Automobile eddy current dual-redundancy Hall sensor and working method thereof

Abstract

The invention discloses an automobile eddy current dual-redundancy Hall sensor and a working method thereof in the field of automobile rotor angle detection and hovercar paddle position detection, the automobile eddy current dual-redundancy Hall sensor comprises a shell, the shell is annular, a mounting cavity is formed in the shell, an annular circuit board is arranged in the mounting cavity, the circuit board is connected with a wiring harness assembly, and the wiring harness assembly is connected with a motor. A sealing glue layer is arranged above the circuit board in the shell mounting cavity, the lower side of the shell is provided with a downward extending cylinder which extends downwards, a Hall sensor is arranged in the downward extending cylinder, and the Hall sensor is correspondingly connected with the circuit board. According to the invention, through the dual-redundancy design, the eddy current sensor can reach ASIC-D at most; the Hall sensor is integrated into the circuit, so that the space occupied by the arrangement of the two sensors can be effectively reduced, and the weight is reduced.

Description

Technical Field

[0001] The invention belongs to the field of automobile rotor angle detection and flying automobile blade position detection, and particularly relates to an automobile eddy current dual-redundancy Hall sensor. Background Art

[0002] In the existing technology, eddy current sensors can measure the distance between the metal conductor being measured and the probe surface statically and dynamically, non-contact, with high linearity and high resolution. It is a non-contact linear measurement tool; it is often used for long-term real-time monitoring of parameters such as shaft displacement, shaft vibration, and shaft speed of rotating machinery.

[0003] At present, the automotive eddy current sensors used for automobile rotor angle detection and flying car blade position detection have the following disadvantages: complex structure, too much space occupied by the arrangement of two sensors, and too heavy weight.

[0004] In the dual redundant design of eddy current of the present invention, the circuits and magnetic circuits of the two eddy currents are independent of each other, thereby achieving the function of redundant detection of rotor angle, rotation speed and rotation direction. Two signal processing chips are selected, and the eddy current sensor can reach ASIC-D at the highest through the dual redundant design; the Hall sensor is integrated into the circuit, and the space occupied by the arrangement of the two sensors can be effectively reduced through integration, thereby reducing the weight. Summary of the invention

[0005] One of the purposes of the present invention is to provide an automotive eddy current dual-redundant Hall sensor. The dual-redundant design enables the eddy current sensor to reach a maximum of ASIC-D. By integrating the Hall sensor into the circuit, the space occupied by the two sensors can be effectively reduced and the weight can be reduced.

[0006] The objective of the present invention is achieved as follows: an automotive eddy current dual redundant Hall sensor comprises a shell, the shell is annular, a mounting cavity is provided on the shell, a ring-shaped circuit board is provided in the mounting cavity, the circuit board is connected to the wiring harness assembly, a sealant layer is provided above the circuit board in the mounting cavity of the shell, a downwardly extending lower extension tube is provided on the lower side of the shell, a Hall sensor is provided inside the lower extension tube, and the Hall sensor is correspondingly connected to the circuit board.

[0007] The circuit board of the present invention is provided with an annular coil, and the magnetic field changes when the rotor passes through the middle hole of the shell; the circuit board is provided with a protrusion, and the shell and the circuit board are matched; the eddy current dual redundant Hall sensor has the following technical and structural functions: first, the eddy current plays an assembly and sealing effect through the wiring harness base matching assembly, and plays a fixing role through four bolts passing through the mounting ears during installation; secondly, the dual redundant circuit and magnetic circuit design enable the eddy current sensor to reach ASIC-D at the highest; finally, the dual redundant eddy current sensor is structurally integrated with the Hall sensor, and the Hall sensor is supported and fixed by a plastic bracket, thereby realizing the high-precision detection function of the automobile rotor angle, rotation speed, rotation direction and the flying car blade position at the same time.

[0008] Compared with the prior art, the beneficial effects of the present invention are: 1. Through the dual redundant design, the eddy current sensor can reach a maximum of ASIC-D; 2. By integrating the Hall sensor into the circuit, the space occupied by the two sensors can be effectively reduced and the weight can be reduced; 3. Through the plastic bracket, the Hall sensor can be fixed and supported.

[0009] As a further improvement of the present invention, the housing includes an annular lower support plate, an inner baffle plate and an outer baffle plate are respectively vertically arranged on the inner and outer sides of the lower support plate, the circuit board is arranged on the lower support plate, and the inner baffle plate and the outer baffle plate are respectively arranged corresponding to the inner and outer sides of the circuit board. The sealant layer is arranged corresponding to the height of the inner baffle plate and the outer baffle plate.

[0010] As a further improvement of the present invention, each wire harness of the wire harness assembly is fixed to the circuit board by soldering, and a sleeve-shaped wire harness base is provided on the outer periphery of the lower end of each wire harness of the wire harness assembly, and the wire harness base is arranged to pass through the sealant layer upward. The wire harness base is arranged on the upper side of the circuit board and fixes each wire harness of the wire harness assembly, and a plurality of positioning holes are provided on the wire harness base for each wire harness to pass through, and each positioning hole positions the wire harness.

[0011] As a further improvement of the present invention, a plurality of positioning posts are vertically arranged on the lower support plate, each positioning post passes through the circuit board upward and is fixed to the circuit board by heat riveting. The housing is fixed to the circuit board.

[0012] As a further improvement of the present invention, a plurality of mounting ears are arranged at intervals along the circumferential direction on the outer circumference of the housing, and a bushing is arranged on the inner wall of the mounting hole of the mounting ear. Bolts pass through the mounting ears to fix the sensor.

[0013] In order to install and fix the Hall sensor, a plastic bracket for fixing the Hall sensor is provided in the lower extension tube.

[0014] In order to fix the wiring harness assembly, a cable tie is provided on the wiring harness assembly, and the wiring harness assembly is bundled and fixed by the cable tie.

[0015] As a further improvement of the present invention, the circuit board is a PCB circuit board, a TX transmitting coil and an RX receiving coil are etched on the PCB circuit board, the TX transmitting coil and the RX receiving coil are distributed around the circuit board, at least one signal processing chip is integrated on the PCB circuit board, and the metal target wheel is set corresponding to the center hole of the annular shell. Two signal processing chips and a Hall sensor are integrated on the PCB circuit board, and the structure and function of each sensor are integrated into one. The metal target wheel is located at a position corresponding to the center hole of the shell of the dual redundant Hall sensor of the eddy current of the automobile, and the metal target wheel can detect the angle or displacement when it rotates.

[0016] The second purpose of the present invention is to provide a working method of an automotive eddy current dual redundant Hall sensor, which can obtain a specific output signal corresponding to the actual position of the target wheel to be detected through chip calculation, and utilize the eddy current effect principle, a reasonably designed coil system and a metal target wheel to achieve angle or displacement detection.

[0017] The object of the present invention is achieved in this way: a working method of an automotive eddy current dual redundant Hall sensor, comprising the following steps: a signal processing chip provides an AC voltage source to a TX transmitting coil on a PCB circuit board, the TX transmitting coil generates a high-frequency alternating electromagnetic field of 3.45-3.55MHz, which acts on the surface of a metal target wheel to form an eddy current effect. When the metal target wheel rotates, the RX receiving coil receives the magnetic field change, forming a high and low value change of the voltage. This signal change is calculated and decoded by the signal processing chip to obtain a specific output signal corresponding to the actual position of the metal target wheel.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention is based on the eddy current effect, and the TX coil etched on the built-in PCB needs to be provided with an AC voltage source by the chip to generate a high-frequency alternating electromagnetic field of about 3.5MHz, which acts on the surface of the metal target wheel to form an eddy current effect; when the target wheel rotates, the RX coil will receive the magnetic field change, forming a high and low value change of the voltage; this signal change is decoded by the chip (extracting the amplitude envelope), and a specific output signal corresponding to the actual position of the target wheel can be obtained. The Hall position sensor senses the target sensor and realizes the switching of high and low voltage output signals through the chip: when far away from the target sensor, the output signal is high voltage; when close to the target sensor, the output signal is low voltage.

[0019] The motor position detection sensor of the present invention utilizes the eddy current effect principle, and a properly designed coil system and metal target wheel can realize angle or displacement detection. Therefore, compared with sensors based on the Hall effect and magnetic resistance principles, the eddy current effect does not require the use of magnets, and can not only replace them in terms of function, but also has the ability to resist interference from stray magnetic fields, which is more in line with the requirements of new energy vehicles for high-frequency magnetic field resistance.

[0020] As a further improvement of the present invention, the frequency of the high-frequency alternating electromagnetic field is 3.5 MHz. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a three-dimensional structural diagram of the present invention.

[0022] Figure 2 It is the bottom structure diagram of the present invention.

[0023] Figure 3 It is a schematic diagram of the structure of the housing and the circuit board.

[0024] Figure 4 It is a schematic diagram of the structure of the shell.

[0025] Figure 5 Schematic diagram of the structure of the Hall sensor and plastic bracket.

[0026] Figure 6 A schematic diagram of the circuit board structure.

[0027] Figure 7 Schematic diagram of the structure of the metal target wheel.

[0028] Figure 8 This is a working principle diagram of the signal processing chip.

[0029] Fig. 9 is the output signal of the eddy current sensor.

[0030] Among them, 1 shell, 101 lower support plate, 102 inner baffle, 103 outer baffle, 1a lower extension tube, 2 installation cavity, 3 circuit board, 4 wiring harness assembly, 4a wiring harness, 5 sealing glue layer, 6 Hall sensor, 7 wiring harness base, 8 positioning column, 9 mounting ear, 10 bushing, 11 plastic bracket, 12 metal target wheel. DETAILED DESCRIPTION

[0031] like Figure 1-9 As shown, an automotive eddy current dual-redundancy Hall sensor of the present invention includes a housing 1, which is annular and has a mounting cavity 2. A ring-shaped circuit board 3 is disposed in the mounting cavity 2. The circuit board 3 is connected to a wiring harness assembly 4. A sealing layer 5 is disposed above the circuit board 3 in the mounting cavity 2 of the housing 1. A downwardly extending lower cylinder 1a is disposed on the lower side of the housing 1. A Hall sensor 6 is disposed inside the lower cylinder 1a. The Hall sensor 6 is correspondingly connected to the circuit board 3. In order to install and fix the Hall sensor 6, a plastic bracket 11 for fixing the Hall sensor 6 is disposed in the lower cylinder 1a.

[0032] The housing 1 includes an annular lower support plate 101, and an inner baffle plate 102 and an outer baffle plate 103 are vertically arranged on the inner and outer sides of the lower support plate 101, respectively. The circuit board 3 is arranged on the lower support plate 101, and the inner baffle plate 102 and the outer baffle plate 103 are arranged corresponding to the inner and outer sides of the circuit board 3, respectively. The sealant layer 5 is arranged corresponding to the height of the inner baffle plate 102 and the outer baffle plate 103. A plurality of positioning columns 8 are vertically arranged on the lower support plate 101, and each positioning column 8 passes through the circuit board 3 upward and is fixed to the circuit board 3 by heat riveting. The housing 1 is fixed to the circuit board 3.

[0033] Each wire harness 4a of the wire harness assembly 4 is fixed to the circuit board 3 by soldering. A sleeve-shaped wire harness base 7 is provided on the outer periphery of the lower end of each wire harness 4a of the wire harness assembly 4. The wire harness base 7 is provided upward through the sealant layer 5. The wire harness base 7 is provided on the upper side of the circuit board 3 and fixes each wire harness 4a of the wire harness assembly 4. A plurality of positioning holes are provided on the wire harness base 7 for each wire harness to pass through, and each positioning hole positions the wire harness. In order to fix the wire harness assembly 4, a cable tie is provided on the wire harness assembly 4. The cable tie is used to bundle and fix the wire harness assembly 4.

[0034] A plurality of mounting ears 9 are arranged at intervals along the circumferential direction on the outer circumference of the housing 1, and a bushing 10 is arranged on the inner wall of the mounting hole of the mounting ear 9. Bolts pass through the mounting ears 9 to fix the sensor.

[0035] The circuit board 3 is a PCB circuit board, on which a TX transmitting coil and an RX receiving coil are etched. The TX transmitting coil and the RX receiving coil are distributed around the circuit board 3. At least one signal processing chip is integrated on the PCB circuit board. The metal target wheel 12 is arranged corresponding to the center hole of the annular shell 1.

[0036] The circuit board 3 of the present invention is provided with a ring coil, and when the rotor passes through the middle hole of the shell 1, the magnetic field changes; the circuit board 3 is provided with a protrusion, and the shell 1 matches the circuit board 3; the eddy current dual redundant Hall sensor 6 has the following functions in terms of technology and structure: first, the eddy current plays an assembly and sealing effect through the wiring harness base 7, and plays a fixing role through four bolts passing through the mounting ears 9 during installation; secondly, the dual redundant circuit and magnetic circuit design enable the eddy current sensor to reach ASIC-D at the highest; finally, the dual redundant eddy current sensor is structurally integrated with the Hall sensor 6, and the Hall sensor 6 is supported and fixed by the plastic bracket 11, so as to simultaneously realize the high-precision detection function of the rotor angle, speed, rotation direction and the blade position of the flying car. The advantages of the present invention are: first, the eddy current sensor can reach ASIC-D at the highest through the dual redundant design; second, by integrating the Hall sensor 6 into the circuit, the occupied space of the two sensors can be effectively reduced and the weight can be reduced; third, the Hall sensor 6 can be fixed and supported by the plastic bracket 11.

[0037] The working method of the automotive eddy current dual redundant Hall sensor of the present invention comprises the following steps: a signal processing chip provides an AC voltage source to a TX transmitting coil on a PCB circuit board, and the TX transmitting coil generates a high frequency alternating electromagnetic field of 3.45-3.55MHz, which acts on the surface of a metal target wheel 12 to form an eddy current effect. When the metal target wheel 12 rotates, the RX receiving coil receives the magnetic field change, forming a high and low value change of the voltage. This signal change is calculated and decoded by the signal processing chip to obtain a specific output signal corresponding to the actual position of the metal target wheel. The frequency of the high frequency alternating electromagnetic field is 3.5MHz.

[0038] The present invention is based on the eddy current effect. The TX coil etched on the built-in PCB needs to be provided with an AC voltage source by the chip to generate a high-frequency alternating electromagnetic field of about 3.5MHz, which acts on the surface of the metal target wheel to form an eddy current effect; when the target wheel rotates, the RX coil will receive the magnetic field change, forming a high and low value change of the voltage; this signal change is decoded by the chip (extracting the amplitude envelope), and a specific output signal corresponding to the actual position of the target wheel can be obtained. The Hall position sensor senses the target sensor and realizes the switching of high and low voltage output signals through the chip: when far away from the target sensor, the output signal is high voltage; when close to the target sensor, the output signal is low voltage.

[0039] Due to the flexibility of design, the sensor can be designed into different coil systems, matching different metal target wheels or sliders, meeting different ranges of angle or displacement measurement, so as to realize the application of various sensors on the car, such as motor position (drive motor, hybrid transmission motor, rotor motor, One-box motor, EMB motor, etc.), seat position, throttle position, steering wheel torque angle, electronic pedal, long stroke linear displacement, etc.

[0040] The present invention is not limited to the above-mentioned embodiments. On the basis of the technical solution disclosed in the present invention, technicians in this field can make some substitutions and deformations to some technical features therein according to the disclosed technical content without creative labor, and these substitutions and deformations are all within the protection scope of the present invention.

Claims

1. An automotive eddy current dual redundant Hall sensor, comprising a housing, characterized in that: The shell is annular and has an installation cavity. An annular circuit board is arranged in the installation cavity. The circuit board is connected to the wiring harness assembly. A sealant layer is arranged above the circuit board in the installation cavity of the shell. A downwardly extending lower extension tube is arranged on the lower side of the shell. A Hall sensor is arranged inside the lower extension tube. The Hall sensor is correspondingly connected to the circuit board.

2. The automotive eddy current dual redundant Hall sensor according to claim 1, characterized in that: The shell includes an annular lower support plate, the inner side and the outer side of the lower support plate are respectively vertically provided with an inner baffle plate and an outer baffle plate, the circuit board is arranged on the lower support plate, and the inner baffle plate and the outer baffle plate are respectively arranged corresponding to the inner and outer sides of the circuit board.

3. The automotive eddy current dual redundant Hall sensor according to claim 2, characterized in that: Each wire harness of the wire harness assembly is fixed to the circuit board by soldering. A sleeve-shaped wire harness base is arranged on the outer periphery of the lower end of each wire harness of the wire harness assembly. The wire harness base is arranged upward through the sealant layer.

4. The automotive eddy current dual redundant Hall sensor according to claim 2 or 3, characterized in that: A plurality of positioning posts are vertically arranged on the lower support plate, and each positioning post passes upward through the circuit board and is fixed to the circuit board by thermal riveting.

5. The automotive eddy current dual-redundant Hall sensor according to any one of claims 1 to 3, characterized in that: A plurality of mounting ears are arranged at intervals along the circumferential direction on the outer circumference of the shell, and bushings are arranged on the inner walls of the mounting holes of the mounting ears.

6. The automotive eddy current dual-redundant Hall sensor according to any one of claims 1 to 3, characterized in that: A plastic bracket for fixing the Hall sensor is arranged in the lower extension tube.

7. The automotive eddy current dual-redundant Hall sensor according to any one of claims 1 to 3, characterized in that: A cable tie is provided on the wiring harness assembly.

8. The automotive eddy current dual-redundant Hall sensor according to any one of claims 1 to 3, characterized in that: The circuit board is a PCB circuit board, on which a TX transmitting coil and an RX receiving coil are etched, the TX transmitting coil and the RX receiving coil are distributed around the circuit board, at least one signal processing chip is integrated on the PCB circuit board, and the metal target wheel is arranged corresponding to the central hole of the annular shell.

9. The working method of the automotive eddy current dual redundant Hall sensor according to claim 8, characterized in that The method comprises the following steps: a signal processing chip provides an AC voltage source to the TX transmitting coil on the PCB circuit board, and the TX transmitting coil generates a high-frequency alternating electromagnetic field of 3.45-3.55MHz, which acts on the surface of the metal target wheel to form an eddy current effect. When the metal target wheel rotates, the RX receiving coil receives the magnetic field change, forming a high and low value change of the voltage. This signal change is calculated and decoded by the signal processing chip to obtain a specific output signal corresponding to the actual position of the metal target wheel.

10. The working method of the automotive eddy current dual redundant Hall sensor according to claim 9, characterized in that: The frequency of the high-frequency alternating electromagnetic field is 3.5 MHz.

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