Rotary connector device

Abstract

To provide a rotary connector device that can be used with various vehicles while reducing manufacturing costs. [Solution] The rotary connector device 2 includes a stator 10, a rotator 20, and a flat cable 52. The rotator 20 is rotatable around a rotation axis A1 relative to the stator 10. The stator 10 and the rotator 20 form a cable housing space 60. The flat cable 52 includes a curved portion 52E provided within the cable housing space 60. The rotator 20 includes a viewing window 20W. The cable length L52 of the flat cable 52 is set to be longer than a reference cable length L52R calculated based on the maximum rotation angle θ defined from the neutral position P0 of the rotator 20 to the rotation end P1 or P2, so that the curved portion 52E is visible from the outside of the rotator 20 through the viewing window 20W when the rotator 20 is in a neutral position P0 relative to the stator 10.

Description

Technical Field

[0001] The technology disclosed in the present application relates to a rotary connector device.

Background Art

[0002] Japanese Patent Application Laid-Open No. 2014-033502 describes a rotary connector device having a viewing window.

Prior Art Document

Patent Document

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In this type of rotary connector device, the maximum rotation angle of the rotor from the neutral position with respect to the stator may vary depending on the vehicle specifications. If the maximum rotation angle is different, there is a possibility that the flat cable may not be visible through the viewing window depending on the length of the flat cable. Changing the position of the viewing window or increasing the number of viewing windows according to the vehicle specifications may increase the manufacturing cost of the rotary connector device.

[0005] The problem of the technology disclosed in the present application is to provide a rotary connector device that can be compatible with various vehicles while reducing the manufacturing cost.

Means for Solving the Problems

[0006] According to the first feature, the rotary connector device includes a stator, a rotator, and a flat cable. The rotator is rotatable about a rotation axis relative to the stator. The stator and rotator form a cable housing space. The flat cable includes a curved section provided within the cable housing space. The rotator includes a viewing window. The cable length of the flat cable is set to be longer than a reference cable length calculated based on the maximum rotation angle defined from the neutral position of the rotator to the end of rotation, so that the curved section is visible from the outside of the rotator through the viewing window when the rotator is in a neutral position relative to the stator.

[0007] In the rotary connector device relating to the first feature, the cable length of the flat cable is set to be longer than the standard cable length so that the curved portion is visible from the outside of the rotator through the viewing window when it is in the neutral position. Therefore, regardless of the maximum rotation angle, the operator can check the curved portion through the viewing window and recognize that the rotator is in the neutral position. Consequently, even if the maximum rotation angle differs, the same rotator can be used. This makes it possible to provide a rotary connector device that can be used with various vehicles while reducing manufacturing costs.

[0008] According to the second feature, in the rotary connector device according to the first feature, the stator includes an outer circumferential wall that partially defines the cable housing space. The rotator includes an inner circumferential wall that partially defines the cable housing space. The flat cable includes a first winding section and a second winding section. The first winding section is wound at least partially along the outer circumferential wall. The second winding section is wound at least partially along the inner circumferential wall. A curved section is provided between the first and second winding sections and connects them.

[0009] In the rotary connector device relating to the second feature, the flat cable includes a first winding section and a second winding section, so the movement of the flat cable accompanying the rotation of the rotator becomes smoother.

[0010] According to the third feature, in the rotary connector device according to the second feature, the flat cable includes an excess portion that makes the cable length longer than the reference cable length. The excess portion is included in at least one of the first winding portion and the second winding portion.

[0011] In the rotary connector device relating to the third feature, the excess portion makes it easier to adjust the cable length, and a rotary connector device that can reliably accommodate various vehicles while reducing manufacturing costs can be provided.

[0012] According to the fourth feature, in the rotary connector device relating to the third feature, the curved portion is positioned so that it is not visible from the outside of the rotator through the viewing window when there is no excess portion.

[0013] In the rotary connector device relating to the fourth feature, when there is no excess portion, i.e., when the cable length is the standard cable length, it is positioned in a location that is not visible from the outside of the rotator through the viewing window. Therefore, by adjusting the cable length with the excess portion, regardless of the maximum rotation angle, the operator can check the curved portion through the viewing window and recognize that the rotator is in the neutral position. This makes it possible to provide a rotary connector device that can reliably accommodate various vehicles while reducing manufacturing costs.

[0014] According to the fifth feature, in a rotary connector device relating to any of the first to fourth features, the stator does not include any other viewing windows besides the viewing window.

[0015] The fifth feature of the rotary connector device makes it possible to provide a rotary connector device that can be used with various vehicles while reliably reducing manufacturing costs.

[0016] According to the sixth feature, in a rotary connector device relating to any of the first to fourth features, the maximum rotation angle is 270 degrees or less.

[0017] In the rotary connector device relating to the sixth feature, the cable length of the flat cable is set to be longer than the standard cable length so that when the maximum rotation angle is relatively small, the curved portion is visible from the outside of the rotator through the viewing window in the neutral position. Therefore, for example, when the rotary connector device is mounted on a steer-by-wire steering system, the manufacturing cost of the rotary connector device can be reduced.

[0018] According to the seventh feature, in a rotary connector device relating to any of the first to fourth features, the maximum rotation angle is greater than 270 degrees and less than or equal to 1800 degrees.

[0019] In the rotary connector device relating to the seventh feature, the cable length of the flat cable is set to be longer than the standard cable length so that when the maximum rotation angle is relatively large, the curved portion can be seen from the outside of the rotator through the viewing window in the neutral position. Therefore, for example, when the rotary connector device is mounted on a steering system other than the steer-by-wire system, the manufacturing cost of the rotary connector device can be reduced.

[0020] According to the eighth feature, a rotary connector device relating to any of the first to fourth features further comprises a stator-side connector and a rotator-side connector. The stator-side connector is provided on the stator. The rotator-side connector is provided on the rotator. A flat cable electrically connects the stator-side connector and the rotator-side connector.

[0021] In the rotary connector device relating to the eighth feature, the vehicle body-side electrical device is connected to the stator-side connector, and the steering-side electrical device is connected to the rotator-side connector, thereby enabling electrical connection between the vehicle body-side electrical device and the steering-side electrical device via the rotary connector device.

[0022] According to the ninth feature, in a rotary connector device relating to any of the first to fourth features, the reference cable length is calculated based on the outer diameter of the cable housing space, the maximum rotation angle, and durability information relating to the durability of the flat cable.

[0023] In the rotary connector device according to the ninth feature, the reference cable length can be accurately calculated.

Advantages of the Invention

[0024] With the technology disclosed in the present application, it is possible to provide a rotary connector device that can cope with various vehicles while reducing manufacturing costs.

Brief Description of the Drawings

[0025] [Figure 1] FIG. 1 is a top view of the rotary connector device according to the embodiment. <000096><000097>FIG. 2 is a schematic view of the flat cable of the rotary connector device shown in FIG. 1. <000098><000099>FIG. 3 is a schematic cross-sectional view of the rotary connector device taken along line III-III of FIG. 4. [Figure 4] FIG. 4 is a schematic cross-sectional view of the rotary connector device taken along line IV-IV of FIG. 3. [Figure 5] FIG. 5 is a schematic cross-sectional view of the flat cable of the rotary connector device shown in FIG. 1. [Figure 6] FIG. 6 is a top view for explaining the maximum rotation angle of the rotary connector device shown in FIG. 1. [Figure 7] FIG. 7 is a schematic view showing the rotary connector device and the length of the flat cable shown in FIG. 1 (when the maximum rotation angle is 270 degrees and the cable length is the reference length). [Figure 8] FIG. 8 is a schematic view showing the rotary connector device and the length of the flat cable shown in FIG. 1 (when the maximum rotation angle is 900 degrees and the cable length is the reference length). [Figure 9] FIG. 9 is a schematic view showing the rotary connector device and the length of the flat cable shown in FIG. 1 (when the maximum rotation angle is 900 degrees and the flat cable includes an excess portion). [Figure 10]Figure 10 is a schematic diagram showing the rotary connector device and flat cable lengths shown in Figure 1 (when the maximum rotation angle is 900 degrees and the cable length is the standard length). [Figure 11] Figure 11 is a schematic diagram showing the rotary connector device and flat cable lengths shown in Figure 1 (when the maximum rotation angle is 270 degrees and the cable length is the standard length). [Figure 12] Figure 12 is a schematic diagram showing the length of the rotary connector device and flat cable shown in Figure 1 (when the maximum rotation angle is 270 degrees and the flat cable includes excess length). [Figure 13] Figure 13 is a schematic block diagram of a computer that calculates the reference cable length. [Modes for carrying out the invention]

[0026] The embodiments will be described below with reference to the drawings. In the drawings, the same reference numerals indicate corresponding or identical components.

[0027] As shown in Figure 1, the rotary connector device 2 is electrically connected to the first electronic control unit 4 and the second electronic control unit 6. The first electronic control unit 4 is mounted on the vehicle body. The second electronic control unit 6 is mounted on a steering wheel that is rotatable relative to the vehicle body. The second electronic control unit 6 is electrically connected to the first electronic control unit 4 via the rotary connector device 2. Electricity is supplied from the first electronic control unit 4 to the second electronic control unit 6 via the rotary connector device 2. Information is also transmitted between the first electronic control unit 4 and the second electronic control unit 6 via the rotary connector device 2. That is, a power supply line and a transmission path are provided between the first electronic control unit 4 and the second electronic control unit 6. The rotary connector device 2 is configured to maintain the electrical connection between the first electronic control unit 4 and the second electronic control unit 6 while allowing the steering wheel to rotate relative to the vehicle body.

[0028] The rotary connector device 2 comprises a stator 10 and a rotator 20. The rotator 20 is rotatable around the rotation axis A1 relative to the stator 10. The stator 10 is configured to be mounted on the vehicle body. The rotator 20 is configured to be connected to the steering wheel.

[0029] The rotary connector device 2 further comprises a stator-side connector 30 and a rotator-side connector 40. The stator-side connector 30 is provided on the stator 10. The rotator-side connector 40 is provided on the rotator 20. The stator-side connector 30 is configured so that a vehicle-side connector can be detachably attached to it. The vehicle-side connector is electrically connected to the first electronic control unit 4. The rotator-side connector 40 is configured so that a steering-side connector can be detachably attached to it. The steering-side connector is electrically connected to the second electronic control unit 6.

[0030] The stator-side connector 30 includes a connector housing 31, a first electrical connector 33, a second electrical connector 34, and a third electrical connector 35. The connector housing 31 is mounted on the stator 10. The connector housing 31 includes a connector housing space 31S. The first electrical connector 33, the second electrical connector 34, and the third electrical connector 35 are provided within the connector housing space 31S. The first electrical connector 33, the second electrical connector 34, and the third electrical connector 35 may also be referred to as electrical connectors 33, 34, and 35, respectively.

[0031] The first electrical connector 33 includes a first connector body 33A and at least two first busbars 33B. The first connector body 33A includes an electrical insulating material and partially covers at least two first busbars 33B. The first busbars 33B are electrically connectable to the first electronic control unit 4.

[0032] The second electrical connector 34 includes a second connector body 34A and at least two second busbars 34B. The second connector body 34A includes an electrical insulating material and partially covers at least two second busbars 34B. The second busbars 34B are electrically connectable to the first electronic control unit 4.

[0033] The third electrical connector 35 includes a third connector body 35A and at least two third busbars 35B. The third connector body 35A includes an electrical insulating material and partially covers at least two third busbars 35B. The third busbars 35B are electrically connectable to the first electronic control unit 4.

[0034] The rotator-side connector 40 includes a first connector housing 41, a second connector housing 42, a first electrical connector 43, a second electrical connector 44, and a third electrical connector 45. The first connector housing 41 and the second connector housing 42 are mounted on the rotator 20. The first connector housing 41 includes a first connector housing space 41S. The second connector housing 42 includes a second connector housing space 42S. The first electrical connector 43 and the second electrical connector 44 are provided within the first connector housing space 41S. The third electrical connector 45 is provided within the second connector housing space 42S. The first electrical connector 43, the second electrical connector 44, and the third electrical connector 45 may also be referred to as electrical connectors 43, 44, and 45, respectively.

[0035] The first electrical connector 43 includes a first connector body 43A and at least two first bus bars 43B. The first connector body 43A includes an electrical insulating material and partially covers at least two first bus bars 43B. The first bus bars 43B are electrically connectable to the second electronic control unit 6.

[0036] The second electrical connector 44 includes a second connector body 44A and at least two second bus bars 44B. The second connector body 44A includes an electrical insulating material and partially covers at least two second bus bars 44B. The second bus bars 44B are electrically connectable to the second electronic control unit 6.

[0037] The third electrical connector 45 includes a third connector body 45A and at least two third busbars 45B. The third connector body 45A includes an electrical insulating material and partially covers at least two third busbars 45B. The third busbars 45B are electrically connectable to the second electronic control unit 6.

[0038] As shown in Figure 2, the rotary connector device 2 includes at least one flat cable 50. The at least one flat cable 50 electrically connects the stator-side connector 30 and the rotator-side connector 40. The at least one flat cable 50 includes flat cable 51, flat cable 52, flat cable 54, and dummy flat cable 53. The dummy flat cable 53 may also be referred to as flat cable 54. That is, the rotary connector device 2 includes flat cable 51, flat cable 52, flat cable 54, and flat cable 53.

[0039] The flat cable 51 electrically connects the stator-side connector 30 and the rotator-side connector 40. For example, the flat cable 51 electrically connects the first electrical connector 33 of the stator-side connector 30 and the first electrical connector 43 of the rotator-side connector 40.

[0040] The flat cable 52 electrically connects the stator-side connector 30 and the rotator-side connector 40. For example, the flat cable 52 electrically connects the second electrical connector 34 of the stator-side connector 30 and the second electrical connector 44 of the rotator-side connector 40.

[0041] The flat cable 54 electrically connects the stator-side connector 30 and the rotator-side connector 40. For example, the flat cable 54 electrically connects the third electrical connector 35 of the stator-side connector 30 and the third electrical connector 45 of the rotator-side connector 40.

[0042] The dummy flat cable 53 is not electrically connected to the stator-side connector 30 and the rotator-side connector 40.

[0043] In addition, similar to the dummy flat cable 53, one or two of the flat cables 51, 52, and 54 may be configured not to be electrically connected to the stator-side connector 30 and the rotator-side connector 40. Conversely, similar to the flat cables 51, 52, and 54, the dummy flat cable 53 may be configured to electrically connect the stator-side connector 30 and the rotator-side connector 40.

[0044] As shown in Figure 3, the stator 10 and rotator 20 form a cable housing space 60. The stator 10 includes an outer perimeter wall 11 and a plate 12. The outer perimeter wall 11 partially defines the cable housing space 60. The outer perimeter wall 11 extends from the plate 12 in an axial direction D4. The axial direction D4 is defined along the rotation axis A1. The plate 12 is annular. The plate 12 partially defines the cable housing space 60. The rotator 20 includes a plate 22. The plate 22 is annular. The plate 22 partially defines the cable housing space 60. The plate 22 is spaced apart from the plate 12. The cable housing space 60 is formed between the plate 12 and the plate 22.

[0045] As shown in Figure 4, the cable housing space 60 is provided so as to surround the axis of rotation A1. For example, the cable housing space 60 is annular and extends in the circumferential direction D5 with respect to the axis of rotation A1. The outer circumferential wall 11 extends in the circumferential direction D5. The rotator 20 includes an inner circumferential wall 21 that extends in the circumferential direction D5. The inner circumferential wall 21 partially defines the cable housing space 60. The inner circumferential wall 21 is provided radially inward of the outer circumferential wall 11. The cable housing space 60 is formed between the outer circumferential wall 11 and the inner circumferential wall 21. The outer diameter DM1 of the cable housing space 60 corresponds to the inner diameter of the outer circumferential wall 11. The inner diameter DM2 of the cable housing space 60 corresponds to the outer diameter of the inner circumferential wall 21.

[0046] At least one flat cable 50 is located at least partially within the cable housing space 60. Each of the flat cables 51, 52, 54, and dummy flat cable 53 is located at least partially within the cable housing space 60. At least one flat cable 50 is located at least partially between the outer wall 11 and the inner wall 21. Each of the flat cables 51, 52, 54, and dummy flat cable 53 is located at least partially between the outer wall 11 and the inner wall 21.

[0047] At least one flat cable 50 is wound around the axis of rotation A1 within the cable housing space 60. Flat cables 51, 52, 54, and dummy flat cable 53 are wound around the axis of rotation A1 within the cable housing space 60. Flat cable 51 is wound at least partially along the outer wall 11. Flat cable 51 is wound at least partially along the inner wall 21. Flat cable 52 is wound at least partially along the outer wall 11. Flat cable 52 is wound at least partially along the inner wall 21. Flat cable 54 is wound at least partially along the outer wall 11. Flat cable 54 is wound at least partially along the inner wall 21. Dummy flat cable 53 is wound at least partially along the outer wall 11. Dummy flat cable 53 is wound at least partially along the inner wall 21.

[0048] The flat cable 51 includes a first winding section 51C, a second winding section 51D, and a curved section 51E. The first winding section 51C is wound at least partially along the outer circumferential wall 11. The second winding section 51D is wound at least partially along the inner circumferential wall 21. The curved section 51E is located between the first winding section 51C and the second winding section 51D and connects them. The curved section 51E is located within the cable housing space 60.

[0049] The flat cable 52 includes a first winding section 52C, a second winding section 52D, and a curved section 52E. The first winding section 52C is wound at least partially along the outer circumferential wall 11. The second winding section 52D is wound at least partially along the inner circumferential wall 21. The curved section 52E is located between the first winding section 52C and the second winding section 52D and connects them. The curved section 52E is located within the cable housing space 60.

[0050] The flat cable 54 includes a first winding section 54C, a second winding section 54D, and a curved section 54E. The first winding section 54C is wound at least partially along the outer circumferential wall 11. The second winding section 54D is wound at least partially along the inner circumferential wall 21. The curved section 54E is located between the first winding section 54C and the second winding section 54D and connects them. The curved section 54E is located within the cable housing space 60.

[0051] The flat cable 53 includes a first winding section 53C, a second winding section 53D, and a curved section 53E. The first winding section 53C is wound at least partially along the outer circumferential wall 11. The second winding section 53D is wound at least partially along the inner circumferential wall 21. The curved section 53E is located between the first winding section 53C and the second winding section 53D and connects them. The curved section 53E is located within the cable housing space 60.

[0052] As shown in Figure 5, the flat cable 51 includes at least two conductors 51A and an electrical insulator 51B that at least partially covers the at least two conductors 51A. The at least two conductors 51A are spaced apart in a first arrangement direction D1. The at least two conductors 51A include, for example, a conductive metallic material (e.g., a copper alloy or tough pitch copper). The electrical insulator 51B includes, for example, an electrically insulating resin material. One end of the conductor 51A is configured to be connected to the first busbar 33B of the first electrical connector 33 (see Figure 2). The other end of the conductor 51A is configured to be connected to the first busbar 43B of the first electrical connector 43 (see Figure 2).

[0053] The flat cable 51 is flexible and has a flat shape extending in the first arrangement direction D1. Therefore, the flat cable 51 may also be called a flexible flat cable 51. In this embodiment, the total number of at least two conductors 51A is six or more. The total number of at least two conductors 51A is eight. However, the total number of at least two conductors 51A is not limited to the above range and number.

[0054] The flat cable 52 includes at least two conductors 52A and an electrical insulator 52B that at least partially covers the at least two conductors 52A. The at least two conductors 52A are spaced apart in a second arrangement direction D2. The at least two conductors 52A include, for example, a conductive metallic material (e.g., a copper alloy or tough pitch copper). The electrical insulator 52B includes, for example, an electrically insulating resin material. One end of the conductor 52A is configured to be connected to the second busbar 34B of the second electrical connector 34 (see Figure 2). The other end of the conductor 52A is configured to be connected to the second busbar 44B of the second electrical connector 44 (see Figure 2).

[0055] The flat cable 52 is flexible and has a flat shape extending in the second arrangement direction D2. Therefore, the flat cable 52 may also be called a flexible flat cable 52. In this embodiment, the total number of at least two conductors 52A is six or more. The total number of at least two conductors 52A is eight. However, the total number of at least two conductors 52A is not limited to the above range and number.

[0056] In this embodiment, the total number of at least two conductors 51A is the same as the total number of at least two conductors 52A. However, the total number of at least two conductors 51A may be different from the total number of at least two conductors 52A.

[0057] The flat cable 54 includes at least two conductors 54A and an electrical insulator 54B that at least partially covers the at least two conductors 54A. The at least two conductors 54A are spaced apart in a third arrangement direction D3. The at least two conductors include, for example, a conductive metallic material (e.g., a copper alloy or tough pitch copper). The electrical insulator 54B includes, for example, an electrically insulating resin material. One end of the conductor 54A is configured to be connected to the third busbar 35B of the third electrical connector 35 (see Figure 2). The other end of the conductor 54A is configured to be connected to the third busbar 45B of the third electrical connector 45 (see Figure 2).

[0058] The flat cable 54 is flexible and has a flat shape extending in the third arrangement direction D3. Therefore, the flat cable 54 may also be called a flexible flat cable 54. In this embodiment, the total number of at least two conductors 54A is six or more. The total number of at least two conductors 54A is eight. However, the total number of at least two conductors 54A is not limited to the above range and number.

[0059] In this embodiment, the total number of at least two conductors 54A is the same as the total number of at least two conductors 51A and the total number of at least two conductors 52A. However, the total number of at least two conductors 54A may be different from the total number of at least two conductors 51A and the total number of at least two conductors 52A.

[0060] The dummy flat cable 53 does not contain a conductor. The dummy flat cable 53 is flexible. The dummy flat cable 53 contains a resin material. For example, the dummy flat cable 53 contains an electrically insulating resin material. However, the material of the dummy flat cable 53 is not limited to a resin material.

[0061] As shown in Figure 2, at least one flat cable 50 has a cable length L50. For example, flat cable 51 has a cable length L51. Flat cable 52 has a cable length L52. Flat cable 54 has a cable length L54. Dummy flat cable 53 has a cable length L53. Cable lengths L51, L52, L53, and L54 may also be referred to as cable length L50.

[0062] Cable length L51 is defined as the maximum length of flat cable 51 by at least one of the conductor 51A and the electrical insulator 51B. Cable length L52 is defined as the maximum length of flat cable 52 by at least one of the conductor 52A and the electrical insulator 52B. Cable length L54 is defined as the maximum length of flat cable 54 by at least one of the conductor 54A and the electrical insulator 54B. Cable length L53 is defined as the maximum length of dummy flat cable 53.

[0063] At least one of the cable lengths L51, L52, L53, and L54 is different from the other cable lengths. For example, cable length L53 is longer than cable lengths L51, L52, and L54. Cable lengths L51 and L54 are longer than cable length L52. Cable length L51 is approximately the same as cable length L54. However, the relationships between cable lengths L51, L52, L53, and L54 are not limited to the relationships described above.

[0064] As shown in Figure 6, the maximum rotation angle θ1 defined from the neutral position P0 to the rotation end P1 of the rotator 20 relative to the stator 10 can be assumed to be 270 degrees or less, or greater than 270 degrees and 1800 degrees or less. The neutral position P0 corresponds to the neutral position of the steering.

[0065] The maximum rotation angle θ2 defined from the neutral position P0 of the rotator 20 to the rotation end P2 relative to the stator 10 can be assumed to be 270 degrees or less, or greater than 270 degrees and 1800 degrees or less. The maximum rotation angles θ1 and θ2 can also be referred to as the maximum rotation angle θ. The maximum rotation angle θ is defined from the neutral position P0 of the rotator 20 to the rotation end P1 or P2.

[0066] If the maximum rotation angle θ is 270 degrees or less, the rotary connector device 2 is installed, for example, in a steer-by-wire vehicle. In the case of a steer-by-wire system, the maximum rotation angle θ may be 150 degrees or less. If the maximum rotation angle θ is greater than 270 degrees, the rotary connector device 2 is installed, for example, in a vehicle using a system other than a steer-by-wire system.

[0067] As shown in Figure 4, the rotator 20 includes a viewing window 20W. The cable housing space 60 is visible from the outside of the rotator 20 through the viewing window 20W. In this embodiment, the stator 10 does not include any other viewing windows besides the viewing window 20W. However, the stator 10 may include other viewing windows besides the viewing window 20W.

[0068] As shown in Figure 1, the curved portion 52E is positioned at a reference position P3 that is visible from the outside of the rotator 20 through the viewing window 20W when the rotator 20 is in a neutral position P0 relative to the stator 10. This allows the operator to recognize whether the rotator 20 is in the neutral position P0 when attaching the rotary connector device 2 to the vehicle body.

[0069] The number of turns of the flat cables 51, 52, and 54 and the dummy flat cable 53 shown in Figure 4 corresponds, for example, to a maximum rotation angle θ of 720 to 900 degrees. The cable lengths L51, L52, L54, and L53 of the flat cables 51, 52, and 54 and the dummy flat cable 53 vary depending on the maximum rotation angle θ.

[0070] For example, as shown in Figure 7, when the maximum rotation angle θ is 270 degrees or less (for example, when the maximum rotation angle θ is set to 270 degrees), the cable length L50 of the flat cable 50 can be shortened. In particular, when the rotary connector device 2 is mounted on a steer-by-wire steering system, the maximum rotation angle θ becomes smaller, and the cable length L50 of the flat cable 50 can be shortened compared to when the rotary connector device 2 is mounted on a steering system other than a steer-by-wire system. In this case, as shown in Figure 7, the curved portion 52E of the flat cable 52 is positioned at a reference position P3 that is visible from the outside of the rotator 20 through the viewing window 20W when in the neutral state.

[0071] On the other hand, as shown in Figure 8, when the maximum rotation angle θ is greater than 270 degrees and less than or equal to 1800 degrees (for example, when the maximum rotation angle θ is set to 900 degrees), the cable length L50 of the flat cable 50 becomes longer. In this case, the curved portion 52E of the flat cable 52 may be positioned in a location that is not visible from the outside of the rotator 20 through the viewing window 20W when in the neutral position.

[0072] Therefore, as shown in Figure 9, in the rotary connector device 2, the cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R, which is calculated based on the maximum rotation angle θ defined from the neutral position P0 of the rotator 20 to the rotation end P1 or P2, so that the curved portion 52E is visible from the outside of the rotator 20 through the viewing window 20W when the rotator 20 is in a neutral position P0 relative to the stator 10. The cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R so that the curved portion 52E is positioned at the reference position P3 when the rotator 20 is in a neutral position. For example, the flat cable 52 includes an excess portion 52F that makes the cable length L52 longer than the reference cable length L52R. The excess portion 52F is included in at least one of the first winding portion 52C (see, for example, Figure 4) and the second winding portion 52D (see, for example, Figure 4). In other words, as shown in Figure 8, the curved portion 52E is positioned in a location that is not visible from the outside of the rotator 20 through the viewing window 20W when there is no excess portion 52F (for example, the position shown by the dashed line).

[0073] Thus, as shown in Figure 9, by providing an excess portion 52F in the flat cable 52, the curved portion 52E can be positioned at a reference position P3 visible through the viewing window 20W in the neutral state, allowing the operator to recognize that the rotator 20 is positioned at the neutral position P0.

[0074] As shown in Figure 4, it is preferable to arrange the curved sections 51E, 52E, 53E, and 54E at approximately equal intervals so that they do not interfere with each other. Therefore, as shown in Figure 9, the flat cable 51 includes an excess section 51F that makes the cable length L51 longer than the reference cable length L51R. The excess section 51F is included in at least one of the first winding section 51C (see, for example, Figure 4) and the second winding section 51D (see, for example, Figure 4). The flat cable 53 includes an excess section 53F that makes the cable length L53 longer than the reference cable length L53R. The excess section 53F is included in at least one of the first winding section 53C (see, for example, Figure 4) and the second winding section 53D (see, for example, Figure 4). The flat cable 54 includes an excess section 54F that makes the cable length L54 longer than the reference cable length L54R. The excess portion 54F is included in at least one of the first winding portion 54C (see, for example, Figure 4) and the second winding portion 54D (see, for example, Figure 4). The lengths of the excess portions 51F, 53F, and 54F are the same as the length of the excess portion 52F.

[0075] In the examples shown in Figures 7 to 9, the cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R so that when the maximum rotation angle θ is large, the curved portion 52E is positioned at the reference position P3 in the neutral state. However, as shown in Figures 10 to 12, the cable length L52 of the flat cable 52 may also be set to be longer than the reference cable length L52R so that when the maximum rotation angle θ is small, the curved portion 52E is positioned at the reference position P3 in the neutral state.

[0076] For example, as shown in Figure 10, when the maximum rotation angle θ is greater than 270 degrees and less than or equal to 1800 degrees (for example, when the maximum rotation angle θ is set to 900 degrees), the curved portion 52E of the flat cable 52 is positioned at a reference position P3 that is visible from the outside of the rotator 20 through the viewing window 20W in the neutral state.

[0077] On the other hand, as shown in Figure 11, when the maximum rotation angle θ is 270 degrees or less (for example, when the maximum rotation angle θ is set to 270 degrees), the curved portion 52E of the flat cable 52 may be positioned in a location that is not visible from the outside of the rotator 20 through the viewing window 20W when in the neutral position.

[0078] Therefore, as shown in Figure 12, in the rotary connector device 2, the cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R, which is calculated based on the maximum rotation angle θ defined from the neutral position P0 of the rotator 20 to the rotation end P1 or P2, so that the curved portion 52E is visible from the outside of the rotator 20 through the viewing window 20W when the rotator 20 is in a neutral position P0 relative to the stator 10. The cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R so that the curved portion 52E is positioned at the reference position P3 when the rotator 20 is in a neutral position. For example, the flat cable 52 includes an excess portion 52F that makes the cable length L52 longer than the reference cable length L52R. The excess portion 52F is included in at least one of the first winding portion 52C (see, for example, Figure 4) and the second winding portion 52D (see, for example, Figure 4). In other words, as shown in Figure 11, the curved portion 52E is positioned in a location that is not visible from the outside of the rotator 20 through the viewing window 20W when there is no excess portion 52F (for example, the position shown by the dashed line).

[0079] Thus, as shown in Figure 12, by providing an excess portion 52F in the flat cable 52, the curved portion 52E can be positioned at the reference position P3 visible through the viewing window 20W in the neutral state, allowing the operator to recognize that the rotator 20 is positioned at the neutral position P0.

[0080] As shown in Figure 4, it is preferable to arrange the curved sections 51E, 52E, 53E, and 54E at approximately equal intervals so that they do not interfere with each other. Therefore, as shown in Figure 12, the flat cable 51 includes an excess section 51F that makes the cable length L51 longer than the reference cable length L51R. The excess section 51F is included in at least one of the first winding section 51C (see, for example, Figure 4) and the second winding section 51D (see, for example, Figure 4). The flat cable 53 includes an excess section 53F that makes the cable length L53 longer than the reference cable length L53R. The excess section 53F is included in at least one of the first winding section 53C (see, for example, Figure 4) and the second winding section 53D (see, for example, Figure 4). The flat cable 54 includes an excess section 54F that makes the cable length L54 longer than the reference cable length L54R. The excess portion 54F is included in at least one of the first winding portion 54C (see, for example, Figure 4) and the second winding portion 54D (see, for example, Figure 4). The lengths of the excess portions 51F, 53F, and 54F are the same as the length of the excess portion 52F.

[0081] Here, we will explain how to calculate the reference cable lengths L51R, L52R, L53R, and L54R. The reference cable lengths L51R, L52R, L53R, and L54R are calculated, for example, using the computer 70 shown in Figure 13.

[0082] As shown in Figure 13, the computer 70 includes an electronic control circuit 71, a user interface 72, and a display 73. The electronic control circuit 71 is electrically connected to the user interface 72 and the display 73.

[0083] The electronic control circuit 71 includes, for example, at least one processor 71P, at least one memory 71M, at least one circuit board 71C, and at least one 71B. The at least one processor 71P includes, for example, at least one of a CPU (Central Processing Unit), an MPU (Micro Processing Unit), and a GPU (Graphic Processing Unit). The at least one memory 71M includes, for example, at least one of volatile memory and non-volatile memory. An example of volatile memory includes at least one of RAM (Random Access Memory) and DRAM (Dynamic Random Access Memory). An example of non-volatile memory includes at least one of ROM (Read Only Memory) and EEPROM (Electrically Erasable Programmable ROM). The at least one memory 71M may also be referred to as a computer-readable storage medium. The at least one processor 71P and the at least one memory 71M are electrically mounted on at least one circuit board 71C. At least one processor 71P and at least one memory 71M are electrically connected to each other via at least one circuit board 71C. The at least one processor 71P may also be referred to as at least one hardware processor 71P or processor circuitry 71P. The at least one memory 71M may also be referred to as at least one hardware memory 71M or memory circuitry 71M.

[0084] The electronic control circuit 71 is programmed to implement the control algorithm of the computer 70. At least one memory 71M of the electronic control circuit 71 stores software, such as a program for implementing the control algorithm of the computer 70. At least one processor 71P implements the control algorithm of the computer 70 by reading and executing the program stored in at least one memory 71M.

[0085] The configuration of the electronic control circuit 71 is not limited to at least one processor 71P, at least one memory 71M, at least one circuit board 71C, and at least one 71B. The configuration of the electronic control circuit 71 can be realized by hardware only, software only, or a combination of hardware and software. Furthermore, at least one processor 71P and at least one memory 71M may be configured as a single chip, such as an ASIC (Application Specific Integrated Circuit) or FPGA (Field Programmable Gate Array). The electronic control circuit 71 may also be referred to as an electronic control circuitry 71. The electronic control circuit 71 may also be referred to as an electronic controller circuit 71 or an electronic controller circuitry 71.

[0086] The user interface 72 is configured to accept user input. The user inputs information such as input data to the computer 70 via the user interface 72. The user interface 72 includes, for example, a keyboard and a mouse. The user interface 72 may also include other input devices such as a touch panel. The electronic control circuit 71 is electrically connected to the user interface 72 to receive user input accepted by the user interface 72. The electronic control circuit 71 is electrically connected to the user interface 72 to store the user input accepted by the user interface 72 in at least one memory 71M.

[0087] For example, the user interface 72 is configured to receive input data relating to the rotary connector device 2. The electronic control circuit 71 is configured to store the input data received by the user interface 72 in at least one memory 71M. The input data includes at least one of the following: the outer diameter DM1 of the cable housing space 60, the maximum rotation angle θ defined from the neutral position P0 of the rotator 20 relative to the stator 10 to the rotation end P1 or P2, and durability information relating to the durability of the flat cable 50. For example, the input data includes the outer diameter DM1 of the cable housing space 60, the maximum rotation angle θ, durability information, and resistance value information relating to the target resistance value of the flat cable 50. For example, the resistance value information includes a target range for the resistance value.

[0088] The display 73 is configured to display the output of the electronic control circuit 71. The electronic control circuit 71 is configured to control the display 73 so that it displays the output. For example, the display 73 is configured to display input data input to the user interface 72. The electronic control circuit 71 is electrically connected to the display 73 so that it controls the display 73 so that it displays the input data.

[0089] At least one memory 71M is configured to store, for example, data necessary for determining the specifications of the rotary connector device 2. The data includes, for example, basic data showing the relationship between the operational durability test conditions until the flat cable 50 breaks and the radius of the curved portion of the flat cable 50. The operational durability test conditions include, for example, the rotation angle, rotation speed, number of repetitions, and ambient temperature until the flat cable 50 breaks.

[0090] The reference cable lengths L51R, L52R, L53R, and L54R are calculated based on the outer diameter DM1 of the cable housing space 60, the maximum rotation angle θ, and durability information regarding the durability of the flat cable 50. The reference cable lengths L51R, L52R, L53R, and L54R are calculated based on input data related to the rotary connector device 2. For example, the reference cable lengths L51R, L52R, L53R, and L54R are calculated by the computer 70 based on the input data. More specifically, the reference cable lengths L51R, L52R, L53R, and L54R are calculated by the computer 70 based on the input data and basic data. The electronic control circuit 71 stores the basic data in memory 71M.

[0091] The basic data shows the relationship between the operational durability test conditions until the flat cable 50 breaks and the radius of the curved portion of the flat cable 50. The items for the operational durability test conditions are the same as the items for the durability information. Therefore, when the durability information of the input data is entered, the computer 70 calculates the radius of the curved portion of the flat cable 50. Once the radius of the curved portion is calculated, the computer 70 calculates the inner diameter DM2 of the cable housing space 60 that can maintain the calculated radius.

[0092] Furthermore, if there are additional portions of the flat cable 50 other than the wound portions, the computer 70 calculates the sum of the lengths of the curved portions 51E, 52E, 53E, or 54E, the length of the portion corresponding to the outer diameter DM1 (e.g., the first winding portion 51C, 52C, 53C, or 54C), the length of the portion corresponding to the inner diameter DM2 (e.g., the second winding portion 51D, 52D, 53D, or 54D), and the length of the additional portions as the standard cable length L50R. The additional portions are, for example, portions provided outside the cable housing space 60.

[0093] As described above, the rotary connector device 2 includes a stator 10, a rotator 20, and a flat cable 52. The rotator 20 is rotatable around the rotation axis A1 relative to the stator 10. The stator 10 and the rotator 20 form a cable housing space 60. The flat cable 52 includes a curved portion 52E provided within the cable housing space 60. The rotator 20 includes a viewing window 20W. The cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R, which is calculated based on the maximum rotation angle θ defined from the neutral position P0 of the rotator 20 to the rotation end P1 or P2, so that the curved portion 52E is visible from the outside of the rotator 20 through the viewing window 20W when the rotator 20 is in a neutral position P0 relative to the stator 10.

[0094] In the rotary connector device 2, the cable length L52 of the flat cable 52 is set to be longer than the reference cable length L52R so that the curved portion 52E is visible from the outside of the rotator 20 through the viewing window 20W when it is in the neutral position. Therefore, regardless of the maximum rotation angle θ, the operator can check the curved portion 52E through the viewing window 20W and recognize that the rotator 20 is in the neutral position P0. Consequently, even if the maximum rotation angle θ is different, the same rotator 20 can be used. This makes it possible to provide a rotary connector device 2 that can be used with various vehicles while reducing manufacturing costs.

[0095] Furthermore, the color of the flat cable 52 visible through the viewing window 20W may be changed to allow identification of which steering system the rotary connector device 2 corresponds to. For example, when the maximum rotation angle θ shown in Figure 7 is 270 degrees, the color of the flat cable 52 may be set to a first color, and when the maximum rotation angle θ shown in Figure 9 is 900 degrees, the color of the flat cable 52 may be set to a second color different from the first color. In the example shown in Figure 7, the colors of the flat cables 51, 53, and 54 may be the first color, or the colors of the flat cables 51, 53, and 54 may be different from the first color. Similarly, in the example shown in Figure 9, the colors of the flat cables 51, 53, and 54 may be the second color, or the colors of the flat cables 51, 53, and 54 may be different from the second color. Similar modifications can be applied to the cases shown in Figures 10 and 12.

[0096] In this application, "comprise" and its derivatives are non-restrictive terms that describe the existence of components and do not exclude the existence of other components not described. This also applies to "have," "include," and their derivatives.

[0097] In this application, ordinal numbers such as "first" and "second" are merely terms used to identify the components and do not have any other meaning (e.g., a specific order). For example, the existence of a "first element" does not implicitly mean that a "second element" exists, nor does the existence of a "second element" implicitly mean that a "first element" exists.

[0098] Words expressing degree, such as "substantially," "about," and "approximately," may mean a reasonable deviation that does not significantly alter the final result. All numerical values ​​described in this application may be interpreted as including words such as "substantially," "about," and "approximately."

[0099] Furthermore, the terms “parallel,” “perpendicular,” and “coincident” in this disclosure should not be interpreted strictly, and allow for deviations resulting from design tolerances, manufacturing errors, and assembly errors. In other words, the terms “parallel,” “perpendicular,” and “coincident” include the meanings of “approximately parallel,” “approximately perpendicular,” and “approximately coincidental,” respectively. Other terms relating to arrangement should also not be interpreted strictly.

[0100] Furthermore, the expression "at least one of A and B" in this disclosure includes, for example, (1) A only, (2) B only, and (3) both A and B. The expression "at least one of A, B, and C" includes, for example, (1) A only, (2) B only, (3) C only, (4) A and B, (5) B and C, (6) A and C, and (7) all of A, B, and C. In this disclosure, the expression "at least one of A and B" is not construed as "at least one of A and at least one of B".

[0101] Based on the above disclosure, it is clear that various changes and modifications to the present invention are possible. Therefore, the present invention may be implemented in a manner different from the specific disclosures of this application, without departing from the spirit of the invention. [Explanation of Symbols]

[0102] 2: Rotary connector device 4: First electronic control unit 6: Second electronic control unit 10: Status 11:Outer wall 20: Rotator 20W: Viewing window 21: Inner wall 30: Stator-side connector 40: Rotator side connector 50: Flat Cable 51: Flat Cable 51C: First volume 51D: Volume 2 51E: Curved section 51F: Surplus 52: Flat Cable 52C: Volume 1 52D: Volume 2 52E: Curved section 52F: Surplus 53: Flat Cable 53C: Volume 1 53D: Volume 2 53E: Curved section 53F: Surplus 54: Flat Cable 54C: First volume 54D: Volume 2 54E: Curved section 60: Cable housing space L51R, L52R, L53R, L54R: Standard cable length L50, L51, L52, L53, L54: Cable length A1: Axis of rotation P0: Neutral position P1: Rotating end P2: Rotating end P3: Reference position θ: Maximum rotation angle

Claims

1. stator and, A rotator that can rotate around the axis of rotation relative to the stator, Equipped with a flat cable, The stator and the rotator form a cable housing space. The flat cable includes a curved portion provided within the cable housing space, The rotator includes a viewing window, The length of the flat cable is set to be longer than the reference cable length calculated based on the maximum rotation angle defined from the neutral position of the rotator to the rotation end, so that the curved portion is visible from the outside of the rotator through the viewing window when the rotator is in a neutral position relative to the stator. Rotary connector device.

2. The stator includes an outer perimeter wall that partially defines the cable housing space, The rotator includes an inner circumferential wall that partially defines the cable housing space, The flat cable includes a first winding portion wound at least partially along the outer circumferential wall and a second winding portion wound at least partially along the inner circumferential wall. The curved portion is provided between the first winding portion and the second winding portion, and connects the first winding portion and the second winding portion. The rotary connector device according to claim 1.

3. The flat cable includes an excess portion that makes the cable length longer than the reference cable length, The excess portion is included in at least one of the first winding portion and the second winding portion. The rotary connector device according to claim 2.

4. The curved portion is positioned so that it is not visible from the outside of the rotator through the viewing window when there is no excess portion. The rotary connector device according to claim 3.

5. The stator does not include any other viewing windows besides the aforementioned viewing window. A rotary connector device according to any one of claims 1 to 4.

6. The maximum rotation angle is 270 degrees or less. A rotary connector device according to any one of claims 1 to 4.

7. The aforementioned maximum rotation angle is greater than 270 degrees and less than or equal to 1800 degrees. A rotary connector device according to any one of claims 1 to 4.

8. A stator-side connector provided on the stator, The rotator further comprises a rotator-side connector provided on the rotator, The flat cable electrically connects the stator-side connector and the rotator-side connector. A rotary connector device according to any one of claims 1 to 4.

9. The standard cable length is calculated based on the outer diameter of the cable housing space, the maximum rotation angle, and durability information regarding the durability of the flat cable. A rotary connector device according to any one of claims 1 to 4.

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