轴连接；传感器组件32包括连接支架321和设于连接支架321下方的传感器本体322，连接支架321连接于散热板21上，传感器本体322悬置于容置空间内。通过在磁环31的外环体311与内环体312之间形成有一容置空间，使传感器本体322能够悬置于该容置空间内，即可实现对磁环31磁场感应，进而完成电机转动信息的检测，磁环31的外环体311还会阻挡电机总成100的散热风扇500运行所产生的风，避免对传感器造成干扰，起到对传感器充分保护的作用，提高了传感器检测的精准性。
进一步地，参考图14，磁环31为圆环结构，则其所形成的容置空间为圆环形；传感器总成30的传感器本体322的数量设置多个，多个传感器本体322位于以磁环31的轴心为圆心的同一虚拟圆上，以与圆环结构的磁环31相适配，便于实现精准检测。多个传感器本体322包括霍尔传感器和温度传感器，其中主要是霍尔传感器来完成电机转动信息的检测，温度传感器根据需要选择性安装；温度传感器具有温度检测功能，使得电机在过热时系统可以及时做出反应。
具体地，参考图12、14和15，传感器总成30还包括传感器支架323和保护罩324，其中，传感器支架323连接于连接支架321上，传感器本体322安装于传感器支架323上，保护罩324则设于连接支架321下方，并罩设于传感器支架323外围，保护罩324内灌封有灌封胶325。由于传感器本体322是敏感器件，因此需要采用保护罩324罩设于传感器支架323外围，并在内部灌封灌封胶325，将传感器本体322包裹和保护起来，以隔绝外界的振动或者污染 物等。可选地，参考图16，在连接支架321上设置有灌封孔3211，灌封孔3211连通保护罩324，胶体可以通过灌封孔3211进入保护罩324内。在保护罩324内灌胶时，可能会发生困气现象，存留在胶体的气泡会在高温下膨胀，挤压整个胶体或者传感器本体322，造成破坏，因此在连接支架321上还设置有与保护罩324连通的排气孔3212，以辅助实现排气，避免困气现象的发生。本实施例中，多个传感器本体322是位于同一虚拟圆上的，因此保护罩324大致为弧形；进一步地，连接支架321上连接保护罩324的部分也大致为弧形；可选地，排气孔3212设置有两个，且分别位于灌封孔3211沿连接支架321周向的两侧。
参考图14和图15，在连接支架321上设置有金属排线3213，金属排线3213的两端均由连接支架321引出，其一端与PCBA壳体10中的PCBA15连接，另一端与传感器本体322连接，进而实现电信号由传感器到PCBA15的传递。进一步可选地，传感器支架323插设于连接支架321上。具体实施时，在传感器支架323上设置插孔，金属排线3213与传感器本体322连接的一端能够插设于插孔中，进而实现传感器支架323与连接支架321的插接连接，然后将传感器支架323上的传感器本体322的引脚与金属排线3213焊接连接，以实现电信号传递。可选地，连接支架321包覆于金属排线3213外，起到对金属排线3213的机械保护和电性能的保护。对于某一电机来说，传感器本体322的设置位置及排列位置是特定的，因此对放置的精确性要求较高，但是在焊接传感器本体322与相应的金属排线3213焊接时很容易发生位置偏移，因此设置传感器支架323来安装传感器本体322能够有效地实现传感器本体322的固定，避免焊接过程中发生传感器本体322的偏移。可选地，传感器支架323上设置卡槽，传感器本体322卡设于卡槽内。
进一步地，继续参考图15，本实施例中，传感器支架323与连接支架321之间为分体式结构，且二者之间为可拆卸连接，即传感器支架323与连接支架321为相互独立的两个零件，这样设置是由于启动发电一体机采用的电机结构不同，传感器本体322的摆放位置不同，装配时只需选择相适配的传感器支架323就可以实现传感器本体322的快速且精准的定位，提高了整个传感器总成30的适用性。
参考图11和图12，启动发电一体机的散热风扇500设于磁环31下方，本实施例在磁环31的容置空间的上方设置了开口，以使传感器本体322由上至下置于该容置空间内，同时该容置空间的底部封闭，避免风由底部进入容置空间内，对放置其内的传感器本体322造成干扰。进一步地，在磁环31的外环体311的内表面设置有一层磁性材料，该磁性材料被磁化后形成有多个磁极，当磁环31跟随电机的转轴200转动时，霍尔传感器感应磁场变化，并形成电信号。具体实施时，电机结构不同，磁极的数量也可以适应性变化，相应的传感器本体322的摆放位置也不同。可选地，参考图12，磁环31的底面向上凹陷以形成有让位槽，散热风扇500部分容纳于让位槽内，且散热风扇500的叶片环绕于磁环31的外环体311外周，避免风流至容置空间内。
继续参考图11和图12，在电机总成100内还设置有轴承400，内环体312与电机的转轴200均连接于轴承400的内圈，以使电机能够同步带动磁环31转动。具体实施时，轴承400的外圈固定于电机总成100的壳体上。
参考图2，逆变器总成300还包括信号接插件40，用于连接PCBA15与整车控制器，以实现信号在PCBA15与整车控制器之间的传输；具体地，参考图3和图4，信号接插件40铆接于盖板11上方，以使盖板11对信号接插件40起到 支撑作用。传统的制造方式中，信号接插件40与盖板11做成一体式注塑成型，由于注塑件尺寸较大，而且信号接插件40中还有信号排线，注塑件的热冲击性能和抗机械冲击能力均差，极易开裂，因此将信号接插件40和盖板11设计成两个单独的零件，使得盖板11可以采用金属材质制成，既有利于提升自身防护性能，起到更好的保护作用，还能改善产品的EMC(即电磁兼容性)性能。具体实施时，参考图17和图18，信号接插件40上有若干热铆柱411，盖板11上设置相应数量的热铆孔111，安装时热铆柱411穿过热铆孔111后，在另一端通过热铆设备将热铆柱411熔化，然后冷却形成盖帽状卡扣，从而将信号接插件40固定在盖板11上。
进一步地，参考图18，在盖板11上设置有安装孔112，信号接插件40热铆于盖板11上后，其上的信号排线由安装孔112进入到保护腔室14内，进而得以与PCBA15连接；具体地，信号接插件40与PCBA15上的PCB接插件连接。进一步地，由于电信号的传递需要满足防尘防水要求，信号接插件40与PCBA15上的PCB接插件之间会通过密封胶形成一密封腔室17，避免外界杂质进入。但由于产品在车辆中的使用环境存在高低温变化的特点，为了防止温度变化引起密封腔室17内部气压变化，进而带来密封胶胀裂等失效风险，需要设计透气孔43连通外界与密封腔室17，来平衡腔室内的气压；透气孔43上设置有透气膜44，以允许气体通过，但可以阻止水、油污、灰尘等杂质进入。由于电信号的传递需要满足防尘防水要求，产品制造完成后均需要进行防尘防水测试，现有的透气孔为直线型设计，直接由信号接插件40的顶部露出，进而在进行IPX9K的防尘防水测试时，高压水枪直接喷到透气膜44上会导致其损坏，进而使得产品的防尘防水功能失效，水进入腔室内导致内部短路或串联，进而引发产品报 废。现有技术中通常需要额外配置护罩或保护盖的方式实现保护，但这无疑增加了成本。
本实施例中，参考图19-22，信号接插件40包括接插件本体41，接插件本体41连接于盖板11上；热铆柱411便设于接插件本体41上。信号接插件40还包括：第一挡墙42，集成于接插件本体41的顶部；透气孔43，连通密封腔室17与外界，保证了气体通过透气孔43进行流通，密封腔室17内的气压得以保持稳定；透气孔43包括第一开口431、第二开口432和设于第一开口431与第二开口432之间的流通通道；第一开口431设于第一挡墙42的周向侧壁上，第二开口432设于接插件本体41上；透气膜44，透气膜44位于透气孔43的气体流通路径上，可以允许气体流通，防止水和灰尘进入密封腔室17，保证防尘防水测试的顺利进行。
在进行IPX9K的防尘防水测试时，高压水枪朝向接插件本体41顶部喷射，本实施例通过在接插件本体41的顶部集成一第一挡墙42，进而在进行防尘防水测试、高压水枪朝向接插件本体41喷射时，高压水先直接冲击第一挡墙42，而不会直接喷到透气孔43处，第一挡墙42的阻挡能够有效降低水流流速和水压，水再通过开设于第一挡墙42周向侧壁的第一开口431进入透气孔43，进而不会直接冲击到透气孔43上的透气膜44，以顺利完成相关的防尘防水检测，有效避免了产品失效。
可选地，第一挡墙42为圆柱形结构，第一开口431设于第一挡墙42的外圆周面上，以方便成型。在一些其他的实施例中，第一挡墙42可以为圆台结构。可选地，上述第一挡墙42为塑性挡墙，即第一挡墙42采用塑性材料制成，如此有助于第一挡墙42与接插件本体41采用注塑工艺进行一体成型。
进一步地，在一种实施方式中，透气膜44设于透气孔43的第二开口432处，即设于透气孔43与密封腔室17的连接处；当然，在一些其他的实施方式中，透气膜44还可以设于透气孔43的第一开口431与第二开口432之间；总之，透气膜44设置的离第一开口431越远，所承受的水压越小，越不容易被破坏，越能保证防尘防水测试的顺利进行。可选地，透气膜44设于第二开口432处的流通通道的内壁上；或者可选地，参考图21，接插件本体41在第二开口432的底部设置有一容纳槽，透气膜44安装于容纳槽内，即将透气膜44设于透气孔43的外侧，同样是在气体流通路径上，保证防尘防水的同时，容纳槽还方便了透气膜44的安装。
本实施例中，参考图21，当透气膜44设于第二开口432处或其附近时，透气孔43可为L型结构，L型结构使得水的流通路径变长，有更加助于减缓水速和降低水压，因此就算有少部分高压水会经过反射直接进入透气孔43，也不会对透气膜44造成过大冲击。具体地，L型的透气孔43包括相互垂直连通的第三分部和第四分部，第三分部在第一挡墙42上形成有第一开口431，第四分部在接插件本体41上形成有第二开口432；进一步地，第三分部可以在与第四分部的连接处进行适当的延长，方便水流在此处形成涡流，仍是起到减缓水速的作用。进一步可选地，参考图22，透气孔43还可以为T型结构，T型的透气孔43同样包括相互垂直连通的第三分部和第四分部，且第三分部在第一挡墙42上形成了两个第一开口431，第四分部在接插件本体41上形成第二开口432，水流从两个第一开口431进入，并能够相互撞击形成涡流，同样能够起到减缓水速的目的。进一步可选地，无论是L型结构，还是T型结构，上述第三分部的截面为矩形、圆形或其它形状；第四分部的截面也为矩形、圆形或其他形状。 当然，具体实施时，对于透气孔43的形状结构及截面形状不做具体限定，只要透气孔43的第一开口431和第二开口432能够分别连通外界和密封腔室17即可，在气体的流通路径上透气孔43弯折角度和次数不做具体限制。
更进一步地，透气孔43的数量设置有多个，以提高透气效率。具体地，一种实施方式中，每个透气孔43均对应设置一个第一开口431和一个第二开口432。又或者，可以将多个透气孔43的第二开口432设置在同一位置，即多个透气孔43的第一开口431分别设置，但是最终都由同一第二开口432出气，如此，在第二开口432处设置一个透气膜44即可，以节省成本。可选地，当采用多个透气孔43时，多个透气孔43沿着第一挡墙42的外周均匀分布。
参考图1和图2，逆变器总成300还包括电源端子50，用于为逆变器总成300供电；可选地，电源端子50安装于散热板21上。参考图23，电源端子50包括绝缘基体51和嵌设于绝缘基体51上的第一端子52和第二端子53，绝缘基体51在第一端子52处和第二端子53外围均形成有第二挡墙511，第二挡墙511上设置有排水槽512。现有的电源端子50没有排水设计，容易在端子处的第二挡墙511中产生积水，腐蚀铜排排线和螺柱，具有短路或断路失效风险。图23示出了电源端子50在启动发电一体机安装至车辆上后的摆放位置，其中，排水槽512设置于相应端子的下方，进而进入电源端子50处的水可以直接由排水槽512流出，避免产生积水腐蚀排线。
注意，上述仅为本发明的较佳实施例及所运用技术原理。本领域技术人员会理解，本发明不限于这里所述的特定实施例，对本领域技术人员来说能够进行各种明显的变化、重新调整和替代而不会脱离本发明的保护范围。因此，虽然通过以上实施例对本发明进行了较为详细的说明，但是本发明不仅仅限于以 上实施例，在不脱离本发明构思的情况下，还可以包括更多其他等效实施例，而本发明的范围由所附的权利要求范围决定。

Claims (10)

  1. 一种启动发电一体机，其特征在于，包括电机总成(100)和逆变器总成(300)，所述逆变器总成(300)包括：
    PCBA壳体(10)，包括壳体本体(12)和盖设于所述壳体本体(12)上方的盖板(11)；所述壳体本体(12)内设置有PCBA(15)；
    散热结构(20)，包括散热板(21)和水管(22)，所述散热板(21)具有沿上下方向设置的第一侧和第二侧，所述散热板(21)的所述第一侧用于与所述壳体本体(12)和功率模块(16)相贴合，所述散热板(21)的所述第二侧设置有容置槽(211)；所述水管(22)过盈配合于所述容置槽(211)内，所述水管(22)的至少部分外壁与所述容置槽(211)的槽壁相贴合。
  2. 根据权利要求1所述的启动发电一体机，其特征在于，所述容置槽(211)为条形结构，且包括沿延伸方向依次设置的多个分槽(2111)，相邻的两个所述分槽(2111)呈夹角设置；
    相邻的两个所述分槽(2111)之间设置过渡槽(2112)，所述过渡槽(2112)开口处的宽度大于置于此处的所述水管(22)的外径。
  3. 根据权利要求2所述的启动发电一体机，其特征在于，所述过渡槽(2112)的槽壁与相邻的所述分槽(2111)的槽壁之间设置倒角，所述倒角的角度大于90度。
  4. 根据权利要求1-3任一项所述的启动发电一体机，其特征在于，所述电机总成(100)包括电机，所述逆变器总成(300)还包括传感器总成(30)，所述传感器总成(30)包括：
    磁环(31)，所述磁环(31)具有同轴心间隔设置的外环体(311)和内环体(312)，所述外环体(311)和所述内环体(312)之间的形成有向上开口的 容置空间；所述内环体(312)与所述电机的转轴(200)同轴连接；
    传感器组件(32)，所述传感器组件(32)包括连接支架(321)和设于所述连接支架(321)下方的传感器本体(322)，所述连接支架(321)连接于所述散热板(21)上，所述传感器本体(322)悬置于所述容置空间内。
  5. 根据权利要求4所述的启动发电一体机，其特征在于，所述传感器总成(30)还包括：
    传感器支架(323)，可拆卸地连接于所述连接支架(321)上，所述传感器本体(322)安装于所述传感器支架(323)上；
    保护罩(324)，设于所述连接支架(321)下方，所述保护罩(324)罩设于所述传感器支架(323)外围，且所述保护罩(324)内灌封有灌封胶(325)。
  6. 根据权利要求1-3任一项所述的启动发电一体机，其特征在于，所述逆变器总成(300)还包括信号接插件(40)，所述信号接插件(40)铆接于所述盖板(11)上方。
  7. 根据权利要求6所述的启动发电一体机，其特征在于，所述信号接插件(40)包括：
    接插件本体(41)，所述接插件本体(41)连接于所述盖板(11)上；所述接插件本体(41)与所述PCBA(15)上的PCB接插件之间形成有一密封腔室(17)；
    第一挡墙(42)，集成于所述接插件本体(41)的顶部；
    透气孔(43)，连通所述密封腔室(17)与外界；所述透气孔(43)包括第一开口(431)、第二开口(432)和设于所述第一开口(431)与所述第二开口(432)之间的流通通道；所述第一开口(431)设于所述第一挡墙(42)的周向侧壁上，所述第二开口(432)设于所述接插件本体(41)上；
    透气膜(44)，位于所述透气孔(43)的气体流通路径上。
  8. 根据权利要求7所述的启动发电一体机，其特征在于，所述第一挡墙(42)与所述接插件本体(41)一体成型；所述透气孔(43)为L型结构或T型结构。
  9. 根据权利要求1-3任一项所述的启动发电一体机，其特征在于，所述盖板(11)的底面的部分区域向上凹陷，以与所述壳体本体(12)的上端面之间形成排水孔(13)；所述排水孔(13)设于所述PCBA壳体(10)的外周，并与所述壳体本体(12)内部相连通。
  10. 根据权利要求1-3任一项所述的启动发电一体机，其特征在于，所述逆变器总成(300)还包括电源端子(50)，所述电源端子(50)包括绝缘基体(51)和嵌设于所述绝缘基体(51)上的第一端子(52)和第二端子(53)，所述绝缘基体(51)在所述第一端子(52)处和所述第二端子(53)外围均形成有第二挡墙(511)，所述第二挡墙(511)上设置有排水槽(512)。
PCT/CN2022/080449 2021-03-12 2022-03-11 一种启动发电一体机 WO2022188880A1 (zh)

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CN113015418A (zh) * 2021-03-12 2021-06-22 上海法雷奥汽车电器系统有限公司 一种散热结构

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