Height sensor for a vehicle chassis

Abstract

The utility model discloses a height sensor for vehicle chassis, include: sensor fixed seat, the sensor fixed seat inside is fixed with sensing element through injection molding process, rocker, the rocker inside is fixed with magnetic element through injection molding process, the sensor fixed seat with the rocker is detachably connected through the joint structure, when the rocker relative the sensor fixed seat rotates, the position change of magnetic element is detected with sensing element and is converted into electric signal, the utility model discloses a sensing element and magnetic element are injection molded respectively and are connected with the joint type, fundamentally simplify the sensor structure, realize the innate sealing of core element, and the process complexity is reduced greatly and improves the dismouting maintenance convenience and structural reliability of product.

Description

Technical Field

[0001] This utility model relates to the field of sensor technology, and in particular to a height sensor for vehicle chassis. Background Technology

[0002] Vehicle height sensors are important components in modern automotive electronic systems. They are mainly used to detect the relative displacement or sway angle changes of the vehicle suspension and convert mechanical motion into electrical signals, providing key input signals for automatic headlight leveling systems and air suspension systems.

[0003] Currently, the mainstream vehicle height sensors on the market mainly adopt the following two technical solutions: The first type is the traditional split structure. Its construction includes: a sensor housing fixed to the vehicle body, with a printed circuit board (PCB) installed inside, and a Hall effect chip soldered onto the PCB; a rocker arm mounted on the housing via a metal shaft and bearings; and a magnet fixed to the rocker arm. The rocker arm is connected to the suspension control arm via a linkage. Suspension movement causes the rocker arm to rotate relative to the housing, thereby changing the relative position of the magnet and the chip, and thus generating a changing electrical signal.

[0004] The second type is an improved press-fit structure. This solution aims to simplify the traditional design, and its core lies in using an elastic material (such as rubber or soft plastic) to form at least part of the bearing structure; the rocker arm's shaft is directly press-fitted into this elastic bearing, relying on the friction generated by the elastic deformation of the material to simultaneously achieve rotational connection and fixation. The chip sensing element is located on the sensor housing, and the magnetic sensing element is located on the shaft. However, both of these existing technical solutions have significant drawbacks: 1. Structural complexity and reliability issues: Traditional split-type structures have a large number of parts, requiring multiple assembly processes such as screw fastening, press fitting, and welding, resulting in low production efficiency and cumulative tolerances affecting accuracy. Rotating parts rely on bearings, posing risks of wear and abnormal noise.

[0005] 2. Sealing Defects: Traditional split-type structures rely heavily on a single rubber seal to seal the gap between the shaft and the housing. Under the harsh conditions of long-term exposure to high temperatures, vibrations, water, mud, and salt spray in vehicle chassis, the seal will age, and the soft rubber part will also fatigue, wear, or permanently deform, leading to seal failure. Once moisture and contaminants enter the sensor, it will cause chip corrosion, magnet performance degradation, or short circuits, ultimately resulting in sensor malfunction.

[0006] 3. Poor maintainability: The assembly structures of both solutions are difficult to disassemble and repair. Once the core components inside the sensor are damaged, repair is difficult and after-sales maintenance costs are high.

[0007] Therefore, there is an urgent need in this field for a vehicle chassis height sensor that is simpler in structure, more reliable in sealing, less complex in manufacturing process, and easier to maintain. Utility Model Content

[0008] To address the aforementioned technical problems, the purpose of this invention is to provide a height sensor for vehicle chassis. This invention fundamentally simplifies the sensor structure by separately injection molding and encapsulating the sensing element and magnetic element, and then connecting them using a snap-fit ​​method. This achieves inherent sealing of the core components, significantly reduces manufacturing complexity, and improves the ease of disassembly and maintenance, as well as structural reliability.

[0009] To achieve the above-mentioned technical objectives and effects, this utility model is implemented through the following technical solution: A height sensor for a vehicle chassis includes: A sensor mounting base, wherein a sensing element is fixed inside the sensor mounting base by injection molding; A rocker arm, wherein a magnetic element is fixed inside the rocker arm by injection molding; The sensor mounting base and the rocker arm are detachably connected via a snap-fit ​​structure; When the rocker arm rotates relative to the sensor base, the position change of the magnetic element is detected by the sensing element and converted into an electrical signal.

[0010] Furthermore, the sensor mounting base has a vertically extending shaft cavity, and the rocker arm has a vertically extending shaft body, which is inserted into the shaft cavity to achieve a rotational engagement.

[0011] Furthermore, the snap-fit ​​structure includes a snap-fit ​​protrusion and a snap-fit ​​groove disposed on the cavity wall of the sensor mounting base, and a mating protrusion and a mating groove disposed on the shaft wall of the rocker arm; the snap-fit ​​protrusion engages with the mating groove and the snap-fit ​​groove engages with the mating protrusion to achieve snap-fit.

[0012] Furthermore, the snap-fit ​​portion between the shaft body and the shaft cavity has a tapered structure.

[0013] Furthermore, the tops of the snap-fit ​​protrusion and the mating protrusion are arc-shaped curved surfaces, and the corresponding mating surfaces of the snap-fit ​​groove and the mating groove are arc-shaped curved surfaces.

[0014] Furthermore, the locking protrusion and the mating groove, as well as the locking groove and the mating protrusion, are fitted with an interference fit.

[0015] Furthermore, the magnetic element is encapsulated in plastic at the end of the rocker arm's shaft.

[0016] Furthermore, the sensing element includes a chip; the magnetic element is a magnet.

[0017] Furthermore, a sealing ring is provided at the junction of the rocker arm and the sensor mounting base.

[0018] Furthermore, the rocker arm includes a lever arm connected to the shaft, and the end of the lever arm is provided with a mechanical interface for connecting to the vehicle suspension system.

[0019] The beneficial effects of this utility model are as follows: 1. This invention directly encapsulates the sensing element and magnetic element within the sensor mounting base and rocker arm via injection molding. This integrated molding method highly integrates multiple parts that would otherwise require separate manufacturing in traditional designs. This high degree of structural integration not only significantly reduces the number of parts, simplifies the product structure, and lowers process complexity, but also reduces cumulative tolerances during assembly. Since the positions of the sensing element and magnetic element are directly ensured by the mold during injection molding, their relative positional accuracy reaches a level that is difficult to achieve with traditional assembly processes, thus improving product precision.

[0020] 2. In this utility model, the sensing element and magnetic element are injection molded during the manufacturing process, thus forming an "inherently sealed structure". This changes the traditional sensor's reliance on the later addition of sealing rings as an "acquired sealing" method, thereby improving the long-term reliability of the sensor in the harsh environment of the vehicle chassis.

[0021] 3. This utility model adopts a snap-fit ​​detachable connection structure, achieving non-destructive assembly and disassembly as well as superior structural reliability through the principle of mechanical interlocking. This connection structure allows for easy assembly of the sensor mounting base and rocker arm with a simple pressing operation, improving assembly efficiency. When a component is damaged, maintenance personnel can quickly separate and replace the individual module. This non-destructive assembly and disassembly feature significantly extends the product lifecycle, improves maintenance convenience, and reduces after-sales maintenance costs and time. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the height sensor for vehicle chassis according to this utility model.

[0023] Figure 2 This is a schematic diagram of the split structure of the height sensor for vehicle chassis according to this utility model.

[0024] Figure 3 This is a cross-sectional view of the height sensor for vehicle chassis according to this utility model.

[0025] In the diagram, 1: sensor mounting base, 11: shaft cavity, 111: snap-fit ​​protrusion, 112: snap-fit ​​groove, 12: sensor chamber, 121: electrical interface, 13: external boss; 2: rocker arm, 21: shaft body, 211: mating protrusion, 212: mating groove, 22: lever arm, 221: mechanical interface; 3: sensing element; 4: magnetic element; 5: connector; 6: sealing ring. Detailed Implementation

[0026] The technical solutions of this utility model will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0027] like Figures 1 to 3 A preferred embodiment of a height sensor for a vehicle chassis is shown, comprising a sensor mounting base 1 and a rocker arm 2; the sensor mounting base 1 and the rocker arm 2 are detachably connected by a snap-fit ​​structure.

[0028] The sensor mounting base 1 has a vertically extending shaft cavity 11 and a horizontally extending sensor compartment 12. The rocker arm 2 includes a vertically extending shaft 21 and a horizontally extending lever arm 22 connected to the shaft 21. The end of the lever arm 22 is provided with a mechanical interface 221 for connecting to the vehicle suspension system. The shaft 21 of the rocker arm 2 is rotatably fitted into the shaft cavity 11 of the sensor mounting base 1 via a snap-fit ​​structure. In addition, an outer boss 13 is provided on the outer periphery of the shaft cavity 11 of the sensor mounting base 1. After the sensor mounting base 1 and the rocker arm 2 are engaged, the outer boss 13 covers the head end of the lever arm 22.

[0029] The snap-fit ​​structure includes a snap-fit ​​protrusion 111 and a snap-fit ​​groove 112 disposed on the cavity wall of the shaft cavity 11 of the sensor fixing seat 1, and a mating protrusion 211 and a mating groove 212 disposed on the shaft wall of the shaft body 21 of the rocker arm 2; the snap-fit ​​protrusion 111 and the mating groove 212 are mated together, and the snap-fit ​​groove 112 and the mating protrusion 211 are mated together, so as to achieve snap-fit.

[0030] The snap-fit ​​part between the shaft body 21 and the shaft cavity 11 has a tapered structure. The snap-fit ​​utilizes the mechanical properties of the inclined surface of the tapered structure, which plays a guiding and self-centering role during assembly, allowing the shaft body 21 to slide into the shaft cavity 11 easily and accurately.

[0031] Furthermore, the tops of the snap-fit ​​protrusion 111 and the mating protrusion 211 are curved surfaces, and the corresponding mating surfaces of the snap-fit ​​groove 112 and the mating groove 212 are also curved surfaces. An interference fit is used between the snap-fit ​​protrusion 111 and the mating groove 212, and between the snap-fit ​​groove 112 and the mating protrusion 211. The curved surface design effectively reduces snap-fit ​​resistance by providing a smooth assembly transition.

[0032] The sensing element 3 is fixed inside the sensing chamber 12 of the sensor mount 1 using an injection molding process; a magnetic element 4 is fixed to the end of the shaft 21 of the rocker arm 2 using an injection molding process. The sensing element 3 includes a chip, and a connector 5 for connecting to the chip is also injection molded inside the sensing chamber 12 of the sensor mount 1; the sensor mount 1 also has an electrical interface 121, into which the connector 5 extends for connection to external devices. The magnetic element 4 is a magnet. When the rocker arm 2 rotates relative to the sensor mount 1, the position change of the magnetic element 4 is detected by the sensing element 3 and converted into an electrical signal. The sensing element 3 and the magnetic element 4 are injection molded during manufacturing, thus forming an "inherently sealed structure," which improves the long-term reliability of the sensor in the harsh environment of the vehicle chassis.

[0033] A sealing ring 6 is provided at the junction of the rocker arm 2 and the sensor mounting base 1. This sealing ring 6 serves as a protective barrier to prevent fine particles such as dust and mud from entering the sensor. It complements the sealing structure formed by injection molding, effectively preventing component wear and significantly improving the long-term durability and reliability of the product in harsh environments.

[0034] The height sensor works as follows: the sensor mount 1 is fixed to the vehicle body or subframe as a static reference; the mechanical interface 221 at the end of the rocker arm 2 is connected to the suspension control arm, which moves with the wheels, via a linkage. When the vehicle encounters bumps or changes in load, the movement of the suspension system is transmitted to the rocker arm 2 via the linkage, causing it to rotate around the shaft 21, which in turn drives the magnetic element 4, encased in plastic within the rocker arm 2, to rotate synchronously. This rotational motion changes the magnetic field distribution between the magnetic element 4 and the sensing element 3 fixed in the sensor mount 1. The sensing element detects the magnetic field change in real time and converts it into a linear electrical signal proportional to the suspension height. This electrical signal is ultimately transmitted to the vehicle ECU, providing accurate height information input to the automatic headlight leveling system and the air suspension system, ensuring that the vehicle maintains optimal lighting performance and driving posture under various operating conditions.

[0035] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention.

[0036] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A height sensor for a vehicle chassis, characterized in that, include: A sensor mounting base, wherein a sensing element is fixed inside the sensor mounting base by injection molding; A rocker arm, wherein a magnetic element is fixed inside the rocker arm by injection molding; The sensor mounting base and the rocker arm are detachably connected via a snap-fit ​​structure; When the rocker arm rotates relative to the sensor base, the position change of the magnetic element is detected by the sensing element and converted into an electrical signal.

2. The height sensor for a vehicle chassis according to claim 1, characterized in that, The sensor mounting base has a vertically extending shaft cavity, and the rocker arm has a vertically extending shaft body, which is inserted into the shaft cavity to achieve a rotational engagement.

3. The height sensor for a vehicle chassis according to claim 2, characterized in that, The snap-fit ​​structure includes a snap-fit ​​protrusion and a snap-fit ​​groove disposed on the cavity wall of the sensor mounting base, and a mating protrusion and a mating groove disposed on the shaft wall of the rocker arm; the snap-fit ​​protrusion engages with the mating groove and the snap-fit ​​groove engages with the mating protrusion to achieve snap-fit.

4. The height sensor for a vehicle chassis according to claim 3, characterized in that, The snap-fit ​​portion between the shaft body and the shaft cavity has a tapered structure.

5. The height sensor for a vehicle chassis according to claim 3, characterized in that, The tops of the snap-fit ​​protrusion and the mating protrusion are arc-shaped curved surfaces, and the corresponding mating surfaces of the snap-fit ​​groove and the mating groove are arc-shaped curved surfaces.

6. The height sensor for a vehicle chassis according to claim 3, characterized in that, The locking protrusion and the mating groove, as well as the locking groove and the mating protrusion, are fitted with an interference fit.

7. The height sensor for a vehicle chassis according to claim 2, characterized in that, The magnetic element is encapsulated in plastic at the end of the rocker arm's shaft.

8. The height sensor for a vehicle chassis according to claim 1, characterized in that, The sensing element includes a chip; the magnetic element is a magnet.

9. The height sensor for a vehicle chassis according to claim 1, characterized in that, A sealing ring is provided at the junction of the rocker arm and the sensor mounting base.

10. The height sensor for a vehicle chassis according to claim 2, characterized in that, The rocker arm includes a lever arm connected to the shaft, and the end of the lever arm is provided with a mechanical interface for connecting to the vehicle suspension system.

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