Method and modular system for assembling a sensor assembly for a motor vehicle

Abstract

The invention relates to a method and a modular system for assembling a sensor assembly (1), to the sensor assembly (1), and to a motor vehicle having the sensor assembly (1). A first variant (5a) or a second variant (5b) of an intermediate component (5) is selected, which intermediate component has a variant-specific intermediate connection element (6 or 9) and a sensor holder (12). Furthermore, a carrier component (13) is provided which has a first carrier connection element (14), which corresponds only to the first intermediate connection element (6) in order to establish a form-locking connection, and a second carrier connection element (15), which corresponds only to the second intermediate connection element (9) in order to establish a form-locking connection. A handling unit (18) is then formed from a sensor component (2) and the intermediate component (5) by fastening the sensor component (2) to the intermediate component (5) by means of a handling form-locking connection (19). The handling unit (18) is then attached to the carrier component (13) by joining the intermediate connection element (6, 9) and the carrier connection element (14, 15) to form a form-locking connection which connects the carrier component (13) and the intermediate component (5), wherein, depending on the variant (5a, 5b) of the intermediate component (5), the first carrier connection element (14) and the first intermediate connection element (6) or the second carrier connection element (15) and the second intermediate connection element (9) can be joined to form the form-locking connection.

Description

[0001] Method and modular system for assembling a sensor arrangement as well as sensor arrangement and motor vehicle

[0002] The present invention relates to a method for assembling a sensor arrangement, as well as a sensor arrangement and a motor vehicle comprising such a sensor arrangement.

[0003] In the series production of motor vehicles, differing exterior designs of model derivatives and / or equipment variants within the same model line result in different installation positions for vehicle sensors. For example, if a basic version and a sport version of the same vehicle model are produced, a radar sensor, for instance, will be located in a different position in the basic version than in the sport version. From an economic and environmental perspective, there is currently a need to design as many parts as possible – sensors and their mountings – as identical components across models, derivatives, versions, and equipment variants, and to use them in as many derivatives and equipment variants as possible (i.e., in both the basic and sport versions).Such a holder therefore has at least two receptacles for the sensor, whereby it must be ensured that the sensor is not inserted into the wrong receptacle. Conventional sensor devices, whose sensor is arranged under a motor vehicle's outer skin (i.e., on an inner surface of a motor vehicle body), are known, for example, from WO 2014 037 194 A1, from DE 103 16 535 B3, or from DE 10 2017210 291 A1. The object of the present invention is to prevent incorrect assembly when assembling a module that has a component that fits into two receptacles of a holder of the module.

[0004] This problem is solved by the subject matter of the independent claims. Further possible embodiments of the invention are disclosed in the dependent claims, the description, and the figures. Features, advantages, and possible embodiments set forth in the description for one of the subject matter of the independent claims are to be regarded, at least analogously, across categories and embodiments as features, advantages, and possible embodiments of the respective subject matter of the other independent claims, as well as of any possible combination of the subject matter of the independent claims, optionally in conjunction with one or more of the dependent claims.

[0005] According to the invention, a method for assembling such a component, which is in particular a sensor arrangement for a motor vehicle, is proposed. In the method according to the invention, a first variant or a second variant of an intermediate component is selected, which has a first intermediate connecting element or a second intermediate connecting element specific to each variant and an identical sensor holder across all variants. The variants of the intermediate component are selected, for example, within the framework of series production of a motor vehicle from a modular system or assortment in which the two intermediate component variants are provided. A different variant of the intermediate component is selected depending on the derivative or model variant to be produced.The choice of intermediate component variant for the further process is therefore determined in particular by which derivative or model variant (for example, basic or sport version) the sensor arrangement is manufactured for, i.e., in which derivative or model variant the sensor arrangement is installed as part of the manufacture of the motor vehicle.

[0006] Furthermore, the process provides a support component comprising a first support connection element and a second support connection element. The first support connection element corresponds only to the first intermediate connection element to create a positive fit, whereas the second support connection element corresponds only to the second intermediate connection element to create a positive fit. In other words, the first support connection element only fits with the first intermediate connection element, and the second support connection element only fits with the second intermediate connection element.It is specifically intended that the first beam connection element and / or the second intermediate connection element are designed in such a way that they cannot be assembled by positive locking, so that if an attempt is made to assemble the second intermediate connection element and the first beam connection element, this is not possible without destroying one or both of the incorrectly engaged connection elements. The same applies in particular to the second beam connection element and / or the first intermediate connection element.

[0007] In this process, a handling unit is formed from a sensor component and the intermediate component (i.e., its selected variant). For this purpose, a positive locking mechanism is created between the sensor component and the intermediate component by means of the sensor holder, thereby fixing the sensor component to the intermediate component. The sensor component and the intermediate component can thus be handled for the subsequent process, whereby the positive locking mechanism ensures that the sensor component does not easily fall off the intermediate component, or vice versa. The positive locking mechanism thus fixes the sensor component and the intermediate component in a position relative to each other, preventing any movement. In other words, in the handling unit, the sensor component is fixed to the intermediate component in a handling position.The handling form-fit connection is in particular a reversible, non-destructive form-fit connection, so that the sensor component and the intermediate component can be easily separated from each other again.

[0008] The handling unit is then attached to the support component by assembling the intermediate connecting element and the support connecting element to form a positive fit connecting the support component and the intermediate component. Depending on the selected variant of the intermediate component, either the first support connecting element and the first intermediate connecting element or the second support connecting element and the second intermediate connecting element can be assembled to form a positive fit. As already explained, it is not possible, by design, to create the positive fit connecting the support component and the intermediate component between the first intermediate connecting element and the second support connecting element or between the second intermediate connecting element and the first support connecting element without having to apply excessive (abusive) force.This means that the geometry of the first support connector and the second intermediate connector, as well as the second support connector and the first intermediate connector, prevents unauthorized assembly of the first support connector and the intermediate connector. For example, the connectors have a coding that prevents incorrect assembly of the handling unit with the support component. When the support component, the sensor component, and the intermediate component are properly connected, the sensor assembly is at least partially or completely manufactured or assembled.

[0009] A human worker will advantageously recognize intuitively that the handling unit cannot be moved into a position on the incorrect connecting element of the supporting component where the intended positive locking connection between the handling unit and the supporting component can be achieved. Alternatively or additionally, the worker recognizes that the force exerted on one or both of the incorrectly connected elements is too high and, consequently, realizes that they were about to connect two incorrect, mismatched connecting elements. They will then check the correctness of their work steps and attempt to attach the handling unit to the supporting component using the other, appropriate connecting element.

[0010] According to the invention, a modular system is proposed with which two or more different variants of the sensor arrangement can be manufactured. The modular system (which can also be referred to as an assortment) comprises exactly one variant of the sensor component. This means that the sensor components in the modular system are identical. Each sensor component has a sensor connection element. The sensor components, and consequently the sensor connection elements, are identical.

[0011] Furthermore, the modular system comprises two variants of the intermediate component, namely a first and a second variant. As explained above, the appropriate variant of the intermediate component is selected depending on the model variant to be produced, particularly within the framework of the method according to the invention. The first intermediate component variant has the first intermediate connecting element, and it is specifically provided that the intermediate component in its first variant has only the first intermediate connecting element and not the second intermediate connecting element. In contrast, the second intermediate component variant has a second intermediate connecting element, and it is specifically provided that the intermediate component in its second variant has only the second intermediate connecting element and not the first intermediate connecting element.The first and second intermediate connecting elements have different shapes, differing in size and / or geometry. However, across all variants, the intermediate components feature the same sensor mount. It should be understood that three or more variants of the intermediate component can be offered within the modular system.

[0012] The modular system also features exactly one variant of the support component. This means that the support components in the modular system are identical. Each support component has both the first and second support connection elements. As already explained in connection with the process, the first support connection element corresponds only to the first intermediate connection element, and not to the second intermediate connection element, to form the positive fit that allows the support component and the intermediate component to be connected. As also explained above, the second support connection element corresponds only to the second intermediate connection element, and not to the first intermediate connection element, to form the positive fit that allows the support component and the intermediate component to be connected. During manufacturing, or...When assembling the sensor arrangement, either the first support connecting element and the first intermediate connecting element or the second support connecting element and the second intermediate connecting element are assembled to form a positive connection, by means of which the support component and the intermediate component are connected to each other.

[0013] Furthermore, the support connecting elements each have the same

[0014] Sensor recording, which is used with the sensor connection element to create a the

[0015] The sensor component and the support component are connected by a positive locking mechanism. Therefore, the sensor component can be attached to the respective support component at the respective support connection element as intended. This is because the support connection elements – regardless of the variant – each have one sensor receptacle.

[0016] Thanks to the modular system, it is possible to quickly and easily build different variations of the sensor arrangement, for example, a first sensor arrangement variant for a basic version of the vehicle and a different second sensor arrangement variant for a sport version of the vehicle. It can be seen that in the sensor arrangement, the intermediate component and the support component are connected, depending on the variant of the intermediate component, either by positive locking, where the first support connecting element and the first intermediate connecting element are positively coupled to each other, or by positive locking, where the second support connecting element and the second intermediate connecting element are positively coupled to each other.The different intermediate component variants, which are assembled with the sensor component to form the handling unit before the handling unit is attached to the carrier component, ensure that the sensor component is always installed in the correct position.

[0017] Another object according to the invention is formed by the sensor arrangement, which is manufactured from parts of the modular system and / or by means of the method. The invention also relates to a motor vehicle that has the sensor arrangement. The motor vehicle can have two or more such sensor arrangements. The sensor arrangement forms, in particular, a component of a driver assistance system and / or driving control system (for semi- or fully autonomous driving), for example, a radar sensor of a distance measuring system for a distance-dependent cruise control system.

[0018] According to a possible further development of the modular system, the intermediate component is designed as an absorber element for electromagnetic radiation, particularly radar radiation. Thus, the intermediate component has a dual function, acting both as a safety element against incorrect assembly and as an absorber or funnel unit for the electromagnetic or radar radiation. In another possible embodiment of the method, when the positive locking connection is formed between the handling unit and the carrier component, a positive locking connection between the intermediate component and the carrier component, as well as a positive locking connection between the sensor component and the carrier component, are formed. This results in the intermediate component and the sensor component being separately and positively locked to the carrier component. Consequently, the sensor assembly is particularly stable.

[0019] Another possible embodiment of the method involves releasing the handling positive locking mechanism by forming the sensor positive locking connection, so that the sensor component is directly coupled to the carrier component in its intended installation position and decoupled from the intermediate component. This allows the sensor component to be easily and quickly removed separately from the carrier component, for example, during maintenance or repair. This advantageously eliminates the need for time-consuming disassembly of the intermediate component from the carrier component. Furthermore, the direct mechanical fastening of the sensor component to the carrier component, or the direct mechanical fastening of the intermediate component to the carrier component, results in a particularly favorable tolerance chain.A tolerance chain is avoided in which a tolerance between sensor component and intermediate component as well as a tolerance between intermediate component and support component are linked together.

[0020] Alternatively, in another possible embodiment, the sensor positive locking is formed in addition to the handling positive locking, so that the sensor component, in its intended installation position, is coupled directly to both the support component and the intermediate component. This makes the sensor arrangement particularly stable.

[0021] Further features of the invention may become apparent from the claims, the figures, and the description of the figures. The features and combinations of features mentioned above in the description, as well as the features and combinations of features shown below in the description of the figures and / or in the figures themselves, can be used not only in the combinations specified, but also in other combinations or on their own, without departing from the scope of the invention.

[0022] The drawing shows in Fig. 1 a common view of two variants of a sensor arrangement for a motor vehicle, wherein in the first sensor arrangement variant a first intermediate component variant and a sensor component are positively fixed to a first support connecting element of a support component of the sensor arrangement, and in the second sensor arrangement variant a second intermediate component variant and the sensor component are positively fixed to a second support connecting element of the same support component.

[0023] Fig. 2 is a block diagram illustrating the steps of a method for manufacturing the sensor assembly.

[0024] Fig. 3 shows an enlarged view of a section of the first sensor arrangement variant,

[0025] Fig. 4 shows an enlarged view of a section of the second

[0026] Sensor arrangement variant,

[0027] Fig. 5 shows an enlarged view from a different perspective of the section of the second sensor arrangement variant and in

[0028] Fig. 6 shows an enlarged view from a different perspective of the section of the second sensor arrangement variant, with the support component not shown.

[0029] The following section describes a method and a modular system – each for manufacturing and assembling a sensor arrangement 1, respectively – as well as the sensor arrangement 1 itself and a motor vehicle comprising the sensor arrangement 1. For this purpose, identical and functionally equivalent elements are designated with the same reference numeral in the figures. The modular system and the motor vehicle are not shown in the figures.

[0030] The motor vehicle, for example a passenger car, has sensor arrangement 1. Sensor arrangement 1 forms a component of a driver assistance and / or driving control system of the motor vehicle. In this case, sensor arrangement 1 is a radar sensor arrangement, for example a short-range radar arrangement or SRR arrangement (SRR: Short Range Radar). Sensor arrangement 1 can be selectively assembled into a first sensor arrangement variant 1a or a second sensor arrangement variant 1b, as will be explained in more detail below.

[0031] Fig. 1 shows the sensor arrangement 1, with sensor arrangement variants 1a and 1b shown together. The components of the sensor arrangement 1 and the sensor arrangement variants 1a and 1b are available in a modular system. Accordingly, sensor arrangement variants 1a and 1b can be selectively manufactured using this modular system. The modular system includes sensor components 2, which are available in a single sensor component variant. In other words, the sensor components 2 available in the modular system are identical, i.e., they are identical parts. Each sensor component 2 has a sensor connection element 3 (shown for the first time in Fig. 3), which has one, two, or more sensor connection means 4.

[0032] Furthermore, the modular system comprises two variants of an intermediate component 5 of the sensor assembly 1, namely a first intermediate component variant 5a and a second intermediate component variant 5b. In the present example, the intermediate component 5 is designed as an absorber element for electromagnetic radiation, here for radar radiation. The first intermediate component variant 5a has a first intermediate connecting element 6, which includes one, two, or more intermediate connecting elements 7 and, in this case, a first coding element arrangement 8 (see Fig. 3). In contrast, the second intermediate component variant 5b has a second intermediate connecting element 9, which includes one, two, or more intermediate connecting elements 10 and, in this case, a second coding element arrangement 11 (see Fig. 4, Fig. 5, and Fig. 6).In this example, the first intermediate component variant 5a has only the first intermediate connecting element 6 and only the first coding element arrangement 8, but neither the second intermediate connecting element 9 nor the second coding element arrangement 11. Conversely, the second intermediate component variant 5b has only the second intermediate connecting element 9 and only the second coding element arrangement 11, but neither the first intermediate connecting element 6 nor the first coding element arrangement 8. The first intermediate connecting element 6 and the second intermediate connecting element 9 are shaped differently, i.e., they differ in size and / or geometry, in this case due to the different coding element arrangements 8, 11, which – as can be seen from the figures – have a different number of coding elements, in particular coding pins.However, the intermediate components 5 - regardless of the intermediate component variant, i.e. across variants - each have the same or identically designed sensor holder 12.

[0033] The modular system further comprises support components 13, which are available in a single component variant. In other words, the support components 13 provided in the modular system are identical, i.e., identical parts. Each support component 13 has both a first support connection element 14 and a second support connection element 15. The first support connection element 14 corresponds to forming a positive fit, by which the support component 13 and the intermediate component 5 can be connected to each other, only with the first intermediate connection element 6, and not with the second intermediate connection element 9. In contrast, the second support connection element 15 corresponds to forming a different positive fit, by which the support component 13 and the intermediate component 5 can be connected to each other, only with the second intermediate connection element 9, and not with the first intermediate connection element 6.The carrier connecting elements 14, 15 – regardless of whether it is the first carrier connecting element 14 or the second carrier connecting element 15 – each have an identical sensor receptacle 16, which corresponds to the sensor connecting element 3 to create a positive connection between the sensor component 2 and the carrier component 13. The respective sensor receptacle 16 includes, for example, as many sensor connecting element receptacles 17 as the sensor component 2 has sensor connecting elements 4.

[0034] According to the present example, the modular system is used in the process for assembling the sensor assembly 1. Steps S1, S2, S3, and S4 of the process are visualized in Fig. 2. The process comprises a process step S1 in which, depending on the model variant of the motor vehicle to be manufactured, the corresponding variant 5a or 5b of the intermediate component 5 is selected. Which intermediate component variant 5a or 5b is selected for the subsequent process is therefore determined, in particular, by which derivative or model variant (for example, basic or sport version) of the motor vehicle the sensor assembly 1 is being manufactured for, that is, into which derivative or model variant the sensor assembly 1 is installed during the manufacturing of the motor vehicle. Furthermore, in a further step S2 of the process, the carrier component 13 described above is provided.It is irrelevant in which order steps S1 and S2 are performed, or whether steps S1 and S2 are performed simultaneously. In any case, after the carrier component 13 has been provided and the corresponding intermediate component variant 5a or 5b has been selected, a further step S3 of the process is performed. In step S3, a handling unit 18 is formed, which comprises the corresponding intermediate component variant 5a or 5b and the sensor component 2. For this purpose, a positive-locking handling connection 19 is formed between the sensor component 2 and the intermediate component 5—that is, the corresponding intermediate component variant 5a or 5b—by means of the sensor holder 12 (best seen in Fig. 6). It should be understood that two or more positive-locking handling connections 19 can be formed. In Fig. 6, only one of the positive-locking handling connections 19 is provided with the corresponding reference numeral.The sensor component 2 is fixed to the intermediate component 5 by means of the (respective) handling positive locking mechanism 19 and, in particular, is held in a fixed position relative to the intermediate component 5. After step S3, the handling unit 18 is attached to the support component 13 in a further process step S4. For this purpose, if the handling unit 18 has the first intermediate component variant 5a, the first intermediate connecting element 6 and the first support connecting element 14 are assembled to form a positive locking mechanism connecting the support component 13 and the intermediate component 5. If the handling unit 18 has the second intermediate component variant 5b instead of the first, the second intermediate connecting element 9 and the second support connecting element 15 are assembled to form a different positive locking mechanism connecting the support component 13 and the intermediate component 5.

[0035] It is not possible, by design, to establish the positive connection by which the support component 13 and the intermediate component 5 are connected between the first intermediate connecting element 6 and the second support connecting element 15, or between the second intermediate connecting element 9 and the first support connecting element 14, without, for example, a human worker having to exert excessive (abusive) force. In other words: A non-abusive joining of the first support connecting element 14 and the second intermediate connecting element 9, or of the second support connecting element 15 and the first intermediate connecting element 6, is prevented by the geometry of the support connecting elements 14, 15 and the intermediate connecting elements 6, 9.In the present example, the first carrier connecting element 14 is designed such that only the first intermediate connecting element 6 and / or the first coding element arrangement 8 can engage in corresponding recesses of the first carrier connecting element 14, whereas when attempting to engage the second intermediate connecting element 9 and the second coding element arrangement 11 in the recesses of the first carrier connecting element 14, the handling unit 18 with the second intermediate component variant 5b is rejected or cannot be attached. This creates a safety mechanism that prevents incorrect assembly of the sensor arrangement 1.

[0036] In the present method, it is further provided that when the positive connection between the handling unit 18 and the support component 13 is formed, both an intermediate component positive connection is formed directly between the intermediate component 5 and the support component 13, and a sensor positive connection is formed directly between the sensor component 2 and the support component 13. The intermediate component positive connection is mediated by the first intermediate connecting element 6 or the intermediate connecting means 7 in conjunction with corresponding receptacles for the intermediate connecting element 6 or the intermediate connecting means 7 arranged on the support component 13. The sensor positive connection is mediated by the sensor connecting element 3 or the sensor connecting means 4 in conjunction with corresponding receptacles for the sensor connecting element 3 or the sensor connecting means 4 arranged on the support component 13.

[0037] Furthermore, in the method or sensor arrangement 1, it is provided that the sensor positive locking mechanism releases the handling positive locking mechanism 19, so that the sensor component 2 is directly coupled to the support component 13 in its intended installation position and decoupled from the intermediate component 5. In an alternative option, the sensor positive locking mechanism is formed in addition to the handling positive locking mechanism 19, so that the sensor component 2 is directly coupled to both the support component 13 and the intermediate component 5 in its intended installation position.

[0038] The method, the modular system, the sensor arrangement 1, and the motor vehicle each demonstrate a possible solution to the problem described at the beginning: preventing incorrect assembly when assembling a module that includes a component fitting into two recesses of a mounting bracket. Reference numeral list

[0039] 1 Sensor arrangement

[0040] 1a first sensor arrangement variant

[0041] 1b second sensor arrangement variant

[0042] 2 Sensor component

[0043] 3 Sensor connection element

[0044] 4 Sensor connectors

[0045] 5 Intermediate component

[0046] 5a first intermediate component variant

[0047] 5b second intermediate component variant

[0048] 6 first intermediate connecting element

[0049] 7 Intermediate connecting elements

[0050] 8 first coding element arrangement

[0051] 9 second intermediate connecting element

[0052] 10 Intermediate connectors

[0053] 11 second coding element arrangement

[0054] 12 Sensor holder

[0055] 13 Support component

[0056] 14 first support connecting element

[0057] 15 second support connecting element

[0058] 16 Sensor recording

[0059] 17 Sensor connection holder

[0060] 18 handling units

[0061] 19 Handling form closure

[0062] 51st procedure step

[0063] 52nd process step

[0064] 53 Procedure step

[0065] 54th process step

Claims

Patent claims 1. Method for assembling a sensor arrangement (1), wherein 51 a first variant (5a) or a second variant (5b) of an intermediate component (5) is selected, which has a first intermediate connecting element (6) or a second intermediate connecting element (9) specific to the variant and an identical sensor holder (12) across variants, 52 a support component (13) is provided which has a first support connection element (14) that corresponds only to the first intermediate connection element (6) to create a positive fit, and a second support connection element (15) that corresponds only to the second intermediate connection element (9) to create a positive fit, 53 a handling unit (18) is formed from a sensor component (2) and the intermediate component (5) by forming a handling positive connection (19) between the sensor component (2) and the intermediate component (5) by means of the sensor holder (12), by means of which the sensor component (2) is fixed to the intermediate component (5), 54 the handling unit (18) is attached to the support component (13) by assembling the intermediate connecting element (6, 9) and the support connecting element (14, 15) to form a positive connection connecting the support component (13) and the intermediate component (5), wherein, depending on the variant (5a, 5b) of the intermediate component (5), the first support connecting element (14) and the first intermediate connecting element (6) or the second support connecting element (15) and the second intermediate connecting element (9) can be assembled to form a positive connection.

2. Method according to claim 1, characterized in that, when forming the positive locking connection between the handling unit (18) and the support component (13), an intermediate component positive locking connection is formed directly between the intermediate component (5) and the support component (13) and a sensor positive locking connection is formed directly between the sensor component (2) and the support component (13).

3. Method according to claim 2, characterized in that by forming the sensor positive locking, the handling positive locking (19) is released, so that the sensor component (2) is directly coupled to the support component (13) in its intended installation position and is decoupled from the intermediate component (5).

4. Method according to claim 2, characterized in that the sensor positive locking is formed in addition to the handling positive locking (19), so that the sensor component (2) is coupled in its intended installation position both directly to the carrier component (13) and directly to the intermediate component (5).

5. Modular system for producing two variants (1a, 1b) of a sensor arrangement (1), wherein the modular system comprises: - exactly one variant of a sensor component (2), comprising a sensor connecting element (3), - two variants (5a, 5b) of an intermediate component (5), namely - a first intermediate component variant (5a) which has a first intermediate connecting element (6), and - a second intermediate component variant (5b) which has a second intermediate connecting element (9) shaped differently from the first intermediate connecting element (6), wherein the intermediate components (6, 9) each have the same sensor holder (12) across variants, - exactly one variant of a support component (13), comprising: - a first carrier connecting element (14) which corresponds only to the first intermediate connecting element (6) for producing the first sensor arrangement variant (1a) to form a positive connection, via which the carrier component (13) and the intermediate component (5) can be connected to each other, and - a second carrier connecting element (15) which, for producing the second sensor arrangement variant (1b) to form a positive connection, via which the carrier component (13) and the intermediate component (13) can be connected to each other, only corresponds to the second intermediate connecting element (9), wherein the carrier connecting elements (6, 9) each have an identical sensor receptacle (16) across variants, which corresponds to the sensor connecting element (3) to produce a positive connection connecting the sensor component (2) and the carrier component (13).

6. Modular system according to claim 5, characterized in that the intermediate component (5) is designed as an absorber element for electromagnetic radiation, in particular for radar radiation.

7. Sensor arrangement (1) manufactured by means of the method carried out according to one of claims 1 to 4 and / or by means of the modular system carried out according to claim 4 or 5.

8. Motor vehicle with a sensor arrangement designed according to claim 7 (1).

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