Sensor assembly

Abstract

The purpose of the present disclosure is to provide a sensor assembly in which a sensor of the sensor assembly is not interfered by a metal member, and in which foreign matter is prevented from adhering to the sensor or the sensor is prevented from coming into contact with another member, etc. To this end, the sensor assembly is provided with: a metal sensor base bracket; a resin plate attached to the sensor base bracket; a sensor mounted on the resin plate; and a cover in which the resin plate is fitted and which accommodates the sensor in a space formed together with the resin plate.

Description

Technical Field

[0001] This disclosure relates to sensor assemblies. Background Technology

[0002] The vehicle is equipped with multiple sensors for detecting obstacles or people in the surrounding environment. Figure 12 This illustrates an example of the structure of a conventional sensor mounting bracket 200 for mounting sensor 201 to a vehicle. Multiple metal sensor mounting position securing brackets 204 are welded onto a metal base bracket 203. Each sensor mounting position securing bracket 204 has a quadrilateral top portion 205 and two triangular side portions 206, formed by bending in a generally U-shaped cross-section. Furthermore, the side portions 206 are joined to the tangential portion 210 of the base bracket 203 by linear welding, such as arc welding.

[0003] Multiple ( ) are mounted on the top surface 205 of the bracket 204 at the sensor mounting location. Figure 12 There are 3 bolts 207 in the middle. On the other hand, multiple ( Figure 12 There are 3 mounting holes 202. And, by inserting bolts 207 through the mounting holes 202 and screwing them into nuts 208, the sensor 201 is secured to the sensor mounting position, ensuring the bracket 204.

[0004] exist Figure 12 In this example, the two sensor mounting positions ensure that the bracket 204 is installed above and below the base bracket 203, respectively. Furthermore, each sensor mounting position ensures that the normal direction of the top surface 205 of the bracket 204 is different from the others; for example, the upper sensor mounting position ensures that the top surface 205 of the bracket 204 faces to the right, and the lower sensor mounting position ensures that the top surface 205 of the bracket 204 faces to the left. The normal direction of the top surface 205 depends on the shape of the side surface 206, which is designed to face the range of obstacles, etc., detected by each sensor 201. Summary of the Invention

[0005] The problem the invention aims to solve

[0006] In the conventional sensor mounting bracket 200 structure, since the sensor 204 is fastened to the metal sensor mounting bracket 204, interference may occur between the electromagnetic waves radiated by the sensor 201 and the sensor mounting bracket 204, resulting in inaccurate obstacle detection. Furthermore, if a cover is provided to prevent foreign objects from adhering to the sensor 201 or the sensor 201 from contacting other components, the cover is mounted on the base bracket 203, leading to a larger cover size.

[0007] The purpose of this disclosure is to provide a sensor assembly in which the sensor is not interfered with by metal components and can prevent foreign objects from adhering to the sensor or the sensor from coming into contact with other components.

[0008] Solution to the problem

[0009] The sensor assembly disclosed herein comprises: a metal sensor base bracket; a resin plate mounted on the sensor base bracket; a sensor mounted on the resin plate; and a cover for fitting the resin plate therein and for accommodating the sensor within a space formed together with the resin plate.

[0010] Invention Effects

[0011] According to the sensor assembly disclosed herein, since a resin plate exists between the sensor base bracket and the sensor, the electromagnetic waves radiated by the sensor are less likely to interfere with the metal sensor base bracket. Furthermore, by providing a cover in a manner that allows the resin plate to be fitted within it, the sensor mounted on the resin plate can be appropriately protected. Attached Figure Description

[0012] Figure 1 This is a diagram showing the sensor assembly.

[0013] Figure 2 The diagram shows the sensor assembly with the cover removed.

[0014] Figure 3 It means Figure 1 A diagram of the back side of the sensor assembly.

[0015] Figure 4 yes Figure 1 An exploded view of the sensor assembly.

[0016] Figure 5 This is an exploded view of the sensor mounting bracket.

[0017] Figure 6 It is a cross-sectional view of the inside of the lid.

[0018] Figure 7 This is a rear view showing the cover and resin plate.

[0019] Figure 8 This is a three-dimensional view showing the back of the cover and resin plate.

[0020] Figure 9 This is a diagram showing a sensor assembly with a frame-like bracket installed.

[0021] Figure 10 It means Figure 9 A diagram of the back side of the sensor assembly.

[0022] Figure 11 yes Figure 9 An exploded view of the sensor assembly.

[0023] Figure 12 This is a diagram showing a traditional sensor mounting bracket.

[0024] Explanation of reference numerals in the attached figures

[0025] 1 Sensor Assembly

[0026] 2 Sensors

[0027] 21 mounting holes

[0028] 22 nuts

[0029] 23 Connectors

[0030] 3. Sensor mounting bracket

[0031] 4. Base bracket

[0032] 41 Flange portion

[0033] 42 Top face

[0034] 43 mounting holes

[0035] 44 Nuts

[0036] 45. Notch

[0037] 5. Sensor mounting position ensures bracket

[0038] 51 Side flange portion

[0039] 52 Top face

[0040] 53 Central flange

[0041] 6. Sensor base bracket

[0042] 61 First Bolt

[0043] 62 Second Bolt

[0044] 7 Resin Board

[0045] 71 mounting holes

[0046] 72. Notch

[0047] 8 lids

[0048] 81 mounting holes

[0049] 82 Nuts

[0050] 9. Frame-shaped bracket

[0051] 91 mounting holes

[0052] 92 bolts

[0053] 93 Opening

[0054] 10 Wire Harness

[0055] 103 Middle section Detailed Implementation

[0056] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. It should be noted that the embodiments described below represent only one specific example of the present disclosure. Therefore, the structural elements, their arrangement positions, and connection methods shown in the following embodiments are merely examples and are not intended to limit the present disclosure. Furthermore, structural elements in the following embodiments not described in the independent claims will be described as arbitrary structural elements.

[0057] In addition, the figures are schematic diagrams and not necessarily strict illustrations. It should be noted that in the various figures, substantially the same structures are labeled with the same reference numerals, and sometimes repeated descriptions are omitted or simplified.

[0058] Figures 1 to 8 This is a diagram illustrating a first embodiment of the sensor assembly of this disclosure. Figure 1 This is a perspective view of sensor assembly 1. Figure 2 Sensor assembly 1, indicating that cover 8 has been removed. Figure 3 This indicates the back side of sensor assembly 1. Figure 4 This is an exploded view of sensor assembly 1. Figure 5 This is an exploded view of sensor mounting bracket 3. Figure 6 This is a cross-sectional view of the interior of the lid (8). Figure 7 This is a rear view showing resin plate 7 and cover 8. Figure 8 This is a three-dimensional view showing the back of resin plate 7 and cover 8.

[0059] The sensor assembly 1 has a sensor mounting bracket 3 and a sensor 2 mounted on the sensor mounting bracket 3. The sensor mounting bracket 3 has a base bracket 4, a sensor mounting position securing bracket 5, and a sensor base bracket 6.

[0060] The base bracket 4 is a plate-shaped component formed by dividing a horizontal plane into a hat-shaped cross-section, and has a central top portion 42 and flange portions 41 formed on both sides of the top portion 42. A notch portion 45 for securing the wiring harness 10 is formed on the flange portion 41. The sensor assembly 1 is mounted on the vehicle body by mounting the base bracket 4.

[0061] The sensor mounting position is secured to the bracket 5 by spot welding on the top surface 42. For example... Figure 5 As shown, the sensor mounting position ensures that the bracket 5 has a shape in which a long strip-shaped component is bent and continuously formed into multiple (two in the example shown) cap-shaped parts. Furthermore, the sensor mounting position ensures that the bracket 5 has a central flange 53 formed in its central part, multiple (two in the example shown) top parts 52 formed on both sides of the central flange 53, and side flanges 51 formed at the upper and lower ends.

[0062] The directions of the normals of the multiple top surfaces 52 are different from each other; for example, the upper top surface 52 faces to the right, and the lower top surface 52 faces to the left. The orientation of each top surface 52 is designed according to the direction in which the installed sensor 2 detects obstacles, etc.

[0063] In this embodiment, three portions—one of the central flange portion 53 and two of the side flange portions 51—are spot-welded to the top surface 42 of the base bracket 4. Figure 5 (Indicated by × and dashed lines). The number of top facets 52 is designed according to the number of sensors 2 mounted thereon, and the central flange 53 is formed between the top facets 52 in such a way that its number is one less than the number of top facets 52. Therefore, the sensor mounting position ensures that the bracket 5 and the base bracket 4 are joined by spot welding, and the number of welds is the sum of the number of central flanges 53 and the number of side flanges 51. That is,

[0064] Number of spot welds = Number of installed sensors - 1 + Number of side flanges

[0065] = Number of installed sensors + 1.

[0066] exist Figure 12 In the conventional technology shown, when the sensor mounting bracket 204 is attached to the base bracket 203, the mounting bracket 204 is welded with two tangent portions 210 for each sensor mounting position. That is, welding is performed at twice the number of installed sensors 201. In contrast, in this embodiment, welding is only required at the number of installed sensors 2 + 1, thus suppressing deformation caused by thermal deformation and reducing operation time.

[0067] In addition, in the past, the sensor mounting position securing bracket 204 and the base bracket 203 were linearly welded by means of arc welding, but in this embodiment, the sensor mounting position securing bracket 5 and the base bracket 4 are spot welded. Therefore, the amount of metal melted by welding is small, it is not easy to cause thermal deformation, and the operation is easy and can be completed in a short time.

[0068] A metal sensor base bracket 6 is spot-welded to the top surface 52 of the sensor mounting bracket 5. The approximate central portion of the sensor base bracket 6 is engaged with the top surface 52 of the sensor mounting bracket 5. Figure 5 (Used as an × mark and dashed line). The sensor base bracket 6 is a bracket for mounting and supporting the sensor 2, and has a size approximately equal to that of the sensor 2. The sensor base bracket 6 is provided with first bolts 61 (3 in the illustrated example) for mounting the resin plate 7 and the sensor 2, and second bolts 62 (2 in the illustrated example) for mounting the cover 8.

[0069] A resin plate 7 and a sensor 2 are securely fastened to the sensor base bracket 6. The resin plate 7 is a plate-shaped component made of resin and is formed to be larger than the sensor base bracket 6. The resin plate 7 has a mounting hole 71 through which the first bolt 61 of the sensor base bracket 6 is inserted, and a notch 72 for securing the wire harness 10 connected to the sensor 2.

[0070] A mounting hole 21 is formed on the periphery of the sensor 2 for the first bolt 61 of the sensor base bracket 6 to be inserted. The mounting hole 71 of the resin plate 7 and the mounting hole 21 of the sensor 2 are both for the first bolt 61 of the sensor base bracket 6 to be inserted, and are fastened together by a nut 22.

[0071] The cover 8 is a resin component that covers and protects the sensor 2. Mounting holes 81 are formed on the periphery of the cover 8 for the second bolt 62 of the sensor base bracket 6 to pass through. The cover 8 covers the sensor 2 and houses the sensor 2 within the space 83 formed by the cover 8 and the resin plate 7 (see reference). Figure 6 That is, the resin plate 7 is fitted into the cover 8, and the internal space of the cover 8 is sealed by the resin plate 7.

[0072] Wiring harness 10 connects sensor 2 to a vehicle control device (not shown) or the like. One end 101 of wiring harness 10 is connected to connector 23 of sensor 2, and the other end 102 is connected to a vehicle control device (not shown) or other wiring harnesses. Near one end 101 of wiring harness 10 is engaged with a notch 72 formed in resin plate 7 and pulled out from space 83 of cover 8 to the outside of cover 8. Additionally, the middle portion 103 is engaged with a notch 45 formed in base bracket 4 and surrounds the back side of base bracket 4.

[0073] Sensor 2 is mounted on the surface of resin plate 7 by a first bolt 61 and nut 22 (see reference). Figure 4 (etc.) Tighten. With the sensor 2 installed on the resin plate 7, the cover 8 covers the resin plate 7 in such a way that the resin plate 7 is fitted inside it, and is secured by the second bolt 62 and nut 82 (see reference). Figure 4 (etc.) Secure it to the sensor base bracket 6.

[0074] The cover 8 is formed into a recessed shape that can accommodate the sensor 2 and the resin plate 7 inside (see reference). Figure 6 The sensor 2 is contained within the space 83 formed by the resin plate 7 and the cover 8 by the cover 8 covering the sensor 2 in such a way that the resin plate 7 in which the sensor 2 is mounted is fitted.

[0075] If sensor 2 is directly mounted on the metal sensor base bracket 6, the distance between sensor 2 and sensor base bracket 6 is too short, and the metal sensor base bracket 6 may affect the radiation of the electromagnetic waves emitted by sensor 2. However, by placing the resin plate 7 between sensor base bracket 6 and sensor 2, the distance between them is increased, and the influence of the metal sensor base bracket 6 on the radiation of the electromagnetic waves emitted by sensor 2 is reduced.

[0076] To minimize the impact on the radiation of the radio waves emitted by sensor 2, it is preferable to make the metal sensor base bracket 6 as small as possible. On the other hand, to further minimize the impact on the radiation of the radio waves emitted by sensor 2, it is preferable to maintain a predetermined distance between the cover 8 covering sensor 2 and sensor 2. Therefore, a gap exists around the sensor base bracket 6 and around the cover 8. However, in this embodiment, by providing a resin plate 7 of a size that fits into the cover 8, the gap between the sensor base bracket 6 and the cover 8 is sealed by the resin plate 7, thus preventing foreign objects from entering through this gap and adhering to sensor 2.

[0077] Figures 9 to 11 This is a diagram illustrating a second embodiment of the sensor assembly of this disclosure. Figure 9 A 3D view of the sensor assembly. Figure 10 This indicates the back side of the sensor assembly. Figure 11 This is an exploded view of the sensor assembly. In this embodiment, a frame-shaped bracket 9 is added to the sensor assembly of the first embodiment.

[0078] The frame bracket 9 has multiple mounting holes 91 (four in the example shown) for bolt insertion. Similarly, the base bracket 4 has multiple mounting holes 43 (four in the example shown) for bolt insertion. The frame bracket 9 is secured to the base bracket 4 by multiple bolts 92 (two in the example shown) inserted into the mounting holes 91 and 43 and fastened with nuts 44. The number of bolts 92 is appropriately selected within the range of the number of mounting holes 91.

[0079] An opening 93 is formed on the frame-shaped bracket 9. The wire harness 10 connected to the sensor 2 is secured in the notch 72 and passes through the back side of the resin plate 7, while the middle portion 103 is secured in the notch 45 and passes through the back side of the base bracket 4. After the frame-shaped bracket 9 is fastened to the base bracket 4, the wire harness 10 is inserted through the opening 93 and passes through the back side of the frame-shaped bracket 9.

[0080] The frame-shaped bracket 9 is located near the middle portion 103 of the wire harness 10 to seal the opening of the notch 45. Therefore, the frame-shaped bracket 9 prevents the wire harness 10 from falling out of the notch 45.

[0081] When installing the sensor assembly 1 onto the vehicle body, the frame bracket 9 is installed onto the vehicle body (not shown) using fastening components such as bolts and nuts. Therefore, the frame bracket 9 functions as a bracket for installing the sensor assembly 1 onto the vehicle body while preventing the wiring harness 10 from falling off the notch 45, thus reducing the number of parts and installation time.

[0082] As described above, the sensor mounting bracket 3 disclosed herein includes: a base bracket 4 formed from a plate-shaped component; and a sensor mounting position securing bracket 5 formed by bending the plate-shaped component into a hat shape. The flange portions 51 and 53 of the sensor mounting position securing bracket 5 are joined to the base bracket 4 by spot welding. Therefore, compared with the conventional technology in which the sensor mounting position securing bracket 204 and the base bracket 203 are joined linearly by arc welding or the like, thermal deformation can be suppressed, the sensor mounting accuracy can be improved, and the operation time can be reduced.

[0083] Furthermore, when multiple sensors 2 are installed, the sensor mounting bracket 3 of this disclosure has multiple cap portions formed in the sensor mounting position bracket 5, which have side flange portions 51 formed at both ends, multiple top portions 52, and one or more central flange portions 53 formed between the multiple top portions. The side flange portions 51 and the central flange portions 53 are joined to the base bracket 4 by spot welding. Therefore, compared with the prior art, the number of welding points relative to the number of sensors 2 can be reduced, thereby suppressing thermal deformation, improving the installation accuracy of the sensors, and reducing operation time.

[0084] Furthermore, the normal directions of the top surface 52 of each of the multiple caps of the sensor mounting bracket 3 disclosed herein are different. Therefore, multiple sensors 2 can be mounted with their respective top surfaces facing different directions, thereby expanding the range of obstacle detection by the sensors. In addition, by appropriately designing the orientation of the top surface 52, various changes can be made to the mounting angle of the sensor 2.

[0085] In addition, the sensor mounting bracket 3 disclosed herein has a sensor base bracket 6, which is fixed to the top part 52 of the sensor mounting position securing bracket 5 by spot welding. Thus, different sizes of sensors 2 can be installed by changing the sensor base bracket 6, and the components of the base bracket 4 and the sensor mounting position securing bracket 5 can be universalized.

[0086] In addition, the sensor assembly 1 disclosed herein includes the aforementioned sensor mounting bracket 3, a resin plate 7 mounted on the sensor base bracket 6, a sensor 2 mounted on the resin plate 7, a wiring harness 10 connected to the sensor 2, and a resin cover 8 covering the sensor 2. This improves the mounting accuracy of the sensor 2 and protects the sensor 2 with the cover 8.

[0087] In addition, the sensor assembly 1 disclosed herein has a notch 45 formed on the base bracket 4, and the wire harness 10 is locked in the notch 45, thereby properly fixing the wire harness 10 without it getting in the way.

[0088] In addition, the sensor assembly 1 disclosed herein has a frame-shaped bracket 9 with an opening 93 installed on the side of the base bracket 4 opposite to the side where the sensor 2 is installed. The frame-shaped bracket 9 seals the opening of the notch 45, thus preventing the wiring harness 10 from falling off the notch 45 due to vehicle vibration or the like.

[0089] Furthermore, the sensor assembly 1 disclosed herein includes a metal sensor base bracket 6, a resin plate 7 mounted on the sensor base bracket 6, a sensor 2 mounted on the resin plate 7, and a cover 8 for housing the sensor 2 within a space 83 formed together with the resin plate 7. As a result, the radiation of the electromagnetic waves from the sensor 2 is less affected by the metal sensor base bracket 6, and the gap between the periphery of the sensor base bracket 6 and the periphery of the cover 8 is sealed by the resin plate 7, thus preventing foreign objects from entering through the gap and adhering to the sensor 2.

[0090] In addition, the sensor assembly 1 disclosed herein has a first bolt 61 and a second bolt 62 on the sensor base bracket 6. The resin plate 7 and the sensor 2 are fastened together by the first bolt 61, and the cover 8 is fastened by the second bolt 62. Thus, the resin plate 7, the sensor 2 and the cover 8 can be efficiently fixed to the sensor base bracket 6 in a small space.

[0091] In addition, the sensor assembly 1 disclosed herein also has a base bracket 4 and a sensor mounting position securing bracket 5. The base bracket 4 is formed from a plate-shaped component, and the sensor mounting position securing bracket 5 is formed by bending the plate-shaped component into a hat shape. The flange portion of the sensor mounting position securing bracket 5 is joined to the base bracket 4 by spot welding, and the sensor base bracket 6 is joined to the hat-shaped top portion 52 of the sensor mounting position securing bracket 5 by spot welding. Therefore, the influence of thermal deformation caused by welding can be reduced and the sensor 2 can be installed with high precision.

[0092] Industrial applicability

[0093] The sensor mounting bracket and sensor assembly disclosed herein are suitable for mounting various sensors on a vehicle body.

Claims

1. A sensor assembly, characterized by, A sensor assembly comprising: a sensor base bracket made of metal; a resin plate mounted to the sensor base bracket; a sensor mounted to the resin plate; and a cover in which the resin plate is fitted, and in which the sensor is accommodated.

2. The sensor assembly according to claim 1, wherein a first bolt and a second bolt are provided on the sensor base bracket, the resin plate and the sensor are fastened together by the first bolt, and the cover is fastened by the second bolt.

3. The sensor assembly according to claim 1, further comprising: a base bracket formed of a plate-shaped member, and a sensor mounting position securing bracket formed by bending a plate-shaped member into a hat shape, and in which a flange portion of the sensor mounting position securing bracket is joined to the base bracket by spot welding, the sensor base bracket being joined to a top surface portion of the hat-shaped sensor mounting position securing bracket by spot welding.

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