Sensor assembly, measuring unit, brake system and vehicle

Abstract

The utility model provides a sensor assembly, a measuring unit, a braking system and a vehicle. The sensor assembly is used for the measuring unit (100) of the brake pedal stroke, and comprises a first shell (1), a second shell (2) and a third shell (3), the movement module (4) can move along with the movement of a brake pedal rod, so that the movement of the movement module (4) can reflect the travel of a brake pedal, the movement module (4) comprises a magnet (41), and the magnet (41) is arranged in the first shell (1); and the sensing module (5) is arranged in the first shell (1) and can sense the magnetic field change of the magnet (41) and output a response signal. The installation convenience of the motion module and the integration degree of the motion module and the sensing module are improved.

Description

Technical Field

[0001] The present disclosure relates to the field of vehicle braking, and in particular, to a sensor assembly, a measuring unit, a braking system and a vehicle. Background Art

[0002] This section is intended to provide background information relevant to understanding the various technologies described herein. As the title of this section implies, this is a discussion of related technologies that should not in any way be considered prior art. Therefore, it should be understood that any statements in this section should be read in this light, rather than as admissions of prior art.

[0003] According to the requirements of GB 12676 and GB / T 13594, vehicle braking systems, such as electronic braking systems (EBS), are widely used in commercial vehicles (CVs). The pedal travel sensor (PTS) is an essential sensor for the brake pedal module of a braking system. The PTS's primary function, for example, is to convert pedal displacement into a pulse-width modulated (PWM) position signal and transmit it to the brake control unit (BCU) of the braking system.

[0004] In some technical solutions, the sensing module is arranged in a shell, which does not contain any moving parts. The moving parts are arranged in another shell. For example, the magnet of the moving part is arranged on the outer peripheral surface of the connecting part or the push rod of the pedal rod used to connect the brake pedal. The installation is relatively complicated, and the moving module and the sensing module are separated in two different shells, and the integration is not high. Utility Model Content

[0005] According to different aspects, the present disclosure aims to improve the installation convenience of the motion module and its integration with the sensor module.

[0006] Furthermore, the present disclosure aims to solve or at least alleviate one or more problems existing in the prior art.

[0007] The present disclosure solves the above-mentioned problems by providing a sensor assembly, a measurement unit, a braking system, and a vehicle. Specifically, according to one aspect of the present disclosure, the present disclosure provides:

[0008] A sensor assembly for a brake pedal stroke measurement unit, wherein the sensor assembly comprises:

[0009] first shell,

[0010] a motion module capable of moving with the movement of the brake pedal rod so that the movement of the motion module can reflect the brake pedal stroke, the motion module comprising a magnet disposed in the first housing,

[0011] The sensing module is arranged in the first housing and is capable of sensing the change of the magnetic field of the magnet and outputting a response signal.

[0012] According to another aspect of the present disclosure, a measuring unit for brake pedal stroke is provided, wherein the measuring unit includes any one of the above-mentioned sensor assemblies, and the measuring unit also includes a second shell and a connecting member, the connecting member is movably arranged at least partially in the second shell and is used to be connected to the brake pedal rod, and the motion module moves with the movement of the connecting member.

[0013] According to yet another aspect of the present disclosure, a braking system is provided, wherein the braking system includes any one of the above-mentioned measuring units and a brake pedal rod, wherein the brake pedal rod is connected to the connecting member.

[0014] According to yet another aspect of the present disclosure, a vehicle is provided, wherein the vehicle includes the above-mentioned braking system. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The above and other features of the present disclosure will become apparent with reference to the accompanying drawings, in which:

[0016] Figure 1 shows a perspective view of a measuring unit according to the present disclosure;

[0017] Figure 2 shows a cross-sectional view of a measurement unit according to the present disclosure;

[0018] Figure 3 A first perspective view of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0019] Figure 4 A second perspective view of a motion module of a sensor assembly of a measurement unit according to the present disclosure is shown;

[0020] Figure 5 A perspective view showing a motion module of a sensor assembly of another measuring unit according to the present disclosure;

[0021] Figure 6 A perspective view showing a spring piece of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0022] Figure 7 An assembly diagram of a spring piece of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0023] Figure 8 An assembly diagram of a bracket and a connector of a motion module of a measurement unit according to the present disclosure is shown;

[0024] Figure 9 A structural diagram showing a bracket of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0025] Figure 10 A perspective view showing a sensor module of a sensor assembly of a measurement unit according to the present disclosure;

[0026] Figure 11 An assembly diagram of a first housing of a sensor assembly of a measuring unit and a circuit board of a sensing module according to the present disclosure is shown;

[0027] Figure 12 shows an internal structural diagram of a first housing of a sensor assembly of a measuring unit according to the present disclosure;

[0028] Figure 13 A perspective view showing a terminal of a sensor assembly of a measuring unit according to the present disclosure;

[0029] Figure 14 A perspective view showing a terminal of a sensor assembly of another measuring unit according to the present disclosure;

[0030] Figure 15 A perspective view showing a latch of a sensor assembly of a measurement unit according to the present disclosure;

[0031] Figure 16 shows a side view of an assembly of a first housing and a second housing of a measuring unit according to the present disclosure;

[0032] Figure 17 A perspective view showing a bushing of a first housing of a measuring unit according to the present disclosure is shown;

[0033] Figure 18 A perspective view showing a first housing of a sensor assembly of a measuring unit according to the present disclosure;

[0034] Figure 19 An assembly diagram showing a first housing, a sealing ring, and a guide member of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0035] Figure 20 A diagram showing the arrangement of a seal of a first housing of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0036] Figure 21 shows a perspective view of a second housing of a measuring unit according to the present disclosure;

[0037] Figure 22 shows a cross-sectional view of another measurement unit according to the present disclosure;

[0038] Figure 23 Shown based on Figure 22 The coordination diagram of the motion module and micro switch of the sensor assembly;

[0039] Figure 24 Shown based on Figure 22 A diagram showing the cooperation between the motion module of the sensor assembly and the first housing; and

[0040] Figure 25 A perspective view of another sensor module of a sensor assembly according to the present disclosure is shown. DETAILED DESCRIPTION

[0041] It is easy to understand that according to the technical solution of the present disclosure, without changing the essential spirit of the present disclosure, a person skilled in the art can propose a variety of interchangeable structural methods and implementation methods. Therefore, the following specific embodiments and drawings are only exemplary descriptions of the technical solution of the present disclosure and should not be regarded as the entire disclosure or as a limitation or restriction of the technical solution of the present disclosure.

[0042] The terms "up," "down," "left," "right," "front," "back," "front," "back," "top," and "bottom" mentioned or potentially mentioned in this specification are defined relative to the structures shown in the accompanying drawings. They are relative concepts and may vary depending on their location or usage. Therefore, these or other directional terms should not be interpreted as restrictive. In addition, the terms "first," "second," "third," and similar expressions are used only for descriptive and distinguishing purposes and should not be understood to indicate or imply the relative importance of the corresponding components.

[0043] refer to Figure 1 and Figure 2 ,in, Figure 1 A perspective view showing a measuring unit according to the present disclosure; and Figure 2 A cross-sectional view of a measurement unit according to the present disclosure is shown.

[0044] The sensor assembly is used for a measurement unit 100 of the brake pedal stroke, wherein the sensor assembly includes: a first shell 1; a motion module 4, which can move with the movement of the brake pedal rod so that the movement of the motion module 4 can reflect the brake pedal stroke, and the motion module 4 includes a magnet 41, which is arranged in the first shell 1; a sensing module 5, which is arranged in the first shell 1 and can sense the magnetic field changes of the magnet 41 and output a response signal.

[0045] It should be noted that the brake pedal stroke can also be understood as the position of the brake pedal or the stroke or position of the brake pedal rod, both of which can be measured using this measurement unit. According to this technical solution, when the driver steps on the brake, the pedal drives the brake pedal rod to perform a corresponding braking movement, and the pedal rod then directly or indirectly drives the motion module (magnet) to perform a corresponding movement, for example, Figure 2 From the perspective of , the movement is a lifting movement or a vertical movement. This movement will cause the magnetic field of the magnet to change. This magnetic field change is sensed by the sensor module, and then a response signal is output. Based on the response signal, technical personnel in this field can directly or indirectly obtain the pedal stroke.

[0046] It can be seen that in the present technical solution, the magnet as the moving part is arranged in the first shell, the sensor module is also arranged in the first shell, and the magnet and the sensor module interact with each other to generate a response signal as the basis of the pedal stroke. Therefore, the magnet and the sensor module, which mainly play a measuring role, are arranged in the same shell, which improves the compactness and integration of the entire unit, and can also have stronger anti-interference and measurement accuracy. In addition, this method can also bring better installation convenience, because on the one hand, it reduces other parts of the measuring unit, such as the number of parts or assembly complexity in its second shell, and on the other hand, the magnet in the first shell only needs to be arranged in a certain way (described in detail later), and does not need to be arranged in a complicated way or steps on other parts of the measuring unit, such as on the connector, thereby achieving one of the purposes of the present disclosure.

[0047] Exemplarily, the measurement unit is based on the principle of a Hall effect sensor or Hall effect. Specifically, the sensing module is capable of converting a changing magnetic field (the magnetic field surrounding the sensing module) into a change in output voltage. This signal is then processed, for example, by an analysis and processing system or processing circuit, and then outputs a pulse-width modulated position signal to a corresponding system, such as a brake control unit of an electronic brake system. This enables a high-precision, energy-efficient, cost-effective measurement system with a wide frequency response range.

[0048] The following is a detailed explanation of the design of the motion module of the measurement unit. Figure 3 and Figure 4 ,in, Figure 3 A first perspective view showing a motion module of a sensor assembly of a measurement unit according to the present disclosure; and Figure 4 A second perspective view of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown.

[0049] The motion module 4 includes a bracket 42 , and the magnet 41 is fixedly arranged on the bracket 42 .

[0050] According to this technical solution and combined Figure 2 As can be seen, the primary portion of the bracket is located within the first housing, while the secondary portion (e.g., the portion of the bracket that interfaces with other components of the measurement unit, such as the connector) is located within the second housing. The magnet is fixedly positioned within the primary portion, optionally near one side of the sensor unit to achieve better measurement results. Thus, movement of the brake pedal lever drives movement of the bracket, which in turn drives movement of the magnet. The sensor module then senses changes in the magnet's magnetic field to generate a response signal.

[0051] In order to standardize or limit the movement mode of the motion module, such as the bracket, in some embodiments of the present disclosure, the motion module 4 includes a fixed guide 43, and the bracket 42 moves along the guide 43. For example, the guide is configured to be linear and parallel to the movement direction of the connecting member, so as to adapt to the movement of the connecting member and make the corresponding movement of the bracket consistent with the movement of the connecting member. In addition, the guide is configured to have a cylindrical body, and a cutout portion 431 ( Figure 3 ), the cutout being, for example, planar. Accordingly, the bracket can be provided with a through hole whose cross-section corresponds to that of the guide member. This allows the bracket to be mounted on the guide member and move vertically along the guide member. Furthermore, the design of the cutout restricts relative rotational movement between the bracket and the guide member, ensuring that the bracket moves in the intended or ideal direction (e.g., vertically) without undesirable rotation. Other guiding methods, such as the combination of the bracket and the guide rail, are also applicable.

[0052] The measurement principle of the measurement unit disclosed herein indicates that the stability of the kinematic relationship, or relative position, between the motion module (e.g., the bracket) and the connector is crucial. Therefore, in some embodiments of the present disclosure, the motion module 4 includes a retaining structure configured to maintain the relative position of the bracket 42 and the brake pedal rod or connector 3. It is understood that, when the relative positions of the bracket and the brake pedal rod or connector remain unchanged, the movement of the brake pedal rod or connector (and the pedal travel) can be more accurately reflected in the movement of the bracket, which in turn is converted into changes in the magnetic field of the magnet for sensing by the sensor module.

[0053] Regarding multiple specific embodiments of the holding structure, the following Figures 3 to 9 To explain, Figure 5 A perspective view showing a motion module of a sensor assembly of another measuring unit according to the present disclosure; Figure 6 A perspective view showing a spring piece of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown; Figure 7An assembly diagram of a spring piece of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown; Figure 8 An assembly diagram showing a bracket and a connector of a motion module of a measurement unit according to the present disclosure; and Figure 9 A structural diagram of a bracket of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown.

[0054] See first Figure 3 and Figure 4 The retaining structure includes a first spring 44, which is sleeved on the guide 43 and abuts between the bracket 42 and the first housing 1. The first spring 44 is used to apply a spring force to the bracket 42. Thus, by applying a spring force to the bracket by the first spring, the bracket (particularly its engaging portion with the corresponding component of the measuring unit, such as the groove of the connector) can be kept in a constant state of contact with the groove of the connector (e.g., the top surface of the groove), ensuring the stability of the relative position of the two. This disclosure does not impose any specific restrictions on the spring constant of the first spring (and the second spring described below). Those skilled in the art can flexibly adjust the spring material, number, series-parallel relationship, size, shape (straight spring or conical spring), etc. to achieve the desired spring force without significantly affecting the feedback force of the pedal. In addition, the sleeve arrangement of the first spring and the guide can improve the compactness and integration of the overall components. From a holistic perspective, the two can be combined to have dual functions, namely, guiding the movement of the bracket and maintaining the relative position of the bracket.

[0055] It should be noted that the first spring also plays an auxiliary role in the assembly of the motion module, such as its bracket. Specifically, during assembly, the motion module's bracket is introduced from the outside into the first shell, sleeved on the guide and supported by the first spring. At this time, due to the spring force of the first spring, the bracket can be pushed upward to the top surface inside the first shell. Here, the corresponding part of the shell top surface can be constructed with a click structure so that a sound is emitted when the bracket engages with the top surface, notifying the installer that the bracket has been installed in place. This also makes it possible to define the initial position of the bracket in a simple and efficient manner.

[0056] See Figures 5 to 7, the retaining structure includes a spring sheet 45, the spring sheet 45 is fixed on the bracket 42 and has an exposed portion 451 extending beyond the bracket 42 (for example, the bottom surface of the bracket for engaging with the connector groove), the exposed portion 451 is compressed, for example, by abutting against the groove 31 so that the spring sheet 45 applies a spring force to the bracket 42. According to this embodiment, by designing the size of the spring sheet relative to the bracket (the exposed portion), when the bracket is installed in the groove of the connector, the exposed portion is squeezed by the bottom surface of the groove to generate a spring force, and the spring force is transmitted upward to the bracket, so that the bracket can always be in a fit state with the groove of the connector (for example, the top surface of the groove), ensuring the stability of the relative position of the two. In this regard, in some embodiments, the spring sheet is also constructed with an abutment portion 452, and the engaging portion of the bracket is constructed with an abutment matching portion 422, the abutment portion abuts against the abutment matching portion, so that the spring force of the bracket can be transmitted to the bracket, and the abutment portion is higher than the exposed portion, so that the transmission direction of the spring force has an upward component. From Figure 6 and Figure 7 It can also be clearly seen that the spring sheet is further configured with an overlapping portion 453, which overlaps within an opening provided for this purpose in the engaging portion of the bracket, so that the spring sheet itself can be stably fixed on the bracket.

[0057] In addition, see Figure 8 and Figure 9 , the control of relative position can also be achieved by a method different from the spring force. Exemplarily, the retaining structure includes a protrusion 46, which is constructed on the bracket 42, and the bracket 42 achieves, for example, an interference fit with the groove 31 via the protrusion 46. It can be seen that by designing the size difference between the engaging portion of the bracket and the groove of the connector (here, the height dimension of the engaging portion of the bracket is slightly larger than the height dimension of the groove of the connector), a certain pressure is generated between the two, ensuring that the bracket can be tightly engaged in the groove, making the connection between the two stable. This connection method has the advantages of simple structure, reliable connection, and ability to withstand large loads. It can be understood that in some other embodiments, the protrusion can be set on the top surface of the engaging portion of the bracket, or the protrusion can be constructed in the groove of the connector, both of which can achieve a similar interference fit effect. In addition, the protrusions can be set symmetrically, for example, on both sides of the bottom surface of the engaging portion of the bracket, so as to provide a more stable and uniform supporting force.

[0058] It should also be understood that these designs of the retaining structures may be used in any combination.

[0059] refer to Figure 3 and Figure 5 , the present disclosure also exemplarily shows different layouts of magnets and brackets. Figure 3The technical solution is that the magnet 41 is attached to the end surface of the bracket 42 (for example, relatively close to the left end surface of the sensor module); Figure 5 The technical solution is that the bracket 42 is provided with a receiving portion 421 , and the magnet 41 is arranged in the receiving portion 421 .

[0060] These technical solutions can ensure that the relative position of the magnet and the bracket remains fixed, so that the pedal stroke can be accurately reflected. The accommodating portion can also be constructed on the left side of the bracket so as to be relatively close to the sensor module and obtain a more accurate and anti-interference measurement result. The present disclosure does not impose any special restrictions on the shape of the magnet itself. For example, for cost control and cost-effectiveness considerations, the magnet can be constructed as a cuboid ( Figure 5 ) or based on the shape of a cuboid ( Figure 3 ), and the corresponding end faces or receiving portions of the bracket can be configured to match the shape. Furthermore, the number and layout of the magnets can be adjusted as necessary. For example, multiple magnets can be arranged in a V- or U-shape to optimize the magnetic field distribution and, therefore, the measurement results.

[0061] Figure 3 and Figure 5 Different ways of matching the magnet with the bracket are also shown. Figure 3 In the embodiment, the connection between the magnet 41 and the bracket 42 is achieved by heat riveting. Specifically, the left end face of the bracket is constructed with a cylindrical protrusion 423. In conjunction with this, the magnet is based on a rectangular parallelepiped and has lugs 411 on both sides. The lugs are provided with through holes, and the protrusions can extend to the left through the through holes to achieve the assembly of the magnet and the bracket. Thereafter, the protrusions are melted and expanded by heating, and after cooling and solidification, they form a tight and reliable connection with the through holes. Similarly, the protrusions are also constructed to be symmetrical so that the connection stress is evenly distributed. The advantages of heat riveting include high efficiency, enhanced connection strength, wide material applicability, and advantages during processing (no vibration and no noise). To this end, the bracket can be made of plastic to well support the development of the heat riveting process. It can also be known that other connection methods between the magnet and the bracket, such as mounting, threading, clamping, welding, gluing, locking, etc., can also be applied.

[0062] refer to Figure 10 , which shows a stereoscopic view of a sensing module of a sensor assembly of a measuring unit according to the present disclosure.

[0063] The sensing module 5 includes a circuit board 51 and a sensor chip 52 arranged on the circuit board 51, and the sensor chip 52 is used to sense the magnetic field changes of the magnet 41. It is feasible that the sensor chip is an ASIC chip (Application Specific Integrated Circuit), or is also connected to or includes an analysis component for data processing or signal processing as described above. In this example, the sensor chip is arranged on the side of the circuit board facing the magnet so as to have a good sensing range and accuracy. The sensor chip is exemplarily constructed in the middle of the circuit board, and multiple sensor chips can be set if necessary, for example, to obtain a more comprehensive result by averaging.

[0064] The sensor module 5 further includes a micro switch 53 disposed on the circuit board 51 . The micro switch 53 can be triggered by the movement of the movement module 4 .

[0065] Those skilled in the art will be aware of the meaning of a microswitch, which refers to a switch with a relatively small contact spacing. It is also known as a sensitive switch, snap-action switch, or touch switch. The microswitch is triggered by a motion module, such as a bracket, and can be designed to interact with the vehicle's electronic braking system and the circuit board of the measurement unit. Specifically, when the microswitch is not triggered, it can be assumed that the driver has not yet applied the brakes. In this case, to reduce energy consumption and costs, the vehicle's electronic braking system is not activated, and the sensor chip on the circuit board is inoperative. When the driver applies the brakes, the pedal rod descends, and the downward movement of the connector to the bracket triggers the microswitch. This awakens the electronic braking system, and the circuit board and its chip begin to operate, outputting a response signal for pedal travel. This shows that the design of the microswitch strikes a balance between power consumption control and pedal travel sensing. Furthermore, the microswitch itself is characterized by its small size, durability, reliability, and high precision.

[0066] The microswitch can be configured as either a mechanical or photoelectric microswitch, each with its own unique advantages. Mechanical microswitches offer high sensitivity, simple structure, strong reliability, and flexible operation; photoelectric microswitches, as non-contact switches, avoid wear, are easy to install, have strong anti-interference capabilities, and offer high precision. Those skilled in the art will be able to determine the appropriate type of microswitch based on the specific application scenario, cost budget, and performance requirements.

[0067] Regarding its operating principle, a mechanical microswitch exemplarily comprises a switch body and a moving portion that interacts with a bracket. As the bracket moves with the connector, the bracket contacts the moving portion, displacing it. This causes the moving portion to contact the contacts of the switch body, triggering the switch body. After the bracket's force on the moving portion is removed, the moving portion resets, disconnecting from the contacts and thereby deactivating the microswitch. The sensitivity and durability of the switch can be optimized by adjusting factors such as the elastic modulus of the moving portion (e.g., a reed), the shape and material of the contacts, and so on. For a photoelectric microswitch, a photoelectric sensor is exemplarily located within the switch. The sensor consists of a transmitter (e.g., a light-emitting diode (LED)) and a receiver (e.g., a photodiode). When light emitted by the transmitter is blocked or reflected by the bracket, the light intensity received by the receiver changes, triggering the opening and closing of the circuit. The detection range and accuracy of the microswitch can be optimized by adjusting factors such as the position, angle, and sensitivity of the transmitter and receiver. Furthermore, the impact of environmental factors (e.g., light interference) on switch performance can be considered, and appropriate measures can be taken to compensate or shield it.

[0068] Combine Figure 4 It can also be clearly seen that the portion of the motion module's bracket that mates with the microswitch is constructed with a rib structure 424, or rather, is based on a square body with grooves. This design is particularly well-suited for brackets manufactured using injection molding. This is because a solid square structure would be prone to deformation during the molding process. The rib structure formed by the grooves can alleviate this deformation and also enhance the bracket's structural strength.

[0069] refer to Figures 11 to 15 ,in, Figure 11 An assembly diagram of a first housing of a sensor assembly of a measuring unit and a circuit board of a sensing module according to the present disclosure is shown; Figure 12 shows an internal structural diagram of a first housing of a sensor assembly of a measuring unit according to the present disclosure; Figure 13 A perspective view showing a terminal of a sensor assembly of a measuring unit according to the present disclosure; Figure 14 A perspective view showing terminals of a sensor assembly of another measuring unit according to the present disclosure; and Figure 15 A perspective view showing a latch of a sensor assembly of a measuring unit according to the present disclosure is shown.

[0070] The measuring unit 100 includes a terminal 6 , and the first housing 1 is electrically connected to the sensor module 5 via the terminal 6 . The first housing 1 is configured with a positioning portion 11 , and the sensor module 5 is positioned relative to the first housing 1 via the positioning portion 11 .

[0071] Therefore, it is feasible that when the sensor module, such as its circuit board, is assembled with the first shell, the circuit board is first positioned or precisely limited by the positioning portion, and thereby also serves to support the circuit board, and then is electrically connected to the first shell through the terminal. It should also be noted that the shape, size, number, etc. of the terminal can be determined according to the requirements of the connector to be connected. The connector is used to power the circuit board of the sensor module, and the sensor chip on the circuit board can output signals via the connector. Moreover, the shapes of the terminals are not necessarily the same. For example, Figure 13 and Figure 14 Two different shapes of terminals are shown respectively, among which, Figure 13 There are four terminals and they are arranged on the outside of the circuit board (the circuit board is provided with through holes for the terminals to pass through). Figure 14 There are three terminals arranged relatively inwardly on the circuit board, a total of seven terminals that electrically connect to the connector at one end and to the circuit board at the other. Furthermore, to facilitate installation, a through-hole 511 is constructed on one long side of the circuit board to match the positioning portion, and an outwardly open through-slot 512 is constructed on the opposite long side to match the positioning portion. During assembly, the through-slot first mates with the corresponding positioning portion to achieve assembly on one side, and then the through-hole mates with the corresponding positioning portion to achieve assembly on the opposite side. This gradually improves positioning accuracy and ensures a smooth assembly process.

[0072] In terms of process, the circuit board of the sensor module and the first housing can be connected by welding terminals, which is efficient and strong. In the case of welding connection, in order to avoid the possibility of warping of the other side of the circuit board due to welding connection on one side of the circuit board, in this example, the measuring unit can also have a latch 8 ( Figure 15 ), and the first housing is configured with a corresponding receiving portion 17 for accommodating the plug. The plug is arranged in the receiving portion and can extend into the opening designed for this purpose in the circuit board. This can achieve a force balance on both sides of the circuit board, preventing warping during the soldering process. In this regard, the connection between the plug and the circuit board does not need to be conductive. In addition, Figure 15 and Figure 13 and Figure 14 A comparison also reveals that the latch has virtually no extension at the end, instead extending directly from the main body to the sides and the upper right corner. This facilitates clamping during injection molding, for example. Furthermore, similar to the connection between the magnet and the bracket, the circuit board and the first housing can also be connected by heat riveting.

[0073] In addition, depending on the assembly method of the guide member of the motion module, the present disclosure also exemplarily proposes another sealing solution. Specifically, considering the length of the guide member, in order to facilitate the assembly of the guide member, in some embodiments of the present disclosure, the first shell 1 is provided with a through hole 13, and the guide member 43 can be installed in the first shell 1 through the through hole 13. Figure 2 For example, the guide is installed from top to bottom through the through-hole in the first housing. The motion module (including the magnet and the first spring) is then introduced from the outside into the interior space of the first housing and mounted on the guide. To this end, a blind hole 18 or a groove can be provided at a corresponding position on the bottom side of the first housing to accommodate the end of the guide. The cross-section of the blind hole matches the cross-section of the guide, for example, being circular with a linear cutout to prevent deflection of the guide.

[0074] Here, in order to improve the sealing performance, the present disclosure has a sealing design for the through hole. Figure 20 As can be seen, the first housing 1 is constructed with a sealant 14, which seals the through-hole 13 to provide a sealant against air leakage, water, dust, and other hazards. Specifically, the sealant 14 can be formed by gluing, or it can be constructed as a plastic part and connected to the through-hole 13 by laser welding. In the former solution, the bonding effect of the adhesive can be utilized to achieve uniform stress distribution while meeting the sealing requirements, thereby improving the fatigue resistance and service life of the sealant. In addition, the gluing process is simple and highly efficient, and is suitable for connecting various similar or dissimilar materials. In the latter solution, a secure connection between the sealant and the through-hole is achieved, with high overall mechanical strength and sealing performance. Laser welding also has the advantages of high precision, high speed, and low thermal impact, making it suitable for applications requiring high precision and sealing performance. Furthermore, as mentioned above, the first housing can be made of a plastic material such as PA or PBT. In this case, the sealant can also be made of plastic and then connected together by laser welding to achieve a seal. This method provides excellent sealing performance, high mechanical strength, and high production efficiency. It should be understood that the assembly method of the guide member is not limited to this. The guide member can also be assembled by directly introducing the guide member from the outside of the first shell into its internal space. In this case, the corresponding top and bottom surfaces inside the first shell can both be constructed with blind holes that match the cross-section of the guide member. Due to the characteristics of the blind hole, a sealing effect can naturally be achieved.

[0075] As mentioned above, in order to power the sensor module and support its signal output, in some embodiments of the present disclosure, the first housing 1 is formed with an interface 16, and the sensor module 5 is powered and outputs the response signal via the interface 16. Figure 2For example, the interface is opened and extended to the left, that is, it is constructed at the end of the first shell away from the second shell so that there is sufficient space for the docking connector. As mentioned above, the connector can cooperate with the terminals in the first shell to achieve power supply and support signal transmission. In this regard, the shape design of the terminals and the interface can be determined in combination with the characteristics of the connector. For example, the interface is constructed in the shape of a rounded rectangle and has a certain accommodation space to facilitate the arrangement of a part of the terminal and the connector.

[0076] Combine Figures 22 to 25 ,in, Figure 22 shows a cross-sectional view of another measurement unit according to the present disclosure; Figure 23 Shown based on Figure 22 The coordination diagram of the motion module and micro switch of the sensor assembly; Figure 24 Shown based on Figure 22 A diagram showing the cooperation between the motion module of the sensor assembly and the first housing; and Figure 25 A perspective view of another sensor module of a sensor assembly according to the present disclosure is shown.

[0077] The retaining structure includes a first spring 44, the motion module 4 includes a guide support 47, the guide support 47 is fixed in the first shell 1, at least two guide members 43 are fixed to the guide support 47, the first spring 44 is respectively mounted on the guide members 43 and abuts between the bracket 42 and the guide support 47, and the first spring 44 is used to apply spring force to the bracket 42.

[0078] These two embodiments provide different design forms of the motion module. It can be seen that the motion module is provided with a guide support for arranging the guide member, rather than the guide member being arranged on the first shell, so that the motion module has a more modular design and is convenient for modification and maintenance. To this end, the guide support can be provided with a through hole, and the first shell is constructed with a corresponding pin portion, and the connection between the two is achieved by matching the pin hole. Two guide members and two corresponding first springs are also shown by way of example, but more guide members and first springs can also be provided. To this end, the guide members can be passed through the two ends of the bracket so as to achieve more even and stable guidance of the motion of the bracket, and thereby the range of the spring force of the first spring as a whole can be designed more widely, and the reset ability of the bracket can be flexibly adjusted.

[0079] Considering the reasons of space compactness, the guide support can be constructed in two parts. Figure 23This can be clearly seen in the figure. The guide support comprises an upper first support 471 and a lower second support 472, each housing the ends of the guide member. This frees up the space between the two supports, for example, to house a sensor module connected to the first housing. This improves space utilization and compactness. Furthermore, since the motion module's bracket also interacts with the sensor module's microswitch, this design also supports this interaction.

[0080] In addition, similarly, the motion module, such as its bracket, can be triggered by the micro switch, that is, Figures 22 to 24 The mechanical micro switch in the circuit board can be mechanically triggered by the movement of the bracket during the pedal stroke, so as to wake up the electronic brake system and the circuit board and its chip when braking occurs, so that the design of the micro switch can achieve a balance between power consumption control and the realization of pedal stroke sensing. On the other hand, Figure 25 The photoelectric sensor is shown as a micro switch by way of example. The photoelectric sensor can also be triggered, for example, by the movement of a bracket. For example, the movement of the bracket affects the size or position of the light spot irradiated by the photoelectric sensor onto the surface of the object, thereby changing the intensity of the reflected light signal. When the signal intensity changes to a certain extent, the switching output of the photoelectric sensor is triggered. It should be noted that the photoelectric sensor can realize the triggering function without direct contact with the object, which reduces wear and failure rate, and has a fast response speed and high sensitivity. The contact micro switch has excellent characteristics in terms of stability and reliability, precise triggering, applicability, cost-effectiveness and safety.

[0081] The present disclosure also relates to a measuring unit 100 for brake pedal stroke, wherein the measuring unit 100 includes any one of the above-mentioned sensor assemblies, and the measuring unit 100 also includes a second shell 2 and a connecting member 3, the connecting member 3 is movably arranged at least partially in the second shell 2 and is used to be connected to the brake pedal rod, and the motion module 4 moves with the movement of the connecting member 3.

[0082] Therefore, the measuring unit disclosed in the present invention can inherit various implementation methods and corresponding technical effects of the sensor assembly. It can also be understood that by setting the connecting member (sometimes also called tappet or valve cylinder, valve cylinder), the brake pedal rod drives the connecting member to move synchronously, and the connecting member then drives the motion module (magnet) to move accordingly. In this regard, the measuring unit can also be regarded as a BPM (Braking Pedal Module) for the electronic braking system. Through the setting of the first and second shells, the two and their internal components can be designed and constructed in a more targeted and responsible manner, focusing on the sensing design and the motion transmission design of the brake pedal rod respectively.

[0083] A groove 31 is defined on the outer periphery of the connecting member 3 , and the motion module, for example, its bracket 42 , is engaged with the groove 31 .

[0084] Here, the connecting member can be exemplarily constructed as a body of revolution, such as a cylindrical structure, with corresponding blind holes provided for engagement with the pedal rod. According to this technical solution, the bracket can transmit the motion of the connecting member to the bracket by engaging with a groove on the outer periphery of the connecting member. This motion transmission method is direct and efficient, with high transmission efficiency. Furthermore, the stability of the connection is ensured while simplifying the structure. Those skilled in the art will appreciate that the location of the connecting member's groove and its engagement with the bracket, as well as the dimensions of the first and second housings, should ensure a large measurement range, preferably capable of measuring the entire pedal stroke of the pedal rod.

[0085] Combine Figure 16 and Figure 17 ,in, Figure 16 A side view showing an assembly of a first housing and a second housing of a measuring unit according to the present disclosure; and Figure 17 A perspective view of a bushing of a first housing of a measuring unit according to the present disclosure is shown.

[0086] The first shell 1 is provided with a bushing 12, and the first shell 1 and the second shell 2 are threadedly connected via the bushing 12. The threaded connection is achieved, for example, by means of metal bolts. As a result, the bushing can provide a certain degree of wear protection, and can also absorb the extrusion force generated when bolting, thereby protecting the first shell. In the case where the first shell is made by injection molding, the bushing can prevent the plastic material of the first shell from creeping during the bolting process, thereby improving reliability. The bushing itself is exemplarily constructed as a hollow cylinder, and is installed in the holes designed for this purpose by the first shell and arranged at its four top corners, and then the first shell is connected to the second shell, for example, by means of a threaded connection.

[0087] In some embodiments of the present disclosure, the first housing 1 is made of plastic, such as PA (polyamide) or PBT (polybutylene terephthalate), and the first housing 1 and the bushing 12 (or the terminals 6) are integrally formed by injection molding. The technical benefits of this solution include: the high strength and rigidity of the PA or PBT material itself enables the first housing to withstand large external forces and is not easily deformed or damaged; injection molding combined with the integrated construction simplifies processing steps, improves production efficiency, and provides a tighter connection between components, enhancing overall sealing performance and preventing the intrusion of gas, liquid, dust, etc.; PA or PBT materials have excellent wear and corrosion resistance, which ensures a long service life for the first housing. Furthermore, the characteristics of PA or PBT materials include high heat resistance, excellent mechanical properties, good dimensional stability, and good moldability. It should also be understood that when the first housing 1 is injection molded, the terminals 6 are placed in the mold. During the injection molding process, for example, the middle portion of the terminals is covered with plastic, while the metal ends of the terminals remain exposed to maintain their electrical connection.

[0088] In addition to the integrated process, the present disclosure also adopts other measures to improve the sealing performance. Figure 2 , and refer to Figures 18 to 21 ,in, Figure 18 A perspective view showing a first housing of a sensor assembly of a measuring unit according to the present disclosure; Figure 19 An assembly diagram showing a first housing, a sealing ring, and a guide member of a motion module of a sensor assembly of a measuring unit according to the present disclosure is shown; Figure 20 A diagram showing the arrangement of a seal of a first housing of a sensor assembly of a measuring unit according to the present disclosure; and Figure 21 A perspective view of a second housing of a measuring unit according to the present disclosure is shown.

[0089] The measuring unit 100 also includes a sealing ring 7. A guide groove 15 is formed on the circumference of the first housing 1. The sealing ring 7 is arranged within the guide groove 15 and sealably abuts the circumference of the second housing 2. It should be understood that the sealing ring is used to prevent air leakage, water, dust, and the like to achieve a seal. In particular, the sealing ring is disposed between the first and second housings to achieve a targeted seal at the connection between the two. It is understood that the specific placement of the sealing ring can be determined based on the assembly relationship and shape of the two housings. In this example, the second housing is generally hollow cylindrical, but has a flat flange surface 21 facing the first housing. To this end, the first housing is configured with a corresponding abutment surface facing the second housing. Furthermore, the sealing ring is mounted in the form of a guide groove so that the sealing ring can abut the circumference of the second housing, or can abut both housings simultaneously to achieve a seal. Furthermore, the annular or closed structure ensures a comprehensive seal. It is also understood that in addition to the sealing ring, the sealing effect can also be achieved through methods such as annular welding.

[0090] The present disclosure also relates to a braking system, wherein the braking system comprises any one of the above-mentioned measuring units 100 and a brake pedal rod, wherein the brake pedal rod is connected to the connecting member 3; and a vehicle, wherein the vehicle comprises the above-mentioned braking system.

[0091] Therefore, the braking system and vehicle disclosed herein inherit the various embodiments and technical effects described in the sensor assembly and the measuring unit, which will not be described in detail here.

[0092] It should be understood that all the above preferred embodiments are illustrative rather than restrictive, and that various modifications or variations made by those skilled in the art to the above-described specific embodiments under the concept of the present disclosure should be within the legal protection scope of the present disclosure.

Claims

1. A sensor assembly for a measuring unit (100) for a brake pedal stroke, characterized in that The sensor assembly comprises: a first housing (1), A motion module (4) capable of moving with the movement of a brake pedal rod, so that the movement of the motion module (4) can reflect the brake pedal stroke, the motion module (4) comprising a magnet (41), the magnet (41) being arranged in the first housing (1), A sensing module (5) is arranged in the first housing (1) and is capable of sensing changes in the magnetic field of the magnet (41) and outputting a response signal.

2. The sensor assembly according to claim 1, wherein The motion module (4) comprises a bracket (42), and the magnet (41) is fixedly arranged on the bracket (42).

3. The sensor assembly according to claim 2, wherein: The movement module (4) includes a guide (43), and the bracket (42) moves along the guide (43).

4. The sensor assembly according to claim 3, wherein: The motion module (4) includes a retaining structure configured to maintain the relative positions of the bracket (42) and the brake pedal rod unchanged.

5. The sensor assembly according to claim 4, wherein: The retaining structure comprises a first spring (44), the first spring (44) being sleeved on the guide member (43) and abutting between the bracket (42) and the first housing (1), the first spring (44) being used to apply a spring force to the bracket (42); and / or The retaining structure includes a spring sheet (45), the spring sheet (45) being fixed to the bracket (42) and having an exposed portion (451) extending beyond the bracket (42), the exposed portion (451) being compressed so that the spring sheet (45) applies a spring force to the bracket (42); and / or The retaining structure includes a protrusion (46) configured on the bracket (42), and the bracket (42) achieves interference fit via the protrusion (46).

6. The sensor assembly according to claim 2, wherein: The magnet (41) is abutted against the end surface of the bracket (42); or the bracket (42) is provided with a receiving portion (421), and the magnet (41) is arranged in the receiving portion (421).

7. The sensor assembly according to claim 6, wherein: The magnet (41) and the bracket (42) are thermally riveted.

8. The sensor assembly according to claim 1, wherein: The sensing module (5) comprises a circuit board (51) and a sensing chip (52) arranged on the circuit board (51), wherein the sensing chip (52) is used to sense changes in the magnetic field of the magnet (41).

9. The sensor assembly according to claim 8, wherein: The sensing module (5) includes a micro switch (53) arranged on the circuit board (51), and the micro switch (53) can be triggered by the movement of the movement module (4).

10. The sensor assembly according to claim 1, wherein The measuring unit (100) includes a terminal (6), the first housing (1) is electrically connected to the sensor module (5) via the terminal (6), the first housing (1) is configured with a positioning portion (11), and the sensor module (5) is positioned relative to the first housing (1) via the positioning portion (11).

11. The sensor assembly according to claim 3, wherein: The first shell (1) is provided with a through hole (13), and the guide member (43) can be installed into the first shell (1) via the through hole (13).

12. The sensor assembly according to claim 11, wherein: The first housing (1) is configured with a sealing member (14), and the sealing member (14) seals the through hole (13).

13. The sensor assembly according to claim 12, wherein: The sealing member (14) is formed by gluing, or the sealing member (14) is constructed as a plastic member and connected to the through hole (13) by laser welding.

14. The sensor assembly according to claim 1, wherein The first housing (1) is formed with an interface (16), and the sensor module (5) is powered via the interface (16) and outputs the response signal.

15. The sensor assembly according to claim 4, wherein The retaining structure includes a first spring (44), the motion module (4) includes a guide support (47), the guide support (47) is fixed in the first shell (1), at least two guide members (43) are fixed to the guide support (47), the first spring (44) is respectively mounted on the guide members (43) and abuts between the bracket (42) and the guide support (47), and the first spring (44) is used to apply a spring force to the bracket (42).

16. A measuring unit (100) for brake pedal travel, characterized in that The measuring unit (100) includes a sensor assembly according to any one of claims 1 to 15, and the measuring unit (100) also includes a second housing (2) and a connecting member (3), wherein the connecting member (3) is movably arranged at least partially in the second housing (2) and is used to be connected to the brake pedal rod, and the motion module (4) moves with the movement of the connecting member (3).

17. The measuring unit (100) according to claim 16, characterized in that A groove (31) is provided on the outer periphery of the connecting member (3), and the motion module (4) is engaged with the groove (31).

18. The measuring unit (100) according to claim 16, characterized in that The first housing (1) is provided with a bushing (12), and the first housing (1) and the second housing (2) are threadedly connected via the bushing (12).

19. The measuring unit (100) according to claim 18, characterized in that The first housing (1) is made of plastic, and the first housing (1) and the bushing (12) are integrally formed by injection molding.

20. The measuring unit (100) according to claim 16, characterized in that The measuring unit (100) further comprises a sealing ring (7). The peripheral surface of the first housing (1) is configured with a guide groove (15). The sealing ring (7) is arranged in the guide groove (15) and sealably abuts against the peripheral surface of the second housing (2).

21. A braking system, characterized in that: The brake system comprises a measuring unit (100) according to any one of claims 16 to 20 and a brake pedal rod, which is connected to the connecting element (3).

22. A vehicle, characterized in that: The vehicle includes a braking system according to claim 21.

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