Sensor device, torque sensor device, and magnetic sensor module

Abstract

The invention provides a sensor device, a torque sensor device, and a magnetic sensor module. The sensor device is provided with sensor bodies (13-16, 21, 22), a sensor housing (30), a connector housing (50), and a flange (51). Sensor bodies (13-16, 21, 22) capture changes in physical quantities, and a sensor housing (30) houses at least a portion of the sensor bodies. The connector housing (50) is provided with a detection element (40) that outputs a signal corresponding to a change in physical quantity, and the portion where the detection element (40) is provided is inserted into the inside of the sensor housing (30). The flange (51) extends outward from the connector housing (50) and is joined to the sensor housing (30) toward a joining surface (53) on the sensor housing (30) side. The joint surface (53) of the flange (51) is inclined with respect to an imaginary plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing (50) where the detection element (40) is provided is inserted into the sensor housing (30).

Description

Cross-reference of related applications

[0001] This application is based on Japanese Patent Application No. 2023-148627, filed on September 13, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to a sensor device, a torque sensor device, and a magnetic sensor module mounted on a vehicle. Background Technology

[0003] The magnetic detection device (hereinafter referred to as the magnetic sensor module) described in Patent Document 1 constitutes part of a torque sensor device for an electric power steering system. This magnetic sensor module is constructed by joining a magnetic collection part holding member that holds a first magnetic collection component and a second magnetic collection component with a base plate holding member that holds a base plate on which a magnetic detection element is mounted. Wiring electrically connected to the base plate is fixed to the base plate holding member. The signal output from the magnetic detection element is transmitted from the base plate to the vehicle-side electronic control unit (hereinafter referred to as "ECU") via the wiring. Furthermore, ECU is an abbreviation for Electronic Control Unit.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent No. 6217608 Summary of the Invention

[0005] However, in the magnetic sensor module described in Patent Document 1, the wiring is fixed to the substrate holding member. Therefore, when the distance between the magnetic sensor module and the ECU varies depending on the vehicle model in which the magnetic sensor module is installed, the specifications of the substrate holding member must be changed, resulting in increased design and manufacturing costs.

[0006] To address these issues, a structure could be considered that allows the external connector to be attached and detached relative to the substrate holding member of the magnetic sensor module. However, in this case, providing an opening on the substrate holding member for attaching and detaching the external connector would result in a larger substrate holding member. Furthermore, since the magnetic sensor module described in Patent Document 1 uses a structure where a flange located on the outer periphery of the substrate holding member is joined to the magnetizing part holding member, the outer periphery of the flange also becomes larger as the substrate holding member increases in size. This makes it difficult to mount the magnetic sensor module within the mounting space of the electric power steering system housing.

[0007] The purpose of this disclosure is to provide a sensor device, a torque sensor device, and a magnetic sensor module that can be fitted with and detached external connectors and can achieve miniaturization.

[0008] According to one aspect of this disclosure, a sensor device mounted on a vehicle includes: The sensor body, which captures changes in physical quantities; A sensor housing that houses at least a portion of the sensor body; A connector housing having a detection element that outputs a signal corresponding to a change in a physical quantity, and the portion having the detection element is inserted into the inside of a sensor housing; and The flange extends outward from the connector housing, and its mating surface facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to an imaginary plane, which is a plane perpendicular to the direction in which the part of the connector housing containing the detection element is inserted into the sensor housing.

[0009] According to this structure, even if the distance between the sensor device and the ECU varies depending on the vehicle model, the sensor device can be adjusted simply by changing the length of the wiring located on the external connector. Therefore, there is no need to change the specifications of the sensor device according to the vehicle model, which can reduce design and manufacturing costs.

[0010] Furthermore, the sensor device has a flange mating surface that is inclined relative to an imaginary plane perpendicular to the direction in which the sensor element is inserted into the connector housing. This allows for miniaturization of the sensor device while ensuring sufficient area of ​​the mating surface to guarantee the strength of the flange-connector housing engagement, as well as the area of ​​the opening in the connector housing for inserting an external connector. Therefore, the sensor device can also be mounted in the narrow mounting space within the housing of a vehicle-side system.

[0011] In addition, the mating surface of the flange is significantly inclined compared to the inclination caused by manufacturing tolerances when the flange is configured to be parallel to an imaginary plane.

[0012] According to another aspect of this disclosure, a torque sensor device for detecting the about-axis torque acting on a shaft comprises: A torsion bar connects a first shaft and a second shaft that form a shaft to the same shaft, and converts the torque acting between the first shaft and the second shaft into torsional displacement. A multipole magnet, which is fixed to one end of a first shaft or torsion bar, and has N poles and S poles alternately arranged in the circumferential direction; A magnetic yoke is fixed to the other end of a second shaft or torsion bar on the outside of a multipole magnet and forms a magnetic circuit within the magnetic field of the multipole magnet. The first magnetic flux guiding component and the second magnetic flux guiding component are located on the outside of the magnetic yoke and guide the magnetic flux flowing through the magnetic yoke; The sensor housing holds the first magnetic flux guiding component and the second magnetic flux guiding component; A magnetic detection element that outputs a signal corresponding to the magnetic flux density at a location adjacent to the first and second magnetic flux guiding components; A connector housing having a magnetic detection element, the portion having the magnetic detection element being inserted into the inside of a sensor housing; and The flange extends outward from the connector housing, and its mating surface facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to an imaginary plane, which is a plane perpendicular to the direction in which the part of the connector housing containing the magnetic sensing element is inserted into the sensor housing.

[0013] Based on this structure, the torque sensor device can perform the same function as the sensor device described above.

[0014] According to another aspect of this disclosure, a magnetic sensor module for detecting magnetic flux flowing in a magnetic yoke comprises: The first and second magnetic flux guiding components guide the magnetic flux flowing through the magnetic yoke. A sensor housing that houses a first magnetic flux guiding component and a second magnetic flux guiding component; A magnetic detection element that outputs a signal corresponding to the magnetic flux density at a location adjacent to the first and second magnetic flux guiding components; A connector housing having a magnetic detection element, the portion having the magnetic detection element being inserted into the inside of a sensor housing; and The flange extends outward from the connector housing, and its mating surface facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to an imaginary plane, which is a plane perpendicular to the direction in which the part of the connector housing containing the magnetic sensing element is inserted into the sensor housing.

[0015] Based on this structure, the magnetic sensor module can perform the same function as the sensor device described above.

[0016] Furthermore, the parenthesized reference symbols attached to each constituent element, etc., exemplarily illustrate an example of the correspondence between the constituent element, etc., and the specific constituent elements, etc., described in the embodiments described later. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of an electric power steering system equipped with the torque sensor device according to the first embodiment.

[0018] Figure 2 This is an exploded perspective view of the torque sensor device according to the first embodiment.

[0019] Figure 3 It is a three-dimensional diagram of the multipole magnet and yoke of the torque sensor device.

[0020] Figure 4 It is a side view showing the relative rotational state of the multipole magnet and the yoke.

[0021] Figure 5 It is a side view showing the relative rotational state of the multipole magnet and the yoke.

[0022] Figure 6 It is a side view showing the relative rotational state of the multipole magnet and the yoke.

[0023] Figure 7 This is an exploded perspective view of the magnetic sensor module used in the torque sensor device according to the first embodiment.

[0024] Figure 8 This is a side view of the magnetic sensor module used in the torque sensor device according to the first embodiment.

[0025] Figure 9 This is an illustrative diagram used to explain the laser welding of the flange to the sensor housing.

[0026] Figure 10 It is used in Figure 9 The diagram illustrates the laser welding of the flange to the sensor housing on the XX-line cross-section.

[0027] Figure 11 This is a side view showing the mounting space of the magnetic sensor module within the housing of the electric power steering system.

[0028] Figure 12 This is a side view showing the state of the magnetic sensor module of the first comparative example being mounted in the mounting space within the housing of the electric power steering system.

[0029] Figure 13 This is an exploded perspective view of the torque sensor device according to the second embodiment.

[0030] Figure 14 This is a cross-sectional view of the multipole magnet, yoke, and flux guiding component included in the torque sensor device according to the second embodiment.

[0031] Figure 15 This is a cross-sectional view of the torque sensor device according to the second embodiment.

[0032] Figure 16 This is an exploded perspective view of the magnetic sensor module used in the torque sensor device according to the second embodiment.

[0033] Figure 17This is a cross-sectional view of the magnetic sensor module used in the torque sensor device according to the third embodiment.

[0034] Figure 18 This is a schematic diagram of the magnetic sensor module of the second comparative example.

[0035] Figure 19 This is a schematic diagram of the magnetic sensor module according to the third embodiment. Detailed Implementation

[0036] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. Furthermore, in the following embodiments, the same or equivalent parts are labeled with the same symbols, and their descriptions are omitted.

[0037] (First Implementation) The sensor device of the first embodiment will be described. The sensor device of the first embodiment is a torque sensor device 10 that detects the about-axis torque acting on a shaft. The torque sensor device 10 is applied to an electric power steering system 1 mounted in a vehicle.

[0038] First, refer to Figure 1 The general structure of the electric power steering system 1 is described below. Furthermore, the electric power steering system 1 can be either column-assisted or rack-assisted. The steering wheel 2 is connected to a steering shaft 3. A torque sensor device 10 is provided on the steering shaft 3 to detect the torque acting on the shaft, i.e., the steering torque. A steering gear mechanism 4 is provided at the end of the steering shaft 3. The steering gear mechanism 4 is connected to a pair of wheels 6 via a linkage mechanism 5.

[0039] A torque sensor device 10 is disposed between the input shaft 11 and the output shaft 12 constituting the steering shaft 3, detects the steering torque and outputs it to the ECU 7. The ECU 7 controls the driving force of the electric motor 8 based on the steering torque. The driving force of the electric motor 8 is transmitted to the output shaft 12 of the steering shaft 3 or the steering gear mechanism 4. Thus, the electric power steering system 1 assists in changing the steering force used to change the direction of the wheels 6.

[0040] Next, refer to Figures 2 to 8 The overall structure of the torque sensor device 10 will be described.

[0041] like Figure 2 As shown, the torque sensor device 10 includes a torsion bar 13, a multipole magnet 14, a magnetic yoke 15 and 16, and a magnetic sensor module 20. Figure 2 and Figure 7 As shown, the magnetic sensor module 20 has a first magnetic flux guiding component 21, a second magnetic flux guiding component 22, a sensor housing 30, a magnetic detection element 40, a connector housing 50, and a flange 51.

[0042] In addition, in the following description, the radial direction of the imaginary circle drawn on a plane perpendicular to the central axis CL with the steering shaft 3 as the center is called "radial", the circumference of the imaginary circle is called "circumferential", and the direction in which the central axis CL extends is called "axial".

[0043] like Figure 2 As shown, one end of the torsion bar 13 is fixed to the input shaft 11, which serves as the "first shaft," via a first fixing pin 17, and the other end is fixed to the output shaft 12, which serves as the "second shaft," via a second fixing pin 18. Thus, the torsion bar 13 coaxially connects the input shaft 11 and the output shaft 12 to the central shaft CL. The torsion bar 13 is a rod-shaped elastic component whose torsional displacement changes according to the steering torque acting between the input shaft 11 and the output shaft 12. That is, the torsion bar 13 converts the steering torque into a torsional displacement. Furthermore, the central shaft CL of the torsion bar 13 coincides with the central shaft CL of the steering shaft 3.

[0044] The multipole magnet 14 is a permanent magnet with alternating N and S poles in the circumferential direction, fixed to the input shaft 11. Alternatively, the multipole magnet 14 can also be fixed to one end of the torsion bar 13. For example, the multipole magnet 14 has eight N poles and eight S poles arranged alternately at 22.5° intervals.

[0045] The first magnetic yoke 15 and the second magnetic yoke 16 (hereinafter referred to as "a pair of magnetic yokes 15, 16") are formed into a ring shape by a soft magnetic material, held radially outside the multipole magnet 14 by a retaining member (not shown), and fixed to the output shaft 12. Furthermore, the pair of magnetic yokes 15, 16 can also be fixed to the other end of the torsion bar 13. For example... Figure 3 As shown, a pair of magnetic yokes 15 and 16 are axially opposed to each other with a gap between them. The pair of magnetic yokes 15 and 16 each have claws 151 and 161, respectively, at equal intervals in the circumferential direction, the same number as the N or S poles of the multipole magnet 14. The claws 151 of the first magnetic yoke 15 and the claws 161 of the second magnetic yoke 16 are circumferentially offset and alternately arranged. Thus, the pair of magnetic yokes 15 and 16 form a magnetic circuit within the magnetic field generated by the multipole magnet 14.

[0046] When the torsional displacement of the torsion bar 13 changes, the multipole magnet 14 rotates relative to the pair of yokes 15 and 16, and the flow of magnetic flux in the magnetic circuit formed by the pair of yokes 15 and 16 changes accordingly. Figure 3 and Figure 4 This shows the state where the torsional torque is not acting on torsion bar 13. Furthermore, in Figures 4 to 6 For ease of explanation, the N pole of the multipole magnet 14, although not a cross-section, is marked with a section line; the S pole is not marked with a section line. Figure 3 and Figure 4In the state shown, the circumferential center positions of the claws 151 and 161 of the pair of magnetic yokes 15 and 16 coincide radially with the boundaries of the N and S poles of the multipole magnet 14. At this time, no magnetic flux flows between the first magnetic yoke 15 and the second magnetic yoke 16.

[0047] Figure 5 and Figure 6 This shows the state where the torsional torque acting on torsion bar 13 gradually increases. Therefore, from Figure 4 state via Figure 5 state to Figure 6 As the state changes, the torsional displacement of the torsion bar 13 gradually increases. Consequently, the radially overlapping area of ​​the N pole of the multipole magnet 14 and the claw 151 of the first yoke 15 gradually increases, as does the radially overlapping area of ​​the S pole of the multipole magnet 14 and the claw 161 of the second yoke 16. Therefore, the influence of the first yoke 15 on the N pole of the multipole magnet 14 gradually increases, and the influence of the second yoke 16 on the S pole of the multipole magnet 14 also gradually increases. Consequently, the magnetic flux density flowing between the first yoke 15 and the second yoke 16 gradually increases.

[0048] like Figure 2 and Figure 7 As shown, the first flux guiding member 21 and the second flux guiding member 22 (hereinafter referred to as "a pair of flux guiding members 21, 22") are formed of a soft magnetic material. The first flux guiding member 21 is located radially and axially outside the first yoke 15, and the second flux guiding member 22 is located radially and axially outside the second yoke 16. The pair of flux guiding members 21, 22 each have a magnetic collecting portion 23, 24 formed in an annular or arcuate shape on the radially outer side of the pair of yokes 15, 16, and an extension portion 25, 26 extending radially outward from the magnetic collecting portion 23, 24. In the first embodiment, the magnetic collecting portions 23, 24 surround most of the radially outer side of the pair of yokes 15, 16. The first extension portion 25 and the second extension portion 26 are adjacent to the first flux guiding member 21 and the second flux guiding member 22. Therefore, the distance between the first extension portion 25 and the second extension portion 26 is less than the distance between the first magnetic collecting portion 23 and the second magnetic collecting portion 24. Therefore, the magnetic flux guided from a pair of magnetic yokes 15, 16 to the magnetic collecting portions 23, 24 of a pair of magnetic flux guiding members 21, 22 flows through the gap between the first extension portion 25 and the second extension portion 26.

[0049] like Figure 7 and Figure 8As shown, a pair of flux guiding components 21 and 22 are housed in the sensor housing 30. The sensor housing 30 has a cylindrical sensor housing body 31, a sensor housing extension 32 extending from the sensor housing body 31 toward the connector housing 50, and a sensor housing side flange 33 extending outward from the sensor housing extension 32. Figure 8 The central axis CL of the inner circumferential surface of the sensor housing body 31 (hereinafter referred to as the "central axis CL of the sensor housing 30") coincides with the central axis CL of the torsion bar 13. The magnetic collecting portions 23 and 24 of a pair of magnetic flux guiding members 21 and 22 are fixed to the radially inner side of the sensor housing body 31. The extension portions 25 and 26 of a pair of magnetic flux guiding members 21 and 22 are fixed to the inner side of the sensor housing extension 32.

[0050] like Figure 7 As indicated by arrow ID, the magnetic detection element 40, mounted on the substrate 41, is inserted into the opening 34 of the sensor housing extension 32 together with a portion of the connector housing 50. In the following description, the direction in which the magnetic detection element 40, along with a portion of the connector housing 50, is inserted into the opening 34 of the sensor housing extension 32 is referred to as the "element insertion direction ID". Inside the sensor housing extension 32, a guide member 341 is provided to guide the substrate 41, etc., during insertion. The guide member 341 extends parallel to the direction in which the magnetic detection element 40 and the substrate 41 are inserted in the connector housing 50 (i.e., the element insertion direction ID). Therefore, in the completed state of the torque sensor device 10 and the magnetic sensor module 20, the element insertion direction ID can be identified as the in-plane direction of the substrate 41, the extending direction of the guide member 341, or the axial extension direction of the cylindrical sensor housing extension 32. Alternatively, as described later, the element insertion direction ID can be identified as the direction in which the magnetic detection element 40 is inserted between the first extension portion 25 and the second extension portion 26. The sensor housing side flange 33 is located around the entire circumference of the opening 34 of the sensor housing extension 32. The flange 51 engages with the flange 51 side face 35 of the sensor housing side flange 33.

[0051] A magnetic sensing element 40 is mounted on a substrate 41 and, when inserted into the opening 34 of the sensor housing extension 32, is positioned between the first extension portion 25 and the second extension portion 26. The magnetic sensing element 40 is, for example, an IC package molded from resin using a Hall element or a magnetoresistive element. The magnetic sensing element 40 outputs an electrical signal corresponding to the magnetic flux density passing through the gap between the adjacent portions of a pair of magnetic flux guiding members 21 and 22, i.e., the first extension portion 25 and the second extension portion 26. Furthermore, to ensure redundancy or accuracy in torque detection, multiple magnetic sensing elements 40 are mounted on the substrate 41.

[0052] The connector housing 50 and flange 51 are integrally formed by resin injection molding. The connector housing 50 has a substrate 41 on which a magnetic detection element 40 is mounted, and terminals 42 electrically connected to the magnetic detection element 40. The connector housing 50 has a cylindrical connector opening 52 for attaching and detaching an external connector 60. Furthermore, in... Figure 8 In the diagram, the external connector 60, which is inserted into the connector opening 52, and the wiring 61 extending from the external connector 60 are shown by double-dotted lines. In the following description, the direction in which the external connector 60 is attached or detached relative to the connector opening 52 is referred to as the "external connector attachment / removal direction RD". Figure 8 In the diagram, the external connector insertion / removal direction RD is indicated by a double arrow. Furthermore, in this embodiment, the component insertion direction ID is parallel to the external connector insertion / removal direction RD. Also, in this embodiment, the component insertion direction ID and the external connector insertion / removal direction RD are orthogonal to the central axis CL of the sensor housing 30.

[0053] also, Figure 8 This is a side view of the magnetic sensor module 20, viewed from a direction perpendicular to the direction extending from the central axis CL of the sensor housing 30, and perpendicular to the component insertion direction ID and the external connector mounting / unmounting direction RD. In the following description, the direction in which the central axis CL of the sensor housing 30 extends is referred to as the "axial direction of the sensor housing 30". Figure 8 The upper side is referred to as "the axial side of the sensor housing 30". Figure 8 The lower side is referred to as "the other axial side of the sensor housing 30".

[0054] like Figure 7 and Figure 8 As shown, flange 51 extends outward from connector housing 50. Flange 51 extends outward around the entire circumference of a surface in connector housing 50 that intersects the component insertion direction ID and the external connector loading / unloading direction RD. Flange 51 is plate-shaped and is inclined relative to an imaginary plane VS perpendicular to the component insertion direction ID. Furthermore, flange 51 can also be described as inclined relative to an imaginary plane VS perpendicular to substrate 41. Flange 51 can also be described as inclined relative to an imaginary plane VS parallel to the central axis CL of torsion bar 13 or sensor housing 30. Flange 51 can also be described as inclined relative to an imaginary plane VS perpendicular to the external connector loading / unloading direction RD. Finally, flange 51 can also be described as inclined relative to an imaginary plane VS perpendicular to the axis of the cylindrical sensor housing extension 32.

[0055] The surface of flange 51 facing the sensor housing 30 is called mating surface 53. The mating surface 53 of flange 51 is the surface that mats with the sensor housing side flange 33. The surface of flange 51 facing the opposite side to mating surface 53 is called anti-matting surface 54. The mating surface 53 and anti-matting surface 54 of flange 51 are parallel. Both the mating surface 53 and anti-matting surface 54 of flange 51 are inclined relative to the imaginary plane VS.

[0056] like Figure 8 As shown, the inclination angle θ of the mating surface 53 of the flange 51 relative to the imaginary plane VS is, for example, in the range of 5° to 45°, preferably in the range of 10° to 40°, and more preferably in the range of 20° to 30°. Furthermore, the inclination angle θ of the mating surface 53 of the flange 51 is not limited to the above-mentioned angle range. This inclination angle θ can be appropriately set within a range that allows the magnetic sensor module 20 to be installed within the housing of the electric power steering system 1, and ensures the engagement strength between the flange 51 and the connector housing 50, as well as the area of ​​the connector opening 52.

[0057] The mating surface 53 of flange 51 is inclined from one axial side of sensor housing 30 toward the other axial side of sensor housing 30, close to the central axis CL of sensor housing 30. Conversely, the flange 51 side face 35 of sensor housing side flange 33 is also inclined from one axial side of sensor housing 30 toward the other axial side of sensor housing 30, close to the central axis CL of sensor housing 30. In this embodiment, the flange 51 side face 35 of sensor housing side flange 33 and the mating surface 53 of flange 51 are joined by laser welding.

[0058] In this embodiment, the following structure is adopted in order to join the sensor housing side flange 33 and flange 51 by laser welding.

[0059] First, the structure is as follows: when viewed from a direction perpendicular to the mating surface 53 of the flange 51, the entire circumference of the flange 51 extends around the outside of the connector housing 50. Figure 8 In the diagram, when viewed from a direction perpendicular to the mating surface 53 of flange 51, arrow α indicates the extent to which the portion of sensor housing 30 on one axial side of flange 51 extends outward from connector housing 50. Similarly, when viewed from a direction perpendicular to the mating surface 53 of flange 51, arrow β indicates the extent to which the portion of sensor housing 30 on the other axial side of flange 51 extends outward from connector housing 50. Furthermore, when viewed from a direction perpendicular to the mating surface 53 of flange 51, the portion of sensor housing 30 on the other axial side of flange 51 extends outward from connector housing 50. Figure 8 The portion of the paper near the front side also extends outward from the connector housing 50, in the flange 51. Figure 8 The portion on the inner side of the paper also extends outward from the connector housing 50. This is in Figure 7As shown in the image.

[0060] When viewed from a direction perpendicular to the mating surface 53 of flange 51, the extent by which flange 51 extends outward from connector housing 50 is such that the upper clamp 71 of the laser welding apparatus 70 (described later) can apply pressure to flange 51. This prevents foaming from forming at the welding surface between flange 51 and sensor housing-side flange 33 during laser welding.

[0061] Furthermore, preferably, when viewed from a direction perpendicular to the mating surface 53 of the flange 51, the extent to which the flange 51 extends outward from the connector housing 50 is preferably such that, when the upper clamp 71 of the laser welding apparatus 70 applies pressure to the flange 51, a laser can be irradiated onto the flange 51. Thus, a laser can be irradiated onto the flange 51 from a direction perpendicular to the mating surface 53 of the flange 51. Moreover, not limited to this, a laser can also be irradiated onto the flange 51 from a direction inclined relative to the mating surface 53 of the flange 51.

[0062] Second, the sensor housing side flange 33 is formed of a resin with higher laser absorption than the resin forming the flange 51. The flange 51 is formed of a resin with higher laser transmittance than the resin forming the sensor housing side flange 33. Furthermore, the flange 51 is formed to a thickness that allows laser transmission. Therefore, the sensor housing side flange 33 and the flange 51 can be laser welded.

[0063] Third, on the axial side of the sensor housing 30 within the connector housing 50, at the point where it connects to the flange 51, a recess 55 is provided that is recessed towards the axial side of the sensor housing 30. Therefore, even if the flange 51 extends only slightly outward from the connector housing 50 when viewed from a direction perpendicular to the mating surface 53 of the flange 51, laser welding can still be performed by irradiating the flange 51 from a direction inclined relative to the mating surface 53 of the flange 51.

[0064] Next, refer to Figure 9 and Figure 10 The method for laser welding flange 51 to sensor housing side flange 33 during the manufacturing process of magnetic sensor module 20 will be described. Furthermore, for convenience, in this description, ... Figure 10 The upper side of the paper is called "top". Figure 10 The bottom side of the paper is called the "bottom".

[0065] like Figure 9 and Figure 10 As shown, the laser welding of flange 51 to sensor housing side flange 33 is performed with the substrate 41, the magnetic detection element 40 mounted on the substrate 41, and a part of connector housing 50 inserted into the inside of sensor housing extension 32.

[0066] First, the sensor housing side flange 33 is placed on the lower clamp 72 of the laser welding apparatus 70. Next, the upper clamp 71 of the laser welding apparatus 70 is positioned on the flange 51. Then, pressure is applied to the entire circumference of the flange 51 and the sensor housing side flange 33 using the upper clamp 71 and the lower clamp 72.

[0067] Next, as Figure 10 As shown by solid line L1, with flange 51 and sensor housing-side flange 33 under pressure, a laser is irradiated from a direction perpendicular to the mating surface 53 of flange 51. The laser irradiates the entire circumference of flange 51 around the outside of connector housing 50. The laser passes through flange 51 and is absorbed by sensor housing-side flange 33. Thus, the interface between flange 51 and sensor housing-side flange 33 is laser-welded. Furthermore, as... Figure 10 As shown by the dotted line L2, the laser can also be irradiated from a direction inclined relative to the mating surface 53 of the flange 51.

[0068] Afterwards, the laser irradiation is stopped, the upper clamp 71 is removed from the flange 51, and the magnetic sensor module 20 is removed from the laser welding device 70. Thus, the laser welding of the flange 51 and the sensor housing side flange 33 is completed.

[0069] The magnetic sensor module 20 is used as part of the torque sensor device 10, such as Figure 11 As shown, the mounting space 90 is located within the housing 9 of the electric power steering system 1.

[0070] like Figure 11 As shown in S1, the magnetic sensor module 20 of this embodiment can ensure the gap between the outer edge 56 of the sensor housing 30 on the axial side in the flange 51 and the inner wall of the housing 9 of the electric power steering system 1. Furthermore, as... Figure 11 As shown in S2, the magnetic sensor module 20 of this embodiment can also ensure the gap between the outer edge 57 of the sensor housing 30 on the other side of the axial direction in the flange 51 and the inner wall of the housing 9 of the electric power steering system 1.

[0071] Here, in order to compare with the magnetic sensor module 20 of the first embodiment, the magnetic sensor module 200 of the first comparative example will be described.

[0072] like Figure 12 As shown, in the magnetic sensor module 200 of the first comparative example, the flange 51 is formed parallel to the imaginary plane VS. Furthermore, in the magnetic sensor module 200 of the first comparative example, the area of ​​the mating surface 53 of the flange 51 and the area of ​​the connector opening 52 are the same as those of the magnetic sensor module 20 of the first embodiment. Figure 12As shown in S3, the magnetic sensor module 200 of the first comparative example can ensure the gap between the outer edge 56 of the sensor housing 30 on the axial side in the flange 51 and the inner wall of the housing 9 of the electric power steering system 1. However, as Figure 12 As shown in S4, in the magnetic sensor module 200 of the first comparative example, the outer edge 57 of the sensor housing 30 on the other side of the axial direction in the flange 51 interferes with the housing 9 of the electric power steering system 1. Therefore, the magnetic sensor module 200 of the first comparative example cannot be mounted or is difficult to mount in the mounting space 90 inside the housing 9 of the electric power steering system 1.

[0073] Compared to the magnetic sensor module 200 of the first comparative example, the magnetic sensor module 20, torque sensor device 10, and sensor device of the first embodiment have the following effects.

[0074] (1) The magnetic sensor module 20 of the first embodiment includes a pair of magnetic flux guiding members 21, 22, a sensor housing 30, a magnetic detection element 40, a connector housing 50, and a flange 51. The mating surface 53 of the flange 51 facing the sensor housing 30 engages with the sensor housing 30. The mating surface 53 of the flange 51 is inclined relative to an imaginary plane VS perpendicular to the element insertion direction ID.

[0075] According to this structure, the magnetic sensor module 20 can be miniaturized while ensuring the area of ​​the mating surface 53 that guarantees the engagement strength between the flange 51 and the connector housing 50, and the area of ​​the connector opening 52 for the insertion of the external connector 60. Therefore, the magnetic sensor module 20 can also be mounted in the narrow mounting space 90 within the housing 9 of a vehicle side system such as the electric power steering system 1.

[0076] Furthermore, even if the distance between the sensor device and the ECU7 varies depending on the vehicle model, the magnetic sensor module 20 of the first embodiment can be accommodated simply by changing the length of the wiring 61 provided on the external connector 60. Therefore, the magnetic sensor module 20 does not need to change its specifications according to the vehicle model it is installed in, which can reduce design and manufacturing costs.

[0077] (2) The torque sensor device 10 of the first embodiment includes a torsion bar 13, a multipole magnet 14, a pair of magnetic yokes 15 and 16, and the magnetic sensor module 20 described in (1) above.

[0078] According to this structure, the torque sensor device 10 enables the miniaturization of the magnetic sensor module 20 and allows it to be installed in the narrow mounting space 90 within the housing 9 of a vehicle side system such as the electric power steering system 1. Furthermore, since the torque sensor device 10 is configured to allow for the attachment and detachment of the external connector 60, there is no need to change the specifications according to the vehicle model in which it is installed, thus reducing design and manufacturing costs.

[0079] (3) The sensor device of the first embodiment includes a sensor body for capturing changes in physical quantities, a sensor housing 30 for accommodating at least a portion of the sensor body, a connector housing 50, and a flange 51. The mating surface 53 of the flange 51 facing the sensor housing 30 engages with the sensor housing 30. The mating surface 53 of the flange 51 is inclined relative to an imaginary plane VS perpendicular to the insertion direction ID of the element.

[0080] The sensor device is used to detect various physical quantities. In addition, when the sensor device is equivalent to the magnetic sensor module 20 described in (1) above, the sensor body of the sensor device is composed of a pair of magnetic flux guiding components 21, 22, etc.

[0081] Furthermore, when the sensor device is equivalent to the torque sensor device 10 described in (2) above, the sensor body of the sensor device is composed of a torsion bar 13, a multipole magnet 14, a pair of magnetic yokes 15 and 16, and a pair of magnetic flux guiding components 21 and 22. In this case, the sensor housing 30 houses the pair of magnetic flux guiding components 21 and 22.

[0082] Therefore, the sensor device can perform the same function as the magnetic sensor module described in (1) and the torque sensor device described in (2) above.

[0083] (4) In the first embodiment, when viewed from the direction perpendicular to the mating surface 53 of the flange 51, the entire circumference of the flange 51 extends around the outside of the connector housing 50.

[0084] According to this structure, laser can be irradiated from a direction perpendicular to the mating surface 53 while the pressure flange 51 is in contact with the sensor housing 30 at its full circumference, thereby enabling laser welding of the flange 51 and the sensor housing 30. Furthermore, laser can also be irradiated from a direction inclined relative to the mating surface 53.

[0085] (5) In the first embodiment, the mating surface 53 of the flange 51 is joined to the sensor housing 30 by laser welding around the entire circumference of the connector housing 50.

[0086] This structure prevents water and other substances from entering the sensor device from the joint between the flange 51 and the sensor housing 30.

[0087] Furthermore, in this embodiment, since the components constituting the magnetic sensor module 20 do not have wiring fixed on them as in the aforementioned Patent Document 1, the wiring will not cause any obstruction during laser welding, and laser welding can be performed easily.

[0088] (6) In the first embodiment, the mating surface 53 of the flange 51 is formed parallel to the anti-matting surface 54.

[0089] This structure allows for a constant plate thickness in flange 51, preventing deviations in the joint strength of laser welding along the entire circumference of flange 51.

[0090] (7) In the first embodiment, the face 35 of the sensor housing side flange 33 of the sensor housing 30 is inclined in the same direction as the flange 51 relative to the imaginary plane VS perpendicular to the element insertion direction ID, and engages with the flange 51.

[0091] According to this structure, the sensor housing side flange 33 can be placed on the lower clamp 72 of the laser welding apparatus 70, and pressure can be applied to the flange 51 and the sensor housing side flange 33 throughout the circumference. Therefore, during laser welding, foaming can be prevented from occurring on the welding surface of the flange 51 and the sensor housing side flange 33.

[0092] (8) In the first embodiment, the flange 51 is formed of a resin with higher laser transmittance than the resin forming the sensor housing side flange 33, and the plate thickness is formed to allow laser transmission.

[0093] According to this structure, the flange 51 can be reliably laser welded to the sensor housing 30.

[0094] (9) In the first embodiment, the mating surface 53 of the flange 51 is inclined from one side toward the other side in a direction extending from the central axis CL of the sensor housing 30, close to the central axis CL of the sensor housing 30. At the part of the connector housing 50 on the other side of the direction extending from the central axis CL of the sensor housing 30, a recess 55 is provided at the part that is connected to the flange 51.

[0095] According to this structure, even when the area of ​​the flange 51 extending outward from the connector housing 50 is small when viewed from a direction perpendicular to the mating surface 53 of the flange 51, a laser can still be irradiated onto the flange 51 from an inclined direction by providing a recess 55 in the connector housing 50. Therefore, the flange 51 and the connector housing 50 can be laser welded.

[0096] (10) In the first embodiment, the magnetic collecting parts 23 and 24 of a pair of magnetic flux guiding members 21 and 22 are arranged in a ring or arc shape on the radial outer side of a pair of magnetic yokes 15 and 16.

[0097] According to this structure, the radially opposing area of ​​a pair of magnetic yokes 15, 16 and a pair of flux guiding components 21, 22 can be increased. Therefore, the flux density guided from the pair of magnetic yokes 15, 16 to the pair of flux guiding components 21, 22 can be increased, improving the signal-to-noise ratio (SN ratio) and thus improving the torque detection accuracy.

[0098] (Second Implementation) The second embodiment will be described. The second embodiment differs from the first embodiment in that a portion of the structure of the magnetic sensor module 20 is changed, while other aspects are the same as the first embodiment. Therefore, only the parts that differ from the first embodiment will be described.

[0099] like Figure 13 As shown, the torque sensor device 10, as a sensor device in the second embodiment, also includes, similarly to the first embodiment, a torsion bar 13, a multipole magnet 14, a pair of magnetic yokes 15 and 16, and a magnetic sensor module 20. Figure 13 and Figure 14 As shown, the magnetic sensor module 20 includes a pair of magnetic flux guiding members 21 and 22, which are rod-shaped and disposed on a portion of the radially outer side of a pair of magnetic yokes 15 and 16. Specifically, the pair of magnetic flux guiding members 21 and 22 have rectangular strip-shaped magnetic collecting portions 27 and 28 disposed on a portion of the radially outer side of the pair of magnetic yokes 15 and 16, and extending portions 25 and 26 extending radially outward from the magnetic collecting portions 27 and 28. Furthermore, the shape of the pair of magnetic flux guiding members 21 and 22 is not limited to... Figure 13 and Figure 14 The shapes shown, such as the magnetic collecting parts 27 and 28, can also be arc-shaped, wavy, elliptical, or polygonal, or they can also be shapes with protrusions (not shown) for fixing to the sensor housing 30.

[0100] like Figure 15 As shown, a pair of flux guiding components 21 and 22 are fixed to the sensor housing 30. Figure 15 and Figure 16 As shown, the sensor housing 30 has a magnetic flux guiding component mounting portion 36, a cylindrical portion 37, and a housing mounting portion 38 protruding outward from the cylindrical portion 37. In the second embodiment, the central axis CL2 of the cylindrical portion 37 of the sensor housing 30 is orthogonal to the central axis CL of the magnetic yokes 15 and 16. Furthermore, in the following description, the direction in which the central axis CL of the magnetic yokes 15 and 16 extends is referred to as the "axial direction of the magnetic yokes 15 and 16". In addition, the central axis CL of the magnetic yokes 15 and 16, the central axis CL of the torsion bar 13, and the central axis CL of the steering shaft 3 are aligned.

[0101] like Figure 16As indicated by arrow ID, the magnetic detection element 40, mounted on the substrate 41, is inserted into the opening 39 of the cylindrical portion 37 of the sensor housing 30, together with a portion of the connector housing 50. In the description of the second embodiment, the direction in which the magnetic detection element 40, mounted on the substrate 41, is inserted into the opening 39 of the cylindrical portion 37 of the sensor housing 30, together with a portion of the connector housing 50, is also referred to as the "element insertion direction ID". Inside the cylindrical portion 37 of the sensor housing 30, a guide member 341 is provided to guide the substrate 41, etc., during insertion. The guide member 341 extends parallel to the direction in which the magnetic detection element 40 and the substrate 41 are inserted in the connector housing 50 (i.e., the element insertion direction ID). Therefore, in the completed state of the torque sensor device 10 and the magnetic sensor module 20, the element insertion direction ID can be identified as the in-plane direction of the substrate 41, the direction in which the guide member 341 extends, or the axial direction in which the cylindrical portion 37 of the sensor housing 30 extends. Alternatively, the element insertion direction ID can be identified as the direction in which the magnetic detection element 40 is inserted between the first extension portion 25 and the second extension portion 26.

[0102] The magnetic detection element 40 is disposed between the first extension portion 25 and the second extension portion 26. The mating surface 53 of the flange 51 is mated with the surface 371 on the flange 51 side in the cylindrical portion 37 of the sensor housing 30.

[0103] The connector housing 50 and flange 51 are integrally formed by resin injection molding. The connector housing 50 has a base plate 41 on which a magnetic detection element 40 is mounted, and terminals 42 electrically connected to the magnetic detection element 40. The connector housing 50 has a cylindrical connector opening 52 for attaching and detaching an external connector 60. Furthermore, in the second embodiment, the external connector attachment / removal direction RD and the element insertion direction ID are aligned with the direction in which the central axis CL2 of the cylindrical portion 37 of the sensor housing 30 extends.

[0104] Flange 51 extends outward from connector housing 50. Flange 51 extends outward around the entire circumference of a surface in connector housing 50 that intersects the component insertion direction ID and the external connector loading / unloading direction RD. Flange 51 is plate-shaped and is inclined relative to an imaginary plane VS perpendicular to the component insertion direction ID. Furthermore, flange 51 can also be described as inclined relative to an imaginary plane VS perpendicular to substrate 41. Flange 51 can also be described as inclined relative to an imaginary plane VS parallel to the central axis CL of torsion bar 13. Flange 51 can also be described as inclined relative to an imaginary plane VS perpendicular to the external connector loading / unloading direction RD. Flange 51 can also be described as inclined relative to an imaginary plane VS perpendicular to the axis of the cylindrical portion 37 of sensor housing 30.

[0105] The mating surface 53 of flange 51 facing the sensor housing 30 engages with the cylindrical portion 37 of sensor housing 30. The surface of flange 51 facing the opposite side to the mating surface 53 is called the anti-matting surface 54. The mating surface 53 and the anti-matting surface 54 of flange 51 are parallel. Both the mating surface 53 and the anti-matting surface 54 of flange 51 are inclined relative to the imaginary plane VS.

[0106] In the second embodiment, the flange 51 side face 371 of the cylindrical portion 37 of the sensor housing 30 and the mating surface 53 of the flange 51 are also joined by laser welding.

[0107] In the second embodiment, the following structure is adopted in order to join the sensor housing 30 and the flange 51 by laser welding.

[0108] First, the structure is as follows: when viewed from a direction perpendicular to the mating surface 53 of the flange 51, the entire circumference of the flange 51 extends around the outside of the connector housing 50. Figure 15 In the diagram, when viewed from a direction perpendicular to the mating surface 53 of flange 51, arrow α indicates the extent to which the axial side of the magnetic yokes 15 and 16 in flange 51 extends outward from connector housing 50. Similarly, when viewed from a direction perpendicular to the mating surface 53 of flange 51, arrow β indicates the extent to which the axial side of the magnetic yokes 15 and 16 in flange 51 extends outward from connector housing 50. Furthermore, when viewed from a direction perpendicular to the mating surface 53 of flange 51, the portion of flange 51... Figure 15 The portion of the paper near the front side also extends outward from the connector housing 50, in the flange 51. Figure 15 The portion on the inner side of the paper also extends outward from the connector housing 50. This is in Figure 16 As shown in the image.

[0109] Second, the cylindrical portion 37 of the sensor housing 30 is formed of a resin with higher laser absorption than the resin forming the flange 51. The flange 51 is formed of a resin with higher laser transmittance than the resin forming the cylindrical portion 37 of the sensor housing 30. Furthermore, the flange 51 is formed with a plate thickness that allows laser transmission. As a result, the cylindrical portion 37 of the sensor housing 30 and the flange 51 can be laser welded.

[0110] Furthermore, in the second embodiment, the recess 55 described in the first embodiment may also be provided on the connector housing 50.

[0111] The magnetic sensor module 20 is used as part of the torque sensor device 10 and is mounted in the mounting space 90 within the housing 9 of the electric power steering system 1.

[0112] The magnetic sensor module 20, torque sensor device 10, and sensor device of the second embodiment described above also have the same effect as those described in the first embodiment.

[0113] Furthermore, in the second embodiment, a pair of flux guiding members 21, 22 are arranged in a rod shape on a portion of the radial outer side of a pair of magnetic yokes 15, 16.

[0114] According to this structure, compared with the torque sensor device 10 of the first embodiment, the torque sensor device 10 of the second embodiment can reduce the inner diameter D1 of the portion 91 in the system-side housing that accommodates a pair of magnetic yokes 15, 16.

[0115] (Third implementation method) The third embodiment will be described. The sensor device in the third embodiment, like that in the first embodiment, is applied to… Figure 1 The torque sensor device 10 of the electric power steering system 1 shown in the figure. Figure 17 As shown, the torque sensor device 10 includes a magnetic sensor module 20 similar to that in the first embodiment. The magnetic sensor module 20 includes a first magnetic flux guiding member 21, a second magnetic flux guiding member 22, a sensor housing 30, a magnetic detection element 40, a connector housing 50, and a flange 51. Hereinafter, the first magnetic flux guiding member 21 and the second magnetic flux guiding member 22 will be referred to as a "pair of magnetic flux guiding members 21, 22". The pair of magnetic flux guiding members 21, 22 includes magnetic collecting portions 23, 24 and extending portions 25, 26.

[0116] A pair of magnetic flux guiding components 21 and 22 are housed in the sensor housing 30. Specifically, the pair of magnetic flux guiding components 21 and 22 are fixed to the sensor housing 30 by means of resin molding or the like.

[0117] A portion of the sensor housing 30 is formed in a cylindrical shape. Specifically, the sensor housing has a cylindrical sensor housing body 31, a sensor housing extension 32 extending from the sensor housing body 31 toward the connector housing 50, and a sensor housing side flange 33 extending outward from the sensor housing extension 32. The magnetic collecting portions 23 and 24 of a pair of magnetic flux guiding members 21 and 22 are fixed to the radially inner side of the sensor housing body 31, and the extending portions 25 and 26 extend from the magnetic collecting portions 23 and 24 toward the inner side of the sensor housing extension 32.

[0118] In the following description, the central axis CL of the inner circumferential surface of the sensor housing body 31 is referred to as the "central axis CL of the sensor housing 30". Furthermore, the central axis CL of the sensor housing 30, the central axis CL of the torsion bar 13 described in the first embodiment, and the central axis CL of the steering shaft 3 are all aligned. Additionally, the radial direction of an imaginary circle drawn with the central axis CL of the sensor housing 30 as its center on a plane perpendicular to the central axis CL is called the "radial direction", the circumferential direction of this imaginary circle is called the "circumferential direction", and the direction in which the central axis CL extends is called the "axial direction". Furthermore, the direction in which the central axis CL extends is referred to as the "axial direction". Figure 17 The upper side is called the "axial side". Figure 17 The lower side is called the "other side of the axis".

[0119] A portion of the connector housing 50 is inserted into the opening 34 of the sensor housing extension 32, along with the magnetic detection element 40 mounted on the substrate 41. The magnetic detection element 40, mounted on the substrate 41, is positioned between the first extension portion 25 and the second extension portion 26 when inserted into the opening 34 of the sensor housing extension 32. The direction in which the magnetic detection element 40, mounted on the substrate 41, is inserted into the opening 34 of the sensor housing extension 32 is called the "element insertion direction ID". The element insertion direction ID can be defined as the in-plane direction of the substrate 41 or the axial extension direction of the sensor housing extension 32. Alternatively, the element insertion direction ID can be defined as the direction in which the magnetic detection element 40 is inserted between the first extension portion 25 and the second extension portion 26 of a pair of magnetic flux guiding members 21 and 22.

[0120] The flange 51 on the connector housing 50 side engages with the flange 33 on the sensor housing side. The sensor housing side flange 33 and the flange 51 are engaged, for example, by laser welding.

[0121] The connector housing 50 and flange 51 are integrally formed by resin injection molding. The connector housing 50 has a substrate 41 on which a magnetic detection element 40 is mounted, and terminals 42 electrically connected to the magnetic detection element 40 via wiring on the substrate 41. The connector housing 50 has a cylindrical connector opening 52 for attaching and detaching an external connector (not shown). One end of the terminal 42 is connected to the magnetic detection element 40, and the other end protrudes from the connector opening 52. In this embodiment, the attachment / removal direction RD of the external connector is parallel to the element insertion direction ID. Furthermore, in this embodiment, the external connector attachment / removal direction RD and the element insertion direction ID intersect (specifically, are orthogonal) the central axis CL of the sensor housing 30.

[0122] Flange 51 extends outward from connector housing 50. Specifically, flange 51 extends outward around the entire circumference of the outer wall surface of connector housing 50 in a direction intersecting the component insertion direction ID and the external connector loading / unloading direction RD.

[0123] Flange 51 is formed in a plate shape and is inclined relative to an imaginary plane VS perpendicular to the insertion direction ID of the component. The surface of flange 51 facing the sensor housing 30 is a mating surface 53 that engages with the sensor housing side flange 33. The anti-matting surface 54 of flange 51 facing the opposite side of the mating surface 53 is formed parallel to the mating surface 53 of flange 51. Both the mating surface 53 and the anti-matting surface 54 of flange 51 are inclined relative to the imaginary plane VS. Furthermore, the inclination angle θ of the mating surface 53 of flange 51 relative to the imaginary plane VS is as described in the first embodiment.

[0124] Here, the connector housing 50 is positioned offset axially relative to the flange 51. Specifically, the axial center position C1 in the connector opening 52 is offset axially relative to the axial center position C2 in the flange 51. The offset ΔC between these two center positions C1 and C2 is greater than the manufacturing tolerance assuming the two center positions C1 and C2 are aligned. Furthermore, although not limited, it is preferable that the offset ΔC between the two center positions C1 and C2 is greater than 10% of the distance D3 along the central axis CL of the sensor housing 30 in the flange 51.

[0125] Alternatively, the connector housing 50 can be positioned offset axially from the flange 51, as follows: Let A be the distance along the central axis CL of the sensor housing 30 between the outer wall 58 on the axial side of the connector housing 50 and the outer edge 56 on the axial side of the flange 51. Let B be the distance along the central axis CL of the sensor housing 30 between the outer wall 59 on the opposite axial side of the connector housing 50 and the outer edge 57 on the opposite axial side of the flange 51. In this case, A>B is satisfied.

[0126] The difference between the two distances A and B is greater than the manufacturing tolerance assuming that the two distances A and B are the same. Furthermore, although not limited, it is preferred that distance B is less than 10% of distance A. Additionally, B can also be 0.

[0127] The effect of setting the connector housing 50 relative to the flange 51 at a position offset to the other side of the axial direction in the magnetic sensor module 20 of this embodiment will be explained in conjunction with a comparison with the magnetic sensor module 201 of the second comparative example.

[0128] like Figure 18As shown, in the magnetic sensor module 201 of the second comparative example, the flange 510 extending outward from the connector housing 500 is formed parallel to an imaginary plane VS perpendicular to the component insertion direction ID and the external connector loading / unloading direction RD. In the magnetic sensor module 201 of the second comparative example, the radial dimension of the sensor housing extension 32 is set to D4. Furthermore, the radial dimensions of the flange 510 and the connector housing 500 are set to D5. The overall radial dimension of the magnetic sensor module 201 is set to D6.

[0129] In contrast, such as Figure 19 As shown, in the magnetic sensor module 20 of this embodiment, the flange 51 extending outward from the connector housing 50 is inclined relative to the imaginary plane VS. Furthermore, the connector housing 50 is positioned offset axially to the other side relative to the flange 51. Additionally, in Figure 19 In the diagram, the position where the connector housing 500 of the magnetic sensor module 201 of the second comparative example is superimposed on the magnetic sensor module 20 of this embodiment is indicated by a dashed line. In this embodiment, the radial size D7 of the magnetic sensor module 20 as a whole can be miniaturized by the difference D8 compared to the radial size D6 of the magnetic sensor module 201 of the second comparative example.

[0130] As described above, in the third embodiment, the axial center position C1 in the connector opening 52 is located offset to the other side of the axial direction relative to the axial center position C2 in the flange 51. This allows the overall radial size D7 of the magnetic sensor module 20 to be miniaturized compared to the size shown in the second comparative example.

[0131] Furthermore, in the third embodiment, the distance A between the outer wall 58 on one axial side of the connector housing 50 and the outer edge 56 on one axial side of the flange 51 is greater than the distance B between the outer wall 59 on the other axial side of the connector housing 50 and the outer edge 57 on the other axial side of the flange 51. Therefore, the radial size D7 of the entire magnetic sensor module 20 can be miniaturized compared to the size shown in the second comparative example. Thus, as... Figure 11 As shown, the magnetic sensor module 20 can be mounted in the narrow mounting space 90 within the housing 9 of the vehicle side system such as the electric power steering system 1.

[0132] (Other implementation methods) (1) In the above embodiments, the sensor device has been described using a torque sensor as an example, but it is not limited thereto. For example, the sensor device can also be used as a detection device that detects various physical quantities, such as a pressure sensor, an acceleration sensor, or a temperature sensor. In this case, the detection element is not limited to the magnetic detection element 40, and an element that can convert the physical quantity detected by the sensor into an electrical signal can be used.

[0133] (2) In the above embodiments, the application of the torque sensor device 10 to the electric power steering system 1 is used as an example, but it is not limited thereto. The torque sensor device 10 can also be applied to various vehicle systems.

[0134] (3) In the above embodiments, the example given is that the input shaft 11 constituting the steering shaft 3 is equivalent to the first shaft and the output shaft 12 is equivalent to the second shaft, but it is not limited to this. For example, the output shaft 12 may be equivalent to the first shaft and the input shaft 11 may be equivalent to the second shaft. In this case, the multipole magnet 14 is fixed to the other end of the output shaft 12 or the torsion bar 13, and a pair of magnetic yokes 15 and 16 are fixed to one end of the input shaft 11 or the torsion bar 13.

[0135] (4) In the first embodiment described above, the structure of laser welding the mating surface 53 of the flange 51 to the sensor housing side flange 33 of the sensor housing 30 was described, but it is not limited thereto. The mating surface 53 of the flange 51 and the sensor housing side flange 33 of the sensor housing 30 can be joined by various joining methods, such as joining by adhesive, fusion by heat, ultrasound or vibration, or joining by screws or rivets.

[0136] (5) In the first embodiment described above, a structure in which the flange 51 extends outward around its entire circumference when viewed from a direction perpendicular to the mating surface 53 of the flange 51 is described, but it is not limited thereto. Alternatively, a structure in which a portion of the flange 51 extends outward from the connector housing 50 when viewed from a direction perpendicular to the mating surface 53 of the flange 51 is also possible.

[0137] (6) In the first embodiment described above, the structure in which the mating surface 53 of the flange 51 and the sensor housing 30 are joined around the entire circumference of the connector housing 50 by laser welding has been described, but it is not limited to this. It is also possible that the mating surface 53 of the flange 51 and the sensor housing 30 are joined partially around the outside of the connector housing 50 by laser welding.

[0138] (7) In the first embodiment described above, an example was given in which the mating surface 53 of the flange 51 is inclined from one axial side of the sensor housing 30 toward the other axial side of the sensor housing 30 in a manner close to the central axis CL of the sensor housing 30, but this is not a limitation. The direction of inclination of the mating surface 53 of the flange 51 can be arbitrarily set according to, for example, the shape of the mounting space 90 of the magnetic sensor module 20 inside the housing 9 of the vehicle system.

[0139] (8) In the first embodiment described above, the shape of the flange 51 as viewed from a direction perpendicular to the mating surface 53 of the flange 51 is set to be approximately quadrilateral, and in the second embodiment described above, its shape is set to be approximately circular, but it is not limited thereto. The shape of the flange 51 can be various shapes such as polygonal, elliptical, circular, curved, etc.

[0140] This disclosure is not limited to the above-described embodiments and appropriate modifications can be made. Furthermore, the above-described embodiments and parts thereof are not unrelated and can be appropriately combined, except in cases where they are clearly incompatible. Additionally, in the above-described embodiments, it is self-evident that elements constituting the embodiments are not necessarily essential, except where specifically stated as necessary or where they are clearly considered necessary in principle. Furthermore, in the above-described embodiments, when referring to the number, value, quantity, range, etc., of the constituent elements of the embodiments, the number is not limited to that specific number, except where specifically stated as necessary or where it is clearly limited to a specific number in principle. Furthermore, in the above-described embodiments, when referring to the shape, positional relationship, etc., of the constituent elements, the shape, positional relationship, etc., is not limited to that shape, positional relationship, etc., except where specifically stated or where it is limited to a specific shape, positional relationship in principle.

[0141] (This is the viewpoint of the publication) Regarding the above disclosure, for example, it can be understood as the following viewpoint.

[0142] [First Viewpoint] A sensor device, mounted on a vehicle, is characterized by comprising: The sensor body (13-16, 21, 22) captures changes in physical quantities; Sensor housing (30) that houses at least a portion of the sensor body; A connector housing (50) is provided with a detection element (40) that outputs a signal corresponding to the change of the physical quantity, and the portion of the detection element is inserted into the inside of the sensor housing; and A flange (51) extends outward from the connector housing, and its mating surface (53) facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to the imaginary plane (VS), which is a plane perpendicular to the direction (ID) in which the portion of the connector housing in which the detection element is located is inserted into the sensor housing.

[0143] [Second Viewpoint] According to the sensor device described in the first viewpoint, wherein... When viewed from a direction perpendicular to the mating surface, a portion or the entire circumference of the flange extends outward from the connector housing.

[0144] [Third Viewpoint] According to the sensor device described in the first or second viewpoint, wherein... The mating surface is joined to the sensor housing by laser welding to a portion or the entire circumference of the outside of the connector housing.

[0145] [Fourth viewpoint] The sensor device according to any one of the first to third viewpoints, wherein... The anti-joining surface (54) on the side opposite to the joining surface in the flange is formed parallel to the joining surface.

[0146] [Fifth Viewpoint] The sensor device according to any one of the first to fourth viewpoints, wherein... The sensor housing has a main body (31) formed in a cylindrical shape and a side flange (33) of the sensor housing that engages with the flange. The face (35) on one side of the flange in the sensor housing side flange is inclined in the same direction as the flange relative to the imaginary plane.

[0147] [Sixth Viewpoint] The sensor device according to any one of the first to fifth viewpoints, wherein... The flange (51) is formed of a resin that has higher laser transmittance than the resin that forms the sensor housing, and the thickness of the flange (51) is such that the laser can pass through.

[0148] [Seventh Viewpoint] The sensor device according to any one of the first to sixth viewpoints, wherein... The sensor housing has a main body (31) formed in a cylindrical shape. The mating surface is inclined from one side toward the other in a manner close to the central axis, extending from the central axis (CL) of the sensor housing body. On the other side of the direction in which the central axis extends in the connector housing, a recess (55) is provided at the part that connects to the flange, recessed on one side in the direction in which the central axis extends.

[0149] [Eighth Viewpoint] A torque sensor device is a torque sensor device for detecting the torque around a shaft (3) acting on it, characterized in that it comprises: Torsion bar (13) connects the first shaft (11) and the second shaft (12) that constitute the shaft to the same shaft and converts the torque acting between the first shaft and the second shaft into torsional displacement; A multipole magnet (14) is fixed to one end of the first shaft or the torsion bar, and has N poles and S poles alternately arranged in the circumferential direction; The magnetic yoke (15, 16) is fixed to the other end of the second shaft or the torsion bar on the outside of the multipole magnet and forms a magnetic circuit in the magnetic field of the multipole magnet. The first magnetic flux guiding component (21) and the second magnetic flux guiding component (22) are disposed on the outside of the magnetic yoke to guide the magnetic flux flowing through the magnetic yoke; Sensor housing (30) which secures the first magnetic flux guiding component and the second magnetic flux guiding component; The magnetic detection element (40) outputs a signal corresponding to the magnetic flux density at the adjacent portions (25, 26) of the first and second magnetic flux guiding components. A connector housing (50) having the magnetic detection element provided therein, and the portion having the magnetic detection element being inserted into the inner side of the sensor housing; and A flange (51) extends outward from the connector housing, and its mating surface (53) facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to the imaginary plane (VS), which is a plane perpendicular to the direction (ID) in which the portion of the connector housing in which the magnetic detection element is located is inserted into the sensor housing.

[0150] [Ninth Viewpoint] According to the torque sensor device described in the eighth point, wherein... The torsion bar undergoes elastic deformation due to the about-axis torque acting between the first shaft and the second shaft. The magnetic yoke has a first magnetic yoke (15) and a second magnetic yoke (16), and the relative position of the magnetic yoke and the multipole magnet in the rotational direction changes according to the torsional displacement of the torsion bar, thereby changing the magnetic flux flowing between the first magnetic yoke and the second magnetic yoke. The first magnetic flux guiding component has a first magnetic collecting part (23) for collecting the magnetic field of the first magnetic yoke, and the second magnetic flux guiding component has a second magnetic collecting part (24) for collecting the magnetic field of the second magnetic yoke. The magnetic detection element converts the magnetic flux collected by the first magnetic flux guiding component and the second magnetic flux guiding component into an electrical signal and outputs it.

[0151] [Tenth Viewpoint] According to the torque sensor device described in the eighth or ninth viewpoint, wherein... The first flux guiding component has a first magnetic collecting part (23) arranged in a ring or arc shape on the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (24) arranged in an annular or arc shape on the radially outer side of the yoke.

[0152] [Eleventh Viewpoint] According to the torque sensor device described in the eighth or ninth viewpoint, wherein... The first flux guiding component has a first magnetic collecting part (27) that is arranged in a rod shape on a portion of the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (28) that is configured in a rod shape on a portion of the radially outer side of the yoke.

[0153] [Twelfth Viewpoint] According to any one of the eighth to eleventh viewpoints, in the torque sensor device, wherein... The torque sensor device can be mounted in the mounting space (90) inside the housing (9) of the electric power steering system (1).

[0154] [Thirteenth Viewpoint] A magnetic sensor module for detecting magnetic flux flowing in a magnetic yoke (15, 16), characterized in that it comprises: A first flux guiding component (21) and a second flux guiding component (22) guide the flux flowing through the yoke; Sensor housing (30) which houses the first magnetic flux guiding component and the second magnetic flux guiding component; The magnetic detection element (40) outputs a signal corresponding to the magnetic flux density at the adjacent portions (25, 26) of the first and second magnetic flux guiding components. A connector housing (50) having the magnetic detection element provided therein, and the portion having the magnetic detection element being inserted into the inner side of the sensor housing; and A flange (51) extends outward from the connector housing, and its mating surface (53) facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to the imaginary plane (VS), which is a plane perpendicular to the direction (ID) in which the portion of the connector housing in which the magnetic detection element is located is inserted into the sensor housing.

[0155] [Fourteenth Viewpoint] According to the magnetic sensor module described in point thirteen, wherein... The first flux guiding component has a first magnetic collecting part (23) arranged in a ring or arc shape on the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (24) arranged in an annular or arc shape on the radially outer side of the yoke.

[0156] [Fifteenth Viewpoint] According to the magnetic sensor module described in point thirteen, wherein... The first flux guiding component has a first magnetic collecting part (27) that is arranged in a rod shape on a portion of the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (28) that is configured in a rod shape on a portion of the radially outer side of the yoke.

[0157] [Sixteenth Viewpoint] According to any one of the viewpoints thirteen to fifteen, the magnetic sensor module wherein, The magnetic sensor module can be mounted in the mounting space (90) inside the housing (9) of the electric power steering system (1).

[0158] [Seventeenth Viewpoint] The sensor device according to any one of the first to seventh viewpoints, wherein... The sensor housing has a main body (31) formed in a cylindrical shape. The mating surface is inclined from one side toward the other in a manner close to the central axis, extending from the central axis (CL) of the sensor housing body. The connector housing has a connector opening (52) for attaching and detaching an external connector (60). The center position (C1) in the connector opening, in the direction in which the central axis extends, is located offset to the other side of the direction in which the central axis extends, relative to the center position (C2) in the flange.

[0159] [Eighteenth Viewpoint] The sensor device according to any one of the first to seventh or seventeenth viewpoints, wherein, The sensor housing has a main body (31) formed in a cylindrical shape. The mating surface is inclined from one side toward the other in a manner close to the central axis, extending from the central axis (CL) of the sensor housing body. Let A be the distance along the direction of the central axis between the outer wall (58) on one side of the connector housing extending from the central axis and the outer edge (56) on one side of the flange extending from the central axis. Let B be the distance along the direction of the central axis between the outer wall (59) on the other side of the direction in which the central axis extends in the connector housing and the outer edge (57) on the other side of the direction in which the central axis extends in the flange. The relationship A > B is satisfied.

[0160] Furthermore, the content described in the second to seventh points, the seventeenth point, and the eighteenth point can be appropriately combined for the eighth and thirteenth points.

Claims

1. A sensor device, which is mounted on a vehicle, characterized in that, have: The sensor body (13-16, 21, 22) captures changes in physical quantities; Sensor housing (30) that houses at least a portion of the sensor body; A connector housing (50) is provided with a detection element (40) that outputs a signal corresponding to the change of the physical quantity, and the portion of the detection element is inserted into the inside of the sensor housing; and A flange (51) extends outward from the connector housing, and its mating surface (53) facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to the imaginary plane (VS), which is a plane perpendicular to the direction (ID) in which the portion of the connector housing in which the detection element is located is inserted into the sensor housing.

2. The sensor device according to claim 1, characterized in that, When viewed from a direction perpendicular to the mating surface, a portion or the entire circumference of the flange extends outward from the connector housing.

3. The sensor device according to claim 1 or 2, characterized in that, The mating surface is joined to the sensor housing by laser welding to a portion or the entire circumference of the outside of the connector housing.

4. The sensor device according to claim 1 or 2, characterized in that, The anti-joining surface (54) on the side opposite to the joining surface in the flange is formed parallel to the joining surface.

5. The sensor device according to claim 1 or 2, characterized in that, The sensor housing has a main body (31) formed in a cylindrical shape and a side flange (33) of the sensor housing that engages with the flange. The face (35) on one side of the flange in the sensor housing side flange is inclined in the same direction as the flange relative to the imaginary plane.

6. The sensor device according to claim 1 or 2, characterized in that, The flange (51) is formed of a resin that has higher laser transmittance than the resin that forms the sensor housing, and the thickness of the flange (51) is such that the laser can pass through.

7. The sensor device according to claim 1 or 2, characterized in that, The sensor housing has a main body (31) formed in a cylindrical shape. The mating surface is inclined from one side toward the other in a manner close to the central axis, extending from the central axis (CL) of the sensor housing body. On the other side of the direction in which the central axis extends in the connector housing, a recess (55) is provided at the part that connects to the flange, recessed on one side in the direction in which the central axis extends.

8. A torque sensor device, which is a torque sensor device for detecting the about-axis torque acting on a shaft (3), characterized in that, have: Torsion bar (13) connects the first shaft (11) and the second shaft (12) that constitute the shaft to the same shaft and converts the torque acting between the first shaft and the second shaft into torsional displacement; A multipole magnet (14) is fixed to one end of the first shaft or the torsion bar, and has N poles and S poles alternately arranged in the circumferential direction; The magnetic yoke (15, 16) is fixed to the other end of the second shaft or the torsion bar on the outside of the multipole magnet and forms a magnetic circuit in the magnetic field of the multipole magnet. The first magnetic flux guiding component (21) and the second magnetic flux guiding component (22) are disposed on the outside of the magnetic yoke to guide the magnetic flux flowing through the magnetic yoke; Sensor housing (30) which secures the first magnetic flux guiding component and the second magnetic flux guiding component; The magnetic detection element (40) outputs a signal corresponding to the magnetic flux density at the adjacent portions (25, 26) of the first and second magnetic flux guiding components. A connector housing (50) having the magnetic detection element provided therein, and the portion having the magnetic detection element being inserted into the inner side of the sensor housing; and A flange (51) extends outward from the connector housing, and its mating surface (53) facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to the imaginary plane (VS), which is a plane perpendicular to the direction (ID) in which the portion of the connector housing in which the magnetic detection element is located is inserted into the sensor housing.

9. The torque sensor device according to claim 8, characterized in that, The torsion bar undergoes elastic deformation due to the about-axis torque acting between the first shaft and the second shaft. The magnetic yoke has a first magnetic yoke (15) and a second magnetic yoke (16), and the relative position of the magnetic yoke and the multipole magnet in the rotational direction changes according to the torsional displacement of the torsion bar, thereby changing the magnetic flux flowing between the first magnetic yoke and the second magnetic yoke. The first magnetic flux guiding component has a first magnetic collecting part (23) for collecting the magnetic field of the first magnetic yoke, and the second magnetic flux guiding component has a second magnetic collecting part (24) for collecting the magnetic field of the second magnetic yoke. The magnetic detection element converts the magnetic flux collected by the first magnetic flux guiding component and the second magnetic flux guiding component into an electrical signal and outputs it.

10. The torque sensor device according to claim 8, characterized in that, The first flux guiding component has a first magnetic collecting part (23) arranged in a ring or arc shape on the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (24) arranged in an annular or arc shape on the radially outer side of the yoke.

11. The torque sensor device according to claim 8, characterized in that, The first flux guiding component has a first magnetic collecting part (27) that is arranged in a rod shape on a portion of the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (28) that is configured in a rod shape on a portion of the radially outer side of the yoke.

12. The torque sensor device according to any one of claims 8 to 11, characterized in that, The torque sensor device can be mounted in the mounting space (90) inside the housing (9) of the electric power steering system (1).

13. A magnetic sensor module for detecting magnetic flux flowing in a magnetic yoke (15, 16), characterized in that, have: A first flux guiding component (21) and a second flux guiding component (22) guide the flux flowing through the yoke; Sensor housing (30) which houses the first magnetic flux guiding component and the second magnetic flux guiding component; The magnetic detection element (40) outputs a signal corresponding to the magnetic flux density at the adjacent portions (25, 26) of the first and second magnetic flux guiding components. A connector housing (50) having the magnetic detection element provided therein, and the portion having the magnetic detection element being inserted into the inner side of the sensor housing; and A flange (51) extends outward from the connector housing, and its mating surface (53) facing the sensor housing engages with the sensor housing. The mating surface is inclined relative to the imaginary plane (VS), which is a plane perpendicular to the direction (ID) in which the portion of the connector housing in which the magnetic detection element is located is inserted into the sensor housing.

14. The magnetic sensor module according to claim 13, characterized in that, The first flux guiding component has a first magnetic collecting part (23) arranged in a ring or arc shape on the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (24) arranged in an annular or arc shape on the radially outer side of the yoke.

15. The magnetic sensor module according to claim 13, characterized in that, The first flux guiding component has a first magnetic collecting part (27) that is arranged in a rod shape on a portion of the radially outer side of the yoke. The second flux guiding component has a second magnetic collecting part (28) that is configured in a rod shape on a portion of the radially outer side of the yoke.

16. The magnetic sensor module according to any one of claims 13 to 15, characterized in that, The magnetic sensor module can be mounted in the mounting space (90) inside the housing (9) of the electric power steering system (1).

17. The sensor device according to claim 1 or 2, characterized in that, The sensor housing has a main body (31) formed in a cylindrical shape. The mating surface is inclined from one side toward the other in a manner close to the central axis, extending from the central axis (CL) of the sensor housing body. The connector housing has a connector opening (52) for attaching and detaching an external connector (60). The center position (C1) in the connector opening, in the direction in which the central axis extends, is located offset to the other side of the direction in which the central axis extends, relative to the center position (C2) in the flange.

18. The sensor device according to claim 1 or 2, characterized in that, The sensor housing has a main body (31) formed in a cylindrical shape. The mating surface is inclined from one side toward the other in a manner close to the central axis, extending from the central axis (CL) of the sensor housing body. Let A be the distance along the direction of the central axis between the outer wall (58) on one side of the connector housing extending from the central axis and the outer edge (56) on one side of the flange extending from the central axis. Let B be the distance along the direction of the central axis between the outer wall (59) on the other side of the direction in which the central axis extends in the connector housing and the outer edge (57) on the other side of the direction in which the central axis extends in the flange. The relationship A > B is satisfied.

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