Assembly of air conditioning system of vehicle

Abstract

The invention relates to an assembly of an air conditioning system of a vehicle, comprising an adjustable flap device (4) for influencing an air flow through a flow line (500-507) and an actuator (1) for adjusting the flap device (4), the actuator (1) having an electric motor (2). A sensor device (11) is arranged on the actuator (1) or on the flap device (4) or is electrically connected to the actuator (1) via a line (14) in order to measure a parameter of the air flow conducted in the region of the flap device (4).

Description

Field of the Invention

[0001] The present invention relates to a component of an air-conditioning system of a vehicle according to the preamble of claim 1. Background Art

[0002] Such a component includes an adjustable flap device for influencing an air flow flowing through a flow line and an actuator for adjusting the flap device. The actuator has an electric motor, such as a stepper motor, for adjusting the flap device.

[0003] With the flap device, for example, a certain flow line of the air-conditioning system can be closed or opened so that the air flow is guided through the flow line, or the flow line is blocked so that the air flow does not flow through the flow line but instead flows through other flow lines. Additionally or alternatively, the air flow is adjusted by the flap device (such as the flap device at the air outlet), for example, by adjusting the opening degree or the flow rate or by adjusting the opening direction of the air flow entering the vehicle interior space.

[0004] In the context of an air-conditioning system for implementing automatic air conditioning in a vehicle, a large number of flap devices are usually installed in the flow line system, and these flap devices can be adjusted via the assigned actuators respectively. The number of actuators used is related to, for example, the complexity of the air-conditioning system, such as the number of zones in the vehicle interior space to be air-conditioned by the automatic air conditioning.

[0005] For example, in a vehicle, there is a trend for a large number of individual air outlets in the vehicle interior space to develop into fewer large air outlets. Then, a large number of flap devices with assigned actuators are arranged behind the large air outlet, and these flap devices are controlled so that the air can flow into the interior space as the case may be.

[0006] In an air-conditioning system, an actuator for adjusting a flap device is, for example, assembled on a ventilation module, and then the ventilation module is installed in the vehicle. The actuator is connected to a control device and is controlled via the control device during operation. Additionally, sensors are usually also present on the ventilation module, and these sensors transmit sensor signals to the control device, so that control depending on the sensor signals (such as temperature signals) can be achieved.

[0007] There is a need to simplify the assembly of such an air-conditioning system and design it inexpensively.

[0008] EP 1 078 786 B1 discloses that a servo motor and a temperature sensor are arranged together on a circuit board in an air-conditioning system.

[0009] In the HVAC system known from US 11,241,931, the flap movement mechanism includes an actuator and a sensor. Summary of the Invention

[0010] The object of the present invention is to provide a component for an air-conditioning system, which can contribute to simplifying the assembly of the air-conditioning system and potentially simplify the integration of sensors in the air-conditioning system.

[0011] This object is solved by the subject matter having the features of claim 1.

[0012] Thus, the component has a sensor device for measuring parameters of the air flow guided in the region of the flap device, which is arranged on the actuator or flap device or is electrically connected to the actuator via a line.

[0013] Within the scope of the component, the flap device, the actuator and the sensor device are combined with each other to provide a component that can be assembled in a simplified manner. The sensor device is arranged on the actuator or flap device or is at least electrically connected to the actuator, for example via a short electrical line, such that the actuator can be assembled together with the sensor device and the flap device on the air-conditioning system, for example on the assigned flow line of the air-conditioning system. The simplification of the assembly is achieved in such a way that the structural unit provided by the flap device, the actuator and the sensor device can be assembled in a unified assembly step, preferably without subsequent cable connection of the sensor device to other components, such as a (higher-level) control device).

[0014] The sensor device is used to measure parameters of the air flow guided in the region of the flap device. Thus, the sensor device measures (during operation) a parameter that is suitable for characterizing the air flow guided in the flow line assigned to the component and optionally influenced via the flap device.

[0015] In one design, such a sensor device can be, for example, a temperature sensor for measuring the temperature of the air flow.

[0016] In a further design, the sensor device can be an air humidity sensor for measuring the air humidity of the air flow.

[0017] In yet another design, the sensor device can be a dew point sensor designed to measure the dew point of the air flow.

[0018] In yet another design, the sensor device can be an air quality sensor, such as a CO2 sensor.

[0019] In yet another design, the sensor device can be an odor sensor, such as a so-called VOC sensor (VOC: Volatile Organic Compound).

[0020] In yet another alternative design, the sensor device can be a pressure sensor for measuring the air pressure of an air flow.

[0021] There can be a single sensor device on the component. In one design, there are multiple sensor devices of the same or different structural types on the component, for example, a combination of a temperature sensor and an air humidity sensor, and these sensing devices are all arranged on the actuator or the flap device or are electrically connected to the actuator.

[0022] In one design, the actuator has a control unit for controlling the operation of the electric motor of the actuator. Preferably, the control unit is electrically connected to the sensor device here.

[0023] Via the control unit, local control of the electric motor of the actuator can be achieved, especially for controlling the adjustment operation for adjusting the flap device between defined positions. For example, the control unit can have a positioning sensor, such as a Hall sensor, which is used to detect the positioning or positioning change of a movable component (such as a shaft) of the actuator or the flap device, and the control unit evaluates the sensor signal of the positioning sensor to control the adjustment movement. Additionally, the control unit is also connected to the sensor device, so that the sensor signal of the sensor device can be evaluated and preprocessed via the control unit when necessary.

[0024] If the sensor device is structurally separate from the actuator of the flap device, the sensor device is connected to the control unit via an electrical line, for example, by coupling the electrical line to the assigned interface of the actuator and connecting to the control unit via the interface.

[0025] This electrical connection is preferably established before the component is assembled on the air conditioning system, so that the flap device, the actuator, and the sensor device can be assembled on the air conditioning system together as a structural unit.

[0026] In one design, the control unit is configured to process the sensor signal of the sensor device. Therefore, preprocessing of the sensor signal of the sensor device can be achieved via the control unit of the actuator, for example, by filtering the signal or by performing a credibility check within the diagnostic range.

[0027] In a design, the control unit is configured to correct the sensor signal of the sensor device by using a calibration value. A sensor element manufactured and delivered by a manufacturer, such as a temperature sensor, may for example have relatively large tolerances. By performing a calibration measurement after the actuator has been manufactured, i.e., when the sensor device is installed in the actuator, the accuracy of the sensor device during actuator operation can be improved. For this purpose, a calibration value can be determined within the scope of the calibration measurement, and this calibration value will be used as a correction value for correcting the sensor signal during operation. For example, when using a sensor element in the form of a temperature sensor, such a correction value can be stored as a temperature offset. The correction value is stored in the control unit and is used during operation when processing the sensor signal.

[0028] In a design, the control unit is configured to filter the sensor signal of the sensor device. For example, an average value filter can be used to perform a time averaging of the sensor signal, within the scope of this time averaging, a predetermined number of consecutive measured values are averaged in order to determine the output value after time averaging. The averaging window changes continuously here (i.e., the so-called "running average"). Other filters can also be used, such as digital filters (e.g., low-pass filters or FIR filters or IIR filters) or analog filters (e.g., R-C filters).

[0029] In a design, the control unit is configured to check the sensor signal of the sensor device in a diagnostic routine. Within the scope of such a diagnostic routine, the credibility of the sensor signal can be continuously or cyclically checked during operation in order to, for example, identify a short circuit, signal interruption or other malfunctioning functions of the sensor device. By means of such persistent or cyclic diagnostics, untrustworthy measured values can be identified, for example due to an unstable connection of the sensor element.

[0030] In a design, the air conditioning system has a separate, higher-level control device, which is used to control the operation of all actuators and other components of the air conditioning system (such as blowers, cooling devices and / or heating devices). The actuator is electrically connected to this control device here, so that the actuator can be controlled via this control device, for example, by the control device forwarding control instructions for adjusting the flap device to the actuator.

[0031] In a design, the actuator has a housing that at least partially surrounds the electric motor. In particular, the housing can surround the components of the actuator, especially the electric motor and the control unit, so that the components of the actuator are encapsulated by the housing.

[0032] In one design, the sensor device is firmly mechanically connected to the housing of the actuator or to a component of the actuator that is firmly connected to the housing, such as the main circuit board of the control unit of the actuator. Thus, the sensor device is firmly placed on the housing of the actuator. The actuator and the sensor device together form a structural unit, in which case the sensor device can be assembled together without additional assembly steps by assembling the actuator on the air-conditioning system.

[0033] In one design, the sensor device protrudes outward relative to the housing of the actuator. For example, the sensor device can protrude from the actuator housing in the form of a pedestal, a spike or a mandrel. The actuator can be assembled via the housing, for example, on the flow wall of the flow line, while the sensor device protruding relative to the housing can extend into the internal flow volume of the flow line in order to measure parameters of the air flow inside the flow line.

[0034] The sensor device can, for example, have sensor elements arranged on a carrier element, such as a circuit board.

[0035] In one design, the sensor device has a circuit board that forms a carrier element. The circuit board is firmly mechanically connected to the housing or a component of the actuator, such as the main circuit board of the control unit of the actuator, and protrudes outward relative to the housing of the actuator, for example. Sensor elements can be arranged on the circuit board, for example, and the sensor elements are positioned via the circuit board, for example, in the internal flow volume of the flow line, and parameters of the guided air flow, such as temperature, air pressure, air quality, air humidity or other parameters, can be measured via the sensor elements.

[0036] Conductor traces can preferably be arranged on the circuit board, and the sensor elements are coupled to the control unit of the actuator via the conductor traces.

[0037] Multiple sensor elements for measuring different parameters of the air flow can also be arranged on the circuit board.

[0038] Such a circuit board can, for example, be surrounded by a housing mandrel that is connected to the housing and protrudes from the housing. The actuator can be assembled via the housing, for example, on the flow wall of the flow line, while the housing mandrel that encloses the sensor device can extend into the internal flow volume of the flow line. The housing mandrel can be closed, for example, in a fluid-tight manner so that the air flow does not come into direct contact with the circuit board. In another design, the housing mandrel can also have one or more openings so that the air flow can flow past the sensor elements on the circuit board.

[0039] The opening in the housing mandrel can be covered, for example, by a membrane which is permeable to the air flow, but isolates the particles and prevents them from penetrating into the housing mandrel.

[0040] In one design, the carrier element, for example composed of a circuit board, can be configured flexibly or have at least one flexible section.

[0041] For example, the circuit board forming the carrier element can be configured as a flexible printed circuit board (so-called Flex-PCB).

[0042] In other designs, the circuit board forming the carrier element can be configured as a so-called rigid-flex circuit board in which the circuit board has rigid and flexible components which are non-detachably connected to each other in such a way that the flexible circuit board component wraps around the rigid circuit board component and is thus arranged as a cladding on the rigid circuit board component. The flexible circuit board component can hereby form a flexible connection section for connecting the circuit board to the main circuit board of the control unit of the actuator.

[0043] In yet another design, the circuit board forming the carrier element can be configured as a so-called semi-flexible circuit board in which the circuit board is in principle made of rigid circuit board material (FR 4), but is milled very thin in a certain area so that flexibility is provided in this area in order to provide a bendable connection section in this flexible area for connecting the circuit board to the main circuit board of the control unit of the actuator.

[0044] In one design, the sensor can be configured as a wired component and connected, for example, via a spacer to the control unit. Such a spacer can be enclosed, for example, in a housing mandrel connected to the housing.

[0045] In one design, the sensor device has a heat-conducting element for conducting heat to or away from the sensor element. Such a heat-conducting element can conduct heat, for example, to the sensor element implementing a temperature sensor. The sensor element can be arranged, for example, inside the housing of the actuator. In contrast, when the actuator is assembled on the flow line, the heat-conducting element can protrude outwards relative to the housing and, for example, extend into the interior of the flow line. The temperature inside the flow line can be detected via the heat-conducting element and temperature measurement can thus be achieved via the sensor element integrated into the actuator.

[0046] Such a heat-conducting element can be, for example, a metal element or a plastic element, and if necessary a plastic element made of a thermally modified plastic for improving the heat-conducting properties.

[0047] Such a heat-conducting element can also be arranged on the circuit board, for example.

[0048] In one design, the sensor device is arranged on the flap device. For example, the flap device can have a flap element connected to the axis of the flap device. The flap device is in operative connection with the actuator via the axis such that the flap device can be adjusted between different positions by torsion of the axis. The sensor device can be arranged, for example, on the axis or the flap element. The sensing device can also be electrically connected to the control unit of the actuator via the axis, for example, by making the axis of an electrically conductive material or integrating an electrical conductor, for example, by stamping it onto or into the axis.

[0049] In one design, the assembly has a flow line and the actuator is connected to the flow line in the assembled position. The flow line defines an internal flow volume for guiding an air flow, and the flap device is arranged in the flow volume and is adjustable therein.

[0050] In one design, the sensor device is arranged in the flow volume. For example, the sensor device is firmly mechanically connected to the actuator but extends from the actuator into the flow volume of the flow line.

[0051] In one design, the flow line has a flow wall bounding the flow volume, and at least one opening for guiding air to the sensor device is formed in the flow wall. For example, the sensor device is firmly arranged inside or on the actuator, but is arranged on the side of the flow wall and is thus functionally arranged outside the flow volume of the flow line. Air can be guided to the sensor device via one or more openings in the flow wall such that the air flow is also guided along the sensor device and parameters of the air flow can be detected via the sensor device.

[0052] The actuator is, for example, assembled on the flow line on the outside of the flow wall. The transition between the flow wall and the housing of the actuator can be sealed in a flow-tight manner such that the actuator seals at least one opening in the flow wall in a flow-tight manner relative to the external space. Thus, air does not flow out. Although air can flow through one or more openings in order to come into contact with the sensor device inside or on the actuator in this way. However, it is possible to prevent the air flow from escaping to the external space by sealing at least one opening in the flow wall in a flow-tight manner by the actuator.

[0053] Within the assembly, the actuator, the flap device and the sensor device provide a structural unit that can be assembled in a simple manner, facilitating assembly. If the sensor device is integrated with the actuator or the flap device, manufacturing costs, weight and structural space can be reduced because a separate sensor device is not required.

[0054] In a design, the electric motor of the actuator has a stator and a rotor that can rotate relative to the stator about a rotational axis. The stator has an inner stator portion, a first outer stator portion, and a second outer stator portion. The inner stator portion, the first outer stator portion, and the second outer stator portion are arranged along the rotational axis. The inner stator portion forms a facility for a first inner stator pole on a first side axially facing the first outer stator portion, and forms a facility for a second inner stator pole on a second side axially facing the second outer stator portion. The first inner stator pole and the second inner stator pole are integrally and monolithically connected to each other.

[0055] Thus, in such a design of the actuator, the stator is composed of (at least) three parts, which have an inner stator portion and axially offset outer stator portions arranged on both sides of the inner stator portion. The inner stator portion forms a first inner stator pole facing the first outer stator portion and interacting with the first outer stator portion here. In addition, the inner stator portion also forms a second inner stator pole facing the second outer stator portion and interacting with the second outer stator portion. The stator poles interact with the respectively assigned outer stator portions here to form a magnetic circuit, so that two magnetic circuits are formed on the inner stator portion.

[0056] Since the first stator pole and the second stator pole of the inner stator portion are integrally and monolithically formed with each other, a simple structural form is obtained, in which the inner stator portion is generally integrally and monolithically formed. The single inner stator portion is sufficient to form two magnetic circuits in interaction with the outer stator portions arranged on both sides. This results in a simple structural form and a stable design with simple manufacturing.

[0057] In a design, the inner stator portion has a first body section, and the first stator pole is formed on the first body section. The first body section is integrally and monolithically formed with a second body section, and the second stator pole is arranged on the second body section. Thus, the inner stator portion can be generally integrally and monolithically formed, and the inner stator portion has two body sections, which form the first inner stator pole on the one hand and the second inner stator pole on the other hand.

[0058] Due to the one-piece construction of the inner stator portion, it is possible to save process steps in manufacturing the stator, in particular, by the fact that no connection steps for connecting separate inner stator portions are required (which would be required if the inner stator poles were constructed on separate structural elements). This enables a reduction in manufacturing time and a reduction in manufacturing costs.

[0059] For example, the inner stator part can be integrally and one-piece formed as a stamped and bent part. In this way, the stator part can be formed from a sheet material, preferably a soft magnetic sheet material, wherein the stator part can be punched out of the sheet material during production and then bent into a shape, for example, round, corresponding to the basic shape of a cylinder, so that the inner stator part can rotatably accommodate the rotor. The outer stator parts are also formed, for example, as stamped and bent parts, for example, from a soft magnetic material.

[0060] In one design, the first outer stator part forms a facility for a first outer stator pole for electromagnetically interacting with the first inner stator pole. Additionally or alternatively, the second outer stator part can form a facility for a second outer stator pole for electromagnetically interacting with the second inner stator pole. The first inner stator pole of the inner stator part is oriented toward the first outer stator pole of the first outer stator part, for example, in such a way that these stator poles are interlaced in the form of axially extending fingers. Correspondingly, the second inner stator of the inner stator part is assigned to and oriented toward the second outer stator pole of the second outer stator part, for example, in such a way that the second inner stator pole and the second outer stator pole are interlaced in the form of axially extending fingers. Thus, two pairs of stator pole facilities are formed, which can respectively form magnetic circuits and can respectively be assigned to stator coils, so that magnetic flux can be fed into the respectively assigned magnetic circuits.

[0061] In one design, the first outer stator pole and the first inner stator pole are interlaced and interlocked, so that the first outer stator pole and the first inner stator pole are arranged alternately along the circumferential direction pointing around the rotation axis. Additionally or alternatively, the second outer stator pole and the second inner stator pole are interlaced and interlocked, so that the second outer stator pole and the second inner stator pole are arranged alternately along the circumferential direction pointing around the rotation axis. The inner stator pole and the respectively assigned outer stator pole preferably extend axially from the assigned body section of the respective stator part in the form of fingers. The finger-shaped stator poles of the inner stator part and the respectively assigned outer stator part are interlaced and interlocked in a nested manner, thereby providing a stator pole sequence (viewed in the circumferential direction), in which an outer stator pole follows an inner stator pole, and vice versa. This results in a first magnetic circuit between the first inner stator pole and the first outer stator pole, and a second magnetic circuit between the second inner stator pole and the second outer stator pole. Each magnetic circuit can be fed with magnetism via the associated stator coil in order in this way to set a rotor, which is, for example, a permanent magnet, into rotational motion in the manner of a claw-pole stepper motor.

[0062] In one embodiment, the first inner stator pole and the second inner stator pole are trapezoidal when viewed along an imaginary envelope surface surrounding the inner stator part around the axis of rotation. The surrounding envelope surface corresponds to an imaginary cylindrical surface surrounding a cylindrical portion of the stator.

[0063] The outer stator poles can preferably be shaped in a complementary manner to the inner stator poles, such that the first outer stator pole and the first inner stator pole are in an interlocking relationship in a complementary manner, and the second outer stator pole and the second inner stator pole are in an interlocking relationship in a complementary manner. This results in a relatively small air gap between adjacent stator poles.

[0064] In one design, the first inner stator pole and the second inner stator pole are offset from each other when viewed in the circumferential direction around the axis of rotation. The first inner stator pole is arranged periodically in the circumferential direction around the axis of rotation. Similarly, the second inner stator pole is also arranged periodically in the circumferential direction around the axis of rotation. However, there is an angular offset in the periodic sequence of the first inner stator pole and the second inner stator pole, such that the first inner stator pole and the second inner stator pole are not arranged axially aligned with each other, but are offset from each other by a certain angle in the circumferential direction.

[0065] This angular offset can be, for example, less than or equal to a quarter of the period angle, where the period angle is determined by the angular pitch between two adjacent first inner stator poles or the corresponding angular pitch between two adjacent second inner stator poles.

[0066] In a 10-pole stator, for example, five first inner stator poles are assigned to five first outer stator poles, and five second inner stator poles are assigned to five second outer stator poles. The periodic angular pitch between adjacent first inner stator poles and the corresponding periodic angular pitch between adjacent second inner stator poles are both 72°. If the angular pitch between the first inner stator pole and the second inner stator pole is, for example, equivalent to a quarter of the periodic angular pitch, the angular offset is 18°.

[0067] By means of this angular offset between the inner stator poles and accordingly between the assigned magnetic circuits, a stepping motor of the claw-pole type with a relatively small step size can be obtained. The rotor can hereby be designed as a permanent magnet, having a magnet arrangement arranged on the rotor, which magnet arrangements are respectively assigned to one of the magnetic circuits, and which can be oriented relative to each other without angular offset when the magnetic circuits are arranged with an angular offset.

[0068] In one design, the motor has a first stator coil and a second stator coil. The inner stator part can hereby form at least one first interlocking section, which is inserted into the first stator coil and thus carries the first stator coil. In addition, the inner stator part can also form at least one second interlocking section, which is inserted into the second stator coil and thus carries the second stator coil.

[0069] The splicing section can in particular be formed radially outside the stator poles, for example, in the form of tabs on the bent ends of the inner stator part formed as a stamped and bent part.

[0070] Advantageously, an outer splicing section is also formed on the outer stator part, which is used for embedding into the stator coil and, together with the splicing section of the inner stator part, bears the stator coil. For example, the first outer stator part can have at least one first outer splicing section, which is arranged overlapping with at least one first inner splicing section and is embedded into the first stator coil. Additionally or alternatively, the second outer stator part can have at least one second outer splicing section, which is arranged overlapping with at least one second inner splicing section and is embedded into the second stator coil. The outer splicing section can also be formed in the form of tabs on the ends of the outer stator part formed as a stamped and bent part, wherein the outer splicing section, together with the inner splicing section of the inner stator part, bears the stator coil and thus closes the respective magnetic circuit.

[0071] For example, the inner stator part can form two first inner splicing sections and two second inner splicing sections. In addition, each outer stator part can form two outer splicing sections. The first outer splicing section of the first outer stator part can here overlap and be alternately arranged with the first inner splicing section of the inner stator part in a sandwich arrangement and thus form a stack group with the first inner splicing section, on which the first stator coil is arranged. Correspondingly, the second outer splicing section of the second outer stator part can also overlap and be alternately arranged with the second inner splicing section of the inner stator part in a sandwich arrangement and thus form a stack group with the second inner splicing section, on which the second stator coil is arranged.

[0072] In a design, the first stator coil and the second stator coil each have a coil body and a coil winding arranged on the coil body. The coil body can, for example, form a splicing opening, into which the inner splicing section of the inner stator part and the respectively assigned outer splicing section of the outer stator part are embedded.

[0073] In a design, the coil body forms a winding section, on which the coil winding is arranged. Preferably, the winding section has a convex spherical shape here, so that sharp edges can be avoided on the winding section and the coil winding can be wound around the winding section in a space-saving manner. This results in a form-fitting and tight grouping arrangement of the winding wire on the line section, wherein, additionally, a molding compound, for example a potting compound, can be arranged on the winding section, for example, in order to encapsulate the coil winding. In this way, movement of the wire caused by electromagnetic forces during operation can be prevented and thus noise generation on the stator coil can be avoided.

[0074] In a design, the actuator has a control unit. The coil winding of each stator coil is electrically connected to the control unit here by means of at least one wire end, for example, by joining the wire end material-locking to the circuit board of the control unit.

[0075] It is also conceivable here that the stator coil has a connection pin, the wire end of the assigned coil winding is connected to the connection pin, and the connection pin can facilitate the establishment of a soldering connection with the circuit board of the control unit.

[0076] In a design, the rotor has a first magnet arrangement belonging to the facility of the first inner stator pole and a second magnet arrangement belonging to the facility of the second inner stator pole. The first magnet arrangement and the second magnet arrangement are axially offset from each other along the axis of rotation here. Each magnet arrangement can be formed, for example, by an arrangement of one or more permanent magnets or by differently magnetized sections on a magnetic body. The magnet arrangement interacts with the magnetic circuit of the stator pole and enables the rotor to be driven step by step in the form of a claw-pole stepping motor, in which the rotor can be adjusted in discrete steps by following the magnetic field on the stator magnetic circuit with the magnet arrangement arranged thereon.

[0077] Here, the first magnet arrangement can be configured, for example, to interact with the first inner stator pole to generate a torque on the rotor, while the second magnet arrangement is configured to interact with the second inner stator pole to generate a torque on the rotor. Therefore, the first magnet arrangement interacts with the first magnetic circuit formed on the first inner stator pole. In contrast, the second magnet arrangement interacts with the second magnetic circuit formed on the second inner stator pole. These magnet arrangements jointly generate a torque on the rotor under the interaction of the magnetic circuits.

[0078] However, in other designs, only one (unique) magnet arrangement can be provided on the rotor, which is integrally constructed and can be arranged on the motor shaft as a unit. Here, the magnet arrangement is configured to interact not only with the first inner stator pole but also with the second inner stator pole to generate a torque on the rotor. The magnet arrangement can have, for example, one or more permanent magnets or differently magnetized sections on a magnetic body.

[0079] In a design, the actuator has a transmission mechanism that can be driven by an electric motor, and the transmission mechanism is configured to adjust the driven part of the flap device. The driven part is formed, for example, by a driven gear that can be driven by the transmission mechanism. The driven gear can be connected to the motor shaft via one or more transmission gears, so that the driven gear can be driven by the motor and can perform a (step-by-step) rotational movement. The adjustment force can be sent to the flap device via the driven gear, so that the flap device can be adjusted via the driven gear.

[0080] Actuators of the above type can in principle be constructed with a completely different number of poles. Thus, the actuator can for example be constructed as 8-pole, 10-pole or 12-pole, and other numbers of poles are also conceivable. The number of poles refers to the total number of stator poles of each magnetic circuit. In a 10-pole motor, the inner stator part has for example 5 first inner stator poles and 5 assigned first outer stator poles for the first magnetic circuit, and 5 second inner stator poles and 5 assigned second outer stator poles for the second magnetic circuit.

[0081] The stator part in particular serves as a yoke plate for providing different magnetic circuits, and exactly one stator coil is preferably assigned to each magnetic circuit for feeding in (time-variable) magnetic fluxes. The stator part is preferably formed integrally and as a single piece from a soft magnetic material, in particular soft iron. Description of the Drawings

[0082] The basic concept of the invention will be explained in detail below in connection with the embodiments shown in the drawings. Among them:

[0083] Figure 1 shows a schematic view of an air conditioning system in a vehicle;

[0084] Figure 2 shows a schematic view of an embodiment of a component including a flap device, an actuator and a sensor device;

[0085] Figure 3 shows a view of an embodiment of an actuator with a sensor device;

[0086] Figure 4 shows a schematic view of a further embodiment of a component including a flap device, an actuator and a sensor device;

[0087] Figure 5 shows a schematic view of yet another further embodiment of a component including a flap device, an actuator and a sensor device;

[0088] Figure 6 shows a schematic view of yet another further embodiment of a component including a flap device, an actuator and a sensor device;

[0089] Figure 7 shows a schematic view of yet another further embodiment of a component including a flap device, an actuator and a sensor device;

[0090] Figure 8 shows a schematic view of yet another further embodiment of a component including a flap device, an actuator and a sensor device;

[0091] Figure 9 shows a view of an embodiment of an actuator;

[0092] Figure 10 Shows another view of the actuator;

[0093] Figure 11 Shows a view of the actuator without a housing;

[0094] Figure 12 Shows a view of the components of the actuator that make up the motor;

[0095] Figure 13 Shows a separate view of the motor shaft and the magnet arrangement disposed thereon;

[0096] Figure 14 Shows a view of an embodiment of a stator composed of a plurality of stator parts, wherein the assigned stator coils are shown in an exploded view;

[0097] Figure 15 Shows an assembled view of the stator;

[0098] Figure 16 Shows a perspective exploded view of the stator parts of the stator;

[0099] Figure 17A Shows a view of an embodiment in which the magnet arrangement of the rotor is in a separated position;

[0100] Figure 17B Shows a view in which the magnet arrangement is in a butted position;

[0101] Figure 18 Shows a view of another embodiment of the magnet arrangement disposed on the motor shaft;

[0102] Figure 19 Shows a view of an embodiment of the stator coil;

[0103] Figure 20A Shows a side view of the stator coil;

[0104] Figure 20B Shows a cross-sectional view taken along line A-A according to Figure 20A ;

[0105] Figure 21 Shows a schematic view of an embodiment of an actuator having a sensor device;

[0106] Figure 22 Shows a schematic view of an embodiment of the sensor device, which has a circuit board connected to the main circuit board of the control unit of the actuator;

[0107] Figure 23Schematic view showing a further embodiment of a sensor device having a circuit board connected to the main circuit board of the control unit of an actuator;

[0108] Figure 24 Schematic view showing a further embodiment of a sensor device having a circuit board connected to the main circuit board of the control unit of an actuator;

[0109] Figure 25 Schematic view showing a further embodiment of a sensor device having a circuit board connected to the main circuit board of the control unit of an actuator;

[0110] Figure 26 Schematic view showing a further embodiment of a sensor device having a circuit board connected to the main circuit board of the control unit of an actuator; and

[0111] Figure 27 Schematic view showing the arrangement of the sensor device in the still air zone of the shaft of a flap device. Detailed description

[0112] Figure 1 Schematic view showing an air conditioning system 5 of a vehicle 8 which provides, for example, heating, ventilation and air conditioning (HVAC for short) to provide automatic air conditioning.

[0113] Such an air conditioning system 5 has a flow system 50 in which, for example, air is supplied from the outside via a flow opening 500, heating, ventilation and / or air conditioning is conveyed via a flow line 501, and / or is directly introduced, for example, into the area of the footwell of the vehicle 8 via a flow opening 502.

[0114] Via the flow line 501, the air is supplied to a cooling device 52 via a blower 51, conveyed to a heating device 53 via a flow line 503, or selectively bypasses the heating device 53 via a flow line 504 and is guided via flow lines 505, 506, 507 to different outlets in the interior of the vehicle.

[0115] For example, an air-conditioning system 5 in a vehicle 8, which can be installed as a so-called ventilation module as a structural unit, usually has a large number of flap devices 4. The air flow is controlled via these flap devices and guided through supply lines 500 to 507. Each flap device 4 is typically assigned an actuator 1, which is used to adjust the respective flap device 4 in a controlled manner, especially within the scope of an automatic air-conditioning system. In an automatic air-conditioning system, the air conditioning of the vehicle interior space is adjusted automatically via a control device in a controlled manner.

[0116] Figure 2 An embodiment of the actuator 1 together with the flap device 4 on the flow line 6 is shown (as Figure 2 and as will be described below Figures 3 to 8 The actuator shown in principle can be installed on any of the flow lines 500 to 507 at completely different locations in the air-conditioning system 5; in this regard, the reference numeral 6 is used as a representative of each flow line in the air-conditioning system 5).

[0117] The actuator 1 has an electric motor 2, a transmission mechanism 3, and an electronic control unit 24. The electric motor 2 is coupled to the shaft 40 of the flap device 4 via the transmission mechanism 3, and the flap element 41 of the flap device 4 can be adjusted via the shaft. During operation, under the control of the control unit 24, the actuator 1 adjusts the flap element 41 of the flap device 4 by driving the shaft 40 via the electric motor 2 and the transmission mechanism 3.

[0118] The actuator 1 has a housing 10, and the electric motor 2, the transmission mechanism 3, and the control unit 24 are all enclosed in the housing 10.

[0119] The actuator 1 is connected to a higher-level control device 7, such as the control device 7 of the (entire) air-conditioning system 5, via an electrical interface 12, especially a plug connector, and a line 13. During operation, the control device 7 especially generates control commands, and the actuator 1 adjusts the flap device 4 in a prescribed manner based on these control commands.

[0120] In Figure 2 the embodiment shown, the actuator 1 has a sensor device 11, which is firmly mechanically connected to the housing 10 of the actuator 1. The sensor device 11 protrudes from the housing 10 and extends into a flow volume 61 defined by a flow wall portion 60 of the assigned flow line 6. During operation, the air flow flows in this flow volume, so that the parameters of the air flow guided in the assigned flow line 6 can be measured via the sensor device 11.

[0121] The sensor device 11 can in particular be configured to measure the temperature of the air flow, the air humidity of the air flow, the dew point of the air flow, the air quality of the air flow, the odor of the air flow, and / or the air pressure of the air flow. Thus, the sensor device can be a temperature sensor, an air humidity sensor, a dew point sensor, an air quality sensor (such as a CO2 sensor), an odor sensor (such as a (VOC) volatile organic compound sensor), or an air pressure sensor.

[0122] Generally speaking, the sensor device 11 can be designed to measure any parameter of the air flow. The sensor device 11 can also be designed to measure different parameters, such as temperature and air pressure, and for this purpose has different sensor elements for measuring different parameters.

[0123] Since in Figure 2 the embodiment shown, the sensor device 11 is integrated into the actuator 1, so that a structural unit is provided by the actuator 1, the flap device 4 and the sensor device 11, which can be assembled in a unified manner on the assigned flow line 6. The possibility of simplified assembly is obtained in that the sensor device 11 does not need to be assembled separately on or in the flow line 6, but is assembled together with the actuator 1 on the assigned flow line 6 without additional assembly steps. In addition, the possibilities of saving materials, saving structural space, reducing weight and reducing the manufacturing costs especially for the sensor device 11 are obtained.

[0124] The sensor device 11 is electrically connected to the control unit 24 and sends its sensor signal (firstly) to the control unit 24, which can for example preprocess the signal.

[0125] In the embodiment shown, the sensor device 11 projects into the flow volume 61 inside the assigned flow line 6. The sensor device 11 is arranged in this position close to the flap device 4, so that the sensor device 11 and the flap device 4 occupy a defined and close positional relationship with each other, and thus the parameters of the air flow adjacent to the flap device 4 can be measured via the sensor device 11.

[0126] The actuator 1 is assembled on the flow line 6 from the outside, wherein the sensor device 11 projects through a defined opening in the flow wall 60, which is closed in a fluid-tight manner in the assembled position, for example by the actuator 1 via a seal in fluid-tight contact with the flow wall 60.

[0127] In Figure 3In the illustrated embodiment of the actuator 1, a sensor device 11 is formed having a mandrel 113, which is mechanically firmly connected to the housing 10, and on which a sensor element 111 is arranged. The sensor element 111 is designed, for example, as a temperature sensor, a barometric pressure sensor or a sensor for measuring other parameters of an air flow, and is arranged at the end of the mandrel 113 remote from the housing 10 such that the mandrel 113 projects into the assigned flow line when the actuator 1 is in the assembled position and the sensor element 111 is arranged in the air flow. The sensor element 111 is connected, for example, via an electrical line extending within the mandrel 113 to a control unit 24 in the interior of the actuator 1.

[0128] In Figure 3 the illustrated embodiment, on the mandrel 113, for example on a circuit board enclosed in the mandrel 113, one or more sensor elements 111 for measuring one or more (different) parameters of an air flow can be arranged.

[0129] In Figure 4 the illustrated embodiment, a sensor element 111 in the form of a temperature sensor of the sensor device 11 is arranged on a circuit board 110. The sensor element 111 is integrated into the housing 10 of the actuator 1 and is thus encapsulated in the housing 10. In the illustrated embodiment, the sensor device 11 has a heat-conducting element 112, for example a metal element with good heat-conducting properties or a plastic element with good heat-conducting properties (optionally made of heat-modified plastic to improve heat conductivity). The heat-conducting element 112 projects into the flow volume 61 in the interior of the assigned flow line 6, absorbs heat in the air flow in the flow line 6 and conducts the heat to the sensor element 111 in the interior of the actuator 1, so that a temperature measurement of the air flow can be carried out via the sensor element 111.

[0130] In Figure 5 a further illustrated embodiment, the sensor device 11 is integrated into the actuator 1. The actuator 1 is externally mounted on the flow wall portion 60 of the assigned flow line 6 and is firmly assembled on the flow line 6 such that the transition between the housing 10 of the actuator 1 and the flow wall portion 60 is sealed in a flow-tight manner. Via openings 600, 601 in the flow wall portion 60, a part of the air flow is guided into the space 602 between the flow wall portion 60 and the actuator 1, so that the air flow can interact with the sensor device 11 and thus parameters of the air flow, such as air temperature, barometric pressure or other parameters, can be measured via the sensor device 11 on the actuator 1.

[0131] In a Figure 5 modified compared to the embodiment according to Figure 6In the embodiment, a single opening 603 is formed in the flow wall portion 60, and this opening opens the flow wall portion 60 towards the actuator 1 externally assembled on the flow line 6. Thus, the air flow can come into contact with the sensor device 11 integrated into the actuator 1, and thereby the parameters of the air flow can be measured via the sensor device 11.

[0132] In the embodiment according to Figure 6 the transition portion between the housing 10 and the flow wall portion 60 is also sealed in a fluid-tight manner, so that the actuator 1 closes the opening 603 relative to the external space in the assembled position, and thus the air flow cannot reach the outside (passing by the actuator 1).

[0133] In Figure 7 the shown embodiment, the sensor device 11 is arranged on the shaft 40 of the flap device 4.

[0134] In the embodiment according to Figure 7 in one design, the electrical contact between the sensor device 11 and the control unit 24 of the actuator 1 can be established via the shaft 40 if necessary. For this purpose, the shaft 40 can generally be electrically conductive. In another design, the shaft 40 can have an electrical circuit integrated into or imprinted on the shaft 40, and the sensor device 11 is electrically connected to the control unit 24 of the actuator 1 via this electrical circuit. In yet another design, the electrical connection can be established via a separate electrical circuit (separate from the shaft 40). Depending on whether the shaft 40 is firmly spliced with the actuator 1 or detachably connected to the actuator 1, the electrical circuit can be implemented as non-detachable or can be implemented as detachable via a plug.

[0135] In Figure 8 the shown embodiment, although the sensor device 11 is structurally formed separately from the actuator 1 and the flap device 4. However, the sensor device 11 is electrically connected to the actuator 1 via the electrical connection line 14 and the interface 15, and thereby is electrically connected to the control unit 24 of the actuator 1. Through the (short) connection line 14, the sensor device 11 can be connected to the actuator 1 especially before the actuator 1 is assembled on the flow line 6, thus providing again a structural unit composed of the actuator 1, the flap device 4 and the sensor device 11, which can be assembled together on the assigned flow line 6 without subsequently (separately) cabling the sensor device 11.

[0136] The different sensor devices 11 of the above embodiments can also be combined with each other. Thus, the actuator 1 can also have a plurality of different sensor devices 11, which are integrated into the actuator 1 and / or the flap device 4 in different ways.

[0137] The actuator 1 has an electric motor 2 and a transmission mechanism 3, which are controlled via the control unit 24 of the actuator 1. In principle, electric motors and transmission mechanisms of different configurations are conceivable and possible. In particular, the electric motor 20 of such an actuator 1 can be a stepper motor.

[0138] Figure 9 and Figure 10 An embodiment of the actuator 1 for adjusting the flap device 4 of the air conditioning system 5 in a vehicle 8 is shown, which actuator can be used according to Figures 2 to 8 in the embodiment of.

[0139] The actuator 1 has a housing 10, which encloses the electric motor and the transmission mechanism. The transmission mechanism particularly includes a driven gear 33, which forms the driven part for driving the flap device 4.

[0140] According to Figure 9 and Figure 10 Viewed from different sides of the actuator 1, the driven gear has a driven element 331, via which the actuator is coupled to the flap device 4. The driven element 331 has the shape of a pinion or a toothed ring and is coupled to the shaft 40 of the flap device 4, for example, in such a way that the shaft 40 is inserted into the toothed ring (such as Figure 10 ) or is sleeved onto the pinion as a hollow shaft ( Figure 9 ).

[0141] Figure 11 An actuator 1 without the housing 10 is shown, Figure 12 the electric motor 2 of the actuator 1 is shown, and Figure 13 an embodiment of the motor shaft 210 of the electric motor 2 is shown, on which a magnetic element facility 211, 212 is arranged.

[0142] In the shown embodiment, the electric motor 2 is realized by a claw-pole type stepper motor, which has a stator 20 and a rotor 21 that can rotate relative to the stator 20 about the rotational axis D. The rotor 21 carries a transmission element in the form of a drive worm 30, which engages with the cylindrical gear engagement portion 300 of the transmission gear 31 of the transmission mechanism 3 by means of a worm engagement portion 300 and is thus used to introduce force into the transmission mechanism 3.

[0143] The transmission mechanism 30 has a plurality of transmission gears 31, 32, which form a transmission ratio chain for transmitting force from the electric motor 2 to the driven gear 33. The transmission gear 31 forms a pinion 311, which engages with the cylindrical gear engaging portion 320 of the transmission gear 32. The transmission gear 32 forms a pinion 321, which engages with the cylindrical gear engaging portion 330 of the driven gear 33. Since the pinions 311, 321 of the transmission gears 31, 32 have a (significantly) smaller diameter than the cylindrical gear engaging portions 310, 320, 330 of the transmission gears 31, 32 and the driven gear 33, the transmission mechanism 3 provides a (force) transmission ratio for adjusting the flap device 4.

[0144] As Figure 9 and Figure 10 shown in, the transmission mechanism 30 and the electric motor 2 are jointly enclosed in the housing 10 of the actuator 1. A driven part is provided via the driven element 331 of the driven gear 33, and the actuator 1 is coupled to the flap device 4 via this driven part.

[0145] The stator 20 of the electric motor 2 is composed of stator parts 25, 26, 27, which provide a yoke plate for conducting a (time-variable) magnetic flux. As can be seen from Figure 12 it, the stator parts 25, 26, 27 implement two magnetic circuits, and stator coils 22, 23 with coil windings 220, 230 arranged thereon are respectively assigned to these magnetic circuits for feeding in the magnetic flux. The rotor 21 can be stepwise adjusted by the fed-in magnetic flux in interaction with the (permanent magnet) magnet facilities 211, 212, wherein the step size is determined by the arrangement and sequence of the stator poles of the stator 20, which will be explained below. Here, the magnet facilities 211, 212 of the rotor 21 are assigned to each magnetic circuit.

[0146] It should be noted here that the rotor 21 can also only have a (unique) magnet facility 211', which will also be explained in connection with Figure 18 this below.

[0147] In Figures 14 to 16 the embodiment of the stator 20 shown, the stator 20 is formed by an inner stator part 25 and two outer stator parts 26, 27 spliced together with the inner stator part 25. In the splicing position, as Figure 15 shown in, the stator parts 25, 26, 27 are arranged along the rotation axis D around which the rotor 21 can rotate relative to the stator 20 and are spliced together with each other such that the stator poles 252, 253, 261, 271 are finger-like and interlocked, and are arranged along the circumferential direction pointing around the rotation axis D for each magnetic circuit.

[0148] The inner stator part 25 is integrally and monolithically formed as one piece. The inner stator part 25 is formed, for example, as a stamped and bent part, from a soft magnetic sheet material.

[0149] Likewise, the outer stator parts 26, 27 are each integrally and monolithically formed, for example, as stamped and bent parts, from a soft magnetic sheet material.

[0150] As can be seen in conjunction with Figure 14 and Figure 15 together, the inner stator part 25 forms a first inner stator pole 252, which faces the first outer stator part 26 of the outer stator parts 26, 27 and is interlocked between the first outer stator poles 261 of the assigned outer stator part 26. Here, the first inner stator pole 252 is formed on the annular body section 250 of the inner stator part 25 and extends axially from the body section 250. In contrast, the first outer stator pole 261 is formed on the annular body section 260 of the first outer stator part 26 and extends axially towards the inner stator part 25.

[0151] As can be seen in conjunction with Figure 14 and Figure 15 together, the inner stator part 25 also forms a second inner stator pole 253, which is finger-shaped and interlocked between the second outer stator poles 271 of the second outer stator part 27. The second inner stator pole 253 is formed on the annular second body section 251 of the inner stator part 25 and extends axially along the axis of rotation D towards the second outer stator part 27. The second outer stator pole 271 is formed on the annular second body section 270 of the second outer stator part 27 and extends axially towards the inner stator part 25.

[0152] From Figure 14 and in conjunction with Figure 16 it can be seen that the first body section 250 of the inner stator part 25 is separated from the second body section 251 by means of circumferentially extending gaps 254 (i.e., two adjacent gaps 254). In this way, magnetic decoupling of the magnetic circuit is achieved, such that the magnetic flux fed in via the stator coils 22, 23 essentially only flows in the respectively assigned magnetic circuit.

[0153] From Figure 15 it can be seen that the stator poles 252, 261; 253, 271 of the respective magnetic circuits are arranged in an interlocking and nested manner, such that the stator poles 252, 261; 253, 271 are arranged alternately in the circumferential direction. Viewed along the enveloping surface that wraps around the cylinder of the stator 20, the stator poles 252, 261; 253, 271 are trapezoidal here, where the stator poles 252, 261; 253, 271 taper towards the other stator parts 25, 26, 27 respectively and are interlocked with each other with a relatively narrow and uniform gap formed therebetween.

[0154] The magnet arrangements 211, 212 on the motor shaft 210 of the rotor 21 rotate within the assigned magnetic circuits formed by the stator poles 252, 261; 253, 271 respectively, and are driven by feeding in magnetic flux. According to the functional principle of the claw-pole type stepping motor, the rotor 21 follows the magnetic field of the stator 20 here, so that the rotor 21 can be adjusted step by step.

[0155] As Figure 14 As depicted, the stator pole arrangements of the magnetic circuits are offset from each other by an angular offset α in the circumferential direction. Accordingly, there is an angular offset α between the center line M1 of the first inner stator pole 252 and the center line M2 of the second inner stator pole 253 axially adjacent to the first inner stator pole 252. The angular offset α corresponds to the angle by which the periodic arrangements of the first inner stator pole 252 and the second inner stator pole 253 are offset from each other in the circumferential direction. The angular offset α is, for example, less than 1 / 4 of the period angle of the inner stator poles 252, 253.

[0156] In the illustrated embodiment, the stator 20 is designed as a 10-pole. Accordingly, five first outer stator poles 261 are assigned to the five first inner stator poles 252, and five second outer stator poles 271 are assigned to the five second inner stator poles 253. For each magnetic circuit, a 10-pole arrangement is obtained. The period angle of the inner stator poles 252, 253 is 72°. If the angular offset α is only 1 / 4 of this period angle, the angular offset α is 18°.

[0157] A relatively small step size can be adjusted for the stepping motor by the angular offset α. The magnet arrangements 211, 212 of the rotor 21 are arranged aligned with each other here, and the arrangement of their magnetic poles is not offset from each other in the circumferential direction.

[0158] As Figure 12 and in combination with Figure 14 it can be seen that stator coils 22, 23 are assigned to each magnetic circuit. The stator parts 25, 26, 27 (realizing the yoke plates) are formed with engagement sections 255, 256, 262, 263; 257, 258, 272, 273 at the ends of the stator parts 25, 26, 27 formed cylindrically when made as stamping and bending parts. From Figure 15 it can be seen that these engagement sections are arranged in a sandwich form and overlap alternately, and provide seats for the assigned stator coils 22, 23 respectively.

[0159] Therefore, from Figure 15It can be seen that first inner engagement sections 255, 256 are formed on the inner stator part 25, the first inner engagement sections pointing to the first outer stator part 26 and being arranged alternately and overlappingly with first outer engagement sections 262, 263 of the first outer stator part 26. The engagement sections 255, 256, 262, 263 are jointly embedded into the coil body of the assigned stator coil 22 and respectively have chamfered portions 259, 264 on the surrounding edges that are conducive to splicing into the stator coil 22.

[0160] In addition, it can be seen from Figure 15 that the inner stator part 25 forms second inner engagement sections 257, 258, the second inner engagement sections overlapping and being arranged alternately with second outer engagement sections 272, 273 of the second outer stator part 27. Again, the engagement sections 257, 258, 272, 273 have chamfered portions 259, 274 on the surrounding edges that facilitate splicing into the coil body of the assigned stator coil 23. The engagement sections 257, 258, 272, 273 jointly form a seat for the assigned stator coil 23 again.

[0161] Since the engagement sections 255, 256, 262, 263; 257, 258, 272, 273 for each magnetic circuit are arranged in a sandwich form with respect to each other and are jointly embedded into the coil bodies of the respectively assigned stator coils 22, 23, the relative positioning of the stator parts 25, 26, 27 with respect to each other is obtained via the engagement sections 255, 256, 262, 263; 257, 258, 272, 273. The stator parts 25, 26, 27 are held relative to each other via the engagement sections 255, 256, 262, 263; 257, 258, 272, 273 and are positioned relative to each other in a prescribed manner by being embedded into the respectively assigned stator coils 22, 23.

[0162] Since the inner stator part 25 is integrally and monolithically formed here, a higher rigidity is obtained for the stator 20. In addition, a simplified manufacture of the electric motor 2 is obtained because the splicing process for a separate inner stator part can be eliminated.

[0163] Since chamfered portions 259, 264, 274 are formed on the surrounding edges of the engagement sections 255, 256, 262, 263, 257, 258, 272, 273 here, a simple splicing of the stator parts 25, 26, 27 with respect to each other and with respect to the stator coils 22, 23 is obtained in the case of accurate positioning of the stator parts 25, 26, 27 and the stator coils 22, 23 with respect to each other.

[0164] From Figure 13As can be seen, the magnet arrangements 211, 212 of the rotor 21 are arranged on the motor shaft 210 and are fixedly placed thereon against relative rotation. Due to the angular offset α between the magnetic circuits, the magnet arrangements 211, 212 and their pole arrangements are not arranged angularly offset from each other. For the magnet arrangements 211, 212, identical parts can be used here, resulting in simple and inexpensive manufacturing.

[0165] To ensure that the magnet arrangements 211, 212 are positioned at the correct angle, as Figure 17A and Figure 17B shown, the magnet arrangements 211, 212 can each have form-locking elements 213, 214 in the form of projections and / or recesses, which, when the magnet arrangements 211, 212 are installed, interlock in a complementary manner and thus cause the magnet arrangements 211, 212 to be automatically positioned relative to each other in an angle-correct manner due to the form-locking interaction. This results in a simple arrangement and splicing of the magnet arrangements 211, 212 on the motor shaft 210.

[0166] In Figure 18 the further embodiment shown, only one (unique) magnet arrangement 211' is arranged on the motor shaft 210. The magnet arrangement 211' interacts with two magnetic circuits formed by the first inner stator pole 252 and the first outer stator pole 261 and by the second inner stator pole 253 and the second outer stator pole 271, and accordingly extends on the motor shaft 210 over such an axial length that the magnet arrangement 211' extends into the regions of the two magnetic circuits.

[0167] Figure 19 and Figure 20A 、 Figure 20B show views of the stator coil 22, where the stator coils 22, 23 are preferably designed identically and thus, in combination with Figure 19 and Figure 20A 、 Figure 20B the content described also applies in exactly the same way to the stator coil 23.

[0168] From Figure 19 and in combination with Figure 11 it can be seen that the stator coil 22 has a coil body 221, which forms a winding section 228 on which a coil winding 220 is arranged. The coil winding 220 is composed of wire wound around the winding section 228, and the wire is guided away from the winding section 228 via wire guides 223, 224 using wire ends 225, 226 and laid towards the circuit board of the control unit 16.

[0169] The wire ends 225, 226 can be joined to the circuit board in a direct material-locking manner, for example, by soldering. Alternatively, the wire ends 225, 226 can also be connected to soldering pins firmly placed on the coil body 221. Through these soldering pins, the stator coil 22 can be inserted into the assigned openings of the circuit board and soldered to the circuit board together.

[0170] The stator body 221 forms an engagement opening 222 into which the engagement sections 255, 256, 262, 263 of the assigned magnetic circuit of the stator 20 are inserted. Through this engagement opening, the stator coil 22 is mechanically positioned on the stator parts 25, 26, 27, and the feeding of the magnetic flux is also achieved.

[0171] From Figure 20A and Figure 20B It can be seen that the winding section 228 has a convex spherical shape without sharp edges. Therefore, the wires forming the coil winding 220 can be arranged on the winding section 228 in a closely grouped manner. Additionally, a molding compound 227, such as potting compound, can be used to encapsulate the coil winding 220 in this way to prevent the wires from moving during operation and the accompanying generation of noise.

[0172] Figure 21 Another embodiment of the actuator 1 is shown in a schematic view, in which the sensor device 11 has a carrier element 114. Through the carrier element, discrete sensor elements 111 arranged at the protruding end of the carrier element 114 are connected to the main circuit board of the control unit 24 of the actuator 1. The carrier element 114 realizing the spacer is similar to that shown in Figure 3 and is, for example, surrounded in a housing mandrel 113. The housing mandrel is firmly connected to the housing 10 of the actuator 1 in such a way that the housing mandrel 113 and the housing 10 are integrally and monolithically formed.

[0173] The housing mandrel 113 can be closed so that the sensor device 11 can be surrounded in a fluid-tight manner in the housing mandrel 113, and thus particles from the air flow cannot enter the interior of the housing. However, one or more openings similar to those shown in Figure 3 can also be formed on the housing mandrel 113. These openings open the housing mandrel 113 so that the air flow can flow around the discrete sensor elements 111.

[0174] In Figure 22In the embodiment shown, the sensor device 11 has a carrier element 114 in the form of a circuit board, which is connected in a plug-in manner to the plug interface 240 of the main circuit board of the control unit 24 of the actuator 1. The carrier element 114 is mechanically connected to the main circuit board of the control unit 24 via the plug interface 240. In addition, the conductor traces 115 on the carrier element 114 implemented by the circuit board are electrically coupled to the control unit 24, so that the sensor element 111 arranged at the end of the circuit board implementing the carrier element 114 remote from the control unit 44 is electrically coupled to the control unit 24.

[0175] In Figure 23 In the embodiment shown, plug pins 116 are provided on the carrier element 114 in the form of a circuit board, which are inserted into the assigned plug openings 241 on the main circuit board of the control unit 24 and are connected to the main circuit board via this. The plug pins 116 can be pressed into the plug openings 241, thereby providing an interference connection. In addition to such an interference connection, or as an alternative to such an interference connection, the plug pins 116 can be soldered into the plug openings 241.

[0176] In Figure 24 In the embodiment shown, the circuit board on which the conductor traces 115 and the sensor element 111 are arranged and which implements the carrier element 114 is connected to the main circuit board of the control unit 24 via so-called circuit board edge soldering. For this purpose, soldering surfaces 117 are arranged on the circuit board implementing the carrier element 114, and these soldering surfaces are connected to the main circuit board of the control unit 24 via soldering connections 242.

[0177] In Figure 25 In yet another additional embodiment shown, the carrier element 114 of the sensor device 11 is connected to the main circuit board of the control unit 24 of the actuator 1 via a flexible connection section 118.

[0178] In this embodiment, the carrier element 114 can generally be composed of a flexible circuit board.

[0179] However, the unit of the connection section 118 and the carrier element 114 can also be implemented by a so-called rigid-flex circuit board, in which the carrier element 114 and the connection section 118 are provided by a composite of a rigid circuit board component and a flexible circuit board component. The flexible circuit board component is arranged as a cladding on the rigid circuit board component constituting the carrier element 114 and forms the flexible connection section 118 for connection to the main circuit board of the control unit 24.

[0180] In a further design, the carrier element 114 can be implemented by means of a so-called semi-flexible circuit board, in which the circuit board implementing the carrier element 114 is made of a rigid circuit board material, in particular conventional FR4 material, but is milled very thin in the region of the connecting section 118 such that the circuit board can be bent in the region of the connecting section 118.

[0181] In the Figure 26 illustrated embodiment schematically shown, the carrier element 114 consists of the main circuit board of the control unit 24 and is thus implemented by a section of the main circuit board. For this purpose, the main circuit board can be arranged in the housing 10 of the actuator 1 such that the section of the circuit board implementing the carrier element 114 projects vertically outwards from the housing 10.

[0182] In the above-mentioned Figures 22 to 26 embodiment, the circuit board of the carrier element 114 is preferably surrounded by a housing mandrel 113 which is firmly connected to the housing 10 of the actuator 1, for example integrally and monolithically formed with the housing 10.

[0183] The carrier element 114 can, for example, additionally be mechanically fixed in the housing mandrel 113, for example by means of a latching part or by means of a guiding part for receiving the carrier element, for example in the form of a guiding groove.

[0184] The housing mandrel 113 can here be configured to be closed such that particles from the air flow cannot penetrate into the interior of the housing mandrel 113 and the housing 10.

[0185] In a further design, similar to Figure 3 shown, openings can be formed in the housing mandrel 113 such that the air flow can flow around the sensor element 111 within the housing mandrel 113, in particular in order to measure parameters of the air flow, such as air humidity, in direct contact with the air flow. Here, a seal can be provided within the housing mandrel 113, for example via an O-ring seal element, a seal element implemented by two-component injection molding or a surface seal, which surface seal is arranged, for example, as a foam part on the carrier element 114 consisting of a circuit board for surface sealing on the circuit board. Via such a seal, for example, the carrier element 114 can be sealed off relative to the housing mandrel 113 and thus it can be prevented that particles enter into the interior of the housing 10, in particular into the region of the control unit 24, via the housing mandrel 113. Additionally or alternatively, the main circuit board of the control unit 24 can be sealed off relative to the housing cover of the housing 10, for example via a surface seal arranged, for example, as a foam part on the main circuit board.

[0186] As Figure 27As shown, the sensor device 11 can be arranged relative to the axis 40 of the flap element 41 that moves by means of the actuator 1 such that the sensor device 11 is arranged in the still air zone WS behind the axis 40. Thus, the air flow S flows past the sensor device 11 but does not strike the sensor device 11 head-on, whereby it is possible to avoid generating turbulence in the air flow S by the sensor device 11 in order to suppress unwanted noise generated by the sensor device 11.

[0187] The sensor device 11 is preferably calibrated during manufacture. In particular, the sensor device 11 is mounted on the actuator 1 and calibrated in the mounted state. Generally speaking, the sensor element 111, for example a temperature sensor, has relatively large tolerances. When calibrating in the mounted state, (when the sensor element 11 is implemented by a temperature sensor) for example, a temperature offset or generally a correction factor can be measured, the correction factor is stored and used in further operation, so as to obtain higher sensor accuracy during operation.

[0188] During operation, diagnostics can also be performed on the sensor device 11, for example, with respect to possible short circuits in the connection lines connecting the sensor element 111 (for example, the conductor traces 115 on the circuit board of the carrier element 114) or with respect to, for example, unstable contact with the main circuit board of the control unit 24 when, as in the embodiment according to Figure 22 the circuit board is plugged into and connected to the main circuit board. It is also possible to identify untrustworthy values, for example, a large jump in the measured value, in order to identify a faulty operation caused, for example, by the sensor element 111.

[0189] Such diagnostics can be continuously performed during operation, for example, by continuously checking the sensor values with respect to predefined limits. However, such diagnostics can also be performed cyclically, for example, once a day, once a week, or once a month.

[0190] The diagnostics can be performed during the actual measurement during operation, or can be performed within the scope of diagnostic measurements independently of the actual measurement.

[0191] When making measurements during operation, filtering can be performed, especially time filtering. Thus, the measured values can be averaged over a predetermined time period, for example via a mean value filter. Additionally or alternatively, a digital signal filter (low-pass filter, FIR filter, or IIR filter or similar filter) can be used, or an analog filter (such as an R-C filter) can be used. For example, a predetermined number of previous measured values (e.g., from 2 to 1000 measured values, such as 10 to 100 measured values) can always be averaged in order to determine the filtered measured value. Different sensor configurations can be emulated through filter adjustment, for example in order to emulate sensor inertia, which causes the measured values to change slowly and can be emulated by a mean filter.

[0192] Within the scope of control and / or within the scope of diagnosis, the measured sensor values can be compared with information regarding the adjustment actions. If, for example, flap element 41 is adjusted via actuator 1 to provide a warm air flow, then the air flow behind the flap element is considered to have a higher temperature, and thus the temperature sensor should output a corresponding measured value. However, if the value actually measured by sensor device 11 deviates from the expected value, then this can be used to control actuator 1 to adjust flap element 41, or for diagnosis in terms of possible untrustworthy values.

[0193] The basic concept of the present invention is not limited to the above-described embodiments, but can also be implemented in other ways.

[0194] In principle, actuators, electric motors, and transmission mechanisms of completely different configurations can be used, and thus the examples should not be understood as limiting in any way.

[0195] List of reference numerals

[0196] 1 Actuator

[0197] 10 Housing

[0198] 11 Sensor device

[0199] 110 Circuit board

[0200] 111 Sensor element

[0201] 112 Conductive element

[0202] 113 Mandrel

[0203] 114 Carrier element

[0204] 115 Conductor trace

[0205] 116 Plug pin

[0206] 117 Brazing surface

[0207] 118 Connecting section

[0208] 12 Interface

[0209] 13 Connecting line

[0210] 14 Connecting line

[0211] 15 Interface

[0212] 2 Motor

[0213] 20 Stator

[0214] 21 Rotor

[0215] 210 Motor shaft

[0216] 211, 212 Magnet arrangement

[0217] 211' Magnet arrangement

[0218] 213, 214 Form-locking elements

[0219] 22, 23 Coil

[0220] 220, 230 Coil winding

[0221] 221 Coil body

[0222] 222 Insertion opening

[0223] 223, 224 Wire guiding part

[0224] 225, 226 Wire ends

[0225] 227 Molding compound

[0226] 228 Winding section

[0227] 24 Control unit (circuit board)

[0228] 240 Plug interface

[0229] 241 Plug opening

[0230] 242 Brazing connection

[0231] 25 Stator part

[0232] 250, 251 Body section

[0233] 252, 253 Stator poles

[0234] 254 Gap

[0235] 255 - 258 splicing section (tab)

[0236] 259 chamfered part

[0237] 26 stator part

[0238] 260 body section

[0239] 261 stator pole

[0240] 262, 263 splicing section (tab)

[0241] 264 chamfered part

[0242] 27 stator part

[0243] 270 body section

[0244] 271 stator pole

[0245] 272, 273 splicing section (tab)

[0246] 274 chamfered part

[0247] 3 transmission mechanism

[0248] 30 driving worm

[0249] 300 worm meshing part

[0250] 31 transmission gear

[0251] 310 cylindrical gear meshing part

[0252] 311 pinion

[0253] 32 transmission gear

[0254] 320 cylindrical gear meshing part

[0255] 321 pinion

[0256] 33 driven gear

[0257] 330 cylindrical gear meshing part

[0258] 331 driven element (pinion)

[0259] 4 flap device

[0260] 40 shaft

[0261] 41 flap element

[0262] 5 air - conditioning system

[0263] 50 flow system

[0264] Flow paths 500 - 507

[0265] 51 Blower

[0266] 52 Cooling device

[0267] 53 Heating device

[0268] 6 Flow paths

[0269] 60 Flow wall section

[0270] 600, 601 Openings

[0271] 602 Space

[0272] 603 Openings

[0273] 61 Flow volume

[0274] 7 Control device

[0275] 8 Vehicle

[0276] α Angle

[0277] D Axis of rotation

[0278] M1, M2 Center lines

[0279] S Air flow

[0280] WS Static wind area

Claims

1. A component of an air conditioning system (5) of a vehicle (8), the component having: An adjustable flap device (4) for influencing an air flow flowing through a flow line (500 - 507), and An actuator (1) for adjusting the flap device (4), wherein, The actuator (1) has an electric motor (2), Characterized in that it has a sensor device (11) arranged on the actuator (1) or the flap device (4) or electrically connected to the actuator (1) via a line (14), the sensor device being used to measure parameters of the air flow guided in the area of the flap device (4).

2. The component according to claim 1, characterized in that, The sensor device (11) is configured to measure parameters indicating the temperature of the air flow, the humidity of the air flow, the dew point of the air flow, the air quality of the air flow, the odor of the air flow, and / or the air pressure of the air flow.

3. The component according to claim 1, characterized in that The actuator (1) has a control unit (24) for controlling the operation of the electric motor (2) of the actuator (1), wherein the control unit (24) is electrically connected to the sensor device (11).

4. The component according to claim 3, characterized in that, The control unit (24) is configured to process the sensor signals of the sensor device (11).

5. The component according to claim 3, characterized in that, The control unit (24) is configured to correct the sensor signals of the sensor device (11) by using calibration values.

6. The component according to claim 3, characterized in that, The control unit (24) is configured to filter the sensor signals of the sensor device (11).

7. The component according to claim 3, wherein The control unit (24) is configured to check the sensor signals of the sensor device (11) in a diagnostic routine.

8. The component according to claim 1, characterized in that, The actuator (1) is electrically connected to a control device (7) separate from the actuator (1).

9. The component according to claim 1, wherein The actuator (1) has a housing (10) that at least partially surrounds the electric motor (2).

10. The component according to claim 9, wherein, The sensor device (11) is firmly mechanically connected to the housing (10) or to a component (24) of the actuator (1) that is firmly connected to the housing (10).

11. The component according to claim 9, wherein, The sensor device (11) protrudes outward relative to the housing (10) of the actuator (1).

12. The component according to claim 9, characterized in that, The sensor device (11) has a sensor element (111), and the sensor element is arranged on a carrier element (114).

13. The component according to claim 12, wherein The carrier element (114) is constituted by a circuit board on which conductor traces (115) are arranged.

14. The component according to claim 12, characterized in that, The carrier element (114) is accommodated in a housing mandrel (113) protruding from the housing (10).

15. The component according to claim 12, characterized in that, The carrier element (114) is formed flexibly or has a flexible section (118).

16. The component according to claim 9, characterized in that, The sensor device (11) has a heat-conducting element (112), and the heat-conducting element is used to conduct heat to the sensor element (111) or conduct heat away from the sensor element (111).

17. The component according to claim 16, wherein The heat-conducting element (112) protrudes outward relative to the housing (10) of the actuator (1), and the sensor element (111) is arranged inside the housing (10) of the actuator (1) or on the housing of the actuator.

18. The component according to claim 1, wherein The sensor device (11) is arranged on the flap device (4).

19. The component according to claim 1, wherein It has a flow line (6), the actuator (1) is connected to the flow line in the assembled position, and the flow line defines an internal flow volume (61) for guiding an air flow, and the flap device (4) is arranged in the flow volume.

20. The component according to claim 19, wherein, The sensor device (11) is arranged in the flow volume (61).

21. The component according to claim 19, wherein The flow line (6) has a flow wall portion (60) bounding the flow volume (61), and at least one opening (600, 601, 603) for guiding air to the sensor device (11) is formed in the flow wall portion.

22. The component according to claim 21, wherein, The actuator (1) is connected to the flow wall portion (60) such that the actuator (1) seals the at least one opening (600, 601, 603) in a flow-tight manner with respect to the external space.

23. The component according to claim 1, characterized in that, The electric motor (2) of the actuator (1) has a stator (20) and a rotor (21) rotatable relative to the stator (20) about a rotation axis (D), wherein the stator (20) has an inner stator portion (25), a first outer stator portion (26) and a second outer stator portion (27), wherein the inner stator portion (25), the first outer stator portion (26) and the second outer stator portion (27) are arranged along the rotation axis (D), and the inner stator portion (25) forms means for a first inner stator pole (252) on a first side axially facing the first outer stator portion (26), and means for a second inner stator pole (253) on a second side axially facing the second outer stator portion (27), wherein the first inner stator pole (252) and the second inner stator pole (253) are integrally and monolithically connected to each other.

24. The component according to claim 23, wherein, The inner stator portion (25) has a first body section (250) on which the first stator pole (252) is formed, and a second body section (251) integrally and monolithically formed with the first body section (250) and on which the second stator pole (253) is formed.

25. The component according to claim 23, characterized in that, The inner stator portion (25) is formed as a stamped and bent part.

26. The component according to claim 23, wherein The first outer stator portion (26) forms means for a first outer stator pole (261) for electromagnetic interaction with the first inner stator pole (252), and / or the second outer stator portion (27) forms means for a second outer stator pole (271) for electromagnetic interaction with the second inner stator pole (253).

27. The component according to claim 26, wherein, The first outer stator pole (261) and the first inner stator pole (252) are interdigitated such that the first outer stator pole (261) and the first inner stator pole (252) are alternately arranged along the circumferential direction pointing around the rotation axis (D), and / or the second outer stator pole (271) and the second inner stator pole (253) are interdigitated such that the second outer stator pole (271) and the second inner stator pole (253) are alternately arranged along the circumferential direction pointing around the rotation axis (D).

28. The component according to claim 23, wherein, The first inner stator pole (252) and the second inner stator pole (253) are angularly offset (α) from each other when viewed in the circumferential direction around the rotational axis (D).

29. The component according to claim 23, wherein, The motor (2) has a first stator coil (22) and a second stator coil (23), wherein the inner stator portion (25) has at least one first inner engagement section (255, 256) embedded in the first stator coil (22) and at least one second inner engagement section (257, 258) embedded in the second stator coil (23).

30. The component according to claim 29, characterized in that, The first outer stator portion (26) has at least one first outer engagement section (262, 263) which is arranged overlapping with the at least one first inner engagement section (255, 256) and embedded in the first stator coil (22), and / or the second outer stator portion (27) has at least one second outer engagement section (272, 273) which is arranged overlapping with the at least one second inner engagement section (257, 258) and embedded in the second stator coil (23).

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