Description:Technical field of the invention
[0002] The present invention relates to a moulded holder for hall sensor and Printed Circuit Board (PCB) assembly. The invention particularly relates to the moulded holder for accommodating the hall sensor and PCB assembly on the stator core of the motor.
Background of the invention
[0003] In hub motors, the PCB (Printed Circuit Board) assembly serves as an integrated controller for the motor. The PCB assembly contains various electronic components and circuitry that are designed to control and monitor the hub motor. It may include components such as microcontrollers, motor drivers, sensors, and other support circuitry. The hub motors often incorporate hall sensors for determining the position of the rotor within the motor. However, by detecting the magnetic field changes produced by the rotor's permanent magnets, the hall sensors can provide feedback on the rotor's position relative to the stator. The hall sensor is usually positioned in close proximity to the stator core, facing the rotor magnets, thereby allowing it to detect the magnetic field changes as the magnets pass by. Further, the hall sensor provides feedback to the motor controller, enabling precise control of the motor's operation.
[0004] In hub motors, there are several conventional methods for holding the PCB assembly and hall sensor in place such as bracket mounting, double-sided tape or adhesive pads to attach the PCB assembly to the inner surface of the motor housing, While conventional methods of holding the PCB assembly and hall sensor to the stator core of a hub motor have their advantages, there are also some potential disadvantages because the hub motors are subjected to various levels of vibration and shocks during operation, especially in applications like electric bikes or vehicles.
[0005] In conventional methods, accessing and removing the PCB assembly or hall sensor for maintenance or repairs is quite challenging. Further, some conventional mounting methods require additional steps and components during assembly, such as brackets, screws, or adhesives. This can increase the complexity of manufacturing and assembly processes, potentially adding to the production costs. Similarly, maintenance or replacement of the PCB assembly or hall sensor may require specialized tools or skills, leading to increased maintenance complexity. Further, conventional mounting methods may not provide sufficient shock and vibration resistance, leading to potential loosening or damage to the PCB assembly or hall sensor over time. This can affect the reliability and accuracy of the motor system.
[0006] The Patent number CN102341677A titled “Position Sensor Holder” relates to a holder for a position sensor of a motor, said holder comprising a pocket for holding said position sensor, an abutment, and a fixing mountable to the motor Biasing means on the device for biasing the abutment relative to the fixing means. Furthermore, the motor includes a stator, a position sensor, and a sensor holder. The sensor holder comprises a pocket portion in which a position sensor is retained, an abutment portion, and a biasing portion biasing the abutment portion towards the stator.
[0007] . The Patent number CN218388156U titled “PCB board holder suitable for SMT printed circuit board paster built-in” relates to a PCB (Printed Circuit Board) clamp holder suitable for an SMT (Surface Mount Technology) printed circuit board chip mounter, which comprises a motor, the motor drives a fan-shaped fluted disc I to rotate, the fan-shaped fluted disc I is meshed with a fan-shaped fluted disc II to drive an oscillating rod to rotate, the oscillating rod drives a V-shaped clamping plate to move, and a limiting rod limits the rotation of the V-shaped clamping plate. According to the structure, the width between the V-shaped clamping plates can be adjusted according to the specification of the PCB or the required mounting width, so that the holder is prevented from being replaced again, the working efficiency is improved, and the utilization area of the PCB is increased.
[0008] The Patent number DE102020208113A1 titled “Circuit board holder with cooling element and system comprising a circuit board holder and a circuit board” relates to printed circuit board holder for holding a printed circuit board and for fixing the printed circuit board to a base printed circuit board in a vehicle, comprising an elongated holding body, the elongated holding body having a holding fixture for arranging a contact section of the printed circuit board therein, and at least one cooling element which is arranged on the elongated holding body.
[0009] The patent number CN206674330 titled “PCB plate holder piece” relates to a PCB plate holder piece. The clamping piece includes bottom plate that the PCB board placed and the clamping piece that uses with the bottom plate cooperation, the clamping piece includes the base, be provided with an elongated slot on the base, be provided with a mounting in the elongated slot, mounting and bottom plate fixed connection, still be provided with the through -hole on the base, be provided with the moving member that can move on the bottom plate on the bottom plate, the moving member passes the through -hole, the base still is connected with a clamp plate. The utility model discloses a PCB plate holder piece, simple structure carries out the center gripping to the PCB board through clamp plate and bottom plate, and the clamp plate can prevent that the PCB board from jumping out of from the bottom plate, drive the clamping piece through the moving member and remove, can carry out the center gripping and loosen the PCB board, easy operation, the center gripping is effectual.
[0010] Hence, there exists a need for an appropriate product that can securely hold the PCB assembly and hall sensor, offering additional support, damping capabilities, easy maintenance, and minimizing the adverse impact of vibrations on their performance.

Summary of the invention
[0011] The present invention overcomes the drawbacks of the prior art by disclosing a moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, wherein the holder comprises an upper surface for accommodating a hall sensor and a Printed Circuit Board (PCB) assembly and a lower surface fitted on a stator core of a hub motor using a plurality of snap locks , wherein the snap locks provided on the holder are fastened onto the stator core using screws for securing the hall sensor and the Printed Circuit Board (PCB) assembly .
[0012] The present invention aims to address the demand for providing additional support and damping, reducing the impact of the shocks and vibrations on the PCB assembly and hall sensor, thereby maintaining the reliability and accuracy over time. Additionally, the holder aids in the calibration process, ensuring the hall sensor is correctly set up and providing consistent and reliable feedback to the motor controller. Further, the holder simplifies the process of the PCB assembly and hall sensor into the hub motor, thereby providing a dedicated space or mounting points, making it easier to position and secure the components. Moreover, during maintenance or replacement, the holder facilitates quick and straightforward removal and reinstallation of the PCB assembly and Hall sensor, minimizing downtime.
Brief description of the drawings
[0013] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.
[0014] FIG 1 illustrates a perspective view of a moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, in accordance with an embodiment of the present invention.
[0015] FIG 2 illustrates an exploded view of the moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, in accordance with an embodiment of the present invention.
[0016] FIG 3 illustrates a schematic view of the moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, in accordance with an embodiment of the present invention.
Detailed description of the invention
[0017] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in the figures. Each example is provided to explain the subject matter and not a limitation. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope, and contemplation of the invention.
[0018] FIG. 1, illustrates a perspective view of a moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, in accordance with an embodiment of the present invention. The holder (100) comprises an upper surface for accommodating a hall sensor (101) and a Printed Circuit Board (PCB) assembly (102) and a lower surface fitted on a stator core (103) of a hub motor using a plurality of snap locks (104), wherein the snap locks (104) provided on the holder (100) are fastened onto the stator core (103) using screws (105) for securing the hall sensor (101) and the Printed Circuit Board (PCB) assembly (102).
[0019] In an embodiment of the present invention, the snap locks (104) securely engage with corresponding threaded slots on the stator core (103) of the hub motor. Further, the screws (105) are inserted through specific holes in the holder (100), securing the hall sensor (101) and PCB assembly (102) in place by fastening them into the corresponding threaded slots on the stator core (103) of the hub motor.
[0020] In an embodiment of the present invention, the holder (100) is equipped with a cavity to achieve weight reduction while maintaining structural integrity and ensuring the secure attachment and protection of the PCB assembly (102) and the hall sensor (101).
[0021] In an embodiment of the present invention, the stator core (103) of the hub motor houses the stator windings responsible for generating the electromagnetic fields necessary for motor operation.
[0022] In an embodiment of the present invention, the hall sensor (101) is a critical component within hub motors, serving vital functions related to position sensing and motor control. Its primary role is to detect the position of the rotor magnets as they rotate within the motor. By sensing changes in the magnetic field, the hall sensor (101) provides feedback to the motor controller, enabling precise control over the motor's operation. Typically, the hall sensor (101) is positioned in close proximity to the stator core (103) of the hub motor, facing the rotor magnets. This strategic placement allows it to accurately detect and monitor variations in the magnetic field as the rotor rotates. The hall sensor (101) operates based on the Hall effect, which involves the generation of a voltage difference across a conductor when it is subjected to a perpendicular magnetic field and current flow. In the context of a hub motor, the hall sensor (101) detects changes in the magnetic field caused by the rotating magnets, generating electrical signals that correspond to the position of the rotor.

[0023] Typically, the hall sensor (101) provides digital output signals, often in the form of three separate channels or signals known as Hall A, Hall B, and Hall C. These signals convey information about the position and direction of the rotor magnets relative to the stator windings. The signals from the hall sensor (101) are then fed into the motor controller, which utilizes this information to synchronize the current flow in the stator windings. This synchronization ensures efficient operation and precise control over the hub motor's speed, torque, and direction. To ensure reliable and accurate performance, it is crucial to properly calibrate and securely mount the hall sensor (101) within the hub motor. Any malfunction or misalignment of the hall sensor (101) can lead to motor instability, reduced efficiency, or even motor failure. Therefore, attention to detail in its calibration and secure installation is of utmost importance.

[0024] In an embodiment of the present invention, the PCB (Printed Circuit Board) assembly (102) contains various electronic components and circuitry that are designed to control and monitor the hub motor. It may include components such as microcontrollers, motor drivers, sensors, and other support circuitry. Further, the PCB have designated connectors or soldering points for the hall sensor (101) wires.

[0025] The holder (100) ensures that the hall sensor (101) and PCB assembly (102) are securely positioned within the hub motor. This helps prevent any movement or shifting during operation, minimizing the risk of damage to the components. Further, the holder (100) optimizes the use of space within the hub motor. It can accommodate the specific dimensions and layout of the hall sensor (101) and PCB assembly (102), ensuring efficient utilization of the available area without obstructing other motor components.

[0026] FIG 2 illustrates an exploded view of the moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, in accordance with an embodiment of the present invention. In an embodiment of the present invention, the molded PCB holder (100) is a component used to securely hold the hall sensor (101) and Printed Circuit Board (PCB) assembly (102) in place. It is made of plastic but not limited to it and is designed to provide mechanical support and stability to the hall sensor (101) and PCB assembly (102). The holder (100) is specifically shaped and manufactured to accommodate the dimensions and form factor of the PCB assembly (102). It features slots, cutouts, or clips that align with the PCB's mounting holes or edges, allowing the PCB assembly (102) to be securely inserted and held in place. Additionally, the holder (100) also includes features for cable management, such as channels or clips to route and secure wires or cables connected to the PCB assembly (102) and hall sensor (101). This helps to organize the wiring and reduces the risk of interference or accidental disconnection.
[0027] Furthermore, the holder (100) simplifies the assembly process by providing a dedicated mounting solution for the hall sensor (101) and PCB assembly (102), eliminating the need for separate brackets or fasteners. The molded construction also provides durability and protection for the assembly, guarding it against mechanical stress or impact.
[0028] FIG 3 illustrates a schematic view of the moulded holder for hall sensor and Printed Circuit Board (PCB) assembly, in accordance with an embodiment of the present invention. In an embodiment of the present invention, the holder (100) incorporates a plurality of snap locks (104), which are fastening mechanisms used to secure the hall sensor (101) and PCB assembly (102) in place. The snap locks (104) engage with corresponding features on the components, ensuring a tight and secure fit. In addition to the snap locks (104), the holder (100) also utilizes screws (105) for added stability and security. The snap locks (104) provided on the holder (100) are fastened onto the stator core (103) using screws (105), providing an extra layer of reinforcement to keep the hall sensor (101) and PCB assembly (102) firmly in position.
[0029] The molded holder (100) provides a reliable and efficient solution for securing and protecting the hall sensor (101) and PCB assembly (102) within the stator core (103) pack of a Hub motor, ensuring proper alignment, stability, and durability, thereby preventing any unintended loosening or detachment of the hall sensor (101) and PCB assembly (102) and contributing to the overall performance and longevity of the motor system.

Reference numbers:
Components Reference Numbers
Holder 100
Hall sensor 101
PCB assembly 102
Stator core 103
Snap locks 104
Screws 105
, Claims:We claim:
1. A moulded holder for a hall sensor and a Printed Circuit Board (PCB) assembly, the holder (100) comprising:

a. an upper surface for accommodating the hall sensor (101) and the Printed Circuit Board (PCB) assembly (102) and a lower surface fitted on a stator core (103) of a hub motor using a plurality of snap locks (104), wherein the snap locks (104) provided on the holder (100) are fastened onto the stator core (103) using one or more screws (105) for securing the hall sensor (101) and the Printed Circuit Board (PCB) assembly (102).

2. The holder (100) as claimed in claim 1, wherein the hall sensor (101) detects change in magnetic field and converts the magnetic field into the electrical signals.

3. The holder (100) as claimed in claim 1, wherein the stator core (103) of the hub motor houses the stator windings responsible for generating the electromagnetic fields necessary for motor operation.

4. The holder (100) as claimed in claim 1, wherein the snap locks (104) securely engage with corresponding threaded slots on the stator core (103) of the hub motor.

5. The holder (100) as claimed in claim 1, wherein the screws (105) are inserted through specific holes in the holder (100), securing the hall Sensor (101) and PCB assembly (102) in place by fastening into the corresponding threaded slots on the stator core (103) of the hub motor.

6. The holder (100) as claimed in claim 1, the holder (100) is equipped with a cavity to achieve weight reduction while maintaining structural integrity and ensuring the secure attachment and protection of the PCB assembly (102) and the hall sensor (101).