Wheel speed sensor and method of manufacturing the same

Abstract

The application relates to a wheel speed sensor, characterized in that the wheel speed sensor comprises a sensor main body and a flange plate which are independently manufactured and installed together, the sensor main body is intended to be connected to a wheel via the flange plate to detect the wheel speed; the sensor main body comprises a chip area and a mounting area for mounting the flange plate, the mounting area comprises a mounting structure, the flange plate comprises a flange for being connected to a wheel and a mounting part for being connected to the mounting structure; wherein the angle orientation and / or height distance of the mounting structure relative to the chip area are different according to the mounting requirements of the flange plate. The application avoids repeated development of molds through a unique mounting structure design, and saves manufacturing costs. The application also relates to a method for manufacturing a wheel speed sensor.

Description

Technical Field

[0001] This invention relates to the field of automotive wheel speed detection technology, specifically to a wheel speed sensor and its manufacturing method. Background Technology

[0002] Currently, wheel speed sensors are increasingly widely used in automobiles and are among the most critical sensors in vehicles. For example, vehicle dynamic control systems (VDC), electronic stability programs (ESP), anti-lock braking systems (ABS), and automatic transmission control systems all require wheel speed information measured by wheel speed sensors.

[0003] In traditional wheel speed sensor manufacturing, injection molding is typically used to wrap the sensor chip, sensor cable, and metal flange with injection molding material to meet the requirements for sealing and installation of the chip.

[0004] Traditional wheel speed sensors are molded as a single unit. This means that even for different sensor heads, differences in flange direction or height necessitate the creation of a new injection mold, leading to high mold development and production costs and long lead times. Furthermore, using different molds means each sensor head design is relatively independent, requiring a series of tests for each design, including high and low temperature shock, environmental resistance, chemical resistance, physical impact, and electromagnetic compatibility. This results in high testing costs, long testing cycles, and the consumption of experimental resources. All these drawbacks indirectly increase the production cost of wheel speed sensors.

[0005] Therefore, there is a need for a new type of wheel speed sensor and its manufacturing method, which can overcome at least some of the defects in the prior art. Summary of the Invention

[0006] One object of the present invention is to provide a wheel speed sensor that is adapted to different flange mounting requirements with a simple design, while reducing research and development and manufacturing costs.

[0007] Another object of the present invention is to provide a method for manufacturing the above-mentioned wheel speed sensor, which can easily manufacture different wheel speed sensors according to different flange installation requirements.

[0008] Therefore, the present invention proposes the following technical solution:

[0009] A wheel speed sensor, characterized in that the wheel speed sensor comprises a sensor body and a flange, which are independently manufactured and mounted together, the sensor body being intended to be connected to a wheel via the flange to detect wheel speed; the sensor body includes a chip region and a mounting region for mounting the flange, the mounting region including a mounting structure, the flange including a flange for connecting to the wheel and a mounting portion for connecting to the mounting structure; wherein the angular orientation and / or height distance of the mounting structure relative to the chip region varies according to the mounting requirements of the flange.

[0010] According to one aspect of the invention, the mounting structure on the sensor body and the mounting portion on the flange are connected by threaded connection, welding, bonding or hot-melt joint.

[0011] According to one aspect of the invention, the sensor body includes an elongated tube portion, and the mounting area includes a plurality of ribs that project radially and extend longitudinally around the elongated tube portion, wherein, according to the mounting requirements of the flange, the mounting structure consists of two parts: one is at least one of the plurality of ribs having a specific angular orientation relative to the chip region, and the other is at least one mounting hole provided on the rib at a specific longitudinal position relative to the chip region.

[0012] According to one aspect of the invention, the mounting portion of the flange includes at least one post for insertion into the mounting hole on the sensor body to achieve connection between the flange and the sensor body.

[0013] According to one aspect of the invention, the plurality of ribs are integrally formed on the elongated tubular portion of the sensor body, and the column is integrally formed on the flange.

[0014] According to one aspect of the invention, two mounting holes are provided on two ribs spaced apart by a central rib, which are located at the same longitudinal position relative to the chip region. The mounting portion of the flange includes two parallel pillars for connecting to the two mounting holes respectively, and an embedding area located between the two parallel pillars, the embedding area having an internal contour adapted to the shape of the central rib for fitting into the central rib.

[0015] The present invention also relates to a method for manufacturing a wheel speed sensor, the wheel speed sensor comprising a sensor body and a flange, the sensor body being intended to be connected to a wheel via the flange to detect wheel speed, characterized in that the method comprises the following steps:

[0016] a) Manufacturing the sensor body, including forming a chip region and a mounting region for mounting the flange, wherein, according to the mounting requirements of the flange, a mounting structure with a specific angular orientation and / or a specific height distance relative to the chip region is determined on the mounting region;

[0017] b) Manufacturing the flange, including forming a flange for connection to a wheel and a mounting portion for connection to the mounting structure;

[0018] c) Connect the mounting part of the flange to the mounting structure on the sensor body to form the wheel speed sensor.

[0019] According to one aspect of the invention, step a) includes forming the sensor body to include an elongated tube portion and forming a plurality of ribs that project radially and extend longitudinally around the elongated tube portion to form the mounting area, wherein, according to the mounting requirements of the flange, at least one of the plurality of ribs having a specific angular orientation relative to the chip area is selected, and at least one mounting hole is provided on the rib at a specific longitudinal position relative to the chip area, the at least one rib and the at least one mounting hole constituting the mounting structure.

[0020] According to one aspect of the invention, step b) includes forming at least one column in the mounting portion of the flange; and

[0021] Step c) includes inserting the column into the mounting hole on the sensor body to connect the flange to the sensor body.

[0022] According to one aspect of the invention, step a) includes selecting two ribs from the plurality of ribs that are spaced apart by an intermediate rib, based on the installation requirements of the flange, and providing two mounting holes on the two ribs at specific, identical longitudinal positions relative to the chip region.

[0023] Step b) includes forming two parallel columns in the mounting portion of the flange, and forming an embedding area between the two parallel columns, the embedding area having an internal contour adapted to the shape of the intermediate rib; and

[0024] Step c) includes fitting the embedding area onto the intermediate rib and inserting the two parallel pillars into the two mounting holes respectively and connecting them by hot-melt pillars.

[0025] By adopting the above technical solution, the present invention can produce at least one of the following beneficial technical effects:

[0026] 1) According to the present invention, the wheel speed sensor includes a sensor body and a flange that are manufactured independently. After the sensor body is manufactured, the mounting structure on the sensor body is determined according to the specific installation requirements of the flange (including orientation and / or height position). Therefore, compared with the traditional wheel speed sensor manufacturing method of integral injection molding, the present invention only requires one mold development and production for a sensor body (and possibly a flange), avoiding the time and money costs of multiple mold development and production, and simplifying the development process.

[0027] 2) According to the present invention, only one type of sensor body needs to be manufactured, and therefore only one type of sensor body needs to be tested for verification. All wheel speed sensors using this type of sensor body can refer to this test report, which greatly reduces the test cost and shortens the development cycle of wheel speed sensors.

[0028] 3) According to the present invention, the mounting structure on the sensor body can be achieved by selecting a protruding rib with a specific orientation and setting a mounting hole at a specific longitudinal position thereon. This can well adapt to different mounting directions and height position requirements of the flange, and the mounting hole is very easy to process in the production line, enabling automated production.

[0029] 4) According to the present invention, the mounting portion of the flange may include a protruding column integrally formed with the flange, and the column and the mounting hole on the sensor body may be joined by a hot melt column process, thereby enabling the wheel speed sensor to be assembled in a simple manner. Attached Figure Description

[0030] Figure 1a This is a schematic diagram of the sensor body of a wheel speed sensor according to an exemplary embodiment of the present invention before the mounting structure is determined;

[0031] Figure 1b This is a schematic diagram of the sensor body of the wheel speed sensor according to this exemplary embodiment of the present invention after the mounting structure has been determined;

[0032] Figure 1c This is a schematic diagram of the flange of a wheel speed sensor according to this exemplary embodiment of the present invention;

[0033] Figure 2a This is a schematic diagram of the installation of the sensor body and flange of the wheel speed sensor according to this exemplary embodiment of the present invention;

[0034] Figure 2b This is a schematic diagram of the sensor body and flange of the wheel speed sensor according to this exemplary embodiment of the present invention after installation and before the hot melt column;

[0035] Figure 2c This is a schematic diagram showing the sensor body and flange of the wheel speed sensor according to this exemplary embodiment of the present invention being installed by a hot-melt column;

[0036] Figures 3a-3f These are schematic diagrams of different exemplary wheel speed sensors obtainable according to the present invention, wherein flanges are mounted on the sensor body in different orientations and at different heights;

[0037] Figure 4 This is a schematic diagram of the process of the hot-melt column used in the wheel speed sensor manufacturing method according to the present invention; and

[0038] Figure 5 This is a schematic flowchart of a wheel speed sensor manufacturing method according to an exemplary embodiment of the present invention. Detailed Implementation

[0039] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings. This description is given by way of example only and does not constitute a limitation on the present invention.

[0040] The wheel speed sensor according to the present invention comprises a sensor body and a flange that are manufactured independently but mounted together. Figures 1a-1c Exemplary embodiments of the separately manufactured sensor body and flange are shown in the figure.

[0041] Specifically, see Figure 1a The figure shows a schematic diagram of the sensor body of a wheel speed sensor according to an exemplary embodiment of the present invention before the mounting structure is determined. Here, the sensor body includes an elongated tube portion 1, with a chip region 1.1 at one end for mounting a chip thereon to detect the wheel speed when the wheel speed sensor is mounted on a wheel. Adjacent to the chip region 1.1, a mounting region 1.2 is provided on the elongated tube portion for mounting a flange thereon, via which the sensor body is intended to be connected to the wheel. The mounting region 1.2 here takes the form of a plurality of ribs that project radially and extend longitudinally around the elongated tube portion. The number of ribs shown in this figure is four, but is not limited thereto; more or fewer ribs are also possible according to the present invention. Preferably, the sensor body including the aforementioned elongated tube portion, chip region, and mounting region is integrally injection molded. To ensure the sealing, corrosion resistance, and mechanical performance of the sensor body, it is preferably manufactured using nylon 612 (PA612).

[0042] In practical applications, depending on the arrangement of the wheel space where the wheel speed sensor will be installed, it may be necessary to mount the flange on the sensor body at different angles and heights. Specifically, it is conceivable to use the chip area of ​​the sensor body as a reference point, for example, the plane containing the chip as a reference plane, and the longitudinal position of the chip along the sensor body as a reference position, to define the angular orientation and height position of the flange mounted on the sensor body. In other words, by selecting and setting a mounting structure with a specific angular orientation and height distance relative to the chip area in the mounting area of ​​the sensor body, the flange mounted on it can achieve the required angular orientation and height position.

[0043] Figure 1b This diagram illustrates the sensor body of a wheel speed sensor according to an exemplary embodiment of the present invention after the mounting structure has been determined. As shown, based on the mounting requirements of the flange, two ribs 1.4 and 1.5, separated by a middle rib 1.3, are selected from among the plurality of ribs constituting the mounting area for mounting the flange. Therefore, the angle formed by the planes of these two ribs relative to the chip area defines the angular orientation of the flange relative to the chip area. Furthermore, a mounting hole 1.6 is provided at the same height distance relative to the chip area on each of these two ribs to serve as a specific connection structure with the flange. Therefore, the longitudinal position of these two mounting holes along the respective ribs defines the height position of the flange relative to the chip area. It can be seen that in this exemplary embodiment, the two ribs with a specific orientation and the mounting holes provided at specific heights together constitute the mounting structure of the sensor body. This mounting structure is determined according to the specific mounting requirements of the flange and is therefore variable, allowing for the configuration of various wheel speed sensors.

[0044] Figure 1c This is a schematic diagram of a flange for a wheel speed sensor according to an exemplary embodiment of the present invention. The flange 2 includes a centrally located hollow flange 2.1, typically a metal flange, for mounting the wheel speed sensor, formed by combining the sensor body and the flange, onto a wheel (e.g., by bolts passing through the flange). The portion of the flange 2 for mounting to the sensor body includes an insert region 2.2 and two parallel posts 2.3. The insert region 2.2 has a recessed shape adapted to the shape of a protruding rib of the sensor body for fitting into the protruding rib. The two posts 2.3 are located on two legs separated by the insert region 2.2, respectively, and are designed to insert into... Figure 1b The two mounting holes 1.6 of the rib shown. Preferably, the flange including the above-mentioned embedding area and the two pillars is integrally injection molded by overlaying the injection molding material onto the metal flange. For example, nylon 6 (PA6) or polybutylene terephthalate (PBT) can be used for injection molding.

[0045] Figure 2a This is a schematic diagram of the installation of the sensor body and flange of the wheel speed sensor according to the above exemplary embodiment of the present invention, in which it can be seen that the two pillars of the flange are respectively inserted into the mounting holes on the corresponding two ribs.

[0046] Figure 2b This is a schematic diagram of the sensor body and flange of the wheel speed sensor according to the above exemplary embodiment of the present invention after installation and before the hot-melt column, in which it can be seen that the two columns have been inserted into the corresponding mounting holes, but have not yet been fixed thereto.

[0047] Figure 2c This is a schematic diagram showing the sensor body and flange of a wheel speed sensor according to an exemplary embodiment of the present invention assembled by thermofusion pins. Through the thermofusion pin connection process, which will be described in detail below, the free ends of the two pins of the flange passing through the mounting holes form "mushroom heads" riveted to the mounting holes, thereby securely mounting the flange onto the sensor body to form the wheel speed sensor according to the present invention.

[0048] Figures 3a-3f These are schematic diagrams of various exemplary wheel speed sensors obtainable according to the present invention, wherein flanges are mounted on the sensor body at different orientations and heights. Therefore, by providing unique mounting structures on the sensor body, the present invention enables the easy acquisition of a wide variety of wheel speed sensors based on a single basic sensor body.

[0049] Figure 4 This is a schematic diagram of the hot-melt column process used in the wheel speed sensor manufacturing method according to the present invention. As shown in the figure, after the column of the flange has been inserted into the mounting hole of the sensor body, the hot-melt head 3 of the hot-melt machine presses downward onto the protruding free end 3.1 of the column, which can be referred to as the "hot-melt column" in this process. The high temperature of the hot-melt head 3 softens the material of the free end 3.1 and, under the pressure of the hot-melt head, rivets it onto the corresponding mounting hole, forming a cap-shaped rivet joint 3.2, commonly referred to as a "mushroom head". This hot-melt column connection process is particularly suitable for the assembly and fixing of components in plastic products.

[0050] It should be noted that the specific structural forms of the sensor body mounting structure and the flange mounting portion described above with reference to the accompanying drawings are not limiting or unique. For example, it is conceivable to select only one rib on the sensor body, fit the flange insert into this rib, and glue or weld it thereto. This solution avoids drilling holes in the rib and avoids setting pillars on the flange. Alternatively, it is conceivable to drill holes in a selected rib and holes in the two legs on both sides of the flange insert, so that the flange can be mounted on the sensor body by threaded fasteners passing through these holes. Or, it is conceivable that the sensor mounting area is a simple cylindrical shape with mounting holes, welding areas, or adhesive areas, and the flange mounting portion includes two arc-shaped legs adapted to the contour of the cylinder, so that the flange can be fixed to the sensor body by screw connection, welding, or adhesive bonding.

[0051] In fact, regardless of the specific structure of the sensor body and the flange mounting section, as long as the angle orientation and / or height distance of the designed mounting structure relative to the chip area can be changed according to the installation requirements of the flange, the purpose of this invention can be achieved.

[0052] Figure 5 A schematic flowchart illustrating a method for manufacturing a wheel speed sensor according to an exemplary embodiment of the present invention is shown. The wheel speed sensor includes a sensor body and a flange, the sensor body being designed to be connected to a wheel via the flange to detect wheel speed.

[0053] Specifically, Figure 5 The method shown includes the following steps:

[0054] Step a): Manufacturing the sensor body, which includes the following sub-steps:

[0055] Step a1): The sensor body, comprising an elongated tube, a chip region, and a mounting region, is formed by integral injection molding, wherein the chip region is located at one end of the elongated tube, the mounting region is adjacent to the chip region, and includes a plurality of ribs that project radially and extend longitudinally around the elongated tube; and

[0056] Step a2): Based on the installation requirements of the flange, select two ribs that are separated by an intermediate rib and have a specific angular orientation relative to the chip area from the plurality of ribs, and set two mounting holes at specific identical longitudinal positions on the two ribs relative to the chip area, thereby determining the mounting structure for connecting to the flange.

[0057] Step b): The flange is integrally injection molded by covering the metal flange with injection molding material, wherein two parallel pillars are formed in the portion of the flange for connection to the sensor body, and an embedding area is formed between the two parallel pillars, the embedding area having an internal contour adapted to the shape of the intermediate rib; and

[0058] Step c): Fit the flange's embedding area onto the middle rib, and insert the two parallel pillars into the two mounting holes on the sensor body, respectively. Use hot-melt pillars to rivet and fix the two parallel pillars into the two mounting holes, thereby completing the installation of the wheel speed sensor.

[0059] As can be seen from the above, Figure 5 The exemplary method shown corresponds to Figures 1a-3f The diagram illustrates a specific structural form of the wheel speed sensor, but this is clearly not limiting. When the specific structural form of the wheel speed sensor to be manufactured changes, the specific steps of the manufacturing method will also change accordingly, but all will fall within the scope of this invention. Furthermore, the order of steps a) and b) above can also be interchanged.

[0060] Each step of the wheel speed sensor manufacturing method according to the present invention can be completed on an automated production line, thus effectively reducing manufacturing costs and shortening processing time.

[0061] While the present invention has been disclosed above with reference to preferred embodiments, it is not limited thereto. Any modifications and alterations made by those skilled in the art without departing from the spirit and scope of the invention should be included within the scope of protection of the invention. Therefore, the scope of protection of the invention should be determined by the scope defined in the claims.

Claims

1. A wheel speed sensor, characterized by, The wheel speed sensor comprises a sensor main body and a flange plate which are manufactured independently and assembled together, the sensor main body is intended to be connected to a wheel via the flange plate to detect wheel speed; the sensor main body comprises a chip area and a mounting area for mounting the flange plate, the mounting area comprises a mounting structure, the flange plate comprises a flange for connecting to a wheel and a mounting portion for connecting to the mounting structure; wherein the angular orientation and / or the height distance of the mounting structure relative to the chip area are different according to the mounting requirements of the flange plate; wherein the sensor main body comprises an elongated tube portion, the mounting area comprises a plurality of rib portions which protrude radially around the elongated tube portion and extend longitudinally, wherein according to the mounting requirements of the flange plate, the mounting structure is composed of at least one rib portion in the plurality of rib portions which has a specific angular orientation relative to the chip area and at least one mounting hole provided on the rib portion at a specific longitudinal position relative to the chip area.

2. The wheel speed sensor of claim 1, wherein, The connection between the mounting structure on the sensor main body and the mounting portion on the flange plate is achieved by threaded connection, welding, bonding or hot melt column.

3. The wheel speed sensor of claim 1, wherein, The mounting portion of the flange plate comprises at least one column which is inserted into the mounting hole on the sensor main body to achieve the connection of the flange plate and the sensor main body.

4. The wheel speed sensor of claim 3, wherein, The plurality of rib portions are integrally formed on the elongated tube portion of the sensor main body, and the column is integrally formed on the flange plate.

5. The wheel speed sensor of claim 3, wherein, Two mounting holes which are located at the same longitudinal position relative to the chip area are provided on two rib portions which are spaced apart by an intermediate rib portion, and the mounting portion of the flange plate comprises two parallel columns for connecting with the two mounting holes respectively, and an embedded area located between the two parallel columns, the embedded area has an internal contour which is matched with the shape of the intermediate rib portion for fitting on the intermediate rib portion.

6. A method for manufacturing a wheel speed sensor, the wheel speed sensor comprising a sensor body and a flange, the sensor body being intended to be connected to a wheel via the flange for detecting a wheel speed, characterized in that, The method comprises the following steps: a) manufacturing the sensor main body, including forming a chip area and a mounting area for mounting the flange plate, wherein according to the mounting requirements of the flange plate, the mounting structure on the mounting area which has a specific angular orientation and / or a specific height distance relative to the chip area is determined; b) manufacturing the flange plate, including forming a flange for connecting to a wheel and a mounting portion for connecting to the mounting structure; c) connecting the mounting portion of the flange plate to the mounting structure on the sensor main body, thereby composing the wheel speed sensor; wherein the step a) comprises forming the sensor main body to comprise an elongated tube portion, and forming a plurality of rib portions which protrude radially and extend longitudinally around the elongated tube portion to constitute the mounting area, wherein according to the mounting requirements of the flange plate, at least one rib portion in the plurality of rib portions which has a specific angular orientation relative to the chip area is selected, and at least one mounting hole is provided on the rib portion at a specific longitudinal position relative to the chip area, the at least one rib portion and the at least one mounting hole constitute the mounting structure.

7. The method for manufacturing a wheel speed sensor according to claim 6, wherein, said step b) comprises forming at least one post in the mounting portion of the flange plate; and said step c) comprises inserting the post into the mounting hole on the sensor body to achieve the connection of the flange plate and the sensor body.

8. The method for manufacturing a wheel speed sensor according to claim 6, wherein, said step a) comprises selecting two ribs among the plurality of ribs which are spaced apart by an intermediate rib according to the mounting requirement of the flange plate, and setting two mounting holes at specific same longitudinal positions relative to the chip region on the two ribs; said step b) comprises forming two parallel posts in the mounting portion of the flange plate, and forming an inlay region between the two parallel posts, the inlay region having an internal profile adapted to the shape of the intermediate rib; and said step c) comprises fitting the inlay region on the intermediate rib, and inserting the two parallel posts into the two mounting holes respectively and connecting by a hot melt post.

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