Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of electric vehicles. More particularly, the present disclosure relates to a sensor positioning element within an electric vehicle hub motor. The present disclosure relates to a bobbin integrated into the stator of the hub motor of an electric vehicle that is utilized for positioning and securing the rotor positioning sensor, specifically, the hall sensor.

BACKGROUND OF THE INVENTION
[0002] In an electric vehicle, the electric motor is a crucial component responsible for converting electrical energy stored in the vehicle's battery into mechanical energy to drive the wheels. A rotor positioning sensor in an electric vehicle is a device used to determine the precise position of the rotor within the electric motor. Knowing the rotor position is essential for controlling the motor's operation, especially in terms of commutation. Commutation refers to the process of switching the current in the motor windings to generate a rotating magnetic field that interacts with the rotor's magnetic field, causing the rotor to turn.
[0003] There are various types of rotor positioning sensors, and one common category includes the use of Hall effect sensors. Hall sensors are frequently employed in the motor control system to determine the rotor position within the motor. A Hall sensor, often referred to as a Hall effect sensor, is a type of transducer that measures magnetic fields. In the context of electric vehicles (EVs), Hall sensors are commonly used to provide feedback on the position of various components, especially in the context of the electric motor.
[0004] In the electric vehicle, the application of Hall effect sensors extends beyond rotor position feedback. These sensors enable commutation control, ensuring the sequential activation of stator windings for effective torque production. Furthermore, Hall sensors contribute to regenerative braking optimization by accurately determining the rotor's position, allowing the control system to fine-tune regenerative braking force. This adjustment enhances energy capture during braking, enabling efficient conversion of kinetic energy into electrical energy for storage in the vehicle's battery. In essence, Hall effect sensors are integral components in the intricate control systems of electric vehicles, enabling precise motor control, efficient energy utilization, and optimal performance.
[0005] The automotive industry is currently undergoing a transformative shift towards electric vehicles (EV), necessitating the widespread adoption of EV motors. This shift has given rise to challenges that, in turn, stimulate innovation. One notable challenge involves the positioning of Hall sensors, which has become crucial due to their critical role in electric hub motor operation. The placement of these sensors must be accomplished with precision to avoid damaging their circuits or structures.
[0006] In some electric motor configurations, especially brushless DC (BLDC) or permanent magnet synchronous motors (PMSM), Hall sensors are embedded in the rotor. These sensors detect the position of the rotor magnets as they rotate. In certain motor designs, Hall sensors can also be placed in the stator core to detect the position of the rotor magnets. This allows for precise control of the electric current supplied to the stator windings, aiding in accurate commutation.
[0007] US20120235668A1 relates to an adjustable Hall effect sensor system having a sensor positioning component is described. In one embodiment, the Hall effect sensor system is an independently adjustable sensor system, having a plurality of Hall effect sensor, wherein one Hall effect sensor may be displaced and adjusted without effecting the location of another Hall effect sensor. A sensor positioning component comprising a paddle coupled to a main body portion by a narrow neck is described. A cam may be configured on a paddle and provide for fine tuning the position of a Hall effect sensor. In one embodiment the main body and extensions are comprised essentially of a circuit board.
[0008] US 20110168466 relates to a hub motor that includes a motor shaft, which is fixed and non-rotational and a rotating wheel hub. The hub includes a plurality of coil windings positioned around the motor shaft; a plurality of magnets positioned around the coil windings; one or more sensors in the wheel hub housing; and a cable to supply power and communicate control signals to a controller.
[0009] In the current state, Hall sensors are typically affixed to the stator core using adhesive, and the removal of this adhesive is often impractical, posing difficulties in terms of servicing. Moreover, the seating of Hall sensors varies, depending on the stator core's height and placement. This variability introduces the risk of wire damage, potentially leading to the failure of the EV hub motor, especially under vibrational conditions. Existing patents addressing Hall sensor seating and servicing are limited and complex, potentially resulting in high costs and posing challenges in terms of serviceability.
[0010] Hence, there is a necessity for a novel and improved system for the positioning of the Hall sensor for the efficient functioning of the electric vehicle.

OBJECTIVE OF THE INVENTION
[0011] An objective of the present disclosure is to provide a sensor positioning element, specifically an integrated stator bobbin, incorporated in a hub motor stator of an electric vehicle.
[0012] Another objective of the present disclosure is to facilitate the easy fixing/positioning and precise accommodation of a rotor positioning sensor, specifically a Hall sensor PCB (Printed Circuit Board) in the integrated stator bobbin.
[0013] Another objective of the present disclosure is the provision of a one-way flip mechanism in the integrated stator bobbin, to facilitate the holding/positioning of the winding coil in the intended slot of the stator, thereby avoiding the removal or coming out of coil windings from the stator core.
[0014] Yet another objective of the present disclosure is to ensure proper separation between the integrated stator and the hall sensor, to prevent a direct electric conduction between the stator coil and Hall sensor and to avoiding shortage of stator winding.
[0015] Even another objective of the present disclosure is to facilitate easier removal and servicing of the hall sensor PCB.

SUMMARY OF THE INVENTION
[0016] To achieve the aforementioned objectives, the present disclosure discloses an integrated stator bobbin with a unilateral flip mechanism for positioning the sensor in rotating machines.
[0017] An aspect of the present disclosure involves a preferred embodiment involving the utilization of a bobbin integrated within the stator of the hub motor. This bobbin is specially designed to accommodate the rotor positioning sensor, specifically the Hall sensor. This configuration not only enhances reliability by mitigating the risk of failure but also facilitates easier servicing of the sensor.
[0018] Another aspect of this invention is the incorporation of a flip mechanism on the top of the bobbin. This feature serves to prevent direct conduction between the stator coil and Hall sensor PCB, thereby contributing to the overall improvement in machine performance. The flip mechanism is unidirectional or unilateral, allowing for the winding of the coil while preventing unwinding from the core. This design innovation adds an extra layer of efficiency to the operation of the hub motor.
[0019] Yet another aspect of the present disclosure emphasizes on the establishment of proper separation between the stator and the sensing system, which includes the Hall sensor. This separation ensures optimal functionality and minimizes the potential for interference, contributing to the robust and reliable performance of the integrated hub motor of the electric vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS
[0020] It is to be noted that the appended drawings illustrate only a typical embodiment of this disclosure and are therefore not to be considered for limiting its scope, for the disclosure may admit to other equally effective embodiments.
[0021] Fig.1a and 1b provides an exploded view of the stator bobbin with unilateral flip mechanism, and hall sensor PCB integrated with a stator core and mounted on a shaft according to the present disclosure.
[0022] Fig.2 provides illustrates a schematic view of the integrated stator bobbin with unilateral flip mechanism according to the present disclosure.
[0023] Fig. 3 illustrate a schematic view of the assembled integrated stator bobbin with unilateral flip mechanism with the hall sensor PCB removably seated on the bobbin according to the present disclosure.
[0024] Fig. 4a and 4b illustrates the provision of the one-way flip atop the integrated stator bobbin according to the present disclosure.
[0025] Fig.5 illustrates the engagement of holes on the hall sensor PCB with the protrusions on the integrated stator bobbin according to the present disclosure.
[0026] It should further be noted that the figures are not drawn to scale. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure.

LIST OF REFERENCES
10 – stator core
20 – stator bobbin
30 – hall sensor PCB (Printed Circuit Board)
40 – one-way flip
50 – shaft
60 – protrusions
70 – holes on hall sensor PCB

DETAILED DESCRIPTION
[0027] The following is a description of the present disclosure depicted in the accompanying drawings. However, it may be understood by a person having ordinary skill in the art that the present subject matter may be practiced without these specific details. In other instances, well-known methods, procedures, and/or components regarding the said method have not been described in detail so as not to obscure the subject matter of the disclosure. The subject matter of the disclosure will be more clearly understood from the following description of the embodiments thereof, given by way of example only with reference to the accompanying drawings, which are not drawn to scale.
[0028] The term “Hall sensor” refers to a device that detects the presence of a magnetic field. Hall sensor PCB is a Printed Circuit Board that incorporates Hall sensors into its design. The terms “Hall sensor” or “Hall sensor PCB” are used interchangeably here for better understanding. Hall sensors PCBs are commonly used for sensing and control purposes in electric vehicles. Furthermore, the terms “integrated stator bobbin”, “integrated bobbin” and “bobbin” have been used interchangeably here. The terms “flip mechanism” and “flip” have been used interchangeably here. The terms “unilateral”, “unidirectional” and “one-way” has been used interchangeably here.
[0029] The present disclosure relates to the incorporation and integration of a hall sensor positioning within the stator core of a hub motor through the utilization an integrated stator bobbin with a unilateral flip mechanism in an electric vehicle (EV).
[0030] Previously, the hall sensor was affixed onto the stator core using adhesive, making it challenging to remove and posing difficulties from a serviceability perspective. Additionally, the placement of the hall sensor was subject to variations depending on the stator core height, which could potentially lead to wire cuts and the failure of the electric vehicle (EV) hub motor, especially under vibration conditions.
[0031] This present disclosure discloses an integrated bobbin for the stator, wherein the integrated bobbin is designed to securely accommodate the rotor positioning sensor, specifically a hall sensor PCB. Furthermore, the integrated stator bobbin comprises a unilateral flip mechanism provided at the top portion of the integrated stator bobbin. The flip mechanism is unidirectional, allowing for the winding of the coils on the stator while restricting any unwinding of the same from the core. The addition of the flip mechanism on the top of the integrated stator bobbin also serves to prevent direct conduction between the stator coil and Hall sensor PCB, thereby enhancing machine performance. Furthermore, the present disclosure ensures the appropriate separation between the stator and the sensing system, specifically the hall sensor.
[0032] Consequently, multiple attached figures illustrating a preferred embodiment are presented to reveal an integrated stator bobbin designed for sensor positioning, incorporating a unidirectional flip mechanism suitable for rotating machines. Furthermore, the present disclosure should be construed to extend to any alterations, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings.
[0033] In an electric vehicle (EV) hub motor, the stator and rotor are essential components of the electric hub motor. These components work together to convert electrical energy into mechanical motion. The rotor is the rotating part, typically surrounding the stator. The stator, on the other hand, is the stationary part located at the centre, often attached with the shaft, and stator consists of stator coils or windings connected to the power supply.
[0034] The stator core generally contains multiple coils, typically made of copper wire, arranged in a specific pattern. When an electric current flows through these coils, it creates a magnetic field. The rotor, often equipped with magnets, is subjected to the influence of this magnetic field, causing it to rotate. The rotor is attached to a rim of the wheel, and as it rotates, which, eventually driving the wheels. This rotation of the rotor generates mechanical energy that is used to drive the vehicle.
[0035] Referring to Figures 1a and 1b, the present disclosure provides an exploded view of the integrated stator bobbin (20) featuring a unilateral flip (40) mechanism integrated with the stator bobbin (20) of a hub motor, wherein the integrated stator bobbin (20) comprises a room for hall sensor PCB (30) that is seated on the protrusions (60) of the bobbin (20). In these figures, the stator assembly includes a stator core (10) mounted on a shaft (50), and a stator bobbin (20) designed to interlock with the stator core (10) where the stator bobbin (20) provides room for stator winding. Notably, there is a provision for a Hall sensor PCB (30) to be removably attached to the stator bobbin (20). The stator bobbin (20), serves as a platform where the hall sensor (30) can be removably affixed, as seen in Figs 1a and 1b. This integrated stator bobbin (20) configuration is instrumental in positioning and securing the rotor positioning sensor, specifically the hall sensor (30).
[0036] Fig. 2 depicts a schematic representation of the integrated stator bobbin (20), demonstrating the flip (40) mechanism on the top portion of the bobbin. The integrated stator bobbin (20) with the one-way flip (40) mechanism is seamlessly incorporated with the stator core (10). Additionally, the attachment of the hall sensor PCB (30) to the integrated stator bobbin (20) with the unilateral flip (40) is depicted in Fig.3.
[0037] Figs. 4a and Fig. 4b illustrates the provision of the unidirectional/unilateral/one-way flip (40) mechanism on the integrated stator bobbin (20) according to the present disclosure. Positioned atop the bobbin (20), the flip (40) mechanism prevents removal of stator windings/coils (not shown), thereby enhancing the motor performance. The one-way or unilateral nature of the flip (40) allows for efficient coil winding and restricts unwinding from the stator core (10). The unilateral flip (40) feature provided in the integrated stator bobbin (20) serves to secure the winding coils in their designated slots, thereby preventing the unintended removal or displacement of the coil windings from the stator core (10). This enhancement further contributes to the overall performance improvement of the motor (not shown).
[0038] Fig.5 depicts the provision of delegated and integrated hall sensor seatings on the integrated stator bobbin (20) for the placement of the hall sensor (30). According to fig.5, the stator bobbin (20) comprises protrusions (60) that engage with holes or perforations (70) present in the hall sensor PCB (30), also depicted in Fig.1b. An alternative embodiment (not shown) may consist of the hall sensor PCB comprising protrusions that engage with the holes or perforations present in the stator bobbin.
[0039] Referring back to Fig.5 and Fig.1b, the Hall sensor PCB (30) is designed with perforations or holes (70), facilitating the placement of the holes (70) present in the hall sensor PCB (30) onto the protrusions (60) on the bobbin (20) within the assigned seating provisions. These protrusions (60) are equipped with button-type fixtures or alternative mechanisms intended to effectively restrain the hall sensor PCB (30) from dislodging from the bobbin's hall sensor protrusions. Once the hall sensor PCB (30) is seated on these protrusions (60), the hall sensor PCB (30) becomes securely locked through the removable button-type engagement, mitigating the risk of inadvertent release due to vibrations of the motor. Importantly, this arrangement allows for easy removal of the hall sensor PCB (30) when servicing of the same is required. Notably, any type of locking features such as mating grooves, snap-fits, hooks, slots can be used in locking the hall sensor protrusions. Further, the hall sensor seating of the hall sensor protrusions (60) provides separation of the stator coil winding from the hall sensor PCB (30), thus preventing short circuits between them.
[0040] Coming back to Figures 1a and 1b, the integrated stator bobbin (20), hence, serves as a crucial support structure, featuring provisions for the placement of the hall sensor PCB (30). This component is indispensable for ensuring the stability and optimal functionality of the stator within the electric vehicle. Furthermore, the integrated stator bobbin (20) incorporates a unilateral flip (40) mechanism, as illustrated in Figures 4a and 4b, thus allowing for efficient coil winding and restricting unwinding from the stator core (10).
[0041] Moreover, the integrated stator bobbin (20) includes protrusions (60) that engage with corresponding holes (70) in the Hall sensor PCB (30), as depicted in Figs. 5 and 1b. This configuration facilitates a button-type engagement between the stator bobbin (20) and the hall sensor PCB (30), effectively preventing the inadvertent release of the sensor due to motor vibrations. This configuration ensures a secure and stable connection, contributing to the reliability and durability of the hub motor system.
[0042] The process of assembly of the integrated stator bobbin (20) with sensor positioning and unilateral flip (30) methodically executed to achieve an efficient configuration, is disclosed. It commences with the placement of the stator core (10), establishing the foundational structure of the motor assembly. Following this, the stator bobbin (20) is seamlessly integrated into the stator core (10), ensuring meticulous alignment and positioning. Subsequently, the winding process of the stator is undertaken, involving the wrapping of the winding coils around the stator core (10) while incorporating the stator bobbin (20) into the winding. The inclusion of the flip (40) mechanism atop the integrated stator bobbin (20) provides support to the winding coils to be held in their designated slots, thereby preventing their displacement from the stator core (10) due to vibration of the motor. Lastly, the rotor positioning sensor, specifically the Hall Sensor PCB (30), is installed into the designated positions provided on the stator bobbin (20). This careful and systematic arrangement underscores the pivotal role of the integrated stator bobbin (20), serving as a central component in accommodating both the stator winding and the rotor positioning sensor. The inclusion of the flip (40) mechanism further contributes to reinforcing the hub motor's reliability and overall performance.
[0043] The present disclosure has several advantages. The integrated stator bobbin (20) serves a dual purpose by securely holding the hall sensor PCB (30) and the incorporation of a one-way flip (40) mechanism, prevents the stator coils from protruding out of the assembly. The stator bobbin (20) is crucial in averting potential rubbing between the stator core (10) and the stator coil winding (not shown), ultimately enhancing motor performance. The one-way flip (40) additionally, provides essential support for the winding coils, ensuring the coils remains in the designated slots and preventing any unintended unwinding or removal from the stator core. Consequently, this comprehensive design significantly contributes to the overall efficiency of the motor.

[0044] Additionally, the rotor positioning sensor (Hall sensor) seated within the protrusions (60) plays a vital role in providing a definite position for the sensor (30). The hall sensor (30) is precisely positioned on the integrated bobbin stator's protrusions (60) through button-type or alternative fixtures. This button-type engagement arrests any movement of the hall sensor (30) from the protrusions on the stator bobbin (20), thereby ensuring the secure placement of the hall sensor PCB (30), preventing its release and displacement due to motor vibrations. Furthermore, the arrangement allows for easy removal of the hall sensor PCB (30) during servicing and maintenance, minimizing the risk of wire damage or failure in real-time working conditions. This meticulous arrangement enhances the reliability and durability of the motor system.

[0045] The described embodiment is susceptible to various modifications and alternative forms. Hence, it should be understood, however, that the embodiment is not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives.
, Claims:1. An assembly of an integrated stator bobbin in a hub motor of an electric vehicle, the assembly comprising
a stator core (10) forming the base structure, mounted on a shaft (50);
an integrated stator bobbin (20) incorporated in alignment within the stator core (10);
a stator coil of wire wound on slots of the stator core (10) aligned with the integrated stator bobbin (20);
wherein the integrated stator bobbin (20) facilitates insulation between the stator core (10) and the stator coil of wire, while forming corresponding slots;
a flip (40) situated atop the integrated stator bobbin (20) provides support for the stator coil of wire within the corresponding slots, such that the stator coil of wire is secured during vibration of the motor; and
a hall sensor PCB (Printed Circuit Board) (30), installed into hall sensor seatings provided on the integrated stator bobbin (20), thereby securing the hall sensor PCB onto the integrated stator bobbin (20).

2. The assembly as claimed in claim 1, wherein the flip (40) establishes a unidirectional winding of the stator coil of wire.

3. The assembly as claimed in claim 1, wherein the flip (40) restricts a displacement of the stator coil of wire wound on the stator core (10).

4. The assembly as claimed in claim 1, wherein the hall sensor seatings comprise of protrusions (60) on the integrated stator bobbin (20) that engage with holes (70), mating grooves, snap-fits, hooks or slots in the hall sensor PCB (Printed Circuit Board) (30).

5. The assembly as claimed in claim 1, wherein the hall sensor seatings comprise of holes in the integrated stator bobbin (20) that engage with protrusions in the hall sensor PCB.

6. The assembly as claimed in claim 1, wherein the hall sensor PCB (Printed Circuit Board) (30) is detachably attached to the integrated stator bobbin (20) for maintenance.

7. The assembly as claimed in claim 1, wherein the integrated stator bobbin (20) establishes a proper separation between the stator core (10) and stator coil windings.

8. The assembly as claimed in claim 1, wherein the hall sensor seating provides a distance between the hall sensor PCB (Printed Circuit Board) (30) and stator coil windings.