DE102016124370A1 - Sensor device and method for assembling a sensor device - Google Patents

Sensor device and method for assembling a sensor device

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Publication number
DE102016124370A1
DE102016124370A1 DE102016124370.1A DE102016124370A DE102016124370A1 DE 102016124370 A1 DE102016124370 A1 DE 102016124370A1 DE 102016124370 A DE102016124370 A DE 102016124370A DE 102016124370 A1 DE102016124370 A1 DE 102016124370A1
Authority
DE
Germany
Prior art keywords
sensor
sensor device
device
housing
rotor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
DE102016124370.1A
Other languages
German (de)
Inventor
Roman Schoepe
Ekkehart Froehlich
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Valeo Schalter und Sensoren GmbH
Original Assignee
Valeo Schalter und Sensoren GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Valeo Schalter und Sensoren GmbH filed Critical Valeo Schalter und Sensoren GmbH
Priority to DE102016124370.1A priority Critical patent/DE102016124370A1/en
Publication of DE102016124370A1 publication Critical patent/DE102016124370A1/en
Application status is Pending legal-status Critical

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Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01LMEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
    • G01L3/00Measuring torque, work, mechanical power, or mechanical efficiency in general
    • G01L3/02Rotary-transmission dynamometers
    • G01L3/04Rotary-transmission dynamometers wherein the torque-transmitting element comprises a torsionally-flexible shaft
    • G01L3/10Rotary-transmission dynamometers wherein the torque-transmitting element comprises a torsionally-flexible shaft involving electrical or magnetic means for indicating
    • G01L3/101Rotary-transmission dynamometers wherein the torque-transmitting element comprises a torsionally-flexible shaft involving electrical or magnetic means for indicating involving magnetic or electromagnetic means

Abstract

The invention relates to a sensor device (100) for a rotatable shaft, in particular for a steering shaft of a motor vehicle, and to a method for assembling a sensor device (100), wherein the sensor device (100) comprises a torque sensor device (30) for detecting a torque applied to the shaft and a steering angle sensor means (40) for detecting a rotational angle of the shaft, wherein the torque sensor means (30) at least one magnetic means (31) for generating a magnetic field and at least one first magnetic sensor (34A, 34B) for generating a sensor signal in response to a on the shaft having applied torque, wherein the steering angle sensor means (40) at least one shaft rotatably connected to the shaft (41) and an angle sensor means for generating at least one sensor signal in response to a rotation angle of the rotor (41), and wherein the sensor device (100) at least a, to a sensor module (10) pre-assembled assembly, and wherein at least the first magnetic sensor (34A, 34B) of the torque sensor means (30) and the angle sensor means of the steering angle sensor means (40) are part of the sensor module (10) pre-assembled assembly.

Description

  • The invention relates to a sensor device for a shaft rotatable about a rotation axis, in particular for a steering shaft of a motor vehicle, wherein the sensor device has a torque sensor device for detecting a torque applied to the shaft and a steering angle sensor device for detecting a rotational angle of the shaft. In this case, the torque sensor device has at least one magnetic device for generating a magnetic field and at least one first magnetic sensor for generating a sensor signal as a function of a torque applied to the shaft. The steering angle sensor device has at least one rotor, which can be connected in a rotationally fixed manner to the shaft, and an angle sensor device for generating at least one sensor signal as a function of a rotational angle of the rotor. Furthermore, the sensor device has at least one module which is preassembled to form a sensor module.
  • Furthermore, the invention relates to a method for assembling such a sensor device.
  • Torque sensor devices for detecting a torque applied to a shaft, in particular a torque applied to a steering shaft of a motor vehicle, are known in principle from the prior art. In motor vehicles, they are used in particular to detect a steering torque applied by a driver to the steering shaft. They are used in particular in electric steering systems in order to control the electric drive motor of the steering system, based on the steering torque applied by the driver, for example, in order to be able to provide appropriate, situation-adapted steering assistance.
  • As a rule, torque sensor devices with a torsion bar with a defined, known torsional rigidity are used, the torsion bar connecting a first part of an axially divided shaft to a second part of the axially divided shaft. If a torque is applied to the shaft, this causes a rotation of the two parts of the shaft to each other by a measurable angle of rotation, wherein the angle of rotation adjusts depending on the applied torque and the stiffness of the torsion bar, so that from the detected angle of rotation at a defined, known stiffness of the Torsionsstabes the applied torque can be determined.
  • Various measuring principles and sensor arrangements are known for measuring the angle of rotation resulting as a result of an applied torque. Magnetic sensor systems are generally used, in which a circumferential ring magnet, usually designed as a permanent magnet, is non-rotatably connected to the first part of the steering shaft as part of a magnetic device and in which a stator device with a stator holder, to which two magnetically conductive stator elements are usually attached, is non-rotatably connected to the second part of the shaft. The stator device, in particular the two stator elements, are usually arranged concentrically around the ring magnet of the magnet device in the radial direction with a small air gap. Via the stator device, in particular the two stator elements, the magnetic flux of the ring magnet of the magnetic device, in particular by means of additional components in the form of so-called flux guides, to a torque magnetic sensor, such as a Hall sensor, and the generated signal to determine the applied Torque can be evaluated.
  • When the ring magnet rotatably connected to the first part of the shaft is moved by rotation of the shaft relative to the stator means connected to the second part of the shaft, the magnetic flux density in the stator elements changes, which can be detected by the torque magnetic sensor. The change in the magnetic flux density in the stator is u.a. depending on the magnitude of the relative movement of the ring magnet relative to the stator means, i. from the angle of rotation. Thus, it can be concluded from the change in the detected flux density to the angle of rotation and turn from the angle of rotation can be determined with knowledge of the torsional stiffness of the torsion bar, the torque applied to the shaft.
  • Generic torque sensor devices are for example from the DE 103 46 332 A1 or the EP 1 584 908 A2 known.
  • Steering angle sensor devices are also known in principle from the prior art, in particular steering angle sensor devices, which have a rotor and an angle sensor device with a gear for detecting a rotational angle of the rotor, for example from DE 10 2008 011 448 A1 or the DE 195 06 938 A1 or the DE 199 62 241 A1 ,
  • The steering angle sensor devices, which in the last three documents DE 10 2008 011 448 A1 . DE 195 06 938 A1 and DE 199 62 241 A1 In this case, each have a rotor rotatably connected to the shaft with a ring gear and an angle sensor device, wherein the angle sensor device a transmission with usually two smaller gears, each having a permanent magnet, via which the rotational movement of the shaft can be transmitted to one, the permanent magnet of the gears associated magnetic sensor, by means of which in each case the rotation of the associated gears can be detected. In this case, the two gears have different numbers of teeth and are each coupled with a defined ratio with the rotor, so that from the detected rotation angles of the two small gears, in particular according to the vernier principle, the angle of rotation of the shaft can be determined.
  • In addition, sensor devices are known from the prior art which have both a generically configured, previously described torque sensor device and a generically configured, above-described steering angle sensor device. Such combined sensor devices are known for example from DE 10 2010 033 769 A1 , of the DE 10 2012 024 382 A1 , of the DE 10 2012 24 383 A1 or the DE 10 2012 025 280 A1 known.
  • Already due to the many components, the assembly of a combined sensor device is relatively complex. A major challenge is, above all, to arrange the individual components precisely and precisely to one another, in particular to arrange the stator elements of the stator devices or the flux guides of the torque sensor device with a defined gap relative to the associated torque magnetic sensor and the permanent magnets of the gears of the angle sensor device precisely and with a to arrange defined gap with respect to the respective associated magnetic sensors of the angle sensor device. If a previously described sensor device is designed to be arranged within a steering gear housing, in which the steering shaft is at least partially mounted, the complexity increases even further and the requirements with respect to dimensional accuracy of the individual components of the sensor device and their positional accuracy increase even further ,
  • In order to avoid a dimensional over-determination when installed in the steering gear housing, some of the known from the prior art sensor devices are therefore designed to be stored floating in the steering gear housing, the sensor devices often with a sensor device almost completely surrounding housing into the steering gear housing be used.
  • The required for the floating mounting of the sensor device distance to the steering gear housing and the often also almost completely arranged in the interior of the steering gear housing connector terminal of the sensor device require a considerable amount of space.
  • It is therefore an object of the invention to provide an alternative sensor device, preferably an improved sensor device, in particular a sensor device, which allows a simplified assembly or a simplified assembly and preferably has a reduced space requirement compared to comparable, known from the prior art sensor devices. Moreover, it is a further object of the invention to provide a corresponding method for assembling such a sensor device.
  • This object is achieved by a sensor device according to the invention and by an inventive method according to the respective independent patent claims. Advantageous embodiments of the invention are the subject of the dependent claims, the description and the figures and are explained in more detail below.
  • A sensor device according to the invention is characterized in that at least the first magnetic sensor of the torque sensor device and the angle sensor device of the steering angle sensor device are part of the module pre-assembled to the sensor module.
  • This makes it possible in a particularly simple manner to achieve a particularly simple assembly of a sensor device according to the invention, in particular a precisely positionally precise arrangement of the first magnetic sensor of the torque sensor device with respect to the other components of the torque sensor device and a particularly positionally accurate and precise arrangement of the angle sensor device of the steering angle sensor device, based on a Functional state of use of the sensor device according to the invention.
  • A sensor device according to the invention is in particular for connection to a shaft rotatable about a rotation axis, in particular for connection to a steering shaft of a motor vehicle, wherein the shaft is preferably divided into at least a first part and a second part, wherein the first part and the second Part in particular via a torsion bar, which extends in the axial direction between the first part of the shaft and the second part of the shaft and having a defined, known torsional stiffness, are interconnected.
  • For the purposes of the invention, a sensor module is understood to mean an assembly which has at least one sensor, preferably at least one sensor and a printed circuit board.
  • The torque sensor device of a sensor device according to the invention is preferably designed to provide a torque signal. Alternatively and / or additionally, the raw signal generated by the first magnetic sensor can also be provided.
  • The magnetic device of the torque sensor device of a sensor device according to the invention is preferably designed as usual in the generic torque sensor devices known from the prior art. For further embodiments, in particular with regard to possible embodiments and the operation is on the EP 0 980 081 B1 , the EP 1 123 794 and in particular to the DE 10 2013 006 567 A1 directed.
  • The steering angle sensor device of a sensor device according to the invention is preferably also designed in principle as known from the prior art, for further information, in particular with regard to detailed embodiments of the possible configuration and operation of the steering angle sensor device is in particular already mentioned in the apron DE 10 2008 011 448 A1 , the DE 195 06 938 A1 , the DE 10 2010 033 769 A1 , the DE 10 2012 024 382 A1 , the DE 10 2012 024 383 A1 as well as the DE 10 2012 025 280 A1 directed.
  • The rotor of a sensor device according to the invention is designed to be rotatably connected to the shaft. The rotor may be either directly, i. directly, without another element in between, or indirectly via another component, in particular via another component of the sensor device according to the invention, are connected to the shaft, wherein the rotor preferably via the magnetic device of the torque sensor device or via a stator of the torque sensor device rotationally fixed to the shaft can be connected.
  • The steering angle sensor device, in particular the angle sensor device of the steering angle sensor device, is preferably designed to provide an absolute rotational angle signal. Alternatively and / or additionally, however, the raw signals of the rotor angle signals generated by the second magnetic sensor and by the third magnetic sensor can also be provided.
  • In an advantageous embodiment of a sensor device according to the invention, the first magnetic sensor of the torque sensor device and the angle sensor device of the steering angle sensor device are received by a common sensor module housing. That is, preferably, the first magnetic sensor of the torque sensor device and the angle sensor device are at least partially disposed within a common sensor module housing and stored in particular in this. In this case, the sensor module housing is preferably designed such that the components of the sensor module, in particular the first magnetic sensor of the torque sensor device and the angle sensor device of the steering angle sensor device respectively can cooperate with the remaining components of the sensor device to fulfill the respective functions of the associated sensor device.
  • In a sensor device according to the invention, the angle sensor device preferably has at least one first transmission element which together with the rotor of the steering angle sensor device forms part of a transmission or forms a transmission and engages the rotor in a functional state of use of the sensor device, wherein the angle sensor device is preferably designed for this purpose to generate a first rotor angle sensor signal in dependence on the angle of rotation of the first gear element.
  • For this purpose, the rotor preferably has a toothed rim, in particular an externally toothed ring gear, and the first gear element is preferably designed as a toothed wheel. In particular, an axis of rotation of the first transmission element of the angle sensor device runs parallel to the axis of rotation of the shaft relative to a state in which the sensor device according to the invention is connected to a shaft from which torque and angle of rotation are to be detected by means of the sensor device. In this case, an incremental steering angle of the rotor can be determined by means of the first gear element, i. the number of revolutions of the rotor.
  • In order for the rotor to be able to engage with the first transmission element unhindered, in particular to mesh with the first transmission element of the angle sensor device, the sensor module housing preferably has a correspondingly formed recess, and the individual components of the sensor device according to the invention are preferably designed and used in a functional state of use Sensor device arranged within the sensor device such that either the rotor protrudes into the sensor module housing and thus is an engagement zone between the rotor and the first gear element within the sensor module housing or the first transmission element of the Sensor module housing protrudes and thus the engagement zone is outside the sensor module housing.
  • In a sensor device according to the invention, the first transmission element of the angle sensor device preferably has a permanent magnet, and the sensor device, in particular the angle sensor device, has a second magnetic sensor for generating the first rotor angle sensor signal as a function of the angle of rotation of the first transmission element. This can be detected in a particularly simple manner by means of the first transmission element of the rotation angle of the rotor or the number of rotor revolutions.
  • For an accurate determination of the angle of rotation of the rotor, in particular for determining the absolute angle of rotation of the rotor, in a further advantageous embodiment of a sensor devices according to the invention, the angle sensor device at least a second transmission element, which forms a gear with the rotor and the first transmission element, wherein the second gear element in a functional use state of the sensor device is preferably in engagement with the rotor and / or the first gear element and wherein the angle sensor device is in particular designed to generate a second rotor angle sensor signal in dependence on the rotation angle of the second gear element.
  • The second transmission element of the angle sensor device makes it possible to determine the angle of rotation of the rotor according to the vernier principle. The determination of the angle of rotation of the rotor in this manner and thus the determination of the angle of rotation of a shaft connected to the sensor device is basically known from the prior art. For more detailed explanations, in particular as to how precisely the rotor angle and thus the angle of rotation of the shaft can be calculated and thus determined on the basis of the first rotor angle sensor signal and the second rotor angle sensor signal will be particularly appreciated DE 195 06 938 A1 and the DE 199 62 241 A1 in which the calculation of the rotor angle in dependence on a first rotor angle sensor signal and a second rotor angle sensor signal, which have been generated with a generic steering angle sensor device, is described in detail.
  • In the aforementioned document DE 195 06 938 A1 is also disclosed which ratios between the rotor and the first gear element and the second gear element of the angle sensor device are advantageous or suitable.
  • As already described in connection with the first transmission element, the sensor module housing is preferably designed in this case and the individual components of the sensor devices according to the invention are also preferably designed and arranged accordingly that the second transmission element unhindered with the rotor and / or the first transmission element can comb. The engagement zone between the second transmission element and the rotor and / or the first transmission element can also be either within the sensor module housing or outside of this.
  • Preferably, the rotor is arranged with the first gear element and / or the second gear element of the angle sensor device in a common plane, wherein the permanent magnets of the gear elements is preferably arranged in each case with a defined gap to the associated second or third magnetic sensor. If an axial distance between the magnetic sensor and the engagement plane or the driven plane to the rotor is to be bridged, the gear elements can each have a correspondingly long shaft in the axial direction in order to bridge this distance, preferably at one end of the shaft in the axial direction the transmission element is arranged and at the other end of the shaft, in particular the permanent magnet.
  • In order to produce a second rotor angle sensor signal in a particularly simple manner as a function of the rotational angle of the second gear element, in a sensor device according to the invention preferably the second gear element of the angle sensor device also has a permanent magnet and the sensor device, in particular the angle sensor device at least a third magnetic sensor for generating of the second rotor angle sensor signal as a function of the angle of rotation of the second transmission element.
  • A particularly advantageous embodiment of a sensor device according to the invention results when the first magnetic sensor of the torque sensor device is arranged together with the second magnetic sensor of the steering angle sensor device and / or the third magnetic sensor of the steering angle sensor device on a common, preferably also received by the sensor module housing and the sensor module associated circuit board. In this case, the printed circuit board is preferably arranged in relation to a functional state of use of the sensor device such that its printed circuit board plane extends perpendicular to the axis of rotation of the shaft. That is, in a sensor device according to the invention is preferably a common circuit board for receiving the first magnetic sensor of Torque sensor device and the two magnetic sensors of the steering angle sensor device is provided, wherein the circuit board is in particular part of the pre-assembled module to the sensor module and preferably extends perpendicular to the axis of rotation of a connectable to the sensor device shaft.
  • In a further advantageous embodiment of a sensor device according to the invention, the torque sensor device has a stator device for collecting the magnetic flux of the magnetic field generated by the magnetic device of the torque sensor device, wherein the rotor of the steering angle sensor device is preferably non-rotatably connected to the stator or rotationally fixed to the magnetic device of the torque sensor device.
  • The stator means of a sensor device according to the invention preferably comprises a stator holder, by means of which the stator means can be non-rotatably connected to a part of the shaft, and preferably two separate, i. separately formed stator elements fastened to the stator holder, wherein each stator element preferably has either a cylinder jacket-shaped or radially outwardly extending annular disk-shaped region in the form of a stator ring and a multiplicity of axially extending tabs which are distributed uniformly in the circumferential direction. In this case, the stator elements are preferably mounted on the stator holder in such a way that the lugs of the two stator elements mesh with one another like a comb. The rotor of a sensor device according to the invention can be arranged in the axial direction either between the stator elements or outside of these.
  • The stator device of a sensor device according to the invention is preferably according to one in the DE 10 2015 122 171.3 described stator device formed, in particular according to one in the DE 10 2015 122 171.3 described starter assembly according to the invention, wherein the DE 10 2015 122 171.3 is hereby incorporated by express reference to the content of the description.
  • In this case, in the case of a stator device of a sensor device according to the invention, the two stator elements can each be fixed in the axial direction by means of a fixing ring on the stator holder. If a sensor device according to the invention has a stator device designed in this way, the rotor can be connected in a particularly simple manner to the stator device in a rotationally secure manner and in this way be connected to the shaft in a particularly easily rotatable manner, namely via the stator holder of the stator device.
  • If the rotor and stator device of a sensor device according to the invention are designed to be connected to one another in a rotationally fixed manner, wherein the rotor can preferably be secured against rotation on the stator holder, the rotor and the stator device are preferably preassembled in a sensor device according to the invention to form a module forming a stator module.
  • Instead of being premounted to form an assembly in the form of a stator module, in a further advantageous embodiment of a sensor device according to the invention, the rotor and the stator device, in particular the rotor and the stator holder, can also be produced integrally, wherein the rotor preferably contains plastic and in particular to the Statoreinrichtung, preferably the stator holder is molded. That is, preferably, the rotor is made in the same operation as the stator holder. In other words, the stator holder and the rotor are preferably produced using the same injection molding tool, in which, in particular, the stator elements can be inserted as inserts and in this way can be connected to the stator holder and the rotor to form a stator module as a stator module.
  • In an alternative but also advantageous embodiment of a sensor device according to the invention, the rotor with the magnet device forms a magnet module, wherein the rotor preferably contains plastic and in particular is molded onto the magnet device. That Preferably, in a sensor device according to the invention, the rotor has either been preassembled with the magnetic device to form a magnetic module or produced as a magnetic module or else preassembled with the stator device to form a stator module or produced as a stator module.
  • In a further advantageous embodiment of a sensor device according to the invention, the sensor device, in particular the torque sensor device, at least one flux guide for forwarding the magnetic flux to the first magnetic sensor, wherein the at least one flux conductor is preferably made by forming from a flat band or a wire, in particular in one piece.
  • Advantageous embodiments of a flux conductor manufactured in one piece by deformation, in particular for a sensor device according to the invention, are particularly in EN 10 2016 124 330.2 and the DE 10 2016 124 331.0 which are hereby incorporated by express reference into the content of the description.
  • Integral flux guides made by forming are particularly advantageous for cost reasons, since only little waste is obtained in this type of production, which is clearly noticeable due to the high cost of materials for the soft magnetic materials from which a flux guide is preferably made.
  • At least one of the flux conductors in this case has, relative to a functional use state of the torque sensor device about the axis of rotation of the shaft cylinder jacket or ring disk or ring segment-shaped circumferentially extending flux conductor body, in particular for collecting a magnetic flux of the stator, and at least a first, from the flux conductor body Outer protruding tab, preferably for forwarding the collected magnetic flux to a first magnetic field sensor of the torque sensor device, in particular two tabs.
  • Alternatively, the flux guide described can also be designed as a one-piece stamped and bent part, wherein after punching out, first the flux conductor tabs and then the flux-cylinder body extending in the circumferential direction of the rotation axis of the shaft are formed by a bending operation.
  • In a further advantageous embodiment of a sensor device according to the invention, the flux guide is open in the circumferential direction. This allows a particularly simple and above all flexible installation, in particular a flexible assembly order.
  • In an alternative embodiment of a sensor device according to the invention, the flux guide is closed in the circumferential direction. As a result, a particularly stable flux guide, in particular a mechanically particularly robust flux guide, can be provided. However, such a trained flux guide requires a specific order in the assembly of a sensor device according to the invention.
  • In a further advantageous embodiment of a sensor device according to the invention, the sensor device has a sensor housing, wherein the sensor housing is preferably designed for receiving the individual components of the sensor device.
  • In a further advantageous embodiment of a sensor device according to the invention, wherein preferably at least one flux guide is arranged in a functional use condition of the sensor device concentric with the stator and this preferably at least partially engages from the outside, at least one flux guide is mounted in the sensor housing, preferably fixed in the sensor housing. Particularly preferably, all flux conductors of a sensor device according to the invention are mounted in the sensor housing and in particular fixed in the sensor housing. Preferably, the sensor device is designed in such a way that the at least one flux guide is received in a stationary manner and in particular at a distance from the stator device without a sliding bearing between the sensor housing.
  • As a result, a precise positioning of at least one flux guide, in particular all flux guides, relative to the respective first magnetic sensors of the torque sensor device can be achieved in a simple manner via the sensor housing. Preferably, the flux guide is held by the sensor housing. For this purpose, the flux guide may for example be glued to the sensor housing and / or held by terminals in the sensor housing.
  • However, particularly preferably, at least one flux guide is produced integrally with the sensor housing and in particular forms an insert part, which has been encapsulated at least partially with the material of the sensor housing in the production of the sensor housing.
  • In an alternative embodiment of a sensor device according to the invention, wherein also at least one flux guide is arranged in a functional use condition of the sensor device concentric with the stator and this preferably at least partially engages from the outside, at least one flux guide is not stored in the sensor housing, but on the stator in the radial direction a sliding bearing supported, wherein the flux guide is secured in this case, preferably by means of the sensor housing against rotation. For this purpose, the sensor housing preferably has one or more projections and / or recesses on which the flux guide is supported in the circumferential direction in such a way that rotation is prevented.
  • In a further advantageous embodiment of a sensor device according to the invention, the sensor housing, based on a functional use state of the sensor device, a extending in the radial direction insertion opening for the sensor module. In this case, in a functional state of use of a sensor device according to the invention, the sensor module is introduced into the insertion opening in the radial direction, preferably plugged in, in particular such that in a functional use state of the sensor device at least one flux guide of the torque sensor device is positioned relative to the first magnetic sensor and / or the rotor of the steering angle sensor device is positioned relative to the angle sensor device.
  • In a further advantageous embodiment of a sensor device according to the invention, the sensor housing, based on a functional use state of the sensor device, extending in the axial direction through hole for the shaft, wherein in a functional use state of the sensor device, the magnetic device and / or the stator and / or the Rotor is rotatably mounted in the through hole of the sensor housing and preferably fixed in the axial direction, wherein the magnetic device and / or the stator device and / or the rotor have been at least partially introduced in the axial direction in the sensor housing, preferably after the magnetic device and / or the Stator and / or the rotor have been rotatably connected to the shaft. In this case, the magnet device and / or the stator device and / or the rotor have been introduced at least partially in the axial direction into the sensor housing such that in a functional state of use of the sensor device at least one flux guide of the torque sensor device is positioned relative to the first magnetic sensor and / or the Rotor defined with respect to the angle sensor device is positioned.
  • If, in a sensor device according to the invention, the rotor and the stator device have been preassembled to form a stator module or form a stator module, the stator module is preferably inserted into the sensor housing at least partially in the axial direction, instead of the individual components. If, on the other hand, the rotor and the magnet device are preassembled to form a magnet module or form a magnet module, the magnet module has accordingly been introduced at least partially in the axial direction into the sensor housing.
  • In a further advantageous embodiment of a sensor device according to the invention, the sensor housing and at least one flux guide are part of a further module preassembled to form a sensor housing module, wherein in particular the sensor module and / or the magnet device and / or the stator device and, based on a functional use state of the sensor device / or the rotor have been introduced into the sensor housing only in the axial direction, after the sensor housing has been preassembled with at least one flux guide to a sensor housing module.
  • In a further advantageous embodiment of a sensor device according to the invention, the sensor housing is part of another housing, preferably part of a connectable to a vehicle body of a motor vehicle housing, in particular part of a steering gear housing, or even forms a connectable to the vehicle body of a motor vehicle housing. That is, preferably, the individual components of the sensor device can be arranged directly in a connectable to the vehicle body of a motor vehicle housing, in particular directly in a steering gear housing, provided that the steering gear housing forms the sensor housing.
  • In an alternative, advantageous embodiment of a sensor device according to the invention, the sensor housing is designed for arrangement in a further housing, in particular for arrangement in a connectable to a vehicle body of a motor vehicle housing, in particular for arrangement in a steering gear housing, wherein the sensor housing, based on a functional use state of Sensor device, preferably in the radial direction in the other housing is inserted, in particular can be inserted. That In other words, that in an alternative, but also advantageous embodiment of a sensor device according to the invention, the sensor housing is adapted to be received by a further housing, in particular a steering gear housing. In this case, the sensor housing can preferably be inserted in the radial direction into the further housing, in particular, with respect to a functional use state of the sensor device.
  • For this purpose, the further housing preferably has a passage opening formed corresponding to the passage opening of the sensor housing and is in particular designed such that after insertion of the sensor housing, the passage opening of the sensor housing and the passage opening of the further housing are preferably concentric with each other and, based on a functional use state of the sensor device, are arranged concentrically to the axis of rotation of the shaft and in particular are formed substantially congruent to each other, so that after insertion of the sensor housing into the further housing, the magnetic device and / or the stator device and / or the rotor, as described above in connection with the sensor housing, in the axial direction in the sensor housing can be at least partially inserted and preferably rotatably mounted in the through hole of the sensor housing and in particular in the axial direction in the sensor housing can be determined.
  • It goes without saying that the sensor housing in this case can only be inserted into the further housing when the shaft and / or the magnet device and / or the stator device and / or the rotor is not yet passed through the passage opening of the sensor housing. are introduced.
  • Such a trained, especially in another housing plug-in sensor housing allows a particularly space-saving recording in another housing. Further, the sensor housing can be formed in this case such that there is a connector terminal outside the steering gear housing, which in particular within the steering gear housing a considerable space can be obtained.
  • A method according to the invention for assembling a sensor device, in particular a sensor device according to the invention, is characterized by the steps:
    • Providing the components of the sensor device,
    • Pre-assembling at least the first magnetic sensor of the torque sensor device and the angle sensor device of the steering angle sensor device to a module forming a sensor module, and
    • - Assemble the remaining components of the sensor device with the sensor module to the sensor device.
  • This can be provided in a particularly simple manner, a particularly easy to assemble sensor device, in particular a sensor device in which the individual components can be positioned precisely and accurately to each other in a simple manner, in particular the components of the torque sensor device relative to the first magnetic sensor and the rotor opposite the angle sensor device.
  • In an advantageous embodiment of a method according to the invention, in a further method step, the stator device of the torque sensor device and the rotor of the steering angle sensor device are preassembled to form a stator module, wherein the stator module is subsequently assembled to the sensor module and the remaining components of the sensor device to the sensor device.
  • Alternatively, the stator device and the rotor can already be produced integrally as a stator module or manufactured as a stator module and then subsequently assembled with the sensor module and the remaining components of the sensor device to the sensor device. Alternatively, the rotor with the magnetic device can also be preassembled or manufactured to form a magnet module and subsequently assembled with the sensor module and the remaining components of the sensor device for the sensor device.
  • In a further advantageous embodiment of a method according to the invention, wherein the sensor device has a sensor housing, which is designed for arrangement in a further housing, in particular for arrangement in a connectable to a vehicle body of a motor vehicle housing, in particular for arrangement in a steering gear housing, the sensor housing is in a further method step in the further housing, wherein the sensor housing is preferably inserted in relation to a functional use state of the sensor device in the radial direction in the further housing, in particular plugged.
  • If the sensor housing itself can be fastened to the vehicle body of a motor vehicle, this method step can be omitted. Also eliminates this process step when the sensor housing is part of a particular attachable to the vehicle body steering gear housing.
  • In a further advantageous embodiment of a method according to the invention, wherein the sensor device has a sensor housing which, based on a functional use state of the sensor device, has a passage opening extending in the axial direction for a shaft, in a further method step, the magnetic device and / or the stator device and / or the rotor rotatably mounted in the through hole of the sensor housing and preferably fixed in the axial direction, wherein the magnetic device and / or the stator device and / or the rotor is at least partially inserted in the axial direction in the sensor housing, preferably after the magnetic device and / or the stator and / or the rotor have been rotatably connected to the shaft and / or after the sensor housing has been arranged in the further housing, wherein the magnetic device and / or the stator device and / or the R In particular in such an at least partially inserted in the axial direction in the sensor housing, that in a functional use state of the sensor device is at least one flux guide of the torque sensor device defined relative to the first magnetic sensor is positioned and / or the rotor is positioned relative to the angle sensor device.
  • If the rotor is already rotatably connected to the stator device or the magnet device and thus part of a stator or magnet module, the stator module and / or the magnet module is correspondingly at least partially inserted into the sensor housing instead of the individual components.
  • In a further advantageous embodiment of a method according to the invention, wherein the sensor device has at least one flux guide, in a further method step at least one flux guide is mounted in the sensor housing, preferably fixed in the sensor housing, in particular in the interior of the sensor housing in the region of the passage opening, wherein the flux guide preferably in the Sensor housing is introduced before the magnetic device and / or the stator device and / or the rotor or the stator module and / or the magnetic module, at least partially inserted in the axial direction in the sensor housing. In particular, all flux conductors are arranged in the sensor housing. Preferably, the sensor housing and at least one flux guide, in particular all flux conductors, thereby preassembled into a sensor housing module.
  • In a further advantageous embodiment of a method according to the invention, wherein the sensor housing, based on a functional use state of the sensor device, has an insertion opening extending in the radial direction for the sensor module, in a further method step, the sensor module is inserted into the insertion opening in the radial direction, preferably inserted in particular such that, in a functional state of use of the sensor device, at least one flux guide of the torque sensor device is positioned relative to the first magnetic sensor and / or the rotor of the steering angle sensor device is positioned relative to the angle sensor device, the sensor module preferably being inserted into the sensor housing after the magnetic device and / or the stator and / or the rotor for this purpose at least partially introduced in the axial direction in the sensor housing are.
  • In an alternative embodiment of a method according to the invention, the sensor module can also first be plugged into the housing, either the sensor housing or the further housing, in the radial direction and then the magnet device and / or the stator device and / or the rotor or the magnet module and / or or the stator module. However, in this case, it must be ensured that the rotor can be brought into engagement at least with the first gear element of the angle sensor device, preferably with the first gear element and the second gear element of the angle sensor device. In this case, it is advantageous if at least the first gear element, preferably the first gear element and the second gear element, if the second gear element is also to be brought into engagement with the rotor, from the sensor module housing in the radial direction inwards, that is to the axis of rotation Shaft out, based on a functional use condition of the sensor device protrude or protrude.
  • A sensor device according to the invention is particularly suitable for use in a motor vehicle with a divided into a first part and a second part steering shaft having a torsion bar in the axial direction therebetween, the torsional stiffness is defined and known, wherein in a functional installation state of a sensor device according to the invention preferably the Magnet device of the sensor device is rotatably connected to the first part of the steering shaft and the stator of the sensor device is rotatably connected to the second part of the steering shaft.
  • The advantageous embodiments presented with reference to a sensor device according to the invention and their advantages also apply correspondingly to a method according to the invention and to a motor vehicle according to the invention.
  • Further features of the invention will become apparent from the claims, the figures and the description of the figures. All features and feature combinations mentioned above in the description and the following features and feature combinations mentioned in the description of the figures and / or shown alone in the figures can be used not only in the respectively indicated combination but also in other combinations or alone, if this is technically possible makes sense.
  • The invention will now be explained in more detail with reference to two advantageous embodiments with reference to the accompanying drawings.
  • They show schematically:
    • 1a A first embodiment of a sensor device according to the invention in a functional use state in perspective,
    • 1b the sensor device according to the invention 1a in exploded view,
    • 1c two flux guides for a sensor device according to the invention in an alternative embodiment in a single representation
    • 2a two flux guides for a sensor device according to the invention in a further alternative embodiment in single part representation and
    • 2 B A second embodiment of a sensor device according to the invention in exploded view with the flux conductors 2a ,
  • 1a shows a first embodiment of a sensor device 100 according to the invention in a functional, assembled use state, but without an associated steering shaft and a receptacle for the sensor device 100 trained steering gear housing 60 (see. 1b ).
  • The sensor device according to the invention 100 has a torque sensor device 30 and a steering angle sensor device 40 on, wherein the torque sensor device 30 a magnetic device 31 and a stator device 33 and two flux guides 32A and 32B which, in this embodiment, a sensor device according to the invention 100 each in the axial direction R1 at least partially in a sensor housing according to the invention 20 , in particular in a passage opening 21 of the sensor housing 20 are inserted and in the sensor housing 20 are stored, the two flux conductors 32A and 32B in this case in the sensor housing 20 are determined by terminals and the magnetic device 31A and the stator device 33 each rotatable relative to the sensor housing 20 inside the sensor housing 20 are arranged.
  • The torque sensor device 30 the sensor device according to the invention 100 is for connection to a divided into a first part and a second part, not shown here shaft, in particular a split steering shaft formed, wherein the first part of the shaft and the second part of the shaft are connected in the axial direction by means of a Torsionsstabs with known torsional stiffness in that the first part of the shaft and the second part are twisted against each other when a torque is applied to the shaft.
  • The thereby adjusting torsion angle is a suitable torsion bar proportional to the applied torque, so that one can draw conclusions on the torque, if one measures the applied angle of rotation and knows the torsional stiffness of the torsion bar. The torque sensor device 30 the sensor device according to the invention 100 is designed to detect the angle of rotation or rather to generate a dependent of the rotation angle, in particular to this proportional, sensor signal.
  • For this purpose, the torque sensor device 30 a magnetic device 31 on which by means of a sleeve 31B rotatably connected to the first part of the shaft can be connected. On the sleeve 31B is a ring magnet 31A attached, which in the axial direction R2 concentric with the stator elements 33A and 33B a stator device 33 can be arranged with a defined gap between them.
  • For further statements regarding the closer embodiment of a magnetic device, in particular an advantageous embodiment of the magnetic device is on the DE 10 2013 006 567 A1 , the DE 10 2015 116 545.7 , the DE 10 2015 122 182.9 as well as the DE 10 2015 122 176.4 referenced, which show particularly advantageous embodiments of a magnetic device for a torque sensor device.
  • The stator device 33 which also forms part of the torque sensor device 30 is, can have a sleeve-shaped section 33E a stator holder 33C to which the stator elements 33A and 33B are fixed and by means of fixing rings 33D are fixed in the axial direction, are rotatably mounted on the second part of the shaft.
  • The two stator elements 33A and 33B are made of a soft magnetic material, in particular of soft magnetic metal, and adapted to the magnetic flux of the ring magnet 31A recorded magnetic field, in particular to collect and forward. Is on the not shown here, with the torque sensor device 30 connected shaft applied a torque and causes a rotation of the first shaft part relative to the second shaft part, this leads to a rotation of the non-rotatably connected to the first part of the shaft magnet device 31 , in particular of the ring magnet 31A , opposite the stator device 33 , which is rotatably connected to the second shaft part, in particular with respect to the two stator elements 33A and 33B , This changes the magnetic flux in the stator elements 33A and 33B What can be detected by means of magnetic sensors, in particular by means of the first magnetic sensors 34A and 34B the torque sensor device.
  • Around the in the stator elements 33A and 33B collected magnetic flux to the first magnetic sensors 34A and 34B to transfer, has the sensor device according to the invention 100 the two, already mentioned and also made of a soft magnetic metal flux guide 32A and 32B on, which in each case in a functional use state of the sensor device according to the invention 100 an adjacent stator element 33A respectively. 33B encompass cylindrical shell (cf. 1b ).
  • For more detailed information or details on the design of the stator elements 33A and 33B will be on the DE 10 2015 122 171.3 directed.
  • The two flux guides 32A and 32B are in 1b , which the sensor device according to the invention from 1a in an exploded view and an associated steering gear housing 60 for receiving the sensor housing 20 shows, to recognize well. The two flux guides 32A and 32B each have an annular flux conductor body 36A on and two tabs 35A respectively. 35B , The flux conductor body 36A , Essentially serves to that of the adjacent stator 33A respectively. 33B collect collected magnetic flux while the two tabs 35A and 35B in particular serve that of the flux guide 32A respectively. 32B each received magnetic flux to an associated, first magnetic sensor 34A respectively. 34B to transmit the torque sensor device.
  • The two flux guides 32A and 32B are so spaced in the radial direction to the stator elements 33A respectively. 33B arranged that no sliding bearing between them is necessary. Although this requires somewhat more installation space in the radial direction than in the case of a sensor device in which the flux conductors are supported on the stator elements via a slide bearing, a sensor device without a slide-mounted flux guide has a lower friction.
  • In this sensor device according to the invention 100 are the river guides 32A and 32B each made of a flat band in one piece by forming the tabs 35A and 35B are formed in particular by folding or folding and partial folding.
  • Furthermore, the flux guides 32A and 32B formed closed, in which case their ends or the ends of the flat strip have been arranged jerky adjacent to each other and have been welded together with a butt weld. For further advantageous embodiment possibilities of a flux guide, in particular for a sensor device according to the invention, is in this context on the EN 10 2016 124 330.2 and the DE 10 2016 124 331.0 referenced, in which particularly advantageous embodiments of flux conductors are described, which are particularly well suited for use in a sensor device according to the invention.
  • The river ladder 32A and 32B or in particular their tabs 35A and 35B are in a functional state of use of the sensor device 100 according to the invention in this case with a defined gap in the axial direction R1 opposite to the first magnetic sensors 34A and 34B arranged.
  • The first magnetic sensors 34A and 34B each serve to do this by using the two flux guides 32A and 32B collected magnetic flux and in response to generate a torque sensor signal, wherein the magnetic flux in response to a with the torque sensor device 30 connected shaft torque applied changes.
  • The steering angle sensor device 40 the sensor device according to the invention 100 are a rotor 41 , And an unspecified angle sensor device with a first transmission element 42 and a second transmission element 43 assigned (see 1b ) and a not shown here in each case, second magnetic sensor 42B and third magnetic sensor 43B , wherein the first transmission element 42 and the second transmission element 43 are each formed as a gear and with the rotor 41 arranged in a common plane. The first gear 42 meshes with the rotor 41 with a defined translation, while the second gear 43 which one from the first gear 42 having different numbers of teeth, with the first gear 42 combs.
  • In 1b is for a better understanding of the structure of the sensor device according to the invention 100 from the sensor device 100 shown in exploded view, based on which the individual components and their arrangement within the sensor device 100 are clearly recognizable. In particular, the first transmission element 42 which in functional use state of the sensor device according to the invention 100 with the rotor 41 the steering angle sensor device 40 meshes and in particular lies with this in a plane, and the second transmission element 43 , which is also designed as a gear and with the first gear element 42 combs, to recognize well.
  • The two gear elements 42 respectively. 42 or the two gears 42 and 43 the angle sensor device which part of the steering angle sensor device 40 is, each have a permanent magnet not shown here, wherein the permanent magnet of the first gear 42 with a defined gap in the axial direction R1 opposite to the second magnetic sensor 42B is arranged and the permanent magnet of the second gear 43 with a defined gap in the axial direction relative to the third magnetic sensor 43B , so that in each case depending on the rotation angle of the respective transmission element 42 respectively. 43 one first rotor angle sensor signal and a second rotor angle sensor signal can be generated, from which the absolute angle of rotation of the rotor 41 and thus the angle of rotation one with the rotor 41 rotatably connected shaft can be determined.
  • The two gears 42 and 43 are inventively together with the first magnetic sensors 34A and 34B the torque sensor device to an assembly in the form of a sensor module 10 pre-assembled and from a common sensor module housing 11 received, in particular stored in this, wherein the sensor module housing 11 in this case from a first sensor module housing part 11A and a second sensor module housing part 11B is composed.
  • The two gear elements 42 and 43 or in particular the gears 42 and 43 form with their permanent magnets and the associated second magnetic sensor 42B and the associated third magnetic sensor 43B the angle sensor device of the steering angle sensor device 40 , where the two magnetic sensors 42B and 43B the angle sensor device together with the two first magnetic sensors 34A and 34B the torque sensor device 30 on a common circuit board 14 arranged, which also from the sensor module housing 11 is included and part of the invention to a sensor module 10 preassembled module is.
  • To forward the from the first magnetic sensors 34A and 34B generated torque sensor signals and the steering angle signal generated from the first rotor angle sensor signal and the second rotor angle sensor signal, for example, to a steering control unit of a motor vehicle, the sensor module 10 further plug contacts 12 as well as a connection 13 for a connector over which the circuit board 14 can be contacted with a control unit.
  • So that the first transmission element 42 with the rotor 41 can be engaged in a functional use state, has the sensor module housing 11 , related to the representation in the 1a and 1b , On its underside a corresponding recess, from which the first transmission element 42 in a functional use state of the sensor device according to the invention 100 stands out (see in particular 1a ), so that an engagement zone between the rotor 41 and the first transmission element 42 outside the sensor module housing 11 lies.
  • Alternatively, the rotor 41 in the sensor module housing 11 protrude. However, in this case, therefore, the sensor module 10 only after the rotor 41 into the sensor housing 20 are introduced when the sensor housing 20 as in the described embodiment of a sensor device according to the invention 100 is trained.
  • In this embodiment of a sensor device according to the invention 100 can the sensor module 10 in the radial direction R2 in an insertion opening 22 in the sensor housing 20 are inserted, in particular plugged in, in particular such that in a functional use state of the sensor device 100 at least one flux guide 32A . 32B the torque sensor device 30 defined opposite to the first magnetic sensor 34A . 34B is positioned and / or the rotor 41 the steering angle sensor device 40 defined with respect to the angle sensor device is positioned.
  • Furthermore, not only are the first magnetic sensors 34A and 34B the torque sensor device 30 and the angle sensor device with the two gears 42 and 43, the associated permanent magnet and the associated second magnetic sensor 42B and the third magnetic sensor 43B each pre-assembled into an assembly, but also the stator 33 with the rotor 41 , where the rotor 41 in this case integral with one of the fixing rings 33D the stator device 33 is formed and together with the mounted stator 33 a preassembled module 50 in the form of a stator module 50 forms.
  • The sensor housing 20 further indicates, based on a functional use state of the sensor device 100 a passage opening extending in the axial direction 21 for the shaft, wherein in a functional use state of the sensor device 100 the magnetic device 31 and / or the stator module 50 rotatable in the passage opening 21 of the sensor housing 20 stored and can be fixed in the axial direction, wherein the magnetic device 31 and / or the stator module can be at least partially inserted into the sensor housing in the axial direction, preferably after the magnetic device 31, the stator module 50 rotatably connected to the shaft. In this case, the magnetic device and / or the stator module 50 in particular in such a way at least partially introduced into the sensor housing in the axial direction, that in a functional use state of the sensor device 100 at least one flux guide 32A . 32B the torque sensor device 30 defined relative to a first magnetic sensor 34A . 34B is positioned and / or the rotor 41 defined with respect to the angle sensor device is positioned.
  • The assembly of the sensor device according to the invention 100 takes place according to the invention by the individual components of the sensor module 10 , At least the angle sensor device of the steering angle sensor device 40 and the first magnetic sensors 34A and 34B, and in this case also the common circuit board 14 and the plug contacts 12 , to an assembly, in particular to the sensor module 10 be pre-assembled, wherein the components of the sensor module in this case of a common sensor module housing 11 be recorded.
  • Further, the rotor 41 and the stator device 33 to a stator module 50 preassembled. Alternatively, the rotor and the stator device can also be produced integrally as a stator module, in particular by the rotor being made of plastic on the stator holder or containing plastic and molded onto the stator holder or produced therewith in one operation.
  • Preferably, the two flux conductors are further 32A and 32B in the radial direction in the sensor housing 20 in particular in the passage opening 21 inserted and in the sensor housing 20 fixed and in this way with the sensor housing 20 to a further assembly in the form of a sensor housing module pre-assembled.
  • Is the sensor housing 20 as in this case, trained in a further housing 60 , in this case a steering gear housing 60 , as in 1b shown to be arranged, in particular in the radial direction R2 , to be inserted or plugged in relation to a functional use state with a mounted shaft, is preferably first the sensor housing 20 with the flux conductors defined therein 32A and 32B pre-assembled to a sensor housing module and then in the radial direction in the other housing 60 inserted or inserted.
  • It is particularly advantageous if the further housing 60 a steering gear housing is. It makes sense to have the other housing 60 or the steering gear housing 60 also a correspondingly formed passage opening 61 up for the wave.
  • Is the sensor housing 20 with the two flux guides 32A and 32B in the steering gear housing 60 are plugged in, then preferably the stator module 50 and the magnetic device 31 in the axial direction R1 in the passage opening 21 of the sensor housing 20 at least partially introduced and in particular such that in a functional use state, the stator module 50 rotatable in the sensor housing 20 is stored, the magnetic device as well.
  • The magnetic device is preferred 31 and the stator module 50 with the shaft, whose sizes by means of the sensor device 100 to be detected, rotatably connected and together with the shaft in the axial direction in the sensor housing 20 introduced.
  • Subsequently, the pre-assembled sensor module 10 in the radial direction R2 into the sensor housing 20 , in particular in the insertion opening 22 be inserted, in particular plugged. This is the pre-assembled sensor module 10 preferably in the sensor housing 20 in the radial direction R2 introduced and positioned that in a functional use state, the first transmission element 42 with the rotor 41 is engaged, in particular with this combs and the first magnetic sensors 34A and 34B the torque sensor device in each case with respect to the tabs 35A and 35B the two flux guides 32A and 32B are positioned with a defined gap in the axial direction.
  • Instead of being arranged in another housing 60 , in particular a steering gear housing 60 Of course, the sensor housing of a sensor device according to the invention can also be designed to be attached to the vehicle body of a motor vehicle. Alternatively, the sensor housing may already be part of another housing, in particular a steering gear housing. In this case, the components of a sensor device according to the invention according to the invention in the other housing or the steering gear housing can be arranged according to the same principle, but the arrangement is carried out directly in the other housing or in the steering gear housing.
  • Protrudes the first gear element 42 or if the second transmission element 43 with the rotor 41 comb, also the second transmission element 43 down from the sensor module housing 11 In addition, it is also possible, first, the sensor module housing 10 in the radial direction R2 into the sensor housing 20 introduce and then the stator 33 , the rotor 41 and the magnetic device 31 in the axial direction R1 introduce. However, it must be ensured that the ring gear of the rotor 41 with the gear 42 or possibly even with the gear 43 can be engaged.
  • In an alternative embodiment of a sensor device according to the invention, the rotor 41 also instead of rotation with the stator 33 to be connected, in particular instead of integral with one of the fixing rings 33D the stator device 33 To be trained, rotatably with the stator holder 33C or also rotatably with the magnetic device 31 be connected, wherein the rotor 41 in the latter case then with the magnetic device 31 forms a magnetic module.
  • Is the rotor 41 not in the axial direction in the middle between the two stator elements 33A and 33B arranged but laterally of these, as in the in the 1a and 1b illustrated, inventive sensor device 100 , in a functional state of use or assembly state of the sensor device according to the invention 100 in particular the common circuit board 14 however, between the two stator elements 33A and 33B so that the second magnetic sensor 42B and the third magnetic sensor 43B between the stator elements 33A and 33B lie, have the two gear elements 42 and 43 As in this case, preferably each one provided for bridging the axial distance shank 42A respectively. 43A on.
  • Are the flux conductors 32A and 32B like the one in the 1a and 1b illustrated sensor device according to the invention 100 formed closed in the circumferential direction, it is advantageous if the sensor housing 20 or, if the components of the sensor device 100 are each arranged directly in another housing, the other housing each one, as the sensor housing from the 1a and 1b Having in the circumferential direction open passage opening, in particular one in the region of the tabs 35A respectively. 35B opened through hole, leaving the flux guide 32A and 32B in the axial direction R1 into the sensor housing 20 can be introduced.
  • Furthermore, it is preferable if the flux guides 32A and 32B are formed closed in the circumferential direction, advantageously, the flux conductors 32A and 32B each with the sensor housing 20 to pre-assemble to a module, in particular a sensor housing module before the stator module 50 as well as the magnetic device 31 and / or the sensor module 10 be inserted into the sensor housing.
  • The 1c shows a further embodiment of two circumferentially closed flux guide 232A and 232B , These flux conductors are designed as stamped and bent parts and can be made according to the flux conductor 1b in the sensor housing 20 be pre-assembled. The tabs 235A and 235B the river conductor 232A and 232B are formed after punching by bending. The substantially annular shape of the flux guides 232A and 232B is also made by a bending process, wherein the respective ends of the substantially annular flux guide 232A and 232B at the connection sections 237A and 237B be connected to each other.
  • In contrast, the flux conductors are open in the circumferential direction, for example as in 2a illustrated flux guide 132A and 132B , the mounting order with regard to the flux conductors is almost arbitrary. Furthermore, it makes sense in this case, the sensor housing as the sensor housing 220 out 2 B form with a closed passage in the circumferential direction 221 ,
  • But it may also be advantageous, the open-formed flux guide 132A and 132B with the sensor housing 220 to pre-assemble into an assembly, in particular to a sensor housing module as in 2 B shown.
  • This in 2 B shown, second embodiment of a sensor device according to the invention 200 not only differs in the differently designed sensor housing 220 and the differently shaped flux conductors 132A and 132B from the basis of the 1a and 1b described first embodiment of a sensor device according to the invention 100 but also that the rotor 141 in this case integral with the stator holder 133C the stator device 133 is formed, wherein the stator holder 133C , the sleeve section 33E as well as the rotor 141 are made as a one-piece plastic injection molded part.
  • The stator elements 33A and 33B are each in the axial direction R1 pushed onto the stator holder and also by means of fixing rings 133D on the stator holder 133C fixed in the axial direction.
  • Further, in this case, the rotor 1414 is centered between the stator elements 33A and 33B and not laterally of these.
  • Due to the axial arrangement of the rotor 141 between the two stator elements 33A and 33B, it is no longer necessary an axial distance to the circuit board 14 to bridge so that each of the shaft 42A respectively. 43A (please refer 1b ) at the gears 42 and 43 can be omitted and the gears 242 and 243 with their permanent magnets corresponding closer to the PCB 14 and the associated magnetic sensors 42A and 42B can be arranged.
  • Is the rotor 41 respectively. 141 as in the previously described sensor device according to the invention 100 and 200 each integral with at least one component of the stator device 33 or 131 formed, in particular as a common plastic injection molded part, can in a particularly simple manner exact positioning of the rotor in the sensor housing 20 respectively. 220 be achieved and thus in particular an accurate positioning of the rotor 41 respectively. 141 relative to the first transmission element 42 or 242, which in a functional use state of a sensor device according to the invention 100 respectively. 200 with the rotor 41 respectively. 141 combs. About the common circuit board 14 as well as the sensor module housing 11 , which in the radial direction R2 into the sensor housing 220 is plugged in and which for receiving the flux conductor 32A and 32B respectively. 132A and 132B Further, accurate positioning of the flux guides with respect to the first magnetic sensors may be provided 34A and 34B the torque sensor device can be achieved, in particular a defined gap between the tabs 35A and 35B respectively. 135A and 135B as well as the first magnetic sensors 34A and 34B of the torque sensor device.
  • Thus, the pre-assembly according to the invention of individual components, in particular of components of the torque sensor device with components of the steering angle sensor device to a common sensor module leads to a particularly simple installation.
  • Furthermore, the arrangement of the magnetic sensors of the torque sensor device, that is, the first magnetic sensors 34A and 34B , together with the magnetic sensors of the angle sensor device, namely the second magnetic sensor 42B and the third magnetic sensor 43B on a common circuit board the advantage that the circuit board can be contacted via a common connector, ie it is not two ports 13 required for connectors and corresponding plug contacts, but only one, whereby a considerable space gain can be achieved.
  • In this case, a variety of modifications, in particular to structural modifications, compared to the illustrated embodiments possible without departing from the content of the claims.
  • LIST OF REFERENCE NUMBERS
  • 100, 200
    Sensor device according to the invention
    10,210
    sensor module
    11
    Sensor module housing
    11A
    first sensor module housing part
    11B
    second sensor module housing part
    12
    plug contacts
    13
    Connector for a connector
    14
    circuit board
    20, 220
    sensor housing
    21, 221
    Through opening for shaft in the sensor housing in the axial direction
    22
    Insertion opening in sensor housing for sensor module in radial direction
    30
    Torque sensor device
    31
    magnetic device
    31A
    ring magnet
    31B
    Sleeve for mounting the magnetic device on the shaft
    32A, 32B, 132A, 132B, 232A, 232B
    river Head
    33, 133
    stator
    33A, 33B
    stator
    33C, 133C
    stator
    33D, 133D
    fixing
    33E
    Sleeve section of the stator holder for mounting the stator device on the shaft
    34A, 34B
    first magnetic sensor of the torque sensor device
    35A, 35B, 135A, 135B, 235A, 235B
    Flaps of the flux conductor
    36A, 36B, 136A, 136B
    Flow conductor body
    237A, 237B
    Connecting sections of the flux conductors
    40
    Steering angle sensor device
    41, 141
    rotor
    42, 242
    first transmission element of the angle sensor device with permanent magnet
    42A, 43A
    shaft
    42B
    second, the first gear member associated magnetic sensor of the angle sensor device
    43, 243
    second transmission element of the angle sensor device with permanent magnet
    43B
    second, the second gear element of the angle sensor device associated magnetic sensor
    50, 150
    stator module
    60
    Steering gear housing
    61
    Through opening of the steering gear housing for the shaft
    62
    Insertion opening of the steering gear housing for the sensor housing
    A
    Rotary axis of the shaft
    R1
    axial direction
    R2
    radial direction
  • QUOTES INCLUDE IN THE DESCRIPTION
  • This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.
  • Cited patent literature
    • DE 10346332 A1 [0007]
    • EP 1584908 A2 [0007]
    • DE 102008011448 A1 [0008, 0009, 0022]
    • DE 19506938 A1 [0008, 0009, 0022, 0031, 0032]
    • DE 19962241 A1 [0008, 0009, 0031]
    • DE 102010033769 A1 [0010, 0022]
    • DE 102012024382 A1 [0010, 0022]
    • DE 10201224383 A1 [0010]
    • DE 102012025280 A1 [0010, 0022]
    • EP 0980081 B1 [0021]
    • EP 1123794 [0021]
    • DE 102013006567 A1 [0021, 0086]
    • DE 102012024383 A1 [0022]
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    • DE 102016124331 [0045, 0094]
    • DE 102015116545 [0086]
    • DE 102015122182 [0086]
    • DE 102015122176 [0086]

Claims (26)

  1. A sensor device (100, 200) for a shaft rotatable about a rotation axis, in particular for a steering shaft of a motor vehicle, wherein the sensor device (100, 200) comprises a torque sensor device (30) for detecting a torque applied to the shaft and a steering angle sensor device (40) for detecting a rotation angle of the shaft, wherein the torque sensor means (30) at least one magnetic means (31) for generating a magnetic field and at least one first magnetic sensor (34A, 34B) (34A, 34B) for generating a sensor signal in response to a torque applied to the shaft and wherein the steering angle sensor device (40) has at least one rotor (41, 141) which can be connected in a rotationally fixed manner to the shaft, and an angle sensor device for generating at least one sensor signal as a function of a rotational angle of the rotor, and wherein the sensor device (100, 200) at least a, to a sensor module (10, 210) vormonti characterized in that at least the first magnetic sensor (34A, 34B) of the torque sensor means (30) and the angle sensor means of the steering angle sensor means (40) are part of the sensor module (10, 210) pre-assembled assembly.
  2. Sensor device (100, 200) after Claim 1 characterized in that the first magnetic sensor (34A, 34B) of the torque sensor device (30) and the angular sensor device of the steering angle sensor device (40) are received by a common sensor module housing (11).
  3. Sensor device (100, 200) after Claim 1 or 2 , characterized in that the angle sensor device comprises at least a first transmission element (42, 242) which forms a transmission with the rotor (41, 141) and in a functional use state of the sensor device (100, 200) with the rotor (41, 141) in Intervention is, wherein the angle sensor device is preferably adapted to generate in response to the rotation angle of the first transmission element (42, 242), a first rotor angle sensor signal.
  4. Sensor device (100, 200) after Claim 3 , characterized in that the first transmission element (42, 242) of the angle sensor device comprises a permanent magnet and the sensor device (100, 200), in particular the angle sensor device, at least one second magnetic sensor (42B) for generating the first rotor angle sensor signal as a function of the rotation angle of first transmission element (42, 242).
  5. Sensor device (100, 200) after Claim 3 or 4 characterized in that the angle sensor means comprises at least one second gear member (43, 243) which forms a gear with the rotor (41, 141) and the first gear member (42, 242), the second gear member (43, 243) in a functional use state of the sensor device (100, 200) preferably with the rotor (41, 141) and / or the first transmission element (42, 242) is engaged, and wherein the angle sensor device is in particular formed, depending on the rotation angle of the second transmission element (43, 243) to generate a second rotor angle sensor signal.
  6. Sensor device (100, 200) after Claim 5 , characterized in that the second transmission element (43, 243) of the angle sensor device comprises a permanent magnet and the sensor device (100, 200), in particular the angle sensor device, at least one third magnetic sensor (43B) for generating the second rotor angle sensor signal as a function of the rotation angle of second transmission element. (43, 243).
  7. Sensor device (100, 200) after Claim 1 or 2 characterized in that the torque sensor means (30) comprises stator means (33, 133) for collecting the magnetic flux of the magnetic field generated by the magnetic means (31) of the torque sensor means (30), the rotor (41, 141) of the steering angle sensor means (40 ) is preferably non-rotatably connected to the stator device (33, 133) or non-rotatably connected to the magnetic device (31) of the torque sensor device (30).
  8. Sensor device (100, 200) after Claim 3 characterized in that the rotor (41, 141) forms a stator module (50, 150) with the stator means (33, 133), the rotor (41, 141) preferably containing plastic and fixed to the stator means (33, 133) is.
  9. Sensor device (100, 200) according to at least one of Claims 1 to 3 , characterized in that the rotor (41, 141) with the magnetic device (31) forms a magnetic module, wherein the rotor (41, 141) preferably contains plastic and in particular to the magnetic device (31) is attached.
  10. Sensor device (100, 200) according to at least one of the preceding claims, characterized in that the sensor device (100, 200), in particular the torque sensor device (30), at least one flux conductor (32A, 32B, 132A, 32B) for transmitting the magnetic flux the first magnetic sensor (34A, 34B) (34A, 34B), wherein the at least one flux guide (32A, 32B; 132A, 32B) is preferably through Forming of a flat strip or a wire is made, in particular in one piece.
  11. Sensor device (200) after Claim 6 , characterized in that the flux guide (132A, 32B) is open in the circumferential direction.
  12. Sensor device (100) after Claim 6 , characterized in that the flux guide (32A, 32B) is closed in the circumferential direction.
  13. Sensor device (100, 200) according to at least one of the preceding claims, characterized in that the sensor device (100, 200) has a sensor housing (20, 220).
  14. Sensor device (100, 200) according to at least one of Claims 6 to 8th combined with Claim 9 , characterized in that at least one flux guide (32A, 32B; 132A, 32B) is mounted in the sensor housing (20, 220), preferably in the sensor housing (20, 220) is fixed.
  15. Sensor device according to at least one of Claims 6 to 8th , wherein at least one flux conductor (32A, 32B, 132A, 32B) is arranged in a functional use state of the sensor device concentric with the stator device (33, 133) and preferably surrounds it at least partially from outside, characterized in that the flux guide (32A, 32B; 132A, 32B) is supported on the stator means (33, 133) in the radial direction via a slide bearing, wherein the flux guide (32A, 32B; 132A, 32B) is preassembled in particular with the stator means (33, 133) to form an assembly.
  16. Sensor device (100, 200) according to at least one of Claims 9 to 11 , characterized in that the sensor housing (20, 220), based on a functional use state of the sensor device (100, 200), in the radial direction (R2) extending insertion opening (22) for the sensor module (10, 210), wherein in a functional state of use of the sensor device (100, 200), the sensor module (10, 210) is inserted into the insertion opening (22) in the radial direction (R2), is preferably plugged in, in particular such that in a functional state of use of the sensor device (100, 200) at least one flux guide (32A, 32B; 132A, 32B) of the torque sensor device (30) is positioned opposite the first magnetic sensor (34A, 34B) and / or the rotor (41, 141) of the steering angle sensor device (40) defined relative to the angle sensor device is positioned.
  17. Sensor device (100, 200) according to at least one of Claims 9 to 12 , characterized in that the sensor housing (20, 220), based on a functional use state of the sensor device (100, 200), in the axial direction (R1) extending through hole (21, 221) for the shaft, wherein in a functionally appropriate Use state of the sensor device (100, 200), the magnetic device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) rotatably mounted in the through hole of the sensor housing and preferably in the axial direction (R1) is fixed , wherein the magnet device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) have been at least partially inserted in the axial direction (R1) into the sensor housing (20, 220), preferably after the magnet device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) have been connected in a rotationally fixed manner to the shaft, the magnet device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) in particular in such a way at least partially in the axial direction (R1) in the sensor housing (20, 220) have been introduced, that in a functional use state of the sensor device (100, 200) at least one flux guide ( 32A, 32B; 132A, 32B) of the torque sensor device (30) is positioned opposite to the first magnetic sensor (34A, 34B) and / or the rotor (41, 141) is positioned in a defined manner relative to the angle sensor device.
  18. Sensor device (100, 200) according to at least one of Claims 10 . 12 or 13 , characterized in that the sensor housing (20, 220) and at least one flux guide (32A, 32B, 132A, 32B) are part of a further module preassembled to a sensor housing module, wherein in particular, based on a functional use state of the sensor device (100, 200), the sensor module (10, 210) and / or the magnetic device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) only in the axial direction (R1) into the sensor housing (20 , 220) after the sensor housing (20, 220) has been preassembled with at least one flux guide (32A, 32B; 132A, 32B) to a sensor housing module.
  19. Sensor device (100, 200) according to at least one of the preceding claims, characterized characterized in that the sensor housing (20, 220) is part of a further housing, preferably part of a connectable to a vehicle body of a motor vehicle housing, in particular part of a steering gear housing, or even forms a connectable to the vehicle body of a motor vehicle housing.
  20. Sensor device (100, 200) according to at least one of Claims 9 to 14 , characterized in that the sensor housing (20, 220) is designed for arrangement in a further housing, in particular for arrangement in a connectable to a vehicle body of a motor vehicle housing, in particular for arrangement in a steering gear housing (60), wherein the sensor housing (20, 220), based on a functional use state of the sensor device (100, 200), preferably in the radial direction (R2) in the further housing is inserted, in particular can be inserted.
  21. Method for assembling a sensor device (100, 200) for a shaft rotatable about a rotation axis, in particular for assembling a device according to at least one of Claims 1 to 16 a sensor device (100, 200), wherein the sensor device (100, 200) has a torque sensor device (30) for detecting a torque applied to the shaft and a steering angle sensor device (40) for detecting a rotational angle of the shaft, wherein the torque sensor device (30) at least a magnetic device (31) for generating a magnetic field and at least one first magnetic sensor (34A, 34B) for generating a sensor signal as a function of a torque applied to the shaft, and wherein the steering angle sensor device (40) at least one rotatably connected to the shaft rotor ( 41, 141) and an angle sensor device for generating at least one sensor signal as a function of a rotational angle of the rotor, characterized by the steps: - providing the components of the sensor device, - pre-assembling at least the first magnetic sensor (34A, 34B) of the torque sensor device (30) and de an angle sensor device of the steering angle sensor device (40) to form a sensor module (10, 210) assembly, and - Assembling the remaining components of the sensor device (100, 200) with the sensor module (10, 210) to the sensor device.
  22. Method according to Claim 17 wherein the sensor device (100, 200) has a stator device (33, 133), characterized in that in a further method step the stator device (33, 133) of the torque sensor device (30) is connected to the rotor (41, 141) of the steering angle sensor device (40 ) is pre-assembled to a stator module (50, 150), wherein subsequently the stator module (50, 150) with the sensor module (10, 210) and the remaining components of the sensor device (100, 200) to the sensor device (100, 200) is assembled.
  23. Method according to Claim 17 or 18 wherein the sensor device (100, 200) has a sensor housing (20, 220) which is designed for arrangement in a further housing, in particular for arrangement in a housing which can be connected to a vehicle body of a motor vehicle, in particular for arrangement in a steering gear housing (60). , characterized in that the sensor housing (20, 220) in a further method step in the further housing (60) is arranged, wherein the sensor housing (20, 220), based on a functional use state of the sensor device (100, 200), preferably in the radial direction (R2) is inserted into the further housing, in particular is plugged.
  24. Method according to at least one of Claims 17 to 19 wherein the sensor device (100, 200) has a sensor housing (20, 220) which, in relation to a functional use state of the sensor device (100, 200), has a through opening (21, 221) extending in the axial direction (R1) for a Has shaft, characterized in that in a further method step, the magnetic means (31) and / or the stator means (33, 133) and / or the rotor (41, 141) rotatably mounted in the passage opening (21, 221) of the sensor housing and preferably in the axial direction (R1), wherein the magnet device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) thereto at least partially in the axial direction (R1) into the sensor housing (20, 220), preferably after the magnet device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) have been connected in a rotationally fixed manner to the shaft and / or after the sensor housing (20, 220) in the we wherein the magnetic device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) is in particular at least partially in the axial direction (R1) in the sensor housing (20, 220). in a functional state of use of the sensor device (100, 200), at least one flux guide (32A, 32B; 132A, 32B) of the torque sensor device (30) is positioned opposite to the first magnetic sensor (34A, 34B) and / or the rotor (41, 141) is positioned in a defined manner relative to the angle sensor device.
  25. Method according to at least one of Claims 17 to 20 wherein the sensor device (100, 200) has at least one flux guide (32A, 32B; 132A, 32B), characterized in that in a further method step at least one flux guide (32A, 32B; 132A, 32B) in the sensor housing (20, 220) is stored, preferably in the sensor housing (20, 220) is fixed, in particular in the interior of the sensor housing in the region of the passage opening, wherein the flux guide (32A, 32B, 132A, 32B) is preferably introduced into the sensor housing (20, 220) before the Magnetic device (31) and / or the stator device (33, 133) and / or the Rotor (41, 141) at least partially in the axial direction (R1) in the sensor housing (20, 220) are introduced.
  26. Method according to at least one of Claims 17 to 21 , wherein the sensor housing (20, 220), based on a functional use state of the sensor device (100, 200), in the radial direction (R2) extending insertion opening (22) for the sensor module (10, 210), characterized in that in a further method step, the sensor module (10, 210) in the radial direction (R2) is inserted into the insertion opening (22), preferably in such a way that in a functional use state of the sensor device (100, 200) at least one flux guide (32A , 32B, 132A, 32B) of the torque sensor device (30) is positioned opposite to the first magnetic sensor (34A, 34B) and / or the rotor (41, 141) of the steering angle sensor device (40) is positioned relative to the angle sensor device, wherein the sensor module ( 10, 210) is preferably plugged into the sensor housing (20, 220) after the magnet device (31) and / or the stator device (33, 133) and / or the rotor (41, 141) has been at least partially introduced in the axial direction (R1) in the sensor housing (20, 220).
DE102016124370.1A 2016-12-14 2016-12-14 Sensor device and method for assembling a sensor device Pending DE102016124370A1 (en)

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