Sensor assembly for a vehicle

Abstract

Sensor assembly (1) for a vehicle, comprising a connector assembly (10) which includes a connector housing (11) and at least two connector pins (18) and forms an external interface (9) of the sensor assembly (1), a circuit carrier (14) on which an electronic circuit (16) corresponding to a sensor concept to be implemented is arranged, and a sensor housing (20) which includes an insertion opening (22), wherein the circuit carrier (14) is connected at a first interface (3) to the connector housing (11) and the at least two connector pins (18), wherein the sensor housing (20) includes a second interface (5) with an opening (25) via which the sensor housing (20) can be connected, depending on the sensor concept to be implemented, to an external sensor arrangement (30) or a cover which covers the opening (25) of the second interface (5) when not in use,wherein the circuit carrier (14) is inserted through the insertion opening (22) into the sensor housing (20), which is connected to the connector housing (11) via a third interface (7), wherein the circuit carrier (14) is pre-fixed at an end region of the sensor housing (20), wherein at least one guide element (24) guides the circuit carrier (14) on a first side and at least one spring element (26) rests on a second side opposite the first side and presses and fixes the circuit carrier (14) against the at least one guide element (24), wherein the first interface (3) and the external interface (9) are designed depending on a communication protocol to be implemented, and wherein the second interface (5) and the third interface (7) are designed identically regardless of the sensor concept and the communication protocol to be implemented.

Description

[0001] The invention relates to a sensor assembly for a vehicle. The present invention also provides a method for assembling such a sensor assembly for a vehicle.

[0002] Sensor assemblies comprising a sensor housing and a connector assembly with a connector housing are known from the prior art. The connector housing with integrated connectors can be designed as an injection-molded housing with inserts for the electrical contacts or as an injection-molded housing with pressed-in contact pins. Connector housings with inserts produced using the injection-molded process typically incur higher costs than connector housings with pressed-in contacts, as the insertion process in the injection-molding machine results in shorter cycle times and additional effort is required for handling the inserts (robots, etc.). To produce different sensor housing variants (width, height, different screw points, etc.) with connector connections, different injection molding tools are usually required for the housings, despite the same external connector interface.For sensors with a so-called A2B interface, special specifications apply to the electrical properties of the connectors. Due to the high transmission frequency of the external interface (similar to a 100 Mbit network interface), the distance between the connector pins must be kept as small as possible. This limits the selection of connectors available on the open market. Customers usually have very different requirements for the sensor modules to implement their desired sensor concepts. In addition, different external interfaces may be required for different data bus topologies and to implement different communication protocols. This leads to a multitude of different sensor module designs.

[0003] DE 10 2014 202 192 A1 discloses a sensor unit for a vehicle comprising a base body that supports a sensor circuit with at least one sensor contact and has, at a first end, a sensor contact that is electrically connected to the at least one sensor contact via at least one counter-sensor contact, and, at a second end, a cable contact that is electrically connected to a connecting cable via at least one cable contact. The sensor contact and the cable contact are arranged on a common contact carrier. The sensor circuit is arranged at one end region of the contact carrier such that the sensor circuit is aligned in a desired detection direction.The detection direction is determined by a bending angle of the end region of the contact carrier to the longitudinal axis of the base body, wherein the sensor contact with the sensor circuit is surrounded by a cup-shaped sleeve fixed to the base body, the shape of which is adapted to the detection direction of the sensor circuit.

[0004] Furthermore, DE 10 2017 113 711 A1 discloses a sensor arrangement for a master cylinder in an automobile, wherein a circuit carrier for sensor electronics is connected to a plug unit, and both are inserted together into a housing, which is thereby sealed. In this case, the sensor is designed as an integral component of the circuit carrier. Disclosure of the invention

[0005] The sensor assembly for a vehicle with the features of independent patent claim 1 has the advantage of providing a flexible housing concept for different sensor applications or sensor concepts. Only small parts of the overall housing are exchanged for each variant. By combining different parts, many different variants of the sensor assembly can be created. The production line can be designed so that all variants can be manufactured on one line. With the help of the present proposal for a sensor kit, a wide range of sensor assemblies can be manufactured by combining different housing parts. The functional principle is always similar in the design, and the same production equipment can be used.The connector assembly allows an external interface of the sensor module to be pre-adapted to the customer's desired bus topology, while a mechanical interface between the sensor housing and the connector housing remains the same. For example, two-pin, four-pin, or eight-pin connectors can be provided, which can meet corresponding signal transmission and communication protocol requirements. Of course, male connectors or similar contact assemblies can also be used as the external interface of the sensor module.

[0006] Embodiments of the present invention provide a sensor assembly for a vehicle with a connector assembly comprising a connector housing and at least two connector pins and forming an external interface of the sensor assembly, a circuit carrier on which an electronic circuit corresponding to a sensor concept to be implemented is arranged, and a sensor housing comprising an insertion opening. The circuit carrier is connected to the connector housing and the at least two connector pins at a first interface. The sensor housing comprises a second interface with an opening via which the sensor housing can be connected, depending on the sensor concept to be implemented, to an external sensor arrangement or a cover which covers the opening of the second interface when not in use.The circuit carrier is inserted through the insertion opening into the sensor housing, which is connected to the connector housing via a third interface. The circuit carrier is pre-fixed to an end region of the sensor housing, with at least one guide element guiding the circuit carrier on a first side and at least one spring element resting on a second side opposite the first side, pressing the circuit carrier against the at least one guide element and fixing it in place. The first interface and the external interface are designed depending on a communication protocol to be implemented. The second interface and the third interface are designed identically regardless of the sensor concept and communication protocol to be implemented.

[0007] Furthermore, a method for assembling such a sensor assembly for a vehicle is proposed. This involves providing a sensor housing and, depending on the sensor concept and communication protocol to be implemented, a connector assembly and a circuit carrier.

[0008] The connector assembly and the circuit carrier are connected to each other at a first interface. The circuit carrier is inserted into an insertion opening of the sensor housing until the connector housing and the sensor housing are connected to each other at a third interface, and the circuit carrier is pre-fixed to an end area of ​​the sensor housing. Depending on the sensor concept to be implemented, an external sensor assembly or a cover is connected to the sensor housing at the second interface.

[0009] For example, by designing the sensor module, an A2B interface can also be easily implemented as an external interface by positioning the required connector pins with the smallest possible spacing in the connector housing to enable a high transmission frequency of the external interface similar to a network interface (100 Mbit). Furthermore, the external interface of the sensor module can be implemented as a MOST bus interface, 100BASE-T1 interface, PS15 interface, CAN interface, CAN-FD interface, VIAS interface, etc.

[0010] The second interface of the sensor housing makes it easy to implement different customer requirements for the sensor modules. For example, the sensor housing can be connected to a cover that covers the opening of the second interface when not in use. This can be the case, for example, if an internal sensor arrangement as part of the electronic circuit on the circuit carrier is sufficient to implement the desired sensor concept, and no further external sensor arrangement is required. Alternatively, depending on the sensor concept to be implemented, various external sensor arrangements can be electrically and mechanically connected to the sensor housing via the second interface.For example, speed sensors, temperature sensors, microphones, etc., can be flanged to the second interface as external sensor arrays with one ASIC (ASIC: Application-Specific Integrated Circuit) or redundantly with two ASICs, or with one ASIC with two sensor elements. The speed sensors can be equipped with HALL, AMR, GMR, TMR, or comparable measurement technology. The shape of the speed sensor can vary in terms of length, reading direction, diameter, with or without O-ring, etc. The electrical contacting of the external sensor array can be achieved, for example, via contact springs mounted on the circuit board. Press-in technology or plug-in contacts for contacting the flanged-on external sensor array are also conceivable.If no electrical contact with the circuit carrier of the sensor assembly is required, retaining pins can be arranged on the outside of the cover, to which, for example, a sensor for measuring acceleration and / or noise (road noise sensor) can be flanged.

[0011] The connector housing and the sensor housing of the sensor assembly can preferably be designed as plastic injection-molded components. This enables simple and cost-effective production in large quantities. The circuit carrier is pre-fixed in the end area of ​​the sensor housing during assembly, preferably using two guide elements designed as compression ribs.

[0012] The at least one spring element can be understood as, for example, mechanical springs such as barrel springs, coil springs, S-springs, etc., or elastic plastic elements such as rubber balls, silicone tubes, etc., which are suitable for pressing and fixing the circuit carrier against the at least one guide element.

[0013] The electronic circuit can, for example, be understood as an evaluation and control circuit that processes and evaluates detected sensor signals. The electronic circuit can have at least one interface, which can be implemented in hardware and / or software. In a hardware implementation, the interfaces can, for example, be part of a so-called system ASIC, which contains a wide variety of functions of the electronic circuit. However, it is also possible for the interfaces to be separate integrated circuits or to consist at least partially of discrete components. In a software implementation, the interfaces can be software modules that are present, for example, on a microcontroller alongside other software modules.Also advantageous is a computer program product with program code stored on a machine-readable medium such as a semiconductor memory, a hard disk memory or an optical memory and used to carry out the evaluation when the program is executed by the electronic circuit.

[0014] The measures and further developments listed in the dependent claims enable advantageous improvements to the sensor assembly for a vehicle specified in independent patent claim 1 and the method specified in independent patent claim 11.

[0015] It is particularly advantageous that the number and arrangement of the at least two connector pins of the connector module can be adapted to the communication protocol to be implemented.

[0016] In an advantageous embodiment of the sensor assembly, the at least one spring element can be arranged in the region of the second interface between the circuit carrier and the sensor housing. In this case, the at least one spring element can be supported on the external sensor arrangement or on the cover. In the case of a flange-mounted external sensor arrangement, the at least one spring element can be designed as a contact spring which electrically connects the external sensor arrangement connected to the sensor housing at the second interface to the circuit carrier. The contact spring can preferably be designed as a barrel spring or as an S-spring. In such an embodiment, the at least one spring element advantageously also takes over the electrical contacting of the external sensor arrangement in addition to fixing the circuit carrier.Additionally or alternatively, the at least one spring element, in particular in combination with the lid, can be designed, for example, as a rubber ball, silicone tube, coil spring, etc.

[0017] In a further advantageous embodiment of the sensor assembly, the at least two connector pins of the connector assembly can be pressed into the connector housing and electrically connected to at least one conductor track structure of the circuit carrier. This contacting of the at least two connector pins additionally provides mechanical fixation of the circuit carrier on the connector side. To minimize the load on the contact points, the connector housing can have at least one support element in the area of ​​the first interface, against which the circuit carrier rests. The at least one support element can, for example, be attached to the connector housing as an additional support lug or be molded onto it.

[0018] In a further advantageous embodiment of the sensor assembly, the external sensor arrangement and / or the connector housing can be fluid-tightly connected to the sensor housing via a welded connection, an adhesive connection, a screw connection, a press-in connection, or a hot-stitched connection. This means that the external sensor arrangement or the cover can be fluid-tightly connected to the sensor housing at the second interface via a welded connection, an adhesive connection, a screw connection, a press-in connection, a hot-stitched connection, or a combination of the aforementioned connection techniques.The connector housing can be connected to the sensor housing in a fluid-tight manner at the third interface via a welded connection or via an adhesive connection or via a screw connection or via a press-in connection or via a hot-stitched connection or via a combination of the aforementioned connection techniques.

[0019] In a further advantageous embodiment of the sensor assembly, the third interface can comprise a circumferential first collar formed on the connector housing and a circumferential second collar formed on the sensor housing, which overlap one another in the joined state.

[0020] In a further advantageous embodiment of the sensor assembly, at least one fastening tab can be formed on the sensor housing. This allows for a simple screwing point for the sensor assembly with a pressed-in, overmolded, or bonded bushing. The use of a captive screw is also conceivable. Compression ribs or an external geometry of the sensor housing, for example, can be used as a second fastening point. Alternatively, the cover can be implemented with a retaining pin for a blind hole or sheet metal mounting as a second fastening point. Alternatively, fastening can also be achieved using rivets.

[0021] In an advantageous embodiment of the method, the at least one spring element can be arranged in the region of the third interface between the circuit carrier and the sensor housing before connecting the external sensor arrangement or the cover, so that the spring element, in the assembled state, can be supported on the external sensor arrangement or the cover and can press and fix the circuit carrier against the at least one guide element. In the embodiment as a contact spring, the at least one spring element can be mounted on the circuit carrier, for example. In combination with the cover, the at least one spring element can be attached to the inside of the cover.

[0022] Embodiments of the invention are illustrated in the drawings and explained in more detail in the following description. In the drawings, like reference numerals designate components or elements that perform the same or similar functions. Short description of the drawings Fig. 1 shows a schematic plan view of an embodiment of a sensor assembly according to the invention for a vehicle. Fig. 2 shows a schematic sectional view of the sensor assembly according to the invention from Fig. 1 along the section line II - II. Fig. 3 shows a perspective view of a circuit carrier and components of a connector assembly of the sensor assembly according to the invention from Fig. 1 and Fig. 2. Fig. 4 shows a side view of the connector assembly from Fig. 3 connected circuit carriers Fig. 3. Fig. 5 shows a perspective view of the connector assembly with the connected circuit carrier before inserting the circuit carrier into a sensor housing of the sensor assembly according to the invention from Fig. 1 and Fig. 2. Fig. 6 shows a schematic flow diagram of an embodiment of a method according to the invention for assembling a sensor assembly for a vehicle. Embodiments of the invention

[0023] As from Fig. 1 to 6, the illustrated embodiment of a sensor assembly 1 according to the invention for a vehicle comprises a connector assembly 10, which comprises a connector housing 11 and at least two connector pins 18 and forms an external interface 9 of the sensor assembly 1, a circuit carrier 14, on which an electronic circuit 16 corresponding to a sensor concept to be implemented is arranged, and a sensor housing 20, which comprises an insertion opening 22. The circuit carrier 14 is connected at a first interface 3 to the connector housing 11 and the at least two connector pins 18. The sensor housing 20 comprises a second interface 5 with an opening 25, via which the sensor housing 20, depending on the sensor concept to be implemented, can be connected to an external sensor arrangement 30 or a cover, which covers the opening 25 of the second interface 5 when not in use.The circuit carrier 14 is inserted through the insertion opening 22 into the sensor housing 20, which is connected to the connector housing 11 via a third interface 7. The circuit carrier 14 is pre-fixed to an end region of the sensor housing 20. At least one guide element 24 guides the circuit carrier 14 on a first side, and at least one spring element 26 rests against a second side opposite the first side and presses and fixes the circuit carrier 14 against the at least one guide element 24. The first interface 3 and the external interface 9 are designed depending on a communication protocol to be implemented. The second interface 5 and the third interface 7 are designed identically regardless of the sensor concept and communication protocol to be implemented.

[0024] The connector housing 11, which has a connector opening 11.1 for inserting a connector not shown in detail, and the sensor housing 20 are each designed as plastic injection-molded components in the illustrated embodiment of the sensor assembly 1.

[0025] The number and arrangement of the at least two connector pins 18 of the connector assembly 10 can be adapted to the communication protocol to be implemented. In the illustrated embodiment of the connector assembly 10, eight connector pins 18 are pressed into corresponding contact openings 11.2 of the connector housing 11. As can be seen in particular from Fig. 3, the circuit carrier 14 has a contact area 14.1 with eight through-holes (not shown in more detail), into which the eight connector pins 18 can be pressed. Alternatively, the connector pins 18 can be soldered into the through-holes. The connector pins 18 are electrically connected via the through-holes to at least one conductor track structure (not shown in more detail) of the circuit carrier 14. In the illustrated embodiment, an ASIC module 16A is arranged on the circuit carrier 14 as part of the electronic circuit. Of course, the electronic circuit can also comprise other active or passive electronic components not shown in more detail here.

[0026] To relieve the contacting of the connector pins 18 in the area of ​​the first interface 3, the connector housing 11 has at least one support element 15 against which the circuit carrier 14 rests. As can be seen in particular from Fig. 2 to 4, two support elements 15 designed as support lugs 15A are formed on the plug housing 11 in the illustrated embodiment, against which the circuit carrier 14 rests with one end face and with its first, here upper, side.

[0027] In the illustrated embodiment of the sensor assembly 1, the external sensor arrangement 30, which is designed here as a speed sensor 30A, and the connector housing 11 are each connected to the sensor housing 20 in a fluid-tight manner via a plastic welded connection. As can be seen in particular from Fig. 1 and Fig. 2, the external sensor arrangement 30, designed as a speed sensor 30A, is fluid-tightly connected to the sensor housing 20 at the second interface 5 via the plastic welded connection. The connector housing 11 is fluid-tightly connected to the sensor housing 20 at the third interface 7 via a plastic welded connection. In an embodiment of the sensor assembly 1 without an external sensor arrangement 30 (not shown), the cover is fluid-tightly connected to the sensor housing 20 at the second interface 5 via an adhesive connection.Of course, the external sensor arrangement 30 or the cover and / or the connector housing 11 can also be connected in a fluid-tight manner to the sensor housing 20 using other connection techniques, such as a welded connection or an adhesive connection or a screw connection or a hot-stitched connection or a press-fit connection or a combination of the aforementioned connection techniques.

[0028] As from Fig. 1 to 5, the third interface 7 comprises a circumferential first collar 12 formed on the connector housing 11 and a circumferential second collar 23 formed on the sensor housing 20, which overlap each other in the joined state. In addition, the circumferential second collar 23 of the sensor housing 20 rests against a connecting region 13 of the connector housing 11 and is fluid-tightly connected to the connector housing 11 at the connecting region 13 via a plastic welded joint. As can be seen in particular from Fig. 2 and Fig. 5, the circuit carrier 14 is arranged between two guide elements 26 designed as press-in ribs and is guided by these during insertion into an insertion opening 22 of the sensor housing 20. In the joined state, the circuit carrier 14 rests with a first, here upper, side against a first guide element 26A and is pressed against the first guide element 26A by two spring elements 26 designed as contact springs 26A in the region of the second interface 5. In the end region of the sensor housing 20, the circuit carrier 14 is clamped between the first guide element 24A and a second guide element 24B, which rests on the second, here lower, side of the circuit carrier 14. The spring elements 26 designed as contact springs 26A are supported on the external sensor arrangement 30.The contact springs 26A electrically connect the external sensor arrangement 30, which is connected to the sensor housing 20 at the second interface 5, to the circuit carrier 14. In an alternative embodiment of the sensor assembly 1 without an external sensor arrangement 30 (not shown), the at least one spring element 26 is supported on the cover, which closes the opening 25.

[0029] As from Fig. As can be further seen in Figure 1, in the illustrated embodiment of the sensor assembly 1, a mounting tab 27 is formed on the sensor housing 20. A mounting bushing 28 is overmolded by the mounting tab. To secure the sensor assembly 1, a screw can be passed through the mounting bushing 8 and the sensor assembly 1 can be screwed into place at the installation location.

[0030] As from Fig.6, the illustrated embodiment of a method 100 according to the invention for assembling such a sensor assembly 1 for a vehicle comprises a step S100 in which a sensor housing 20 is provided. Depending on a sensor concept to be implemented and a communication protocol to be implemented, a connector assembly 10 and a circuit carrier 14 are additionally provided in step S100. In a step S110, the connector assembly 10 and the circuit carrier 14 are connected to one another at a first interface 3. In a step S120, the circuit carrier 14 is inserted into an insertion opening 22 of the sensor housing 20 until the connector housing 11 and the sensor housing 20 are connected to one another at a third interface 7 and the circuit carrier 14 is pre-fixed to an end region of the sensor housing 20.In step S130, depending on the sensor concept to be implemented, an external sensor arrangement 30 or a cover is connected to the sensor housing 20 at the second interface 5.

[0031] In addition, before connecting the external sensor assembly 30 or the cover, the at least one spring element 26 is arranged in the region of the third interface 7 between the circuit carrier 14 and the sensor housing 20, so that the spring element 26, in the assembled state, is supported on the external sensor assembly 30 or the cover and presses and fixes the circuit carrier 14 against the at least one guide element 24. The at least one spring element 26 can be attached, for example, to the circuit carrier 14 or to the sensor assembly 30 or to the cover.

Claims

[1] Sensor assembly (1) for a vehicle, comprising a connector assembly (10) comprising a connector housing (11) and at least two connector pins (18) and forming an external interface (9) of the sensor assembly (1), a circuit carrier (14) on which an electronic circuit (16) corresponding to a sensor concept to be implemented is arranged, and a sensor housing (20) comprising an insertion opening (22), wherein the circuit carrier (14) is connected to the connector housing (11) and the at least two connector pins (18) at a first interface (3), wherein the sensor housing (20) comprises a second interface (5) with an opening (25) via which the sensor housing (20) can be connected, depending on the sensor concept to be implemented, to an external sensor arrangement (30) or a cover which covers the opening (25) of the second interface (5) when not in use,wherein the circuit carrier (14) is inserted through the insertion opening (22) into the sensor housing (20), which is connected to the connector housing (11) via a third interface (7), wherein the circuit carrier (14) is pre-fixed to an end region of the sensor housing (20), wherein at least one guide element (24) guides the circuit carrier (14) on a first side and at least one spring element (26) rests on a second side opposite the first side and presses and fixes the circuit carrier (14) against the at least one guide element (24), wherein the first interface (3) and the external interface (9) are designed depending on a communication protocol to be implemented, and wherein the second interface (5) and the third interface (7) are designed identically regardless of the sensor concept and the communication protocol to be implemented. [2] Sensor assembly (1) according to claim 1, characterized bythat the number and arrangement of the at least two connector pins (18) of the connector assembly (10) can be adapted to the communication protocol to be implemented. [3] Sensor assembly (1) according to claim 1 or 2, characterized by that the at least one spring element (26) is arranged in the region of the second interface (5) between the circuit carrier (14) and the sensor housing (20). [4] Sensor assembly (1) according to claim 3, characterized by that the at least one spring element (26) is supported on the external sensor arrangement (30) or on the cover. [5] Sensor assembly (1) according to one of claims 1 to 4, characterized by that the at least one spring element (26) is designed as a contact spring (26A) which electrically connects the external sensor arrangement (30) connected to the sensor housing (20) at the second interface (5) to the circuit carrier (14). [6] Sensor assembly (1) according to one of claims 1 to 5, characterized bythat the at least two connector pins (18) of the connector assembly (10) are pressed into the connector housing (11) and are electrically conductively connected to at least one conductor track structure of the circuit carrier (14). [7] Sensor assembly (1) according to one of claims 1 to 6, characterized by that the plug housing (11) has at least one support element (15) in the region of the first interface (3), against which the circuit carrier (14) rests. [8] Sensor assembly (1) according to one of claims 1 to 7, characterized by that the third interface (7) comprises a circumferential first collar (12) formed on the plug housing (11) and a circumferential second collar (23) formed on the sensor housing (20), which overlap one another in the joined state. [9] Sensor assembly (1) according to one of claims 1 to 6, characterized bythat the external sensor arrangement (30) or the cover and / or the plug housing (20) are connected to the sensor housing (11) in a fluid-tight manner via a welded connection or via an adhesive connection or via a screw connection or via a press-in connection or via a hot-cast connection or via a combination of the said connection techniques. [10] Sensor assembly (1) according to one of claims 1 to 9, characterized by that at least one fastening tab (27) is formed on the sensor housing (20). [11] Method (100) for assembling a sensor assembly (1) for a vehicle, which is designed according to one of claims 1 to 10, wherein a sensor housing (20) and, depending on a sensor concept to be implemented and a communication protocol to be implemented, a plug assembly (10) and a circuit carrier (14) are provided, wherein the plug assembly (10) and the circuit carrier (14) are connected to one another at a first interface (3), wherein the circuit carrier (14) is inserted into an insertion opening (22) of the sensor housing (20) until the plug housing (11) and the sensor housing (20) are connected to one another at a third interface (7) and the circuit carrier (14) is pre-fixed to an end region of the sensor housing (20), wherein, depending on the sensor concept to be implemented, an external sensor arrangement (30) or a cover is connected to the sensor housing (20) at the second interface (5). [12] Method according to claim 11, characterized by that the at least one spring element (26) is arranged in the region of the third interface (7) between the circuit carrier (14) and the sensor housing (20) before the external sensor arrangement (30) or the cover is connected, so that the spring element (26) is supported on the external sensor arrangement (30) or on the cover in the mounted state and presses and fixes the circuit carrier (14) against the at least one guide element (24).

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