Sensor device, electric power steering device, and method for manufacturing sensor device

Abstract

To provide a sensor device and the like that make assembling easy.SOLUTION: A sensor device comprises: a main driving gear 35 that is rotatably provided integrally with an opinion shaft; a first driven gear 51 that engages with the main driving gear 35; a second driven gear 52 that engages with the main driving gear 35, and is different in the number of teeth from the first driven gear 51; a first sensor 55 that is provided corresponding to the first driven gear 51; a second sensor 56 that is provided corresponding to the second driven gear 52; a substrate 58 that has the first sensor 55 and second sensor 56 packaged; a holding member 70 that holds the first driven gear 51, second driven gear 52 and substrate 58 on the same side; and a housing 90 to which the holding member 70 in a state of holding the first driven gear 51, second driven gear 52 and substrate 58 is fitted, and a connector supplying electric power to at least the first sensor 55 and second sensor 56 is connected.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a sensor device, an electric power steering device, and a method for manufacturing the sensor device. [Background technology]

[0002] 2. Description of the Related Art Conventionally, a steering device of a vehicle is provided with a sensor device that detects the steering angle of a steering wheel. For example, the sensor device described in Patent Document 1 is configured as follows. That is, the sensor device includes an external gear that rotates with the shaft, a driven gear that rotates in mesh with the external gear, a permanent magnet that rotates with the driven gear, a magnetic sensor that detects the magnetic field of the permanent magnet, a mounting board on which the magnetic sensor is mounted on a printed circuit board, a cylindrical first housing member that accommodates the external gear, and a second housing member that supports the driven gear and accommodates the mounting board. The first housing member has a fitting hole that opens in a radial direction perpendicular to an axial direction parallel to the rotation axis of the shaft. The second housing member has a flange portion that abuts against an open end face of the fitting hole of the first housing member, and a part of the driven gear protruding from the flange portion meshes with the external gear inside the first housing member.

[0003] In the sensor device described in Patent Document 1, the second housing member integrally includes a flange portion that abuts against the first housing member, a bottomed frame portion provided on the opposite side of the flange portion from the first housing member, and a protruding plate portion that protrudes toward the first housing member from the flange portion. The bottomed frame portion has a frame portion that is substantially trapezoidal when viewed in the axial direction, and a bottom portion that closes one side of the frame portion in the axial direction. A board introduction port for introducing a mounting board into the bottomed frame portion is formed at the end of the frame portion opposite the bottom portion. The protruding plate portion has a support hole into which the protrusion of the first driven gear is loosely fitted, and a support hole into which the protrusion of the second driven gear is loosely fitted. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2019-074364 A Summary of the Invention [Problem to be solved by the invention]

[0005] When assembling the sensor device described in Patent Document 1, it is necessary to support the driven gear in advance in the support hole of the protruding plate part that protrudes toward the first housing member side relative to the flange part, and to introduce the mounting board from the board introduction port formed in the bottomed frame part provided on the opposite side of the flange part from the first housing member side. In addition, when introducing the mounting board into the bottomed frame part, it is necessary to move the mounting board in the axial direction of the pinion shaft and then in a direction perpendicular to the axial direction to insert a part of the mounting board into the inside of the flange part. As described above, in the sensor device described in Patent Document 1, the position where the driven gear is supported on the second housing member and the position where the mounting board is introduced into the second housing member are different, and the mounting board must be moved in the axial direction of the pinion shaft and then in a direction perpendicular to the axial direction, making it difficult to assemble. An object of the present invention is to provide a sensor device etc. that is easy to assemble. [Means for solving the problem]

[0006] The present disclosure will be described below. One aspect of the present disclosure is a sensor device comprising: a main gear rotatably mounted on a rotating shaft; a first driven gear meshing with the main gear; a second driven gear meshing with the main gear and having a different number of teeth than the first driven gear; a first rotation angle sensor provided corresponding to the first driven gear; a second rotation angle sensor provided corresponding to the second driven gear; a board on which the first rotation angle sensor and the second rotation angle sensor are mounted; a holding member that holds the first driven gear, the second driven gear, and the board on the same side; and a housing into which the holding member holding the first driven gear, the second driven gear, and the board is fitted and to which a connector that supplies power to at least the first rotation angle sensor and the second rotation angle sensor is connected. Here, the holding member may hold the first driven gear and the second driven gear in a state where they are inserted therein. The holding member may hold the substrate in a state where the substrate is inserted therein. The device may further include a terminal member having a terminal connected to the substrate and a plate-shaped portion that is penetrated by the terminal and fixes the terminal that is penetrated therethrough, and the plate-shaped portion may be sandwiched between the retaining member and the housing. Furthermore, the substrate may further include a first torque sensor and a second torque sensor that detect a torque applied to rotate the rotation shaft, the first torque sensor being mounted on a first surface of the substrate, and the second torque sensor being mounted on a second surface of the substrate that is a surface opposite to the first surface and on which the first rotation angle sensor and the second rotation angle sensor are mounted, and may be disposed between the first rotation angle sensor and the second rotation angle sensor. The holding member may hold a collector that collects magnetic flux, and may have a limiting portion that limits movement of the collector. Another aspect of the present disclosure is an electric power steering device including a steering wheel and the sensor device according to the above aspect that detects a rotation angle of the steering wheel. Another aspect of the present disclosure is a method for manufacturing a sensor device, comprising the steps of: inserting a first driven gear that meshes with a main gear that is rotatably mounted integrally on a rotating shaft into a holding member in a first direction; inserting a second driven gear that meshes with the main gear and has a different number of teeth than the first driven gear into the holding member in the first direction; inserting a board on which a first rotation angle sensor provided corresponding to the first driven gear and a second rotation angle sensor provided corresponding to the second driven gear are mounted into the holding member in the first direction; and fitting the holding member holding the first driven gear, the second driven gear, and the board into a housing to which connectors that supply power to at least the first rotation angle sensor and the second rotation angle sensor are connected. Effect of the Invention

[0007] According to the present invention, it is possible to provide a sensor device etc. that is easy to assemble. [Brief description of the drawings]

[0008] [Figure 1] 1 is a diagram showing an example of a schematic configuration of an electric power steering device 100 according to a first embodiment. [Diagram 2] 2 is an example of an exploded perspective view of some of the components that configure the sensor device 1. FIG. [Diagram 3] 1 is a diagram showing an example of a cross section of a sensor device 1. FIG. [Figure 4] FIG. 13 is an example of a view of the subunit 50 and the housing 90 before they are assembled, viewed obliquely from a second side on the radially outer side. [Diagram 5] 13 is an example of a view of the sensor unit 40 before it is assembled, as viewed obliquely from a second side on the inside in the radial direction. FIG. [Figure 6] 1 is an example of a schematic configuration of a first collector 41, a second collector 42, a magnetic body 45, a first driven gear 51, a second driven gear 52, and a substrate 58, viewed in a radial direction from the radially inner side. [Figure 7] 1 is an example of a view of the subunit 50 as viewed from the second radially outer side toward the center of rotation C. FIG. [Figure 8] 1 is a cross-sectional view showing an example of a schematic configuration of a terminal member 59. FIG. [Figure 9] 1 is an example of a view of a first driven gear 51, a second driven gear 52, and an elastic body 60 as viewed in the axial direction from a first side. [Figure 10] 1 is a diagram showing an example of a schematic configuration of a holding member 70, as viewed obliquely from a second side on the radially inner side. [Figure 11] 1 is an example of a view of the housing 90 as viewed obliquely from a second radially inner side. [Figure 12] FIG. 11 is an example of a schematic configuration of a first sensor 243 and a second sensor 244 of a sensor unit 240 of a sensor device 2 according to a second embodiment, viewed in a radial direction from a radially inner side. [Figure 13] 13 is a diagram showing an example of a schematic configuration of a holding member 370 of a sensor unit 340 of a sensor device 3 according to a third embodiment. FIG. [Figure 14] 13 is a diagram showing an example of a schematic configuration of a housing 390 of a sensor unit 340 of a sensor device 3 according to a third embodiment. FIG. [Figure 15] 13 is a diagram showing an example of a schematic configuration of a holding member 470 of a sensor unit 440 of a sensor device 4 according to a fourth embodiment. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings. Note that the embodiment described below is an example of the present invention, and the present invention is not limited to the embodiment described below. <First embodiment> FIG. 1 is a diagram showing an example of a schematic configuration of an electric power steering device 100 according to the first embodiment. The electric power steering device 100 (hereinafter, sometimes simply referred to as "steering device 100") is a steering device for arbitrarily changing the direction of travel of a vehicle, and in this embodiment, a configuration applied to an automobile is illustrated as an example.

[0010] The steering device 100 includes a steering wheel 101 operated by a driver, and a steering shaft 102 that is integral with the steering wheel 101. The steering shaft 102 and an upper shaft 103 are connected via a universal joint 103a, and the upper shaft 103 and a lower shaft 108 are connected via a universal joint 103b.

[0011] The steering device 100 also includes a tie rod 104 connected to each of the left and right front wheels 150 serving as rolling wheels, and a rack shaft 105 connected to the tie rod 104. The steering device 100 also includes a pinion 106a which constitutes a rack-pinion mechanism together with rack teeth 105a formed on the rack shaft 105. The pinion 106a is formed at the lower end of the pinion shaft 106.

[0012] The steering device 100 also has a steering gear box 107 that houses the pinion shaft 106. The pinion shaft 106 is coaxially connected to a lower shaft 108 in the steering gear box 107 via a torsion bar 112, and the pinion shaft 106 and the lower shaft 108 rotate relatively in response to the torsion of the torsion bar 112. The torsion of the torsion bar 112 corresponds to the steering torque applied to the steering wheel 101.

[0013] A sensor device 1 is provided inside the steering gear box 107, which detects the steering torque applied to the steering wheel 101 based on the relative rotation angle between a lower shaft 108 and a pinion shaft 106. The sensor device 1 also detects the rotation angle of the steering wheel 101 (hereinafter, sometimes referred to as the "steering angle").

[0014] The steering device 100 also has an electric motor 110 supported by a steering gear box 107, and a speed reduction mechanism 111 that reduces the driving force of the electric motor 110 and transmits it to the pinion shaft 106. The steering device 100 further includes a control device 120 that controls the operation of the electric motor 110. An output value of the sensor device 1 described above is input to the control device 120.

[0015] <Configuration of sensor device 1> FIG. 2 is an example of an exploded perspective view of some of the components that constitute the sensor device 1. As shown in FIG. FIG. 3 is a diagram showing an example of a cross section of the sensor device 1. As shown in FIG. FIG. 4 is an example of a view of the subunit 50 and the housing 90 before they are assembled, viewed obliquely from the second side on the radially outer side. FIG. 5 is an example of a view of the sensor unit 40 before it is assembled, as viewed obliquely from the second side on the inside in the radial direction. FIG. 6 is an example of a schematic configuration of the first collector 41, the second collector 42, the magnetic body 45, the first driven gear 51, the second driven gear 52, and the substrate 58, viewed in the radial direction from the radially inner side. FIG. 7 is an example of a view of the subunit 50 as viewed from the second radially outer side toward the center of rotation C. FIG. 8 is a cross-sectional view showing an example of a schematic configuration of the terminal member 59. As shown in FIG. FIG. 9 is an example of a view of the first driven gear 51, the second driven gear 52, and the elastic body 60 as viewed in the axial direction from the first side. FIG. 10 is an example of a schematic configuration of the holding member 70, viewed obliquely from the second side on the radially inner side. FIG. 11 is an example of a view of the housing 90 as viewed obliquely from the second radially inner side.

[0016] The sensor device 1 includes a magnet collar 21 and a permanent magnet 22 fixed to the lower shaft 108, and a first stator 31, a second stator 32, a stator holder 33, a collar 34, and a main driving gear 35 fixed to the pinion shaft 106. The sensor device 1 also includes a sensor unit 40 that collects magnetic flux guided by the first stator 31 and the second stator 32, and outputs an electric signal corresponding to the relative rotation angle between the lower shaft 108 and the pinion shaft 106. The sensor unit 40 also outputs an electric signal corresponding to the steering angle.

[0017] In the following description, the axial direction of the lower shaft 108 and the pinion shaft 106, which are arranged concentrically, may be simply referred to as the "axial direction." In addition, in the axial direction, the side on which the lower shaft 108 is arranged (upper side in FIG. 2) may be referred to as the "first side," and the side on which the pinion shaft 106 is arranged (lower side in FIG. 2) may be referred to as the "second side." In addition, the direction perpendicular to the axial direction (left-right direction in FIG. 2) may be referred to as the "radial direction." In addition, in the radial direction, the side of the rotation center C of the lower shaft 108 and the pinion shaft 106 may be referred to as the "radial inner side," and the side away from the rotation center C may be referred to as the "radial outer side."

[0018] The permanent magnet 22 is formed in a ring shape with N poles and S poles arranged alternately in the circumferential direction, and is magnetized in the circumferential direction. For example, the permanent magnet 22 has eight N poles and eight S poles arranged at equal angular intervals. The magnet collar 21 is made of iron and formed into a cylindrical shape, with the permanent magnet 22 fitted onto the outer circumferential surface 21a and fixed to the magnet collar 21 by, for example, gluing. The lower shaft 108 is inserted into the inner circumferential surface 21b of the magnet collar 21, and the magnet collar 21 is fixed to the lower shaft 108 by press-fitting, welding, crimping, or the like. This causes the permanent magnet 22 to rotate together with the lower shaft 108.

[0019] The first stator 31 and the second stator 32 are formed of a soft magnetic material such as permalloy. The first stator 31 has an annular portion 31b formed in an annular shape. The first stator 31 also has a plurality of (e.g., eight) stator claws 31a that extend from the inner peripheral edge of the annular portion 31b in the axial direction of the lower shaft 108 and are aligned in the circumferential direction. The plurality of stator claws 31a are formed at equal angular intervals (e.g., 45 degree intervals) in the circumferential direction.

[0020] The first stator 31 has a plurality of (e.g., three) protruding pieces 31c that protrude in the axial direction from the outer circumferential edge of the annular portion 31b. The plurality of protruding pieces 31c are formed at equal angular intervals (e.g., 120 degree intervals) in the circumferential direction. Each protruding piece 31c is pressed radially inward by a tool or the like to be plastically deformed, and is crimped to a positioning portion 33j of the stator holder 33, and the first stator 31 is joined to the stator holder 33.

[0021] The second stator 32 is the same as the first stator 31 arranged upside down as shown in the figure, and the annular portion 32b, stator claws 32a and protrusions 32c correspond to the annular portion 31b, stator claws 31a and protrusions 31c of the first stator 31, respectively. Similar to the first stator 31 , the second stator 32 is also positioned at the positioning portion 33 j of the stator holder 33 and crimped, so that the second stator 32 is joined to the stator holder 33 .

[0022] The stator holder 33 is formed into a cylindrical shape and is made of a non-magnetic material (for example, resin). The collar 34 is formed into a cylindrical shape from, for example, an iron material, and is integrated with the stator holder 33 by insert molding. The main driving gear 35 is a spur gear, and is integrated with the stator holder 33 by insert molding.

[0023] As described above, the first stator 31, the second stator 32, the stator holder 33, the collar 34 and the main driving gear 35 are integrated together to form the stator unit 36. As shown in FIG. 3, the pinion shaft 106 is inserted into the inner circumferential surface 34b of the collar 34, and the stator unit 36 ​​is fixed to the pinion shaft 106 by press fitting, welding, crimping, or the like.

[0024] Here, with no steering torque acting on the torsion bar 112, the stator unit 36 ​​is fixed to the pinion shaft 106 so that the circumferential center line of each stator claw 31a, 32a of the stator unit 36 ​​fixed to the pinion shaft 106 coincides with the boundary line between the N pole and S pole of the permanent magnet 22 fixed to the lower shaft 108. As shown in FIG. 3, the magnet collar 21 and the permanent magnet 22 on the input shaft side and the stator unit 36 ​​on the output shaft side are covered by a steering gear box 107.

[0025] (Configuration of sensor unit 40) The sensor unit 40 will be described in detail below mainly with reference to FIGS. The sensor unit 40 includes a first collector 41 that collects the magnetic flux guided by the first stator 31, a second collector 42 that collects the magnetic flux guided by the second stator 32, and a first sensor 43 and a second sensor 44 for torque detection. The sensor unit 40 also includes a magnetic body 45 disposed between the first sensor 43 and the second sensor 44.

[0026] The sensor unit 40 also includes a first driven gear 51 that meshes with the main gear 35, and a second driven gear 52 that meshes with the main gear 35 and has a different number of teeth from the first driven gear 51. The sensor unit 40 also includes a first permanent magnet 53 that rotates with the first driven gear 51, and a second permanent magnet 54 that rotates with the second driven gear 52. The sensor unit 40 also includes a first sensor 55 and a second sensor 56 for detecting a rotation angle according to the steering angle.

[0027] The sensor unit 40 also includes a substrate 58 on which the first sensor 43, the second sensor 44, the first sensor 55, and the second sensor 56 are mounted, and a terminal member 59 connected to the substrate 58. The substrate 58 is rectangular and disposed so as to be perpendicular to the axial direction. In the following description, the longitudinal direction of the substrate 58 may be referred to as the "width direction." In addition, in the width direction, the side on which the first driven gear 51 is disposed (the left side in FIG. 7) may be referred to as the "third side," and the side on which the second driven gear 52 is disposed (the right side in FIG. 7) may be referred to as the "fourth side."

[0028] The sensor unit 40 also includes an elastic body 60 that applies a force to the first driven gear 51 and the second driven gear 52 in a direction that moves them closer to the main driving gear . The sensor unit 40 also includes a holding member 70 that holds the first collector 41, the second collector 42, the magnetic body 45, the first driven gear 51, the second driven gear 52, the substrate 58, the elastic body 60, and the like. The first collector 41, the second collector 42, the magnetic body 45, the first driven gear 51, the second driven gear 52, the substrate 58, the elastic body 60, and the holding member 70 constitute a subunit 50.

[0029] The sensor unit 40 also includes a housing 90 into which the subunit 50 is fitted and to which a connector 130 that supplies power to the first sensor 43, the second sensor 44, the first sensor 55 and the second sensor 56 is connected. Each part is described in detail below.

[0030] {First collector 41, second collector 42, magnetic body 45} As shown in FIG. 5, the first collector 41 includes an arc portion 410 formed in the shape of an arc of a flat plate, a first protrusion 411 protruding radially and axially from the circumferential center of the arc portion 410, and a second protrusion 412 provided on both circumferential sides of the first protrusion 411 and protruding radially. The first protrusion 411 has a rectangular parallelepiped tip 415. The tip 415 is in the shape of a flat plate parallel to the arc portion 410.

[0031] As shown in FIG. 5, the second collector 42 includes an arc portion 420 formed in the shape of an arc of a flat plate, a first protrusion 421 protruding radially and axially from the circumferential center of the arc portion 420, and a second protrusion 422 provided on both circumferential sides of the first protrusion 421 and protruding radially. The first protrusion 421 has a rectangular parallelepiped tip 425. The tip 425 is in the shape of a flat plate parallel to the arc portion 420.

[0032] The tip portion 415 of the first collector 41 and the tip portion 425 of the second collector 42 are disposed so as to face each other in the axial direction, and a rectangular parallelepiped magnetic body 45 is provided between the tip portion 415 and the tip portion 425. The magnetic body 45 is formed from a soft magnetic material such as permalloy.

[0033] {First sensor 43, second sensor 44, substrate 58} The first sensor 43 and the second sensor 44 can be, for example, a magnetic sensor that utilizes a change in resistance value due to a magnetic field. The first sensor 43 and the second sensor 44 output an electric signal corresponding to the amount of magnetic flux introduced by the first collector 41 and the amount of magnetic flux introduced by the second collector 42, that is, an electric signal corresponding to the relative rotation angle between the lower shaft 108 and the pinion shaft 106.

[0034] The first sensor 43 is mounted on a first surface 581 which is a surface on a first side of the substrate 58. The first sensor 43 is disposed between the tip portion 415 of the first collector 41 and the magnetic body 45. The second sensor 44 is mounted on a second surface 582 which is the second surface of the substrate 58. The second sensor 44 is disposed between the tip portion 425 of the second collector 42 and the magnetic body 45.

[0035] {First driven gear 51, second driven gear 52} The first driven gear 51 has a disk-shaped first toothed portion 511 having a plurality of teeth formed on its outer periphery that mesh with the teeth of the main driving gear 35, and a pair of first shaft portions 512 provided on both axial sides of the first toothed portion 511. The second driven gear 52 has a disk-shaped second toothed portion 521 having a plurality of teeth formed on its outer periphery that mesh with the teeth of the main driving gear 35, and a pair of second shaft portions 522 provided on both axial sides of the second toothed portion 521.

[0036] The first toothed portion 511 and the second toothed portion 521 have the same tooth shape but different numbers of teeth. For example, the number of teeth of the first toothed portion 511 can be 28, and the number of teeth of the second toothed portion 521 can be 26. In addition, due to the fact that the tooth shapes are the same but the numbers of teeth are different, the pitch circle diameter of the first toothed portion 511 is larger than the pitch circle diameter of the second toothed portion 521. Therefore, the distance from the rotation center C of the pinion shaft 106 to the rotation center C1 of the first driven gear 51 (see FIG. 9) is larger than the distance from the rotation center C of the pinion shaft 106 to the rotation center C2 of the second driven gear 52 (see FIG. 9). In other words, the rotation center C1 of the first driven gear 51 is located radially outward from the rotation center C2 of the second driven gear 52. The pair of first shaft portions 512 and the pair of second shaft portions 522 all have the same outer diameter.

[0037] The first driven gear 51 is provided on a third side in the width direction, and the second driven gear 52 is provided on a fourth side in the width direction. The first driven gear 51 and the second driven gear 52 can be, for example, molded from resin.

[0038] {First permanent magnet 53, second permanent magnet 54, first sensor 55, second sensor 56} The first permanent magnet 53 and the second permanent magnet 54 are each a disk-shaped permanent magnet having a north pole and a south pole. 9, the first permanent magnet 53 is fitted to an end of the first shaft portion 512 on the first side of the pair of first shaft portions 512 of the first driven gear 51 such that at least a portion of the N pole and S pole are exposed. The second permanent magnet 54 is fitted to an end of the second shaft portion 522 on the first side of the pair of second shaft portions 522 of the second driven gear 52 such that at least a portion of the N pole and S pole are exposed.

[0039] The first sensor 55 and the second sensor 56 can be, for example, a magnetic sensor that utilizes a change in resistance value due to a magnetic field. The first sensor 55 and the second sensor 56 are mounted on a second surface 582 of the substrate 58 . The first sensor 55 is provided to face the first permanent magnet 53 fitted in the first shaft portion 512 of the first driven gear 51. The second sensor 56 is provided to face the second permanent magnet 54 fitted in the second shaft portion 522 of the second driven gear 52.

[0040] As described above, the first permanent magnet 53 and the second permanent magnet 54 each have a pair of magnetic poles (N pole and S pole), and the first sensor 55 and the second sensor 56 output a sinusoidal signal according to the rotation angle of the first driven gear 51 and the second driven gear 52. Due to the difference in the number of teeth of the first driven gear 51 and the second driven gear 52, even if the steering wheel 101 is steered to the maximum steering angle in the left and right directions and the pinion shaft 106 rotates multiple times, the phases of the output signals of the first sensor 55 and the second sensor 56 are not synchronized. This allows the control device 120 to detect the rotation angle of the pinion shaft 106 based on the output signals of the first sensor 55 and the second sensor 56.

[0041] {Substrate 58} As shown in FIG. 5, the substrate 58 has a first portion 583 cut out along the outer periphery of the stator unit 36 ​​at the radially inner end. The substrate 58 also has a second portion 584 cut out in a rectangular parallelepiped shape from the circumferential center of the first portion 583 radially outward. The substrate 58 also has a third portion 585 cut out in a rectangular parallelepiped shape from the radially inner end at the third end in the width direction. The substrate 58 also has a fourth portion 586 cut out in a rectangular parallelepiped shape from the radially inner end at the fourth end in the width direction. The third portion 585 and the fourth portion 586 form protrusions 587 at both ends in the width direction of the substrate 58.

[0042] 5, the substrate 58 has the first sensor 43 mounted on a radially inner end portion and widthwise center portion of the first surface 581, and the second sensor 44 mounted on a radially inner end portion and widthwise center portion of the second surface 582. Furthermore, the substrate 58 has the first sensor 43 mounted on a first side of the second portion 584, and the second sensor 44 mounted on a second side of the second portion 584, as shown in FIG. 6. The magnetic body 45 is disposed in the second portion 584. The substrate 58 uses a processing circuit to convert the electrical signals output from the first sensor 43 and the second sensor 44 into electrical signals corresponding to the steering torque, and outputs the signals to the control device 120 (see FIG. 1) from a terminal 591 (described later) via an electric wire.

[0043] In addition, as shown in FIG. 5, a first sensor 55 is mounted on the second surface 582 of the substrate 58 between the second portion 584 and the third portion 585, and a second sensor 56 is mounted on the second surface 582 of the substrate 58 between the second portion 584 and the fourth portion 586. The substrate 58 converts the electrical signals output from the first sensor 55 and the second sensor 56 into electrical signals corresponding to the steering angle using a processing circuit, and outputs the signals to the control device 120 from a terminal 591 (described later) via an electric wire.

[0044] {Terminal part 59} As shown in FIG. 4, the terminal member 59 has a plurality of terminals 591 and a plate-like portion 592 which is penetrated by the plurality of terminals 591 and which fixes the plurality of terminals 591 penetrating therethrough. 8, the terminal 591 is L-shaped, with one end connected to the substrate 58 (see FIG. 4) and the other end disposed radially outward and disposed inside an outer peripheral wall 93 (described later) of the housing 90. An electric wire connector 130 (see FIG. 4) is fitted into the other end of the terminal 591 from the radially outer side. The terminal 591 supplies power to the first sensor 43, the second sensor 44, the first sensor 55, and the second sensor 56 mounted on the substrate 58, and outputs electric signals according to the detection values ​​of these sensors to the control device 120.

[0045] Plate-like portion 592 is flat and is penetrated in the thickness direction by a plurality of terminals 591. Furthermore, both ends of plate-like portion 592 in the thickness direction (radial direction) are in contact with holding member 70 and housing 90, respectively, and are sandwiched between holding member 70 and housing 90.

[0046] {Elastic body 60} The elastic body 60 can be exemplified as a so-called leaf spring formed by bending a plate, as shown in Fig. 5. The elastic body 60 has a body 61 provided at the center in the width direction, a first arm 62 provided on a third side in the width direction and applying a force to the first driven gear 51, and a second arm 63 provided on a fourth side in the width direction and applying a force to the second driven gear 52. The elastic body 60 also has a first connecting portion 64 connecting the body 61 and the first arm 62, and a second connecting portion 65 connecting the body 61 and the second arm 63.

[0047] 9, the body 61 is fitted into a rectangular parallelepiped fifth holding portion 75 of the holding member 70, which will be described later. The body 61 is formed by bending a rectangular plate at the center in the longitudinal direction. When viewed in the axial direction, the body 61 has a V-shape before being fitted into the fifth holding portion 75, and becomes U-shaped after being fitted into the fifth holding portion 75.

[0048] As shown in Fig. 5, a pair of first arms 62 are provided so as to contact the pair of first shaft portions 512 of the first driven gear 51, respectively. That is, the first arms 62 are arranged so as to sandwich the first tooth portion 511 of the first driven gear 51 in the thickness direction. When viewed in the axial direction, the first arms 62 have an arc-shaped portion with the same curvature as the curvature of the outer circumferential surface of the first shaft portion 512, as shown in Fig. 9. Note that the curvature of the first arms 62 may be larger than that of the outer circumferential surface of the first shaft portion 512.

[0049] As shown in FIG. 5, a pair of second arms 63 are provided so as to contact the pair of second shaft portions 522 of the second driven gear 52, respectively. That is, the second arms 63 are arranged so as to sandwich the second tooth portion 521 of the second driven gear 52 in the thickness direction. When viewed in the axial direction, as shown in FIG. 9, the second arms 63 have an arc-shaped portion with the same curvature as the curvature of the outer circumferential surface of the second shaft portion 522. That is, the second arms 63 have the same shape as the first arms 62. The curvature of the second arms 63 may be larger than that of the outer circumferential surface of the second shaft portion 522.

[0050] As shown in Fig. 5, a pair of first connecting portions 64 are provided so as to connect to the pair of first arm portions 62, respectively. As shown in Fig. 9, the first connecting portion 64 has a width direction portion 641 extending in the width direction from the body portion 61 to the third side, and an inclined portion 642 linearly connecting the width direction portion 641 and the first arm portion 62 in a direction inclined in the width direction.

[0051] As shown in Fig. 5, a pair of second connecting portions 65 are provided so as to connect to the pair of second arm portions 63, respectively. As shown in Fig. 9, the second connecting portion 65 does not have a portion corresponding to the width direction portion 641 of the first connecting portion 64, but has an inclined portion 652 that linearly connects the body portion 61 and the second arm portion 63 in a direction inclined in the width direction.

[0052] As shown in Fig. 9, the shape of the first connecting portion 64 and the shape of the second connecting portion 65 are different, and the first connecting portion 64 and the second connecting portion 65 are asymmetrical with respect to the body portion 61. For example, in the embodiment shown in Fig. 9, the inclination angle of the inclined portion 642 with respect to the width direction is smaller than the inclination angle of the inclined portion 652 with respect to the width direction, so that the first connecting portion 64 and the second connecting portion 65 are asymmetrical with respect to the body portion 61. In other words, the first angle α1, which is the angle between the body portion 61 and the inclined portion 642 when fitted into the fifth holding portion 75, is larger than the second angle α2, which is the angle between the body portion 61 and the inclined portion 652 when fitted into the fifth holding portion 75, so that the first connecting portion 64 and the second connecting portion 65 are asymmetrical with respect to the body portion 61.

[0053] {Retaining member 70} 4 and 10, the holding member 70 is inserted into the housing 90 in a state in which it holds the first collector 41, the second collector 42, the magnetic body 45, the first driven gear 51, the second driven gear 52, the substrate 58, the elastic body 60, etc. As shown in Fig. 4, the sensor unit 40 is inserted into an inner peripheral wall 92 (described later) formed on the radially inner side of the housing 90 from the terminal member 59 side, with the terminal member 59 mounted on the substrate 58 facing radially outward and the first collector 41 and the second collector 42 facing radially inward.

[0054] As shown in FIG. 5, the holding member 70 has a first holding portion 71 that holds the first collector 41 and a second holding portion 72 that holds the second collector 42. The first holding portion 71 has a recess that opens radially inward into which the second protrusion 412 of the first collector 41 is fitted, and holds the first collector 41 with the first protrusion 411 exposed, as shown in FIG. 10. The second holding portion 72 has a recess that opens radially inward into which the second protrusion 422 of the second collector 42 is fitted, and holds the second collector 42 with the first protrusion 421 exposed, as shown in FIG. 10. The first collector 41 and the second collector 42 are fitted into the first holding portion 71 and the second holding portion 72, respectively, from the radially inner side.

[0055] 10, the holding member 70 has a third holding portion 73 that holds the magnetic body 45. The third holding portion 73 has a recess that opens to the outside in the radial direction. The magnetic body 45 is fitted into the third holding portion 73 from the outside in the radial direction. 10, the holding member 70 has a fourth holding portion 74 that holds the substrate 58. The fourth holding portion 74 has recesses at both ends in the width direction that hold both ends in the width direction of the substrate 58. The substrate 58 is fitted into the fourth holding portion 74 from the radial outside.

[0056] 10, the holding member 70 has a first bearing 81 that serves as a bearing for the first shaft portion 512 of the first driven gear 51. The first bearing 81 has a curved surface 811 with the same curvature as the outer circumferential surface of the first shaft portion 512, and a notch 812 is formed in the axial center of the first bearing 81. The first driven gear 51 is mounted such that the first tooth portion 511 is inserted into the notch 812 from the radial outside, and the pair of first shaft portions 512 come into contact with the curved surface 811.

[0057] 10, the holding member 70 has a second bearing 82 which serves as a bearing for the second shaft portion 522 of the second driven gear 52. The second bearing 82 has a curved surface 821 with the same curvature as the outer circumferential surface of the second shaft portion 522, and a notch 822 is formed in the axial center of the second bearing 82. The second driven gear 52 is mounted such that the second tooth portion 521 is inserted into the notch 822 from the radial outside, and the second shaft portion 522 comes into contact with the curved surface 821.

[0058] The holding member 70 also has a fifth holding portion 75 that holds the elastic body 60. The fifth holding portion 75 has a rectangular parallelepiped shape with the axial direction being the longitudinal direction and the width direction being the short side, and is a recess that is open on the radially outer side. The elastic body 60 is held by the holding member 70 by fitting the body portion 61 into the fifth holding portion 75 from the radially outer side.

[0059] The holding member 70 is provided with connecting portions 76 for connecting to a housing 90 at each of the four corners when viewed in the radial direction. The holding member 70 has a limiting portion 77 that limits the movement of the first collector 41. The limiting portion 77 has walls provided on both sides in the width direction of a portion where the first protruding portion 411 of the first collector 41 is exposed. Furthermore, the holding member 70 has a limiting portion 78 that limits the movement of the second collector 42. The limiting portion 78 has walls provided on both sides in the width direction of a portion where the first protruding portion 421 of the second collector 42 is exposed.

[0060] {Housing 90} The housing 90 has a flat base 91, an elongated cylindrical inner peripheral wall 92 protruding radially inward from the base 91, and an elongated cylindrical outer peripheral wall 93 protruding radially outward from the base 91. The subunit 50 is fitted into the inside of the inner peripheral wall 92 from the inside in the radial direction. Ends of the multiple terminals 591 of the terminal member 59 are disposed inside the outer peripheral wall 93. Then, an electric wire connector 130 (see FIG. 4) is fitted into the inside of the outer peripheral wall 93 from the outside in the radial direction.

[0061] 8 and 11, a plurality of through holes 94 through which the plurality of terminals 591 pass are formed in the housing 90 at portions corresponding to the inside of the inner peripheral wall 92 and the outer peripheral wall 93. A wall 95 surrounding the plate-shaped portion 592 of the terminal member 59 is formed around the plurality of through holes 94 at a portion corresponding to the inside of the inner peripheral wall 92. The wall 95 prevents the plate-shaped portion 592 from moving in the axial or width direction.

[0062] 9, the housing 90 has a support portion 96 inside the inner peripheral wall 92, which protrudes radially inward from the base portion 91 in a rectangular parallelepiped shape and is capable of supporting the elastic body 60. The support portion 96 supports the entire area of ​​the elastic body 60 in the axial direction. The support portion 96 is also provided in the center in the width direction, and supports a width direction portion 641 of the first connecting portion 64 of the elastic body 60 and a connection portion between the body portion 61 and the second connecting portion 65. The support portion 96 prevents the elastic body 60 from moving radially outward.

[0063] 5, the housing 90 has a fastening portion 97 on each of both ends in the width direction, the fastening portion 97 having a through hole 971 through which a bolt passes. The fastening portion 97 is a plate-shaped portion parallel to the axial direction, and the housing 90 is fastened to the steering gear box 107 by a bolt passed through the through hole 971.

[0064] As shown in FIG. 5, the housing 90 has, at each of its four corners when viewed from the radially inner side, a base 98 with a surface parallel to the axial direction, and a cylindrical protrusion 99 protruding radially inward from the base 98. The housing 90 and the holding member 70 are crimped by melting the tip of the protrusion 99 while the protrusion 99 is passed through the through hole of the connecting portion 76 of the holding member 70 and the connecting portion 76 is abutted against the base 98. In other words, the housing 90 and the holding member 70 are integrated by applying thermal crimping.

[0065] {Manufacturing method} An operator can manufacture the sensor unit 40 of the sensor device 1 configured as above in the following manner. That is, the worker fits the first collector 41 and the second collector 42 into the first holding portion 71 and the second holding portion 72 of the holding member 70, respectively. The worker also fits the magnetic body 45 into the third holding portion 73 of the holding member 70. At that time, the worker inserts the magnetic body 45 into the holding member 70 from the side opposite to the side where the first collector 41 and the second collector 42 are fitted, toward the side where the first collector 41 and the second collector 42 are fitted (hereinafter, may be referred to as the "first direction") (see FIG. 5). At least one of the first collector 41, the second collector 42, and the magnetic body 45 may be integrated with the resin holding member 70 by insert molding.

[0066] The worker also inserts the first driven gear 51 and the second driven gear 52 in the first direction into the holding member 70 so that they contact the first bearing 81 and the second bearing 82 of the holding member 70, respectively, and fits the body 61 of the elastic body 60 into the fifth holding portion 75 of the holding member 70. Furthermore, the worker fits the board 58, on which the first sensor 43, the second sensor 44, the first sensor 55, the second sensor 56 and the terminal member 59 are mounted, into the fourth holding portion 74 of the holding member 70. At that time, the worker inserts the board 58 into the holding member 70 in the first direction. In this manner, the subunit 50 is assembled.

[0067] Thereafter, the worker fits the subunit 50 inside the inner peripheral wall 92 of the housing 90. At that time, the worker passes the protrusion 99 of the housing 90 through the through hole of the connecting portion 76 of the holding member 70, and with the connecting portion 76 abutting against the base 98, performs thermal caulking so as to melt the tip of the protrusion 99, thereby integrating the housing 90 and the holding member 70 together.

[0068] As described above, the manufacturing method of the sensor device 1 includes a step of inserting the first driven gear 51, which meshes with the driving gear 35, which is rotatably provided integrally with the pinion shaft 106 as an example of a rotation shaft, into the holding member 70 in a first direction, and a step of inserting the second driven gear 52 into the holding member 70 in the first direction. The manufacturing method of the sensor device 1 also includes a step of inserting the substrate 58, on which the first sensor 55 as an example of a first rotation angle sensor provided corresponding to the first driven gear 51 and the second sensor 56 as an example of a second rotation angle sensor provided corresponding to the second driven gear 52 are mounted, into the holding member 70 in the first direction. The manufacturing method of the sensor device 1 also includes a step of fitting the holding member 70, which holds the first driven gear 51, the second driven gear 52, and the substrate 58, into the housing 90 to which the connector 130, which supplies power to at least the first sensor 55 and the second sensor 56, is connected.

[0069] According to the above manufacturing method, the first driven gear 51, the second driven gear 52, and the substrate 58 can be assembled to the holding member 70 by inserting the first driven gear 51, the second driven gear 52, and the substrate 58 into the holding member 70 in a first direction. Then, the holding member 70 holding the first driven gear 51, the second driven gear 52, and the substrate 58, in other words, the subunit 50, can be fitted into the housing 90. Therefore, according to the above manufacturing method, assembly is easier than, for example, a case in which the first driven gear 51, the second driven gear 52, and the substrate 58 are inserted into the holding member 70 from different directions.

[0070] {Sensor device 1} The sensor device 1 includes a main gear 35 that is rotatably provided integrally with the pinion shaft 106, a first driven gear 51 that meshes with the main gear 35, and a second driven gear 52 that meshes with the main gear 35 and has a different number of teeth from the first driven gear 51. The sensor device 1 also includes a first sensor 55 provided in correspondence with the first driven gear 51, a second sensor 56 provided in correspondence with the second driven gear 52, and a substrate 58 on which the first sensor 55 and the second sensor 56 are mounted. The sensor device 1 also includes a holding member 70 that holds the first driven gear 51, the second driven gear 52, and the substrate 58 on the radially outer side as an example of the same side, and a housing 90 into which the holding member 70 that holds the first driven gear 51, the second driven gear 52, and the substrate 58 is fitted and to which a connector 130 that supplies power to at least the first sensor 55 and the second sensor 56 is connected.

[0071] In the sensor device 1 configured as above, the first driven gear 51, the second driven gear 52, and the board 58 are held on the same side by the holding member 70, so that these components can be easily assembled to the holding member 70. Also, since the holding member 70 in a state in which the first driven gear 51, the second driven gear 52, and the board 58 are held, in other words, the subunit 50 is configured to be fitted into the housing 90, it is possible to easily assemble the first driven gear 51, the second driven gear 52, and the board 58 to the housing 90. Also, by separating the subunit 50 from the housing 90, even if the shape of the coupler portion of the connector 130 is changed, for example, this can be accommodated by changing the shape of the portion of the housing 90 to which the connector 130 is connected, and it is possible to avoid changing the subunit 50.

[0072] The holding member 70 holds the first driven gear 51 and the second driven gear 52 in a state where they are inserted inside. This makes it possible to assemble the first driven gear 51 and the second driven gear 52 simply by inserting them into the holding member 70. Furthermore, the holding member 70 holds the substrate 58 in a state in which the substrate 58 is inserted therein. This allows the substrate 58 to be assembled simply by inserting it into the holding member 70.

[0073] 8, the plate-like portion 592 is sandwiched between the holding member 70 and the housing 90. As a result, even if a force acts on the terminal 591 due to the connection of the connector 130 to the terminal 591, the stress is received by the holding member 70 and the housing 90 which sandwich the plate-like portion 592, and therefore, the stress is prevented from concentrating on the portion of the substrate 58 to which the terminal 591 is connected (e.g., the solder).

[0074] The substrate 58 further mounts a first sensor 43 as an example of a first torque sensor that detects torque applied to rotate the pinion shaft 106, and a second sensor 44 as an example of a second torque sensor. The first sensor 43 is mounted on a first surface 581 of the substrate 58, and the second sensor 44 is mounted on a second surface 582, which is the reverse surface of the first surface 581 of the substrate 58 and is the surface on which the first sensor 55 and the second sensor 56 are mounted, and is disposed between the first sensor 55 and the second sensor 56. In this manner, by simply inserting the substrate 58, on which the first sensor 43 and the second sensor 44 are mounted in addition to the first sensor 55 and the second sensor 56, into the holding member 70, it is possible to easily assemble the sensor device 1 that can also detect torque.

[0075] The holding member 70 holds the first collector 41 as an example of a collector that collects magnetic flux, and has a limiting portion 77 that limits the movement of the first collector 41. The holding member 70 holds the second collector 42 as an example of a collector that collects magnetic flux, and has a limiting portion 78 that limits the movement of the second collector 42. This allows the holding member 70, which holds at least one of the first collector 41 and the second collector 42 in addition to the first driven gear 51, the second driven gear 52, and the substrate 58, to be fitted into the housing 90, making it possible to easily assemble the sensor device 1. In addition, when the first collector 41 and the second collector 42 are integrated with the resin holding member 70 by insert molding, it is possible to suppress the position of the first collector 41 or the second collector 42 from moving during or after molding, and to suppress stress generated in the first collector 41 or the second collector 42.

[0076] Moreover, in the sensor device 1, the first driven gear 51 and the second driven gear 52 are provided on the second axial side of the substrate 58. The second side is the side on which the pinion shaft 106 is disposed. Therefore, it is possible to prevent wear powder caused by the meshing of the first driven gear 51 and the second driven gear 52 with the main driving gear 35 from adhering to the substrate 58 even if it falls due to gravity.

[0077] <Second embodiment> FIG. 12 is an example of a schematic configuration of a first sensor 243 and a second sensor 244 of a sensor unit 240 of a sensor device 2 according to the second embodiment, viewed in a radial direction from the radially inner side. The sensor unit 240 according to the second embodiment differs from the sensor unit 40 according to the first embodiment in that a magnetic body 45 is not provided between a first sensor 243 corresponding to the first sensor 43 and a second sensor 244 corresponding to the second sensor 44. The following describes the differences from the first embodiment. The same reference numerals are used for the same parts in the first and second embodiments, and detailed descriptions thereof will be omitted.

[0078] The first sensor 243 is mounted on the first surface 581 of the substrate 58 in the same manner as the first sensor 43, but is mounted symmetrically to the first sensor 43 with respect to the first surface 581. The second sensor 244 is mounted on the second surface 582 of the substrate 58 in the same manner as the second sensor 44 , but is mounted symmetrically to the second sensor 44 with respect to the second surface 582 . The first sensor 243 and the second sensor 244 are mounted such that a portion of each of them is accommodated within the second portion 584 of the substrate 58.

[0079] In addition, the surface of the first sensor 243 on the first side in the axial direction may be on the same plane as the first surface 581 or may be located on the second side of the first surface 581. In addition, the surface of the second sensor 244 on the second side in the axial direction may be on the same plane as the second surface 582 or may be located on the first side of the second surface 582. Instead of forming the second portion 584 in the substrate 58, a rectangular parallelepiped through hole may be formed, and the first sensor 243 and the second sensor 244 may be accommodated in the through hole. Thereby, when the substrate 58 on which the first sensor 243 and the second sensor 244 are mounted is fitted into the holding member 70, the first sensor 243 and the first protruding portion 411 of the first collector 41 are unlikely to come into contact, and the second sensor 244 and the first protruding portion 421 of the second collector 42 are unlikely to come into contact.

[0080] <Third embodiment> FIG. 13 is a diagram showing an example of a schematic configuration of a holding member 370 of a sensor unit 340 of a sensor device 3 according to the third embodiment. FIG. 14 is a diagram showing an example of a schematic configuration of a housing 390 of a sensor unit 340 of a sensor device 3 according to the third embodiment. The sensor unit 340 according to the third embodiment is different from the sensor unit 40 according to the first embodiment in the shapes of the connecting portion 76 of the holding member 70 and the base 98 of the housing 90. The points that differ from the first embodiment will be described below. The same reference numerals are used for the same parts in the first and third embodiments, and detailed descriptions thereof will be omitted.

[0081] A connecting portion 376 of a holding member 370 according to the third embodiment is annular. A wall 399 protruding radially inward from the base 398 is provided at a portion of the base 398 of the housing 390 according to the third embodiment on the side of the inner peripheral wall 92. The wall 399 is provided such that a radially inner end face is flush with a radially inner end face of the inner peripheral wall 92.

[0082] Then, the connecting portion 376 of the holding member 370 is fitted between the protrusion 99 of the housing 390 and the wall 399, and the tip of the protrusion 99 is melted and crimped. The wall 399 functions as a wall that suppresses the outflow of the molten resin when the holding member 370 and the housing 390 are thermally crimped. For example, when a wall that suppresses the outflow of the molten resin is formed around the through hole of the connecting portion 376, the thickness of the wall becomes thin, or the through hole needs to be formed on the center side in the width direction to ensure the thickness of the wall. However, according to the connecting portion 376 and the base 398 of the third embodiment, it is possible to suppress the thickness of the holding member 370 from becoming thin, and it is possible to provide the portion to be thermally crimped on the outside in the width direction. This also makes it possible to make the widthwise size of the two first side portions and the two second side portions of the four thermally crimped portions the same, so that the four portions can be easily thermally crimped by axially moving holding member 370 and housing 390 relative to a thermally crimping jig. Also, the curvature of the inner surface of wall 399 can be reduced, improving waterproofing.

[0083] <Fourth embodiment> FIG. 15 is a diagram showing an example of a schematic configuration of a holding member 470 of a sensor unit 440 of a sensor device 4 according to the fourth embodiment. The sensor unit 440 according to the fourth embodiment differs from the sensor unit 40 according to the first embodiment in that a substrate 58 and a holding member 70 are fixed. The differences from the first embodiment will be described below. The same reference numerals are used for the same parts in the first and fourth embodiments, and detailed descriptions thereof will be omitted.

[0084] A rod-shaped portion 471 extending in the axial direction is provided at each of both ends in the width direction of a holding member 470 corresponding to a holding member 70 according to the fourth embodiment. Then, the rod-shaped portion 471 at the end on the third side in the width direction is fitted into a third portion 585 formed on a substrate 58, and the rod-shaped portion 471 at the end on the fourth side in the width direction is fitted into a fourth portion 586 formed on a substrate 58. At that time, the rod-shaped portion 471 is fitted so that a protrusion 587 formed on the substrate 58 surrounds a part of the periphery of the rod-shaped portion 471. Then, the end in the axial direction of the rod-shaped portion 471 is pressurized and heated by a pair of jigs 400 that move in the axial direction, thereby performing thermal caulking. This makes it possible to suppress the substrate 58 from moving relative to the holding member 470.

[0085] Instead of fixing the holding member 470 and the substrate 58 by thermal caulking, they may be fixed by snap fitting. For example, a notch may be formed at the tip of the rod-shaped portion 471 of the holding member 470, and a protrusion extending radially inwardly and provided on the housing 90 may be inserted into the notch to expand the tip of the rod-shaped portion 471 to a width larger than that of the third portion 585 and the fourth portion 586 of the substrate 58. This makes it possible to prevent the substrate 58 from moving relative to the holding member 470. [Explanation of symbols]

[0086] 1, 2, 3, 4... sensor device, 35... driving gear, 40, 240, 340, 440... sensor unit, 41... first collector (collector), 42... second collector (collector), 43... first sensor (first torque sensor), 44... second sensor (second torque sensor), 50... subunit, 51... first driven gear, 52... second driven gear, 53... first permanent magnet, 54... second permanent magnet, 55... first sensor (first rotation angle sensor), 56...second sensor (second rotation angle sensor), 58...substrate, 59...terminal member, 60...elastic body, 70, 370, 470...holding member, 77, 78...limiting portion, 81...first bearing, 82...second bearing, 90...housing, 96...support portion, 100...electric power steering device, 106...pinion shaft (rotating shaft), 130...connector, 581...first surface, 582...second surface, 591...terminal, 592...plate-shaped portion

Claims

1. A main driving gear provided on the rotating shaft so as to be integrally rotatable; A first driven gear that meshes with the main driving gear; a second driven gear that meshes with the main gear and has a number of teeth different from that of the first driven gear; a first rotation angle sensor provided corresponding to the first driven gear; a second rotation angle sensor provided corresponding to the second driven gear; a substrate on which the first rotation angle sensor and the second rotation angle sensor are mounted; a holding member that holds the first driven gear, the second driven gear, and the substrate on the same side; a housing into which the holding member holding the first driven gear, the second driven gear, and the substrate is inserted and fitted, and to which a connector for supplying power to at least the first rotation angle sensor and the second rotation angle sensor is connected; Equipped with the substrate further includes a first torque sensor and a second torque sensor mounted thereon for detecting a torque applied to rotate the rotation shaft; the first torque sensor is mounted on a first surface of the substrate; The second torque sensor is mounted on a second surface of the substrate, which is a surface opposite to the first surface and on which the first rotation angle sensor and the second rotation angle sensor are mounted, and is disposed between the first rotation angle sensor and the second rotation angle sensor.

2. The holding member holds the first driven gear and the second driven gear in a state where they are inserted therein. The sensor device according to claim 1 .

3. The holding member holds the substrate in a state where the substrate is inserted therein. The sensor device according to claim 1 or 2.

4. a terminal member including a terminal connected to the board and a plate-like portion that is penetrated by the terminal and fixes the terminal that is penetrated, The plate-shaped portion is sandwiched between the holding member and the housing. The sensor device according to any one of claims 1 to 3.

5. a permanent magnet that rotates together with a second rotating shaft that rotates relatively to the rotating shaft; a stator that rotates together with the rotating shaft and guides magnetic flux generated by the permanent magnet; Further equipped with The holding member holds a collector that collects magnetic flux guided by the stator, and has a limiting portion that limits movement of the collector. The sensor device according to any one of claims 1 to 4.

6. A steering wheel; A sensor device according to any one of claims 1 to 5, which detects a rotation angle of the steering wheel; An electric power steering device comprising:

7. a step of inserting a first driven gear that meshes with a driving gear that is provided on a rotating shaft so as to be integrally rotatable with the rotating shaft, into a holding member in a first direction; a step of inserting a second driven gear, which meshes with the main driving gear and has a number of teeth different from that of the first driven gear, into the holding member in the first direction; a step of inserting a substrate on which a first rotation angle sensor provided corresponding to the first driven gear and a second rotation angle sensor provided corresponding to the second driven gear are mounted, into the holding member in the first direction; a step of inserting and fitting the holding member holding the first driven gear, the second driven gear, and the substrate into a housing to which a connector for supplying power to at least the first rotation angle sensor and the second rotation angle sensor is connected; Equipped with the substrate further includes a first torque sensor and a second torque sensor mounted thereon for detecting a torque applied to rotate the rotation shaft; the first torque sensor is mounted on a first surface of the substrate; the second torque sensor is mounted on a second surface of the substrate, the second surface being a surface opposite to the first surface on which the first rotation angle sensor and the second rotation angle sensor are mounted, and is disposed between the first rotation angle sensor and the second rotation angle sensor. A method for manufacturing a sensor device.

Images