Rotary control assembly

Abstract

A rotary control assembly (100) includes a housing (110) and a rotary controller (120) supported in the housing (110). The rotary controller (120) is rotatable about an axis of rotation (101). The printed circuit board (700) includes a transmitting coil (TX) and a plurality of receiving coils (RX). A metal target (260) is fixedly connected to the rotary controller (120) and proximate to the printed circuit board (700). When the rotary controller (120) rotates within the housing (110), the metal target (260) is displaced relative to the plurality of receiving coils (RX). The transmitting coil (TX) induces an eddy current within the metal target (260), which in turn induces a voltage in the receiving coil (RX), allowing the position of the metal target (260) to be determined.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 583,803, filed on September 19, 2023. Background Technology

[0002] A rotary gear selector in a car is a gear selector mechanism used to control the vehicle's transmission. Unlike column-mounted or floor-mounted gear levers, rotary gear selectors use a dial or knob that the driver can rotate to select the desired gear or transmission mode. Rotary gear selectors have become increasingly popular in modern vehicles due to their space-saving design, improved aesthetics, and enhanced functionality. They are particularly beneficial when used in conjunction with electronic transmission control systems or electric drive systems. They can improve safety by preventing accidental gear shifts.

[0003] In the context of this application, the term "shifter" is used broadly to refer to a driving mode selector. It can be used with a multi-speed transmission in conjunction with an internal combustion engine, and also for driving mode or direction selection in conjunction with an electric drivetrain. Rotary shifters are typically used to switch a vehicle between drive, reverse, and neutral driving modes. Rotating a control knob provides access to additional driving modes and, optionally, additional features.

[0004] A rotary gear selector is typically a rotary control unit that includes a knob rotatably supported in a housing. Driving modes are assigned to this knob within its rotational range. Driving modes can be selected by turning the knob.

[0005] For example, a selector lever assembly for selecting and switching different driving modes in a vehicle's transmission is known from U.S. Patent Application Publication No. 2022 / 0373080. The selector lever assembly includes a permanent magnet on the end of the shaft element away from the knob, having a dedicated sensor capable of detecting its movement. A 3D sensor may preferably be used here. The sensor is fixed in place relative to the housing such that it is dedicated to the permanent magnet, thereby enabling the sensor to detect movement of the permanent magnet connected to the shaft element. The sensor is typically a Hall effect type sensor. Summary of the Invention

[0006] In one example, the rotary control assembly includes a housing. A rotary controller is supported within the housing. The rotary controller is rotatable about a rotation axis. The rotary control assembly also includes a printed circuit board with a transmitting coil (TX) and multiple (three) receiving coils (RX). A metal target is fixedly attached to the rotary controller and proximates the printed circuit board. As the rotary controller rotates within the housing, the metal target shifts relative to the multiple receiving coils.

[0007] The printed circuit board includes one or more electronic components configured to excite a transmitting coil (TX) and induce eddy currents in a metal target. These eddy currents then induce a voltage in a receiving coil (RX). The electronic components evaluate the voltage induced in the receiving coil (RX) to determine the position of the metal target and generate a driving mode signal for the vehicle based on the position of the metal target.

[0008] Typically, multiple receiver coils (RX) refer to two or more receiver coils (RX). These multiple receiver coils (RX) can specifically be three receiver coils (RX) electrically connected to each other in a star configuration.

[0009] The metal target is preferably shaped as a ring-shaped sector. In particular, the metal target may be shaped as a flat ring-shaped sector extending at an angle of 90°.

[0010] The rotary controller includes an externally accessible knob and a shaft fixedly connected to the knob (210). The shaft includes an annular flange forming the lower end of the rotary controller. A metal target is connected to this annular flange. The metal target can be secured in a downwardly opening cavity formed within the annular flange.

[0011] The knob may include an annular engagement groove formed between an outer cylindrical engagement sector and an inner cylindrical engagement sector. A key may extend between the outer and inner cylindrical engagement sectors. A shaft may include a corresponding cylindrical engagement portion received within the annular engagement groove. This cylindrical engagement portion may include a positioning slot in which the key is received. Additionally, the shaft may include a plurality of hooks that engage through corresponding windows extending through the outer cylindrical engagement sector.

[0012] The transmitting coil (TX) and multiple receiving coils (RX) can be formed by traces within a ring-shaped portion of a printed circuit board. Electronic components can be arranged on the upper side of the printed circuit board and located inside the ring-shaped portion. The electronic components may include an inductive sensor interface IC.

[0013] External connector terminals may extend vertically from the underside of the printed circuit board and be located inside the annular portion. Internal connectors may be arranged on the top side of the printed circuit board and inside the annular portion to connect the printed circuit board to another printed circuit board.

[0014] The housing may include outer walls and partition walls extending between these outer walls. The metal target and the printed circuit board can be separated from each other by the partition walls.

[0015] The rotary controller may include an externally accessible knob and a shaft fixedly connected to the knob. An annular bearing recess may extend upward from a partition wall about the axis of rotation. The shaft may include a cylindrical journal rotatably disposed within the annular bearing recess.

[0016] Multiple receiving coils (RX), i.e. at least two receiving coils (RX), can be three receiving coils (RX) electrically connected to each other in a star configuration.

[0017] The following detailed description is exemplary in nature only and is not intended to limit the invention or its application and use. Furthermore, it is not intended to be bound by the foregoing background or any theories set forth in the following detailed description. Attached Figure Description

[0018] Figure 1 This is a perspective front-view top view of the rotary control component.

[0019] Figure 2 Is it like this? Figure 1 An exploded view of the rotary control component.

[0020] Figure 3 This is an exploded detailed view of the rotary controller used within the rotary control assembly.

[0021] Figure 4 This is a perspective top view of the printed circuit board used within the rotary control assembly.

[0022] Figure 5 Is it like this? Figure 4 A perspective bottom view of the circuit board.

[0023] Figure 6 Is it like this? Figure 1 The control component is shown in perspective top and front cross-sectional views, with the right side cut off.

[0024] Figure 6 Is looking at Ru Figure 1 The diagram shows a perspective top, front, and right side cross-sectional view of the left half of the control component, with the right half of the component having been cut off.

[0025] Figure 7 Is looking at Ru Figure 1 The diagram shows a top- and front-section perspective view of the rear half of the control component, with the front half of the component having been cut off. Detailed Implementation

[0026] Figures 1 to 7A perspective view shows a rotary control assembly 100. The rotary control assembly 100 includes a housing 110. The housing 110 includes a housing body 500. A bottom cover 600 is secured to the bottom of the housing body 500 by a snap-fit ​​connection. A frame 400 is snap-fitted to the top of the housing body 500.

[0027] User interface 105 is disposed on the top of housing 110 and extends through frame 400. User interface 105 includes rotary controller 120. Rotary controller 120 is accessible to the driver in the form of knob 210. Knob 210 has a driver-accessible serrated cylindrical housing surface 217. Knob 210 is rotatable about axis of rotation 101.

[0028] An indicator assembly 130 is centrally located within a rotary controller 120. The indicator assembly 130 is fixedly connected to a housing 110. The rotary controller 120 is rotatable about the indicator assembly 130. The indicator assembly 130 includes a display 310. The display 310 includes translucent letters 311, 312, and 313 molded therein. The translucent letters preferably include the letter "R" 312, the letter "N" 311, and the letter "D" 313. A display printed circuit board 340 is arranged within the indicator assembly 130. The translucent letters can be illuminated by LED backlighting mounted on the display printed circuit board 340.

[0029] Button 320 may be centrally located within indicator assembly 130. The button may be a "Parking" button, labeled "P," used to switch the vehicle to parking mode. Button 320 may be biased upwards by resilient contact pad 330. Resilient contact pad 330 may interact with display printed circuit board 340 on its underside to activate electrical connections within display printed circuit board 340 when button 320 is pressed downwards. Resilient contact pad 330 may be light-transmitting and function as a light guide.

[0030] The indicator assembly 130 is enclosed on its sides and bottom by a can-shaped indicator cover 350. The display printed circuit board 340, the resilient contact pad 330, and the button 320 are clamped within the indicator cover 350. The display 310 forms the top surface of the indicator assembly 130 and is attached to the indicator cover 350 by a clip.

[0031] The indicator assembly 130 is fixedly connected to the housing body 500. This connection is achieved by screws 351. Screws 351 are arranged within the rotation axis 101 and secure the indicator cover 350 to the upper end of the housing body 500. A locating pin 532 extends upward from the housing body 500 and passes through a corresponding hole in the bottom wall of the indicator cover 350. The indicator cover 350 is thus aligned with and rotatably fixed relative to the housing body 500.

[0032] The housing body 500 is generally rectangular. It includes an outer wall 510 extending parallel to the axis of rotation 101. Partition walls 515 extend between the outer walls 510. The partition walls 515 divide the housing body 500 into a lower housing chamber 517 and an upper housing chamber 516. The outer walls 510 include an upper housing wall 511 above the partition walls 515 and a lower housing wall 512 below the partition walls 515.

[0033] The rotary controller 120 includes an externally accessible knob 210 and a hollow shaft 250 rotatably fixed to the knob 210. The shaft 250 is rotatably connected to the housing body 500 via a sliding bearing 520. The sliding bearing 520 includes an annular bearing groove 521 extending upward from a partition wall 515 about a rotation axis 101. A journal 270 extends downward from a top surface 256 of the shaft 250. The journal 270 is rotatably disposed within the annular bearing groove 521. The journal 270 is a cylindrical body arranged within the rotation axis 101. The journal 270 extends downward from the top surface 256 of the shaft 250 at its radially inner end.

[0034] Flange 251 extends radially outward at the lower end of shaft 250. Flange 251 includes a downwardly opening cavity 252. Metal target 260 is fixed within the downwardly opening cavity 252. The metal target is arranged such that it is flush with flange 251.

[0035] The metal target 260 has a ring-shaped sector. The metal target 260 has an angular width of 90 degrees. The inner radius of the ring sector is between 20 mm and 30 mm. The outer radius of the ring sector is between 30 mm and 40 mm. The radial extension of the ring sector is between 5 mm and 15 mm.

[0036] The metal target 260 is conductive and magnetically but not permanently magnetized.

[0037] The metal target 260 can be a stamped metal sheet part with a thickness of 0.5 mm to 2 mm. The metal target 260 can be fixed to the flange 251 by adhesive or ultrasonic welding. The metal target 260 can also be overmolded into the flange 251. In this case, the metal target 260 can have a trapezoidal cross-sectional shape. Then, the top surface of the metal target 260 is larger than its bottom surface. For example, the flat top surface of the metal target 260 can occupy 495 mm. 2 The area, while the flat bottom surface of the metal target 260 can occupy 450mm. 2 The area.

[0038] The rotary controller 120 includes a haptic feedback mechanism in the form of variable mechanical resistance. The mechanical resistance is generated by a stop 540. The stop 540 is biased upwards by a spring 541. The lower end of the spring 541 is supported on a partition wall 515. The upper end of the spring 541 is supported on the head 542 of the stop 540. The head 542 of the stop 540 has a rounded tip. The rounded tip engages with a notch 257 formed on the bottom of the upper surface 256 of the shaft 250. A total of 16 notches 257 are evenly distributed circumferentially. The rotary controller 120 thus presents a stable latching position when rotated by 22.5 degrees or multiples thereof.

[0039] The stop 540 is hollow and is mounted on the stop pin 519. The stop pin 519 extends upward from the partition wall 515 within the hollow cylindrical stop guide 518. The bottom of the hollow cylindrical stop guide 518 may be formed by a downward extension below the partition wall 515.

[0040] The rotary controller 120 includes an operator-accessible knob 210 and an operator-inaccessible shaft 250. The knob 210 has an annular engagement groove 213 formed between an outer cylindrical engagement sector 211 and an inner cylindrical engagement sector 212. A key 214 extends between the outer and inner cylindrical engagement sectors 211 and 212. The shaft 250 includes a cylindrical engagement portion 253 received within the annular engagement groove 213. The cylindrical engagement portion 253 includes a positioning slot 254 in which the key 214 is received. The shaft 250 includes a plurality of circumferentially distributed hooks 255 that engage and extend through corresponding windows 215 of the outer cylindrical engagement sector 211, thereby providing a snap-fit ​​connection between the knob 210 and the shaft 250.

[0041] The printed circuit board 700 is secured to the housing body 500 from below. The printed circuit board 700 may have a rectangular shape. The printed circuit board 700 is aligned relative to the housing body 500 by two guide pins 501 extending downward below the partition wall 515. The guide pins 501 extend through holes 701, 703 at opposite corners of the printed circuit board 700. The printed circuit board 700 is fastened to the housing body 500 by two screws 502 extending through additional holes 702, 704 near the remaining corners of the printed circuit board 700.

[0042] Printed circuit board 700 includes a transmitting coil TX and a plurality of receiving coils RX. The transmitting coil TX and the receiving coils RX are formed by traces within two or more layers of the printed circuit board 700. These traces are arranged within an annular portion 710 of the printed circuit board 700. The plurality of receiving coils RX may include three receiving coils electrically connected in a star (Y) configuration.

[0043] The annular portion 710 may have an inner diameter of 50 mm to 60 mm and an outer diameter of 60 mm to 80 mm. The annular portion 710 may have a radial width between 5 mm and 15 mm.

[0044] The transmitting coil TX and receiving coil RX interact with the metal target 260 in the form of inductive position sensors. As the rotary controller 120 rotates within the housing 110, the metal target 260 shifts relative to the plurality of receiving coils RX. The position of the metal target 260 relative to the receiving coils RX can be used to generate a driving mode output for the rotary control assembly 100. Alternatively, when power is applied, the rotary control assembly 100 can present a predetermined state, such as a "parking" driving mode. Subsequently, the driving mode output of the rotary control assembly 100 can be determined by rotating the rotary controller 120 relative to its initial orientation when energized.

[0045] The printed circuit board 700 and the metal target 260 are arranged on opposite sides of the partition wall 515 and separated by the partition wall 515. That is, inductive sensing is achieved through the partition wall 515. This allows the printed circuit board 700 to be encapsulated in the lower housing chamber 517, while the shaft 250 and the metal target 260 are arranged in the upper housing chamber 516.

[0046] The metal target 260 can be positioned 3mm to 6mm above the printed circuit board 700. The flange 251 extends parallel to the printed circuit board 700.

[0047] In an inductive position sensor, the transducer is a coil group comprising a transmitting (TX) coil and a receiving (RX) coil, which is connected to an inductive position sensor interface integrated circuit (IC). Within this coil group, the circular transmitting (TX) coil generates a cylindrical symmetrical alternating magnetic field. The TX coil is actively driven by the interface IC at a carrier frequency, which can be in the range of 2-5 MHz. The magnetic field of the TX coil excites eddy currents in a metal target 260, which generate a secondary magnetic field, called the target magnetic field. Because the metal target 260 only covers a 90° circular sector, the target magnetic field is not rotationally symmetric but rather angle-dependent.

[0048] The receiving (RX) coil is designed to capture the target's magnetic field while being insensitive to the TX magnetic field. The sensor utilizes multiple RX coils to enable ratiometer angle calculations independent of signal strength. The driving mode signal is then derived using the position of the metal target 260°.

[0049] The operating principle of inductive position sensors is described in the paper "High speed inductive position sensor for E-machine" by L. Lutani et al., and its contents are incorporated into this paper in their entirety by reference.

[0050] Inductive sensing is superior to traditional Hall effect sensors that use permanent magnets. In particular, compared to Hall effect sensors, inductive sensing is less sensitive to magnetic fields generated by high currents in an electrodynamic system. The positioning of the metal target 260 relative to the TX and RX coils is less affected by mechanical tolerances than the positioning of the permanent magnet relative to the 3D Hall effect sensor.

[0051] To achieve a space-saving design, electronic component 722 is arranged on the upper side of printed circuit board 700 and inside the annular portion 710. Electronic component 722 may include an inductive sensor interface IC, a microprocessor, a network transceiver, and power supply components for interfacing to the vehicle's power distribution system. The network transceiver can connect the microprocessor to the vehicle's CAN, Flexray, LIN, or Ethernet bus.

[0052] External connector terminal 730 extends vertically from the underside of printed circuit board 700 and is located inside annular portion 710. External connector terminal 730 extends through correspondingly shaped connector 610 of bottom cover 600 to form a downwardly open vehicle connector. Rotary control assembly 100 can be connected to the vehicle's power and signal distribution system via connector 610.

[0053] The internal connector 721 may also be placed on the upper side of the printed circuit board 700 and inside the annular portion 710 to connect the printed circuit board 700 to the display printed circuit board 340. The printed circuit board 700 and the display printed circuit board 340 are connected by a flat cable 341 that passes through a slot in the housing body 500 inside the annular bearing groove 521.

[0054] While the invention has been described with reference to exemplary embodiments, it will be apparent to those skilled in the art that the invention is not limited to the disclosed or illustrated embodiments, but rather is intended to cover numerous other modifications, substitutions, variations and broad equivalent arrangements falling within the spirit and scope of the appended claims.

Claims

1. A rotary control assembly (100), comprising: Shell (110); A rotary controller (120) is supported in the housing (110) and is capable of rotating about a rotation axis (101). A printed circuit board (700) including a transmitting coil (TX) and a plurality of receiving coils (RX); as well as A metal target (260) is fixedly connected to the rotary controller (120) and close to the printed circuit board (700), such that when the rotary controller (120) rotates within the housing (110), the metal target (260) is displaced relative to the plurality of receiving coils (RX).

2. The rotary control assembly (100) according to claim 1, in, The printed circuit board (700) includes one or more electronic components (722), which are configured to: The transmitting coil (TX) is excited, inducing eddy currents in the metal target (260), which in turn induce a voltage in the receiving coil (RX). The voltage induced in the receiving coil (RX) is evaluated to determine the position of the metal target (260), and A driving mode signal for the vehicle is generated based on the position of the metal target (260).

3. The rotary control assembly (100) according to claim 1, in, The metal target (260) is shaped into an annular sector.

4. The rotary control assembly (100) according to claim 1, in, The metal target (260) is shaped into a flat annular sector extending at an angle of 90°.

5. The rotary control assembly (100) according to claim 1, in, The rotary controller (120) includes: Externally accessible knob (210), and A shaft (250) is fixedly connected to the knob (210), and wherein the shaft (250) includes an annular flange (251) forming the lower end of the rotary controller (120). The metal target (260) is connected to the annular flange (251).

6. The rotary control assembly (100) according to claim 5, in, The metal target is fixed in a downwardly open cavity (252) formed in the annular flange (251).

7. The rotary control assembly (100) according to claim 5, in, The knob (210) includes an annular engagement groove (213) formed between an outer cylindrical engagement sector (211) and an inner cylindrical engagement sector (212). The key (214) extends between the outer cylindrical engagement sector (211) and the inner cylindrical engagement sector (212), wherein the shaft (250) includes a cylindrical engagement portion (253) received within the annular engagement groove (213). The cylindrical engagement portion (253) includes a positioning slot (254), within which the key (214) is received, and The shaft (250) includes a plurality of hooks (255) that engage and extend through the corresponding window (215) of the outer cylindrical engagement sector (211).

8. The rotary control assembly (100) according to claim 1, in, The transmitting coil (TX) and the plurality of receiving coils (RX) are formed by traces within the annular portion (710) of the printed circuit board (700).

9. The rotary control assembly (100) according to claim 8, in, Electronic component (722) is arranged on the upper side of the printed circuit board (700) and inside the annular portion (710), and The electronic components (722) include an inductive sensor interface IC.

10. The rotary control assembly (100) according to claim 8, in, The external connector terminal (730) extends vertically from the underside of the printed circuit board (700) and is located inside the annular portion (710).

11. The rotary control assembly (100) according to claim 8, in, An internal connector (721) is arranged on the upper side of the printed circuit board (700) and inside the annular portion (710) to connect the printed circuit board (700) to another printed circuit board (340).

12. The rotary control assembly (100) according to claim 1, in, The housing (110) includes: Outer wall (510), and Partition wall (515), which extends between the outer walls, The metal target (260) and the printed circuit board (700) are separated by the partition wall (515).

13. The rotary control assembly (100) according to claim 12, in, The rotary controller (120) includes: Externally accessible knob (210), and A shaft (250) is fixedly connected to the knob (210), and an annular bearing groove (521) extends upward from the partition wall (515) about the axis of rotation (101). The shaft (250) includes a cylindrical journal (270) rotatably disposed within the annular bearing groove (521).

14. The rotary control assembly (100) according to claim 1, in, The plurality of receiving coils (RX) are formed by three receiving coils (RX) electrically connected to each other in a star configuration.

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