Sensor module for a motor vehicle

Abstract

A sensor module (18) for a motor vehicle (1000) is proposed, comprising an environment sensor (22) for detecting a vehicle environment, a sensor module tray (28), a drive (30), and an adjustment mechanism (32), wherein the sensor module tray (28) defines a wet area (34) in which the environment sensor (22) and at least a part of the adjustment mechanism (32) are arranged, wherein the sensor module tray (28) forms an interface (36) to a dry area (38), and wherein at least a part of the drive (30) is arranged in the dry area (38) and is connected via the interface (36) to the adjustment mechanism (32) for adjusting the environment sensor (22).

Description

[0001] The invention relates to a sensor module for a motor vehicle. The invention also relates to a vehicle roof with such a sensor module and / or a motor vehicle with such a vehicle roof and / or such a sensor module. State of the art

[0002] Vehicle roofs are a familiar concept in practice. A vehicle roof can, for example, be designed as a roof sensor module, which can be mounted as a separate unit onto the body shell of a passenger car. The vehicle body includes roof rails, which can be longitudinal and / or transverse, serving as the interface to the roof and forming a support structure within the body shell. The vehicle roof comprises a roof skin that forms an outer viewing surface and has sensor viewing areas through which environmental sensors, located beneath the roof skin, can detect the vehicle's surroundings.

[0003] Autonomous or semi-autonomous vehicles include, for example, a roof designed as a sensor roof module (RSM), which is equipped with a variety of environmental sensors. These sensors, integrated into the vehicle roof in a dry area, and which may be lidar sensors, radar sensors, and / or cameras, detect the surroundings of the vehicle and provide corresponding measurement signals to the vehicle's control electronics. This allows the vehicle to determine the current traffic situation and adapt its driving behavior accordingly.

[0004] One of the biggest challenges in developing such RSM systems is to protect the sensitive electronic and mechanical components inside from external influences such as water, dust and temperature fluctuations, while at the same time maintaining the module's mobility and functionality without restriction.

[0005] The integration of a flexible seal is a key focus of current developments. Bellows or waterproof membranes are frequently used for this purpose, designed to ensure complete sealing while still allowing mechanical movement. These flexible structures must guarantee a watertight connection between the module's fixed and moving parts, as well as meet the demands for durability and robustness in challenging environments.

[0006] The complexity of the design and the selection of suitable materials present significant challenges. Both the sealing structure itself and the transition interfaces between the various module components must be precisely executed to ensure the system's long-term functionality and reliability. These requirements lead to increased effort in design, manufacturing, and assembly, while simultaneously ensuring that the systems are cost-efficient and easy to maintain.

[0007] German patent application DE 10 2022 111 627 A1 discloses a sensor module for a motor vehicle, comprising an environmental sensor for detecting the vehicle's surroundings, a drive mechanism, and an adjustment mechanism. A sealing area separates a wet area from a dry area.

[0008] It is therefore an object of the invention to provide an improved sensor module.

[0009] The problem is solved by a sensor module with the features of claim 1.

[0010] Advantageous embodiments of the invention are the subject of the dependent claims. The scope of the invention encompasses all combinations of at least two features disclosed in the description, the claims, and / or the figures. It is understood in particular that linguistic transformations and / or the meaningful substitution of respective terms within the framework of usual linguistic practice, especially the use of synonyms supported by generally accepted linguistic literature, are included in the present disclosure without being explicitly mentioned in their respective formulations.

[0011] In a preferred aspect, a sensor module for a motor vehicle is proposed. The sensor module comprises an environment sensor for detecting the vehicle's surroundings, a sensor module housing, a drive unit, and an adjustment mechanism, wherein the sensor module housing defines a wet area in which the environment sensor and at least part of the adjustment mechanism are arranged, the sensor module housing forming an interface to a dry area, and wherein at least part of the drive unit is arranged in the dry area and connected via the interface to the adjustment mechanism for adjusting the environment sensor.

[0012] The sensor module in this case has a sensor module frame designed as a sensor module tray. The sensor module tray is preferably designed as a tray open at the roof end. The sensor module tray acts as a separating barrier between the wet area, which is located inside the tray, and the dry area, which is located outside the sensor module tray. The sensor module tray thus preferably seals against the vehicle roof skin from the inside. This eliminates the need for a flexible seal, such as a water bag. The interior of the sensor module tray forms the wet area, which serves as the installation space for the wet-area components of the sensor module within the sensor module tray. This allows all components of the sensor module suitable for being located in the wet area to be placed within the sensor module tray (e.g., adjustment mechanism, ambient sensor, and / or cleaning nozzles, etc.).All sensor module components that are unsuitable or only partially suitable for placement in the wet area (defined by their respective IP protection class) can be located outside the wet area in the dry area. The interface in the sensor module housing serves to separate the wet and dry areas. This interface can provide a watertight seal between the wet and dry areas. For this purpose, the interface can, for example, incorporate one or more sealing surfaces to which sealing assemblies can make a tight seal.

[0013] The drive mechanism, in particular, is usually not designed to be waterproof due to its complexity and cost, and is therefore preferably located in a dry area protected from water and / or moisture. For reasons of feasibility, the adjustment mechanism is preferably located in a wet area. To provide a waterproof interface between the drive and the kinematics, the drive and the sensor module housing can each incorporate a sealing interface.

[0014] In this case, it is possible that the drive does not need to be completely sealed. This eliminates the need for expensive, complex, and / or time-consuming sealing of cables and connectors. Furthermore, a cost-effective and simple, and in particular waterproof, interface can be provided. Installation is also simplified with fewer steps. Additionally, flexible sealing, such as a water bag, is unnecessary. This reduces the overall cost of the sensor module.

[0015] In another aspect, it is proposed that the sensor module tray has an opening that forms the interface, with at least part of the adjustment mechanism or at least part of the drive reaching through the opening.

[0016] The opening can, for example, be a penetration in a wall of the sensor module tray. The wall of the sensor module tray can define a rim area around the opening, which is designed for sealing. The opening is preferably dimensioned such that part of the drive or part of the adjustment mechanism can extend through it. This creates a transition between the dry and wet areas that is particularly simple in design and easy to manufacture. "Extending through" means that at least a part or component of the drive or adjustment mechanism projects from the wet area into the dry area or from the dry area into the wet area. The respective part does not have to project completely, but can also project only partially.

[0017] In another aspect, it is proposed that the drive comprises a drive housing, a motor-side bearing and a drive shaft, wherein the drive housing is arranged in the dry area on the sensor module tray, wherein the motor-side bearing extends at least partially through the opening into the wet area, and wherein the drive shaft is arranged in the wet area and is connected to the adjustment mechanism for adjusting the environment sensor.

[0018] The drive housing is preferably mounted in the dry area on an outer wall of the sensor module tray. The outer wall is preferably oriented towards the vehicle interior. The motor-side bearing is preferably coupled to the drive shaft. An integral design is also possible. The drive shaft is located in the wet area and is preferably movably held in a bearing on one side. The drive shaft preferably engages with the adjustment mechanism to adjust the ambient sensor. The motor may have a drive pinion. The drive pinion may be designed as a drive gear.

[0019] In another aspect, it is proposed that the sensor module has a sealing device located between the motor-side bearing and a wall of the sensor module tray surrounding the opening.

[0020] The sealing device can include an O-ring seal. The motor-side bearing preferably has an external running surface for the sealing device. The sealing device preferably slides on the rotating running surface. The sensor module housing preferably includes an internal mounting surface on which the sealing device is arranged. Thus, the sealing device is preferably firmly seated in the sensor module housing. Sealing pressure is preferably ensured radially by appropriately designed diameters, including tolerances, of the first sealing device. However, the sealing device can also be optionally omitted if a purely wet-room solution is not required.

[0021] In another aspect, it is proposed that the sensor module has a second sealing device located between the drive housing and the wall of the sensor module tray surrounding the opening.

[0022] The drive housing preferably has an external running surface for the second sealing element. The second sealing element preferably seals against an internal housing geometry within the drive. Any fixed sealing geometry can be defined between the sensor module housing and the drive housing. Preferably, the second sealing element is an O-ring seal. Sealing pressure is preferably ensured axially (in the mounting direction) by appropriately designed geometries, including tolerances. The second sealing element can optionally be omitted if a purely wet-room solution is not required. Two options can be defined for the drive (with / without a seal).

[0023] In a further aspect, it is proposed that the sensor module has a spindle assembly comprising a coupling element, a bearing and a drive shaft connected to the coupling element, wherein the drive has a coupling interface and a drive housing, wherein the bearing is arranged on the coupling element and extends from the wet area through the opening into the dry area, wherein the coupling interface engages the coupling element from the dry area, and wherein the drive housing is arranged in the dry area on the sensor module tray.

[0024] After the spindle assembly has been mounted, the drive unit is attached to the outside of the sensor module housing. Preferably, the coupling interface (preferably a gear) of a drive motor is inserted into the coupling element of the spindle assembly.

[0025] Preferably, the drive shaft can be supported by a plain bearing and a ball bearing. In this design, the axial forces are preferably absorbed by the ball bearing in the spindle assembly. The drive unit therefore does not have to absorb these axial forces, resulting in quieter operation. Furthermore, the elimination of axial forces within the drive unit leads to reduced power losses due to the simpler design. This allows for the use of a smaller drive unit, which in turn results in a smaller installation space and lower costs. It is also possible to use an existing standard drive unit. The coupling element can be adapted to the respective drive interface.

[0026] In another aspect, it is proposed that the spindle assembly has a sealing arrangement which is arranged, in particular slidingly, between the bearing and a wall of the sensor module tray surrounding the opening.

[0027] The coupling element can have an external running surface for the sealing assembly. The sealing assembly preferably slides on the rotating running surface. The sensor module housing preferably has an internal mounting surface. The sealing assembly preferably includes an O-ring seal. The sealing assembly is preferably firmly seated in the sensor module housing. The separate spindle assembly is preferably first mounted inside the sensor module housing. Here, the coupling element, including the sealing assembly and first bearing, is preferably inserted into the frame interface. Subsequently, the opposing, second bearing is attached to the sensor module housing using the bearing holder.

[0028] In another aspect, it is proposed that the adjustment mechanism has a lever arrangement by which the environmental sensor can be adjusted, and wherein at least part of the lever arrangement is connected to the drive for adjusting the environmental sensor.

[0029] The lever assembly can have multiple levers that enable a rotational and / or translational adjustment movement of the environmental sensor when the lever assembly is driven by the actuator. For example, the drive shaft or drive spindle can engage with a guide lever of the lever assembly and transmit the drive force or drive torque to move the environmental sensor via this lever. The lever assembly can preferably be configured to adjust the environmental sensor between a retracted position and an extended position. The lever assembly can preferably be configured to lock the actuator in the retracted and / or extended position.

[0030] In the present case, a vehicle roof of a motor vehicle comprising at least one such sensor module is also claimed.

[0031] A preferred embodiment of the vehicle roof is designed as a roof sensor module. Such a roof sensor module forms an integrated unit that incorporates components required for the autonomous or semi-autonomous driving of the vehicle in question. The roof sensor module, which can integrate a multitude of functional elements, thus represents a compact unit that is connected by the vehicle manufacturer to a vehicle body or body shell, which includes roof pillars such as side pillars and / or longitudinal pillars. The vehicle roof designed as a roof sensor module is therefore a roof sensor module (RSM) that enables autonomous or semi-autonomous driving of the vehicle in question.

[0032] A motor vehicle equipped with such a roof and designed as an autonomous vehicle drives independently in autonomous driving mode, at least without significant driver intervention. In a semi-autonomous driving mode, the vehicle roof, according to the invention, forms, for example, part of a driver assistance system.

[0033] The vehicle roof may be equipped with a transparent fixed roof section and / or a roof opening system for a roof opening.

[0034] In particular, the vehicle roof forms at least part of the roof of a passenger car. However, it can also be the roof of a commercial vehicle, such as a delivery van, a bus, an autonomous minibus (like a so-called people mover), or a truck tractor.

[0035] The present claim also includes a motor vehicle comprising a sensor module and / or a vehicle roof of the type described above. The vehicle roof preferably forms a roof sensor module (RSM) that can be arranged as a pre-assembled unit on the vehicle body. In other words, a vehicle body shell can be provided with a prefabricated or pre-assembled roof sensor module designed as a roof sensor module.

[0036] It is understood that the aforementioned and subsequently explained embodiments and exemplary embodiments can be implemented not only individually, but also in any combination with one another, without departing from the scope of the present invention. It is also understood that the aforementioned and subsequently explained embodiments and exemplary embodiments relate in an equivalent or at least similar manner to all embodiments of the invention, without each being specifically named.

[0037] Embodiments of the invention are shown schematically in the drawings and are explained below by way of example. Fig. Figure 1 shows a schematic representation of a vehicle roof with a sensor module. Fig. Figure 2 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 3 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 4 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 5 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 6 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 7 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 8 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 9 shows a schematic view of an exemplary embodiment of a sensor module. Fig. Figure 10 shows a schematic view of an exemplary embodiment of a sensor module.

[0038] In Fig. Figure 1 schematically shows a motor vehicle 1000, which has a vehicle body 1002. Furthermore, the motor vehicle 1000 has a roof sensor module 10, which is arranged as a unit on the vehicle body 1002 and forms at least a portion of the vehicle roof 100 of the motor vehicle 1000. The roof sensor module 10 can be provided as a pre-assembled unit. The vehicle roof 100 extends along a longitudinal direction x of the vehicle and along a lateral direction y of the vehicle. The longitudinal direction x of the vehicle is orthogonal to the lateral direction y of the vehicle.

[0039] In alternative versions, the vehicle roof 100 can also refer to a vehicle roof that is not configured as a roof sensor module. Therefore, all versions also refer to such a vehicle roof 100.

[0040] The roof sensor module 10 comprises a surface component 12, which at least partially forms a roof skin 14 of the vehicle roof 100. The roof sensor module 10 comprises, according to Fig. 1. A fixed roof element 16, which forms at least a partially transparent area of ​​the vehicle roof 100. The roof sensor module 10 may, in other or supplementary versions, have a roof opening system comprising a cover element that can be moved to selectively open or close a roof opening.

[0041] The roof sensor module 10, or the vehicle roof 100, has a sensor module 18. The sensor module 18 may have a cover 20. Furthermore, the sensor module 18 has at least one environmental sensor 22 for detecting the vehicle's surroundings. The environmental sensor 22 is configured to detect the vehicle's surroundings via a viewing area 24. The viewing area 24 is located on the cover 20. The environmental sensor 22 can be a lidar sensor and / or a camera and / or a radar sensor and / or an ultrasonic sensor and / or a multi-camera sensor. Other sensors are also conceivable. The environmental sensor 22 preferably has a sensor housing 26.

[0042] The sensor module 18 also includes a sensor module tray 28, a drive 30, and an adjustment mechanism 32.

[0043] The sensor module tray 28 defines a wet area 34 in which the environmental sensor 22 and at least part of the adjustment mechanism 32 are arranged. The sensor module tray 28 forms an interface to a dry area 38. At least part of the drive 30 is arranged in the dry area 38 and connected via the interface to the adjustment mechanism 32 for adjusting the environmental sensor 22. The adjustment mechanism 32 has a lever arrangement (not shown) by which the environmental sensor 22 can be adjusted. At least part of the lever arrangement is connected to the drive 30 for adjusting the environmental sensor 22. Furthermore, a circumferential seal, designated by reference numeral 29, is arranged between the sensor module tray 28 and the roof skin 14.

[0044] The sensor module tray 28 has an opening 40 that forms the interface, wherein at least part of the adjustment mechanism 32 or at least part of the drive 30 extends through the opening, as is particularly evident in the Fig. Figures 7-10 are shown. The sensor module tray 28 has a drain 42 through which water can flow out of the wet area 34.

[0045] The drive 30 comprises a drive housing 44, a motor-side bearing 46, and a drive shaft 48. The drive housing 44 is located in the dry area 38 on the sensor module tray 28. The motor-side bearing 46 extends at least partially through the opening 40 into the wet area 34. The drive shaft 48 is located in the wet area 34 and is connected to the adjustment mechanism 32 for adjusting the environmental sensor 22 (not explicitly shown). The drive shaft 48 is supported by a bracket or bearing 50, which is provided in a base area of ​​the sensor module tray 28. The bearing 50 of the drive shaft 48 is designed to absorb axial and radial forces.

[0046] The sensor module 18 further comprises a sealing device 52, which is arranged between the motor-side bearing 46 and a wall of the sensor module housing 28 surrounding the opening 40. The sensor module 18 may also have a second sealing device (not explicitly shown), which is arranged between the drive housing 44 and the wall of the sensor module housing 28 surrounding the opening 40.

[0047] According to the in the Fig. 9 and Fig.In the embodiment shown in Figure 10, the sensor module 18 has a spindle assembly 56. The spindle assembly 56 comprises a coupling element 58, a bearing 60, and the drive shaft 48, which is connected to the coupling element 58, preferably integrally. The bearing 60 of the spindle assembly 56 is arranged close to the drive 30 to absorb axial forces. This ensures that the spindle assembly 56 is fully supported. The drive 30 is preferably centered by the coupling interface 66 or by a pinion gear and mounted to the sensor module housing 28.

[0048] The drive 30 has a coupling interface 66. The bearing 60 is arranged on the coupling element 58 and extends from the wet area 34 through the opening 40 into the dry area 38. The coupling interface 66 engages the coupling element 58 from the dry area 38. The drive housing 44 is located in the dry area 38 on the sensor module tray 28.

[0049] The spindle assembly 56 further comprises a sealing arrangement 68, which is arranged, in particular in a sliding manner, in a wall of the sensor module tray 28 surrounding the opening 40. Reference symbol list 10 Roof sensor module 12 Surface component 14 Roof membrane 16 fixed roof elements 18 Sensor module 20 Cover 22 Environmental sensor 24 viewing area 26 sensor housings 28 Sensor module tray 30 drive 32 Adjustment mechanism 34 Wet area 38 Dry area 40 Opening 42 Procedure 44 Drive housings 46 engine-side bearings 48 Drive shaft 50 Drive shaft bearing 52 Sealing device 56 Spindle assembly 58 Coupling element 60 Spindle assembly bearing 66 Coupling interface 68 Sealing arrangement 100 vehicle roof 1000 motor vehicles 1002 Vehicle body x Vehicle longitudinal direction y Vehicle width direction

Claims

Sensor module (18) for a motor vehicle (1000), comprising an environment sensor (22) for detecting a vehicle environment, a sensor module tray (28), a drive (30), and an adjustment mechanism (32), wherein the sensor module tray (28) defines a wet area (34) in which the environment sensor (22) and at least a part of the adjustment mechanism (32) are arranged, wherein the sensor module tray (28) forms an interface to a dry area (38), and wherein at least a part of the drive (30) is arranged in the dry area (38) and is connected via the interface to the adjustment mechanism (32) for adjusting the environment sensor (22). Sensor module (18) according to claim 1, wherein the sensor module tray (28) has an opening (40) which forms the interface, wherein at least a part of the adjustment mechanism (32) or at least a part of the drive (30) extends through the opening. Sensor module (18) according to claim 2, wherein the drive (30) comprises a drive housing (44), a drive pinion (46) and a drive shaft (48), wherein the drive housing (44) is arranged in the dry area (38) on the sensor module tray (28), wherein the drive pinion (46) extends at least partially through the opening (40) into the wet area (34), and wherein the drive shaft (48) is arranged in the wet area (34) and is connected to the adjustment mechanism (32) for adjusting the environment sensor (22). Sensor module (18) according to claim 3, wherein the sensor module (18) has a sealing device (52) arranged between the drive pinion (46) and a wall of the sensor module tray (28) surrounding the opening (40). Sensor module (18) according to claim 4, wherein the sensor module (18) has a second sealing device arranged between the drive housing (44) and the wall of the sensor module tray (28) surrounding the opening (40). Sensor module (18) according to claim 2, wherein the sensor module (18) has a spindle assembly (56) comprising a coupling element (58), a bearing (60) and a drive shaft (48) connected to the coupling element (58), wherein the drive (30) has a coupling interface (66) and a drive housing (44), wherein the bearing (60) is arranged on the coupling element (58) and extends from the wet area (34) through the opening (40) into the dry area (38), wherein the coupling interface (66) engages in the coupling element (58) from the dry area (38), and wherein the drive housing (44) is arranged in the dry area (38) on the sensor module tray (28). Sensor module (18) according to claim 6, wherein the spindle assembly (56) has a sealing arrangement (68) which is arranged, in particular slidably, between the bearing (60) and a wall of the sensor module tray (28) surrounding the opening (40). Sensor module (18) according to one of the preceding claims, wherein the adjustment mechanism (32) has a lever arrangement by which the environment sensor (22) is adjustable, and wherein at least a part of the lever arrangement is connected to the drive (30) for adjusting the environment sensor (22). Vehicle roof (100) of a motor vehicle (1000), comprising at least one sensor module (18) according to one of claims 1 to 8. Motor vehicle (1000) comprising a sensor module (18) according to one of claims 1 to 8 and / or a vehicle roof (100) according to claim 9, wherein the vehicle roof (100) forms a roof sensor module (18) which can be arranged as a pre-assembled assembly unit on a vehicle body (1002) of the motor vehicle (1000).

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