A torque and angle sensor

Abstract

The present application relates to the technical field of automobile power steering device, and particularly relates to a torque and angle sensor, which comprises an upper rotor assembly having an upper rotor for generating an induced magnetic field and a large gear for being fixed to the outer periphery of an input shaft; a lower rotor for being fixedly connected with an output shaft; a pinion having outer teeth for engaging with the large gear, the pinion having a magnet for generating a magnetic field; a PCB board located between the upper rotor assembly and the lower rotor for cooperating with the upper rotor and the lower rotor to generate a first angle signal, the pinion being rotatably installed on the PCB board for cooperating with the pinion to generate a second angle signal, the PCB board having an inductor coil and a chip; the present application solves the technical problems of the prior art, such as the multiple and complex structure components of the torque and angle sensor, the increased process complexity, and the large friction noise between the input shaft rotor and the upper housing during rotation.

Description

Technical Field

[0001] This invention relates to the field of automotive power steering equipment technology, specifically to a torque and angle sensor. Background Technology

[0002] Power steering systems are used to assist drivers in making directional adjustments, reducing the effort required to operate the steering wheel. Torque and angle sensors are a type of power steering system.

[0003] For common torque and angle sensors, please refer to the instruction manual. Figure 1 It includes a gear cover 7, an upper housing 2, a lower housing 5, an input shaft rotor 4, a driving gear 6, a driven gear 8, a magnet 9, a PCB assembly 3, and an output shaft rotor 1. The input shaft rotor 4 is mounted on the input shaft of the power steering system and is sleeved on the upper part of the upper housing 2. The PCB assembly 3 is mounted on the lower part of the upper housing 2. The upper housing 2 and the lower housing 5 are fastened together, fixing the PCB assembly 3 in the space formed by the upper housing 2 and the lower housing 5. The upper housing 2 is sleeved on the input shaft of the power steering system, and the output shaft rotor 1 is mounted on the output shaft of the power steering system. When the power steering system is running, the input shaft rotor 4 rotates coaxially and at the same speed as the input shaft, and the output shaft rotor 1 rotates at the same speed as the output shaft. Thus, the upper housing 2 remains concentric and coaxial with the input shaft rotor 4. The driving gear 6 is fixedly connected to the input shaft rotor 4. The driving gear 6 and the input shaft rotate on the same axis and at the same speed. The gear cover 7 is sleeved on the driven gear 8. The driven gear 8 is fixedly connected to the magnet 9. The rotation of the driving gear 6 will drive the driven gear 8 to rotate together. The magnet 9 and the driven gear 8 rotate on the same axis and at the same speed.

[0004] In addition, the torque and angle sensors are equipped with a first angle measuring device, a second angle measuring device, a gear set, and a control module. The first angle measuring device is located between the input shaft and the output shaft, and measures the rotation angle of the input rotor and the rotation angle of the output rotor, respectively. The gear set is meshed with the input shaft, and the input shaft drives the gear set based on the gear ratio i. The second angle measuring device is located outside the gear set and measures the rotation angle of the gear set. The control module receives the rotation angle of the input rotor, the rotation angle of the output rotor, and the rotation angle of the gear set, and measures the torque and absolute angle based on the difference between the rotation angle of the input rotor, the rotation angle of the gear set, and the rotation angle of the output rotor.

[0005] In practical use, the above torque and angle sensors have at least the following shortcomings: 1) The structure has many and complex components, resulting in complicated processing technology and high manufacturing costs; 2) The input shaft rotor generates a lot of friction noise with the upper housing when it rotates, and excessive wear occurs during its lifespan, which affects the driver's driving experience; 3) The air gap between the input shaft rotor and the PCB and the air gap between the output shaft rotor and the PCB are difficult to control. Summary of the Invention

[0006] This invention provides a torque and angle sensor to solve the technical problems of existing torque and angle sensors having many complex structural components, increasing manufacturing complexity, and causing high frictional noise between the input shaft rotor and the upper housing during rotation.

[0007] To solve the above problems, the torque and angle sensor provided by the present invention adopts the following technical solution:

[0008] A torque and angle sensor, comprising:

[0009] The upper rotor assembly has an upper rotor for generating an induced magnetic field and a large gear for fixing to the outer periphery of the input shaft.

[0010] The lower rotor is used for fixed connection with the output shaft;

[0011] The small gear has external teeth for meshing with the large gear, and the small gear has a magnet for generating a magnetic field;

[0012] A PCB board is located between the upper rotor assembly and the lower rotor, and is used to cooperate with the upper rotor and the lower rotor to generate a first angle signal. The pinion gear is rotatably mounted on the PCB board and is used to cooperate with the pinion gear to generate a second angle signal. The PCB board has an induction coil and a chip.

[0013] The beneficial effects of the torque and angle sensor provided by this invention are as follows: Compared with many existing structures, this invention eliminates the gear cover and upper and lower housings of the sensor, simplifying the sensor structure and making assembly easier, thereby reducing the sensor cost. Simultaneously, since there is no friction between the housing and the input shaft rotor, the sensor noise problem can be reduced, and the sensor reliability can be improved. Finally, the air gap between the PCB board and the lower rotor is a key factor affecting the sensor accuracy. When there is a housing between the PCB board and the lower rotor, the product can only control the distance between the lower rotor and the housing. Due to the housing thickness, the air gap distance is small and the tolerance requirements are strict. This solution eliminates the housing, allowing for better control of the assembly air gap and improving sensor accuracy. Through the above design, this invention solves the technical problems of existing torque and angle sensors having many complex structural components, increasing manufacturing complexity, and causing high friction noise between the input shaft rotor and the upper housing during rotation.

[0014] Furthermore, the upper rotor and the large gear are formed into an upper rotor assembly using an injection molding process.

[0015] Furthermore, the pinion and the magnet are integrally formed using an injection molding process. Injection molding offers advantages such as high production efficiency, stable product quality, low production cost, and high production precision.

[0016] Furthermore, the PCB board has a mounting base, within which the pinion is rotatably mounted. The pinion can rotate 360° within the mounting base without restriction.

[0017] Furthermore, the PCB board also has a mounting structure for fixing the PCB board to the customer's main assembly structure.

[0018] Furthermore, the PCB board has multiple mounting holes, which together form the mounting structure.

[0019] Furthermore, a connector assembly is also mounted on the PCB board, the connector assembly having a connector interface for connecting the customer's main assembly structure to transmit torque and angle signals.

[0020] Furthermore, the lower rotor and the output shaft are connected by welding, riveting or interference fit to rotate coaxially and at the same speed. Attached Figure Description

[0021] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent upon reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of the invention are illustrated by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein:

[0022] Figure 1 A three-dimensional schematic diagram of the torque and angle sensor provided by the present invention. Figure 1 ;

[0023] Figure 2 A three-dimensional schematic diagram of the torque and angle sensor provided by the present invention. Figure 2 ;

[0024] Figure 3 A three-dimensional schematic diagram of the torque and angle sensor provided by the present invention. Figure 3 ;

[0025] Figure 4 This is a schematic diagram showing the connection between the torque and angle sensors provided by this invention and the customer's main assembly structure.

[0026] Explanation of reference numerals in the attached figures:

[0027] 1. Upper rotor assembly; 2. Upper rotor; 3. Large gear; 4. Lower rotor; 5. Small gear; 6. Input shaft; 7. Output shaft; 8. PCB board; 9. Mounting base; 10. Mounting hole; 11. Connector assembly; 12. Connector interface; 13. Customer's main assembly structure; 14. Connecting bolts. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Those skilled in the art should understand that the embodiments described below are only some, not all, of the embodiments disclosed. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0029] It should be noted that the main concept of this invention is that, compared with many structures in the prior art, this invention eliminates the gear cover and upper and lower housings of the sensor, simplifying the sensor structure and making assembly simpler, thereby reducing the cost of the sensor; at the same time, since there is no friction between the housing and the input shaft rotor, the noise problem of the sensor can be reduced, and the reliability of the sensor can also be improved; finally, since there is no housing between the PCB board 8 and the upper and lower rotors, the assembly air gap can be better controlled, improving the accuracy of the sensor; thus solving the technical problems of existing torque and angle sensors having many complex structural components, increasing process complexity, and causing large friction noise between the input shaft rotor and the upper housing when rotating.

[0030] After introducing the basic principles of the present invention, various non-limiting embodiments of the present invention are described in detail below. Any number of elements in the accompanying drawings is for illustrative purposes only and not for limitation, and any naming is for distinction only and has no limiting meaning.

[0031] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0032] Embodiment 1 of the torque and angle sensor provided by the present invention:

[0033] like Figures 1 to 4 As shown, a torque and angle sensor includes an upper rotor assembly 1, which has an upper rotor 2 for generating an induced magnetic field and a large gear 3 for fixing to the outer periphery of an input shaft 6; it also includes a lower rotor 4 for fixed connection to an output shaft 7, the large gear 3 also meshing with a small gear 5, the outer teeth of the small gear 5 for meshing with the large gear 3, and the small gear 5 having a magnet for generating a magnetic field.

[0034] Finally, a PCB board 8 is also provided between the upper rotor assembly 1 and the lower rotor 4. The PCB board 8 is used to cooperate with the upper rotor 2 and the lower rotor 4 to generate a first angle signal. The aforementioned pinion 5 is rotatably mounted on the PCB board 8. During operation, the PCB board 8 cooperates with the pinion 5 to generate a second angle signal. The PCB board 8 has an induction coil and a chip.

[0035] The air gap between the PCB board 8 and the lower rotor 4 is a key factor affecting the accuracy of the sensor. When there is a housing between the PCB board and the lower rotor, the product can only control the distance between the lower rotor and the housing. Due to the housing thickness, the air gap distance is small and the tolerance requirements are strict. However, this solution does not have a housing and directly controls the air gap distance between the lower rotor 4 and the PCB board, which allows for a larger air gap.

[0036] Regarding the manufacturing method: The upper rotor 2 and the large gear 3 are formed into the upper rotor assembly 1 using injection molding. The small gear 5 and the magnet are formed into a single unit using injection molding. Injection molding has advantages such as high production efficiency, stable product quality, low production cost, and high production precision.

[0037] Regarding the installation of pinion 5: The PCB board 8 has a mounting base 9, within which pinion 5 is rotatably mounted. Pinion 5 can rotate 360° within mounting base 9 without restriction.

[0038] In addition, the PCB board 8 also has a mounting structure for fixing the PCB board 8 to the customer's main assembly structure 13. Specifically, the PCB board 8 has a plurality of mounting holes 10, which together constitute the mounting structure. Connecting bolts 14 are inserted into the mounting holes 10 to connect with the customer's main assembly structure 13.

[0039] To facilitate docking with the customer's main assembly structure 13, a connector assembly 11 is also mounted on the PCB board 8. The connector assembly 11 has a connector interface 12 for connecting to the customer's main assembly structure 13 to transmit torque and angle signals.

[0040] In this embodiment, the lower rotor 4 and the output shaft 7 are connected by welding, riveting or interference fit to rotate coaxially and at the same speed.

[0041] The torque and angle sensor provided by this invention has the following advantages in actual operation: Firstly, by eliminating the gear cover and upper and lower housings, the sensor structure is simplified, assembly is easier, and thus the sensor cost is reduced. Secondly, the absence of friction between the housing and the input shaft rotor reduces sensor noise and improves reliability. Finally, the air gap between the PCB board 8 and the lower rotor 4 is a key factor affecting sensor accuracy. When there is a housing between the PCB board 8 and the lower rotor 4, the product can only control the distance between the lower rotor and the housing. Due to the housing thickness, the air gap distance is small and has strict tolerance requirements. This solution, however, eliminates the housing, allowing for better control of the assembly air gap and improving sensor accuracy.

[0042] Embodiment 2 of the torque and angle sensor provided by the present invention:

[0043] Its main difference from Example 1 is:

[0044] In Example 1, the PCB board has multiple mounting holes, which together form a mounting structure. Connecting bolts are inserted into the mounting holes to connect with the customer's main assembly structure.

[0045] In this embodiment, the PCB board is connected to the customer's main assembly structure through a snap-fit ​​and slot-plug connection.

[0046] Embodiment 3 of the torque and angle sensor provided by the present invention:

[0047] Its main difference from Example 1 is:

[0048] In Example 1, the upper rotor and the large gear are formed into an upper rotor assembly using injection molding. The small gear and the magnet are formed into a single unit using injection molding.

[0049] In this embodiment, the upper rotor is fixedly connected to the large gear to form the upper rotor assembly, and the small gear is fixedly connected to the magnet.

[0050] Based on the above description in this specification, those skilled in the art will also understand that the following terms, such as "upper," "lower," "front," "rear," "left," "right," "width," "horizontal," "top," "bottom," "inner," and "outer," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings of this specification. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description, and do not explicitly or implicitly suggest that the device or element involved must have the specific orientation, or be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms should not be understood or interpreted as limitations on the present invention.

[0051] In addition, in the description of this specification, "multiple" means at least two, such as two, three or more, etc., unless otherwise expressly and specifically defined.

Claims

1. A torque and angle sensor, characterized in that, include: The upper rotor assembly has an upper rotor for generating an induced magnetic field and a large gear for fixing to the outer periphery of the input shaft. The lower rotor is used for fixed connection with the output shaft; The small gear has external teeth for meshing with the large gear, and the small gear has a magnet for generating a magnetic field; A PCB board is located between the upper rotor assembly and the lower rotor, and is used to cooperate with the upper rotor and the lower rotor to generate a first angle signal. The pinion gear is rotatably mounted on the PCB board and is used to cooperate with the pinion gear to generate a second angle signal. The PCB board has an induction coil and a chip. The PCB board is assembled with the upper and lower rotors without a housing to control the assembly air gap and improve sensor accuracy. The upper rotor and the large gear are formed into an upper rotor assembly using an injection molding process.

2. The torque and angle sensor according to claim 1, characterized in that: The pinion and the magnet are formed into a single unit using an injection molding process.

3. The torque and angle sensor according to claim 1 or 2, characterized in that: The PCB board has a mounting base, and the small gear is rotatably mounted inside the mounting base.

4. The torque and angle sensor according to claim 1 or 2, characterized in that: The PCB board also has a mounting structure for fixing the PCB board to the customer's main assembly structure.

5. The torque and angle sensor according to claim 4, characterized in that: The PCB board has multiple mounting holes, which together form the mounting structure.

6. The torque and angle sensor according to claim 4, characterized in that: The PCB board is also equipped with a connector assembly, which has a connector interface for connecting the customer's main assembly structure to transmit torque and angle signals.

7. The torque and angle sensor according to claim 1 or 2, characterized in that: The lower rotor and the output shaft are connected by welding, riveting or interference fit to rotate coaxially and at the same speed.

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