Fitting optimized sensor head with mounting plug

Abstract

A rotation detector system for determining the angular position of a rotor and a corresponding sensor head are disclosed, wherein the sensor head has a housing which in the state of use of the sensor head is closed in a sealing manner, a circuit board on which a sensor is fixed, a plug having an outer plug housing and a connection part which is provided separately for this purpose and which is arranged coaxially to the plug housing along a mounting axis of the plug, wherein the connection part is fixed on the circuit board in a first angular region of the circuit board such that the connection part projects laterally from the circuit board with a projection, a second region of the circuit board which is opposite the connection part along the mounting axis is recessed and is at least as large as the projection, such that the circuit board can be inserted with the connection part first into the housing, then the connection part can be moved along the mounting axis into the plug housing and then the circuit board can be rotated about the mounting axis into its final assembly state such that the sensor is in a previously determined measuring position.

Description

TECHNICAL FIELD

[0001] The present application relates to a sensor head for a rotary sensor system and to the rotary sensor system itself. BACKGROUND

[0002] Rotary sensor systems which work optically, magnetically, capacitively and / or inductively are known. Rotary sensors are used to detect finely resolved angular positions (absolute angle within 360° of rotation, Single Turn, ST) and to detect a number of complete or full 360° rotations (rotation counter, Multi Turn, MT). The present application relates to such rotary sensor systems.

[0003] For example, mechanical MT (Multi Turn) rotary sensors are known, for example from DE 196 26 654 Al. MT rotary sensors with an electronic counting unit are also known, for example from EP 0 516 572 Bl, in which an additional code disk is used instead of a mechanical drive, which is directly connected to the sensor shaft to be measured and serves to determine the number of rotations of the sensor shaft. For example, the document DE 34 08 478 Cl shows a magnetic inductive incremental sensor which is energy self-sufficient and is equipped with so-called Wigand or pulse wires.

[0004] A common feature of known rotary sensors is that the sensor is provided with corresponding evaluation electronics which are located on a circuit board which is arranged inside the housing.

[0005] In general, there is a need to miniaturize rotary sensors, in particular in order to be able to integrate the rotary sensors, for example, into electric motors in which there are strong electromagnetic fields and in which the number of rotations of the motor shaft is to be detected. Furthermore, it is desirable that the sensor already provides the angular position to be determined of the shaft to be measured directly as an output signal. In this case, the sensor must have corresponding evaluation electronics. The output signal is output periodically via standardized plug connectors or plug connections.

[0006] The arrangement of the corresponding sensor elements within the (sensor) housing is position-sensitive. This means that the sensor must be located in the housing in a previously exactly defined relative position in order to detect the shaft to be measured (indirectly via a signal transmitter fixed thereto), which makes assembly and mounting of the sensor head more difficult. In particular, automated assembly and mounting is difficult. SUMMARY

[0007] It is therefore an object of the present application to provide a sensor head for a rotary probe system and a rotary probe system itself which is suitable for determining the (angular) position of a rotor (to be detected), wherein in particular the circuit board area of the sensor head is to be fully utilized and assembly and mounting are to be possible automatically, preferably without subsequent (manual) adjustment of the sensitive sensor elements. Furthermore, the sensor head is to be as small and compact as possible so that it can be used in any application environment as unobtrusively as possible.

[0008] This object is achieved by a sensor head for determining the angular position (ST and / or MT) of a rotor (to be detected), for example an electric motor shaft, having a (slot-like, semi-open) housing which is closed in a sealed manner in the state of use of the sensor head by means of an (optional) housing cover and / or an (optional) potting compound, a (planar) circuit board on which the position sensors are fixed and which is configured for being fixed in a form- and force-locking manner in the housing, a preferably cylindrical plug of a (mounting) plug connector having an outer plug housing and a separately provided (internal, convex or concave) connection part which is arranged coaxially to the plug housing along a mounting axis of the plug, wherein the housing and the plug housing are preferably configured in one piece, the connection part being (permanently) fixed on the circuit board in a first angular region of the circuit board such that the connection part projects laterally (horizontally) from the circuit board as a projection, a second (angular) region of the circuit board which is opposite the connection part along the mounting axis is recessed and at least as large as the projection in terms of area, such that the circuit board can be inserted into the housing from the outside during assembly thereof with the connection part first, the connection part can then be moved into the plug housing along the mounting axis (linearly), and the circuit board can then be rotated about the mounting axis into its final assembly state such that the sensors are in a previously determined measurement position.

[0009] The circuit board has a recess which enables the projection of the connection part to be installed in a space-saving manner. The space required for the projection of the connection part before assembly in conjunction with the plug housing is provided by the recess of the circuit board. The remaining region of the circuit board can be shaped as desired and in particular has a greater circuit board width than the angular region with the connection part. The area provided for electronic components on the circuit board is optimized in terms of size. Double-sided equipping (front and back) of the circuit board can be avoided, which minimizes manufacturing costs and manufacturing times and significantly simplifies the mounting of the circuit board and the electrical connection / wiring of the electrical components on the circuit board.

[0010] The sensor head still meets the high requirements for the positioning accuracy (measurement position) of the sensors. The sensors are located exactly at the point within the housing such that they can be optimally matched to the (external) signal transmitter.

[0011] The automation of the plug assembly and the automation of the assembly of the circuit board within the housing are possible. The assembly and the mounting can be performed by robots. No subsequent (fine) adjustment of the sensor is necessary, in particular no manual adjustment. The degree of automation is high. The production costs are low.

[0012] The housing preferably has at least one positioning element.

[0013] The positioning element of the housing can contribute to the positioning accuracy of the circuit board within the housing, so that the sensor in the final mounted state of the circuit board is positioned in a pre-accurately defined measuring position inside the housing. The positioning element can achieve a mechanical guidance during the mounting and an accurate positioning at the end of the assembly. In particular, the positioning element is designed in such a way that the assembly can be automated, for example, the assembly can be performed by robots with little monitoring.

[0014] Preferably, each positioning element of the housing is selected from the group consisting of at least one (flexible) post, at least one pedestal, a (rigid) pin, at least one starting ramp and / or at least one detent nose.

[0015] The post is in particular resilient and can (vertically) extend from the bottom of the housing in order to hold the circuit board in the final mounted state by means of a spring force. At the same time, the post can (mechanically) introduce the circuit board into the final mounted state during the mounting.

[0016] In the final mounted state, the pedestal can align the circuit board in the desired (measuring) plane. The upper side of the pedestal can be aligned and configured in such a way that the circuit board lies flat on the pedestal in its final mounted state, which corresponds to the desired measuring position of the sensor.

[0017] The pin can cooperate with a hole and / or a recess on the circuit board and can also be used for fine positioning, so that a fine positioning of the desired measuring position of the sensor is achieved.

[0018] The starting ramp can be aligned in such a way that the circuit board is guided mechanically towards the respective measuring position during the mounting, i.e. to the final mounted state.

[0019] The latching nose can achieve a force-locked fixing of the circuit board in the final assembled state corresponding to the measuring position. The circuit board cannot be unintentionally released, so the sensor always remains in the previously determined and required measuring position. The force required to overcome the latching nose is greater than during the previous assembly movement. This greater force can be detected and can be used by the assembly robot as a signal that the movement is about to end, for example by monitoring the current of the corresponding drive motor. It is also possible to use so-called "force-torque sensors" which determine the force or torque required with sufficient sensitivity, for example by means of strain measuring strips.

[0020] Preferably, the circuit board has at least one further positioning element, wherein each further positioning element is in particular selected from the group consisting of: a hole and / or a recess.

[0021] The further positioning element of the circuit board can cooperate with the positioning element of the housing in order to achieve the desired alignment and adjustment of the circuit board and thus also of the sensor.

[0022] The positioning elements can generally make it easier to automate the assembly by the robot, in that the robot first roughly positions the circuit board in the housing of the sensor head and the positioning elements then achieve the fine positioning during the assembly movement. While the robot can or must be able to perform only the rough movement, the positioning elements can achieve the fine positioning.

[0023] Preferably, the positioning elements are arranged in such a way that the sensor is in a previously determined measuring position when the circuit board is in its final assembled state, as has already been explained above.

[0024] In particular, the housing has a base and at least one wall segment (in the circumferential direction of the base), wherein the base transitions (in a side view) into the at least one wall segment with an arc-shaped transition segment, which preferably has a constant radius of curvature, in particular with the centre of the radius of curvature being positioned along the mounting axis.

[0025] During the initial assembly, the circuit board can be placed on the start of the transition segment, which adjoins the (flat) base of the housing, which can be achieved by a straight robot movement. The base serves as a stop. The circuit board can then be pushed straight into the plug housing with its connection part along the mounting axis. The circuit board can then be simply rotated about the mounting axis, preferably by means of a robot, the circuit board again being supported on the transition segment during the rotation. The transition segment guides the circuit board during the rotational movement.

[0026] By designing the connection part (and the plug housing) to be cylindrical, this mechanical guidance during the rotational movement can additionally be supported. This means that the circuit board can be mechanically supported at several points during the rotational movement, which in turn facilitates the automation of the rotational movement. Lower requirements can be placed on the positioning accuracy of the robot.

[0027] In particular, an evaluation electronics is arranged on the circuit board, which evaluation electronics is electrically connected to the sensor and to the connection part.

[0028] Thus, the signal detection and the signal evaluation take place in the sensor head housing. The required output signal, which already contains the angular position (ST and / or MT) to be determined, can be output directly without having to be calculated externally.

[0029] The sensor is preferably a magnet sensor, in particular an XMR element.

[0030] The magnetic sensor system has the advantage of high resolution and high accuracy. The components are still inexpensive, which makes the sensor head attractive in terms of price.

[0031] The positioning of the magnet sensor requires a high degree of accuracy, which is achieved by the sensor head without the need for (manual) readjustment. This facilitates the automated production of the sensor head for industrial use.

[0032] Furthermore, it is advantageous if one of the sensor heads is used in a rotary sensor system with a corresponding signal transmitter, which preferably has one or more (permanent) magnets, which can in particular be mounted on a shaft of the device, the angular position of which can be determined.

[0033] Of course, the features described above and explained below can be used not only in the combinations given in each case, but also in other combinations or individually, without departing from the scope of the invention as claimed. BRIEF DESCRIPTION OF DRAWINGS

[0034] Embodiments of the application are shown in the drawings and explained in more detail in the following description. Therein:

[0035] Figure 1 a side view of a rotary sensor system comprising a sensor head and a signal transmitter is shown;

[0036] Fig. 2 shows the assembly process Figures 2A-2D in which the circuit board of the sensor head is assembled in the housing of the sensor head Figure 1 ;

[0037] Figure 3 a sectional view along the line III-III in Fig. Figure 2D ; and

[0038] Figure 4 a sectional view along the line IV-IV in Fig. Figure 4 . DETAILED DESCRIPTION

[0039] Figure 1 A side sectional view of an exemplary rotation detector system 10 is shown, which has a rotation detector sensor head 12 and a separately arranged signal transmitter 14, which can be mounted on a rotor 16 to be detected, which rotates about a rotation axis 18, see arrow 20. The rotation detector system 10 is configured for determining the (absolute) angular position (ST) and / or the number of revolutions (MT) of the (external) rotor 16, for example a motor output shaft or the like.

[0040] The sensor head 12 comprises a (sensor) housing 22 and a circuit board 24. The housing 22 is preferably designed in a trough-like manner, in that the bottom 47 is particularly circumferentially surrounded by a wall, as will be explained in more detail below.

[0041] The housing 22 is configured for completely accommodating the circuit board 24 inside it in order to protect the circuit board 24 from external influences, for example heat, dust, moisture or the like. The housing 22 is preferably made of synthetic material and can be manufactured by injection molding. The housing 22 can be sealingly closed, for example with a housing cover (not shown) and / or with a (not shown) potting compound (gas-tight).

[0042] For the sake of simplicity, the housing 22 in the figures is always in an open state, i.e. without a cover and / or a potting compound. In the open state, the circuit board 24 can be loaded into the housing 22 and removed therefrom, as will be explained in more detail below. The corresponding housing opening 25 is indicated in Figure 1 by a dotted line. After assembly is complete, the housing 22 can be closed, which will not be described in more detail here.

[0043] In the Figure 1 , the circuit board 24 is arranged in its final assembly position in the final assembly state. In the final assembly state, the circuit board 24 is completely located inside the housing 22. In the final assembly state, the (position) sensor 26, which is fixed on the circuit board 24, is located in a predetermined (measuring) position inside the housing 22. As shown in Figure 1 , the measuring position is for example such that the sensor 26 mounted on the circuit board 24 directly opposes the separately arranged signal transmitter 14 in radial direction, i.e. essentially perpendicular to the rotation axis 18, at which point the wall thickness of the housing 22, viewed from the housing 22, is preferably reduced. Depending on the measuring principle used, the housing 22 can also be transparent, particularly in the region of the sensor 26, in order to allow light to pass through in the case of optical sensors. When a magnetic field is used, the housing can be designed to be completely opaque.

[0044] Even in general terms, the term "sensor head" is always understood to mean the combination of the sensor 26 and the evaluation electronics 27 (see Figure 2A), the sensor 26 and the evaluation electronics 27 are fixed on the circuit board 24 and are electrically connected to one another in order to output the angle and / or revolution information to be determined directly, it being understood that the evaluation electronics 27 can also be arranged externally. In the present case, the sensor head 12 comprises at least the housing 22, the circuit board 24 and the sensor 26. The evaluation electronics 27 are optional.

[0045] When the evaluation electronics 27 are not present on the circuit board 24, the processing of the sensor output signals into the desired angular position information is usually carried out exclusively outside the housing 22. This does not exclude, however, that the sensor output signals are already stored and / or processed, for example filtered, within the housing 22. For this purpose, one or more further electronic components can be arranged on the circuit board 24 in addition to the sensor 26, which are not shown in more detail in Fig. 2. It is understood, however, that the size of the area required on the circuit board 24 increases with the number of components. The housing 22 limits the maximum possible area which can be occupied by the circuit board 24. This also limits the number of components which can be placed on the circuit board 24. Figure 1 It is understood, however, that the size of the area required on the circuit board 24 increases with the number of components. The housing 22 limits the maximum possible area which can be occupied by the circuit board 24. This also limits the number of components which can be placed on the circuit board 24.

[0046] Returning to Figure 1 It is shown that the relative distance between the signal transmitter 14 and the sensor 26 should be chosen as small as possible, in particular when using a magnetic measuring principle, so that the sensor 26 can receive the strongest possible effective field from the signal transmitter 14. The strength of the effective field can positively influence the quality of the angular position to be determined.

[0047] In the Figure 1 In the

[0048] In the present case, the signal transmitter 14 is exemplarily formed by a ring-shaped pole wheel 28 which is formed by a plurality of magnetic poles of alternating polarity which are arranged next to one another, preferably in direct contact with one another, in circumferential direction. In this case, the sensor 26 is preferably a magnet sensor, for example a Hall sensor or an XMR-element.

[0049] It is understood that the sensor 26 and the signal transmitter 14 can also alternatively cooperate in an optical, capacitive or inductive manner. In the case of an optical interaction, the signal transmitter can be implemented using an optically scannable code. The signal transmitter 14 can be an encoder disk which is mounted in a torsion-proof manner on the rotor 16. The signal transmitter 14 can be an encoder portion of the shaft which is mounted directly on the rotor 16 (for example in a glued, engraved or the like manner).

[0050] Figure 1 The magnetic pole wheel 28 is mounted on the rotor 16, in particular on its shell face, in a torsionally rigid manner (in the circumferential direction). The magnetic pole wheel 28 thus rotates synchronously with the rotor 16.

[0051] The rotor 16 can be a socket-shaped magnetic pole wheel carrier 29, the clear inner diameter of which is adapted to the outer diameter of the shaft (not shown) to be detected. The magnetic pole wheel 28 can also be mounted in a torsionally rigid manner directly on the shaft to be detected, i.e. without a magnetic pole wheel carrier 29.

[0052] The connection part 30 of the plug 32 (see Figure 2A ) of the (mounting) plug connection, which is not shown in detail, can be permanently fixed on the circuit board 24.

[0053] The plug connection or plug connector serves for the separation and connection of electrical lines. Each connector consists of two plugs 32, wherein each plug 32 has a connection part 30 and optionally also a plug housing 34. Only one of the plugs 32 is shown in the figures.

[0054] When the relevant plugs 32 are introduced into each other in a telescopic manner (axially, see the mounting axis E in Figures 2 and Figure 3 ), the connection parts 30 of the plug connector are suitably aligned by means of a form fit, are detachably fixed in a force-locked manner by means of a spring force and are (optionally) additionally fixed, usually by screwing (with a union nut, not shown), in order to prevent unintentional loosening.

[0055] There is a distinction between male connection parts 30 of the plug connection (with outwardly pointing contact pins) and female connection parts 30 (with inwardly pointing contact openings). The present application is suitable for both connection part variants, even though the connection parts 30 shown in the figures, which are mounted on the circuit board 24, are exemplified as male.

[0056] In the present application, mounting plug connectors are preferably considered, which differ from the usual plug connectors in that the male or female connection parts 30 are fixed on the cable end. The mounting plug connectors are designed for permanent installation in a device housing or sensor head housing, for example the housing 22. In the case of a mounting plug connector, at least one connection part 30 is firmly and permanently connected to the circuit board 24 in an electrical and physical manner.

[0057] There is also a distinction between direct and indirect mounting plug connectors. In the case of a direct mounting plug connector, the connection part 30 on the circuit board side is formed by one or more contact pins, which are special shaped (e.g. cantilevered) conductor tracks on the circuit board 24, so that the connection part 30 of the housing side plug 32 is directly realized by the circuit board 24 itself. In the case of an indirect mounting plug connector, the connection part 30 is initially provided separately from the circuit board 24 in order to then be permanently connected (e.g. soldered) to the circuit board 24, as shown. Indirect mounting plug connectors will be preferably considered in the following. It goes without saying that the present development concept can also be applied to direct mounting plugs.

[0058] In addition to the connection part 30, the plug 32 shown in the figures also has a plug housing 34, which is preferably integrally constructed with the housing 22, see Figure 2A . The plug housing 34 can be designed like a sleeve in order to preferably form a positive fit (and coaxially) for the connection part 30, see Figure 2D and Figure 3 .

[0059] The connection part 30 has, for example, a cylindrical shape, the net inner diameter of the plug housing 34 substantially matching the outer diameter of the cylindrical section of the connection part 30, so that the connection part 30 can be placed in the plug housing 34 in the final assembled state of the circuit board 24 with the press-in seat coaxially to the mounting axis E and aligned (see also Figure 2C , Figure 2D , Figure 3 and Figure 4 ). A small air gap can also be provided radially and in the circumferential direction, for example also an O-ring for sealing purposes.

[0060] The plug housing 34 can have (outer) threads 36 in order to be screwed on a fixed union nut (not shown) when two plugs 32 (only one of which is shown in the figures) are connected to each other, as described above.

[0061] The connection part 30 is positioned and fixed in the corner region 46 (see Figure 2D and Figure 3 ) of the circuit board 24. In the corner region 46, two (side) edges of the circuit board 24 meet at an angle (preferably 90 degrees) and form a corner of the circuit board 24. The sensor 26 can be arranged in an edge region adjacent to the corner region 46. This edge region only comprises one of these edge, here for example the longitudinal edge.

[0062] The connecting part 30 projects with the projection 40 laterally, preferably horizontally, i.e. parallel to the plane of the circuit board 24, out of the circuit board 24. The projection 40 corresponds to the projection face of the projecting section 42 of the connecting part 30 in the plane of the circuit board 24, which projects laterally (horizontally) out of the circuit board 24, when this projection is perpendicular to the plane of the circuit board 24, see also Figure 3 In Figure 3 , the circuit board 24 (in the final assembled state) is shown as viewed from the projection direction. Thus, the connecting part 30 consists of its projecting section 42 and its overlapping section 44, see Figure 3 . The overlapping section 44 corresponds to the part of the connecting part 30 which overlaps the circuit board 24, while the projecting section 42 projects laterally out of the circuit board 24, free, i.e. without overlapping the circuit board 24. The longitudinal axis of the connecting part 30 (not shown in detail and in the figure) is oriented parallel to the circuit board plane. In Figure 3 , the longitudinal axis of the connecting part 30 is oriented parallel to the mounting axis E and the Z-axis. In Figure 2A , the circuit board plane is oriented parallel to the Y-Z plane, and the longitudinal axis of the connecting part 30 is oriented parallel to the Z-axis.

[0063] In the following, the assembly process of mounting the circuit board 24 into the housing 22 to assemble the sensor head 12 will be described with reference to Figures 2A-2D , while aligning the circuit board 24. The housing 22 and the plug housing 34 are integrally constructed in that the housings 22 and 34 are either manufactured (at the same time) as one piece (e.g. injection molded) or are permanently and sealingly connected to each other in advance, as shown in the initial state of Figure 2A .

[0064] In Figure 2A , the circuit board 24 (preferably constructed, equipped and functionally tested in advance) is positioned outside the housing 22 in order to be introduced into the housing opening 25, together with the connecting part 30, in particular along a straight line at first, in that the circuit board 24 is introduced, e.g. vertically, i.e. parallel to the Y-direction, into the housing 22, i.e. moved into the housing (see introduction movement 38). It goes without saying that the circuit board 24 can initially be oriented differently and moved into the housing 22 along a different direction. This initial movement brings the circuit board 24 to the position shown in Figure 2B .

[0065] In Figure 2B , the circuit board 24 lies with its (front) longitudinal edge preferably plane against the bottom 47 of the housing 22, see also the dashed line in Figure 1 , wherein the connecting part 30 (with its longitudinal edge) is oriented parallel to the mounting axis E. In the figure, the mounting axis E is oriented parallel to the Z-direction.

[0066] InFigure 2B In this connection, the connection part 30 or the axis thereof is also coaxially positioned and aligned with the central axis of the socket-like plug housing 34. The circuit board 24 is (at least partially) sunken into the interior of the housing 22 in a manner that only the corner region 46 of the circuit board 24 is positioned within the housing 22. This is possible because the (corner) region (i.e. the second region) 48 of the circuit board 24, which is opposite the corner region 46 of the circuit board 24 in which the connection part 30 is positioned and fixed, along the mounting axis E, is recessed, see also the dotted virtual dividing line in Figure 2B and Figure 3 . Thus, the second region 48 of the circuit board 24 is absent in order to give the space required for assembling the plug 32 and (positionally accurately) fitting the circuit board 24, taking into account an optimized circuit board area utilization.

[0067] As shown in Figure 2B , the length L (in the Z direction) and the width B (in the Y direction) of the second region 48 of the circuit board 24 are chosen such that the area of the (recessed) second region 48 defined by the length L and the width B is at least as large as the overhanging region 40. Preferably, the dimensions of the recessed region are essentially the same as the dimensions of the protrusion 40. The recessed second (circuit board) region 48 can then be used for introducing the circuit board 24 (linearly) into the plug housing 34 along the mounting axis E (in the negative Z direction), as shown by the arrow (introduction movement) 51 in Figure 2B . At the same time, the circuit board 24 is displaced by the length L.

[0068] It is shown in Figure 2C that the connection part 30 is fully introduced into the plug housing 34. The connection part 30 is arranged coaxially with the plug housing 34 (and the mounting axis E). The connection part 30 is seated in the plug housing 34 in a press-fit manner. However, the above-described configuration with air gap and sealing is preferred.

[0069] The connection part 30 can have a radially protruding stop on its outer shell surface in order to limit the push-in movement 51 once the connection part 30 has been pressed into the plug housing 34 to the desired (push-in) depth. The (width) edge of the circuit board 24 can also be used as a mechanical stop, which simplifies the automation of the push-in movement 51, which will be explained in more detail below.

[0070] The circuit board 24 can then be rotated about the mounting axis E into its final fitting position (see Figure 2D ), see arrow (rotation movement) 52 in Figure 2C . For example, the circuit board 24 is rotated by approximately 90 degrees to move from the position shown in Figure 2C to Figure 2Dthe position shown in the middle (final installation and measurement position). It goes without saying that the size of the respective angle of rotation can depend on the initial orientation of the circuit board 24 during the introduction movement 38 (see Figure 2A ) and, if necessary, also on the desired final angle, and thus not necessarily on 90 degrees.

[0071] In the final assembled state as shown in Figure 1 , Figure 2D , Figure 3 and Figure 4 , the plug 32 is assembled, i.e. the connection part 30 is arranged in its installation position inside the plug housing 34 and the circuit board 24 and thus also the sensor 26 is arranged in its measurement position inside the housing 22, so that an angular position determination can be carried out when the respective sensor head 12 is used in the system 10.

[0072] It can be seen from Figure 1 that the circuit board 24 is not arranged exactly perpendicularly opposite the rotation plane of the pole wheel 28, but can be slightly angled. In this case, the longitudinal axis of the sensor 26 (see Figure 1 dotted line) is not oriented perpendicularly to the housing surface of the pole wheel 28. One reason for the (slightly) inclined arrangement of the circuit board 24 (inside the housing 22) is that the available structural height of the electronic components also increases with increasing distance to the sensor 26, i.e. to the right in Figure 1 . This additionally contributes to the miniaturization measures.

[0073] As already mentioned above, the opening 25 of the housing 22 is preferably hermetically closed with a (not shown here) housing cover and / or with a (not shown here) potting material when the sensor head 12 is in the state of use. The housing overhangs 53 shown in the figures are optionally and preferably configured for fixing the housing 22 on the (not shown) housing of the device whose axial movement is to be detected. More or less overhangs 53 in various shapes can be provided.

[0074] In Figure 2D , Figure 3 and Figure 4 , the circuit board 24 is positioned in the housing 22 with the maximum available area, which is only reduced by the second area 48 required for assembling the connector 32. Figure 3 The sectional view shows the optimized area utilization. In addition to the part of the circuit board 24 which extends along the installation axis E and which comprises the corner area 46 and the second (corner) area 48, the remaining area 50 of the circuit board 24 (see Figure 3The shape and size of the circuit board 24 (shown as the double-dashed line in FIG. 4 ) can be formed and dimensioned as desired. In this example, excluding the recessed second region 48, the entire circuit board 24 has a substantially rectangular area. In this example, this rectangular area is defined by the cross-sectional shape of the housing 22 in the corresponding (measurement and assembly) plane. The shape of the circuit board 24 is preferably adapted (in an area-optimized manner) to the shape of this assembly plane.

[0075] Figure 3 and Figure 4 The cross-sectional view also shows a positioning device 54 provided on the housing 22 and the circuit board 24. The positioning device 54 includes one or more positioning members 56 on the housing 22 and / or one or more positioning members 58 on the circuit board 24. The positioning members 56 and 58 can function independently or in conjunction with each other. The positioning device 54 is configured to accurately position the circuit board 24 and the sensor 26 at the aforementioned measurement position within the housing 22. This positioning can be achieved through positive locking or friction locking.

[0076] The positioning member 56 on the housing 22 may include: one or more posts 60; one or more bases 62 ( Figure 4 ); one or more pins 64; one or more starting bevels 66; and / or one or more latching protrusions 68. The positioning member 56 can be formed integrally with the housing 22 (e.g., by injection molding). The positioning member 56 can also be provided separately and then fixed.

[0077] As an example, the housing 22 is shown having two integrated posts 60 - 1 and 60 - 2 , a base 62 , a pin 64 , and a plurality of start ramps 66 .

[0078] The post 60 is preferably elastic and in particular extends vertically (in the form of a needle) from the bottom 47 of the housing 22, see Figure 1 , so that during its installation it can be Figure 1 The circuit board 24 is avoided on X and Z in FIG. 1 and a pushing force can be applied in the opposite direction (friction lock).

[0079] The first column 60-1 is arranged approximately in the center in the width direction of the housing 22 ( Figure 1 ), and is provided on the bottom 47 in the longitudinal direction ( Figure 1 The first column 60-1 is arranged in the longitudinal direction at a distance from the wall segment of the housing 22, which can circumferentially surround the bottom 47 of the housing 22 and is preferably oriented approximately perpendicular to the bottom 47. The bottom 47 can be designed in a stepped manner (for example in the width direction), and in addition to the optional steps, the bottom 47 is substantially parallel to the bottom 47. Figure 1The first post 60-1 may have one of the starting bevels 66 at its upper end, which allows the circuit board 24 to enter the interior of the housing 22 and the circuit board 24 to be aligned during the rotational movement 52 (see Figure 2C As the height increases, the starting slope 66 of the first column 60 - 1 gradually becomes thinner from the inside to the outside.

[0080] The second column 60-2 can be arranged centrally in the longitudinal direction of the housing 22 and in the width direction (X direction) in the outer edge region of the bottom 47 opposite the plug housing 34. The second column 60-2 is also slightly spaced apart from the wall segment of the housing 22 so that it can avoid the circuit board 24 during installation. The second column 60-2 can have one of the retaining protrusions 68, which can slightly overhang inward in the width direction, see Figure 1 , in order to fix the circuit board 24 laterally outwardly and from above in the final assembly position.

[0081] In the final assembled position, the circuit board 24 lies flush on the base 62, see Figure 4 The base 62 is opposite the first column 60-1 in the longitudinal direction (Z direction) and extends into the housing 22 in the longitudinal direction (Z direction). The base 62 has a preferably constant height (Y direction) along the longitudinal direction so that the circuit board 24 is supported from below by the platform in its final assembly position and is aligned horizontally (within the housing 22).

[0082] Above the bottom 62, the adjacent wall segment of the housing 22 may be provided with another starting slope 66 that tapers outwards as the height increases. This starting slope 66 and the starting slope 66 of the first column 60-1 are located in a common (vertical) plane ( Figure 4 ), which in its assembled position is oriented perpendicularly to the circuit board 24 and forms an introduction funnel which tapers towards the bottom 47 and which is rotated in the rotational movement 52 (see Figure 2C ) during which the circuit board 24 is centered in the longitudinal direction (Z direction).

[0083] Pin 64 is constructed similarly to post 60, extending vertically from base 47. Pin 64 is preferably not elastic, but rather rigid, and thus forces circuit board 24 into a predetermined final assembly position. To this end, pin 64 may have an effective height (in the Y direction) that is greater than that of first post 60-1 and the starting bevel 66 of the adjacent wall segment.

[0084] The pins 64 can engage with holes 70 in the circuit board 24 (see Figure 2A) in coordination with this hole represents a possible embodiment of the positioning means 58 of the circuit board 24. Other embodiments of the positioning means 58 on the circuit board 24 include for example one or more notches in the circuit board 24, as shown (but not functional there). Of course, the position and shape of the hole 70 on the circuit board 24 and the pin 64 on the housing 22 are coordinated in such a way that the hole 70 and the pin 64 are sealingly interlocked when the circuit board 24 is in the final assembled position.

[0085] It is noted that the connecting part 30 can also assume the function of one of the positioning means 58 and the plug housing 34 can assume the function of one of the positioning means 56 on the housing 22. This is caused by the (optional) cylindrical shape of the connector 30 and the plug housing 34.

[0086] Furthermore, the bottom 47 of the housing 22 can transition in the region of the plug housing 34 in an arc to the wall of the housing 22, as Figure 1 shown. The corresponding arc-shaped transition section 72 can be arranged concentrically to the mounting axis E and have a corresponding constant radius of curvature KR. The transition section 72 can facilitate the automation of the rotational movement 52 in that the front longitudinal edge of the circuit board 24 is supported and guided on the inside of the transition section 72 during the rotation.

[0087] It goes without saying that the transition section 72 does not have to extend over the entire length (in the Z direction) of the bottom 47, but as shown. The transition section 72 can be designed in the Z direction (not shown) in a much shorter length (or width) in a tab-like or rib-like manner, so that the bottom 47 can furthermore transition essentially perpendicularly to the directly (in the X direction) adjacent wall section. A plurality of rib-like transition sections 72 can be provided in the region of the housing 22 facing away from the sensor and close to the plug in the Z direction. However, the rib-like transition section 72 should also have a radius of curvature KR.

[0088] The base 62 can limit and terminate the rotational movement 52 by the circuit board 24 coming into contact with the base 62. In this case, the base 62 acts as an end stop.

[0089] The rotational movement 52 can in particular be assisted by the cylindrical shape of the connecting part 30. It goes without saying that the shape of the connecting part 30 does not have to be cylindrical.

[0090] All movement steps 38, 51 and 52 can be reliably carried out with an (unshown) assembly robot, for example a joint-arm robot. The movements 38, 51 and 52 are preferably one-dimensional, respectively. The positioning safety is ensured at all times during the assembly of the circuit board 24 and during the assembly of the plug 32. After the automated assembly, the sensor 26 is located in the previously determined measuring position without the need for a (manual) subsequent fine positioning (trimming).

[0091] List of reference signs

[0092] 10 rotation detector system

[0093] 12 sensor head of 10

[0094] 14 signal transmitter of 10

[0095] 16 rotor

[0096] 18 rotation axis

[0097] 20 rotational movement

[0098] 22 housing

[0099] 24 circuit board

[0100] 25 housing opening

[0101] 26 (position) sensor

[0102] 27 evaluation electronics

[0103] 28 magnet wheel

[0104] 29 magnet wheel carrier

[0105] 30 connecting part

[0106] 32 plug

[0107] 34 (plug) housing

[0108] 36 thread

[0109] 38 introduction movement

[0110] 40 protrusion

[0111] 42 protruding section of 30

[0112] 44 overlapping section of 30

[0113] 46 corner region of 24

[0114] 47 base of 22

[0115] 48 second region of 24

[0116] 50 remaining region of 24

[0117] 51 push-in movement

[0118] 52 rotational movement

[0119] 53 housing protrusion

[0120] 54 positioning means

[0121] 56 positioning member on 22

[0122] 58 positioning member on 24

[0123] 60 post

[0124] 62 base

[0125] 64 pin

[0126] 66 start ramp

[0127] 68 detent nose

[0128] 70 hole in 24

[0129] 72 transition segment

[0130] A axial direction

[0131] B width of 48

[0132] E installation axis

[0133] KR radius of curvature

[0134] L length of 48

[0135] R radial direction

Claims

1. A sensor head (12) for determining the angular position of a rotor (16), wherein: The sensor head (12) comprises: a housing (22), which, in the use state of the sensor head (12), is sealed by means of a housing cover and / or a potting compound; a circuit board (24) on which a position sensor (26) is fixed and which is configured to be fixed in the housing (22) in a positive-locking manner; and A plug (32) of a plug-in connector, comprising a plug housing (34) and a connecting element (30) provided separately for the plug housing, the connecting element being arranged coaxially with the plug housing (34) along a mounting axis (E) of the plug (32), wherein the connecting element (30) is fastened to the circuit board (24) in a first corner region (46) of the circuit board (24) such that the connecting element (30) projects laterally beyond the circuit board (24) with a projection (40); The second region (48) of the circuit board (24) opposite the connecting part (30) along the mounting axis (E) is recessed and at least as large as the projection (40), so that the circuit board (24) can first be inserted into the housing (22) together with the connecting part (30) during its assembly from the outside, and then the connecting part (30) can be moved along the mounting axis (E) into the plug housing (34), and then the circuit board (24) can be rotated about the mounting axis (E) into its final assembled state, so that the sensor (26) is in a previously determined measuring position.

2. The sensor head (12) according to claim 1, wherein The housing (22) and the plug housing (34) are constructed in one piece.

3. The sensor head (12) according to claim 1, wherein The housing (22) has at least one positioning element (56).

4. The sensor head (12) according to claim 3, wherein Each positioning member (56) of the housing (22) is selected from: column(60); base (62); pin(64); a starting bevel (66); and / or Positioning nose (68).

5. The sensor head (12) according to claim 1, wherein The printed circuit board (24) has at least one further positioning element (58).

6. The sensor head (12) according to claim 5, wherein Each additional locating feature (58) of the circuit board (24) is selected from: a hole (70); and / or a recess.

7. The sensor head (12) according to any one of claims 3 to 6, wherein: Each of the positioning elements (56, 58) is arranged in such a way that when the circuit board (24) is in its final assembled state, the sensor (26) is in a predetermined measuring position.

8. The sensor head (12) according to any one of claims 1 to 6, wherein The housing comprises a bottom (47) and a wall segment, wherein the bottom (47) transitions into the wall segment in an arc-shaped transition segment (72) with a radius of curvature (KR), wherein the center of the radius of curvature (KR) is located along the installation axis (E).

9. The sensor head (12) according to claim 8, wherein The radius of curvature (KR) is constant.

10. The sensor head (12) according to any one of claims 1 to 6, wherein The plug (32) is cylindrical.

11. The sensor head (12) according to any one of claims 1 to 6, wherein Evaluation electronics (27) are arranged on the printed circuit board (24), said evaluation electronics being electrically connected to the sensor (26) and the connecting element (30).

12. The sensor head (12) according to any one of claims 1 to 6, wherein The sensor (26) is a magnetic sensor.

13. The sensor head (12) according to claim 12, wherein The sensor (26) is an XMR element.

14. A rotation detector system (10) comprising a signal transmitter (14) and a sensor head (12) according to any one of claims 1 to 13, wherein: The signal transmitter (14) has at least one permanent magnet.

Images