Connecting element for connecting contacts of a sensor unit of a steering aid system to an electrical control unit, as well as a steering aid system with connecting element

Abstract

Connecting element for connecting contacts of a sensor unit of a power steering system with contacts of an electrical control unit, comprising a carrier element (30) with a first connection side (32) and a second connection side (34), wherein several control unit contact elements (36a-h) are arranged on the first connection side (32) and wherein sensor unit contact elements (38a-h) corresponding to the control unit contact elements (36a-h) are arranged on the second connection side (34), which are in electrically conductive connection with the control unit contact elements (36a-h), wherein the first connection side (32) and the second connection side (34) are arranged opposite each other, wherein - the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) are slidably arranged on the carrier element (30) and - the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) are arranged in a mirror-symmetrical manner.

Description

[0001] The invention relates to a connecting element for connecting contacts of a sensor unit of a power steering system to contacts of an electrical control unit. Furthermore, the invention relates to a power steering system with a connecting element.

[0002] In practice, the following electronic steering assistance systems are currently used: • Axis-parallel drive (APA): Electric motor is arranged parallel to the rack axis, • Rack Concentric Electronic Power Steering (RC-EPS): The electric motor is designed as a hollow shaft motor and arranged concentrically around the rack axis, • Column Electric Power Steering (C-EPS): Electric motor provides the steering assistance torque in the area of ​​the steering column.

[0003] The invention is suitable for all of the aforementioned power steering systems and other power steering systems, even if it is described primarily with reference to the RC-EPS system in the context of this application. Control units are often referred to as "electronic control units" (ECUs) in the prior art.

[0004] DE 10 2008 018 477 A1 discloses a power steering system with a control unit, in which replacing the control unit is simplified because the power steering device does not have to be removed from the transmission housing. A connection between a sensor unit and the control unit is not described in this document.

[0005] US 2005 / 0167183 A1 discloses a power steering system that includes a connecting element for connecting a torque sensor to a control unit. The installation position of the individually designed contact elements of the connecting element is predetermined by the design of the connecting element.

[0006] DE 10 2006 034 991 A1 discloses an electric power steering device with a sensor connector, which can be considered a connecting element for connecting contacts of a sensor unit. A synthetic resin body of the sensor connector can be considered a carrier element, which has upper terminals as the first terminal side and lower terminals as the second terminal side. The contacts of the sensor connector are arranged offset (point-symmetrically).

[0007] From DE 10 2005 059 162 A1 an electric motor for a steering assistance device with a sensor is known, which is connected to a control unit via axially pluggable sensor lines not described in detail.

[0008] DE 10 2009 001 419 A1 discloses an electric motor for a power steering device that is arranged in a housing sleeve. The connection between a sensor and an electronic unit interacting with it is not described in detail in this document.

[0009] From US 2012 / 0229005 A1 an electric motor for a steering aid device is known in which a control unit, a connecting element and the electric motor are arranged axially one behind the other.

[0010] The invention is based on the object of providing a connecting element for connecting contacts of a sensor unit of a power steering system to an electrical control unit and a power steering system with a connecting element with improved usability.

[0011] The object is achieved according to the invention with the features of claims 1 and 8 respectively.

[0012] A connecting element according to the invention for connecting contacts of a sensor unit of a steering assistance system to contacts of an electrical control unit comprises a carrier element with a first connection side and a second connection side, wherein a plurality of control unit contact elements are arranged on the first connection side and wherein sensor unit contact elements corresponding to the control unit contact elements are arranged on the second connection side. The sensor unit contact elements are in electrically conductive connection with the control unit contact elements, wherein the first connection side and the second connection side are arranged opposite one another. The control unit contact elements and / or the sensor unit contact elements are arranged displaceably on the carrier element, and the control unit contact elements and / or the sensor unit contact elements are arranged mirror-symmetrically.A connecting element designed in this way has the advantage that it can be used with various electric motors and therefore in motor vehicle steering systems of different power classes. This allows the number of identical parts to be increased and the costs for the use of electric steering systems to be reduced. As will be explained in more detail below in connection with preferred variants, a connecting element according to the invention can be combined in a particularly simple manner with two or more electric motors of different lengths but otherwise identical in design, and with the same control unit and the same steering gear housing. In this case, even the electric motor can be manufactured largely from identical parts, and its performance can be adjusted essentially by adjusting the active length.

[0013] Because the control unit contact elements are arranged mirror-symmetrically, the connecting element according to the invention can be connected to the same control unit rotated by 180°. By arranging the sensor unit contact elements offset from one another, the connecting element can be easily connected to a control unit by rotating it in two different orientations. As a result, the connecting element according to the invention can be used to create at least two different relative positions between the contact elements of a sensor unit of an electric motor and the contact elements of a control unit. An offset arrangement can be achieved, for example, by connecting the control element contact elements and the sensor unit contact elements via connecting regions in the carrier element that run transversely to the direction of extension of the contact elements.Preferably, the sensor unit contact elements are also arranged mirror-symmetrically, so that the arrangement of the contacts of the sensor unit of the electric motor can be geometrically identical in both alignment variants.

[0014] In addition to the mirror-symmetrical arrangement described above, the control unit contact elements and / or the sensor unit contact elements are arranged so that they can be moved on the support element. While such an arrangement is technically more complex than a design with fixed contact elements and therefore involves additional manufacturing costs, it also significantly expands the possible applications because the distance between the sensor unit contact elements and the control unit contact elements can be individually adjusted in this case.

[0015] In a practical embodiment of a connecting element according to the invention, the control unit contact elements and / or the sensor unit contact elements are arranged parallel to one another in a control unit contact element plane or a sensor unit contact element plane, respectively, and the mirror axis runs transversely (preferably perpendicularly) to the respective plane. The aforementioned arrangement in "planes" is understood in particular to mean that the central axes of the contact elements lie in one plane, so that the contact elements are centered around the respective plane. This arrangement is particularly simple and cost-effective to manufacture. An example of such an arrangement can be found in the description of the figures.

[0016] In a further practical embodiment of a connecting element according to the invention, the control unit contact elements are arranged parallel to one another in a control element contact element plane, and the sensor unit contact elements are arranged parallel to one another in a sensor unit contact element plane, wherein the control element contact element plane and the sensor unit contact element plane run parallel to one another and are spaced apart from one another. This arrangement has the advantage that the contacts of the control unit and the contacts of the sensor unit can be geometrically identical, regardless of the orientation of the connecting element. The arrangement is particularly suitable for use with electric motors of different lengths, the length difference of which corresponds to twice the distance between the sensor unit contact element plane and the control element contact element plane.

[0017] In a particularly simple and cost-effective embodiment of a connecting element according to the invention, the control unit contact elements and / or the sensor unit contact elements are designed as contact plates, wherein the direction of extension runs transversely (preferably perpendicularly) to the corresponding plane. "Plates" refers to elements whose thickness is very small in relation to the length and width. Preferably, the thickness is less than 10% and particularly preferably less than 5% of the length and width. A course "transversely to the corresponding plane" means that the direction of extension of the control unit contact elements runs transversely to the control unit contact element plane and / or that the direction of extension of the sensor unit contact elements runs transversely to the direction of extension of the sensor unit contact element plane.

[0018] If a pressure compensation membrane connecting the first side to the second side is arranged in the support element of the connecting element according to the invention, a corresponding pressure compensation membrane in a housing enclosing the electric motor can be omitted. This simplifies the manufacture of the housing and can be carried out at a lower cost.

[0019] In a further practical embodiment of the connecting element according to the invention, a circumferential seal is arranged on the second side in order to create a sealing plane together with the motor housing and thus to shield the engine compartment from the area surrounding the motor housing, in which, among other things, the control unit is located.

[0020] The invention also relates to a steering assistance system comprising: a) an electric motor with a motor housing, b) a sensor unit arranged within the motor housing, c) a control unit located outside the motor housing and d) a connecting element for connecting contacts of the sensor unit to contacts of the control unit comprising a carrier element with a first connection side and a second connection side, e) wherein several control unit contact elements are arranged on the first connection side and f) wherein control unit contact elements corresponding to the control unit contact elements are arranged on the second connection side and are in electrically conductive connection with the sensor unit contact elements, g) wherein the first connection side and the second connection side are arranged opposite each other, h) wherein the connecting element is a connecting element as described above and / or wherein each contact of the control unit and / or each control unit contact element has a width of more than 30 mm in the axial direction of the electric motor.

[0021] The control unit contact elements preferably have a width of more than 40 mm and particularly preferably a width of more than 50 mm. Regarding the embodiments with a connecting element as described above, reference is made to the previously described embodiments and advantages of the connecting element itself according to the invention.

[0022] Steering systems in which - additionally or alternatively - each contact of the control unit and / or each control unit contact element has a width of more than 30 mm in the axial direction of the electric motor, offer the advantage that length differences of the electric motor can be compensated by this design in that the connection between the contacts of the control unit and the corresponding control unit contact elements can be established in different, in particular axially offset, relative positions.

[0023] In this case, it is preferred if the control unit contact elements and / or the sensor unit contact elements of the connecting element are arranged mirror-symmetrically and the mirror axis runs parallel to the motor axis of the electric motor.

[0024] It is further preferred if the control unit contact elements and the sensor unit contact elements of the connecting element are each arranged parallel to one another in a control unit contact element plane and a sensor unit contact element plane, respectively, and the control unit contact element plane and the sensor unit contact element plane both extend perpendicular to the motor axis of the electric motor and are spaced apart from one another. In this regard, reference is also made to the advantages already described in connection with the connecting element according to the invention.

[0025] Further practical embodiments and advantages of the invention are described below in conjunction with the drawings. They show: Fig. 1 a steerable front axle of a motor vehicle with steering aid device in a perspective view, Fig. 2 shows a connecting element according to the invention arranged between contacts of a sensor and contacts of a control unit in a first arrangement in a front view, Fig. 3 that in Fig. 2 shows a connecting element according to the invention in a second arrangement in a front view, Fig. 4 that in the Fig. 2 and Fig. 3 shown connecting element according to the invention in the Fig. 2 shown first arrangement in a perspective view, Fig. 5 that in the Fig. 2 to 4 shown connecting element according to the invention in the Fig. 3 shown second arrangement in a perspective view, Fig. 6 the connecting element according to the invention from the Fig. 2 to 5 in a view from above and Fig. 7 the connecting element according to the invention from the Fig. 2 to 6 in a sectional view according to the arrows VII-VII in Fig. 6.

[0026] Fig. Figure 1 shows a steerable front axle 10 of a motor vehicle with a pinion shaft 12, by means of which a rack 14 can be driven in a known manner via a pinion (not shown). A steering assist device 16 with an electric motor 18 designed as a hollow shaft motor is arranged in the area of ​​the rack 14. The electric motor 18 has a length L H and is pushed onto the rack 14 from the left in the axial direction. It rests with its right axial end against a stop 20 and is thereby fixed in its position relative to the rack 14. The electric motor 18 is controlled from the right side. The left axial end of the electric motor is in the Fig. 2 to 5 shown enlarged.

[0027] As in the Fig. As can be seen in Figures 2 to 5, contacts 22a-h of a sensor unit are located at the left axial end of the electric motor 18 within the housing (not shown) surrounding the electric motor 18. This sensor unit, not shown in detail, is a so-called resolver, by means of which, in particular, the position of the rotor and the temperature in the housing of the electric motor 18 are determined.

[0028] Outside the motor housing (not shown) is a control unit 24 with contacts 26a-h. The contacts 22a-h of the sensor unit are connected to the contacts 26a-h of the control unit 24 via a connecting element 28 according to the invention.

[0029] As in the Fig. As can be seen in Figures 2 to 7, the connecting element 28 according to the invention comprises a carrier element 30 designed as a plate with a first connection side 32 and a second connection side 34. Control unit contact elements 36a-h designed as contact plates are arranged on the first connection side 32. Flat, clamp-like sensor unit contact elements 38a-h are formed on the second connection side 34. The control unit contact elements 36a-h and the sensor unit contact elements 38a-h are electrically conductively connected to one another via connecting regions (not shown) running in the carrier element 30 in such a way that the control unit contact element 36a is electrically conductively connected to the sensor unit contact element 38a, the control unit contact element 36b is electrically conductively connected to the sensor unit contact element 38b, 36c is electrically conductively connected to 38c, 36d is electrically conductively connected to the sensor unit contact element 38d, etc.It should be noted that the control unit contact elements 36a-h and the sensor unit contact elements 38a-h are only shown schematically in connection with the described embodiment. They can be geometrically varied as needed and, in particular, their length can be adjusted to ensure secure contact with the corresponding contacts 26a of the control unit or with the contacts 22a-h of the sensor unit.

[0030] As in Fig. 6, the support element 30 has a flange 40a, 40b with a through-opening 42a, 42b at its upper and lower ends. These serve to screw the support element 30 to the motor housing (not shown). The flanges 40a, 40b are in the Fig. 2 to 5 not shown.

[0031] Furthermore, a circumferential seal 44 is arranged on the second connection side 34 of the support element 30. When the support element 30 is installed, this seal rests on the engine housing (not shown) and thus seals the engine compartment in a fluid-tight manner. Pressure equalization can be achieved via a pressure equalization membrane 46, which is arranged in the support element 30 and allows gas to pass through. Pressure changes occurring due to internal and / or external heating in the engine compartment or corresponding cooling can thus be compensated.

[0032] The sensor unit contact elements 38a-h are plugged onto the corresponding contacts 22a-h of the sensor unit. The control unit contact elements 36a-h are plugged into the clamp-type contacts 26a-h of the control unit. Additionally, the support element 30 is screwed to the motor housing (not shown) via the through-holes 42a, 42b.

[0033] As in Fig. 2, the sensor unit contact elements 38a-h are arranged on a common central plane, which is also referred to as the sensor unit contact element plane E SE The control unit contact elements 36a-h are also arranged on a common center plane, which is also referred to as control unit contact element plane E ST The control unit-contact element plane E ST and the sensor unit contact element level E SE parallel to each other and are offset by the amount d E spaced apart from each other.

[0034] As in Fig. 6, the control unit contact elements 36a-h are mirror-symmetrical about the mirror axis S ST The sensor unit contact elements 38a-h are arranged mirror-symmetrically around the mirror axis S SE , where the two mirror axes S ST and S SEare identical in the embodiment shown. The mirror axes S ST and S SE run perpendicular to the planes E SE and E ST .

[0035] The control unit contact elements 36a-h shown have a width B ST which is larger than the width of the corresponding contacts 26a-h of the control unit 24 (cf. Fig. 6). The width B ST is preferably between 5 mm and 25 mm. This allows the axial alignment of the connecting element 28 according to the invention relative to the contacts 26a-h of the control unit 24 to be varied within certain limits, for example, to compensate for joining, manufacturing, and positioning tolerances.

[0036] As in the Fig. 2 to 5, the connecting element 28 according to the invention is designed as a double-sided plug-in element (also called a reversible connector). It can - as shown in the Fig. 2 and Fig. 4 - in an arrangement for short electric motors 18 and - as shown in the Fig. 3 and Fig. 5 - can be used in an arrangement for longer electric motors 18, the length difference of the motors 18 in the embodiment shown being twice the amount d E By designing the connecting element 28 as a reversible connector, the number of parts and thus the availability of the connecting element 28 increases. This leads to a reduction in the probability of failure or the possible downtime in the event of a defect.

[0037] Signals with relatively low power levels, particularly power levels of less than 1 kW, are transmitted via the connecting element 28 according to the invention. Therefore, materials with low contact resistance are preferred for the electrically conductive elements, i.e., the sensor element contact elements 38a-h, the control unit contact elements 36a-h, and the connecting regions. All conductive metals are particularly suitable as such. Gold contact plugs are particularly preferred.

[0038] The features of the invention disclosed in the present description, the drawings, and the claims may be essential, both individually and in any combination, for the realization of the invention in its various embodiments. The invention is not limited to the described embodiments. It may be varied within the scope of the claims and taking into account the knowledge of the person skilled in the art. List of reference symbols 10 steerable front axle 12 pinions 14 Rack 16 Steering assistance device 18 electric motor 20 stops 22a-h Contact (of the sensor unit 24 Control unit 26a-h Contact (of the control unit) 28 Connecting element 30 support element 32 first connection page 34 second connection side 36a-h Control unit contact element 38a-h Sensor unit contact element 40a, 40b flange 42a, 42b passage opening 44 Seal 46 Pressure equalization membrane

Claims

[1] Connecting element for connecting contacts of a sensor unit of a steering assistance system to contacts of an electrical control unit, comprising a carrier element (30) with a first connection side (32) and a second connection side (34), wherein a plurality of control unit contact elements (36a-h) are arranged on the first connection side (32) and wherein sensor unit contact elements (38a-h) corresponding to the control unit contact elements (36a-h) are arranged on the second connection side (34), which sensor unit contact elements are in electrically conductive connection with the control unit contact elements (36a-h), wherein the first connection side (32) and the second connection side (34) are arranged opposite one another, wherein - the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) are arranged displaceably on the carrier element (30) and - the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) are arranged mirror-symmetrically. [2] Connecting element according to the preceding claim, characterized by that corresponding contact elements (36a-h, 38a-h) are arranged offset from one another. [3] Connecting element according to one of the preceding claims, characterized by that the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) are parallel to one another in a control unit contact element plane (E ST ) or a sensor unit contact element level (E SE ) and the mirror axis (S ST , S SE ) runs transversely to the respective plane. [4] Connecting element according to one of the preceding claims, characterized by that the control unit contact elements (36a-h) are parallel to each other in a control element contact element plane (E ST), the sensor unit contact elements (38a-h) are arranged parallel to one another in a sensor unit contact element plane (E SE ), wherein the control element contact element plane (E ST ) and the sensor unit contact element level (E SE ) run parallel to each other and are spaced apart from each other. [5] Connecting element according to one of the preceding claims, characterized by that the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) are designed as contact plates, wherein the direction of extension runs transversely to the corresponding plane. [6] Connecting element according to one of the preceding claims, characterized by that a pressure compensation membrane (46) connecting the first side to the second side is arranged in the carrier element (30). [7] Connecting element according to one of the preceding claims, characterized bythat a circumferential seal (44) is arranged on the second side. [8] Steering assistance system comprehensive a) an electric motor (18) with a motor housing, b) a sensor unit arranged within the motor housing, c) a control unit (24) arranged outside the motor housing and d) a connecting element for connecting contacts of the sensor unit (22a-h) to contacts of the control unit (26a-h) comprising a carrier element (30) with a first connection side (32) and a second connection side (34), e) wherein a plurality of control unit contact elements (36a-h) are arranged on the first connection side (32) and f) wherein control unit contact elements corresponding to the control unit contact elements (36a-h) are arranged on the second connection side (34), which are in electrically conductive connection with the sensor unit contact elements (38a-h), g) wherein the first connection side (32) and the second connection side (34) are arranged opposite one another, characterized by , h) that the connecting element is a connecting element (28) according to one of the preceding claims and / or that each contact of the control unit (26a-h) and / or each control unit contact element (36a-h) has a width of more than 30 mm in the axial direction of the electric motor (18). [9] Steering assistance system according to the preceding claim, characterized by that the control unit contact elements (36a-h) and / or the sensor unit contact elements (38a-h) of the connecting element (28) are arranged mirror-symmetrically and the mirror axis (S ST , S SE ) runs parallel to the motor axis of the electric motor (18). [10] Steering assistance system according to claim 8 or 9, characterized bythat the control unit contact elements (36a-h) and the sensor unit contact elements (38a-h) of the connecting element (28) are each parallel to one another in a control unit contact element plane (E ST ) or a sensor unit contact element level (E SE ) and the control unit contact element level (E ST ) and the sensor unit contact element level (E SE ) both run perpendicular to the motor axis of the electric motor (18) and are spaced apart from each other.

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