A speed sensor and a method of manufacturing the same

Abstract

This invention provides a speed sensor and its manufacturing method. The speed sensor includes a sensor detection unit and a flange. The flange includes a first flange flap and a second flange flap, which are combined to form the flange. The combined first and second flange flaps form a receiving hole for accommodating the sensor detection unit. This invention's speed sensor and manufacturing method solve the problems existing in the prior art, achieving standardization, universality, and flexibility in speed sensor manufacturing, and significantly shortening the development cycle and reducing manufacturing costs.

Description

Technical Field

[0001] This invention belongs to the field of detection technology, and in particular relates to a speed sensor and its manufacturing method. Background Technology

[0002] Current speed sensors are manufactured using resin injection molding to meet practical installation requirements. Once manufactured, the height of the sensing surface (the sensing end of the sensor head) from the flange and the phase angle are fixed and cannot be adjusted. To match the installation requirements of different customers under different working conditions, speed sensors with different structures need to be designed and different molds developed to manufacture these sensors. This obviously consumes a significant amount of manpower and resources. Furthermore, for some customers with similar installation requirements, designing similar sensor structures requires developing two different sets of molds, also resulting in resource waste. Moreover, the mold development cycle for new products is long, and extensive testing and verification are required afterward, which obviously cannot meet customer time constraints. Therefore, how to achieve standardization, flexibility, and universality of speed sensors, as well as shorten the development cycle and reduce costs, is a pressing problem to be solved in this field. Summary of the Invention

[0003] In order to overcome the shortcomings of the prior art, this invention provides a speed sensor and its manufacturing method, which realizes the standardization and universality of speed sensor manufacturing, and enables flexible assembly according to different needs, greatly shortening the development cycle and manufacturing cost.

[0004] To achieve the above objectives, the present invention provides a speed sensor, including a sensor detection part and a flange. The flange includes a first flange flap and a second flange flap, which are combined to form a receiving hole that can accommodate the sensor detection part.

[0005] Preferably, the sensor detection unit, the first flange, and the second flange are fixedly connected to each other.

[0006] Preferably, the first flange and the second flange are constructed as two separate, independent components.

[0007] Preferably, the first flange and the second flange are constructed as a single unit that is partially connected and can be hinged relative to each other.

[0008] Preferably, the sensor detection unit, the first flange, and the second flange are fixed together by ultrasonic welding.

[0009] Preferably, the surfaces where the first flange and the second flange contact are provided with weld lines.

[0010] Preferably, the outer wall of the sensor detection part is provided with a plurality of positioning ribs, which extend along the direction in which the sensor detection part extends.

[0011] Preferably, a plurality of grooves are formed on the inner wall of the receiving hole formed by the first flange and the second flange, and the grooves can accommodate the positioning rib.

[0012] Preferably, the number of grooves and the number of positioning ribs are the same, and they are all evenly distributed in the circumferential direction.

[0013] To achieve the above objectives, the present invention also provides a method for manufacturing a speed sensor, the method comprising at least the following steps:

[0014] The steps of manufacturing the sensor detection unit, the first flange, and the second flange respectively;

[0015] The step of assembling the sensor detection unit, the first flange, and the second flange together;

[0016] The step of fixing the sensor detection unit, the first flange, and the second flange together in pairs.

[0017] Preferably, the fixing step includes fixing the sensor detection part, the first flange and the second flange together by ultrasonic welding.

[0018] Preferably, the assembly step includes assembling the sensor detection unit relative to the first flange and the second flange at preset values ​​in terms of axial distance and circumferential angle.

[0019] Compared with existing technologies, the speed sensor and its manufacturing method of the present invention adopt a split structure to manufacture the traditional one-piece injection molded speed sensor. That is, the speed sensor is divided into three components: a sensor detection unit, a first flange, and a second flange. Each component can be standardized and universally produced. According to the customer's different working conditions, the required speed sensor can be obtained simply by assembling and welding the three components according to different requirements, resulting in greater assembly flexibility. Therefore, the technical solution of the present invention effectively avoids the waste of manpower and resources caused by the development of too many molds, improves production efficiency, reduces costs, and shortens the development cycle of new products. Attached Figure Description

[0020] Figure 1 This is a three-dimensional schematic diagram of a speed sensor according to a preferred embodiment of the present invention;

[0021] Figure 2 This is an exploded view of a speed sensor according to a preferred embodiment of the present invention;

[0022] Figure 3 This is a schematic diagram of the first flange of a preferred embodiment of the present invention;

[0023] Figure 4 This is a schematic diagram of the second flange of a preferred embodiment of the present invention. Detailed Implementation

[0024] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.

[0025] In the following description, numerous specific details are set forth to enable those skilled in the art to more fully understand the invention. However, it will be apparent to those skilled in the art that implementation of the invention may not include some of these specific details. Furthermore, it should be understood that the invention is not limited to the specific embodiments described. Rather, the invention can be practiced with any combination of the following features and elements, regardless of whether they relate to different embodiments. Therefore, the following aspects, features, embodiments, and advantages are for illustrative purposes only and should not be construed as elements or limitations of the claims unless expressly set forth in the claims. Furthermore, the use of directional terms such as up, down, left, right, upper, lower, etc., in this document is merely for convenience of description based on the relative positions of components in the current drawings and should not be construed as a limitation on the scope of protection.

[0026] Figure 1 This is a three-dimensional schematic diagram of a speed sensor according to a preferred embodiment of the present invention; Figure 2 This is an exploded view of a speed sensor according to a preferred embodiment of the present invention.

[0027] See Figure 1 and Figure 2 In one embodiment of the present invention, a speed sensor is provided, including a sensor detection unit 10 and a flange 20. The sensor detection unit 10 is constructed as a separate component formed from a chip, pins, etc., using resin or plastic material through an injection molding process. The flange 20 includes a first flange flap 21 and a second flange flap 22. Figure 2 As shown, the first flange 21 and the second flange 22 are constructed as two separate independent components. Alternatively, in other embodiments, the first flange 21 and the second flange 22 may be constructed as a partially connected, hinged assembly. The first flange 21 and the second flange 22, when combined, form a flange 20, which in turn forms a receiving hole for accommodating the sensor detection unit 10. During assembly, the sensor detection unit 10 can move axially and rotate circumferentially within the receiving hole of the flange 20 to adjust the axial distance and circumferential phase angle of the sensor detection unit 10's head sensing surface 102 relative to the flange 20.

[0028] Figure 3This is a schematic diagram of the first flange of a preferred embodiment of the present invention; Figure 4 This is a schematic diagram of the second flange of a preferred embodiment of the present invention.

[0029] See Figure 3 and Figure 4 The first flange 21 has welding lines 211 on the surface of the receiving hole that contacts the sensor detection unit 10. Preferably, there are three parallel welding lines 211 spaced apart. The first flange 21 also has mounting holes 213 through which fixing bolts can pass. The second flange 22 also has welding lines 221 on the surface of the receiving hole that contacts the sensor detection unit 10 and the surface that contacts the first flange 21. Preferably, there are three parallel welding lines 221 spaced apart. The welding lines 211 and 221 can be molten after being heated by a welding process, especially ultrasonic welding. When the sensor detection unit 10, the first flange 21, and the second flange 22 are assembled together, the welding lines between them are heated to a molten state through welding, filling the gaps between each pair of components with the molten welding line material. After cooling, the three components are firmly fused together, ultimately forming a speed sensor that meets the requirements.

[0030] Furthermore, such as Figure 2 As shown, the outer wall of the sensor detection unit 10 is provided with a plurality of positioning ribs 101, which extend along the extension direction of the sensor detection unit 10. The inner walls of the receiving holes of the first flange 21 and the second flange 22 that contact the sensor detection unit 10 are respectively provided with a plurality of grooves 212 and 222. These grooves 212 and 222 can accommodate the plurality of positioning ribs 101 on the sensor detection unit 10. The number of grooves 212 and 222 is not less than the number of positioning ribs 101, so that all positioning ribs 101 can be accommodated in these grooves 212 and 222. Preferably, the number of grooves 212 and 222 is the same as the number of positioning ribs 101, and they are all evenly distributed in the circumferential direction.

[0031] During assembly, the positioning ribs 101 of the sensor detection unit 10 can slide in the grooves 212 and 222 to adjust the axial distance between the head sensing surface 102 of the sensor detection unit 10 and the flange 20; and the grooves 212 and 222 can provide circumferential positioning for the positioning ribs 101 so as to keep the sensor detection unit 10 relative to the flange 20 at a predetermined circumferential angle.

[0032] In one embodiment of the present invention, a method for manufacturing the above-described speed sensor is also provided.

[0033] The manufacturing method includes at least the following steps:

[0034] The component pre-manufacturing step involves manufacturing three components: the sensor detection unit 10, the first flange 21, and the second flange 22. These three components can be manufactured in one or more batches using injection molding or other processes.

[0035] The component assembly step involves assembling the sensor detection unit 10, the first flange 21, and the second flange 22 together as required. During assembly, the axial distance and circumferential phase angle of the sensor detection unit 10 relative to the first flange 21 and the second flange 22 are adjusted to preset values ​​according to customer requirements.

[0036] In the fastening step, the sensor detection unit 10, the first flange 21 and the second flange 22 are fastened together by fusion welding, such as ultrasonic welding, to form the final speed sensor product.

[0037] 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 speed sensor comprising a sensor detecting portion and a flange, characterized by, The flange includes a first flange flap and a second flange flap, which are combined to form a receiving hole for accommodating the sensor detection part. The outer wall of the sensor detection part has multiple positioning ribs extending along the direction of the sensor detection part. The inner wall of the receiving hole formed by the first and second flange flaps has multiple grooves that can accommodate the positioning ribs. During assembly, these positioning ribs of the sensor detection part can slide within these grooves to adjust the axial distance between the head sensing surface of the sensor detection part and the flange. Furthermore, these grooves can provide circumferential positioning for the positioning ribs, thereby maintaining the sensor detection part at a predetermined circumferential angle relative to the flange.

2. The speed sensor of claim 1, wherein, The sensor detection unit, the first flange, and the second flange are fixedly connected to each other.

3. The speed sensor of claim 1, wherein, The first flange and the second flange are constructed as two separate, independent components.

4. The speed sensor of claim 1, wherein, The first flange and the second flange are constructed as a single unit that is partially connected and can be hinged relative to each other.

5. The speed sensor of claim 2, wherein, The sensor detection unit, the first flange, and the second flange are fixed together by ultrasonic welding.

6. The speed sensor of any one of claims 1-5, wherein, Welded weld lines are provided on the surfaces where the first flange and the second flange contact.

7. The speed sensor of claim 1, wherein, The number of grooves and the number of positioning ribs are the same, and they are all evenly distributed in the circumferential direction.

8. A method of manufacturing a velocity sensor, characterized by, The speed sensor is the speed sensor according to any one of claims 1-7, and the manufacturing method includes at least the following steps: The steps of manufacturing the sensor detection unit, the first flange, and the second flange are as follows: The outer wall of the sensor detection unit is provided with multiple positioning ribs extending along the direction of the sensor detection unit; the inner wall of the receiving hole formed by the first and second flanges is formed with multiple grooves that can accommodate the positioning ribs; during assembly, these positioning ribs of the sensor detection unit can slide in these grooves to adjust the axial distance between the head sensing surface of the sensor detection unit and the flange; and these grooves can provide circumferential positioning for the positioning ribs to maintain the sensor detection unit relative to the flange at a predetermined circumferential angle. The step of assembling the sensor detection unit, the first flange, and the second flange together; The step of fixing the sensor detection unit, the first flange, and the second flange together in pairs.

Images