POSITION TRACKING DEVICE

Abstract

Position detection device, comprising: a first sensor section (20) which includes a first magnetic sensor (21), a first wiring (22) extending from the first magnetic sensor (21), and a first resin molded object (23) which is shaped for the first magnetic sensor (21) and the first wiring (22); a second sensor section (30) includes a second magnetic sensor (31), a second wiring (32) extending from the second magnetic sensor (31), and a second resin molded object (33) which is shaped for the second magnetic sensor (31) and the second wiring (32); a terminal (40) which is connected to a part of the first wiring (22) that protrudes from the first resin mold object (23), and to a part of the second wiring (32) that protrudes from the second resin mold object (33); and a third resin molded object (50) which is shaped for the first sensor section (20), the second sensor section (30) and the connector (40) to cover the first wiring (22), the second wiring (32) and the connector (40), wherein the third resin mold object (50) attached the first sensor section (20) and the second sensor section (30) to be opposite each other, the first sensor section (20) and the second sensor section (30) have surfaces that are opposite each other and have a protruding part (60) on the surfaces to provide a gap between the first magnetic sensor (21) and the second magnetic sensor (31), the first sensor section (20) further comprises a first stepped section (23A, 223A, 323A) on a surface of the first resin mold object (23) adjacent to the second resin mold object (33), the second sensor section (30) further comprises a second stepped section (33A, 233A, 333A) on a surface of the second resin mold object (33) adjacent to the first resin mold object (23), and the protruding part (60) is defined by the first stepped section (23A, 223A, 323A) and the second stepped section (33A, 233A, 333A) in contact with each other.

Description

TECHNICAL AREA

[0001] The present disclosure relates to a position tracking device. BACKGROUND

[0002] A position sensing device detects the position of a component in a device. JP 2012-233875A (equivalent to US 2012 / 0268111A1) describes a position sensing device applied to a rotation angle sensing device for calculating the opening degree of a throttle valve in an electronic throttle control device for a vehicle. The rotation angle sensing device is a non-contact device that detects the rotation angle of a shaft based on a change in a magnetic field and is attached to the shaft. The rotation angle sensing device includes a permanent magnet that rotates on the rotor side and a magnetic sensor that is attached to the stator side in a non-contact state.

[0003] A position sensing device has one or two magnetic sensors for standalone use. For example, in JP 2012-233875A, the position sensing device has two magnetic sensors molded together with resin material onto a mounting object, such as a housing or cover. However, this position sensing device cannot be used as a position sensing device having only one magnetic sensor. Similarly, a position sensing device having only one magnetic sensor molded with resin material onto a mounting object cannot be used as a position sensing device having two magnetic sensors.

[0004] Reference is further made to DE 10 2010 049 520 A1, which was identified as prior art. DE 10 2010 049 520 A1 discloses a position detection device comprising: a first sensor section comprising a first magnetic sensor, a first wiring section extending from the first magnetic sensor, and a first resin molded object formed for the first magnetic sensor and the first wiring; a second sensor section comprising a second magnetic sensor, a second wiring section extending from the second magnetic sensor, and a second resin molded object formed for the second magnetic sensor and the second wiring; a connection connected to a portion of the first wiring section protruding from the first resin molded object and to a portion of the second wiring section protruding from the second resin molded object;and a third resin molded object formed for the first sensor section, the second sensor section and the connector to cover the first wiring, the second wiring and the connector, wherein the third resin molded object secures the first sensor section and the second sensor section to be opposite each other, and the first sensor section and the second sensor section have surfaces that are opposite each other and have a protruding portion on the surfaces to provide a gap between the first magnetic sensor and the second magnetic sensor. OVERVIEW OF THE INVENTION

[0005] It is an objective of the present disclosure to provide a position detection device which includes two magnetic sensors as identical parts, whereby variations and fluctuations in the output characteristics of the magnetic sensors are limited.

[0006] The problem is solved by the subject matter of the independent claims. Advantageous further developments can be found in the dependent claims.

[0007] A position sensing device comprises a first sensor section and a second sensor section. The first sensor section includes a first magnetic sensor, first wiring extending from the first magnetic sensor, and a first resin molded object formed to accommodate the first magnetic sensor and the first wiring. The second sensor section includes a second magnetic sensor, second wiring extending from the second magnetic sensor, and a second resin molded object formed to accommodate the second magnetic sensor and the second wiring. A terminal is connected to a portion of the first wiring extending from the first resin molded object and to a portion of the second wiring extending from the second resin molded object.A third resin mold is formed for the first sensor section, the second sensor section, and the connector to cover the first wiring, the second wiring, and the connector. This third resin mold secures the first and second sensor sections so that they are aligned. The first and second sensor sections each have a protruding portion on their opposing surfaces to provide a gap between the first and second magnetic sensors.

[0008] Accordingly, the position sensing device has two independent sensor sections as its basic composition. These two sensor sections are formed by identical parts with the same configuration, designated as a first and a second sensor section. By achieving this part uniformity, the position sensing device with two magnetic sensors, as well as the position sensing device with one magnetic sensor, can be produced using either one or two magnetic sensors. This reduces design, manufacturing, and management costs, allowing the position sensing device to be produced at a low cost.

[0009] The first and second sensor sections each have a projection that separates the first and second magnetic sensors from each other on their opposing surfaces. The remaining stress caused by the mold fabrication of the third resin molded object does not affect the first and second magnetic sensors, thus preserving their initial properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The foregoing and further tasks, features and advantages of the present disclosure will become more apparent from the following detailed description in conjunction with the drawings.

[0011] They show: Fig. 1 a schematic sectional view illustrating an electronic throttle control device including a rotation angle detection device according to one embodiment; Fig. 2 a perspective view of a cover of the rotation angle detection device of the embodiment; Fig. 3 a cross-sectional view illustrating a stator of the rotation angle detection device of the embodiment; Fig. 4 a perspective view illustrating a mounting relationship between two sensor sections in the stator of the rotation angle detection device of the embodiment; Fig. 5 a sectional view illustrating a processing operation to produce a sensor section of the stator of the rotation angle detection device of the embodiment; Fig. 6 a cross-sectional view illustrating a stator of a rotation angle detection device of a comparative example, Fig. 7 a cross-sectional view illustrating a stator of a rotation angle detection device in a modification of the embodiment; and Fig. Figure 8 shows a cross-sectional view illustrating a stator of a rotation angle detection device in a modification of the embodiment. DETAILED DESCRIPTION

[0012] Embodiments of the present invention are described below with reference to the drawings. In these embodiments, a part corresponding to an element described in a previous embodiment may be provided with the same reference numeral, and a redundant explanation for that part may be omitted. If only one part of a configuration is described in one embodiment, another previous embodiment may be applied to the other parts of the configuration. The parts may be combined, even if it is not explicitly stated that the parts may be combined. The embodiments may be partially combined, even if it is not explicitly stated that the embodiments may be combined, provided that such combination does not entail any disadvantage.

[0013] A position detection device according to one embodiment is applied to a rotation angle detection device 10 which is suitable for an electronic throttle control device 1 which is installed in a vehicle.

[0014] The electronic throttle control device 1 is based on Fig. 1 and Fig. 2 explained.

[0015] The electronic throttle control device 1 electronically controls the opening degree of a throttle valve 2 according to the operating status of an internal combustion engine (not shown) of the vehicle. The rotation angle sensing device 10 detects and calculates the opening degree of the throttle valve 2 as a position sensing device. The rotation angle sensing device 10 is a contactless device with a rotor 11 and a stator 12 and detects the rotation angle of a shaft 2A of the throttle valve 2.

[0016] The throttle valve 2 comprises the shaft 2A and a valve object 2B with an approximate plate shape, the valve object 2B being located in an inlet passage 3. The shaft 2A is integrally formed with the valve object 2B as a single component such that the central section of the valve object 2B is connected to the shaft 2A in the thickness direction. The shaft 2A has a first end section 2Aa and a second end section 2Ab, which are exposed by the valve object 2B. The first end section 2Aa and the second end section 2Ab are rotatably supported by a throttle body 4, which defines the inlet passage 3. Thus, the valve object 2B can rotate in the inlet passage 3 together with the shaft 2A, and the inlet passage 3 is opened or closed by the throttle valve 2.

[0017] The throttle body 4 connects the combustion engine to an air purifier (not shown), from which outside air is drawn. Fig. Figure 1 is a view seen in the direction of extension of the inlet passage 3, and an intake port of the internal combustion engine is connected to an outlet port of the air cleaner through the inlet passage 3. The throttle valve 2 is arranged relative to the inlet passage 3 such that the shaft 2A and the valve body 2B are approximately perpendicular to the direction of flow of intake air. The first end section 2Aa and the second end section 2Ab of the shaft 2A protrude from the throttle body 4.

[0018] A motor 5 is attached to the first end section 2Aa of shaft 2A. The motor 5 rotates the shaft 2A based on a control signal output by an electronic control unit (ECU, not shown). The ECU controls the opening degree of the throttle valve 2 by controlling the rotation of the motor 5 to regulate the amount of intake air supplied to the internal combustion engine. The motor 5 and the ECU have generally known structures.

[0019] A bracket 6 is attached to the second end section 2Ab of the shaft 2A. The bracket 6 has a tube section 6A and a base 6B, which closes one end of the tube section 6A such that the bracket 6 has a cylindrical shape closed at one end, with a U-shaped cross-section. The center of the base 6B of the bracket 6 is attached to the second end section 2Ab of the shaft 2A. A magnet (permanent magnet) 7 is located inside the tube section 6A of the bracket 6. The magnet 7 can, for example, be a composite magnet in which the N pole and the S pole are arranged alternately in the circumferential direction of the tube section 6A. When the shaft 2A is rotated, the magnetic field inside the tube section 6A varies. In this way, the rotor 11 of the rotation angle sensing device 10 is provided by the bracket 6 and the magnet 7.

[0020] A cover 8, made of resin material, protects the rotation angle sensing device 10 and is attached to the throttle body 4 by a fastening element such as a bolt 9. A terminal 81 extends within the cover 8 and has a predetermined circuit pattern for connecting the rotation angle sensing device 10 to the ECU, which is an external device. A stator 12 of the rotation angle sensing device 10 is attached to the cover 8 and projects inwards from the cover 8.

[0021] The rotation angle sensing device 10 comprises the rotor 11 and the stator 12, which are in a non-contact state. The rotor 11 is attached to the shaft 2A of the throttle valve 2, and the stator 12 protrudes inwards from the cover 8. Specifically, a sensor assembly 12A of the stator 12 is loosely arranged within the rotor 11, for example, within the tube section 6A of the bracket 6, so that the sensor assembly 12A is located within a magnetic field. When the shaft 2A of the throttle valve 2 rotates, the magnetic field in the tube section 6A is varied, causing a signal (voltage) corresponding to the opening degree of the throttle valve 2 to be detected by the sensor assembly 12A. This signal is transmitted to the ECU via the terminal 81 and used as a control signal.

[0022] The stator 12 of the rotation angle detection device 10 is described with reference to Fig. 3 and Fig. 4 explained.

[0023] The stator 12 has the sensor assembly 12A and a mounting section 12B that holds the sensor assembly 12A. The mounting section 12B is molded with resin material to be integral with the cover 8.

[0024] The sensor arrangement 12A includes a first sensor section 20, a second sensor section 30 and a terminal 40, which is electrically connected to a wiring 22 extending from the first sensor section 20 and a wiring 32 extending from the second sensor section 30.

[0025] The mounting section 12B, which holds the sensor assembly 12A, has a third resin molded object 50 and is essentially constructed by the third resin molded object 50. The third resin molded object 50 is shaped for the first sensor section 20, the second sensor section 30, and the terminal 40 of the sensor assembly 12A such that the first sensor section 20 and the second sensor section 30 are mounted to face each other. Furthermore, the wiring 22 exposed by the first sensor section 20, the wiring 32 exposed by the second sensor section 30, and the terminal 40 are enclosed and protected by the third resin molded object 50. In this embodiment, the terminal 40 forms part of a terminal 81 that is entirely enclosed within the cover 8, and the third resin molded object 50 forms part of the cover 8.

[0026] The first sensor section 20 and the second sensor section 30 have almost completely the same structure, including their appearance. In other words, the first sensor section 20 and the second sensor section 30 are identical parts.

[0027] The common structure of the first sensor section and the second sensor section 30 is explained.

[0028] The first sensor section 20 has a first magnetic sensor 21, the wiring (first wiring) 22 extending from the first magnetic sensor 21, and a first resin mold 23 formed for the first wiring 22 of the first magnetic sensor 21. Similarly, the second sensor section 30 has a second magnetic sensor 31, the wiring (second wiring) 32 extending from the second magnetic sensor 31, and a second resin mold 33 formed for the second magnetic sensor 31 and the second wiring 32. A terminal end of the wiring 22, 32 forms a wiring section extending from the resin mold 23, 33 to the wire connection in the exposed state and is electrically connected to terminal 40 (terminal 81), for example, by welding.

[0029] Each of the magnetic sensors 21, 31 has a magnetic sensing element 21a, 31a, a sealing element 21b, 31b, and a conductor 21c, 31c. The magnetic sensing element 21a, 31a is a magnetic sensor element, such as a Hall-effect IC or MR element, and can be a general-purpose element that includes an integral signal amplification circuit if required. The sealing element 21b, 31b is made of plastic material (resin material) and is arranged to cover the entire magnetic sensing element 21a, 31a to protect it from external shock, heat, or moisture. The conductor 21c, 31c is connected to the wiring 22, 32 for wire connection, for example, by welding.

[0030] A chip capacitor 13 is installed in each of the first wiring 22 and the second wiring 32, for example by soldering. The chip capacitor 13 is also completely enclosed within the resin molded object 23, 33 together with the wiring 22, 23 for protection.

[0031] The external form and appearance of the first sensor section 20 and the second sensor section 30 are explained.

[0032] As in Fig. 3 and Fig. As shown in Figure 4, the first sensor section 20 and the second sensor section 30 are attached to be positioned opposite and overlapping each other. The appearance of the first sensor section 20 and the second sensor section 30 is primarily constructed by the first resin mold object 23 and the second resin mold object 33, respectively. The first resin mold object 23 and the second resin mold object 33 together form an approximately rectangular body with a head end section that partially projects from the rectangular body. The first resin mold object 23 and the second resin mold object 33 each have a first stepped section 23A and a second stepped section 33A, respectively, which corresponds to a projection 60. The stepped section represents a section that forms a step height (difference in height) relative to the other surface.

[0033] The first stepped section 23A projects from a right-angled main body 23B of the first resin mold object 23, and the second stepped section 33A projects from a right-angled main body 33B of the second resin mold object 33. The head end section of the stepped section 23A, 33A, which projects from the right-angled main body 23B, 33B, holds the magnetic sensor 21, 31. The first sensor section 20 and the second sensor section 30 have surfaces that face each other. The first stepped section 23A is defined on the surface of the first sensor section 20, and the second stepped section 33A is defined on the surface of the second sensor section 30. The surfaces of the magnetic sensors 21, 31 that face each other are exposed externally.

[0034] This means that the first stepped section 23A covers only the lower end part of the surface of the first magnetic sensor 21, and the second stepped section 33A covers only the lower end part of the surface of the second magnetic sensor 31. The lower end part is an end part of the magnetic sensor 21, 31 adjacent to the conductor 21c, 31c. The first stepped section 23A is in contact with at least one end part of the sealing object 21b adjacent to the conductor 21c, and the second stepped section 33A is in contact with at least one end part of the sealing object 31b adjacent to the conductor 31c.

[0035] Furthermore, the first stepped section 23A and the second stepped section 33A have surfaces that face each other, and these surfaces are on the same plane as the surfaces of the rectangular main bodies 23B and 33B, which face each other. The first resin molded object 23 and the second resin molded object 33 are in contact with each other through the plane, causing the first sensor section 20 and the second sensor section 30 to be in contact with each other.

[0036] The projecting part 60 is designed to define a gap between the first magnetic sensor 21 and the second magnetic sensor 31, so that the first magnetic sensor 21 and the second magnetic sensor 31 are not in contact with each other. That is, the lower end parts of the magnetic sensors 21 and 31, which are opposite each other, are covered by the first stepped section 23A and the second stepped section 33A, respectively, which are in contact with each other, thus causing the first magnetic sensor 21 and the second magnetic sensor 31 to be designed to separate from each other.

[0037] As in Fig. As shown in Figure 4, the first resin mold object 23 has the surface that is in contact with the second resin mold object 33, and the surface of the first resin mold object 23 has a first protruding part 23C and a first recessed part 23D. The second resin mold object 33 has the surface that is in contact with the first resin mold object 23, and the surface of the second resin mold object 33 has a second protruding part 33C and a second recessed part 33D.

[0038] In particular, the first projecting section 23C and the first recessed section 23D are formed symmetrically on the surface of the rectangular main body 23B of the first resin mold object 23 in contact with the rectangular main body 33B of the second resin mold object 33. Similarly, the second projecting section 33C and the second recessed section 33D are formed symmetrically on the surface of the rectangular main body 33B of the second resin mold object 33 in contact with the rectangular main body 23B of the first resin mold object 3.

[0039] The first protrusion part 23C and the second protrusion part 33C present the tapered protrusion shape in which the outer diameter decreases towards the head end, and the first recess section 23D and the second recess section 33D present the tapered recess shape in which the inner diameter decreases towards the bottom end.

[0040] Accordingly, when the first sensor section 20 and the second sensor section 30 are manufactured in opposite positions and in contact with each other, the first protrusion 23C of the first sensor section 20 and the second recess 33D of the second sensor section 30 fit together, and the first recess 23D of the first sensor section 20 and the second protrusion 33C of the second sensor section 30 fit together. This prevents the first sensor section 20 and the second sensor section 30 from deviating from each other in position, and they can be combined as a single sensor unit.

[0041] The production process for the rotation angle detection device 10, such as the production process for the stator 12, is described with reference to Fig. 5 explained.

[0042] First, sensor sections 20 and 30 are produced so that they have essentially the same configuration, including appearance. Therefore, the production process for the first sensor section 20 is described, and the explanation of the production process for the second sensor section 30 is omitted.

[0043] During the production of the first sensor section 20, the first wiring 22, which has a ribbon shape and is made from an electrical circuit board (e.g., a copper plate), is connected to the conductor 21c of the first magnetic sensor 21 by welding. The chip capacitor 13 is soldered onto the first wiring 22, if required. Then the primary fabrication of the first resin mold object 23 is carried out.

[0044] In this primary manufacturing process, as in Fig. As shown in Figure 5, a composite object consisting of the first magnetic sensor 21, the first wiring 22, and the chip capacitor 13 is arranged in a mold 100 for the sensor section in an injection molding machine. A thermosetting resin, such as epoxy resin, is injected into the mold 100 and cured, and the primary fabricated product is removed from the mold 100 such that the first sensor section 20 is produced, in which the composite object is covered with the first resin molded object 23, which has the first stepped section 23A. The second sensor section 30 is produced similarly. Thus, the sensor sections 20 and 30 can be mass-produced as identical parts.

[0045] After bending the first wiring 22 of the first sensor section 20 and the second wiring 32 of the second sensor section 30 at right angles at a predetermined position, the first sensor section 20 and the second sensor section 30 are fixed as a unit by fitting and overlapping the protruding part and the recessed part, while the first sensor section 20 and the second sensor section 30 are fixed to be opposite each other.

[0046] Then, after the wiring 22, 32 is connected to terminal 40 (a predetermined part of terminal 81) by soldering, the entire unit, including the first sensor section 20, the second sensor section 30, and terminal 81, is placed in a mold for forming the cover 8 in the injection molding machine. An injection mold is filled with resin as a secondary fabrication of the entire unit, including terminal 81, and the secondary fabrication product is removed from the mold.

[0047] The resin used for this secondary fabrication can be a thermoplastic resin such as polybutylene terephthalate (PBT) resin, which is referred to as an engineering plastic. In this way, the stator 12, which is equipped with the third resin molded object 50 (part of the cover 8), is produced. As in Fig. As shown in Figure 3, an end surface 51 of the third resin mold object 50, which is adjacent to the first magnetic sensor 21, is located between the protruding part 60 and the connection 40.

[0048] According to the rotation angle detection device (position detection device) 10 of the embodiment, the first sensor section 20 and the second sensor section 30 are identical parts that have the same configuration, including their appearance. Thus, a position detection device having one magnetic sensor and a position detection device having two magnetic sensors can be correctly produced and used by using one or two sensor sections with the identical configuration to achieve part equality. Design, manufacturing, and management costs can be reduced, and the position detection device can be produced at a low cost.

[0049] According to this embodiment, two components, namely the first sensor section 20 and the second sensor section 30, can be precisely joined to form a single unit. When the first protruding section 23C and the second recessed section 33D are fitted together, and when the second protruding section 33C and the first recessed section 23D are fitted together, the first sensor section 20 and the second sensor section 30 can be positioned with accuracy. This allows for an increase in the accuracy of the positions of the magnetic sensors 21 and 31 of the stator 12.

[0050] According to this embodiment, positioning is achieved by the protruding parts and the recessed sections. The similarity of parts is not limited by the positioning achieved by the protruding parts and the recessed sections. The protruding part and the recessed section are produced using primary manufacturing processes, and no special processing is required for the protruding part and the recessed section.

[0051] According to this embodiment, the projection 60 separates the first magnetic sensor 21 and the second magnetic sensor 31 from each other, while the first sensor section 20 and the second sensor section 30 are manufactured in the essential contact state. This limits variations and fluctuations in the output characteristics of the first magnetic sensor 21 and the second magnetic sensor 31.

[0052] According to the embodiment, the separation of the magnetic sensors, achieved by the projecting part 60, is realized by manufacturing the shoulder sections 23A and 33A in contact with each other, which are formed in the resin molded objects 23 and 33, respectively. The identicalness of the parts is not affected by the stepped sections. The stepped sections are produced using the primary manufacturing process, and no special processing is required for the stepped sections.

[0053] The advantage of the present disclosure, namely that the initial properties of the first magnetic sensor 21 and the second magnetic sensor 31 are preserved from exhibiting variations, becomes more specific in contrast to a comparative example given in Fig. Figure 6 is shown and explained.

[0054] One position detection device in the comparison example is equipped with identical parts to account for the difference in the number of magnetic sensors.

[0055] In the comparative example, the position sensing device, which has two magnetic sensors, includes the first and second sensor sections, which overlap in the contact state, as identical parts. The entire position sensing device is molded with resin for fixation. However, the initial properties of the magnetic sensor vary in the comparative example because a load S is exerted on the parts in contact with each other by the residual load RS, which is generated in the resin mold (produced by the secondary fabrication) to fix the two common parts (i.e., the first and second sensor sections), even though the magnetic sensors are adequately protected during the primary fabrication.

[0056] In particular, as in Fig. As shown in Figure 6, when the resin molded object is produced by secondary fabrication for two identical parts (the first sensor section 20 and the second sensor section 30) to be fixed in the contact state, the remaining stress RS in the third resin molded object 50 is generated due to resin hardening when the resin temperature decreases. The stress S between the two magnetic sensors 21 and 31, which are in contact with each other, is caused by the remaining stress RS. Consequently, variation and fluctuation are generated in the output properties of the magnetic sensors 21 and 31. In the case where the magnetic sensing element is manufactured by a Hall-effect IC, when an external load is added, the output property is simply changed according to the piezoelectric effect.

[0057] In contrast, according to this embodiment, while the first sensor section 20 and the second sensor section 30 are being manufactured in contact with each other, the projection 60, which is defined on the opposing surfaces of the first sensor section 20 and the second sensor section 30, creates a space between the first magnetic sensor 21 and the second magnetic sensor 31. Therefore, even if a residual stress occurs in the third resin mold 50 due to the secondary manufacturing process, this residual stress does not affect the first magnetic sensor 21 and the second magnetic sensor 31. Consequently, changes in the initial properties of the first magnetic sensor 21 and the second magnetic sensor 31 are limited.

[0058] Since the positions of the first magnetic sensor 21 and the second magnetic sensor 31 affect the detection accuracy, it is desirable to position both sensors as close as possible to the center of a magnetic circuit. For this reason, the thickness of the protruding section 60 is set to a predetermined value that effectively minimizes the distance between the sensors. When the Hall-effect IC is used as a magnetic detection element, the distance is uniformly determined by the thickness of the protruding section 60. If the position of the Hall-effect IC is located away from the center of a magnetic circuit, and the linearity, which is one of the sensor characteristics, is affected, a generally known correction section with a multipoint compensation function can be used to correct the output characteristics and achieve the desired linearity.

[0059] The first sensor section 20 and the second sensor section 30 have identical configurations, including appearance. Therefore, due to the identical parts, both the position sensing device with one magnetic sensor and the position sensing device with two magnetic sensors can be used correctly with one or two sensor sections that have the same configuration. Consequently, design, manufacturing, and management costs can be reduced, and the position sensing device can be produced at a low cost.

[0060] The first sensor section 20 and the second sensor section 30 have the first shoulder section 23A and the second shoulder section 33A, respectively, on the surfaces of the first resin molded object 23 and the second resin molded object 33, which are opposite each other. The projection section 60 is defined by the first shoulder section 23A and the second shoulder section 33A, which are in contact with each other.

[0061] Accordingly, the magnetic sensors are spaced apart by the protruding part 60, which is brought into contact with each other by the first stepped section 23A and the second stepped section 33A. These sections are formed in the resin molded objects 23 and 33, respectively, using the primary fabrication process without sacrificing the uniformity of parts and appearance. Thus, no special processing is required to produce the first stepped section 23A and the second stepped section 33A.

[0062] The first sensor section 20 has the first protrusion 23C and a first recess 23D on its surface in contact with the second sensor section 30. The second sensor section 30 has the second protrusion 33C and the second recess 33D on its surface in contact with the first sensor section 20. The first sensor section 20 and the second sensor section 30 are positioned by the first protrusion 23C and the second recess 33D, which fit together, and by the second protrusion 33C and the first recess 23D, which fit together.

[0063] Accordingly, two components, namely the first sensor section 20 and the second sensor section 30, are precisely combined into a single unit. This allows for an increase in the accuracy of the positions of the magnetic sensors 21 and 31 of the stator 12.

[0064] Furthermore, positioning can be achieved by fitting the protruding portion and the recessed portion. Part equality is not compromised by the addition of the protruding portion and the recessed portion. The protruding portion and the recessed portion can be formed during primary manufacturing processes, and no special processing is required to produce them.

[0065] Modifications to the embodiment are described.

[0066] In this embodiment, the projecting portion 60 is defined by the stepped sections 23A and 33A, which project over the entire surfaces of the opposing sensor sections 20 and 30. Alternatively, the stepped sections 23A and 33A can be substantially omitted, and the projecting portion 60 can be defined by the main bodies 23B and 33B. That is, the stepped sections 23A and 33A are partially formed on the surfaces of the opposing main bodies 23B and 33B, such that the first magnetic sensor 21 and the second magnetic sensor 31 are separated from each other by the stepped sections 23A and 33A, which are in contact with each other.

[0067] Furthermore, the surfaces of the stepped sections 23A and 33A, which face each other, are not confined to a plane through which their entire surfaces are in contact. The surfaces of the main bodies 23B and 33B, which face each other, are not confined to a plane through which their entire surfaces are in contact. The projecting part 60 can be defined by a depression and a projecting surface (not planar) through which the surfaces are partially in contact.

[0068] In the case where the projecting part 60 is defined by the recess and the projecting surface in the area surrounded by the third resin molded object 50, the third resin molded object 50 is caused to flow into the gap between the surfaces during secondary fabrication. This increases the strength required to attach the sensor sections 20 and 30 to each other in the opposite arrangement.

[0069] While the sensor sections 20 and 30 are spaced apart by the protruding part 60 at a desired distance, the first resin mold object 23 can cover the surface of the first magnetic sensor 21, which is opposite the second magnetic sensor 31, and the second resin mold object 33 can cover the surface of the second magnetic sensor 31, which is opposite the first magnetic sensor 21.

[0070] In this embodiment, the projecting parts 23C and 33C and the recessed sections 23D and 33D have the same round shape for positioning. Alternatively, different combinations of shapes can be used, provided that the parts remain identical. For example, it is also possible to manufacture the shape as a triangular or rectangular shape, as a combination of these variants.

[0071] The conductor 21c, 31c of the magnetic sensor 21, 31 can be used as the wiring 22, 32 depending on the sensors in the sensor sections 20 and 30.

[0072] In this embodiment, the third resin molded object 50 is configured as part of the cover 8. The connector 81, located within the cover 8, and the connector 40, located within the third resin molded object 50, can be produced separately. The secondary fabrication product, including the connector 40, can be produced individually as a further object. Thus, the entire stator 12 can be manufactured using the two sensor sections as identical parts to accommodate the cover 8, which has different shapes.

[0073] In this embodiment, the first stepped section 23A is located in an area that can overlap a projection area defined by the protrusion of the first magnetic sensor 21 to the second magnetic sensor 31.

[0074] Alternatively, as in Fig. As shown in Figure 7, the first stepped section 223A is located in an area that cannot overlap a projection area defined by the protrusion of the first magnetic sensor 21 to the second magnetic sensor 31. The end face of the first magnetic sensor 21, from which the conductor 21c protrudes, is aligned with the end face of the first stepped section 223A. The end face of the second magnetic sensor 31, from which the conductor 31c protrudes, is aligned with the end face of the second stepped section 233A.

[0075] Furthermore, as in Fig. Figure 8 shows the end surface of the first stepped section 323A between terminal 40 and the end surface of the first magnetic sensor 21, from which conductor 21c protrudes. The end surface of the second stepped section 233A is located between terminal 40 and the end surface of the second magnetic sensor 31, from which conductor 31c protrudes.

[0076] In these cases, no resin is positioned between the first magnetic sensor 21 and the second magnetic sensor 31. Therefore, it is difficult for the remaining load resulting from the third resin molded object 50 to act on the first magnetic sensor 21 and the second magnetic sensor.

[0077] The rotation angle sensing device 10 is described as an example of a position sensing device suitable for an electronic throttle control device. The present disclosure is applicable to various position sensing devices, such as a rotation angle sensor that detects the rotation angle of a tumble control valve and the rotation angle of an accelerator pedal, and a stroke sensor that detects the amount of strokes of a clutch actuator. Such changes and modifications are said to be within the scope of the present disclosure as defined by the claims.

[0078] The invention can be summarized as follows. A position sensing device comprises a first sensor section, which has a first resin molded object shaped for a first magnetic sensor and first wiring, and a second sensor section, which has a second resin molded object shaped for a second magnetic sensor and second wiring. The first sensor section and the second sensor section each have a projection defined between the first magnetic sensor of the first sensor section and the second magnetic sensor of the second sensor section, in order to provide a gap between the first magnetic sensor and the second magnetic sensor.

Claims

[1] Position detection device comprising: a first sensor section (20) which includes a first magnetic sensor (21), a first wiring (22) extending from the first magnetic sensor (21), and a first resin molded object (23) which is shaped for the first magnetic sensor (21) and the first wiring (22); a second sensor section (30) includes a second magnetic sensor (31), a second wiring (32) extending from the second magnetic sensor (31), and a second resin molded object (33) which is shaped for the second magnetic sensor (31) and the second wiring (32); a terminal (40) which is connected to a part of the first wiring (22) that protrudes from the first resin mold object (23), and to a part of the second wiring (32) that protrudes from the second resin mold object (33); and a third resin molded object (50) which is shaped for the first sensor section (20), the second sensor section (30) and the connector (40) to cover the first wiring (22), the second wiring (32) and the connector (40), wherein the third resin mold object (50) attached the first sensor section (20) and the second sensor section (30) to be opposite each other, the first sensor section (20) and the second sensor section (30) have surfaces that are opposite each other and have a protruding part (60) on the surfaces to provide a gap between the first magnetic sensor (21) and the second magnetic sensor (31), the first sensor section (20) further comprises a first stepped section (23A, 223A, 323A) on a surface of the first resin mold object (23) adjacent to the second resin mold object (33), the second sensor section (30) further comprises a second stepped section (33A, 233A, 333A) on a surface of the second resin mold object (33) adjacent to the first resin mold object (23), and the protruding part (60) is defined by the first stepped section (23A, 223A, 323A) and the second stepped section (33A, 233A, 333A) in contact with each other. [2] Position detection device comprising: a first sensor section (20) which includes a first magnetic sensor (21), a first wiring (22) extending from the first magnetic sensor (21), and a first resin molded object (23) which is shaped for the first magnetic sensor (21) and the first wiring (22); a second sensor section (30) includes a second magnetic sensor (31), a second wiring (32) extending from the second magnetic sensor (31), and a second resin molded object (33) which is shaped for the second magnetic sensor (31) and the second wiring (32); a terminal (40) which is connected to a part of the first wiring (22) that protrudes from the first resin mold object (23), and to a part of the second wiring (32) that protrudes from the second resin mold object (33); and a third resin molded object (50) which is shaped for the first sensor section (20), the second sensor section (30) and the connector (40) to cover the first wiring (22), the second wiring (32) and the connector (40), wherein the third resin mold object (50) attached the first sensor section (20) and the second sensor section (30) to be opposite each other, the first sensor section (20) and the second sensor section (30) have surfaces that are opposite each other and have a protruding part (60) on the surfaces to provide a gap between the first magnetic sensor (21) and the second magnetic sensor (31), the first sensor section (20) further comprises a first projection section (23C) and a first recess section (23D) on a surface of the first sensor section (20) in contact with the second sensor section (30), the second sensor section (30) further comprises a second projection section (33C) and a second recess section (33D) on a surface of the second sensor section (30) in contact with the first sensor section (20), and the first sensor section (20) and the second sensor section (30) are positioned by the first protrusion section (23C) and the second recess section (33D) that fit together, and the second protrusion section (33C) and the first recess section (23D) that fit together. [3] Position detection device according to claim 1 or 2, wherein the first sensor section (20) and the second sensor section (30) are configured to have the same structure including appearance. [4] Position detection device according to claim 2, wherein the first sensor section (20) further comprises a first stepped section (23A, 223A, 323A) on a surface of the first resin mold object (23) adjacent to the second resin mold object (33), the second sensor section (30) further comprises a second stepped section (33A, 233A, 333A) on a surface of the second resin mold object (33) adjacent to the first resin mold object (23), and the protruding part (60) is defined by the first stepped section (23A, 223A, 323A) and the second stepped section (33A, 233A, 333A) in contact with each other. [5] Position detection device according to claim 1, wherein the first sensor section (20) further comprises a first projection section (23C) and a first recess section (23D) on a surface of the first sensor section (20) in contact with the second sensor section (30), the second sensor section (30) further comprises a second projection section (33C) and a second recess section (33D) on a surface of the second sensor section (30) in contact with the first sensor section (20), and the first sensor section (20) and the second sensor section (30) are positioned by the first projection section (23C) and the second recess section (33D) which are fitted together, and the second projection section (33C) and the first recess section (23D) which are fitted together. [6] Position detection device according to one of claims 1 or 4, wherein the first magnetic sensor (21) comprises a first magnetic detection element (21a), a first sealing object (21b) and a first conductor (21c), and the first stepped section (23A, 223A) is in contact with at least one end part of the first sealing object (21b) adjacent to the first conductor (21c). [7] Position detection device according to one of claims 1 or 4, wherein the first magnetic sensor (21) comprises a first magnetic detection element (21a), a first sealing object (21b) and a first conductor (21c), and the first stepped section (223A, 323A) is arranged in an area which cannot overlap with a projection area defined by the projection of the first magnetic detection element (21a) to the second magnetic sensor (31).

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