Shaft-hub connection and angle sensor

Abstract

A shaft-hub connection and an angle sensor, comprising a hub in the form of a circuit board that is form-lockingly connected to the shaft, the circuit board having a recess through which the shaft projects, in particular in the axial direction. The circuit board, at the edge of the recess, has radially oriented relief portions into which radially oriented elevations of the shaft project.

Description

[0001] Shaft-hub connection and angle sensor

[0002] Description:

[0003] The invention relates to a shaft-hub connection and angle sensor and a method for manufacturing.

[0004] A keyway connection is commonly known as a shaft-hub connection.

[0005] From DE 698 10 504 T2, a position sensor is known as the closest prior art.

[0006] DE 195 32 519 A1 discloses a method for producing a rotationally symmetrical metallic workpiece.

[0007] The invention is therefore based on the object of providing a connection that is easy to produce.

[0008] According to the invention, the object is achieved in the shaft-hub connection according to the features specified in claim 1 or 2 and in the angle sensor according to the features specified in claim 14 and a method for manufacturing according to the features specified in claim 15.

[0009] Important features of the invention in the shaft-hub connection according to claim 1 are that a hub designed as a printed circuit board, which is positively connected to the shaft, is provided, wherein the printed circuit board has a recess, in particular a hole, through which the shaft projects, in particular in the axial direction, wherein the printed circuit board has, at the edge, in particular the edge of the hole, of the recess, radially directed recesses, in particular radially outwardly directed recesses, in particular of its base material, into which radially directed elevations, in particular radially outwardly directed elevations, of the shaft project, in particular wherein the area covered by the shaft in the axial direction comprises the area covered by the printed circuit board in the axial direction.

[0010] The advantage here is that a play-free connection between the metal shaft and a circuit board can be achieved quickly and easily. This only requires pressing on an area of ​​the shaft, in particular the collar area, using a tool to deform the shaft material so that the displaced material protrudes radially outwards and in the process displaces material from the circuit board, in particular the base material of the circuit board. This creates a connection that is positively locking and free of play in the circumferential direction. Because the displaced material also partially protrudes radially next to the circuit board slightly further than in the area covered by the circuit board in the axial direction, the circuit board is also axially limited. In the opposite direction to the axial direction, however, the circuit board rests against a flat surface of the shaft. The circuit board is therefore axially limited on both sides and is therefore connected in a positively locking manner.Since the shaft is pushed through the recess of the circuit board, a positive connection is also created in the radial direction.

[0011] Important features of the invention in the shaft-hub connection according to claim 2 are that a hub designed as a printed circuit board, which is positively connected to the shaft, is provided, wherein the printed circuit board has a recess which has radially directed recesses, in particular radially outwardly directed recesses, of the base material of the printed circuit board, into which radially directed elevations, in particular radially outwardly directed elevations, of the shaft protrude, wherein the shaft protrudes through the recess, in particular wherein the area covered by the shaft in the axial direction comprises the area covered by the printed circuit board in the axial direction.

[0012] The advantage here is that a play-free connection between the metal shaft and a circuit board can be achieved quickly and easily. This only requires pressing on an area of ​​the shaft, in particular the collar area, using a tool to deform the shaft material so that the displaced material protrudes radially outwards and in the process displaces material from the circuit board, in particular the base material of the circuit board. This creates a connection that is positively locking and free of play in the circumferential direction. Because the displaced material also partially protrudes radially next to the circuit board slightly further than in the area covered by the circuit board in the axial direction, the circuit board is also axially limited. In the opposite direction to the axial direction, however, the circuit board rests against a flat surface of the shaft. The circuit board is therefore axially limited on both sides and is therefore connected in a positively locking manner.Since the shaft is pushed through the recess of the circuit board, a positive connection is also created in the radial direction.

[0013] In an advantageous embodiment, the radially directed elevations engage behind the circuit board, particularly in the areas covered by the radially directed recesses in the circumferential direction, so that the circuit board is positively connected to the shaft in all directions, particularly in the radial direction, in the axial direction, and in the circumferential direction. The advantage here is that a positive connection in all directions can be easily achieved by plugging the circuit board onto the shaft and reshaping areas of the shaft.

[0014] In an advantageous embodiment, the shaft is designed as a hollow shaft. This allows for easy connection to an additional shaft by simply slipping the shaft onto the additional shaft. The rotationally fixed connection between the shaft and the additional shaft can be achieved using adhesive and / or a keyway.

[0015] In an advantageous embodiment, the shaft is connected to another shaft, in particular the rotor shaft of an electric motor, in a rotationally fixed manner, in particular by means of a keyway. This is advantageous in that a printed circuit board can be connected to the rotor shaft in a rotationally fixed manner, thus forming an electric motor with an integrated encoder, i.e., angle sensor. In an advantageous embodiment, the recess is arranged centrally in the printed circuit board and / or is axially continuous. This is advantageous in that the shaft can be pushed through the recess, thus allowing the printed circuit board to be snug against a flat surface of the shaft.

[0016] In an advantageous embodiment, the radially outer circumference of the circuit board is circular, in particular circularly cylindrical. This is advantageous in that the imbalance is as low as possible.

[0017] In an advantageous embodiment, the radially directed protrusions of the shaft are regularly spaced from one another in the circumferential direction, in particular with the protrusions all arranged at the same radial distance and / or all at the same axial position. This is advantageous in that several protrusions are provided on the circumference, thus ensuring that, in the event of one of the protrusions failing, a sufficient number of other protrusions are in operative connection with the circuit board, thus ensuring increased safety.

[0018] In an advantageous embodiment, the radially directed recesses of the circuit board are regularly spaced from one another in the circumferential direction, in particular with the recesses all arranged at the same radial distance and / or all at the same axial position. This provides the advantage of increased safety while keeping imbalance as low as possible.

[0019] In an advantageous embodiment, the edge of the recess rests against a collar area formed, in particular a molded collar, on the shaft. This is advantageous in that a play-free connection can be achieved.

[0020] In an advantageous embodiment, a collar region formed on the shaft, in particular a molded collar region, protrudes through the recess, particularly in the axial direction. This advantageously ensures that the circuit board fits tightly and without play against the shaft.

[0021] In an advantageous embodiment, the circuit board rests on the side facing away from the collar area in the axial direction against a flat surface section of the shaft, the normal direction of which is aligned parallel to the axial direction. This is advantageous because the circuit board is aligned on the one hand and rests without play on the other. During the forming of the collar area, the deformed material also presses the circuit board against the flat surface, i.e., the flat surface section of the shaft, with an elastic residual stress.

[0022] In an advantageous embodiment, the shaft has a bead projecting in the radial direction, in particular radially outward, on which the surface section is formed and / or arranged, in particular wherein the radial spacing region covered by the bead is arranged radially outside the radial spacing region covered by the collar region of the shaft or overlaps with it. The advantage here is that the bead running circumferentially and projecting radially beyond the collar region provides a flat surface for the printed circuit board to rest on. By means of the collar region, the printed circuit board can be connected to the shaft in a form-fitting manner in the circumferential direction and thus in a rotationally fixed manner.

[0023] In an advantageous embodiment, the circuit board has continuous, in particular spaced-apart, holes, in particular centering holes, in the axial direction, wherein pin areas are formed on the shaft, which protrude from the shaft in the axial direction and protrude through the holes in the circuit board in the axial direction. The advantage here is that centering of the circuit board relative to the shaft is made easy. Alternatively, the pin areas are not formed on the shaft, but on the tool with which the forming is carried out and which presses the material in such a way that the material is deformed as radially directed elevations. The relative position of the tool to the circuit board is then determined by means of the pin areas inserted into the holes.

[0024] In an advantageous embodiment, the collar region is adjacent to the bead or is spaced axially from the bead. This is advantageous because the circuit board can be designed with a thin wall thickness, since the collar region is arranged as close as possible to the bead or is adjacent to it.

[0025] In an advantageous embodiment, the area covered by the collar region in the axial direction is adjacent to the area covered by the bead in the axial direction or is spaced apart from it. This is advantageous in that the circuit board can be designed with a thin wall thickness, since the collar region is arranged as close as possible to the bead or is adjacent to it.

[0026] In an advantageous embodiment, radially directed elevations are created by forming, in particular by means of a tool whose circumferentially spaced punch areas projecting from the tool are pressed axially onto the collar area. The advantage here is that a play-free connection can be achieved due to the displaced material.

[0027] In an advantageous embodiment, the radially directed recesses are created by means of the radially directed elevations, in particular when they are produced by forming, in particular so that the circuit board is connected to the shaft without play. The advantage here is that the material displaced during forming penetrates into the base material of the circuit board and displaces it, thus creating the recesses. Since the tool only presses with its punch areas at points spaced apart from one another in the circumferential direction, the formed material only flows into the base material of the circuit board at correspondingly spaced apart points in the radial direction. The recesses are therefore correspondingly spaced apart from one another in the circumferential direction.

[0028] Important features of the angle sensor with shaft-hub connection or electric motor with angle sensor with shaft-hub connection are that the angle sensor has a first part, in particular a first part, in particular the rotor of the angle sensor, which is rotatably mounted to a second part, in particular the stator of the angle sensor, and the second part, wherein the first part has the printed circuit board acting as a measuring embodiment, which is connected in a rotationally fixed manner to the shaft by deforming the shaft, in particular the collar region of the shaft, in particular wherein the angle sensor works or functions according to an inductive operating principle and / or wherein the first part is in an inductive active connection with the second part.

[0029] The advantage here is that an inductively operating angle sensor can be provided via the circuit board, so that a measuring scale designed as a circuit board with copper surfaces is detected by the second part. This means that the moment of inertia of the shaft, in particular of a rotor shaft connected to the shaft, is only slightly increased, and the dynamics of an electric motor remain essentially unchanged. Integration of an angle sensor into an electric motor is easily achieved because the circuit board requires only a small amount of space in the axial direction. Likewise, the second part can be designed as a populated second circuit board, thus enabling simple assembly and requiring only a small amount of space.

[0030] Important features in the method for producing an angle sensor with a shaft-hub connection or for producing a shaft-hub connection are that

[0031] (i) in a first process step, a particularly circular hole, in particular a round hole, is made in the printed circuit board acting as a hub and / or measuring standard,

[0032] (ii) in a second step following the first step of the procedure

[0033] In a method step, a shaft is at least partially inserted through the bore and then, by pressing a tool in the axial direction onto the shaft, in particular by pressing punch areas of a tool in the axial direction onto a collar area of ​​the shaft projecting axially on the shaft, areas of the shaft, in particular the collar area, are deformed, so that radially directed elevations of the shaft, in particular the collar area, are created and displace material of the circuit board, in particular wherein the radially directed elevations at least partially engage behind the circuit board, in particular wherein the shaft is designed as a turned part and / or as a rotational body before the second method step, in particular therefore before the tool acts on the shaft, in particular therefore at each axial position the shaft has a maximum outer radius, in particular outer diameter, or radial distance that is independent of the circumferential angle,in particular, wherein, before the second method step, the rotational position of the tool relative to the circuit board is adjusted optically, in particular by detecting the copper surfaces and aligning the tool by rotating it, before the second method step, or wherein, before the second method step, the rotational position of the tool relative to the circuit board is achieved by threading a pin area projecting from the tool into an index hole in the circuit board before the tool is pressed onto the shaft.

[0034] The advantage is that only a circular hole needs to be drilled into the circuit board, and by pressing the tool, i.e., the stamping areas, onto the collar area of ​​the shaft, it can be connected to the circuit board without play and without rotation. This allows a circuit board to be connected to a metal shaft part in a simple manufacturing step. The shaft can be made of aluminum or steel.

[0035] Further advantages emerge from the dependent claims. The invention is not limited to the combination of features in the claims. Further possible combinations of claims and / or individual claim features and / or features of the description and / or the figures will become apparent to those skilled in the art, particularly from the problem and / or the problem posed by comparison with the prior art.

[0036] The invention will now be explained in more detail using schematic illustrations:

[0037] Figure 1 shows a cross-section through a shaft-hub arrangement according to the invention in plan view.

[0038] Figure 2 shows an enlarged section of Figure 1.

[0039] Figure 3 shows the shaft-hub arrangement in a sectional view.

[0040] Figure 4 shows an enlarged section of Figure 3.

[0041] Figure 5 shows a plan view of the hub designed as a printed circuit board 1.

[0042] Figure 6 shows a cross-section through the circuit board 1.

[0043] Figure 7 shows an enlarged section of Figure 5.

[0044] Figure 8 shows the machining of a shaft-hub arrangement using a tool in a sectional view.

[0045] As shown in the figures, the hub of the shaft-hub connection is designed as a printed circuit board 1, which functions as the first part of an angle sensor. A second part of the angle sensor, arranged so as to be rotatable relative to the first part, is not shown in the figures.

[0046] The circuit board 1 has copper surfaces 3 spaced apart from one another in the circumferential direction, in particular at regular intervals. The copper surfaces 3 are detected by the second part, since this second part has at least one sensor for detecting copper surfaces 3.

[0047] The copper surfaces 3 are all arranged at the same radial distance and have a similar shape. In particular, each copper surface 3 transitions into another copper surface 3 through an imaginary rotation around the axis of rotation of the shaft 2 by an angular amount, in particular by 360° / N, where N is the number of copper surfaces 3.

[0048] The axial direction, as well as the radial direction and the circumferential direction, is related to the axis of rotation of shaft 2.

[0049] Preferably, the circuit board 1 has a base material made of an epoxy resin.

[0050] For the rotationally fixed connection of the printed circuit board 1 to the shaft 2, the shaft 2 is deformed with a tool 80, in particular a forming tool, so that a collar region protruding axially on the shaft and extending completely around the circumference in the circumferential direction is deformed by the tool 80 in such a way that radially directed elevations 4 are created, which project into radially directed recesses of the printed circuit board 1. Thus, the printed circuit board 1 is connected to the shaft 2 in a form-fitting, i.e. rotationally fixed, manner in the circumferential direction.

[0051] Preferably, the shaft 2 is designed as a hollow shaft.

[0052] The tool 80 has centring pin regions 81 which are spaced apart from one another in the circumferential direction, in particular arranged at the same radial distance, which protrude into corresponding, in particular axially through holes 6, in particular centring holes, and thus determine the relative position of the tool 80 to the shaft 2.

[0053] The centering pin areas 81 are arranged radially inside the copper surfaces 3 and radially outside the shaft 2.

[0054] The printed circuit board 1 has a centrally arranged, axially continuous recess, the edge of which rests on the collar area of ​​the shaft and / or through which the collar area of ​​the shaft projects.

[0055] The tool 80 has circumferentially spaced, in particular regularly spaced, stamping regions 82 that project axially toward the shaft. These stamping regions apply such a high axial force to the material of the collar region that the material is deformed and deflects, i.e., bulges, in the radial direction. The resulting radially directed elevations 4 project into corresponding radially directed recesses in the base material of the circuit board 1. Preferably, the stamping regions 82 are designed to be uniform relative to one another and / or are all arranged at the same radial distance from the rotational axis of the shaft 2.

[0056] As shown in Figure 7, the radially directed elevations 4 are preferably rounded, in particular in the shape of a circular segment.

[0057] The clear diameter of the holes 6, in particular centering holes, is smaller than the recess axially passing through the circuit board 1 and arranged radially centrally in the circuit board 1.

[0058] The shaft-hub connection is preferably used in a drive component such as an electric motor, gearbox or brake.

[0059] When used in an electric motor, the shaft 2 is rotationally fixedly connected to the rotor shaft of the electric motor or is integrally formed therewith, in particular, as a single piece. The second part is rotationally fixedly connected to the stator housing of the electric motor, so that the angular position of the rotor shaft can be determined by detecting the copper surfaces 3 of the circuit board 1, in particular by means of the second part of the angle sensor, which comprises evaluation electronics.

[0060] In further embodiments according to the invention, a different base material of the circuit board 1 is selected instead of the epoxy resin.

[0061] List of reference symbols

[0062] 1 Printed circuit board 2 Shaft, especially hollow shaft

[0063] 3 copper surface

[0064] 4 radially directed elevation

[0065] 5 axially directed elevation

[0066] 6 Hole, in particular centering hole 80 Tool, in particular forming tool

[0067] 81 Centering pin area

[0068] 82 Stamping area of ​​the tool 80

Claims

Patent claims:

1. Shaft-hub connection, comprising a hub designed as a printed circuit board which is positively connected to the shaft, characterized in that the printed circuit board has a recess, in particular a hole, through which the shaft projects, in particular in the axial direction, wherein the printed circuit board has, at the edge, in particular the edge of the hole, of the recess, radially directed recesses, in particular radially outwardly directed recesses, in particular in its base material, into which radially directed elevations, in particular radially outwardly directed elevations, of the shaft project, in particular wherein the area covered by the shaft in the axial direction comprises the area covered by the printed circuit board in the axial direction.

2. Shaft-hub connection, comprising a hub designed as a printed circuit board, which is positively connected to the shaft, characterized in that the printed circuit board has a recess which has radially directed recesses, in particular radially outwardly directed recesses, of the base material of the printed circuit board, into which radially directed elevations, in particular radially outwardly directed elevations, of the shaft protrude, wherein the shaft protrudes through the recess, in particular wherein the area covered by the shaft in the axial direction comprises the area covered by the printed circuit board in the axial direction.

3. Shaft-hub connection according to claim 1 or 2, characterized in that the radially directed elevations engage behind the printed circuit board, in particular in the areas covered by the radially directed recesses in the circumferential direction, in particular so that the printed circuit board is positively connected to the shaft in all directions, in particular in the radial direction and in the axial direction and in the circumferential direction.

4. Shaft-hub connection according to one of the preceding claims, characterized in that the shaft is designed as a hollow shaft and / or that the shaft is connected to another shaft, in particular the rotor shaft of an electric motor, in a rotationally fixed manner, in particular by means of a key connection, and / or that the recess is arranged centrally in the circuit board and / or is designed to be axially continuous.

5. Shaft-hub connection according to one of the preceding claims, characterized in that the radially outer circumference of the circuit board is circular, in particular circular-cylindrical.

6. Shaft-hub connection according to one of the preceding claims, characterized in that the radially directed elevations of the shaft are regularly spaced from one another in the circumferential direction, in particular wherein the elevations are all arranged at the same radial distance and / or all at the same axial position, and / or that the radially directed recesses of the printed circuit board are regularly spaced from one another in the circumferential direction, in particular wherein the recesses are all arranged at the same radial distance and / or all at the same axial position.

7. Shaft-hub connection according to one of the preceding claims, characterized in that the edge of the recess rests against a collar region formed on the shaft, in particular a shaped collar region, or the collar region formed on the shaft, in particular a shaped collar region, projects through the recess, in particular in the axial direction.

8. Shaft-hub connection according to one of the preceding claims, characterized in that the printed circuit board rests on the side facing away from the collar region in the axial direction against a flat surface section of the shaft, the normal direction of which is aligned parallel to the axial direction.

9. Shaft-hub connection according to one of the preceding claims, characterized in that the shaft has a bead projecting in the radial direction, in particular radially outward, on which the surface section is formed and / or arranged, in particular wherein the radial spacing region covered by the bead is arranged radially outside the radial spacing region covered by the collar region of the shaft or overlaps therewith.

10. Shaft-hub connection according to one of the preceding claims, characterized in that the printed circuit board has continuous, in particular spaced-apart, holes, in particular centering holes, in the axial direction, wherein the shaft has pin areas which protrude through the holes in the axial direction.

11. Shaft-hub connection according to one of the preceding claims, characterized in that the collar region adjoins the bead or is spaced apart from the bead in the axial direction, and / or that the region covered by the collar region in the axial direction adjoins the region covered by the bead in the axial direction or is spaced apart therefrom.

12. Shaft-hub connection according to one of the preceding claims, characterized in that radially directed elevations are produced by forming, in particular by means of a tool, the punch areas of which project from the tool and are spaced apart from one another in the circumferential direction are pressed in the axial direction onto the collar area.

13. Shaft-hub connection according to one of the preceding claims, characterized in that the radially directed recesses are produced by means of the radially directed elevations, in particular when they are produced by forming, in particular so that the printed circuit board is connected to the shaft without play.

14. Angle sensor with shaft-hub connection, in particular according to one of the preceding claims, or electric motor with angle sensor with shaft-hub connection, in particular according to one of the preceding claims, characterized in that the angle sensor has a first part, in particular a rotor of the angle sensor, which is rotatably mounted in particular to a second part, in particular a stator of the angle sensor, and the second part, wherein the first part has the printed circuit board acting as a measuring embodiment, which is connected in a rotationally fixed manner to the shaft by deforming the shaft, in particular the collar region of the shaft, in particular wherein the angle sensor works or functions according to an inductive operating principle and / or wherein the first part is in an inductive active connection with the second part.

15. A method for producing an angle sensor with a shaft-hub connection according to one of the preceding claims or for producing a shaft-hub connection, characterized in that (i) in a first process step, a particularly circular hole, in particular a round hole, is made in the printed circuit board acting as a hub and / or measuring standard, (ii) in a second step following the first step of the procedure In a method step, a shaft is at least partially inserted through the bore and then, by pressing a tool in the axial direction onto the shaft, in particular by pressing punch areas of a tool in the axial direction onto a collar area of ​​the shaft projecting axially on the shaft, areas of the shaft, in particular the collar area, are deformed, so that radially directed elevations of the shaft, in particular the collar area, are created and displace material of the circuit board, in particular wherein the radially directed elevations at least partially engage behind the circuit board, in particular wherein the shaft is designed as a turned part and / or as a rotational body before the second method step, in particular therefore before the tool acts on the shaft, in particular therefore at each axial position the shaft has a maximum outer radius, in particular outer diameter, or radial distance that is independent of the circumferential angle,In particular, before the second method step, the rotational position of the tool relative to the circuit board is adjusted optically, in particular by detecting the copper surfaces and aligning the tool by rotating it, before the tool is pressed onto the shaft, or before the second method step, the rotational position of the tool relative to the circuit board is achieved by threading a pin area projecting from the tool into an index hole in the circuit board before the tool is pressed onto the shaft.

Images