Sensor assembly for a vehicle

Abstract

The invention relates to a sensor assembly (1) for a vehicle, comprising a sensor housing (20) and a plug connection (10) between a plug housing (11) and a plug (14), which is connected to the sensor housing (20) and in which at least one first contact element (12) is arranged, and a plug-in connector (14) which is connected to the at least one connection cable (3) and which has at least one second contact element (15) which interacts with the first contact element (12) in order to produce an electrical connection, the plug-in connector (14) being introduced into a receiving opening (13) of the plug-in connector housing (11), and the plug-in connector (14) being connected to the at least one connection cable (3) and having at least one second contact element (15) which interacts with the first contact element (12) in order to produce an electrical connection. The at least one second contact element (15) and the at least one first contact element (12) are electrically connected in such a way that the at least one second contact element (15) and the at least one first contact element (12) establish an electrical connection, the plug-in connector (14) being non-detachably connected to the plug-in connector housing (11) by means of a welded connection (18), in particular a laser transmission welded connection, which forms a fluid-tight radial seal (18A) between the plug-in connector (14) and the plug-in connector housing (11). The invention also relates to a method for assembling such a sensor assembly for a vehicle.

Description

Technical Field

[0001] The present invention relates to a sensor assembly for a vehicle and a method for assembling the sensor assembly for a vehicle. Background Art

[0002] Sensor assemblies for vehicles are known from the prior art. These sensor assemblies comprise a sensor housing and a detachable plug connection between a plug housing and a plug connector, the plug housing being connected to the sensor housing, and the plug connector being connected to at least one connecting cable. Direct cable connections for sensor assemblies are also known, in which the cable sheath of the connecting cable is overmolded, bonded, or laser-welded to the sensor assembly in a fluid-tight manner. Fluid-tight overmolding of the connecting cable is technically demanding, particularly with regard to maintaining the seal over its service life and handling the connecting cable on a workpiece holder, and is also costly.

[0003] Document DE 10 2017 216 533 A1 discloses a sensor unit comprising a support with at least two busbars. An internal electrical connection to a measured value transmitter is formed at the first ends of the at least two busbars, and an external electrical connection for a plug-in module is formed at the second ends of the at least two busbars. An orientation component surrounds the at least two busbars and is arranged between the internal electrical connection and the external electrical connection. The orientation of the orientation component determines the second ends of the at least two busbars and the outlet direction of the external electrical connection. The second ends of the at least two busbars can each be designed as contact pins of the plug-in module, which can make electrical contact with corresponding contacts of the plug-in module. The plug-in module and the plug-in module of the sensor unit form a detachable plug connection.

[0004] Document DE 20 2014 106 056 A1 discloses a hermetically sealed plug connector comprising two removably pluggable plug parts, each having a front housing portion adapted to fit within the other and electrical contact elements adapted to fit within the other. When plugged together, the two front housing portions overlap in the region facing each other. The two front housing portions seal the plug connection created when the two plug parts are plugged together to the outside by means of a sealing lip arranged on one front housing portion and an annular groove arranged on the other front housing portion. The groove is surrounded internally by an annular sealing surface and externally by an annular flange. Summary of the Invention

[0005] The sensor component for a vehicle having the features of independent claim 1 has the advantage that sensor components with a detachable plug connection for at least one connecting cable and sensor components with a non-detachable plug connection for at least one connecting cable can be manufactured based on the same production line concept.

[0006] In a sensor assembly with a detachable plug connection, a plug component is arranged directly on a portion of the sensor housing and a corresponding counter-plug component is fitted to at least one connecting cable.For various reasons, some customers require sensors with direct cable outlet.

[0007] In an embodiment of the sensor assembly according to the invention, the connecting cable is not conveyed through all the production steps of an existing production line. Instead, the corresponding plug-in connection between the connector housing connected to the sensor housing and the connector with the connecting cable is not established until the end of production. The connector is then connected to the connector housing in a fluid-tight manner by a welded connection, in particular a laser transmission welded connection. This eliminates the need for overmolding the entire sensor assembly and the at least one connecting cable, which could in some cases cause problems for the electronic components of the sensor assembly due to temperature. In addition, the removable plug-in connection already used in the sensor assembly can be largely retained. Since the plug-in connection is based on proven plug-in connection technology, the technical risks are also low.

[0008] Embodiments of the present invention provide a sensor assembly for a vehicle, comprising a sensor housing and a plug connection between a plug housing and a plug connector. The plug housing is connected to the sensor housing and has at least one first contact element arranged therein. The plug connector is connected to at least one connecting cable and has at least one second contact element that cooperates with the first contact element to establish an electrical connection. The plug connector is inserted into a receiving opening in the plug housing, establishing an electrical connection between the at least one second contact element and the at least one first contact element. The plug connector is non-detachably connected to the plug housing via a welded connection, particularly a laser transmission welded connection, which forms a fluid-tight radial seal between the plug connector and the plug housing.

[0009] Furthermore, a method for assembling such a sensor assembly for a vehicle is proposed. A sensor housing is provided, and depending on the sensor concept and communication protocol to be employed, a plug housing having at least one first contact element, a circuit carrier having an electronic circuit, and a plug connector having at least one second contact element and at least one connecting cable are provided. The at least one first contact element and the circuit carrier are connected to each other at an internal interface. The circuit carrier is introduced into the sensor housing, and the plug connector housing and the sensor housing are connected to each other at a connection region. To form a direct cable connection, the plug connector having the at least one second contact element is introduced into a receiving opening of the plug connector housing, so that the at least one second contact element and the at least one first contact element are electrically connected at the external interface. Furthermore, the plug connector is non-detachably connected to the plug connector housing by a welded connection, in particular a laser transmission welded connection, which forms a fluid-tight radial seal between the plug connector and the plug connector housing.

[0010] To produce welded connections, particularly laser transmission welded connections, a connector and / or connector housing can be prepared accordingly in the area where the welded connection is to be provided. For example, sealing elements can be mounted on the connector to seal the individual cable cores. In addition, the contact elements connected to the individual cable cores of the connecting cable can be pressed into the plastic portion of the connector. Since the welded connection forms a non-detachable connection between the two joining parts, the latching lugs or latching plates used to secure the connector to the connector housing can be omitted. Forces, such as vibrations, that are typically transmitted through external ribs can also be compensated for by the welded connection. Therefore, such guide ribs and / or connector flanges can also be omitted. Since the welded connection between the connector and the connector housing acts as a radial seal, additional radial seals can also be omitted. By eliminating the guide ribs or connector flanges and eliminating the latching lugs or latching plates, installation space can be advantageously saved. Furthermore, the manufacturing process of connectors manufactured as plastic injection molded parts can be simplified.

[0011] An embodiment of a sensor arrangement for a vehicle can be designed, for example, as a rotational speed sensor having an ASIC (ASIC: Application Specific Integrated Circuit) or redundantly having two ASICs or an ASIC with two additional sensor elements, a temperature sensor, a microphone, etc. The rotational speed sensor can be equipped with HALL, AMR, GMR, TMR, or similar measuring technology.

[0012] The connector housing and the sensor housing of the sensor assembly can preferably be designed as plastic injection-molded components, respectively. This enables convenient and cost-effective mass production.

[0013] The measures and developments listed in the dependent claims make it possible to advantageously improve the sensor arrangement for a vehicle specified in independent claim 1 and the method for assembling such a sensor arrangement for a vehicle specified in independent claim 10 .

[0014] It is particularly advantageous that a circuit carrier with an electronic circuit can be arranged in the sensor housing. The electronic circuit can be understood, for example, as an evaluation and control circuit that processes and evaluates the detected sensor signals. The electronic circuit can have at least one interface that can be designed using hardware and / or software. In the case of a hardware design, the interface can, for example, be part of a so-called ASIC system that includes the various functions of the electronic circuit. However, it is also feasible that the interface is a dedicated integrated circuit or is at least partially composed of discrete components. In the case of a software design, the interface can be a software module that, for example, exists on a microcontroller together with other software modules. Also advantageous is a computer program product with program code that is stored on a machine-readable carrier, such as a semiconductor memory, hard disk storage, or optical storage, and is used to evaluate when the electronic circuit executes the program.

[0015] In an advantageous embodiment of the sensor assembly, the plug housing and the first end of the at least one first contact element extending into the plug housing can form the external interface of the sensor assembly. The second end of the at least one first contact element, opposite the first end, can be connected to the circuit carrier and form the internal interface of the sensor assembly. The number and arrangement of the at least one first contact element and the at least one second contact element can be adapted to the communication protocol to be used. A plug housing with at least one first contact element allows the external interface of the sensor assembly to be pre-adapted to the customer's desired bus topology, while the mechanical interface between the sensor housing and the plug housing, or between the plug housing and the plug connector, can be designed identically. For example, a two-, four-, or eight-pin plug-in connection with a direct cable connection can be provided, which meets the corresponding requirements for signal transmission and communication protocols. This embodiment of the sensor assembly also makes it possible, for example, to simply implement the external interface with a direct cable connection as an A2B interface, with the required plug pins positioned as close together as possible in the plug housing to enable high transmission frequencies (100 Mbit) for the external interface, similar to those of network interfaces. Furthermore, the external interface of the sensor component with direct cable connection can be designed as a MOST bus interface, a 100BASE-T1 interface, a PSI5 interface, a CAN interface, a CAN-FD interface, a VIAS interface or the like.

[0016] In another advantageous embodiment of the sensor assembly, at least one first contact element can be designed as a contact pin and pressed into the connector housing and electrically conductively connected to at least one conductor track of the circuit carrier. This contact portion of the at least one first contact element can also serve to mechanically secure the circuit carrier relative to the connector. To keep the loads on the contact points as low as possible, the connector housing can have at least one support element in the area of ​​the internal interface, on which the circuit carrier rests. The at least one support element can, for example, be attached to or integrally molded onto the connector housing as an additional support lug.

[0017] In another advantageous embodiment of the sensor assembly, the connector housing can have a first connecting flange at the end opposite the receiving opening, which is connected to a second connecting flange of the sensor housing. The first connecting flange of the connector housing and the second connecting flange of the sensor housing can be connected to each other in a fluid-tight manner by welding, adhesive bonding, press-fitting, heat-sealing, screwing, or a combination of these connection techniques.

[0018] In another advantageous embodiment of the sensor assembly, at least one fixing plate can be formed on the sensor housing. This allows for convenient screwing points for the sensor assembly using press-fit or overmolded sleeves. Furthermore, the use of captive screws is also conceivable. For example, compression ribs or the external geometry of the sensor housing can serve as a second fixing point.

[0019] The embodiments of the present invention are shown in the drawings and are further explained in the following description. In the drawings, the same reference numerals represent components or elements that perform the same or similar functions. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A schematic perspective view shows an embodiment of a sensor assembly for a vehicle according to the present invention.

[0021] Figure 2 Shown Figure 1 FIG. 1 is a schematic top view of a sensor assembly for a vehicle according to the present invention.

[0022] Figure 3 Shown Figure 1 and Figure 2 Schematic sectional view of the sensor assembly according to the present invention along the section line III-III.

[0023] Figure 4 A schematic flow chart of an embodiment of a method for assembling a sensor assembly for a vehicle according to the present invention is shown. DETAILED DESCRIPTION

[0024] from Figures 1 to 3 As can be seen, the illustrated embodiment of the sensor assembly 1 for a vehicle according to the present invention comprises a sensor housing 20 and a plug connection 10 between a plug housing 11 and a plug connector 14. The plug housing is connected to the sensor housing 20 and has at least one first contact element 12 arranged therein. The plug connector is connected to at least one connecting cable 3 and has at least one second contact element 15 that cooperates with the first contact element 12 to establish an electrical connection. The plug connector 14 is inserted into the receiving opening 13 of the plug connector housing 11, so that the at least one second contact element 15 and the at least one first contact element 12 establish an electrical connection. The plug connector 14 is non-detachably connected to the plug housing 11 via a welded connection 18, in particular a laser transmission welded connection, which forms a fluid-tight radial seal 18A between the plug connector 14 and the plug housing 11.

[0025] In the illustrated embodiment of the sensor assembly 1 , the plug housing 11 , the sensor housing 20 and the plug connector 14 are all designed as plastic injection-molded components.

[0026] from Figures 1 to 3 It can also be seen that in the illustrated embodiment of sensor assembly 1, two connection cables 3 are electrically contacted with plug connector 14 at cable receptacles 16. The first connection cable 3A, shown at the top in the figure, has four cable cores 5, and the second connection cable 3B, shown at the bottom in the figure, has two cable cores 5. Consequently, plug connector 14 includes a total of six second contact elements 15 designed as contact receptacles 15A, which receive six first contact elements 12 designed as contact pins 12A to establish the electrical connection.

[0027] Especially from Figure 3 It can also be seen that a circuit carrier 21 with an electronic circuit 22 is arranged in the sensor housing 20. In the exemplary embodiment shown, an ASIC module 22A as part of the electronic circuit 22 is arranged on the circuit carrier 21. Of course, the electronic circuit 22 can also include other active or passive electronic components that are not shown in detail here.

[0028] The connector housing 11 and the first ends of the six first contact elements 12 extending into the connector housing 11 form the external interface 17 of the sensor assembly 1. The second ends of the six first contact elements 12, opposite the first ends, are connected to the circuit carrier 21 and form the internal interface 23 of the sensor assembly 1. The number and arrangement of the six first contact elements 12, designed as contact pins 12A, are adapted to the communication protocol to be used. In the illustrated embodiment, the six first contact elements 12 are pressed into corresponding contact openings (not shown in detail) of the connector housing 11, so that the first ends of the six first contact elements 12 extend into the interior of the connector housing 11. The second ends of the six first contact elements 12 are pressed into corresponding through-contact portions (not shown in detail) of the circuit carrier 21. Alternatively, the second ends of the first contact elements 112 can be soldered into the through-contact portions. The first contact elements 12 are electrically connected to at least one printed conductor structure (not shown in detail) of the circuit carrier 21 via the through-contact portions.

[0029] from Figures 1 to 3 It can also be seen that the connector housing 11 has a first connecting flange 19 at the end opposite the receiving opening 13, which is connected to a second connecting flange 24 of the sensor housing 20. In the illustrated embodiment, the first connecting flange 19 of the connector housing 11 and the second connecting flange 24 of the sensor housing 20 are connected to each other in a fluid-tight manner via a welded connection. Of course, the sensor housing 20 and the connector housing 11 can also be connected to each other using other connection techniques, such as adhesive bonding, press-fit connections, heat-sealing connections, screw connections, or combinations of these connection techniques.

[0030] Especially from Figure 2 It can be seen that in the illustrated embodiment of the sensor assembly 1, a fixing plate 27 is formed on the sensor housing 20. A fixing sleeve 28 is pressed into this fixing plate. To fix the sensor assembly 1, a screw can be inserted through the fixing sleeve 28 and the sensor assembly 1 can be screwed into the installed position.

[0031] FIG6 also shows that the illustrated embodiment of the method 100 according to the present invention for assembling such a sensor assembly 1 for a vehicle includes a step S100 in which a sensor housing 20 is provided. Depending on the sensor concept and communication protocol to be employed, a plug housing 11 with at least one first contact element 12, a circuit carrier 21 with an electronic circuit 22, and a plug connector 14 with at least one second contact element 15 and at least one connecting cable 3 are provided in step S100. In step S110, the at least one first contact element 12 and the circuit carrier 21 are connected to one another at the internal interface 23. In step S120, the circuit carrier 21 is introduced into the sensor housing 20. In step S130, the plug housing 11 and the sensor housing 20 are connected to one another at the connection region 25. To form a direct cable connection, in step S140, the plug connector 14 with the at least one second contact element 15 is introduced into the receiving opening 13 of the plug connector housing 11, so that the at least one second contact element 15 and the at least one first contact element 12 are electrically connected at the external interface 17. In step S150, the plug connector 14 is non-detachably connected to the plug connector housing 11 via a welded connection 18, in particular a laser transmission welded connection, which forms a fluid-tight radial seal 18A between the plug connector 14 and the plug connector housing 11.

Claims

1. A sensor assembly (1) for a vehicle, comprising a sensor housing (20) and a plug connection (10) between a plug housing (11) and a plug connector (14), the plug housing being connected to the sensor housing (20) and having at least one first contact element (12) arranged therein, the plug connector being connected to at least one connecting cable (3) and having at least one second contact element (15) which cooperates with the first contact element (12) to establish an electrical connection, wherein: The plug connector (14) is introduced into the receiving opening (13) of the plug connector housing (11), so that the at least one second contact element (15) and the at least one first contact element (12) are electrically connected, wherein the plug connector (14) is non-detachably connected to the plug connector housing (11) via a welding connection (18), in particular a laser transmission welding connection, which forms a fluid-tight radial seal (18A) between the plug connector (14) and the plug connector housing (11).

2. The sensor assembly (1) according to claim 1, characterized in that A circuit carrier (21) having an electronic circuit (22) is arranged in the sensor housing (20).

3. The sensor assembly (1) according to claim 1 or 2, characterized in that The connector housing (11) and a first end of the at least one first contact element (12) projecting into the connector housing (11) form an external interface (17) of the sensor assembly (1).

4. The sensor assembly (1) according to claim 3, characterized in that A second end of the at least one first contact element (12), which is opposite the first end, is connected to the circuit carrier (21) and forms an internal interface (23) of the sensor component (1).

5. The sensor assembly (1) according to any one of claims 1 to 4, characterized in that The number and arrangement of the at least one first contact element (12) and the at least one second contact element (15) can be adapted to the communication protocol to be used.

6. The sensor assembly (1) according to any one of claims 2 to 5, characterized in that The at least one first contact element (12) is designed as a contact pin (12A) and is pressed into the connector housing (11) and is electrically conductively connected to at least one conductor track structure of the circuit carrier (14).

7. The sensor assembly (1) according to any one of claims 1 to 6, characterized in that The connector housing (11) has a first connecting flange (19) at the end opposite the receiving opening (13), which is connected to a second connecting flange (24) of the sensor housing (20).

8. The sensor assembly (1) according to claim 7, characterized in that The first connecting flange (19) of the connector housing (11) and the second connecting flange (24) of the sensor housing (20) are connected to each other in a fluid-tight manner by welding, bonding, pressing, shrink-fitting, screwing or a combination of the above connection techniques.

9. The sensor assembly (1) according to any one of claims 1 to 8, characterized in that At least one fixing plate (27) is formed on the sensor housing (20).

10. Method (100) for assembling a sensor assembly (1) for a vehicle, the sensor assembly being designed according to any one of claims 1 to 9, wherein: A sensor housing (20) is provided and, depending on the sensor concept and the communication protocol to be used, a plug housing (11) with at least one first contact element (12), a circuit carrier (21) with an electronic circuit (22), and a plug connector (14) with at least one second contact element (15) and at least one connecting cable (3) are provided; wherein the at least one first contact element (12) and the circuit carrier (21) are connected to each other at an internal interface (23); wherein the circuit carrier (21) is introduced into the sensor housing (20) and the plug housing (11) and the sensor are connected at a connection area (25). The housings (20) are connected to each other; wherein, in order to form a direct cable connection, a plug connector (14) with at least one second contact element (15) is introduced into a receiving opening (13) of the plug connector housing (11), so that the at least one second contact element (15) and the at least one first contact element (12) establish an electrical connection at an external interface (17); wherein the plug connector (14) is non-detachably connected to the plug connector housing (11) by a welding connection (18), in particular a laser transmission welding connection, which forms a fluid-tight radial seal (18A) between the plug connector (14) and the plug connector housing (11).

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