Sensor Housing｜Toyoda Iron Works Co., Ltd.(TOYOTETSU)

Sensor Housing

This is an important component that serves as the basis for current sensors (HVs and other basic components of motor control in electric vehicles) that detect the current flowing into the inverter.
It is responsible for sending a high voltage of several hundred volts and a large current of several hundred amperes to the motor, and insulation performance is required even under severe operating conditions.
We have realized the world's first integrated three-motor system for regeneration, running, and 4WD operation, contributing to the downsizing of the inverter.

Strengths of Sensor Housing

Increasing size and complexity of precision parts

10 busbars (copper plates for high-current energization) are insert-molded using a 3-motor integrated system. Dimensional accuracy significantly affects sensor performance, so the size and complexity of the shape became larger and more complicated.
However, high-precision manufacturing was still required.
We repeatedly checked the shape of the deformation countermeasures after resin molding using flow analysis, and optimized the gate (resin inlet) position and number and molding conditions.
As a result, we have realized manufacturing that satisfies dimensional accuracy even for complex and large parts.

Differential Thickness Junction by Electron Beam Welding

The difference thickness coaptation of t1.5×t0.8 was realized by electron beam welding.
Since the electron beam has high energy density and deep penetration into the bead width, the heat effect is minimal and the dimensional accuracy after welding is extremely high.
The conversion rate to thermal energy is as high as 90%, which enables sputtering (metal grains scattered during welding) and void (bubble) free welding in vacuum, making it a very high-quality welding.

Structure Proposal System

We can be done in-house from development to design, analysis, prototyping, evaluation, and mass production. Our strength is that we can offer proposals that meet the needs of our customers.

Technical Information

Here are some of the key technologies of TOYOTETSU Group.

Products

Here are some of the key products of TOYOTETSU Group.