Sensor assembly

Abstract

To provide a sensor assembly that prevents interference from metal components with the radio waves emitted by the sensor, and also prevents foreign matter from adhering to the sensor and the sensor from coming into contact with other components. [Solution] A sensor assembly comprising a metal sensor base bracket, a resin plate attached to the sensor base bracket, a sensor attached to the resin plate, and a cover that fits the resin plate and houses the sensor in the space formed together with the resin plate.

Description

Technical Field

[0001] The present disclosure relates to a sensor assembly.

Background Art

[0002] A plurality of sensors for detecting surrounding obstacles, people, etc. are provided in a vehicle. FIG. 12 shows an example of the structure of a conventional sensor mounting bracket 200 for mounting a sensor 201 on a vehicle. A plurality of metal sensor mounting position securing brackets 204 are attached to a metal base bracket 203 by welding. The sensor mounting position securing bracket 204 has one rectangular top surface portion 205 and two triangular side surface portions 206, is formed by bending into a substantially U-shaped cross section, and the tangent portion 210 between the side surface portion 206 and the base bracket 203 is linearly welded and joined by arc welding or the like.

[0003] A plurality (three in FIG. 12) of bolts 207 are attached to the top surface portion 205 of the sensor mounting position securing bracket 204. On the other hand, a plurality (three in FIG. 12) of mounting holes 202 are formed in the sensor 201. Then, by inserting the bolt 207 through the mounting hole 202 and screwing the nut 208, the sensor 201 is fastened to the sensor mounting position securing bracket 204.

[0004] In the example of FIG. 12, two sensor mounting position securing brackets 204 are attached vertically to the base bracket 203. And the normal directions of the top surface portions 205 of the respective sensor mounting position securing brackets 204 are different from each other. For example, the top surface portion 205 of the upper sensor mounting position securing bracket 204 faces rightward, and the top surface portion 205 of the lower sensor mounting position securing bracket 204 faces leftward. The normal direction of the top surface portion 205 is determined by the shape of the side surface portion 206, and the shape of the side surface portion 206 is designed so that each sensor 201 faces the range for detecting obstacles or the like.

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the conventional sensor mounting bracket 200 structure, the sensor 201 is fastened to a metal sensor mounting position securing bracket 204. This can cause interference between the radio waves emitted by the sensor 201 and the sensor mounting position securing bracket 204, potentially preventing accurate detection of obstacles. Furthermore, if a cover is provided to prevent foreign matter from adhering to the sensor 201 or contact between the sensor 201 and other components, the cover must be attached to the base bracket 203, resulting in a larger cover.

[0006] The present disclosure aims to provide a sensor assembly that prevents interference from metal components with radio waves emitted by the sensor, and also prevents foreign matter from adhering to the sensor and the sensor from coming into contact with other components. [Means for solving the problem]

[0007] The sensor assembly of this disclosure comprises a metal sensor base bracket, a resin plate attached to the sensor base bracket, a sensor attached to the resin plate, and a cover that fits the resin plate and houses the sensor in a space formed together with the resin plate. [Effects of the Invention]

[0008] According to the sensor assembly of this disclosure, since there is a resin plate between the sensor base bracket and the sensor, the radio waves emitted by the sensor are less likely to interfere with the metal sensor base bracket. In addition, by providing a cover that fits over the resin plate, the sensor attached to the resin plate can be properly protected. [Brief explanation of the drawing]

[0009] [Figure 1] This is a diagram showing the sensor assembly. [Figure 2] This diagram shows the sensor assembly with the cover removed. [Figure 3] This figure shows the back side of the sensor assembly shown in Figure 1. [Figure 4] Figure 1 is an exploded view of the sensor assembly. [Figure 5] This is an exploded view of the sensor mounting bracket. [Figure 6] This is a cross-sectional view of the inside of the cover. [Figure 7] This is a rear view showing the cover and resin plate. [Figure 8] This is a rear perspective view showing the cover and resin plate. [Figure 9] This figure shows a sensor assembly with a frame-shaped bracket attached. [Figure 10] This figure shows the back side of the sensor assembly shown in Figure 9. [Figure 11] Figure 9 is an exploded view of the sensor assembly. [Figure 12] This diagram shows a conventional sensor mounting bracket. [Modes for carrying out the invention]

[0010] The embodiments of this disclosure will be described below with reference to the drawings. The embodiments described below are all specific examples of this disclosure. Therefore, the components, their arrangement positions, and connection configurations shown in the following embodiments are examples and are not intended to limit this disclosure. Furthermore, components in the following embodiments that are not described in an independent claim will be described as optional components.

[0011] Furthermore, each figure is a schematic diagram and not necessarily a strictly accurate representation. Note that in each figure, substantially identical components are denoted by the same reference numerals, and redundant explanations may be omitted or simplified.

[0012] Figures 1 to 8 are diagrams for explaining a first embodiment of the sensor assembly of the present disclosure. FIG. 1 shows a perspective view of the sensor assembly 1, FIG. 2 shows the sensor assembly 1 with the cover 8 removed, FIG. 3 shows the back side of the sensor assembly 1, FIG. 4 is an exploded view of the sensor assembly 1, FIG. 5 is an exploded view of the sensor mounting bracket 3, FIG. 6 is a cross-sectional view inside the cover 8, FIG. 7 is a rear view showing the resin plate 7 and the cover 8, and FIG. 8 is a rear perspective view showing the resin plate 7 and the cover 8.

[0013] The sensor assembly 1 includes a sensor mounting bracket 3 and a sensor 2 attached to the sensor mounting bracket 3. The sensor mounting bracket 3 includes a base bracket 4, a sensor mounting position securing bracket 5, and a sensor pedestal bracket 6.

[0014] The base bracket 4 is a plate-like member having a cross-section formed in a hat shape when cut in a horizontal plane, and includes a central top surface portion 42 and flange portions 41 formed on both sides of the top surface portion 42. A notch portion 45 for locking the harness 10 is formed in the flange portion 41. When the base bracket 4 is attached to the vehicle body, the sensor assembly 1 is attached to the vehicle body.

[0015] The sensor mounting position securing bracket 5 is joined to the top surface portion 42 by spot welding. As shown in FIG. 5, the sensor mounting position securing bracket 5 is formed by bending a long plate-like member so that a plurality (two in the example of the figure) of hat portions are continuously formed, and includes a central flange portion 53 formed in the central portion, a plurality (two in the example of the figure) of top surface portions formed on both sides of the central flange portion 53. 52, and side flange portions 51 formed at both upper and lower ends.

[0016] The directions of the normal lines of each of the plurality of top surface portions 52 are different. For example, the upper top surface portion 52 faces to the right, and the lower top surface portion 52 faces to the left. The orientation of each top surface portion 52 is designed according to the direction in which the attached sensor 2 detects obstacles and the like.

[0017] In this embodiment, a total of three locations, namely one central flange portion 53 and two side flange portions 51, are joined to the top surface portion 42 of the base bracket 4 by spot welding (indicated by an 'x' mark and a dotted line in Fig. 5). The number of top surface portions 52 is designed according to the number of sensors 2 to be attached. The central flange portion 53 is formed between the top surface portions 52 by a number that is one less than the number of top surface portions 52. Therefore, the sensor mounting position securing bracket 5 and the base bracket 4 are joined by spot welding at the total number of the central flange portion 53 and the side flange portion 51. That is, Number of spot welds = Number of sensors to be attached - 1 + Number of side flange portions = Number of sensors to be attached + 1 This is the case.

[0018] In the prior art shown in Fig. 12, when joining the sensor mounting position securing bracket 204 to the base bracket 203, welding was performed at two tangent portions 210 for each sensor mounting position securing bracket 204, and welding was carried out at a location that was twice the number of sensors 201 to be attached. In this embodiment, however, welding can be performed at a location of the number of sensors 2 to be attached + 1, so deformation due to thermal strain can be suppressed and the number of working hours can be reduced.

[0019] Also, conventionally, the sensor mounting position securing bracket 204 and the base bracket 203 were linearly welded by arc welding or the like. In this embodiment, however, the sensor mounting position securing bracket 5 and the base bracket 4 are spot welded in a dot shape by spot welding, so the amount of metal melted by welding is small, thermal strain is unlikely to occur, and the work is easy and can be completed in a short time.

[0020] A metal sensor base bracket 6 is spot-welded to the top surface 52 of the sensor mounting position securing bracket 5. The approximate center portion of the sensor base bracket 6 is joined to the top surface 52 of the sensor mounting position securing bracket 5 (shown by an "x" and dotted line in Figure 5). The sensor base bracket 6 is a bracket for mounting and supporting the sensor 2, and is approximately the same size as the sensor 2. The sensor base bracket 6 is provided with first bolts 61 (three in the example shown) for attaching the resin plate 7 and the sensor 2, and second bolts 62 (two in the example shown) for attaching the cover 8.

[0021] The resin plate 7 and the sensor 2 are fastened to the sensor base bracket 6. The resin plate 7 is a plate-shaped member made of resin and is larger than the sensor base bracket 6. The resin plate 7 has a mounting hole 71 through which the first bolt 61 of the sensor base bracket 6 is inserted, and a notch 72 into which the harness 10 connected to the sensor 2 is secured.

[0022] The sensor 2 has a mounting hole 21 formed around its periphery through which the first bolt 61 of the sensor base bracket 6 is inserted. The first bolt 61 of the sensor base bracket 6 is inserted through both the mounting hole 71 of the resin plate 7 and the mounting hole 21 of the sensor 2, and they are fastened together with a nut 22.

[0023] The cover 8 is a resin component that covers and protects the sensor 2. Mounting holes 81 are formed around the periphery of the cover 8 through which the second bolt 62 of the sensor base bracket 6 is inserted. The cover 8 covers the sensor 2, and the sensor 2 is housed in the space 83 formed by the cover 8 and the resin plate 7 (see Figure 6). That is, when the resin plate 7 is fitted into the cover 8, the internal space of the cover 8 is sealed by the resin plate 7.

[0024] The harness 10 connects the sensor 2 to a vehicle control device (not shown), etc. One end 101 of the harness 10 is connected to the connector 23 of the sensor 2, and the other end 102 is connected to a vehicle control device (not shown) or other harnesses, etc. The vicinity of the one end 101 of the harness 10 is locked into a notch 72 formed in the resin plate 7 and pulled out from the cover 8 through the space 83 of the cover 8. The middle section 103 is locked into a notch 45 formed in the base bracket 4 and routed to the back side of the base bracket 4.

[0025] Sensor 2 is fastened to the surface of the resin plate 7 by a first bolt 61 and nut 22 (see Figure 4, etc.). With sensor 2 attached to the resin plate 7, cover 8 covers the resin plate 7 so as to fit inside it and fastens to sensor base bracket 6 by a second bolt 62 and nut 82 (see Figure 4, etc.).

[0026] The cover 8 is formed in a recessed shape that can accommodate the sensor 2 and the resin plate 7 inside (see Figure 6). By placing the cover 8 over the sensor 2 so that the resin plate 7 on which the sensor 2 is attached is fitted, the sensor 2 is housed in the space 83 formed by the resin plate 7 and the cover 8.

[0027] If sensor 2 is directly attached to the metal sensor base bracket 6, the distance between sensor 2 and sensor base bracket 6 becomes small, and the metal sensor base bracket 6 may affect the radiation of radio waves from sensor 2. However, by placing a resin plate 7 between sensor base bracket 6 and sensor 2, the distance between sensor base bracket 6 and sensor 2 increases, and the radiation of radio waves from sensor 2 is less affected by the metal sensor base bracket 6.

[0028] It is desirable to make the metal sensor base bracket 6 as small as possible to minimize its influence on the radiation of the sensor 2. On the other hand, it is desirable to maintain a certain distance between the cover 8 that covers the sensor 2 and the sensor 2 to minimize its influence on the radiation of the sensor 2. Therefore, a gap is created between the periphery of the sensor base bracket 6 and the periphery of the cover 8. However, in this embodiment, by providing a resin plate 7 that fits into the cover 8, the gap between the periphery of the sensor base bracket 6 and the periphery of the cover 8 is sealed by the resin plate 7, thereby preventing foreign matter from entering through the gap and adhering to the sensor 2.

[0029] Figures 9 to 11 illustrate a second embodiment of the sensor assembly of the present disclosure, with Figure 9 showing a perspective view of the sensor assembly, Figure 10 showing the back side of the sensor assembly, and Figure 11 showing an exploded view of the sensor assembly. In this embodiment, a frame-shaped bracket 9 is added to the sensor assembly of the first embodiment.

[0030] The frame-shaped bracket 9 has multiple mounting holes 91 for inserting bolts (four in the example shown). The base bracket 4 also has multiple mounting holes 43 for inserting bolts (four in the example shown). Multiple bolts 92 (two in the example shown) are inserted through the mounting holes 91 and 43, and the frame-shaped bracket 9 is fastened to the base bracket 4 by tightening nuts 44. The number of bolts 92 is appropriately selected within the range of the number of mounting holes 91.

[0031] An opening 93 is formed in the frame-shaped bracket 9. The harness 10 connected to the sensor 2 is secured in the notch 72 and passed through the back side of the resin plate 7, and the intermediate part 103 is secured in the notch 45 and passed through the back side of the base bracket 4. When the frame-shaped bracket 9 is fastened to the base bracket 4, the harness 10 is inserted through the opening 93 and passed through the back side of the frame-shaped bracket 9.

[0032] The frame-shaped bracket 9 is positioned near the middle portion 103 of the harness 10 so as to cover the opening of the notch 45. Therefore, the frame-shaped bracket 9 prevents the harness 10 from falling out of the notch 45.

[0033] When attaching the sensor assembly 1 to the vehicle body, the frame-shaped bracket 9 is attached to the vehicle body (not shown) with fasteners such as bolts and nuts. Therefore, the frame-shaped bracket 9 prevents the harness 10 from falling out of the notch 45 and also functions as a bracket for attaching the sensor assembly 1 to the vehicle body, thus reducing the number of parts and installation time.

[0034] As described above, the sensor mounting bracket 3 of this disclosure comprises a base bracket 4 formed from a plate-shaped member and a sensor mounting position securing bracket 5 formed by bending the plate-shaped member into a hat shape. Since the flange portions 51 and 53 of the sensor mounting position securing bracket 5 and the base bracket 4 are joined by spot welding, thermal distortion is suppressed compared to conventional technology in which the sensor mounting position securing bracket 204 and the base bracket 203 are linearly joined by arc welding or the like, improving the accuracy of sensor mounting and reducing the number of work hours.

[0035] Furthermore, when mounting multiple sensors 2, the sensor mounting position securing bracket 5 of the present disclosure has multiple hat sections, each having side flange sections 51 formed at both ends, multiple top surfaces 52, and one or more central flange sections 53 formed between the multiple top surfaces 52. Since the side flange sections 51 and the central flange sections 53 are joined to the base bracket 4 by spot welding, the number of welding points relative to the number of sensors 2 can be reduced compared to the conventional technology, thereby suppressing thermal distortion, improving the accuracy of sensor mounting, and reducing the amount of work required.

[0036] Furthermore, since the top surfaces 52 of each of the multiple hat-shaped sections of the sensor mounting bracket 3 disclosed herein have different normal directions, multiple sensors 2 can be mounted in different directions, thereby widening the obstacle detection range of the sensors. In addition, by appropriately designing the direction of the top surfaces 52, the mounting angle of the sensors 2 can be changed in various ways.

[0037] Furthermore, the sensor mounting bracket 3 of this disclosure has a sensor base bracket 6 fixed to the top surface 52 of the sensor mounting position securing bracket 5 by spot welding. By changing the sensor base bracket 6, sensors 2 of different sizes can be attached, and the base bracket 4 and the sensor mounting position securing bracket 5 can be standardized.

[0038] Furthermore, the sensor assembly 1 of this disclosure includes the sensor mounting bracket 3, a resin plate 7 attached to the sensor base bracket 6, a sensor 2 attached to the resin plate 7, a harness 10 connected to the sensor 2, and a resin cover 8 covering the sensor 2. This improves the mounting accuracy of the sensor 2 and protects the sensor 2 with the cover 8.

[0039] Furthermore, in the sensor assembly 1 of this disclosure, a notch 45 is formed in the base bracket 4, and the harness 10 is secured to the notch 45, so the harness 10 can be properly fixed and does not get in the way.

[0040] Furthermore, in the sensor assembly 1 of this disclosure, a frame-shaped bracket 9 with an opening 93 is attached to the side of the base bracket 4 opposite to the side to which the sensor 2 is attached. Since the frame-shaped bracket 9 closes the opening of the notch 45, it is possible to prevent the harness 10 from falling out of the notch 45 due to vehicle vibrations or the like.

[0041] Furthermore, the sensor assembly 1 of this disclosure comprises a metal sensor base bracket 6, a resin plate 7 attached to the sensor base bracket 6, a sensor 2 attached to the resin plate 7, and a cover 8 that fits the resin plate 7 and houses the sensor 2 in a space 83 formed together with the resin plate 7. As a result, the radiation of radio waves from the sensor 2 is less affected by the metal sensor base bracket 6, and the gap between the periphery of the sensor base bracket 6 and the periphery of the cover 8 is sealed by the resin plate 7, preventing foreign matter from entering through the gap and adhering to the sensor 2.

[0042] Furthermore, in the sensor assembly 1 of this disclosure, the sensor base bracket 6 is provided with a first bolt 61 and a second bolt 62. The resin plate 7 and the sensor 2 are fastened together by the first bolt 61, and the cover 8 is fastened by the second bolt 62. This allows the resin plate 7, the sensor 2, and the cover 8 to be efficiently fixed to the sensor base bracket 6 in a small space.

[0043] Furthermore, the sensor assembly 1 of this disclosure further comprises a base bracket 4 formed from a plate-shaped member, and a sensor mounting position securing bracket 5 formed by bending the plate-shaped member into a hat shape, with the flange portion and the base bracket 4 joined by spot welding. The sensor base bracket 6 is joined to the hat-shaped top surface portion 52 of the sensor mounting position securing bracket 5 by spot welding, thereby reducing the effect of thermal distortion due to welding and enabling the sensor 2 to be mounted with high precision. [Industrial applicability]

[0044] The sensor mounting bracket and sensor assembly disclosed herein can be suitably used when mounting various sensors to a vehicle body. [Explanation of Symbols]

[0045] 1. Sensor assembly 2 sensors 21 mounting holes 22 nuts 23 Connectors 3. Sensor mounting bracket 4 Base brackets 41 Flange section 42 Top part 43 mounting holes 44 nuts 45 Notch 5. Bracket for securing the sensor mounting position 51 Side flange portion 52 Top part 53 Central flange section 6. Sensor base bracket 61 First bolt 62 Second bolt 7. Resin plate 71 Mounting holes 72 Notch 8 Covers 81 Mounting holes 82 nuts 9 Frame-shaped bracket 91 Mounting holes 92 volts 93 Opening 10 Harnesses 103 Middle section

Claims

1. A metal sensor base bracket, A resin plate attached to the aforementioned sensor base bracket, The sensor attached to the aforementioned resin plate, A cover into which the resin plate is fitted and which houses the sensor in the space formed together with the resin plate, A sensor assembly having a sensor.

2. The sensor base bracket is provided with a first bolt and a second bolt. The resin plate and the sensor are fastened together by the first bolt. The cover is fastened by the second bolt. The sensor assembly according to claim 1.

3. A base bracket formed from a plate-shaped member, A sensor mounting position securing bracket is formed by bending a plate-shaped member into a hat shape, and the flange portion and the base bracket are joined by spot welding. It further possesses, The sensor base bracket is joined to the hat-shaped top surface of the sensor mounting position securing bracket by spot welding. The sensor assembly according to claim 1.

Images