Sensor module, actuating device

Abstract

The invention relates to a sensor module (50) for an actuating device (1) of a motor vehicle, comprising a plate-shaped sensor element (51), in particular one that can be assigned or is assigned to an actuating element of the actuating device (1), comprising a sensor housing (52), wherein the sensor housing (52) has at least a first cylindrical housing part (53), wherein the sensor element (51) is mounted in the first housing part (53) for longitudinal displacement, and comprising at least one force sensor element (55) assigned to the sensor element (51) for detecting a force exerted on the sensor element (51), in particular by means of the actuating element, and / or at least one displacement sensor element (56) assigned to the sensor element (51) for detecting a displacement path of the sensor element (51).

Description

[0001] The invention relates to a sensor module for an actuating device of a motor vehicle and to an actuating device with such a sensor module. State of the art

[0002] It is known from the prior art to detect the actuation of an actuating device for a motor vehicle that can be actuated by a driver using a sensor assigned to the actuating device. If the driver actuates the actuating device, the driver's braking or acceleration request is recognized as a function of this. For example, braking systems with electromechanical brake boosters are known which, together with a vehicle assistance system, in particular an electronic stability program (ESP), form a redundant "brake-by-wire" system in which there is no mechanical connection between the actuating device and the braking system. A braking request is forwarded, for example, depending on the actuation of the actuating device, to an electromechanical actuator that is designed to build up pressure in the braking system.

[0003] Similarly, actuating devices for drive units, particularly those with internal combustion engines and / or electric motors, of motor vehicles are known. These actuating devices are part of a drive-by-wire system without a mechanical connection to the drive unit. For example, an acceleration request is detected based on actuation of the actuating device and forwarded to the drive unit. Due to the lack of mechanical coupling of the actuating devices to the braking system and / or drive unit, it is possible to design such actuating devices with zero travel or at least with only a small stroke of a few millimeters. Various measurement methods are known for detecting actuation.

[0004] For example, from the applicant's as yet unpublished application DE 10 2022 212 470.7, such an actuating device is known, which has a first and a second housing part, wherein the first housing part is mounted on the second housing part so as to be displaceable in the vertical extent of the second housing part, wherein the first housing part has an actuating surface on an upper side facing away from the second housing part or wherein a cover with the actuating surface is arranged on the upper side, wherein a sensor arrangement for detecting an actuation of the actuating device, in particular an actuating force exerted on the actuating surface, is arranged in the second housing part, and wherein a partition wall is formed or arranged in the second housing part, which partition wall forms a chamber with the second housing part in order to enclose at least one component of the sensor arrangement in a media-tight manner.

[0005] From the applicant's application DE 10 2022 212 450.2, which has also not yet been published, a matching sensor arrangement is known which has a force transmission element, in particular assignable or assigned to the actuating surface of the actuating device, for transmitting an actuating force exerted on the actuating device, in particular on the actuating surface, and a measuring head arranged in a printed circuit board, wherein the measuring head has a measuring membrane, and wherein the measuring membrane has a force sensor element at one end and is assigned to the force transmission element at the other end. Disclosure of the invention

[0006] The sensor module according to the invention with the features of claim 1 is characterized in that it comprises a plate-shaped sensor element, in particular one that can be assigned or is assigned to an actuating element of the actuating device, a sensor housing, wherein the sensor housing has at least a first cylindrical housing part, wherein the sensor element is mounted for longitudinal displacement in the first housing part, and at least one force sensor element assigned to the sensor element for detecting a force exerted on the sensor element, in particular by means of the actuating element, and / or at least one displacement sensor element assigned to the sensor element for detecting a displacement of the sensor element. This creates a particularly advantageous possibility for the flexible use of the sensor module in the corresponding actuating device.In contrast to the initially mentioned sensor arrangement of the applicant, the sensor module according to the invention comprises, in particular, the plate-shaped sensor element mounted longitudinally displaceably in the housing part, which can be used or is used advantageously both for directly transmitting an actuating force exerted on the actuating device (the sensor element then serves as a force transmission element) and for transmitting a displacement of the actuating device (the sensor element then serves as a displacement transmission element). The sensor module can thus be manufactured and assembled independently of the actuating device and can be easily inserted into the actuating device as a pre-assembly group, i.e., as a finished module. The force sensor element, in particular, comprises strain gauges.

[0007] According to a preferred development of the invention, the first housing part has on its inner side at least one groove running along its longitudinal extent and / or one web, in particular at least two grooves and / or webs arranged distributed over the circumference of the inner side, for example diametrically opposite one another, in and / or on which the sensor element is guided. Such grooves and / or webs create a geometrically particularly advantageously simple possibility for guiding the sensor element, so that the sensor element is designed as a movable carriage. For this purpose, the sensor element is preferably assigned with one longitudinal side to the respective groove or web, in particular inserted into the respective groove or placed on the respective web. For this purpose, the sensor element preferably has a groove on the longitudinal side with an inner contour corresponding to the respective outer contour of the web.In particular, the sensor element is guided in or on the groove or web with or without play.

[0008] It is particularly preferred that the sensor module has at least one first spring element, in particular a helical spring, and that the sensor element is operatively connected to the force sensor element by means of the first spring element and / or is supported on the sensor housing, wherein, in particular, the sensor element protrudes from the first housing part at least in an unactuated rest position of the spring element. The first spring element provides the advantage that an actuating force exerted on the actuating device is transmitted particularly easily and reliably to the force sensor element and / or is supported on the sensor housing.If the sensor element additionally protrudes from the first housing part in the rest position, further assembly advantages arise because the sensor module can then be arranged particularly easily in or on the actuating device, for example by the protruding sensor element being assigned to a correspondingly displaceable housing part of the actuating device, in particular by being able to be arranged or arranged adjacent to this. Preferably, the spring element is designed to press the sensor element against an actuating element of the actuating device in order to receive the driver's input via this. Particularly preferably, the spring element is designed to serve as a return spring, for example as additional redundancy for a main return spring in order to replace it in the event of a defect, for example if it is broken, and to move the corresponding displaceable housing part of the actuating device back to an initial position.This also advantageously prevents the sensor element from falling towards the force sensor element and / or the sensor housing if the corresponding main return spring is defective, and an emergency braking or full throttle is sensed even without a driver request.

[0009] According to a preferred development of the invention, it is provided that the first spring element can be or is pushed with a first end at least partially onto a projection of the sensor element. By pushing the spring element onto the projection in this way, it is advantageously ensured that the spring element is securely fixed in its position on the sensor element. For example, the spring element is designed as a helical spring. Thus, at least in the assembled state of the sensor module, the spring element is held in a form-fitting manner because the projection projects into the spring element. The projection has, in particular, an outer contour that geometrically corresponds to an interior of the helical spring, wherein the helical spring is then held on the projection in particular without play.For example, the coil spring is pushed onto the projection with frictional engagement; alternatively, a predetermined clearance is provided between the interior of the coil spring and the outer contour of the projection to simplify assembly.

[0010] It is particularly preferably provided that the first spring element can be or is pushed with a second end at least partially onto a projection of a further sensor element operatively connected to the force sensor element. By pushing the spring element onto the projection in this way, it is advantageously ensured that the spring element is securely fixed in its position on the sensor element and in relation to the force sensor element. For example, the spring element is designed as a helical spring. Thus, at least in the assembled state of the sensor module, the spring element is held in a form-fitting manner because the projection projects into the spring element. The projection has, in particular, an outer contour that geometrically corresponds to an interior of the helical spring, wherein the helical spring is then held on the projection in particular without play.For example, the coil spring is frictionally slid onto the projection; alternatively, a predetermined clearance is provided between the interior of the coil spring and the outer contour of the projection to simplify assembly. The force sensor element is designed, in particular, as described in the applicant's previously known prior art.

[0011] According to a preferred development of the invention, a sensor element, in particular a magnetic element, is arranged on the sensor element and is assigned to the displacement sensor element, in particular having a Hall sensor. Such a sensor element assigned to the displacement sensor element advantageously ensures that a displacement of the sensor element is reliably detected by the displacement sensor element. For example, a magnetic element designed as a permanent magnet is provided, which is arranged on a longitudinal side of the sensor element and is connected thereto in a form-fitting, non-positive and / or material-fitting manner. The displacement sensor element is then based on a magnetic measuring principle. Alternatively, other measuring principles are provided for the displacement sensor element.In particular, a displacement sensor element with an optical measuring principle is provided, wherein the encoder element then has, for example, at least one optical marking, by means of which the displacement sensor element can determine the displacement path.

[0012] Particularly preferably, the displacement sensor element and the force sensor element are arranged on or on a common circuit board, or on a separate circuit board arranged in the sensor housing. The corresponding arrangement of the sensor elements on a separate circuit board, or on a separate circuit board, results in the advantage that the sensor elements are particularly easily and securely mounted in the sensor housing. If a common circuit board is provided, a particularly advantageous option for jointly manufacturing the actual sensor system is created, whereby the circuit board only needs to be inserted into the sensor housing.

[0013] According to a preferred development of the invention, the common circuit board has a first section with the force sensor element and a second section with the displacement sensor element, which is angled to the first section, in particular at least approximately at right angles, or that a first circuit board with the force sensor element is arranged at an angle, in particular at least approximately at right angles, to a second circuit board with the displacement sensor element and is electrically connected to the second circuit board. The first section or the first circuit board with the force sensor element is arranged at least substantially at right angles to a displacement direction of the sensor element, and the second section or the second circuit board with the displacement sensor element is arranged parallel to the displacement direction of the sensor element.

[0014] By having sections of the same circuit board or circuit boards angled in this way, it is advantageously ensured that both the actuating force and the displacement path of the sensor element are detected particularly robustly.

[0015] It is particularly preferably provided that the sensor housing has a second housing part that is connected to the first housing part or formed integrally with the first housing part, and that the first circuit board or the first section is arranged within the second housing part and the second circuit board or the second section is arranged within the first housing part. Such an arrangement of the sections or circuit boards results in the advantage that the different sensors are also spatially separated from one another and / or can be geometrically assigned to the sensor element particularly easily. In particular, the sensor element is arranged in the same housing part as the displacement sensor element, i.e. in particular within the second housing part. The spatial separation of the sensors results in the advantage that, for example, in the event of a leak or water ingress, sensing can continue with the side that is still sealed.This advantageously prevents all sensors from failing simultaneously due to one event.

[0016] According to a preferred development of the invention, at least one second spring element for supporting the circuit board on the sensor housing, in particular in the second section or on the second circuit board, is arranged on the circuit board or at least one of the circuit boards, in particular on a side of the circuit board facing away from the sensor element. Such a spring element advantageously ensures that the circuit board is securely fixed in its position within the corresponding sensor housing or housing part. If the spring element is arranged in the second section or on the second circuit board, it is correspondingly assigned to the displacement sensor element and thus particularly advantageously ensures that the displacement sensor element is at a predetermined distance from the transmitter element.For example, the spring element has a predetermined preload so that the circuit board or the corresponding section of the circuit board within the sensor housing rests at least partially against a housing wall of the sensor housing, in particular of the respective housing part.

[0017] Particularly preferably, it is provided that at least one third spring element for electrically contacting the circuit board with a connector, in particular in the first section or on the first circuit board, is arranged on the circuit board or at least one of the circuit boards, in particular on a side of the circuit board facing away from the sensor element. Such a spring element offers the advantage that the circuit board and thus the force sensor element and / or displacement sensor element arranged thereon can be electrically contacted or contacted particularly reliably and easily, in particular by being supplied with power and / or by being connected or connected to an electrical data bus.

[0018] According to a preferred development of the invention, it is provided that the circuit board or at least one of the circuit boards is at least partially separated from the sensor element by at least one housing wall of the sensor housing, in particular one in each case, arranged, for example, within the first housing part and / or between the housing parts. Such a housing wall advantageously ensures that the circuit board or circuit boards are arranged in a closed area and thus, in particular, mechanically protected. For example, the housing wall runs at least partially parallel to the longitudinal extent of the sensor element and / or to at least one longitudinal extent of one of the circuit boards.Alternatively or additionally, the housing wall extends at least partially at right angles to the longitudinal extension of the sensor element, or parallel to its transverse extension and / or at right angles to at least one longitudinal extension of one of the circuit boards. For example, the housing wall forms a receiving pocket for at least one of the circuit boards with an outer wall of the sensor housing.

[0019] Particularly preferably, the additional sensor element is assigned to an opening in the housing wall, and the housing wall is otherwise free of openings. The housing wall, which is otherwise free of openings except for the opening, offers the advantage that the circuit board or circuit boards are arranged in an area that is otherwise completely enclosed, in particular media-tight, by the housing wall.

[0020] The actuating device of a motor vehicle with the features of claim 14 is characterized by at least one sensor module according to the invention. This results in the aforementioned advantages. In particular, the actuating device is designed to specify a braking and / or acceleration command. For example, a motor vehicle is provided that has two such actuating devices, one for specifying a braking command, i.e., as a brake pedal, and one for specifying an acceleration command, i.e., as an accelerator pedal. Alternatively, a motor vehicle is provided that has such an actuating device for specifying a braking and acceleration command, i.e., as a combined accelerator pedal. This also results in the aforementioned advantages.

[0021] Particularly preferably, a housing is provided into which the sensor module can be or is inserted, at least in part. Such a housing provides a particularly advantageous and simple option for securely mounting the sensor module on the actuating device. In particular, the sensor module can be arranged or is arranged in or on the actuating device as an independently mounted, finished pre-assembly group, as described above. The sensor module is then an electronic module, and the housing of the actuating device is a mechanical module surrounding the electronic module, so that the corresponding functions—electronics and mechanics—are separated from one another.

[0022] Further preferred features and combinations of features emerge from the above description and from the claims. The invention is explained in more detail below with reference to the drawings. Fig. 1 an advantageous actuating device, Fig. 2 the actuating device in a sectional view, Fig. 3A a first detailed view of the actuating device, Fig. 3B a second detailed view of the actuating device, Fig. 4 a sensor module for the actuating device in a sectional view, Fig. 5A a first detailed view of the sensor module, Fig. 5B a second detailed view of the sensor module, and Fig. 6 the actuating device with the sensor module in a further sectional view.

[0023] Fig. Figure 1 shows an exemplary embodiment of an advantageous actuating device 1, in this case for a motor vehicle not otherwise shown in detail. The actuating device 1 is designed to specify a braking command and / or an acceleration command. For this purpose, the actuating device 1 can be foot-operated by a driver of the motor vehicle, i.e., it is designed as a brake pedal, accelerator pedal, and / or gas pedal. In this case, it is an actuating device with a short stroke, with which only small displacement travels in the range of a few millimeters can typically be achieved.

[0024] The actuating device 1 comprises a first housing part 2 and a second housing part 3. The first housing part 2 is mounted on the second housing part 3 so as to be displaceable along the longitudinal extent of the second housing part 3. In the present case, a cover 5 with an actuating surface 6, which can be actuated by the driver, is arranged on an upper side 4 of the first housing part 2 facing away from the second housing part 3.

[0025] The cover 5 can be formed in one piece or, as shown here, in multiple parts, with the individual parts being connected to one another, for example, by a form-fitting connection. According to an embodiment not shown, the cover 5 with the actuating surface 6 is alternatively arranged directly on the upper side 4.

[0026] The second housing part 3 has a plurality of flanges 7, in particular formed integrally with the second housing part 3 or connected thereto, each of which has an opening 8 for a fastening means 9, which in the present case, merely by way of example, is designed as a screw. Using the fastening means 9, the second housing part 3 can be fastened in a footwell of an interior of the motor vehicle, so that the second housing part 3 is arranged stationary relative to the motor vehicle.

[0027] A circumferential, bellows-like, elastically deformable sealing element 10 is arranged between the first housing part 2 and the second housing part 3 for sealing against an area outside the housing parts 2, 3. According to an alternative embodiment (not shown), the sealing element 10 bears against the entire surface of the first housing part 2 and completely covers it.

[0028] Fig. Figure 2 shows the actuating device 1 in a sectional view. Fig. 2, the previously described components and their relative arrangement can be seen in more detail. The first housing part 2 and the second housing part 3 are each cylindrical, at least in sections, with a closed shell wall. Thus, the first housing part 2 has a first thin-walled shell wall 11, and the second housing part 3 has a second thin-walled shell wall 12, each of which has an at least substantially constant wall thickness, in particular at least approximately the same wall thickness.

[0029] In this case, the first casing wall 11 merges into the surface 4, so that the first housing part 2 has a closed end face, while the second housing part 3 is open at the end. The two housing parts 2, 3 each have a constant cross-section only in certain areas or sections. For example, the housing parts 2, 3 are formed as plastic parts or metal parts. The housing parts 2, 3 are designed, in particular, as deep-drawn sheets, turned, drawn, or extruded aluminum profiles, or as injection-molded plastic parts.

[0030] A first sliding element 13 and a second sliding element 14 are arranged between the first housing part 2 and the second housing part 3, in this case between the first casing wall 11 and the second casing wall 12. The first sliding element 13 and the second sliding element 14 each axially bear against at least one of the housing parts 2, 3. The sliding elements 13, 14 are designed in particular as plastic plain bearings with a low coefficient of friction or as sintered metal bushings.

[0031] Between the sliding elements 13, 14, at least one spring element 15, in this case designed as a helical spring, is arranged axially preloaded as a return spring, in this case coaxially to the housing parts 2, 3, in order to urge the housing parts 2, 3 into a non-actuated rest position. In this case, the spring element 15 is designed as a single helical spring.

[0032] According to alternative embodiments not shown, the use of several spring elements connected in series, or the use of one or more disc springs or similar spring elements, is also possible. The use of one or more, preferably cylindrical, elastomers or any combination of different spring elements, in particular a helical spring, disc spring, and / or elastomer, is also conceivable.

[0033] In this case, one of the sliding elements 13, 14, in this case the first sliding element 13, is displaceable along the longitudinal extent of the second housing part 3 together with the first housing part 2 relative to the second housing part 3. One of the sliding elements 13, 14, in this case the second sliding element 14, is fixedly arranged on the second housing part 3. The first housing part 2 is correspondingly displaceable along the longitudinal extent of the second housing part 3 relative to the second sliding element 14.

[0034] The sliding elements 13, 14 thus perform a beneficial dual function. Firstly, they ensure that the housing parts 2, 3 can be moved relative to each other with minimal friction, and secondly, they securely fix the spring element 15 in its position.

[0035] The first housing part 2 has an outer side 16, on which the surface 4 is also located, and an inner side 17 facing away from the outer side 16. Analogously, the second housing part 3 has an outer side 18 facing the inner side 17, and an inner side 19 facing away from the outer side 18.

[0036] The first sliding element 13 has a first, outer surface 20 and an inner surface 21 facing away from the first surface 20. Similarly, the second sliding element 14 has a first, outer surface 22 and an inner surface 23 facing away from the first surface 22.

[0037] The first sliding element 13 rests with its first surface 20 against the inner side 17 of the first housing part 2 and with its second surface 21 against the outer side 18 of the second housing part 3. The second sliding element 14, in turn, rests with its first surface 22 against the inner side 17 and with its second surface 23 against the outer side 18.

[0038] In this case, the first housing part 2 has, in addition to cylindrical sections, a conical section along its longitudinal extent. This means that, along its longitudinal extent, it has at least one region in which its cross-sectional area or diameter is not constant, but constantly changes.

[0039] In a first region 24 associated with the first sliding element 13, it has a first constant inner diameter and in a second region 25 associated with the second sliding element 14, it has a second constant inner diameter which is larger than the first inner diameter.

[0040] For example, the second inner diameter is at least, and in particular exactly, twice as large as the first inner diameter. Thus, the two regions 24 and 25 are each cylindrical.

[0041] This applies analogously to the corresponding outer diameters, the first housing part 2 has a first constant outer diameter in the first region 24 and a second constant outer diameter in the second region 25, which is larger than the first outer diameter.

[0042] The first region 24 is arranged, viewed in the longitudinal direction, at a first end, in the region of the surface 4, and the second region 25 is arranged at the second end of the first housing part 2, facing away from the first end. The conical shape is created by the fact that the first region 24 and the second region 25 are connected by a third region 26, in which the first inner diameter and outer diameter continuously widen to form the second inner diameter and outer diameter. The three regions 24, 25, 26 are thus part of the casing wall 11, or at least form it in some regions.

[0043] According to an alternative embodiment not shown, the third region 26 has a constant inner diameter and / or outer diameter, in particular the same inner diameter and / or outer diameter as one of the two other regions 24, 25, so that the first housing part 2 is then not conical in shape overall, but consists of at least two or three cylindrical sections.

[0044] In terms of its basic geometric shape, it would then correspond to the second housing part 3. In the present case, this has several such cylindrical sections arranged one after the other, connected to one another or formed integrally with one another.

[0045] Thus, the second housing part 3 has a first constant inner diameter and a first constant outer diameter in a first region 27 assigned to the first sliding element 13, and a second constant inner diameter and a second constant outer diameter in a second region 28 assigned to the second sliding element 14, wherein the second inner diameter and outer diameter are each larger than the first inner diameter and outer diameter. Here, too, the regions 27, 28 are analogously part of the casing wall 12 or form it at least in certain regions.

[0046] The sliding elements 13, 14 are geometrically designed to correspond thereto in that they are each at least substantially cylindrical or each have at least one correspondingly cylindrical section. At least in this section, they have an outer diameter corresponding to the respective inner diameter of the first housing part 2 and / or an inner diameter corresponding to the respective outer diameter of the second housing part 3.

[0047] For example, the first sliding element 13 is arranged in a form-fitting, force-fitting and / or material-fitting manner in the first region 24, in particular pressed in, so that it does not shift relative to the first housing part 2, and / or the second sliding element 14 is arranged in a form-fitting, force-fitting and / or material-fitting manner on the second region 28, in particular pressed on, so that it does not shift relative to the second housing part 3.

[0048] In the present case, the spring element 15 is arranged surrounding the first region 27, is thereby radially fixed and accordingly has an inner diameter which corresponds to the first outer diameter of the second housing part 3, i.e. is at least as large as or larger than the first outer diameter.

[0049] In order to securely fix the spring element 15 axially between the sliding elements 13, 14, the first sliding element 13 in this case has a circumferential radial projection 29 at an end assigned to the spring element 15. At least one, in particular also circumferential, axial projection 30 adjoins the projection 29. The spring element 15 bears, at least in part, with a first end 32 against a surface 31 of the radial projection 29 facing the second sliding element 14 and is thus axially fixed. It is additionally radially fixed by the projection 29 between the projection 29 and the outer side 18 of the second housing part 3.

[0050] In order to axially fix the spring element 15 at another end as well, the second sliding element 14 has an end face 33 with an opening 34 with a diameter corresponding to the first outer diameter for the first region 27 of the second housing part 3. The second sliding element 14 is pushed onto the second housing part 3 until an inner surface 35 of the end face 33 and an outer surface 36 of the outer side 18, aligned in the radial extension of the second housing part 3, touch each other.

[0051] The spring element now rests at least partially against a surface 37 of the end face 33, facing the first sliding element 13 and remote from the inner surface 35, with a second end 38 remote from the first end 32, and is thus axially secured. The second sliding element 14 additionally has axial projections 39 projecting from the surface 37, by which the second end 38 is additionally radially secured between the respective projection 39 and the outer side 18 of the second housing part, analogous to the projection 30 of the first sliding element 13.

[0052] At least one first pin 40 is arranged on the first housing part 2 as an anti-twist device. This is shown in a first detailed view of the Fig. 3A, which is a further sectional view in a plane approximately perpendicular to the section plane of the Fig. 2 arranged cutting plane.

[0053] The first housing part 2 has a circumferential radial projection 41 adjoining the second region 25. The first pin 40 is arranged on the projection 41 and protrudes in the direction of the second housing part 3. In particular, the first pin 40 is arranged in an opening of the projection 41. The second housing part 3 has a circumferential radial projection 42 adjoining the second region 28. A first opening 43 is provided in the projection 42, which corresponds to an outer contour of the pin 40 and into which the pin 40 is inserted.

[0054] An axial stop 45, in this case in the form of a compression sleeve circumferentially surrounding the pin, is arranged on the first pin 40 at its end region 44 facing away from the first housing part 2. It is used to limit the relative travel of the housing parts 2, 3. The axial stop 45 is mounted when the first pin 40 is inserted through the opening 43 and, in this respect, advantageously also ensures that the housing parts 2, 3 are held securely against one another. The first pin 40 also defines a preload of the spring element 15, or the preload is adjusted depending on its length.

[0055] With regard to the sealing element 10, in particular in the Fig. 3A that this rests against the respective outer sides of the housing parts 2, 3 in order to seal the area in which the first pin 40 is located, and thus the interior of the housing parts 2, 3 as a whole. Specifically, the sealing element 10 rests against the second area 25 and against the projection 41 of the first housing part 2, as well as against a further axial circumferential projection 46 of the second housing part 3 adjoining the radial projection 42. The radially extending flanges 7 already described then adjoin the projection 46. The sealing element 10 therefore rests in certain areas against a respective circumferential radial or axial projection 41, 46 of the respective housing part 2, 3.

[0056] Finally, at least one second pin 47 is arranged on the second housing part 3 for adjusting the stroke of the housing parts 2, 3 relative to each other. In the present case, at least two second pins 47 are provided. This is shown in a second detailed view of the Fig. 3B, which shows a section of the Fig. 2 is shown enlarged in the lower left area.

[0057] It can be seen that the second pin 47 is arranged in a second opening 48 of the already described circumferential radial projection 42. It protrudes in the direction of the first housing part 2, specifically in the direction of the projection 41. For example, the pin 47 is pressed into the opening 48; in this case, it also has a serration along its longitudinal extent.

[0058] Depending on how far the pin 47 is inserted into the opening 48 or protrudes in the direction of the projection 41, the maximum stroke results from when the pin 47 strikes the end of a surface 49 of the projection 41 facing it.

[0059] Each of the pins 40, 47 is connected to the corresponding housing part 2, 3 in a form-fitting, force-fitting, and / or material-fitting manner, in particular by being glued, welded, and / or pressed and / or screwed into the corresponding opening 43, 48. Alternatively, at least one of the pins 40, 47 is formed integrally with the corresponding housing part 2, 3.

[0060] In particular, at least one of the pins 40, 47 is coated, and / or the opening 43, 48 associated with it is provided with a noise-damping element. Alternatively or additionally, an elastic buffer element, for example a plastic disc, is provided, particularly on the axial stop, as a noise-damping measure.

[0061] The components of the actuating device 1 described so far are purely mechanical or a type of mechanical module of the actuating device 1. In the Fig. 2, however, it can be seen that the interior of the second housing part 3 forms a cavity. To fill this cavity, a Fig. 4, a sensor module 50 is provided as an exemplary embodiment shown in detail in a sectional view.

[0062] The sensor module 50 can be arranged with a precise fit in the second housing part 3 and is designed to detect an actuation of the actuating device 1, in particular an actuation force exerted on the actuation surface 6 and / or an actuation path of the actuation surface 6.

[0063] The sensor module 50 has a plate-shaped sensor element 51, made in particular of metal or plastic. The sensor element 51 can be assigned or is assigned to an actuating element of the actuating device 1. The actuating element is in particular the actuating surface 6 or the first housing part 2 connected thereto.

[0064] The sensor module 50 further comprises a sensor housing 52. The sensor housing 52 comprises a first cylindrical housing part 53 and a second cylindrical housing part 54 adjoining it, i.e., connected thereto, and in this case formed integrally therewith. The housing parts 53, 54 have identical, at least largely constant, wall thicknesses. The inner diameter and outer diameter of the first housing part 53 are smaller than the inner diameter and outer diameter of the second housing part 54.

[0065] Furthermore, the sensor module 50 in the present case has at least one force sensor element 55 assigned to the sensor element 51 for detecting a force exerted on the sensor element 51, in particular by means of the actuating element, and at least one displacement sensor element 56 assigned to the sensor element 51 for detecting a displacement of the sensor element 51. The force sensor element 55 has, in particular, strain gauges and is designed, in particular, as described in the previously known prior art of the applicant mentioned at the beginning.

[0066] For the sensor module 50 to function as described, it is sufficient if either the force sensor element 55 or the displacement sensor element 56 is present. The presence of both provides advantageous redundancy due to the different measurement principles. In particular, at least two force sensor elements 55 and / or displacement sensor elements 56 are provided to further improve measurement reliability and redundancy.

[0067] Such redundancy, in particular, ensures compliance with relevant standards and / or laws to meet quality and safety requirements. For example, two different measurement principles, each redundant, are required for brake pedals to achieve ASIL-D compliance. For accelerator pedals, two redundant sensors with the same measurement principle are sufficient.

[0068] If a sensor fails or drifts significantly, it must be ensured that the remaining sensors still detect the "true" signal of the driver's input. If a sensor fails, for example, a warning message is issued to the driver. An entire circuit could fail, in which case two sensors on the brake pedal and one on the accelerator pedal would be affected. In this case, the respective redundant sensors take over the detection of the driver's input, preferably accompanied by a warning message to the driver.

[0069] The sensor element 51 is mounted for longitudinal displacement in the first housing part 53. For this purpose, the first housing part 53 has, in this case, on its inner side 57, at least one groove 58 extending along its longitudinal extent and / or one web 59, in particular at least two grooves 58 and / or webs 59 arranged distributed over the circumference of the inner side 57, for example, diametrically opposed to one another, in and / or on which the sensor element 51 is guided.

[0070] For this purpose, the sensor element 51 is assigned with one longitudinal side to the respective groove 58 or the web 59, in particular inserted into the respective groove 58 or placed on the respective web 59. For this purpose, the sensor element 51 preferably has a groove on the longitudinal side with an inner contour corresponding to the respective outer contour of the web 59. The sensor element 51 is guided in or on the groove 58 or the web 59, at least approximately, with or without play.

[0071] The sensor module 50 further comprises at least one first spring element 60, in this case embodied as a helical spring. According to alternative embodiments not shown, the use of several spring elements connected in series, or the use of one or more disc springs or similar spring elements, is also possible. The use of one or more, preferably cylindrical, elastomers or any combination of different spring elements, in particular a helical spring, disc spring, and / or elastomer, is also conceivable.

[0072] The sensor element 51 is operatively connected to the force sensor element 55 by means of the first spring element 60. According to an alternative embodiment (not shown), in which no force sensor element 55 is present, the sensor element 51 can be supported on the sensor housing 52 by means of the first spring element 60. In the present case, the sensor element 51 also protrudes from the first housing part 53, at least in an unactuated rest position of the spring element 60, i.e., in the assembled state, in the direction of the actuating element of the actuating device 1.

[0073] The first spring element 60 is pushed with a first end 61 at least partially onto a projection 62 of the sensor element 51 and with a second end 63 facing away from the first end 61 at least partially onto a projection 64 of a further sensor element 65 operatively connected to the force sensor element 55.

[0074] A sensor element 66, in this case a magnetic element, is arranged on the sensor element 51 and is associated with the displacement sensor element 56, which in this case has a Hall sensor. For example, a magnetic element designed as a permanent magnet is provided, which is arranged on a longitudinal side of the sensor element 51 and is connected thereto in a form-fitting, non-positive, and / or material-fitting manner. The displacement sensor element 56 is then based on a magnetic measuring principle. Alternatively, other measuring principles, in particular optical ones, are provided for the displacement sensor element 56.

[0075] In the present case, the displacement sensor element 56 and the force sensor element 55 are arranged on a common circuit board 67 arranged in the sensor housing 52. According to a further exemplary embodiment (not shown), the displacement sensor element 56 and the force sensor element 55 are each arranged on a circuit board arranged in the sensor housing 52.

[0076] The common circuit board 67 has a first section 68 with the force sensor element 55 and a second section 69 with the displacement sensor element 56. The second section 69 is angled to the first section 67, in this case at least approximately at a right angle.

[0077] In their original form, the two sections 68, 69 of the circuit board 67 lie in a common plane, and only before assembly in the sensor housing 52 is the second section 69 angled accordingly. Fig. 4 both states (flat and angled) and the mobility are indicated by a dashed double arrow

[0078] According to an alternative embodiment not shown, a first circuit board with the force sensor element 55 is provided, which is arranged, in particular at least approximately at right angles, angled to a second circuit board with the displacement sensor element 56 and is electrically connected to the second circuit board.

[0079] The first section 68 of the circuit board 67 (or, alternatively, the corresponding first circuit board) is arranged within the second housing part 54, and the second section 69 of the circuit board 67 (or, alternatively, the corresponding second circuit board) is arranged within the first housing part 53. The second section 69 then runs parallel to the longitudinal extent of the sensor element 51, and the first section 68 runs perpendicular to the longitudinal extent of the sensor element 51.

[0080] In the Fig. Figure 5 shows a detailed view of the circuit board 67 in its original state, i.e., without the sections being angled relative to each other. The two sections 68, 69 are electrically connected to each other by a flexible electrical connection 70, in this case comprising several wires, so that, in particular, the force sensor element 55 and the displacement sensor element 56 arranged thereon can be connected or are connected to an external power supply and / or a communication bus.

[0081] In addition, further spring elements are arranged on the circuit board 67, on the side of the circuit board 67 facing away from the sensor element 51 as well as the displacement sensor element 56 and the force sensor element 55.

[0082] Firstly, at least one second spring element 71 is arranged to support the circuit board 67 on the sensor housing 52, in this case in the second section 69 (or, alternatively, on the corresponding second circuit board). The second spring element 71 ensures that the displacement sensor element 56 is at a defined distance from the encoder element 66. In the assembled state, it is supported on the inner side 57 in the first housing part 53.

[0083] On the other hand, a plurality of third spring elements 72 (of which only one is provided with a reference number for reasons of clarity) for electrically contacting the circuit board with a connector plug 73, in this case in the first section 68 (or, alternatively, on the corresponding first circuit board), is arranged. Fig. 5B is shown in a second detailed view, showing the connector 73, which has a plurality of connection pins 74. Each of the connection pins 74 is in contact with one of the third spring elements 73.

[0084] The connector plug 73 is in turn connected to a Fig. 4, housing cover 75 is inserted, with which the sensor housing 52 is closed as soon as the circuit board 67 is inserted into the sensor housing 52.

[0085] Within the sensor housing 52, a housing wall 76 consisting of several sections is also provided. In this case, the housing wall 76 is formed integrally with the sensor housing 52. A first section 77 of the housing wall 76 runs at least substantially perpendicular to the longitudinal extent of the sensor element 51 or parallel to the longitudinal extent of the housing cover 75 and, in the assembled state, the first section 68 of the circuit board 67.

[0086] Adjacent to the first section 77 is a second section 78, oriented at right angles thereto, which accordingly runs at least substantially parallel to the longitudinal extent of the sensor element 51 or, in the assembled state, parallel to the second section 69 of the circuit board 67. A third section 79, again oriented at right angles to the second section 78, runs parallel to the first section 77 at a corresponding distance. Thus, the housing wall 76, together with an outer wall of the sensor housing 52, forms a receiving pocket for the second section 69 of the circuit board 67.

[0087] The first section 77 runs exactly between the two housing parts 53, 54, or at the level of and parallel to an end face 80 of the second housing part 54, which has an opening 81 from which the first housing part 53 protrudes. The first section 77 partially fills the opening 81. The second section 78 and the third section 79 are arranged accordingly within the first housing part 53.

[0088] The housing wall 76 has an opening 82 for the additional sensor element 63 only in the first section 77 and is otherwise designed without any openings (if multiple force sensor elements 55 with corresponding sensor elements 63 are provided, a separate opening is preferably provided for each of them). In this respect, the circuit board 67 is completely separated from the sensor element 51, preferably in a media-tight manner.

[0089] In the Fig.Figure 6 finally shows the fully assembled actuating device 1 together with the sensor module 50. For clarity, only the most important components are provided with reference numerals. The sensor module 50 is now inserted into the second housing part 3 and closed with the housing cover 75.

[0090] Due to the pretension of the spring element 60, the sensor element 51 rests against the inside of the first housing part 2 connected to the actuating surface 6, so that each actuation of the actuating surface 6 is transmitted by means of the sensor element 51 to the displacement sensor element 56 and the spring element 60 and subsequently to the force sensor element 55 and the displacement sensor element 56. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2022 212 470.7

[0004] DE 10 2022 212 450.2

[0005]

Claims

[1] Sensor module (50) for an actuating device (1) of a motor vehicle, with a plate-shaped sensor element (51), in particular one that can be assigned or is assigned to an actuating element of the actuating device (1), with a sensor housing (52), wherein the sensor housing (52) has at least a first cylindrical housing part (53), wherein the sensor element (51) is mounted in the first housing part (53) for longitudinal displacement, and with at least one force sensor element (55) assigned to the sensor element (51) for detecting a force exerted on the sensor element (51), in particular by means of the actuating element, and / or at least one displacement sensor element (56) assigned to the sensor element (51) for detecting a displacement path of the sensor element (51). [2] Sensor module according to claim 1, characterized bythat the first housing part (53) has on its inner side (57) at least one groove (58) running along its longitudinal extent and / or one web (59), in particular at least two grooves (58) and / or webs (59) distributed over the circumference of the inner side (57), for example diametrically opposite one another, in and / or on which the sensor element (51) is guided. [3] Sensor module according to one of the preceding claims, characterized by that the sensor module (50) has at least one first spring element (60), in particular a helical spring, and that the sensor element (51) is operatively connected to the force sensor element (55) by means of the first spring element (60) and / or is supported on the sensor housing (52), wherein in particular the sensor element (51) protrudes from the first housing part (53) at least in an unactuated rest position of the spring element (60). [4] Sensor module according to one of the preceding claims, characterized bythat the first spring element (60) with a first end (61) can be pushed or is pushed at least partially onto a projection (62) of the sensor element (51). [5] Sensor module according to one of the preceding claims, characterized by that the first spring element (60) can be pushed or is pushed with a second end (63) at least partially onto a projection (64) of a further sensor element (65) which is operatively connected to the force sensor element (55). [6] Sensor module according to one of the preceding claims, characterized by that a sensor element (66), in particular a magnetic element, is arranged on the sensor element (51) and is assigned to the displacement sensor element (56), in particular having a Hall sensor. [7] Sensor module according to one of the preceding claims, characterized bythat the displacement sensor element (56) and the force sensor element (55) are arranged on or on a common circuit board (67) or on a respective circuit board (67) arranged in the sensor housing (52). [8] Sensor module according to claim 7, characterized by that the common circuit board has a first section (68) with the force sensor element (55) and a second section (69) with the displacement sensor element (56) which is angled to the first section, in particular at least approximately at right angles, or that a first circuit board with the force sensor element (55) is arranged at an angle to a second circuit board with the displacement sensor element (56), in particular at least approximately at right angles, and is electrically connected to the second circuit board. [9] Sensor module according to claim 8, characterized bythat the sensor housing (52) has a second housing part (54) which is connected to the first housing part (53) or formed integrally with the first housing part (53), and that the first circuit board or the first section (68) is arranged within the second housing part (54) and the second circuit board or the second section (69) is arranged within the first housing part (53). [10] Sensor module according to one of claims 7 to 9, characterized by that on the circuit board (67) or at least one of the circuit boards, in particular on a side of the circuit board (67) facing away from the sensor element (51), at least one second spring element (71) for supporting the circuit board (67) on the sensor housing (52), in particular in the second section (69) or on the second circuit board, is arranged. [11] Sensor module according to one of claims 7 to 10, characterized bythat on the circuit board (67) or at least one of the circuit boards, in particular on a side of the circuit board (67) facing away from the sensor element (51), at least one third spring element (72) for electrically contacting the circuit board (67) with a connection plug (73), in particular in the first section (68) or on the first circuit board, is arranged. [12] Sensor module according to one of claims 7 to 11, characterized by that the circuit board (67) or at least one of the circuit boards is separated from the sensor element (51) at least in regions by at least one, in particular one in each case, housing wall (76) of the sensor housing (52) arranged, for example, within the first housing part (53) and / or between the housing parts (53, 54). [13] Sensor module according to claim 12, characterized bythat the further sensor element (65) is assigned to an opening (82) in the housing wall (76), and that the housing wall (76) is otherwise designed to be free of openings. [14] Actuating device (1) of a motor vehicle, in particular for specifying a braking and / or acceleration request, characterized by at least one sensor module (50) according to one of claims 1 to 13. [15] Actuating device according to claim 14, characterized by a housing (3) into which the sensor module (50) can be or is inserted at least in part.

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