Sensor module and system

Abstract

A sensor module (100) is proposed, comprising - a sensor housing (102), - a Hall sensor (104) and a magnet (106), - a movement transmission means (108) which projects from the sensor housing (102) and has a longitudinal axis (L), - wherein the Hall sensor (104) or the magnet (106) is fastened to the movement transmission means (108) for joint movement and the other of the Hall sensor (104) and magnet (106) is arranged stationary with respect to the sensor housing (102), - wherein the sensor housing (102) forms ribs (102.4) which run in the radial direction (R) with respect to the longitudinal axis (L).

Description

[0001] The invention relates to a sensor module according to claim 1 and a system according to claim 10.

[0002] DE 102011 107 819 A1, DE 197 38 316 A1 and also DE 10 2007 062 099 B4 all disclose sensors.

[0003] Hall sensors are known. Electromagnets that use a Hall sensor to sense the armature stroke position are also known. However, Hall sensors typically require a large amount of space, especially when integrated into the electromagnet's housing. Furthermore, such Hall sensors are costly to develop because they represent specific solutions. Furthermore, Hall sensors installed in this way are usually difficult to handle during assembly. Furthermore, due to space constraints, known Hall sensors can have distances between the sensor and the target, which lead to insufficient resolution.

[0004] The invention aims to improve the state of the art accordingly.

[0005] The object is achieved according to the invention with a sensor module according to claim 1 and a system according to claim 10. Refinements are the subject of the embodiments.

[0006] According to the invention, a sensor module is proposed, comprising a sensor housing, a Hall sensor and a magnet, a movement transmission means which protrudes from the sensor housing, wherein the Hall sensor or the magnet is fastened to the movement transmission means for common movement and the other of the Hall sensor and magnet is arranged stationary with respect to the sensor housing.

[0007] Because of its own sensor housing, the sensor module does not need to be integrated into another housing for the component to be sensed, such as an electromagnet housing. The movement and / or position of the component to be sensed can be easily transmitted to the Hall sensor using the motion transmission medium in the sensor housing. The sensor module enables very precise position detection with high resolution due to the close arrangement of the Hall sensor and magnet in the sensor housing. Furthermore, the sensor module can be designed as a single unit, significantly reducing assembly effort. Furthermore, since the sensor module can be mounted outside of another housing, the sensor technology is no longer limited by space constraints within the housing. Furthermore, the sensor module avoids extensive verification and design effort, as it only needs to be designed and verified once and can then be used in a variety of ways.

[0008] This creates a universal and compact sensor module that can be easily attached to the outside of another housing (e.g., to an electromagnet) and can very accurately evaluate the movement and / or position of the component to be sensed (e.g., an armature stroke position).

[0009] The advantages of the sensor module are particularly evident in combination with an electromagnet. The compact sensor module can be attached to the electromagnet housing like a backpack, allowing the position of the armature to be sensed externally using the motion transmission device. Furthermore, the sensor module's inherent scalability allows for minimal design and adaptation effort.

[0010] The magnet can be a permanent magnet. The magnet is the sensor target of the Hall sensor. The Hall sensor and the magnet are arranged in the sensor housing, preferably in every operating position. The Hall sensor and the magnet are arranged so that they can move relative to each other.

[0011] According to a further development, the motion transmission means can be a coupling rod. This advantageously requires only a single component for motion transmission. Furthermore, a rod can be easily scaled in length and / or diameter. Furthermore, a rod can extend deeply into another housing to detect movement there.

[0012] According to a further development, the motion transmission means can carry the Hall sensor or the magnet at one end and have a motion input surface at the other end, preferably on its front side. A motion force can be input into the motion transmission means via the motion input surface. Therefore, the motion transmission means only needs to be as large as necessary. It is conceivable for the motion input surface to be a contact surface. Another component can rest against the contact surface without a connection. Advantageously, no connection is required to input a motion force.

[0013] According to a further development, the motion transmission means can be an injection-molded part that includes the magnet as an insert. Preferably, the motion transmission means is injection-molded around the magnet. This allows the component to be manufactured easily and without the need for tools. Loosening or relative movement of the motion transmission means and the magnet is prevented. The motion transmission means can be a plastic injection-molded part (thermoplastic or thermoset). This is associated with low weight. Furthermore, the magnet in the sensor / magnet pair can advantageously be an insert, as it requires no electrical contacts.

[0014] According to a conceivable development, the motion transmission means can have a longitudinal guide means and / or a rotation-preventing means on the sensor module side. The longitudinal guide means serves to control and guide the motion transmission means in its longitudinal direction. The rotation-preventing means prevents rotation of the motion transmission means about its longitudinal axis. This enables consistently high-quality sensing.

[0015] According to a further development, the Hall sensor and the magnet can be arranged within the sensor housing, preferably across the entire adjustment range of the motion transmission means. This emphasizes the compact and modular design and prevents external influences on the sensor / magnet pair.

[0016] According to a further development, the sensor housing can be formed in one piece, preferably as an injection-molded part. Preferably, the Hall sensor or the magnet can be an insert of the sensor housing. The overmolded component then serves as an insert. If the magnet is already an insert in the motion transmission means, only the Hall sensor can be an insert in the sensor housing. The sensor housing can be a plastic injection-molded part (thermoplastic or thermoset). This results in a low weight. Furthermore, the magnet in the sensor / magnet pair can advantageously be an insert, as it requires no electrical contacts.

[0017] According to a further development, the sensor housing can be bottomless, preferably being an electromagnet housing cover. Since the sensor module is suitable for being arranged externally on or with another housing, it can use the other housing (e.g., electromagnet housing) to close off its own interior space. Therefore, the sensor housing as such can be without a bottom. Advantageously, the sensor housing itself can be a cover of an electromagnet housing. Thus, further weight can be saved by having the electromagnet housing open at one end and the sensor housing open at the bottom, so that both in combination close off an interior space (e.g., armature space).

[0018] It is conceivable for the sensor housing to comprise an annular disc section and a blind hole section. This reduces the installation space requirement, as the annular disc section can be flat, and the blind hole section forms an interior space for accommodating the Hall sensor, magnet, and motion transmission device. The Hall sensor and / or magnet and / or motion transmission device (the latter at least partially) can be arranged in the blind hole section.

[0019] According to the invention, the sensor housing is formed with ribs extending in the radial direction. The reference is the longitudinal axis of the motion transmission means. The ribs serve to stiffen the sensor housing. This allows it to be connected to another housing in a pressure-tight manner and thus withstand internal pressure. This is especially true when the sensor housing seals off the interior of an electromagnet in a pressure-tight manner.

[0020] According to a further development, the sensor housing can carry an electrical contact of the sensor module and / or an electrical contact of an electromagnet. The contact can be an insert. This allows for functional integration into the sensor housing to optimize installation space. It is conceivable for the sensor housing to be formed integrally with a control box. The control box can contain electronic components of the sensor module and / or an electromagnet. This also allows for functional integration into the sensor housing to optimize installation space.

[0021] According to a further development, the sensor housing can be provided with mounting points for attachment to another housing. This reduces design and adaptation effort, as only the mounting points of the sensor housing need to be adapted to the respective other housing. The other housing is a separate housing from the sensor housing.

[0022] According to a conceivable further development, a preloading means can be provided that preloads the motion transmission means in one direction, preferably in a direction facing away from the sensor module. The preloading means can preload the motion transmission means toward the armature. This ensures interaction in every operating state. The preloading means can be a compression spring. The preloading means ensures a defined position relative to the component whose movement is to be sensed. Therefore, the motion transmission means and the component to be sensed do not need to be fastened to one another. The preloading means also serves to compensate for tolerances. The preloading means can be arranged in a receiving pot formed by the motion transmission means, which is structurally simple and saves space. The preloading means can be supported at one end on the sensor housing and at the other end on the motion transmission means, preferably in the receiving pot.

[0023] According to a conceivable further development, the motion transmission device can be loosely applied to a component to be sensed via its motion input surface. Since a fixed connection is no longer necessary, assembly effort is significantly reduced and failure of a fixed connection is avoided from the outset.

[0024] According to a conceivable further development, the sensor module could be a subassembly. It could be assembled in a self-contained manner. It could then be attached to another housing. This reduces assembly effort, as the sensor module can be manufactured separately and independently.

[0025] According to a conceivable development, the sensor housing can have an annular recess in which a core of an electromagnet can be mounted. This allows the sensor module and the electromagnet to reduce the installation space required.

[0026] According to the invention, a system is also proposed, comprising a sensor module according to the disclosure and an electromagnet with an electromagnet housing, wherein the sensor housing is arranged on the end face of the electromagnet housing and the movement transmission means protrudes into the electromagnet housing. This allows the movement of the armature to be tapped from outside the electromagnet housing in a very simple and high-quality manner. The Hall sensor and the magnet are arranged outside the electromagnet housing. The movement transmission means rests on the armature. The sensor housing can be flanged to the electromagnet housing. If the electromagnet housing has plastic components, it can alternatively be ultrasonically and laser welded, or hot-stamped. An end edge of the electromagnet housing can engage around the sensor housing, preferably the annular disk section, on the outer circumference in a flanged manner.The other housing can be the solenoid housing. The solenoid housing and the sensor housing are separate housings.

[0027] According to a conceivable further development, the motion transmission means can extend through a through-bore in the core and into an armature chamber, with its outer diameter being greater than or equal to that in the core region than in the armature chamber region. The motion transmission means can serve to guide the armature spring.

[0028] According to a conceivable further development, the motion transmission means can form a travel limit stop. The travel limit stop can strike the core. It serves to limit the actuating movement and prevents uncontrolled slipping into the electromagnet. The travel limit stop can be formed by a wall of a receiving pot for the preloading means.

[0029] Furthermore, an electromagnet according to the disclosure is conceivable, which is designed to be connected to the sensor module according to the disclosure.

[0030] Further features, details, and advantages of the invention will become apparent from the wording of the claims and from the following description of exemplary embodiments with reference to the drawings. They show: Fig. 1 a longitudinal section through a system in the first state and Fig. 2 a longitudinal sectional view through the system in the second state.

[0031] In the figures, identical or corresponding elements are each designated by the same reference numerals and are therefore not described again unless expedient. Features already described are not described again to avoid repetition and are applicable to all elements with identical or corresponding reference numerals, unless explicitly excluded. The disclosures contained in the entire description are analogously transferable to identical parts with identical reference numerals or identical component designations. The positional information chosen in the description, such as top, bottom, side, etc., also relates to the directly described or illustrated figure and, in the event of a change in position, is to be transferred analogously to the new position.Furthermore, individual features or combinations of features from the different embodiments shown and described can represent independent, inventive or inventive solutions.

[0032] The Fig. 1 and Fig. 2 show a single system 300 comprising a sensor module 100 and an electromagnet 200. The system 300 is traversed by a longitudinal axis L, with a radial direction R perpendicular thereto.

[0033] The sensor module 100 comprises a one-piece sensor housing 102 formed as a plastic injection-molded part. The sensor housing 102 is bottomless on the electromagnetic side and forms an electromagnet housing cover 102.1 as a separate housing. The sensor housing 102 comprises an annular disc section 102.2 and a blind hole section 102.3, with the annular disc section 102.2 forming ribs 102.4 extending in the radial direction R. The sensor housing 102 supports an electrical contact 112 of the sensor module 100 and an electrical contact 212 of the electromagnet 200. The sensor housing 102 is formed integrally with a control box 120, which contains electronic components of the sensor module 100 and / or the electromagnet 200. Furthermore, the sensor housing 102 forms a longitudinal guide means 114 in the form of a longitudinal rib in the blind hole section 102.3, which engages in a corresponding longitudinal groove 108.2 in a movement transmission means 108.The sensor housing 102 has an annular recess 124 in which a core 206 of the electromagnet 200 is fastened.

[0034] The sensor module 100 also includes a Hall sensor 104, which is fixedly arranged relative to the sensor housing 102, as it is contained therein as an insert. The Hall sensor 104 is located in the blind hole section 102.3.

[0035] The sensor module 100 further includes a magnet 106, which is a permanent magnet and represents the sensor target for the Hall sensor 104. The magnet 106 is also located in the blind hole section 102.3, but is movable relative to the Hall sensor 104.

[0036] The sensor module 100 further comprises the motion transmission means 108 in the form of a coupling rod 108.1. The motion transmission means 108 is a plastic injection-molded part, with the magnet 106 being an insert thereof. At one end, the motion transmission means 108 carries the magnet 106, and at the opposite end along the longitudinal axis L, a motion input surface 110 is formed on the front side. The motion input surface 110 is a contact surface, as it rests loosely and without connection against an armature 204 of the electromagnet 200. The motion transmission means 108 protrudes from the sensor housing 102 and into the electromagnet 200. The motion transmission means 108 forms a receiving pot 122 arranged in the blind hole section 102.3. The motion transmission means 108 forms a travel limit stop 108.3.

[0037] The sensor module 100 also includes a preloading means 118 in the form of a compression spring 118.1, which preloads the motion transmission means 108 in a direction D facing away from the sensor module 100. The preloading means 118 is arranged in the receiving pot 122 and is supported at one end on the sensor housing 102 and at the other end on the motion transmission means 108.

[0038] The electromagnet 200 comprises an electromagnet housing 202, in which an armature 204 with armature rod 204.1 is movably mounted along the longitudinal axis L. Adjacent to this is the core 206 with its through-bore 206.1, through which the motion transmission means 108 extends. A coil 210 is carried by a coil carrier 208, which can be selectively energized to adjust the armature 206 along the adjustment path W. An armature spring 214 is supported between the core 206 and the armature 204 for its extension. The armature 206 is located in an armature chamber 216.

[0039] The sensor housing 102 is arranged on the end face of the electromagnet housing 202 and seals the interior of an electromagnet 200 in a pressure-tight manner. The Hall sensor 104 and the magnet 106 are arranged within the sensor housing 102 over the entire adjustment range W. The Hall sensor 104 and the magnet 106 are arranged outside the electromagnet housing 202. The motion transmission means 108 has an outer diameter in the area of ​​the core 206 that is greater than or equal to that in the area of ​​the armature space 216. The travel limit stop 108.3 can strike against the core 206.

[0040] The invention is not limited to one of the above-described embodiments, but can be modified in a variety of ways. All features and advantages apparent from the claims, the description, and the drawings, including structural details, spatial arrangements, and method steps, may be essential to the invention both individually and in a wide variety of combinations.

[0041] The scope of the invention includes all combinations of at least two of the features disclosed in the description, the claims and / or the figures.

[0042] To avoid repetition, features disclosed by the device should also be considered as disclosed by the method and claimable. Likewise, features disclosed by the method should also be considered as disclosed by the device and claimable. List of reference symbols 100 sensor modules 102 sensor housings 102.1 Solenoid housing cover 102.2 Ring disc section 102.3 Blind hole section 102.4 Rib 104 Hall sensor 106 Magnet 106.1 Through hole 108 Motion transmission devices 108.1 Coupling rod 108.2 Longitudinal groove 108.3 Travel limit stop 110 movement entry area 112 Contact 114 Longitudinal guidance devices 118 preloading devices 118.1 Compression spring 120 control box 122 receiving pot 200 electromagnet 202 Electromagnet housing 204 anchors 204.1 Anchor rod 206 core 208 coil carriers 210 coil 212 Contact 214 Anchor spring 216 Anchor room 300 system D direction L Longitudinal axis R Radial direction W Adjustment range

Claims

[1] Sensor module (100), comprising - a sensor housing (102), - a Hall sensor (104) and a magnet (106), - a motion transmission means (108) which protrudes from the sensor housing (102) and has a longitudinal axis (L), - wherein the Hall sensor (104) or the magnet (106) is attached to the movement transmission means (108) for common movement and the other of the Hall sensor (104) and the magnet (106) is arranged stationary with respect to the sensor housing (102), - wherein the sensor housing (102) forms ribs (102.4) extending in the radial direction (R) with respect to the longitudinal axis (L). [2] Sensor module (100) according to claim 1, characterized by that the movement transmission means (108) is a coupling rod (108.1). [3] Sensor module (100) according to one of the preceding claims, characterized bythat the movement transmission means (108) carries the Hall sensor (104) or the magnet (106) at one end and has a movement input surface (110) at the other end, preferably on its front side. [4] Sensor module (100) according to one of the preceding claims, characterized by that the motion transmission means (108) is an injection-molded part which includes the magnet (106) as an insert. [5] Sensor module (100) according to one of the preceding claims, characterized by that the Hall sensor (104) and the magnet (106) are arranged within the sensor housing (102), preferably over an entire adjustment path (W) of the movement transmission means (108). [6] Sensor module (100) according to one of the preceding claims, characterized by that the sensor housing (102) is formed in one piece, preferably is an injection-molded part, preferably the Hall sensor (104) or the magnet (106) is an insert of the sensor housing (102). [7] Sensor module (100) according to one of the preceding claims, characterized by that the sensor housing (102) is bottomless, preferably an electromagnet housing cover (102.1). [8] Sensor module (100) according to one of the preceding claims, characterized by that the sensor housing (102) carries an electrical contact (112) of the sensor module (100) and / or carries an electrical contact (212) of an electromagnet (200). [9] Sensor module (100) according to one of the preceding claims, characterized by that the sensor housing (102) forms fastening points for fastening to another housing. [10] System (300), comprising - a sensor module (100) according to one of the preceding claims and - an electromagnet (200) with an electromagnet housing (202), - wherein the sensor housing (102) is arranged on the front side of the electromagnet housing (202) and - the movement transmission means (108) projects into the electromagnet housing (202).

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