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 a measuring unit (100) of the brake pedal stroke, the sensor assembly comprises a movement module (3) and a rack (4), the movement module (3) can move along with movement of a brake pedal rod so that the movement of the movement module (3) can reflect the brake pedal stroke, the rack (4) is provided with at least two guiding pieces (41), and the guiding pieces (41) are arranged on the rack (4). The movement module (3) is slidably sleeved on the guide piece (41). The stroke of the pedal rod is stably reflected in a high-cost-performance mode, and the accuracy of the measuring unit is guaranteed.

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. Utility Model Content

[0004] According to various aspects, the present disclosure aims to stably reflect the travel of the pedal rod in a cost-effective manner, ensuring the accuracy of the measuring unit.

[0005] Furthermore, the present disclosure aims to solve or at least alleviate one or more problems existing in the prior art.

[0006] 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 following are provided:

[0007] A sensor assembly for a measuring unit of a brake pedal stroke, wherein the sensor assembly includes a motion module and a frame, the motion module can move with the movement of the brake pedal rod, so that the movement of the motion module can reflect the brake pedal stroke, and the frame is provided with at least two guide members, and the motion module can be slidably mounted on the guide members.

[0008] 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 connecting member and a second sub-housing, the connecting member being movably arranged at least partially in the second sub-housing and being used to be connected to the brake pedal rod, and the motion module moves with the movement of the connecting member.

[0009] 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.

[0010] 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

[0011] The above and other features of the present disclosure will become apparent with reference to the accompanying drawings, in which:

[0012] Figure 1 shows a perspective view of a measuring unit according to the present disclosure;

[0013] Figure 2 shows a cross-sectional view of a measurement unit according to the present disclosure;

[0014] Figure 3 shows an internal structural diagram of a first sub-housing of a sensor assembly of a measuring unit according to the present disclosure;

[0015] Figure 4 A perspective view showing a housing of a sensor assembly of a measurement unit according to the present disclosure;

[0016] Figure 5 A perspective view showing a motion module area of ​​a sensor assembly of a measurement unit according to the present disclosure;

[0017] Figure 6 A perspective view showing a sensor module of a sensor assembly of a measurement unit according to the present disclosure;

[0018] Figure 7 A bottom view of a sensor assembly of a measuring unit according to the present disclosure in a first sub-housing area is shown;

[0019] Figure 8 A diagram showing the coordination relationship between a rack and a motion module of a sensor assembly of another measuring unit according to the present disclosure is shown;

[0020] Figure 9 A diagram showing the matching relationship between a circuit board and a housing of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0021] Figure 10 A diagram showing the matching relationship between a frame and a magnet of a sensor assembly of a measuring unit according to the present disclosure is shown;

[0022] Figure 11 A plan view showing an interior-facing first sub-housing of a sensor assembly of a measuring unit according to the present disclosure; and

[0023] Figure 12 A diagram showing the matching relationship between a circuit board and terminals of a sensor assembly of a measuring unit according to the present disclosure is shown. DETAILED DESCRIPTION

[0024] 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.

[0025] 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.

[0026] refer to Figures 1 to 4 ,in, Figure 1 shows a perspective view of a measuring unit according to the present disclosure; Figure 2 shows a cross-sectional view of a measurement unit according to the present disclosure; Figure 3 A diagram showing the internal structure of a first sub-housing of a sensor assembly of a measuring unit according to the present disclosure; and Figure 4 A perspective view of a frame of a sensor assembly of a measurement unit according to the present disclosure is shown.

[0027] The sensor assembly is used for a measurement unit 100 of the brake pedal stroke, wherein the sensor assembly includes a motion module 3 and a frame 4, the motion module 3 can move with the movement of the brake pedal rod, so that the movement of the motion module 3 can reflect the brake pedal stroke, and the frame 4 is provided with at least two guide members 41, and the motion module 3 can be slidably mounted on the guide members 41.

[0028] 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 brake pedal rod directly or indirectly drives the motion module to perform a corresponding movement, for example, Figure 2 From the perspective of the present invention, the movement is a lifting movement or a vertical movement, which causes the position of the motion module to change and can be sensed by the sensor assembly. Therefore, those skilled in the art can directly or indirectly obtain the pedal stroke in real time.

[0029] This technical solution specifically limits the number of guides to at least two, which together provide guidance and limiting functions for the movement of the motion module, so that the motion module can stably slide along a predetermined path, that is, along the longitudinal direction of the guide, ensuring the stability and reliability of the measurement. In this regard, it should be known how to specifically set the structure and layout position of the guide. For example, the guide is constructed in a cylindrical shape and oriented vertically (or in accordance with the direction of movement of the motion module or the connector) so that the movement of the connector can be more accurately reflected on the motion module, and the two guides can ensure that the motion module slides smoothly and can also reduce the possibility of tilting of the motion module during movement, thereby reducing the impact on the sensing accuracy of the sensor module. Exemplarily, the guides are respectively arranged on both sides of the motion module to obtain a larger range of motion guidance effects and do not occupy the middle space of the motion module, making it easier to arrange other components. Depending on the specific structure and size or requirements of the motion module, more guides can also be set or the layout position of the guides can be adjusted. In addition, the design of the rack makes the motion module more modular, easy to modify and maintain, and to a certain extent protects the interior of the shell from wear and tear during operation.

[0030] The sensor assembly includes a first sub-shell 12, the motion module 3 is at least partially arranged in the first sub-shell 12, and the frame 4 is fixedly arranged in the first sub-shell 12. The first sub-shell is relative to the entire measuring unit. For the sensor assembly, the first sub-shell can be a complete and independent shell, or it can be a part of the shell of the measuring unit. The first sub-shell 12 provides physical protection for the sensor assembly to prevent its internal components from being disturbed by external environmental factors such as dust, moisture, and impact. The frame 4 is fixedly arranged in the first sub-shell 12, providing a stable support for the motion module 3 and other internal components, improving the structural stability and shock resistance of the entire sensor assembly, helping to reduce displacement and deformation in a motion or vibration environment, ensuring that the sensor can work accurately and stably, and the frame assumes the supporting role of the guide and motion module, etc., which is convenient for later maintenance without the need to replace the entire shell.

[0031] The sensor assembly includes a sensing module 5 arranged in the first sub-shell 12, which is used to sense the position of the motion module 3, thereby improving the integration and facilitating sensing accuracy and timely performance. The present disclosure does not particularly limit the specific structure or working principle of the sensing module. For example, the sensing module can be based on the principle of a capacitive sensor, which is composed of two or more capacitor plates, one of which moves with the motion module. Thus, when the motion module moves and causes the distance or facing area between the capacitor plates to change, it will cause a change in capacitance, thereby generating an electrical signal output, that is, the position or position change of the motion module is reflected by the change in capacitance or electrical signal. This will be described in detail below using a magnetic sensor as an example.

[0032] Combine Figure 5 , which shows a perspective view of a motion module area of ​​a sensor assembly of a measuring unit according to the present disclosure.

[0033] The motion module 3 includes a bracket 31 and a magnet 32 ​​fixed to the bracket 31 . The sensor module 5 is used to sense the magnetic field change of the magnet 32 ​​and output a response signal.

[0034] It can be seen that the measuring unit of this example is based on the principle of the Hall sensor or the Hall effect. Specifically, the sensing module can convert the changing magnetic field (the magnetic field surrounding the sensing module) into a change in the output voltage, and perform signal processing, for example, through an analysis and processing system or a processing circuit, and then output a pulse-width modulated position signal to the corresponding system, such as the brake control unit of the electronic brake system, so as to obtain a high-precision, high-energy-efficiency, cost-controlled measurement system with a wide frequency response range. In this regard, the magnet can be arranged in the frame, and the main part of the bracket is also arranged in the frame, and the engaging portion of the bracket for engaging with the connecting member extends outward beyond the range of the frame, and the guide member is also arranged in the frame. The sensing range is, for example, 0 to 10 mm.

[0035] In addition, regarding the fixing method between the bracket and the magnet, for example, the magnet is arranged on the end face of the bracket facing the sensor module so that the sensor module can more conveniently perform sensing with the magnet, and the dimensions of the end face and the magnet can be designed to be larger to increase the range of the magnetic field. Specific fixing methods may include, for example, snap-fitting, bonding, screwing, welding, etc. The fixed connection between the magnet and the bracket allows the motion module to be constructed as a pre-assembled integrated component, which is easy to assemble on the guide member and ensures that the two are more stable and consistent during movement. In some embodiments, the magnet and the bracket are connected by heat riveting. The left end face of the bracket is constructed with a cylindrical protrusion 315. In conjunction with this, the magnet is based on a rectangular parallelepiped and has lugs 321 on both sides. The lugs are provided with through holes, and the protrusions can extend to the left through the through holes to achieve 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 designed to be symmetrical to ensure uniform stress distribution during the connection. The advantages of hot riveting include high efficiency, increased connection strength, a wide range of material compatibility, and advantages during processing (no vibration or noise). To this end, the bracket can be made of plastic to effectively support the hot riveting process.

[0036] In some embodiments of the present disclosure, the measuring unit 100 further includes a spring 6 , which is abutted between the bracket 31 and the frame 4 and is used to provide spring force to the bracket 31 .

[0037] The spring design serves multiple purposes. On the one hand, the spring ensures that the relative position of the bracket and the connector remains fixed, thereby ensuring that the travel of the pedal rod and connector is accurately reflected in the position changes of the bracket. On the other hand, when the bracket is assembled into the frame, the spring force causes the bracket to press against the inner wall of the frame, providing the user with sensory feedback that the installation is complete. This state is also considered the bracket's initial state or initial position. Those skilled in the art can adjust the spring's spring constant, material, number, series-parallel connection, size, shape, and other factors to achieve the desired spring force characteristics. Furthermore, according to the present technical solution, in addition to guiding the bracket's movement and providing space for movement, the frame also provides space for the spring. Therefore, the frame plays multiple roles and effects on the entire motion module and the forces acting on the motion module. The spring is illustratively arranged between the guide members on both sides, fully utilizing the space available for the frame and bracket, improving space utilization. Furthermore, the spring can also act as a shock absorber or buffer, absorbing or dissipating shock and vibration generated by the system, helping to improve the system's dynamic stability and response speed.

[0038] The bracket 31 is configured with a first support column 311 , and the frame 4 is configured with a second support column 42 . Both ends of the spring 6 are respectively sleeved on the first support column 311 and the second support column 42 .

[0039] This technical solution provides a centralized and compact space for the spring and motion module through the design of the support column. The support column is exemplarily constructed as a column with a cross-shaped cross-section, which has higher torsion resistance and can better resist the torsional force generated by spring deformation, maintain the stability and reliability of the structure, and facilitate the fixing, installation and maintenance of the spring, reducing the difficulty and cost of installation. It also provides a stable support point for the spring, ensuring that the spring can maintain a stable shape and force when compressed or extended, thereby improving the accuracy of measurement and the stability of the system. The support column also plays a guiding role, ensuring that the spring can move along the predetermined path when compressed or extended, reducing errors caused by deviation or shaking. In addition, the cross-shaped cross-section is easy to process and standardize production, and is cost-controlled. It also enables the support column to more evenly distribute stress when subjected to force, maintain stability, and is less likely to deform or lose stability, avoiding damage caused by local stress concentration, helping to extend the service life of the support column and improve the reliability of the system. It is also understood that the two support columns can be aligned in the vertical direction to better cooperate with the spring.

[0040] Combine Figure 6 and Figure 7 ,in, Figure 6 A perspective view showing a sensor module of a sensor assembly of a measurement unit according to the present disclosure; and Figure 7 A bottom view of a sensor assembly of a measuring unit according to the present disclosure in a first housing sub-region is shown.

[0041] The sensor module 5 includes a circuit board 51 , a sensor chip 52 arranged on the circuit board 51 , and a micro switch 53 . The micro switch 53 can be triggered by the movement of the bracket 31 . The sensor chip 52 is used to sense the change in the magnetic field of the magnet 32 ​​.

[0042] It should be understood that the sensor chip cooperates with the magnet to sense the magnetic field changes of the magnet. To this end, the sensor chip is, for example, an ASIC chip (Application Specific Integrated Circuit), or is further connected to or includes an analysis component and a transmission circuit or processing circuit 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 illustratively constructed in the middle of the circuit board, and multiple sensor chips can also be provided if necessary, for example, to obtain a more comprehensive result by averaging.

[0043] A microswitch is a switch with a relatively small contact spacing and is also known as a sensitive switch, snap-action switch, or tactile switch. It is triggered by a motion module, such as a bracket, and can be designed to interface with the vehicle's electronic braking system and the measurement unit's circuit board, resulting in a highly targeted and automated design. 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 activates the electronic braking system, and the circuit board and its chip begin operating, outputting a response signal indicating pedal travel. This demonstrates that the microswitch design strikes a balance between power consumption control and pedal travel sensing. Furthermore, microswitches are compact, durable, reliable, and highly accurate.

[0044] Micro switches can be configured as either mechanical or photoelectric, each with its own unique advantages. Mechanical micro switches offer high sensitivity, simple structure, strong reliability, and flexible operation. Photoelectric micro switches, 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 micro switch based on the specific application scenario, cost budget, and performance requirements.

[0045] from Figure 2 or Figure 7 It can also be seen that the sensor chip and magnet on the circuit board are placed on either side of the frame, or separated by the frame, which can provide a certain degree of thermal insulation. In this regard, it should also be understood that this design does not affect the sensor chip's ability to sense changes in the magnet's magnetic field. For example, a magnet with high flux density and strong magnetic field can be selected to ensure sufficient magnetic field changes for the sensor chip to detect even at a certain distance. The shape and size of the magnet can also be made larger. On the other hand, a sensor chip with high sensitivity can be selected to more accurately detect subtle magnetic field changes. Furthermore, the sensor chip's sensitivity can be enhanced by adjusting its operating parameters and signal processing circuitry. Furthermore, the sensor chip and magnet can be positioned relatively close to each other and aligned to reduce signal attenuation and interference. Furthermore, measures such as a shielding cover can be used to further minimize the impact of external electromagnetic interference on the sensor chip. Finally, the material of the frame can also be reasonably selected, such as non-ferromagnetic materials (such as aluminum, copper, stainless steel, etc.) or non-metallic materials (such as plastic, ceramic, etc.), and the magnetic permeability, magnetic shielding performance and the impact on sensor performance can be controlled by selecting materials.

[0046] In terms of interaction, illustratively, the rack 4 is provided with a through hole 43 , and the side of the bracket 31 is configured with a wing structure 312 , and the micro switch 53 can interact with the wing structure 312 via the through hole 43 .

[0047] As can be seen, in the case of a mechanical microswitch, it has a switch body and a moving part that interacts with the bracket. When the bracket moves with the connecting member, the bracket's side structure contacts the moving part and causes the moving part to displace, so that the moving part contacts the contacts of the switch body, thereby triggering the switch body. After the bracket's force on the moving part is removed, the moving part can reset, thereby disconnecting from the contacts and deactivating the microswitch. The sensitivity and durability of the switch can be optimized by adjusting factors such as the elastic modulus of the moving part (for example, configured as a reed), the shape and material of the contacts, etc. In the case of a photoelectric microswitch, a photoelectric sensor is exemplarily arranged inside it. The sensor consists of a transmitter (such as a light-emitting diode (LED)) and a receiver (such as a photodiode). When the light emitted by the transmitter is blocked or reflected by the bracket's side structure, the light intensity received by the receiver changes, thereby 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. In addition, the impact of environmental factors (such as light interference) on switch performance can also be considered, and corresponding measures can be taken to compensate or shield.

[0048] There are no specific restrictions on the specific shape and position of the wing structures, as long as they can maintain two different interaction modes with the microswitch during the movement of the bracket (i.e., the microswitch is triggered and not triggered). In this example, when the bracket is in its initial position (i.e., the assembled bracket is moved to its uppermost position by the spring force, at which point the pedal rod is also in its initial travel), the microswitch is not triggered. When the driver applies the brakes, the pedal rod descends, which, through the connector, triggers the microswitch. The wing structures are illustratively constructed in a plate-like shape and arranged relative to corresponding portions of the microswitch to achieve desired interaction. Furthermore, this technical solution makes the bracket and microswitch relatively compact, effectively utilizing the space provided by the chassis itself. Those skilled in the art can easily adjust the microswitch's triggering position and sensitivity by adjusting the shape, position, or size of the wing structures, thereby providing greater flexibility to accommodate diverse application requirements.

[0049] refer to Figure 8 , which shows a diagram of the matching relationship between the rack and the motion module of the sensor assembly of another measuring unit according to the present disclosure.

[0050] The frame 4 is formed with a recess 47 , and the bracket 31 is formed with a protrusion 314 . In the initial position of the bracket 31 , the protrusion 314 engages with the recess 47 .

[0051] As mentioned above, the initial position can be understood as corresponding to the assembled bracket being moved to the top by the spring force of the spring, at which time the pedal rod stroke is also in the initial stroke. The precise physical constraint is achieved by the engagement of the recess and the protrusion. This design ensures the stability and accuracy of the bracket in the initial position, prevents accidental movement or misalignment of the bracket, and can support the long-term reusable use of the bracket and the entire system. In addition, the design of the protrusion and the recess makes the installation process of the bracket faster and easier. The operator only needs to align the protrusion with the recess and insert it to complete the initial fixation, which greatly improves the assembly efficiency. In some other embodiments, the top of the frame can also be set to a flat surface, and the top of the bracket is set accordingly, so that the initial position can be easily determined by the surface engagement of the two.

[0052] from Figure 3 It can also be seen that the frame 4 and the first sub-shell 12 are threadedly connected via the self-tapping screws 7 of the sensor assembly. It should be understood that self-tapping screws have the characteristic of tapping out threads on the connecting material by themselves. Therefore, when connecting the frame and the shell, the holes of the shell do not need to be pre-threaded, which greatly simplifies the installation process, improves assembly efficiency, saves material and labor costs, and reduces overall manufacturing costs. In addition, the thread design of the self-tapping screw can form a tight threaded connection with the connected material, thereby enhancing the connection strength and ensuring the stability between the frame and the shell. In addition, when the frame and the shell need to be repaired or replaced, the threaded connection method of the self-tapping screw makes disassembly and reinstallation relatively simple and quick. In addition or alternatively, welding, bonding, snap-fitting or other threaded connection methods can also be used to achieve the connection between the two.

[0053] To this end, the frame can be configured with through-holes for self-tapping screws, while the housing can be configured with columns with through-holes or blind holes at corresponding locations. Thus, the self-tapping screws can penetrate the columns through the housing through-holes and establish a threaded connection. Furthermore, considering the range of action and force distribution, for example, a self-tapping screw connection can be provided at each of the four corners of the frame (depending on the specific structure of the frame) to achieve a more stable and uniformly stressed connection.

[0054] refer to Figure 9 , which shows a diagram of the matching relationship between the circuit board and the housing of a sensor assembly of a measuring unit according to the present disclosure.

[0055] The measuring unit 100 also includes a terminal 8, the first sub-housing 12 is configured with a positioning column 11, the circuit board 51 is interference-fitted with the first sub-housing 12 via the positioning column 11, the circuit board 51 is electrically connected to the terminal 8, and the circuit board 51 is welded to the first sub-housing 12 via the terminal 8.

[0056] It should be understood that the shape, size, quantity, position, etc. of the terminals 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. In this technical solution, the fixation between the circuit board and the housing is achieved by the positioning posts and the terminals, thereby enhancing the mechanical stability of the entire measuring unit. In addition, in order to enhance the fixing effect, an additional fixing pin 10 can be provided, which is inserted into the housing and penetrates the circuit board and is welded to the circuit board. The fixing pin can be arranged on a different side of the circuit board from the terminal so as to obtain a more comprehensive fixing effect. The interference fit of the positioning post reduces the need for additional fasteners, making the installation of the circuit board easier and faster, while also achieving precise positioning. Here, the circuit board is formed by a main body located in the middle and an extension plate extending from the main body to both sides. The terminals are mainly distributed on the extension plate on one side, and the positioning posts are distributed on the diagonal corners of the circuit board body.

[0057] In terms of process, the terminals and fixing pins can be constructed on the housing through injection molding or formed into an integrated structure. In this regard, the housing can be made of a plastic material, such as PA (polyamide) or PBT (polybutylene terephthalate). These materials have high strength and rigidity, allowing the housing to withstand large external forces and not easily deform or damage. Injection molding combined with an integrated structure simplifies the processing steps, improves production efficiency, and makes the connection between the various components tighter, improving the overall sealing performance and preventing the intrusion of gas, liquid, dust, etc. PA or PBT materials have good wear and corrosion resistance, which makes the housing have a long service life. On the other hand, the characteristics of PA or PBT materials include high heat resistance, excellent mechanical properties, good dimensional stability, and good formability. It should also be understood that when the housing is injection molded, the terminals are placed in the mold. During the injection molding process, for example, the middle part of the terminals is covered with plastic, and the metal ends of the terminals are still exposed to maintain the electrical connection function of the terminals.

[0058] Combine Figure 4The frame 4 is a frame structure consisting of a frame base plate 44 and a frame side wall 45 extending from the frame base plate 44 toward one side (for example, toward the direction of the connecting member), the second support column 42 and the opening 46 for fixing the guide member 41 are constructed on the frame side wall 45, and the through hole 43 is opened on the frame base plate 44.

[0059] This technical solution provides an exemplary description of the specific structure of the frame. It can be seen from this technical solution that the frame utilizes its own structure to provide accommodation space for the magnet, spring, guide, and part of the bracket, simplifying the installation process and enabling the relevant components to be quickly and accurately positioned and secured. The frame also bears the wear and tear that may occur during the fixing to the housing and operation, protecting the internal components and extending their service life. Furthermore, through the layout design of the second support column, openings, and through-holes, the layout and interaction design of the guide, bracket, and micro switch are rationally allocated, allowing them to fully utilize the space in the frame and achieve their respective functions while maintaining a certain degree of compactness.

[0060] refer to Figure 10 , which shows a diagram of the matching relationship between a frame and a magnet of a sensor assembly of a measuring unit according to the present disclosure.

[0061] The frame side wall 45 defines a first avoidance space 451, and the frame base plate 44 defines a second avoidance space 441. The first avoidance space 451 is aligned with the magnet 32 ​​( Figure 10 ), the second avoidance space 441 is aligned with the positioning column 11 ( Figure 3 ).

[0062] It should be understood that the alignment here means, for example, that the magnet does not interfere with the first avoidance space and the magnet can be seen from the outside through the first avoidance space. Similarly, the positioning post does not interfere with the second avoidance space and the positioning post can be seen from the outside through the second avoidance space. For example, after the positioning post is interference-fitted with the circuit board, it extends into the second avoidance space; after the bracket and the frame are assembled, the magnet at least partially extends into the first avoidance space. This design scheme can further improve the compactness of the entire measuring unit, including the sensor module, the motion module and the frame, optimize the internal structure of the frame, make the layout between the various components more reasonable, provide more room for the shape and size design of the positioning post and the magnet, and improve space utilization. The avoidance space is exemplarily designed to adapt to the shape of the component to be matched, for example, the first avoidance space is designed as a rectangular through hole, and the second avoidance space is designed as a circular through hole.

[0063] In addition, the frame and the housing can also be equipped with an anti-error mechanism to prevent the frame from being installed upside down during assembly. For example, the anti-error structure includes an anti-error portion 48 constructed on the outside of the frame side wall, which is presented in the form of a recess. Correspondingly, the inner side wall of the housing is provided with an anti-error matching portion 14 at a corresponding position, which is presented in the form of a protrusion. If the assembly position or direction is incorrect, the anti-error matching portion will interfere with the frame and hinder the assembly process. When the assembly orientation is correct, the anti-error matching portion can engage with the anti-error portion, which can also provide a certain degree of guidance for the assembly process.

[0064] from Figure 2 It can also be seen that, in some embodiments of the present disclosure, the magnet 32 ​​and the sensor module 5 are arranged in the first sub-housing 12 .

[0065] It can be seen that in this technical solution, the magnet as the moving part is arranged in the first sub-shell, the sensor module is also arranged in the first sub-shell, and the magnet interacts with the sensor module 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 the number of parts or assembly complexity in the second sub-shell, and on the other hand, the magnet in the first sub-shell only needs to be arranged in a certain way (as explained above) without being arranged on the connector in a complicated way or steps. Specifically, the magnet is arranged in the accommodation space formed by the frame, and the sensor module, such as the sensor chip, is arranged close to the magnet in the first sub-shell and the magnet and the sensor chip are separated by the frame.

[0066] Combine Figure 1 、 2 It can also be seen from FIG. 7 that the first sub-housing 12 is formed with an interface 121 , and the sensor module 5 is powered via the interface 121 and outputs the response signal.

[0067] Therefore, the sensor module can be powered and its signal output can be supported through the interface. Figure 2 For example, the interface is opened and extended to the left, that is, it is constructed at the end of the first sub-housing away from the second sub-housing so that there is sufficient space for the docking connector. The connector can cooperate with the terminals in the first sub-housing 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 portion of the terminal and the connector.

[0068] Combine Figure 2 And refer to Figure 12 , which shows a diagram of the matching relationship between the circuit board and the terminals of a sensor assembly of a measuring unit according to the present disclosure.

[0069] The terminal 8 is at least partially arranged in the interface 121 and penetrates into the circuit board 51. As mentioned before, a total of seven terminals are provided to realize power supply and data communication between the circuit board and the connector, and the shapes of the seven terminals can be constructed differently, for example, adaptively adjusted according to the design of the connector to be matched. For example, the structure of the terminal as a whole has a main body part and an extension part extending from the main body part to both sides, and the outward extension part is longer and wider, and is allowed to be constructed with a bend so that it can be flexibly extended from the shell to the interface area. A fixing pin is provided on the other side relative to the terminal for fixing the circuit board to the shell, which may not have an electrical connection function.

[0070] 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 connecting member 2 and a second sub-housing 13, the connecting member 2 is movably arranged at least partially in the second sub-housing 13 and is used to be connected to the brake pedal rod, and the motion module 3 moves with the movement of the connecting member 2.

[0071] Therefore, the measuring unit disclosed in the present invention inherits the implementation methods and technical effects of various sensor assemblies. Among them, the first sub-housing and the second sub-housing can be constructed in an integrated manner to form a housing 1, or can be connected to form a housing 1. As explained before, the driver steps on the pedal, and the brake pedal rod then drives the connecting member (sometimes also called a tappet or valve cylinder, valve cylinder) to make corresponding movements. In this regard, the side where the connecting member of the measuring unit is located can also be regarded as a BPM (Braking Pedal Module) for the electronic braking system, and the side where the sensing module is located can be called a pedal travel sensor.

[0072] Regarding the fixing method between the first and second sub-shells, exemplarily, the first sub-shell 12 is provided with a bushing 123, and the first sub-shell 12 and the second sub-shell 13 are threadedly connected via the bushing 123. This 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 sub-shell. In the case where the first sub-shell is made by injection molding, the bushing can prevent the plastic material of the first sub-shell from creeping during the bolting process, thereby improving reliability. The bushing itself is exemplarily constructed as a hollow cylinder and is inserted into the holes designed for this purpose by the first sub-shell and arranged at its four top corners, and then the first sub-shell is connected to the second sub-shell, for example, by means of a threaded connection.

[0073] It can also be seen that a recessed portion 21 is formed on the outer periphery of the connecting member 2 , and the motion module 3 , such as the bracket 31 , is configured with an engaging portion 313 , which is engaged with the recessed portion 21 .

[0074] Here, the connecting member can be constructed as a rotating body, such as a structure based on a cylinder, and a corresponding blind hole is opened to engage with the pedal rod. Figure 2 As can be seen, the main part of the bracket is arranged in the first sub-housing, while the secondary part (such as the bracket's engaging portion for engaging with the connector) is arranged in the second sub-housing. The magnet is fixedly arranged in the main part, optionally close to one side of the sensing unit to obtain better measurement results. Thus, the movement of the connector drives the movement of the bracket, and the movement of the bracket drives the movement of the magnet. The sensor module then senses the change in the magnetic field of the magnet to generate a response signal.

[0075] According to this technical solution, the bracket cooperates with the recessed portion on the outer periphery of the connector to transmit the movement of the connector to the bracket. This direct and efficient motion transmission method provides high transmission efficiency, simplifies the structure, and ensures connection stability. Those skilled in the art will understand that the location of the connector's recessed portion and its engagement with the bracket, as well as the dimensions of the first and second sub-housings, should ensure a wide measurement range, preferably capable of measuring the entire pedal stroke of the pedal rod.

[0076] Combine Figure 2 And refer to Figure 11 , which shows a plan view of a first sub-housing of a sensor assembly of a measuring unit according to the present disclosure facing inward.

[0077] The measuring unit 100 further includes a sealing ring 9 . A groove 122 is formed on the end surface of the first sub-housing 12 . The sealing ring 9 is arranged in the groove 122 and sealably abuts against the circumference of the second sub-housing 13 .

[0078] It should be understood that the sealing ring is used to prevent air leakage, water, dust, etc. to achieve sealing. In particular, the sealing ring is arranged between the first sub-shell and the second sub-shell to achieve sealing at the connection point between the two. It can be understood that the specific arrangement position of the sealing ring can be determined according to the assembly relationship and shape of the two sub-shells. In this example, the second sub-shell is a hollow cylinder as a whole, but is constructed with a flat flange surface in the direction toward the first sub-shell. For this purpose, the first sub-shell is constructed with a corresponding abutment surface in the direction toward the second sub-shell, and the sealing ring is further installed in the form of a guide groove so that the sealing ring can abut the circumferential surface of the second sub-shell, or can also abut the two sub-shells at the same time to complete the sealing. In addition, the annular or closed structure can also ensure the comprehensiveness of the seal. It can also be known that in addition to the sealing method of the sealing ring, the sealing effect can also be achieved by annular welding and other methods.

[0079] The present disclosure also relates to a braking system comprising any of the aforementioned measurement units 100 and a brake pedal rod connected to the connector 2; and a vehicle comprising the aforementioned braking system. The braking system and vehicle of the present disclosure inherit various embodiments and technical effects of the sensor assembly and measurement unit, and are not further detailed here.

[0080] 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 brake pedal travel measuring unit (100), characterized in that The sensor assembly comprises a motion module (3) and a frame (4); the motion module (3) can move along with the movement of a brake pedal rod, so that the movement of the motion module (3) can reflect the brake pedal stroke; the frame (4) is provided with at least two guide members (41), and the motion module (3) can be slidably sleeved on the guide members (41).

2. The sensor assembly according to claim 1, wherein The sensor assembly comprises a first sub-housing (12), the motion module (3) is at least partially arranged in the first sub-housing (12), and the frame (4) is fixedly arranged in the first sub-housing (12).

3. The sensor assembly according to claim 2, wherein: The sensor assembly comprises a sensing module (5) arranged in the first sub-housing (12) and used for sensing the position of the motion module (3).

4. The sensor assembly according to claim 3, wherein: The motion module (3) comprises a bracket (31) and a magnet (32) fixed to the bracket (31); the sensing module (5) is used to sense changes in the magnetic field of the magnet (32) and output a response signal.

5. The sensor assembly according to claim 4, wherein: The sensor assembly further comprises a spring (6), wherein the spring (6) abuts between the bracket (31) and the frame (4) and is used to provide spring force to the bracket (31).

6. The sensor assembly according to claim 5, wherein: The bracket (31) is constructed with a first support column (311), the frame (4) is constructed with a second support column (42), and both ends of the spring (6) are respectively sleeved on the first support column (311) and the second support column (42).

7. The sensor assembly according to claim 6, wherein: The sensing module (5) comprises a circuit board (51), a sensing chip (52) arranged on the circuit board (51), and a micro switch (53), wherein the micro switch (53) can be triggered by the movement of the bracket (31), and the sensing chip (52) is used to sense the change in the magnetic field of the magnet (32).

8. The sensor assembly according to claim 7, wherein: The frame (4) is provided with a through hole (43), the side of the bracket (31) is constructed with a wing structure (312), and the micro switch (53) can interact with the wing structure (312) via the through hole (43).

9. The sensor assembly according to claim 4, wherein: The frame (4) is configured with a recess (47), and the bracket (31) is configured with a protrusion (314), and in an initial position of the bracket (31), the protrusion (314) engages with the recess (47).

10. The sensor assembly according to claim 2, wherein: The frame (4) and the first sub-housing (12) are threadedly connected via the self-tapping screws (7) of the sensor assembly.

11. The sensor assembly according to claim 8, wherein The sensor assembly further comprises a terminal (8), the first sub-housing (12) is configured with a positioning column (11), the circuit board (51) is interference-fitted with the first sub-housing (12) via the positioning column (11), the circuit board (51) is electrically connected to the terminal (8), and the circuit board (51) is welded to the first sub-housing (12) via the terminal (8).

12. The sensor assembly according to claim 11, wherein: The frame (4) is a frame structure consisting of a frame base plate (44) and a frame side wall (45) extending from the frame base plate (44) to one side, the second support column (42) and the opening (46) for fixing the guide member (41) are constructed on the frame side wall (45), and the through hole (43) is opened in the frame base plate (44).

13. The sensor assembly according to claim 12, wherein: The frame side wall (45) is provided with a first avoidance space (451), and the frame base plate (44) is provided with a second avoidance space (441). The first avoidance space (451) is aligned with the magnet (32), and the second avoidance space (441) is aligned with the positioning column (11).

14. The sensor assembly according to claim 11, wherein The first sub-housing (12) is formed with an interface (121), and the sensor module (5) is powered via the interface (121) and outputs the response signal.

15. The sensor assembly according to claim 14, wherein: The terminal (8) is at least partially arranged in the interface (121) and penetrates into the circuit board (51).

16. The sensor assembly according to claim 4, wherein The magnet (32) and the sensor module (5) are arranged in the first sub-housing (12).

17. 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 16, and the measuring unit (100) also includes a connecting member (2) and a second sub-housing (13), wherein the connecting member (2) is movably arranged at least partially in the second sub-housing (13) and is used to be connected to the brake pedal rod, and the motion module (3) moves with the movement of the connecting member (2).

18. The measuring unit (100) according to claim 17, characterized in that The outer periphery of the connecting member (2) is provided with a recessed portion (21), and the motion module (3) is configured with a joint portion (313), and the joint portion (313) is joined to the recessed portion (21).

19. The measuring unit (100) according to claim 17, characterized in that The measuring unit (100) further comprises a sealing ring (9), the end face of the first sub-housing (12) is configured with a groove (122), the sealing ring (9) is arranged in the groove (122) and sealably abuts against the circumference of the second sub-housing (13).

20. A braking system, characterized in that: The brake system comprises a measuring unit (100) according to any one of claims 17 to 19 and a brake pedal rod, which is connected to the connecting element (2).

21. A vehicle, characterized in that: The vehicle includes a braking system according to claim 20.

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