新能源汽车电流传感器press-fit结构设计及其可靠性验证  

New Energy Vehicle Current Sensor Press-Fit Structure Design and Its Reliability Verification

作　　者：胡玄 周邦 郑华雄 朱胜平 王辰玥 叶柳凯 HU Xuan;ZHOU Bang;ZHENG Huaxiong;ZHU Shengping;WANG Chenyue;YE Liukai(Ningbo CRRC Times Transducer Technology Co.,Ltd.,Ningbo,Zhejiang 315021,China)

机构地区：[1]宁波中车时代传感技术有限公司,浙江宁波315021

出　　处：《汽车零部件》2024年第11期18-23,共6页Automobile Parts

摘　　要：新能源汽车电流传感器的实际应用工况复杂,要求其内部零件必须采用牢固可靠的连接方式。为此,基于press-fit技术快速装联的优势设计了一种压接结构,并对其可靠性进行了系统验证。首先,定性分析了压接工艺与压接结构之间的关系,通过推出力试验评估了press-fit的微观变形及推出力变化趋势,验证了机械连接的可靠性。其次,根据电性能测试结果进一步识别了接触点电阻分布。最后,借助有限元仿真工具分析了整车运行时press-fit的变形状态及随机振动过程中的应力分布,保证了电流传感器全生命周期可靠性。这些研究结果为压接结构的设计和可靠性验证提供了支持。The complexity of the practical application working conditions of the current sensor of new energy vehicle requires that its internal parts must be connected in a firm and reliable way.For this reason,this paper designs a crimping structure based on the advantages of press-fit technology’s rapid assembly and systematically verifies its reliability.Firstly,the relationship between the crimping process and the crimping structure is qualitatively analyzed,and the micro-deformation of press-fit and the trend of pull-out force change are evaluated through the push-out force test to verify the reliability of the mechanical connection.Secondly,the contact point resistance distribution was further identified based on the electrical performance test results.Finally,with the help of finite element simulation tools,the deformation state of the press-fit under the operation of the whole vehicle and the stress distribution during random vibration were analyzed to ensure the reliability of the current sensor throughout its life cycle.These findings support the design and reliability verification of the press-fit structure.

关 键 词：电流传感器 PRESS-FIT 可靠性 

分 类 号：TP212[自动化与计算机技术—检测技术与自动化装置]