Mounting unit for a radar proximity sensor with elastic deformation element

Abstract

A mounting unit (10) for a radar proximity sensor (50) is provided, comprising a mounting body (20) with a through-opening (24) forming the signal exit area; a deformation element (30, 130) which can be inserted into the through-opening (24) in a form-fitting manner and is made of an elastic material in order to shield external forces acting on the radar proximity sensor (50) and to distribute the acting force over the entire surface of the radar proximity sensor (50) onto the fastening body (20), wherein the fastening body (10) has a resiliently elastic shape in order to convert the acting force into movement and deformation and to dampen it, wherein the fastening body (20) is connected to a fixed bearing in order to compensate for the force effect, wherein the fastening body (20) is designed to receive the radar proximity sensor (50), wherein the radar proximity sensor (50) can be mounted on the fastening body (20).

Description

[0001] The invention relates to a fastening unit for a radar proximity sensor with an elastic deformation element for impact shielding and distribution, as well as a method for protecting a radar proximity sensor.

[0002] Radar proximity sensors are known from the state of the art in a wide variety of applications. Particularly in industrial applications and automation technology, radar proximity sensors are used to monitor a work area or measure distances. If an object is detected in the detection range, the radar proximity sensor emits a switching signal that is forwarded to a higher-level unit, such as a controller (e.g., a PLC).

[0003] Such a radar proximity sensor is known, for example, from DE102021116537A1.

[0004] A radar proximity sensor determines the distance, position, speed and direction of movement of objects, e.g. based on FMCW radar (frequency modulated continuous wave).

[0005] The sensor emits high-frequency electromagnetic waves, which are reflected by an object. The reflected energy is picked up and evaluated by the device's receiver antenna.

[0006] The application areas for radar proximity sensors are very diverse, e.g. detection of conditions, recording the loading height and speed of bulk material on conveyor belts, collision avoidance by detecting obstacles in the movement area of a vehicle, intelligent access control by means of automatic opening / closing of gates or barriers, etc.

[0007] Over the course of the development of automation technology, the requirements regarding impact and shock resistance have steadily increased. According to ATEX directives and European Union standards, the housing must be able to withstand impact and shock energy of up to 7 joules. This requires either very robust housings, for example, made of stainless steel, or the desired impact and shock resistance can be achieved through supplied additional devices such as protective covers, protective caps, or similar protective structures.

[0008] A proximity switch with an impact and shock absorption device that effectively compensates for shocks and impacts on the device is known from DE102012223261A1.

[0009] Many applications require the housing of such a radar proximity sensor to be dust-proof and waterproof (IP67) and to have a high level of mechanical strength. Plastics are often used as the housing material. In particular, a surface or a portion of a surface of the housing where the radar transmission signal exits or the reflected portion of the radar transmission signal (radar reception signal) re-enters the housing, i.e. the active sensor surface, is made of thin-walled plastic. The disadvantage of this design is that external forces such as impacts or shocks can cause the housing to break.

[0010] To avoid attenuating the transmitted and received signals of a radar proximity sensor, protective hoods, caps, or similar protective structures are often omitted in the area above the radome, i.e., in the active transmit / receive range of the radar sensor. This results in the radome's impact protection being inadequately designed according to ATEX guidelines, so that ATEX certification for radar proximity sensors of this type cannot be achieved.

[0011] Protective devices used to protect radar proximity sensors from impact often consist of multiple parts. The manufacture and assembly of such protective devices is complex and expensive.

[0012] An object of the invention is to overcome the above-mentioned disadvantages of the prior art and to provide a mounting unit for a radar proximity sensor which enables simple mounting and, at the same time, robust operation of the radar proximity sensor.

[0013] The object is achieved by the fastening unit having the features of claim 1 and with regard to the method for protecting a radar proximity sensor having the features of claim 10.

[0014] Advantageous embodiments of the invention are specified in the dependent claims.

[0015] The present invention relates to an impact protection device and a mounting unit for a radar proximity sensor. To protect the radar proximity sensor from impacts, an elastic, and thus shock-absorbing, metal housing is proposed, which also serves as a mounting unit.

[0016] According to one aspect, the object of the invention is achieved by a fastening unit with a deformation element which is inserted in a form-fitting manner into a through-opening of the fastening unit.

[0017] The mounting unit comprises a mounting body and a deformation element. The mounting body has a through-hole into which the deformation element is inserted with a form-fitting fit. The through-hole forms the signal exit area of the mounting unit, into which an elastic deformation element, i.e., an elastic insert made of, for example, rubber or plastic (elastomer), can be inserted. This insert serves to shield the device from external forces, i.e., impact and vibration, and to distribute the applied force across the radar proximity sensor onto the mounting body.

[0018] Advantageously, the insert is designed in such a way that it can be inserted into the through-opening by hand so that it can be replaced if necessary, e.g. if it is damaged.

[0019] The deformation element is preferably made of a radar-permeable elastomer (PU), e.g., thermoplastic polyurethane. PU is a thermoplastic material characterized by its high elasticity, strength, and processability. PU is particularly suitable due to its high abrasion resistance, high temperature resistance, and chemical resistance.

[0020] The mounting body is designed to accommodate the radar proximity sensor. Furthermore, the radar proximity sensor can be mounted to the mounting body using fastening means, e.g., a screw connection.

[0021] The resilient mounting unit absorbs impacts to the functional surface of the radar proximity sensor, partially converting the impact energy into movement and deformation. The remaining impact initially deforms the insert and is then distributed evenly across the radar proximity sensor to the mounting unit. This dampens impacts on the radar proximity sensor, and the device is protected from damage by the mounting body and insert.

[0022] The mounting unit acts as an additional housing for the radar proximity sensor and does not affect the tightness of the device.

[0023] In addition, the radar proximity sensor's cable connection is largely covered by the mounting unit, improving impact protection, and any indicators on the radar proximity sensor remain visible through the open, perforated enclosure. This allows the mounting unit to be used in a variety of environments and applications without limiting the radar proximity sensor's functionality.

[0024] Advantageously, the openings of the fastening unit have a light-conducting insert or clearances to enable and improve the visibility of displays, e.g. LEDs of the radar proximity sensor.

[0025] The fastening body preferably consists of a U-shaped sheet metal part. The U-shape allows for better distribution of the impact energy. The sheet metal part converts the impact energy into kinetic and deformation energy, effectively attenuating the remaining impact energy acting on the radar proximity sensor.

[0026] In a preferred embodiment, the fastening body consists of a single sheet metal part. The fastening body has a base with a through-hole, on which tabs are arranged. The tabs have axially concentric bores through which fastening means can be inserted, via which the radar proximity sensor can be attached to a fixed bearing.

[0027] The mounting body forms a robust and durable structure that protects the radar proximity sensor from mechanical damage and extends the service life of the entire system.

[0028] Advantageously, the deformation element is designed to be insertable into the through-hole by means of a form-fitting mechanism and is replaceable. The replaceable deformation element allows for quick and easy replacement in the event of damage, without having to replace the entire fastening unit. This saves time and money.

[0029] A lateral extension of the deformation element has the technical advantage that structures can be attached to the extended extension, which can be coupled to the mounting body to dampen oscillations or vibrations that occur during operation of the radar proximity sensor and interfere with the radar proximity sensor's measurements. For this purpose, the extension has a section on which a rib-like structure is formed on an upper side facing away from the radar proximity sensor. This rib-like structure has at least one rib with a coupling surface, via which the deformation element is connected to the inside of the mounting body in a vibration-damping manner.

[0030] To enhance the damping, the rib-like structure is advantageously formed from a plurality of adjacent ribs, each of which is connected to the mounting body via its coupling surface to provide vibration-damping properties. This design improves measurement quality and increases the system's robustness against external forces.

[0031] In a technically advantageous embodiment of the fastening unit, the rib-like structure comprises the shape of a curved elongated hole with a radius that arises from the flat shape of the deformation element, wherein the radius results from a circle around a pivot point of the fastening body. The fastening body has a corresponding elongated hole in the form of an opening or a recess into which the rib-like structure is inserted. The circumference of the rib-like structure in the shape of an elongated hole forms a coupling surface with which the deformation element is connected to the fastening body in a vibration-damping manner.

[0032] The elongated hole design creates a larger coupling surface, which increases damping. Furthermore, the curved shape of the elongated hole around the pivot point of the mounting body reduces the deformation forces and vibrations acting around the pivot point. The curved shape of the elongated hole achieves greater damping. This design reinforces and improves measurement quality and increases the robustness of the system against external forces.

[0033] The invention is explained in more detail below using exemplary embodiments with reference to the drawings.

[0034] In the following description of the preferred embodiments, like reference numerals designate like or comparable components.

[0035] They show schematically: Fig. 1a a mounting unit for a radar proximity sensor in a sectional view; Fig. 1b the fastening unit according to Fig. 1a in another sectional view; Fig. 2 the fastening unit according to Fig. 1a or Fig. 1b in a perspective view; Fig. 3a a deformation element according to Fig. 1a or Fig. 1b in a side view; Fig. 3b the deformation element according to Fig. 3a in a perspective view; Fig. 4a is a perspective view of a mounting unit for a radar proximity sensor; Fig. 4b the fastening unit according to Fig. 4a in a side view; Fig. 5a a deformation element according to Fig. 4a or Fig. 4b in a side view; Fig. 5b the deformation element according to 5a in a perspective view.

[0036] Fig. 1a shows a radar proximity sensor 50 with a mounting unit 10 according to the invention. The radar proximity sensor 50 is attached to the mounting unit 10 via fastening means 48. Due to the shape of the mounting unit 10, the radar proximity sensor is protected against external forces such as impacts or vibrations that act on the device 50 from the outside during operation of the radar proximity sensor 50. The mounting unit 10 consists of a mounting body 20, which has resilient elastic properties due to its shape, and a deformation element 30, which is inserted into a through-opening 24 of the mounting body 20. The through-opening 24 is arranged on a base surface G of the mounting body 20. The mounting body 20 consists of a formed sheet metal part and has a U-shape. For this purpose, tabs 42 are arranged on the edges of the base surface G.The radar proximity sensor 50 is incorporated into the U-shape so that at least three side surfaces of the radar proximity sensor are covered by the U-shape. The impact energy is better distributed due to the U-shape. The sheet metal part converts the impact energy into movement and deformation energy and reduces the impact energy remaining on the radar proximity sensor. The deformation element 30 is made of an elastic material. Preferably, the elastic material consists of a radar-permeable elastomer PU. PU is a thermoplastic material characterized by its high elasticity, strength, and processability. PU is particularly suitable due to its high abrasion resistance, its high temperature resistance, and its chemical resistance. The resilient fastening unit 10 dampens an impact on the functional top side of the radar proximity sensor 50 and converts the impact energy into movement and deformation.The remaining impact initially deforms the insert 30 and is then distributed over the radar proximity sensor 50 onto the mounting unit 10 or the mounting body 20. The deformation element 30 is connected to the radar proximity sensor 50. This attenuates impacts acting on the radar proximity sensor 50. Furthermore, the mounting unit 10 is coupled to a fixed bearing to transmit vibrations and impacts to the fixed bearing.

[0037] Fig. 1b shows the fastening unit 10 according to Fig. 1a in a further sectional view. The deformation element 30 is inserted into the through-opening 24 of the fastening body 20. A part of the deformation element 30 protrudes from the through-opening 24, which part is laterally extended. This extension forms a section 33 on which a rib-like structure 36 is formed on an upper side facing away from the radar proximity sensor 50. The rib-like structure 36 has a coupling surface K, via which the deformation element 30 is connected to the sheet metal part 20, so that oscillations that arise at the fastening unit during operation, in particular vibrations or natural resonances, are suppressed and compensated.

[0038] In Fig. 2, the fastening unit 10 is according to Fig. 1a or Fig. 1b in a perspective view. The deformation element 30 is inserted into the through-opening 24 of the fastening body 20, such that the through-opening 24 is completely filled by the deformation element 30. The radar proximity sensor 50 is inserted into the fastening unit 10 and fastened to the fastening body 20 by means of fastening means 48. To protect the cable connection of the radar proximity sensor 50, the fastening body 20 covers the cable connection. Furthermore, axially concentric bores are provided on the tabs 42 of the fastening body 20, through which fastening means 48 can be inserted, via which the cable connection is protected from external forces, e.g., from impacts on the cable connection. Displays on the radar proximity sensor remain visible through the open fastening body provided with cutouts 55. The cutouts 55 can be filled with a light-conducting insert 54.This improves the visibility of the radar proximity sensor displays even through the mounting unit.

[0039] Fig. 3a shows the deformation element 30 according to Fig. 1a or Fig. 1b in a side view. Fig. 3b shows the deformation element 30 according to Fig. 3a in a perspective view. The deformation element 30 is made of an elastic material and can be inserted into the through-opening 24 with a form-fitting fit. Due to its elastic properties, external forces such as impacts or vibrations acting on the radar proximity sensor 50 are attenuated. Furthermore, the deformation element 30 is radar-permeable, so that a sufficiently strong radar signal from the radar proximity sensor 50 is sent and received through the deformation element 30. The deformation element 30 is flat and has a stepped elevation 32 on its upper side, which is shaped such that it can be inserted into the through-opening 24 of the fastening body 20. When inserted into the fastening body 20, the stepped elevation 32 completely fills the through-opening 24.To prevent the formation of moisture, fogging, or dirt on the radome, the stepped elevation 32 has a circumferential sealing contour 34. During assembly of the radar proximity sensor 50, the sealing contour 34 is compressed, so that a force acts on the outer edge of the flat support, which protects the radome surface from the penetration of moisture or dirt. The radar proximity sensor 50 rests flat against the underside of the deformation element 30. The deformation element 30 is laterally extended to one side. The extension has a constriction 38 and a section 33, on the upper side of which a rib-like structure 36 is formed. In one embodiment, the rib-like structure 36 has at least one rib with a coupling surface K. The deformation element 30 is connected to a surface of the fastening body 20 via the coupling surface K in a vibration-damping manner.The coupling surface K and the flat contact of the deformation element 30 with the housing surfaces of the radar proximity sensor dampen vibrations or natural oscillations of the system that occur during operation. Furthermore, the rib-like structure can be designed as shown in . Fig. 3b, it can be formed from a plurality of ribs arranged next to one another, each of which can be connected to the fastening body 20 via its coupling surface K in a vibration-damping manner and suppress vibrations and natural resonances during operation of the radar proximity sensor 50.

[0040] Fig. 4a shows a perspective view of a technically advantageous embodiment of a fastening unit 10 for a radar proximity sensor 50 according to Fig. 1. In contrast to Fig. 1, the deformation element 130 has a coupling surface K designed like a slot.

[0041] Fig. 4b shows the fastening unit 10 according to Fig. 4a in a side view. The deformation element 130 has a rib-like structure in the form of a curved elongated hole with a radius that protrudes from the flat shape of the deformation element 130, wherein the radius results from a circle around a pivot point P of the fastening body. The fastening body 20 has a corresponding elongated hole in the form of an opening into which the rib-like structure is inserted. The circumference of the rib-like structure in the form of an elongated hole forms a coupling surface K, via which the deformation element 130 is connected to the fastening body 20 in a vibration-damping manner. The elongated hole shape achieves a larger coupling surface K, thereby increasing the damping. Furthermore, the shape of the elongated hole, which is curved around the pivot point P of the fastening body 20, reduces the deformation forces and vibrations acting around the pivot point P. The curved elongated hole shape increases the damping.

[0042] Fig. 5a shows the deformation element according to Fig. 4a or Fig. 4b in a side view. The rib-like structure and the stepped elevation rise from the flat shape of the deformation element 30. The deformation element 130 is made of an elastic material and can be inserted into the through-opening 24 with a form-fitting fit. Due to its elastic properties, external forces such as impacts or vibrations acting on the radar proximity sensor 50 are attenuated. Furthermore, the deformation element 130 is radar-permeable, so that a sufficiently strong radar signal from the radar proximity sensor 50 is transmitted through the deformation element 130 and received. The deformation element 130 is essentially flat and has a stepped elevation 32 on its upper side, which is shaped such that it can be inserted into the through-opening 24 of the fastening body 20. When inserted into the fastening body 20, the stepped elevation 32 completely fills the through opening 24.To prevent moisture buildup, fogging, or dirt on the radome, the stepped elevation 32 has a circumferential sealing contour 34. During assembly of the radar proximity sensor 50, the sealing contour 34 is compressed, so that a force acts on the outer edge of the flat support, which protects the radome surface from the penetration of moisture or dirt. The radar proximity sensor 50 rests flat against the underside of the deformation element 130. The deformation element 130 is laterally extended to one side. The extension has a section 33 on which a rib-like structure 36 is formed on the upper side. The circumference of the rib-like structure forms a coupling surface K with which the deformation element 130 is connected to the fastening body 20 in a vibration-damping manner.The coupling surface K and the flat contact of the deformation element 130 with the housing surfaces of the radar proximity sensor dampen vibrations or natural oscillations of the system that occur during operation. To increase the contact of the deformation element 130 with the mounting body 20 and ensure contact even in the event of severe deformation, the extension is angled at its end.

[0043] In addition to the slot-shaped structure, the deformation element 130 can also have further rib structures. Furthermore, the rib-like structure can be formed from a plurality of adjacently arranged ribs, each of which can be connected to the fastening body 20 via its coupling surface K in a vibration-damping manner in order to suppress vibrations and natural resonances during operation of the radar proximity sensor 50.

[0044] Fig.Figure 5b shows the deformation element according to Figure 5a in a perspective view. The deformation element 130 has a rib-like structure in the form of a curved elongated hole with a radius on one side, which protrudes from the flat shape of the deformation element 130. The periphery of the rib-like structure in the form of an elongated hole forms a coupling surface K with which the deformation element 130 is connected to the fastening body 20 in a vibration-damping manner. The present invention offers a cost-effective and simple solution by using an open fastening body 20 with a deformation element 30 as impact protection and as the fastening unit 10. The housing thus formed protects the device 50 from damage and impacts and suppresses vibrations and natural resonances in the assembled system.

[0045] Furthermore, the invention shows a method for protecting a radar proximity sensor 50 from external forces, comprising the steps of: providing the fastening unit 10 according to the invention; introducing the deformation element 30, 130 into the through-opening 24 of the fastening body 20 such that the deformation element 30, 130 completely fills the through-opening; attaching the fastening unit 10 to a radar proximity sensor 50 such that the deformation element 30, 130 is positioned in the region of the signal exit; ensuring that at least one rib of the deformation element 30, 130 is connected to the sheet metal part 20 in a vibration-damping manner in order to suppress vibrations and natural resonances during operation of the radar proximity sensor 50.

[0046] In particular, the fastening unit 10 protects the fragile radar top surface from destruction or breakage.

[0047] The invention makes it possible to meet the impact and shock resistance requirements of the ATEX directives and EU standards without the use of complex and expensive additional equipment. The mounting unit 10 is easy to install and is resistant to contamination.

[0048] It should be noted that the above-described embodiments of the invention are merely exemplary, and various modifications and variations are possible within the scope of the invention. For example, the invention may be embodied in different sizes and other shapes to meet the requirements of different applications. List of reference symbols 10 Mounting unit 20 fastening bodies 24 passage opening 30 deformation element 32 stepped elevation Section 33 34 Sealing contour 36 rib-like structure 38 Constriction 42 tab 48 fasteners 50 radar proximity sensor 54 light-conducting insert 55 Postage 130 Deformation element G Floor area K coupling surface P pivot point PU elastomer

Claims

[1] Mounting unit (10) for a radar proximity sensor (50), comprising: a fastening body (20) with a through opening (24) forming the signal exit area; a deformation element (30, 130) which can be inserted into the through-opening (24) in a form-fitting manner and consists of an elastic material in order to shield external forces acting on the radar proximity sensor (50) and to distribute the acting force over the entire surface of the radar proximity sensor (50) onto the fastening body (20), wherein the fastening body (10) has a resilient elastic shape in order to convert the acting force into movement and deformation and to dampen, wherein the fastening body (20) is connected to a fixed bearing to compensate for the force effect, wherein the fastening body (20) is designed to receive the radar proximity sensor (50), wherein the radar proximity sensor (50) is mountable to the mounting body (20). [2] Fastening unit according to claim 1, wherein the elastic material of the deformation element (30) consists of a radar-permeable elastomer (PU). [3] Fastening unit (10) according to one of the preceding claims, wherein the fastening body (20) consists of a sheet metal part. [4] Mounting unit (10) according to one of the preceding claims, wherein the mounting unit (10) is designed so that it does not affect the tightness of the radar proximity sensor (50). [5] Mounting unit (10) according to one of the preceding claims, wherein the mounting unit (10) covers a cable connection of the radar proximity sensor (50). [6] Fastening unit (10) according to one of the preceding claims, characterized byin that the deformation element (30, 130) is laterally extended and the extension has a section (33) on which a rib-like structure (36) is formed on an upper side facing away from the radar proximity sensor (50), which structure has at least one rib with a coupling surface (K) via which the deformation element (30, 130) is connected to the inside of the fastening body (20) in a vibration-damping manner. [7] Fastening unit (10) according to one of the preceding claims, characterized by that the rib-like structure (36) is formed from a plurality of ribs arranged next to one another, each of which is connected to the fastening body (20) in a vibration-damping manner via its coupling surface (K). [8] Fastening unit (10) according to claim 6, wherein the rib-like structure (36) has the shape of a curved elongated hole with a radius, the radius resulting from a circle around a pivot point (P) of the fastening body (20) and the fastening body (20) has a corresponding elongated hole into which the rib-like structure (36) is inserted, the circumference of the rib-like structure (36) forming the coupling surface (K). [9] Mounting unit (10) according to one of the preceding claims, wherein the mounting unit (10) has a light-conducting insert (54) or cutouts (55) to enable visibility of displays of the radar proximity sensor. [10] A method for protecting a radar proximity sensor (50) from external forces, comprising the steps of: - Providing a fastening unit (10) according to one of claims 1 to 9; - introducing the deformation element (30, 130) into the through-opening (24) of the fastening body (20) so that the deformation element (30) completely fills the through-opening; - attaching the fastening unit (10) to a radar proximity sensor (50) so that the deformation element (30, 130) is positioned in the region of the signal exit; - Ensure that at least one rib of the deformation element (30, 130) is connected to the fastening body (20) consisting of a shaped sheet metal part in a vibration-damping manner.

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