Lower rotor assemblies for torque sensors

Patent metadata

Field	Value
Publication number	US-2023278621-A1
Application number	US-202217720839-A
Country	US
Kind code	A1
Filing date	Apr 14, 2022
Priority date	Mar 1, 2022
Publication date	Sep 7, 2023
Grant date	—

Abstract

A lower rotor assembly for a torque sensor includes a lower rotor over-mold including at least one heat staking structure extending from an upper surface thereof. The lower rotor assembly further includes a lower stator integrally formed with the lower rotor over-mold as a single, unitary component. The lower rotor assembly also includes an upper stator including at least one receiving structure, where each receiving structure receives a respective heat staking structure of the lower rotor over-mold when the upper stator is coupled to the lower stator.

First claim

What is claimed is:

1 . A lower rotor assembly for a torque sensor, the lower rotor assembly comprising:
a lower rotor over-mold including at least one heat staking structure extending from an upper surface thereof; a lower stator integrally formed with the lower rotor over-mold as a single, unitary component; and an upper stator including at least one receiving structure, wherein each receiving structure receives a respective heat staking structure of the lower rotor over-mold when the upper stator is coupled to the lower stator.

2 . The lower rotor assembly of claim 1 , wherein the at least one heat staking structure is formed of plastic.

3 . A lower rotor assembly for a torque sensor, the lower rotor assembly comprising:
a lower rotor over-mold including at least one first heat staking structure extending from an upper surface thereof and at least one second heat staking structure extending from the upper surface thereof; a lower stator integrally formed with the lower rotor over-mold as a single, unitary component; and an upper stator including:
at least one first receiving structure, wherein each first receiving structure receives a respective first heat staking structure of the lower rotor over-mold when the upper stator is coupled to the lower stator; and
at least one second receiving structure, wherein each second receiving structure receives a respective second heat staking structure of the lower rotor over-mold when the upper stator is coupled to the lower stator.

4 . The lower rotor assembly of claim 3 , wherein the at least one first heat staking structure is formed of plastic.

5 . The lower rotor assembly of claim 3 , wherein the at least one first heat staking structure is a heat staking rib.

6 . The lower rotor assembly of claim 3 , wherein the at least one second heat staking structure is formed of plastic.

7 . The lower rotor assembly of claim 3 , wherein the at least one second heat staking structure is a heat staking post.

8 . The lower rotor assembly of claim 3 , wherein the at least one first and second heat staking structures are positioned on the upper surface of the lower rotor over-mold in an alternating manner.

9 . A method of assembling a lower rotor assembly for a torque sensor of an electric power steering (EPS) system, the method comprising:
pressing a lower rotor over-mold and a lower stator integrally formed therewith together to a shoulder of a lower assist shaft of the EPS system, the lower rotor over-mold including at least one first heat staking structure extending from an upper surface thereof; placing a probe housing assembly (PHA) onto a surface of the lower stator when the lower stator and the lower rotor over-mold are positioned at the shoulder of the lower assist shaft of the EPS system; mounting the PHA onto an assist housing of the EPS system; coupling an upper stator onto the lower stator, the upper stator including at least one first receiving structure, wherein each first receiving structure receives a respective first heat staking structure of the lower rotor over-mold when the upper stator is coupled to the lower stator; heating the at least one first heat staking structure of the lower rotor over-mold to join the upper stator with the lower rotor over-mold; and cooling the lower rotor over-mold, the lower stator, and the upper stator, resulting in the assembling of the lower rotor assembly.

10 . The method of claim 9 , wherein the lower stator is integrally formed with the lower rotor over-mold as a single, unitary component.

11 . The method of claim 9 , wherein the at least one first heat staking structure is formed of plastic.

12 . The method of claim 9 , wherein the at least one first heat staking structure is a heat staking rib.

13 . The method of claim 9 , wherein the lower rotor over-mold further includes at least one second heat staking structure extending from the upper surface thereof.

14 . The method of claim 13 , wherein the at least one second heat staking structure is formed of plastic.

15 . The method of claim 13 , wherein the at least one second heat staking structure is a heat staking post.

16 . The method of claim 13 , wherein the at least one first and second heat staking structures are positioned on the upper surface of the lower rotor over-mold in an alternating manner.

17 . The method of claim 13 , wherein the upper stator further includes at least one second receiving structure, wherein each second receiving structure receives a respective second heat staking structure of the lower rotor over-mold when the upper stator is coupled to the lower stator.

18 . The method of claim 17 , wherein the at least one second receiving structure is a through hole defined by the upper stator.

19 . The method of claim 9 , wherein the PHA includes a plastic member mountable to the assist housing of the EPS system.

20 . The method of claim 19 , wherein the PHA further includes a printed circuit board (PCB) coupled to the plastic member.

Assignees

• Steering Solutions Ip Holding

Inventors

• Zhang Rong (Jason)
• He Keyi (Michael)
• Zhao Fusong (Stuart)

Classifications

• B62D6/10 Primary

  characterised by means for sensing {or determining} torque · CPC title

• G01L5/221 Primary

  to steering wheels, e.g. for power assisted steering · CPC title

• G01L3/104

  involving permanent magnets · CPC title

• G01L3/02

  Rotary-transmission dynamometers · CPC title

• B62D15/02

  Steering position indicators {; Steering position determination; Steering aids} · CPC title