Sensor device, torque sensor device, magnetic sensor module

Abstract

This sensor device comprises a sensor body (13 to 16, 21, 22), a sensor housing (30), a connector housing (50), and a flange 51. The sensor body (13 to 16, 21, 22) captures changes in a physical quantity, and the sensor housing (30) accommodates at least a portion of the sensor body. The connector housing (50) is provided with a detecting element (40) that outputs a signal corresponding to a change in the physical quantity, and the part in which the detecting element (40) is provided is inserted inside the sensor housing (30). The flange (51) extends outward from the connector housing (50), and a joining surface (53) facing the sensor housing (30) side is joined to the sensor housing (30). The joint surface (53) of the flange (51) is inclined with respect to a virtual plane (VS) that is perpendicular to a direction (ID) in which the part of the connector housing (50) in which the detecting element (40) is provided is inserted into the sensor housing (30).

Description

Cross-reference to Related Applications

[0001] This application is based on Japanese Patent Application No. 2023-148627 filed on September 13, 2023, the contents of which are incorporated herein by reference.

Technical Field

[0002] The present disclosure relates to a sensor device mounted on a vehicle, a torque sensor device, and a magnetic sensor module.

Background Art

[0003] The magnetic detection device (hereinafter referred to as a magnetic sensor module) described in Patent Document 1 constitutes a part of a torque sensor device used in an electric power steering system. This magnetic sensor module has a configuration in which a magnetic flux concentrating member holding a first magnetic flux concentrating member and a second magnetic flux concentrating member is joined to a substrate holding member holding a substrate on which a magnetic detection element is mounted. Wiring electrically connected to the substrate is fixed to the substrate holding member. A signal output from the magnetic detection element is transmitted from the substrate to an electronic control unit (hereinafter referred to as "ECU") on the vehicle side via the wiring. Note that ECU is an abbreviation for Electronic Control Unit.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

[0005] However, in the magnetic sensor module described in Patent Document 1, wiring is fixed to the substrate holding member. Therefore, if the distance between the magnetic sensor module and the ECU varies depending on the vehicle type on which the magnetic sensor module is mounted, the specifications of the substrate holding member must be changed, resulting in problems such as an increase in design costs and manufacturing costs. To address these problems, one possible solution is to provide a substrate holding member for the magnetic sensor module that allows for the attachment and detachment of an external connector. However, in this case, providing an opening in the substrate holding member for the attachment and detachment of an external connector would increase the size of the substrate holding member. Furthermore, since the magnetic sensor module described in Patent Document 1 has a configuration in which a flange provided on the outer circumference of the substrate holding member is joined to the magnetic collecting part holding member, the outer circumference of the flange also increases in size along with the size of the substrate holding member. As a result, it becomes difficult to mount the magnetic sensor module in the mounting space within the housing of the electric power steering system.

[0006] The present disclosure aims to provide a sensor device, a torque sensor device, and a magnetic sensor module that have a detachable external connector and can be miniaturized.

[0007] According to one aspect of this disclosure, the sensor device mounted on the vehicle is The sensor body that captures changes in physical quantities, A sensor housing that accommodates at least a portion of the sensor body, A connector housing is provided in which a detection element that outputs a signal corresponding to a change in a physical quantity is provided, and the part in which the detection element is provided is inserted inside the sensor housing, It comprises a flange that extends outward from the connector housing and has a bonding surface facing the sensor housing that is bonded to the sensor housing, The bonding surface is inclined with respect to a virtual plane perpendicular to the direction in which the part of the connector housing on which the detection element is located is inserted into the sensor housing.

[0008] According to this, even if the distance between the sensor device and the ECU differs depending on the vehicle model, the sensor device can be adapted simply by changing the length of the wiring provided on the external connector. Therefore, the sensor device does not need to be modified according to the vehicle model, and design and manufacturing costs can be reduced.

[0009] Furthermore, the sensor device has a flange joint surface that is inclined with respect to a virtual plane perpendicular to the direction in which the part of the connector housing where the detection element is located is inserted into the sensor housing. This allows for a smaller sensor device while ensuring sufficient joint surface area to guarantee the joint strength between the flange and the connector housing, as well as sufficient opening area for the connector housing into which the external connector is inserted. Therefore, the sensor device can be mounted even in the narrow mounting space within the vehicle system housing. Furthermore, the flange joint surface is inclined more than the inclination due to manufacturing tolerances when the flange is configured parallel to a virtual plane.

[0010] According to another aspect of this disclosure, a torque sensor device for detecting torque around an axis acting on a shaft is: A torsion bar connects the first and second shafts that make up the shaft coaxially, and converts the torque acting between the first and second shafts into a torsional displacement, A multipole magnet fixed to one end of a first shaft or torsion bar, with north poles and south poles arranged alternately in the circumferential direction, A yoke is fixed to the second shaft or the other end of the torsion bar outside the multipole magnet, forming a magnetic circuit within the magnetic field of the multipole magnet, A first magnetic flux guiding member and a second magnetic flux guiding member are provided on the outside of the yoke and guide the magnetic flux flowing through the yoke, A sensor housing for fixing the first magnetic flux induction member and the second magnetic flux induction member, A magnetic detection element that outputs a signal corresponding to the magnetic flux density passing through a location where the first magnetic flux induction member and the second magnetic flux induction member are adjacent, A connector housing is provided with a magnetic detection element, and the portion of the connector housing where the magnetic detection element is provided is inserted inside the sensor housing. It comprises a flange that extends outward from the connector housing and has a bonding surface facing the sensor housing that is bonded to the sensor housing, The bonding surface is inclined with respect to a virtual plane perpendicular to the direction in which the portion of the connector housing on which the magnetic detection element is located is inserted into the sensor housing.

[0011] According to this, the torque sensor device exhibits the same operational effects as the above-described sensor device.

[0012] According to yet another aspect of the present disclosure, a magnetic sensor module that detects magnetic flux flowing through a yoke includes a first magnetic flux inducing member and a second magnetic flux inducing member that induce magnetic flux flowing through the yoke, a sensor housing that houses the first magnetic flux inducing member and the second magnetic flux inducing member, a magnetic detection element that outputs a signal according to the magnetic flux density passing through a location where the first magnetic flux inducing member and the second magnetic flux inducing member are adjacent, a connector housing provided with the magnetic detection element, and a portion where the magnetic detection element is provided is inserted inside the sensor housing, a flange that extends outward from the connector housing and whose joining surface facing the sensor housing side is joined to the sensor housing. The joining surface is inclined with respect to a virtual plane perpendicular to the direction in which the portion where the magnetic detection element is provided in the connector housing is inserted into the sensor housing.

[0013] According to this, the magnetic sensor module exhibits the same operational effects as the above-described sensor device.

[0014] Note that the reference numerals with parentheses attached to each component etc. indicate an example of the correspondence relationship between the component etc. and the specific components etc. described in the embodiments described later.

Brief Description of the Drawings

[0015] [Figure 1] It is a schematic diagram of an electric power steering system equipped with a torque sensor device according to the first embodiment. [Figure 2] It is an exploded perspective view of the torque sensor device according to the first embodiment. [Figure 3] It is a perspective view of the multi-pole magnet and the yoke included in the torque sensor device. [Figure 4] It is a side view showing the relative rotational state of the multi-pole magnet and the yoke. [Figure 5]It is a side view showing the relative rotational state of the multi-pole magnet and the yoke. [Figure 6] It is a side view showing the relative rotational state of the multi-pole magnet and the yoke. [Figure 7] It is an exploded perspective view of the magnetic sensor module used in the torque sensor device according to the first embodiment. [Figure 8] It is a side view of the magnetic sensor module used in the torque sensor device according to the first embodiment. [Figure 9] It is an explanatory diagram for explaining the state of laser welding of the flange and the sensor housing. [Figure 10] It is an explanatory diagram for explaining the state of laser welding of the flange and the sensor housing in the cross section of the X-X line in FIG. 9. [Figure 11] It is a side view showing the state in which the magnetic sensor module is mounted in the mounting space in the housing of the electric power steering system. [Figure 12] It is a side view showing the state in which the magnetic sensor module of the first comparative example is mounted in the mounting space in the housing of the electric power steering system. [Figure 13] It is an exploded perspective view of the torque sensor device according to the second embodiment. [Figure 14] It is a cross-sectional view of the multi-pole magnet, yoke and magnetic flux induction member provided in the torque sensor device according to the second embodiment. [Figure 15] It is a cross-sectional view of the torque sensor device according to the second embodiment. [Figure 16] It is an exploded perspective view of the magnetic sensor module used in the torque sensor device according to the second embodiment. [Figure 17] It is a cross-sectional view of the magnetic sensor module used in the torque sensor device according to the third embodiment. [Figure 18] It is a schematic diagram of the magnetic sensor module of the second comparative example. [Figure 19] It is a schematic diagram of the magnetic sensor module of the third embodiment.

Embodiments for Carrying Out the Invention

[0016] The embodiments of this disclosure will be described below with reference to the drawings. In the following embodiments, parts that are the same or equivalent to each other will be denoted by the same reference numerals, and their descriptions will be omitted.

[0017] (First Embodiment) The sensor device of the first embodiment will now be described. The sensor device of the first embodiment is a torque sensor device 10 that detects torque around the shaft acting on the shaft. The torque sensor device 10 is applied to an electric power steering system 1 mounted on a vehicle.

[0018] First, the general configuration of the electric power steering system 1 will be described with reference to Figure 1. The electric power steering system 1 may be a column-assist type or a rack-assist type. A steering shaft 3 is connected to the steering wheel 2. The steering shaft 3 is equipped with a torque sensor device 10 that detects the torque acting on the steering shaft 3 around its axis, i.e., the steering torque. A steering gear mechanism 4 is provided at the tip of the steering shaft 3. The steering gear mechanism 4 is connected to a pair of wheels 6 via a linkage mechanism 5.

[0019] The torque sensor device 10 is installed between the input shaft 11 and the output shaft 12 that constitute the steering shaft 3, and detects the steering torque and outputs it to the ECU 7. The ECU 7 controls the driving force of the electric motor 8 according to the steering torque. The driving force of the electric motor 8 is transmitted to the output shaft 12 of the steering shaft 3 or the steering gear mechanism 4. As a result, the electric power steering system 1 assists the steering force to change the direction of the wheels 6.

[0020] Next, the overall configuration of the torque sensor device 10 will be explained with reference to Figures 2 to 8. As shown in Figure 2, the torque sensor device 10 comprises a torsion bar 13, a multipole magnet 14, yokes 15 and 16, and a magnetic sensor module 20. As shown in Figures 2 and 7, the magnetic sensor module 20 includes a first magnetic flux induction member 21, a second magnetic flux induction member 22, a sensor housing 30, a magnetic detection element 40, a connector housing 50, and a flange 51.

[0021] In the following explanation, the radial direction of a virtual circle drawn on a plane perpendicular to the central axis CL of the steering shaft 3, with the central axis CL as the center, is referred to as the "radial direction," the circumferential direction of that virtual circle is referred to as the "circumferential direction," and the direction in which the central axis CL extends is referred to as the "axial direction."

[0022] As shown in Figure 2, one end of the torsion bar 13 is fixed to the input shaft 11, which acts as the "first axis," by a first fixing pin 17, and the other end is fixed to the output shaft 12, which acts as the "second axis," by a second fixing pin 18. In this way, the torsion bar 13 coaxially connects the input shaft 11 and the output shaft 12 on the central axis CL. The torsion bar 13 is a rod-shaped elastic member, and the amount of torsional displacement changes in accordance with the steering torque acting between the input shaft 11 and the output shaft 12. In other words, the torsion bar 13 converts the steering torque into a torsional displacement. Note that the central axis CL of the torsion bar 13 coincides with the central axis CL of the steering shaft 3.

[0023] The multipole magnet 14 is a permanent magnet with alternating north and south poles arranged in the circumferential direction, and is fixed to the input shaft 11. The multipole magnet 14 may also be fixed to one end of the torsion bar 13. For example, the multipole magnet 14 has eight north poles and eight south poles arranged at 22.5° intervals.

[0024] The first yoke 15 and the second yoke 16 (hereinafter referred to as "the pair of yokes 15 and 16") are formed in an annular shape from a soft magnetic material, held by a holding member (not shown) on the radially outer side of the multipole magnet 14, and fixed to the output shaft 12. The pair of yokes 15 and 16 may also be fixed to the other end of the torsion bar 13. As shown in Figure 3, the pair of yokes 15 and 16 face each other in the axial direction with a gap between them. Each of the pair of yokes 15 and 16 has the same number of claws 151 and 161 as the N pole or S pole of the multipole magnet 14, spaced equally in the circumferential direction. The claws 151 of the first yoke 15 and the claws 161 of the second yoke 16 are arranged alternately with a circumferential offset. In this way, the pair of yokes 15 and 16 form a magnetic circuit within the magnetic field generated by the multipole magnet 14.

[0025] When the torsional displacement of the torsion bar 13 changes, the multipole magnet 14 and the pair of yokes 15 and 16 rotate relative to each other, and consequently, the flow of magnetic flux in the magnetic circuit formed by the pair of yokes 15 and 16 changes. Figures 3 and 4 show the state in which no torsional torque is acting on the torsion bar 13. Note that in Figures 4 to 6, for explanatory purposes, a hatch is added to the north pole of the multipole magnet 14, although it is not a cross-section, and the south pole is not hatched. In the state shown in Figures 3 and 4, the circumferential center positions of the claws 151 and 161 of the pair of yokes 15 and 16 and the boundary between the north and south poles of the multipole magnet 14 are located radially overlapping. At this time, no magnetic flux flows between the first yoke 15 and the second yoke 16.

[0026] Figures 5 and 6 show the state in which the torsional torque acting on the torsion bar 13 gradually increases. As a result, the torsional displacement of the torsion bar 13 gradually increases from the state in Figure 4 through the state in Figure 5 to the state in Figure 6. Consequently, the area in which the north pole of the multipole magnet 14 and the claw 151 of the first yoke 15 overlap radially gradually increases, and the area in which the south pole of the multipole magnet 14 and the claw 161 of the second yoke 16 overlap radially gradually increases. Therefore, the influence of the north pole of the multipole magnet 14 on the first yoke 15 gradually increases, and the influence of the south pole of the multipole magnet 14 on the second yoke 16 also gradually increases. Consequently, the magnetic flux density flowing between the first yoke 15 and the second yoke 16 gradually increases.

[0027] As shown in Figures 2 and 7, the first magnetic flux induction member 21 and the second magnetic flux induction member 22 (hereinafter referred to as "the pair of magnetic flux induction members 21 and 22") are made of a soft magnetic material. The first magnetic flux induction member 21 is provided radially outward and axially on the first yoke 15, and the second magnetic flux induction member 22 is provided radially outward and axially on the second yoke 16. Each of the pair of magnetic flux induction members 21 and 22 has a magnetic collection portion 23 and 24 formed in an annular or arc shape on the radially outward side of the pair of yokes 15 and 16, and an extension portion 25 and 26 extending radially outward from the magnetic collection portion 23 and 24. In the first embodiment, the magnetic collection portions 23 and 24 surround most of the radially outward side of the pair of yokes 15 and 16. The first extension portion 25 and the second extension portion 26 are adjacent to the first magnetic flux induction member 21 and the second magnetic flux induction member 22. Therefore, the distance between the first extension 25 and the second extension 26 is smaller than the distance between the first magnetic collector 23 and the second magnetic collector 24. Consequently, the magnetic flux induced from the pair of yokes 15 and 16 to the magnetic collectors 23 and 24 of the pair of magnetic flux induction members 21 and 22 flows through the gap between the first extension 25 and the second extension 26.

[0028] As shown in Figures 7 and 8, the pair of magnetic flux induction members 21 and 22 are housed in the sensor housing 30. The sensor housing 30 has a cylindrical sensor housing body 31, a sensor housing extension 32 extending from the sensor housing body 31 toward the connector housing 50, and a sensor housing side flange 33 extending outward from the sensor housing extension 32. As shown in Figure 8, the central axis CL of the inner circumferential surface of the sensor housing body 31 (hereinafter referred to as "central axis CL of the sensor housing 30") coincides with the central axis CL of the torsion bar 13. The magnetic collection portions 23 and 24 of the pair of magnetic flux induction members 21 and 22 are fixed to the radially inner portions of the sensor housing body 31. The extension portions 25 and 26 of the pair of magnetic flux induction members 21 and 22 are fixed to the inside of the sensor housing extension 32.

[0029] As shown by arrow ID in Figure 7, the magnetic detection element 40, mounted on the substrate 41 together with a part of the connector housing 50, is inserted into the opening 34 of the sensor housing extension 32. In the following description, the direction in which the magnetic detection element 40, mounted on the substrate 41 together with a part of the connector housing 50, is inserted into the opening 34 of the sensor housing extension 32 is referred to as the "element insertion direction ID". Inside the sensor housing extension 32, a guide 341 is provided to guide the substrate 41, etc., during insertion. The guide 341 extends parallel to the direction in which the magnetic detection element 40 and the substrate 41 are inserted into the connector housing 50 (i.e., the element insertion direction ID). Therefore, in the completed state of the torque sensor device 10 and magnetic sensor module 20, the element insertion direction ID can be identified as the in-plane direction of the substrate 41, the direction in which the guide 341 extends, or the direction in which the axis of the rectangular tubular sensor housing extension 32 extends. Alternatively, as will be described later, the element insertion direction ID can be identified as the direction in which the magnetic detection element 40 is inserted between the first extension portion 25 and the second extension portion 26. The sensor housing side flange 33 is provided around the entire outer circumference of the opening 34 of the sensor housing extension portion 32. The flange 51 is joined to the flange 51 side surface 35 of the sensor housing side flange 33.

[0030] The magnetic detection element 40 is mounted on the substrate 41 and inserted into the opening 34 of the sensor housing extension 32, positioned between the first extension 25 and the second extension 26. The magnetic detection element 40 is composed of an IC package in which, for example, a Hall element or a magnetoresistive element is resin-molded. The magnetic detection element 40 outputs an electrical signal corresponding to the magnetic flux density passing through the gap between the first extension 25 and the second extension 26, which are adjacent to the pair of magnetic flux induction members 21 and 22. In order to ensure redundancy or detection accuracy of torque detection, multiple magnetic detection elements 40 are mounted on the substrate 41.

[0031] The connector housing 50 and the flange 51 are integrally formed by resin injection molding. The connector housing 50 is provided with a substrate 41 on which a magnetic detection element 40 is mounted, and a terminal 42 electrically connected to the magnetic detection element 40. The connector housing 50 is provided with a cylindrical connector opening 52 from which an external connector 60 can be attached and detached. In Figure 8, the external connector 60 inserted into the connector opening 52 and the wiring 61 extending from the external connector 60 are shown by a dashed line. In the following description, the direction in which the external connector 60 is attached and detached from the connector opening 52 is referred to as the "external connector attachment / detachment direction RD". In Figure 8, the external connector attachment / detachment direction RD is shown by a double-headed arrow. In this embodiment, the element insertion direction ID and the external connector attachment / detachment direction RD are parallel. Also, in this embodiment, the element insertion direction ID and the external connector attachment / detachment direction RD are perpendicular to the central axis CL of the sensor housing 30.

[0032] Figure 8 is a side view of the magnetic sensor module 20, viewed from a direction perpendicular to the direction in which the central axis CL of the sensor housing 30 extends, and perpendicular to the element insertion direction ID and the external connector attachment / detachment direction RD. In the following explanation, the direction in which the central axis CL of the sensor housing 30 extends will be referred to as the "axial direction of the sensor housing 30," the upper side of Figure 8 will be referred to as "one axial side of the sensor housing 30," and the lower side of Figure 8 will be referred to as "the other axial side of the sensor housing 30."

[0033] As shown in Figures 7 and 8, the flange 51 extends outward from the connector housing 50. The flange 51 extends outward from the entire circumference of the surface of the connector housing 50 that faces in a direction intersecting the element insertion direction ID and the external connector attachment / detachment direction RD. The flange 51 is formed in a plate shape and is inclined with respect to a virtual plane VS perpendicular to the element insertion direction ID. It can also be said that the flange 51 is inclined with respect to a virtual plane VS perpendicular to the substrate 41. It can also be said that the flange 51 is inclined with respect to a virtual plane VS parallel to the central axis CL of the torsion bar 13 or the sensor housing 30. It can also be said that the flange 51 is inclined with respect to a virtual plane VS perpendicular to the external connector attachment / detachment direction RD. It can also be said that the flange 51 is inclined with respect to a virtual plane VS perpendicular to the axis of the rectangular tubular sensor housing extension 32. The side of the flange 51 facing the sensor housing 30 is called the joining surface 53. The joining surface 53 of the flange 51 is the surface that is joined to the sensor housing side flange 33. The side of the flange 51 facing the opposite side from the joining surface 53 is called the non-jointing surface 54. The joining surface 53 and the non-jointing surface 54 of the flange 51 are formed parallel to each other. Both the joining surface 53 and the non-jointing surface 54 of the flange 51 are inclined with respect to a virtual plane VS.

[0034] As shown in Figure 8, the inclination angle θ of the joint surface 53 of the flange 51 with respect to the virtual plane VS is, for example, in the range of 5° to 45°, preferably in the range of 10° to 40°, and more preferably in the range of 20° to 30°. However, the inclination angle θ of the joint surface 53 of the flange 51 is not limited to the above angle range. The inclination angle θ is set appropriately within a range that allows the magnetic sensor module 20 to be mounted in the housing of the electric power steering system 1, ensures the bonding strength between the flange 51 and the connector housing 50, and secures the area of ​​the connector opening 52.

[0035] The joining surface 53 of the flange 51 is inclined so as to approach the central axis CL of the sensor housing 30, moving from one axial side of the sensor housing 30 to the other axial side of the sensor housing 30. On the other hand, the surface 35 of the sensor housing side flange 33 that is on the flange 51 side is also inclined so as to approach the central axis CL of the sensor housing 30, moving from one axial side of the sensor housing 30 to the other axial side of the sensor housing 30. In this embodiment, the surface 35 of the sensor housing side flange 33 that is on the flange 51 side and the joining surface 53 of the flange 51 are joined by laser welding.

[0036] In this embodiment, the sensor housing side flange 33 and flange 51 are joined by laser welding, and the following configuration is used.

[0037] Firstly, the flange 51 is configured to extend around the entire circumference of the connector housing 50, as viewed from a direction perpendicular to the joint surface 53 of the flange 51. In Figure 8, arrow α indicates the range in which the portion of the flange 51 on one axial side of the sensor housing 30 extends outward from the connector housing 50, as viewed from a direction perpendicular to the joint surface 53 of the flange 51. Arrow β indicates the range in which the portion of the flange 51 on the other axial side of the sensor housing 30 extends outward from the connector housing 50, as viewed from a direction perpendicular to the joint surface 53 of the flange 51. Furthermore, as viewed from a direction perpendicular to the joint surface 53 of the flange 51, the portion of the flange 51 on the near side of the page in Figure 8 also extends outward from the connector housing 50, and the portion of the flange 51 on the far side of the page in Figure 8 also extends outward from the connector housing 50. This is shown in Figure 7.

[0038] When viewed from a direction perpendicular to the joint surface 53 of the flange 51, the extent to which the flange 51 extends outward from the connector housing 50 is such that the upper jig 71 of the laser welding device 70, described later, can apply pressure to the flange 51. This prevents foaming from occurring at the welding surface between the flange 51 and the sensor housing side flange 33 when laser welding is performed. Furthermore, when viewed from a direction perpendicular to the joint surface 53 of the flange 51, it is preferable that the area in which the flange 51 extends outward from the connector housing 50 is large enough to allow laser light to be irradiated onto the flange 51 while the upper jig 71 of the laser welding device 70 is pressurizing the flange 51. This allows the laser light to be irradiated onto the flange 51 from a direction perpendicular to the joint surface 53 of the flange 51. However, the laser light may also be irradiated onto the flange 51 from an oblique direction relative to the joint surface 53 of the flange 51.

[0039] Secondly, the sensor housing side flange 33 is made of a resin that absorbs laser light more than the resin that forms the flange 51. The flange 51 is made of a resin that transmits laser light more than the resin that forms the sensor housing side flange 33. In addition, the flange 51 has a thickness that allows laser light to pass through. This allows the sensor housing side flange 33 and the flange 51 to be laser-welded together.

[0040] Thirdly, the connector housing 50 is provided with a recess 55 on the other axial side of the sensor housing 30 at the point where it connects to the flange 51, which is recessed on one side in the axial direction of the sensor housing 30. This allows laser welding to be performed by irradiating the joint surface 53 of the flange 51 with laser light from an oblique direction, even if the area where the flange 51 extends outward from the connector housing 50 is small when viewed from a direction perpendicular to the joint surface 53 of the flange 51.

[0041] Next, the method for laser welding the flange 51 and the sensor housing side flange 33 in the manufacturing process of the magnetic sensor module 20 will be explained with reference to Figures 9 and 10. For convenience, in this explanation, the upper side of Figure 10 will be referred to as "top" and the upper side of Figure 10 will be referred to as "bottom".

[0042] As shown in Figures 9 and 10, the laser welding of the flange 51 and the sensor housing side flange 33 is performed with the substrate 41, the magnetic detection element 40 mounted on the substrate 41, and a part of the connector housing 50 inserted inside the sensor housing extension 32.

[0043] First, the sensor housing side flange 33 is placed on the lower jig 72 of the laser welding device 70. Next, the upper jig 71 of the laser welding device 70 is placed on top of the flange 51. Then, the upper jig 71 and the lower jig 72 apply pressure to the flange 51 and the sensor housing side flange 33 all around.

[0044] Next, as shown by the solid line L1 in Figure 10, with the flange 51 and the sensor housing side flange 33 under pressure, a laser beam is shone onto the joint surface 53 of the flange 51 from a direction perpendicular to it. The laser beam circulates around the outside of the connector housing 50 and irradiates the entire circumference of the flange 51. The laser beam passes through the flange 51 and is absorbed by the sensor housing side flange 33. As a result, the interface between the flange 51 and the sensor housing side flange 33 is laser-welded. Note that, as shown by the dashed line L2 in Figure 10, the laser beam may also be shone onto the joint surface 53 of the flange 51 from an oblique direction.

[0045] Afterward, the laser beam irradiation is stopped, the upper jig 71 is removed from the flange 51, and then the magnetic sensor module 20 is removed from the laser welding device 70. This completes the laser welding between the flange 51 and the sensor housing side flange 33.

[0046] The magnetic sensor module 20 is used as part of the torque sensor device 10 and is mounted in a mounting space 90 within the housing 9 of the electric power steering system 1, as shown in Figure 11. As shown in S1 of Figure 11, the magnetic sensor module 20 of this embodiment can ensure clearance between the outer edge 56 on one axial side of the flange 51 of the sensor housing 30 and the inner wall of the housing 9 of the electric power steering system 1. Furthermore, as shown in S2 of Figure 11, the magnetic sensor module 20 of this embodiment can also ensure clearance between the outer edge 57 on the other axial side of the flange 51 of the sensor housing 30 and the inner wall of the housing 9 of the electric power steering system 1.

[0047] Here, in order to compare it with the magnetic sensor module 20 of the first embodiment, the magnetic sensor module 200 of the first comparative example will be described.

[0048] As shown in Figure 12, the magnetic sensor module 200 of the first comparative example has a flange 51 formed parallel to the virtual plane VS. The area of ​​the joining surface 53 of the flange 51 and the area of ​​the connector opening 52 are the same as those of the magnetic sensor module 20 of the first embodiment. As shown in S3 of Figure 12, the magnetic sensor module 200 of the first comparative example can secure clearance between the outer edge 56 on one axial side of the flange 51 of the sensor housing 30 and the inner wall of the housing 9 of the electric power steering system 1. However, as shown in S4 of Figure 12, the outer edge 57 on the other axial side of the flange 51 of the magnetic sensor module 200 of the first comparative example interferes with the housing 9 of the electric power steering system 1. Therefore, the magnetic sensor module 200 of the first comparative example cannot be mounted in the mounting space 90 within the housing 9 of the electric power steering system 1, or is difficult to mount.

[0049] Compared to the magnetic sensor module 200 of the first comparative example described above, the magnetic sensor module 20, torque sensor device 10, and sensor device of the first embodiment provide the following advantages and benefits.

[0050] (1) The magnetic sensor module 20 of the first embodiment comprises a pair of magnetic flux induction members 21, 22, a sensor housing 30, a magnetic detection element 40, a connector housing 50, and a flange 51. The flange 51 has a bonding surface 53 facing the sensor housing 30 that is bonded to the sensor housing 30. The bonding surface 53 of the flange 51 is inclined with respect to a virtual plane VS perpendicular to the element insertion direction ID.

[0051] According to this, the magnetic sensor module 20 can be made smaller in size while ensuring sufficient area for the bonding surface 53 that guarantees the bonding strength between the flange 51 and the connector housing 50, and for the connector opening 52 into which the external connector 60 is inserted. Therefore, this magnetic sensor module 20 can be mounted in the narrow mounting space 90 within the housing 9 of a vehicle-side system such as the electric power steering system 1.

[0052] Furthermore, the magnetic sensor module 20 of the first embodiment can accommodate different distances between the sensor device and the ECU 7 depending on the vehicle model, simply by changing the length of the wiring 61 provided on the external connector 60. Therefore, the magnetic sensor module 20 does not need to be modified according to the vehicle model, reducing design and manufacturing costs.

[0053] (2) The torque sensor device 10 of the first embodiment comprises a torsion bar 13, a multipole magnet 14, a pair of yokes 15 and 16, and the magnetic sensor module 20 described in (1) above. According to this, the torque sensor device 10 can be made smaller in size than the magnetic sensor module 20, and can be installed in the narrow mounting space 90 within the housing 9 of the vehicle-side system, such as the electric power steering system 1. In addition, since the torque sensor device 10 has a detachable external connector 60, there is no need to change the specifications depending on the vehicle model in which it is installed, which can reduce design and manufacturing costs.

[0054] (3) The sensor device of the first embodiment comprises a sensor body that captures changes in physical quantities, a sensor housing 30 that houses at least a part of the sensor body, a connector housing 50, and a flange 51. The flange 51 has a bonding surface 53 facing the sensor housing 30 that is bonded to the sensor housing 30. The bonding surface 53 of the flange 51 is inclined with respect to a virtual plane VS perpendicular to the element insertion direction ID. The sensor device detects various physical quantities. If the sensor device corresponds to the magnetic sensor module 20 described in (1) above, the sensor body of that sensor device is composed of a pair of magnetic flux induction members 21, 22, etc. Furthermore, if the sensor device corresponds to the torque sensor device 10 described in (2) above, the sensor body of the sensor device is composed of a torsion bar 13, a multipole magnet 14, a pair of yokes 15 and 16, and a pair of magnetic flux induction members 21 and 22. In that case, the sensor housing 30 houses the pair of magnetic flux induction members 21 and 22. Therefore, the sensor device can achieve the same effects as the magnetic sensor module described in (1) and the torque sensor device described in (2) above.

[0055] (4) In the first embodiment, when viewed from a direction perpendicular to the joining surface 53 of the flange 51, the entire circumference of the flange 51 extends outwards so as to surround the outside of the connector housing 50. According to this, with the entire circumference of the flange 51 and the sensor housing 30 under pressure, a laser beam is irradiated onto the joining surface 53 from a direction perpendicular to it, making it possible to perform laser welding between the flange 51 and the sensor housing 30. The laser beam may also be irradiated onto the joining surface 53 from a direction oblique to it.

[0056] (5) In the first embodiment, the joint surface 53 of the flange 51 and the sensor housing 30 are joined together by laser welding, so that the entire outer circumference of the connector housing 50 is joined. According to this, it is possible to prevent water or other substances from entering the inside of the sensor device through the joint between the flange 51 and the sensor housing 30. Furthermore, in this embodiment, since the wiring is not fixed to the components constituting the magnetic sensor module 20 as in Patent Document 1, the wiring does not get in the way when performing laser welding, making laser welding easy.

[0057] (6) In the first embodiment, the joining surface 53 and the non-joining surface 54 of the flange 51 are formed parallel to each other. According to this, the thickness of the flange 51 can be kept constant, and variations in the joint strength of laser welding can be prevented around the entire circumference of the flange 51.

[0058] (7) In the first embodiment, the surface 35 of the sensor housing side flange 33 of the sensor housing 30 that is on the flange 51 side is inclined in the same direction as the flange 51 with respect to a virtual plane VS perpendicular to the element insertion direction ID, and is joined to the flange 51. According to this, the sensor housing side flange 33 is placed on the lower jig 72 of the laser welding device 70, and the flange 51 and the sensor housing side flange 33 can be pressed around their entire circumference. Therefore, when performing laser welding, it is possible to prevent foaming from occurring at the welding surface between the flange 51 and the sensor housing side flange 33.

[0059] (8) In the first embodiment, the flange 51 is made of a resin that has higher laser light transmittance than the resin that forms the sensor housing side flange 33, and has a thickness that allows laser light to pass through. According to this, the flange 51 and the sensor housing 30 can be reliably laser-welded together.

[0060] (9) In the first embodiment, the joining surface 53 of the flange 51 is inclined to approach the central axis CL of the sensor housing 30, moving from one side in the direction in which the central axis CL of the sensor housing 30 extends to the other side. On the other side of the connector housing 50 in the direction in which the central axis CL of the sensor housing 30 extends, a recess 55 is provided at the location where it connects to the flange 51, recessed to one side in the direction in which the central axis CL of the sensor housing 30 extends. According to this, even if the area of ​​the flange 51 that extends outward from the connector housing 50 when viewed from a direction perpendicular to the joint surface 53 of the flange 51 is small, providing a recess 55 in the connector housing 50 makes it possible to irradiate the flange 51 with laser light from an oblique direction. Therefore, the flange 51 and the connector housing 50 can be laser-welded together.

[0061] (10) In the first embodiment, the magnetic flux induction members 21 and 22 have magnetic collection portions 23 and 24 arranged in an annular or arc shape on the radially outer side of a pair of yokes 15 and 16. This allows for a larger radially opposed area between the pair of yokes 15 and 16 and the pair of magnetic flux induction members 21 and 22. As a result, the magnetic flux density induced from the pair of yokes 15 and 16 to the pair of magnetic flux induction members 21 and 22 can be increased, improving the signal-to-noise ratio and enhancing torque detection accuracy.

[0062] (Second Embodiment) A second embodiment will now be described. The second embodiment is a modification of the configuration of the magnetic sensor module 20 compared to the first embodiment, and is otherwise the same as the first embodiment. Therefore, only the parts that differ from the first embodiment will be described.

[0063] As shown in Figure 13, the torque sensor device 10 of the second embodiment, as a sensor device, also includes a torsion bar 13, a multipole magnet 14, a pair of yokes 15 and 16, and a magnetic sensor module 20, just like the first embodiment. As shown in Figures 13 and 14, the pair of magnetic flux induction members 21 and 22 provided in the magnetic sensor module 20 are provided in a rod shape on a part of the radially outer side of the pair of yokes 15 and 16. Specifically, the pair of magnetic flux induction members 21 and 22 have rectangular strip-shaped magnetic collection parts 27 and 28 arranged on a part of the radially outer side of the pair of yokes 15 and 16, and extensions 25 and 26 extending radially outward from the magnetic collection parts 27 and 28. Note that the shape of the pair of magnetic flux induction members 21 and 22 is not limited to those shown in Figures 13 and 14, and for example, the magnetic collection parts 27 and 28 may be arc-shaped, wave-shaped, elliptical, or polygonal, or they may have a shape with a projection (not shown) for fixing to the sensor housing 30.

[0064] As shown in Figure 15, the pair of magnetic flux induction members 21 and 22 are fixed to the sensor housing 30. As shown in Figures 15 and 16, the sensor housing 30 has a magnetic flux induction member mounting portion 36, a cylindrical portion 37, and a housing mounting portion 38 that protrudes outward from the cylindrical portion 37. In the second embodiment, the central axis CL2 of the cylindrical portion 37 of the sensor housing 30 is perpendicular to the central axis CL of the yokes 15 and 16. In the following description, the direction in which the central axis CL of the yokes 15 and 16 extends is referred to as the "axial direction of the yokes 15 and 16". The central axis CL of the yokes 15 and 16 coincides with the central axis CL of the torsion bar 13 and the central axis CL of the steering shaft 3.

[0065] As shown by the arrow ID in Figure 16, the magnetic detection element 40, mounted on the substrate 41 together with a part of the connector housing 50, is inserted into the opening 39 of the cylindrical portion 37 of the sensor housing 30. In the description of the second embodiment, the direction in which the magnetic detection element 40, mounted on the substrate 41 together with a part of the connector housing 50, is inserted into the opening 39 of the cylindrical portion 37 of the sensor housing 30 is referred to as the "element insertion direction ID". Inside the cylindrical portion 37 of the sensor housing 30, a guide 341 is provided to guide the substrate 41, etc., during insertion. The guide 341 extends parallel to the direction in which the magnetic detection element 40 and the substrate 41 are inserted into the connector housing 50 (i.e., the element insertion direction ID). Therefore, in the completed state of the torque sensor device 10 and the magnetic sensor module 20, the element insertion direction ID can be confirmed as the in-plane direction of the substrate 41, or the direction in which the guide 341 extends, or the direction in which the axis of the cylindrical portion 37 of the sensor housing 30 extends. Alternatively, the element insertion direction ID can be identified as the direction in which the magnetic detection element 40 is inserted between the first extension portion 25 and the second extension portion 26. The magnetic detection element 40 is positioned between the first extension portion 25 and the second extension portion 26. The joining surface 53 of the flange 51 is joined to the flange 51 side surface 371 of the cylindrical portion 37 of the sensor housing 30.

[0066] The connector housing 50 and the flange 51 are integrally formed by resin injection molding. The connector housing 50 is provided with a substrate 41 on which a magnetic detection element 40 is mounted, and a terminal 42 electrically connected to the magnetic detection element 40. The connector housing 50 is provided with a cylindrical connector opening 52 from which an external connector 60 can be attached and detached. In the second embodiment, the external connector attachment / detachment direction RD, the element insertion direction ID, and the direction in which the central axis CL2 of the cylindrical portion 37 of the sensor housing 30 extends coincide.

[0067] The flange 51 extends outward from the connector housing 50. The flange 51 extends outward from the entire circumference of the surface of the connector housing 50 that faces in a direction intersecting the element insertion direction ID and the external connector attachment / detachment direction RD. The flange 51 is formed in a plate shape and is inclined with respect to a virtual plane VS perpendicular to the element insertion direction ID. It can also be said that the flange 51 is inclined with respect to a virtual plane VS perpendicular to the substrate 41. It can also be said that the flange 51 is inclined with respect to a virtual plane VS parallel to the central axis CL of the torsion bar 13. It can also be said that the flange 51 is inclined with respect to a virtual plane VS perpendicular to the external connector attachment / detachment direction RD. It can also be said that the flange 51 is inclined with respect to a virtual plane VS perpendicular to the axis of the cylindrical portion 37 of the sensor housing 30. The side of the flange 51 facing the sensor housing 30, i.e., the joining surface 53, is joined to the cylindrical portion 37 of the sensor housing 30. The side of the flange 51 facing the opposite side of the joining surface 53 is called the non-jointing surface 54. The joining surface 53 and the non-jointing surface 54 of the flange 51 are formed parallel to each other. Both the joining surface 53 and the non-jointing surface 54 of the flange 51 are inclined with respect to a virtual plane VS.

[0068] In the second embodiment as well, the surface 371 of the cylindrical portion 37 of the sensor housing 30 that faces the flange 51 and the joining surface 53 of the flange 51 are joined by laser welding.

[0069] In the second embodiment, the sensor housing 30 and the flange 51 are joined by laser welding, and the following configuration is used.

[0070] Firstly, the flange 51 is configured to extend around the entire circumference of the connector housing 50, as viewed from a direction perpendicular to the joint surface 53 of the flange 51. In Figure 15, arrow α indicates the range in which the axial portions of the yokes 15 and 16 of the flange 51 extend outward from the connector housing 50, as viewed from a direction perpendicular to the joint surface 53 of the flange 51. Arrow β indicates the range in which the axial portions of the yokes 15 and 16 of the flange 51 extend outward from the connector housing 50, as viewed from a direction perpendicular to the joint surface 53 of the flange 51. Furthermore, as viewed from a direction perpendicular to the joint surface 53 of the flange 51, the portion of the flange 51 closest to the viewer in Figure 15 also extends outward from the connector housing 50, and the portion of flange 15 furthest from the viewer also extends outward from the connector housing 50. This is shown in Figure 16.

[0071] Secondly, the cylindrical portion 37 of the sensor housing 30 is made of a resin that has higher laser light absorption than the resin that forms the flange 51. The flange 51 is made of a resin that has higher laser light transmittance than the resin that forms the cylindrical portion 37 of the sensor housing 30. In addition, the flange 51 has a thickness that allows laser light to pass through. This makes it possible to laser-weld the cylindrical portion 37 of the sensor housing 30 and the flange 51.

[0072] In the second embodiment as well, the connector housing 50 may also be provided with the recess 55 described in the first embodiment.

[0073] The magnetic sensor module 20 is used as part of the torque sensor device 10 and is mounted in a mounting space 90 within the housing 9 of the electric power steering system 1.

[0074] The magnetic sensor module 20, torque sensor device 10, and sensor device of the second embodiment described above also provide the same effects and advantages as those described in the first embodiment.

[0075] Furthermore, in the second embodiment, the pair of magnetic flux induction members 21 and 22 are provided in a rod shape on a portion of the radially outer part of the pair of yokes 15 and 16. According to this, the torque sensor device 10 of the second embodiment can reduce the inner diameter D1 of the portion 91 that houses the pair of yokes 15 and 16 in the system-side housing compared to that of the first embodiment.

[0076] (Third embodiment) A third embodiment will now be described. The sensor device of the third embodiment is a torque sensor device 10 applied to the electric power steering system 1 shown in Figure 1, etc., similar to the first embodiment. As shown in Figure 17, the torque sensor device 10 includes a magnetic sensor module 20 similar to that of the first embodiment. The magnetic sensor module 20 includes a first magnetic flux induction member 21, a second magnetic flux induction member 22, a sensor housing 30, a magnetic detection element 40, a connector housing 50, and a flange 51. Hereinafter, the first magnetic flux induction member 21 and the second magnetic flux induction member 22 will be referred to as "a pair of magnetic flux induction members 21, 22". The pair of magnetic flux induction members 21, 22 have magnetic collection parts 23, 24 and extension parts 25, 26.

[0077] The pair of magnetic flux induction members 21 and 22 are housed in the sensor housing 30. Specifically, the pair of magnetic flux induction members 21 and 22 are fixed to the sensor housing 30 by resin molding or the like. The sensor housing 30 is partially formed in a cylindrical shape. Specifically, the sensor housing has a cylindrical sensor housing main body 31, a sensor housing extension 32 extending from the sensor housing main body 31 toward the connector housing 50, and a sensor housing side flange 33 extending outward from the sensor housing extension 32. The magnetic field collecting portions 23 and 24 of the pair of magnetic flux induction members 21 and 22 are fixed to the radially inward portion of the sensor housing main body 31, and the extension portions 25 and 26 extend inward from the magnetic field collecting portions 23 and 24 toward the sensor housing extension 32.

[0078] In the following explanation, the central axis CL of the inner circumferential surface of the sensor housing body 31 is referred to as the "central axis CL of the sensor housing 30". Note that the central axis CL of the sensor housing 30, the central axis CL of the torsion bar 13 described in the first embodiment, and the central axis CL of the steering shaft 3 are all the same. Furthermore, the radial direction of a virtual circle drawn on a plane perpendicular to the central axis CL of the sensor housing 30 with the central axis CL as the center is referred to as the "radial direction", the circumferential direction of that virtual circle is referred to as the "circumferential direction", and the direction in which the central axis CL extends is referred to as the "axial direction". Also, the upper side of Figure 17 is referred to as the "one axial side", and the lower side of Figure 17 is referred to as the "other axial side".

[0079] A magnetic detection element 40, mounted on the substrate 41 together with a part of the connector housing 50, is inserted into the opening 34 of the sensor housing extension 32. The magnetic detection element 40 is mounted on the substrate 41 and inserted into the opening 34 of the sensor housing extension 32, and is positioned between the first extension 25 and the second extension 26. The direction in which the magnetic detection element 40 mounted on the substrate 41 is inserted into the opening 34 of the sensor housing extension 32 is called the "element insertion direction ID". The element insertion direction ID can be identified as the in-plane direction of the substrate 41, or the direction in which the axis of the sensor housing extension 32 extends. Alternatively, the element insertion direction ID can be identified as the direction in which the magnetic detection element 40 is inserted between the first extension 25 and the second extension 26 of the pair of magnetic flux induction members 21 and 22. The flange 51 on the connector housing 50 side is joined to the flange 33 on the sensor housing side. The flange 33 on the sensor housing side and the flange 51 are joined, for example, by laser welding.

[0080] The connector housing 50 and the flange 51 are integrally formed by resin injection molding. The connector housing 50 is provided with a substrate 41 on which a magnetic detection element 40 is mounted, and a terminal 42 that is electrically connected to the magnetic detection element 40 via wiring on the substrate 41. The connector housing 50 is provided with a cylindrical connector opening 52 from which an external connector (not shown) can be attached and detached. One end of the terminal 42 is connected to the magnetic detection element 40, and the other end is exposed to the connector opening 52. In this embodiment, the attachment / detachment direction RD of the external connector and the element insertion direction ID are parallel. Also in this embodiment, the attachment / detachment direction RD of the external connector and the element insertion direction ID intersect (specifically, are perpendicular to) the central axis CL of the sensor housing 30.

[0081] The flange 51 extends outward from the connector housing 50. Specifically, the flange 51 extends outward from the entire circumference of the outer wall surface of the connector housing 50 that faces in a direction intersecting the element insertion direction ID and the external connector attachment / detachment direction RD. The flange 51 is formed in a plate shape and is inclined with respect to a virtual plane VS perpendicular to the element insertion direction ID. The surface of the flange 51 facing the sensor housing 30 is the joining surface 53 that is joined to the sensor housing side flange 33. The non-jointing surface 54 of the flange 51, which faces away from the joining surface 53, is formed parallel to the joining surface 53 of the flange 51. Both the joining surface 53 and the non-jointing surface 54 of the flange 51 are inclined with respect to the virtual plane VS. The inclination angle θ of the joining surface 53 of the flange 51 with respect to the virtual plane VS is as described in the first embodiment.

[0082] Here, the connector housing 50 is positioned offset axially to the other side relative to the flange 51. More specifically, the axial center position C1 in the connector opening 52 is positioned offset axially to the other side relative to the axial center position C2 in the flange 51. The amount of offset ΔC between the two center positions C1 and C2 is greater than the manufacturing tolerance when the two center positions C1 and C2 are assumed to coincide. Although not limited, it is preferable that the amount of offset ΔC between the two center positions C1 and C2 is greater than 10% of the distance D3 along the central axis CL of the sensor housing 30 in the flange 51.

[0083] Furthermore, the fact that the connector housing 50 is positioned offset from the flange 51 to the other axial side can also be described as follows: Let A be the distance along the central axis CL of the sensor housing 30 between the outer wall 58 on one axial side of the connector housing 50 and the outer edge 56 on one axial side of the flange 51. Let B be the distance along the central axis CL of the sensor housing 30 between the outer wall 59 on the other axial side of the connector housing 50 and the outer edge 57 on the other axial side of the flange 51. In this case, the relationship is A > B. The difference between two distances A and B is greater than the manufacturing tolerance when distances A and B are assumed to be the same. While not a requirement, it is preferable that distance B is less than 10% of distance A. B may also be 0.

[0084] In this embodiment, the effects of positioning the connector housing 50 in the magnetic sensor module 20 at a location offset axially to the other side relative to the flange 51 will be explained in comparison with the magnetic sensor module 201 of the second comparative example.

[0085] As shown in Figure 18, in the second comparative example, the magnetic sensor module 201 has a flange 510 extending outward from the connector housing 500, which is formed parallel to a virtual plane VS perpendicular to the element insertion direction ID and the external connector attachment / detachment direction RD. In the magnetic sensor module 201 of the second comparative example, the radial size of the sensor housing extension 32 is D4. The radial size of the flange 510 and the connector housing 500 is D5. The radial size of the entire magnetic sensor module 201 is D6.

[0086] In contrast, as shown in Figure 19, the magnetic sensor module 20 of this embodiment has a flange 51 extending outward from the connector housing 50 that is inclined with respect to a virtual plane VS. Furthermore, the connector housing 50 is positioned offset axially to the other side relative to the flange 51. In Figure 19, the position where the connector housing 500 of the magnetic sensor module 201 of the second comparative example is superimposed on the magnetic sensor module 20 of this embodiment is shown by a dashed line. In this embodiment, the radial dimensions D7 of the entire magnetic sensor module 20 can be reduced by the difference D8 compared to the radial dimensions D6 of the entire magnetic sensor module 201 of the second comparative example.

[0087] As described above, in the third embodiment, the axial center position C1 in the connector opening 52 is shifted to the other axial side relative to the axial center position C2 in the flange 51. This makes it possible to reduce the overall radial size D7 of the magnetic sensor module 20 compared to that shown in the second comparative example.

[0088] Furthermore, in the third embodiment, the distance A between the outer wall 58 on one axial side of the connector housing 50 and the outer edge 56 on one axial side of the flange 51 is greater than the distance B between the outer wall 59 on the other axial side of the connector housing 50 and the outer edge 57 on the other axial side of the flange 51. This makes the overall radial size D7 of the magnetic sensor module 20 smaller than that shown in the second comparative example. Therefore, as shown in Figure 11, the magnetic sensor module 20 can be mounted in the narrow mounting space 90 within the housing 9 of a vehicle-side system such as the electric power steering system 1.

[0089] (Other embodiments) (1) In the above embodiments, a torque sensor was used as an example of a sensor device, but it is not limited to this. For example, the sensor device may be a detection device that detects various physical quantities, such as a pressure sensor, an acceleration sensor, or a temperature sensor. In that case, the detection element is not limited to the magnetic detection element 40, but an element capable of converting the physical quantity detected by the sensor into an electrical signal can be used.

[0090] (2) In each of the above embodiments, the torque sensor device 10 has been described as being applied to the electric power steering system 1, but is not limited to this. The torque sensor device 10 may be applied to various vehicle systems.

[0091] (3) In the above embodiments, the input shaft 11 constituting the steering shaft 3 was described as corresponding to the first shaft and the output shaft 12 as corresponding to the second shaft, but the invention is not limited to this. For example, the output shaft 12 may correspond to the first shaft and the input shaft 11 may correspond to the second shaft. In that case, the multipole magnet 14 is fixed to the other end of the output shaft 12 or the torsion bar 13, and the pair of yokes 15 and 16 are fixed to one end of the input shaft 11 or the torsion bar 13.

[0092] (4) In the first embodiment described above, a configuration was described in which the joining surface 53 of the flange 51 and the sensor housing side flange 33 of the sensor housing 30 are laser-welded, but the invention is not limited to this. Various joining methods can be used to join the joining surface 53 of the flange 51 and the sensor housing side flange 33 of the sensor housing 30, such as joining with adhesive, welding by heat, ultrasound or vibration, or joining with screws or rivets.

[0093] (5) In the first embodiment described above, a configuration was described in which the entire circumference of the flange 51 extends outside the connector housing 50 when viewed from a direction perpendicular to the joining surface 53 of the flange 51, but the embodiment is not limited to this. A configuration in which a part of the flange 51 extends outside the connector housing 50 when viewed from a direction perpendicular to the joining surface 53 of the flange 51 is also possible.

[0094] (6) In the first embodiment described above, the joining surface 53 of the flange 51 and the sensor housing 30 are joined all around on the outside of the connector housing 50 by laser welding, but the embodiment is not limited to this. The joining surface 53 of the flange 51 and the sensor housing 30 may be joined only in part on the outside of the connector housing 50 by laser welding.

[0095] (7) In the first embodiment described above, the joining surface 53 of the flange 51 is inclined to approach the central axis CL of the sensor housing 30, moving from one axial side of the sensor housing 30 to the other axial side of the sensor housing 30, but the invention is not limited to this. The direction in which the joining surface 53 of the flange 51 is inclined can be arbitrarily set, for example, according to the shape of the mounting space 90 for the magnetic sensor module 20 within the housing 9 of the vehicle system.

[0096] (8) In the first embodiment described above, the shape of the flange 51 as viewed from a direction perpendicular to the joint surface 53 of the flange 51 was made substantially rectangular, and in the second embodiment described above, its shape was made substantially circular, but it is not limited to these. Various shapes can be adopted for the flange 51, such as polygonal, elliptical, circular, or curved shapes.

[0097] This disclosure is not limited to the embodiments described above and can be modified as appropriate. Furthermore, the embodiments and parts thereof are not unrelated to each other and can be combined as appropriate, except in cases where the combination is clearly impossible. In addition, it goes without saying that the elements constituting the embodiments are not necessarily essential unless they are explicitly stated to be particularly essential or are clearly considered essential in principle. Furthermore, when numerical values ​​such as the number, numerical values, quantities, or ranges of the components of the embodiments are mentioned in the embodiments, they are not limited to those specific numbers unless they are explicitly stated to be particularly essential or are clearly limited to a specific number in principle. Furthermore, when the shapes, positional relationships, etc. of the components are mentioned in the embodiments, they are not limited to those shapes, positional relationships, etc. unless they are explicitly stated to be particular or are clearly limited to a specific shape, positional relationship, etc. in principle.

[0098] (Perspective of this disclosure) The above disclosure can be understood from the following perspectives, for example. [First point of view] In a sensor device mounted on a vehicle, The sensor body (13-16, 21, 22) that captures changes in physical quantities, A sensor housing (30) that houses at least a part of the sensor body, A detection element (40) that outputs a signal corresponding to the change in the aforementioned physical quantity is provided, and the part of the connector housing (50) on which the detection element is provided is inserted inside the sensor housing, The connector housing extends outward from the connector housing and has a flange (51) with a bonding surface (53) facing the sensor housing side that is bonded to the sensor housing, The bonding surface is inclined with respect to a virtual plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing on which the detection element is provided is inserted into the sensor housing. [Second perspective] The sensor device according to the first aspect, wherein, when viewed from a direction perpendicular to the joining surface, a part or the entire circumference of the flange extends outside the connector housing. [Third perspective] The sensor device according to the first or second aspect, wherein the joining surface and the sensor housing are joined to the outside of the connector housing by laser welding, either partially or entirely. [Fourth perspective] The sensor device according to any one of the first to third views, wherein the anti-joint surface (54) of the flange opposite to the joint surface and the joint surface are formed parallel to each other. [Fifth perspective] The sensor housing comprises a cylindrical sensor housing body (31) and a sensor housing side flange (33) to which the flange is joined. The sensor device according to any one of the first to fourth views, wherein the flange-side surface (35) of the sensor housing side flange is inclined in the same direction as the flange with respect to the virtual plane. [Sixth perspective] The sensor device according to any one of the first to fifth views, wherein the flange (51) is made of a resin that has higher laser light transmittance than the resin forming the sensor housing, and has a plate thickness through which the laser light can pass. [Seventh perspective] The sensor housing has a cylindrical sensor housing body portion (31), The aforementioned joining surface is inclined so as to approach the central axis (CL) of the sensor housing body, moving from one side to the other in the direction in which the central axis (CL) extends. The sensor device according to any one of the first to sixth views, wherein the other side of the connector housing in the direction in which the central axis extends is provided with a recess (55) that is recessed to one side in the direction in which the central axis extends, at the location where it connects to the flange. [Perspective 8] In a torque sensor device that detects the torque around the shaft acting on the shaft (3), A torsion bar (13) connects the first shaft (11) and the second shaft (12) that constitute the shaft coaxially, and converts the torque acting between the first shaft and the second shaft into a torsional displacement, A multipole magnet (14) fixed to one end of the first shaft or the torsion bar, having N poles and S poles alternately arranged in the circumferential direction, A yoke (15, 16) is fixed to the outside of the multipole magnet and to the other end of the second shaft or the torsion bar, forming a magnetic circuit within the magnetic field of the multipole magnet, A first magnetic flux guiding member (21) and a second magnetic flux guiding member (22) are provided on the outside of the yoke and guide the magnetic flux flowing through the yoke, A sensor housing (30) for fixing the first magnetic flux induction member and the second magnetic flux induction member, A magnetic detection element (40) that outputs a signal corresponding to the magnetic flux density passing through adjacent locations (25, 26) of the first magnetic flux induction member and the second magnetic flux induction member, A connector housing (50) is provided with the magnetic detection element, and the portion of the connector housing where the magnetic detection element is provided is inserted inside the sensor housing. The connector housing extends outward from the connector housing and has a flange (51) with a bonding surface (53) facing the sensor housing side that is bonded to the sensor housing, The torque sensor device wherein the bonding surface is inclined with respect to a virtual plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing on which the magnetic detection element is provided is inserted into the sensor housing. [Perspective 9] The torsion bar twists and elastically deforms in response to the torque acting around the axis between the first shaft and the second shaft. The yoke has a first yoke (15) and a second yoke (16), and the amount of magnetic flux flowing between the first yoke and the second yoke changes as the rotational relative position with respect to the multipole magnet changes according to the amount of twisting displacement of the torsion bar. The first magnetic flux induction member has a first magnetic collection section (23) that collects the magnetic field of the first yoke, and the second magnetic flux induction member has a second magnetic collection section (24) that collects the magnetic field of the second yoke. The torque sensor device according to the eighth aspect, wherein the magnetic detection element converts the magnetic flux collected by the first magnetic flux induction member and the second magnetic flux induction member into an electrical signal and outputs it. [Perspective 10] The first magnetic flux induction member has a first magnetic collection portion (23) provided in an annular or arc shape on the radially outer side of the yoke, The torque sensor device according to the eighth or ninth aspect, wherein the second magnetic flux induction member has a second magnetic collecting portion (24) provided in an annular or arc shape on the radially outer side of the yoke. [Perspective 11] The first magnetic flux induction member has a first magnetic collection portion (27) provided in the shape of a rod on a part of the radially outer side of the yoke, The torque sensor device according to the eighth or ninth aspect, wherein the second magnetic flux induction member has a second magnetic collecting portion (28) provided in the shape of a rod on a part of the radially outer side of the yoke. [Perspective 12] A torque sensor device according to any one of the eighth to eleventh aspects, which can be mounted in a mounting space (90) within the housing (9) of an electric power steering system (1). [Perspective 13] In a magnetic sensor module that detects the magnetic flux flowing through the yoke (15, 16), A first magnetic flux guiding member (21) and a second magnetic flux guiding member (22) that guide the magnetic flux flowing through the yoke, A sensor housing (30) housing the first magnetic flux induction member and the second magnetic flux induction member, A magnetic detection element (40) that outputs a signal corresponding to the magnetic flux density passing through adjacent locations (25, 26) of the first magnetic flux induction member and the second magnetic flux induction member, A connector housing (50) is provided with the magnetic detection element, and the portion of the connector housing where the magnetic detection element is provided is inserted inside the sensor housing. The connector housing extends outward from the connector housing and has a flange (51) with a bonding surface (53) facing the sensor housing side that is bonded to the sensor housing, The bonding surface is inclined with respect to a virtual plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing on which the magnetic detection element is provided is inserted into the sensor housing, in this magnetic sensor module. [Perspective 14] The first magnetic flux induction member has a first magnetic collection portion (23) provided in an annular or arc shape on the radially outer side of the yoke, The magnetic sensor module according to the thirteenth aspect, wherein the second magnetic flux induction member has a second magnetic collecting portion (24) provided in an annular or arc shape on the radially outer side of the yoke. [Perspective 15] The first magnetic flux induction member has a first magnetic collection portion (27) provided in the shape of a rod on a part of the radially outer side of the yoke, The magnetic sensor module according to the thirteenth aspect, wherein the second magnetic flux induction member has a second magnetic collection portion (28) provided in the shape of a rod on a part of the radially outer side of the yoke. [Perspective 16] A torque sensor device according to any one of the 13th to 15th aspects, which can be mounted in a mounting space (90) within the housing (9) of an electric power steering system (1). [Perspective 17] The sensor housing has a cylindrical sensor housing body portion (31), The aforementioned joining surface is inclined so as to approach the central axis (CL) of the sensor housing body, moving from one side to the other in the direction in which the central axis (CL) extends. The connector housing has a connector opening (52) through which an external connector (60) is attached and detached. The sensor device according to any one of the first to seventh views, wherein the center position (C1) in the direction in which the central axis extends in the connector opening is shifted to the other side in the direction in which the central axis extends, relative to the center position (C2) in the flange in the direction in which the central axis extends. [Perspective 18] The sensor housing has a cylindrical sensor housing body portion (31), The aforementioned joining surface is inclined so as to approach the central axis (CL) of the sensor housing body, moving from one side to the other in the direction in which the central axis (CL) extends. Between the outer wall (58) on one side of the connector housing in the direction in which the central axis extends and the outer edge (56) on one side of the flange in the direction in which the central axis extends, the distance along the direction in which the central axis extends is A. If B is the distance along the direction in which the central axis extends between the outer wall (59) on the other side of the connector housing in the direction in which the central axis extends and the outer edge (57) on the other side of the flange in the direction in which the central axis extends, A sensor device as described in any one of the first to seventh or seventeenth viewpoints, wherein the relationship A > B holds true.

[0099] Furthermore, the content described in sections 2 through 7, 17, and 18 can be appropriately combined with the eighth and thirteenth perspectives.

Claims

1. In a sensor device mounted on a vehicle, The sensor body (13-16, 21, 22) that captures changes in physical quantities, A sensor housing (30) that houses at least a part of the sensor body, A detection element (40) that outputs a signal corresponding to the change in the aforementioned physical quantity is provided, and the part of the connector housing (50) on which the detection element is provided is inserted inside the sensor housing, The connector housing extends outward from the connector housing and has a flange (51) with a joining surface (53) facing the sensor housing side that is joined to the sensor housing, The aforementioned bonding surface is inclined with respect to a virtual plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing on which the detection element is provided is inserted into the sensor housing, in a sensor device.

2. The sensor device according to claim 1, wherein, when viewed from a direction perpendicular to the joining surface, a part or the entire circumference of the flange extends outside the connector housing.

3. The sensor device according to claim 1 or 2, wherein the joining surface and the sensor housing are joined together on the outside of the connector housing, either partially or entirely, by laser welding.

4. The sensor device according to claim 1 or 2, wherein the non-jointing surface (54) of the flange opposite to the joining surface and the joining surface are formed parallel to each other.

5. The sensor housing comprises a cylindrical sensor housing body portion (31) and a sensor housing side flange (33) to which the flange is joined. The sensor device according to claim 1 or 2, wherein the flange-side surface (35) of the sensor housing side flange is inclined in the same direction as the flange with respect to the virtual plane.

6. The sensor device according to claim 1 or 2, wherein the flange (51) is made of a resin that has higher laser light transmittance than the resin forming the sensor housing, and has a plate thickness through which the laser light can pass.

7. The sensor housing has a cylindrical sensor housing body portion (31), The aforementioned joining surface is inclined so as to approach the central axis (CL) of the sensor housing body, moving from one side to the other in the direction in which the central axis (CL) extends. The sensor device according to claim 1 or 2, wherein the other side of the connector housing in the direction in which the central axis extends is provided with a recess (55) that is recessed to one side in the direction in which the central axis extends, at the location where it connects to the flange.

8. In a torque sensor device that detects the torque around the shaft acting on the shaft (3), A torsion bar (13) connects the first shaft (11) and the second shaft (12) that constitute the shaft coaxially, and converts the torque acting between the first shaft and the second shaft into a torsional displacement, A multipole magnet (14) fixed to one end of the first shaft or the torsion bar, having N poles and S poles alternately arranged in the circumferential direction, A yoke (15, 16) is fixed to the outside of the multipole magnet and to the other end of the second shaft or the torsion bar, forming a magnetic circuit within the magnetic field of the multipole magnet, A first magnetic flux guiding member (21) and a second magnetic flux guiding member (22) are provided on the outside of the yoke and guide the magnetic flux flowing through the yoke, A sensor housing (30) for fixing the first magnetic flux induction member and the second magnetic flux induction member, A magnetic detection element (40) that outputs a signal corresponding to the magnetic flux density passing through adjacent locations (25, 26) of the first magnetic flux induction member and the second magnetic flux induction member, A connector housing (50) is provided with the magnetic detection element, and the portion of the connector housing where the magnetic detection element is provided is inserted inside the sensor housing. The connector housing extends outward from the connector housing and has a flange (51) with a joining surface (53) facing the sensor housing side that is joined to the sensor housing, The torque sensor device wherein the bonding surface is inclined with respect to a virtual plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing on which the magnetic detection element is provided is inserted into the sensor housing.

9. The torsion bar twists and elastically deforms in response to the torque acting around the axis between the first shaft and the second shaft. The yoke has a first yoke (15) and a second yoke (16), and the amount of magnetic flux flowing between the first yoke and the second yoke changes as the rotational relative position with respect to the multipole magnet changes according to the amount of twisting displacement of the torsion bar. The first magnetic flux induction member has a first magnetizing section (23) that collects the magnetic field of the first yoke, and the second magnetic flux induction member has a second magnetizing section (24) that collects the magnetic field of the second yoke. The torque sensor device according to claim 8, wherein the magnetic detection element converts the magnetic flux collected by the first magnetic flux induction member and the second magnetic flux induction member into an electrical signal and outputs it.

10. The first magnetic flux induction member has a first magnetic collection portion (23) provided in an annular or arc shape on the radially outer side of the yoke, The torque sensor device according to claim 8, wherein the second magnetic flux induction member has a second magnetic collecting portion (24) provided in an annular or arc shape on the radially outer side of the yoke.

11. The first magnetic flux induction member has a first magnetic collection portion (27) provided in the shape of a rod on a part of the radially outer side of the yoke, The torque sensor device according to claim 8, wherein the second magnetic flux induction member has a second magnetic collection portion (28) provided in the shape of a rod on a part of the radially outer side of the yoke.

12. A torque sensor device according to any one of claims 8 to 11, which can be mounted in a mounting space (90) within the housing (9) of an electric power steering system (1).

13. In a magnetic sensor module that detects the magnetic flux flowing through the yoke (15, 16), A first magnetic flux guiding member (21) and a second magnetic flux guiding member (22) guide the magnetic flux flowing through the yoke, A sensor housing (30) housing the first magnetic flux induction member and the second magnetic flux induction member, A magnetic detection element (40) that outputs a signal corresponding to the magnetic flux density passing through adjacent locations (25, 26) of the first magnetic flux induction member and the second magnetic flux induction member, A connector housing (50) is provided with the magnetic detection element, and the portion of the connector housing where the magnetic detection element is provided is inserted inside the sensor housing. The connector housing extends outward from the connector housing and has a flange (51) with a joining surface (53) facing the sensor housing side that is joined to the sensor housing, The bonding surface is inclined with respect to a virtual plane (VS) perpendicular to the direction (ID) in which the portion of the connector housing on which the magnetic detection element is provided is inserted into the sensor housing, in this magnetic sensor module.

14. The first magnetic flux induction member has a first magnetic collection portion (23) provided in an annular or arc shape on the radially outer side of the yoke, The magnetic sensor module according to claim 13, wherein the second magnetic flux induction member has a second magnetic collection portion (24) provided in an annular or arc shape on the radially outer side of the yoke.

15. The first magnetic flux induction member has a first magnetic collection portion (27) provided in the shape of a rod on a part of the radially outer side of the yoke, The magnetic sensor module according to claim 13, wherein the second magnetic flux induction member has a second magnetic collection portion (28) provided in the shape of a rod on a part of the radially outer side of the yoke.

16. A magnetic sensor module according to any one of claims 13 to 15, which can be mounted in a mounting space (90) within the housing (9) of an electric power steering system (1).

17. The sensor housing has a cylindrical sensor housing body portion (31), The aforementioned joining surface is inclined so as to approach the central axis (CL) of the sensor housing body, moving from one side to the other in the direction in which the central axis (CL) extends. The connector housing has a connector opening (52) through which an external connector (60) is attached and detached. The sensor device according to claim 1 or 2, wherein the center position (C1) in the direction in which the central axis extends in the connector opening is shifted to the other side in the direction in which the central axis extends, with respect to the center position (C2) in the flange in the direction in which the central axis extends.

18. The sensor housing has a cylindrical sensor housing body portion (31), The aforementioned joining surface is inclined so as to approach the central axis (CL) of the sensor housing body, moving from one side to the other in the direction in which the central axis (CL) extends. Between the outer wall (58) on one side of the connector housing in the direction in which the central axis extends and the outer edge (56) on one side of the flange in the direction in which the central axis extends, the distance along the direction in which the central axis extends is A. If B is the distance along the direction in which the central axis extends between the outer wall (59) on the other side of the connector housing in the direction in which the central axis extends and the outer edge (57) on the other side of the flange in the direction in which the central axis extends, The sensor device according to claim 1 or 2, wherein the relationship A > B.

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