DE102016211450A1 - Rotor bearing sensor assembly with double-sided sensor arrangement and clutch release system - Google Patents

Abstract

The invention relates to a rotor-bearing sensor assembly (1) for a clutch release system (2) having a stator (3) and a rotor (4) which can be rotated relative thereto, wherein the rotor-bearing sensor assembly (1) has a circuit board (10) on which electrical sensors (11, 12) are arranged for magnetic-field-dependent position determination of at least one rotor-fixed magnet (5), wherein on each of a first side (18) of the board (10) and on a second side (19) of the board (10) at least one electrical sensor (11, 12 ) is attached. Furthermore, the invention relates to a clutch release system of a motor vehicle, with a rotor (3), a stator (4) and a disengaging element wherein a position of the rotor (3) relative to the stator (4) by means of a rotor position sensor assembly (1) according to the invention can be realized.

Description

The present invention relates to a rotor position sensor assembly for a clutch release system, preferably for use in a motor vehicle, having a stator and a rotor rotatable relative thereto, wherein the rotor position sensor assembly comprises a board on which electrical sensors for magnetic field-dependent position determination of at least one rotor-fixed magnet are arranged. Furthermore, the inventive idea comprises a clutch release system of a motor vehicle, with a rotor and a stator, as well as with a release element, wherein in the clutch release system, a rotor position sensor assembly according to the invention is used.

From the prior art sensor units for use in a coupling system are known which detect a rotor position relative to a stator via magnetic field-dependent parameters. So revealed the German patent application 10 2014 218 544 A1 an electric motor with an evaluation for rotor position determination. Here, a carrier element, on which a sensor is arranged, arranged in a housing which is open on one side. This geometric arrangement causes the sensor is arranged offset to the rotor, which adversely affects the required space.

Furthermore, generic rotor position sensor assemblies are known, which in addition to a circuit board have a sensor carrier extending in the circumferential direction of a housing in the manner of a ring portion. Since a large number of sensors is usually arranged on the board, the ring section extends over an angular span of up to 180 degrees. This angular span, as well as a juxtaposition of circuit board and sensor carrier, continues to have a negative effect on the required space. In addition, the rotor bearing sensor assemblies known from the prior art can be mounted only from one side, which causes a complex assembly process.

Against the background of this prior art, the object of the present invention is to disclose a rotor-bearing sensor assembly which, while maintaining the quality of the rotor-layer, takes up less space and simplifies the assembly process.

In addition, the invention addresses the problem of presenting a clutch release system that is more efficient in terms of time and in which individual components are easier to replace.

This object is achieved in that on a first side of the board and on a second side of the board in each case at least one electrical sensor is mounted. In this way, the required space is optimized because the remote from the rotor side of the board is also provided with at least one electrical sensor. In addition, such an arrangement increases the flexibility of the arrangement, since multiple locations are possible for attachment of the at least one electrical sensor.

Furthermore, according to the invention a clutch release system is disclosed in which a rotor position sensor assembly can be used with such a board. This is on the one hand in a few steps mountable, since the rotor position sensor assembly is integrable from both sides in the clutch release system. On the other hand, the components arranged therein are individually interchangeable over a life cycle, which enables a time and economically efficient maintenance.

Further embodiments are the subject of the dependent claims and are explained in more detail in the following text.

Thus, it is advantageous if the at least one electrical sensor on the first side differs from the at least one electrical sensor on the second side in terms of its type and / or control. This mutual arrangement causes an exact positioning of the rotor is facilitated. Furthermore, there are advantages in the assembly of the board, since only one sensor type is used per side.

As soon as at least one electrical sensor is designed as a Hall sensor / Hall probe / Hall sender, the strength of the magnetic field can be precisely determined on the basis of the Hall effect. Thus, a rotor position with high accuracy can be determined. Hall sensors also have the advantage of being economical as a standard component in the supply chain.

A further advantageous embodiment consists in that the at least one electrical sensor on the first side is designed as a digital switch Hall sensor and / or the at least one electrical sensor on the second side is configured as an analog Hall sensor. The use of both functions in rotor position determination minimizes the influence of error variables and thus enables a high degree of measurement accuracy. Thus, a coupling and disengaging operation can be carried out with high precision, which has a gentle effect on the components involved, whereby the life of the clutch release system according to the invention is extended.

Even if the first side faces an actuator and / or the second side faces a dual mass flywheel in a state in which the rotor position sensor assembly is integrated into a drive train, the assembly of the individual components of the rotor position sensor assembly can be carried out efficiently. This orientation is compatible with known systems, which is why the module according to the invention can be integrated into existing drive trains without high overhead.

A further advantage results from the fact that the circuit board has a sensor section extending in a circumferential direction and has a fastening section extending in an axial direction, wherein the sensor section and the fastening section are connected to one another via a bending point. This angling of the board makes it possible to use existing axial space and thus reduce the required space in the circumferential direction. Furthermore, the axial offset realized in this way enables the sensors to be mounted on both sides of the board without great design effort.

If at least one insertion pocket is inserted into the sensor section, preferably milled in, into which at least one electrical sensor can be inserted, on the one hand the axial installation space is additionally lowered, on the other hand a sensor is centered on the board, which simplifies the assembly of the board. In addition, it can be prevented by means of a poka-yoke principle that sensors are inserted incorrectly. This reduces the exclusion of components and additionally reduces the complexity of the assembly.

In a further advantageous embodiment, the circuit board is rigidly coupled to a sensor carrier, which is designed as a separate component. In this way, the handling of the rotor position sensor assembly is simplified. Furthermore, it is thus easier to realize interfaces with other components for simplified assembly by designing them on the sensor carrier.

It is also advantageous if the magnet is prepared in its rotational position relative to at least one electrical sensor to be calibrated with respect to its position by means of software. This eliminates a mechanical calibration, which is time consuming. Furthermore, the software calibration is characterized by its accuracy.

Another advantage arises when the sensor carrier has insertion sockets, by means of which it can be fixed to an adjacent component. Thus, a prefabricated interface between the rotor position sensor assembly and the adjacent components is made. This has a positive effect on the installation, for example.

If the electrical sensors, which are arranged on the circuit board, are encapsulated by a thermosetting material in order to realize a sensor final encapsulation, the rotor position sensor assembly according to the invention is protected against dirt and also against mechanical and thermal disturbances. This increases the life and the accuracy of the rotor position sensor assembly.

As soon as a cable, which couples the circuit board to another electrical circuit, can be coupled to the rotor-bearing sensor assembly in such a way that it runs only in the circumferential direction without undergoing angling, a gentler handling of the components involved and also a decreasing complexity of the assembly ensue.

The cable is advantageously coupled to the rotor-bearing sensor assembly such that it passes through a narrowed cable channel. This allows a secure and at the same time structurally realizable connection of the cable to the board

In a further advantageous embodiment, the rotor position sensor assembly is configured completely sealing to the transmission chamber. This can be realized by the fact that the final sensor injection molding is configured as an encapsulation and / or a jacket.

In a preferred embodiment, three digital switch Hall sensors are arranged on the first side and two analog Hall sensors on the second side. It is also possible to arrange on both sides between one and 10 electrical sensors.

In other words, it can be stated that the object according to the invention consists of exchangeable and with a small space requirement a sensor system installed from one side, preferably the side facing the dual mass flywheel in the installed state. Another object is to perform a rotor position calibration by software.

This is realized according to the invention via a pluggable solution with a very compact space. This is still to install without much effort. It is advantageous that the board is equipped on both sides with sensors to optimize in addition to the magnetic field and the space. This is made possible by means of a 90 ° bent board. This is for example milled or executed by means of Flex PCB. Furthermore, in order to optimize the distance to the magnetic ring, in the board still milled a pocket into which the analog and or digital Hall sensors can be inserted in order to facilitate the assembly process. According to the invention is still a combined Strain relief solution implemented, which reduces the load on the board.

The aforementioned position calibration is feasible by means of software that is integrated directly in the control unit.

A plug which can be connected to the rotor-bearing sensor assembly or can be integrated into it ensures the mechanical fixation, the electrical strength and the insulation / sealing of the individual lines. The rotor position sensor assembly according to the invention can be used for example in electrical central release (EZA). For this EZA the interface to the rotor position sensor assembly is unchanged, but according to the invention disappear disadvantages, such as mechanical and electrical strength of contact points.

The sensor carrier according to the invention is preferably made of plastic. Furthermore, three digital Switch-Hall sensors are fitted on the front side of the board, and two analogue Hall sensors are fitted on the back of the board. The circuit board according to the invention is preferably bent. Thus, the Einsteckquerfläche is reduced and the axial portion of the board can be used for the assembly of other electronic components. In addition, the angular distances between each sensor are optimized according to the pole pair number of the sensor magnet or motor.

In the invention further some physical properties are exploited.

A magnetic field has the special property that as the distance to the sensitive element is reduced, the magnetic field becomes stronger, the slope in the north-south passage becomes steeper, and the nonlinearity becomes larger. If, on the other hand, the distance between the magnet ring and the sensitive element increases, the magnetic flux density becomes smaller and the nonlinearity becomes better.

In addition, in order to reduce a hysteresis of the hysteresis of the switch-Hall sensor, the north-south passage is to be realized as steeply as possible. In order to minimize the error of the analog Hall sensor, the non-linearity of the magnetic field is to be kept low. On the other hand, the height of the switch-hall sensor is greater than that of the analog hall sensor.

According to the invention, the angular error due to the hysteresis is less than 2 ° and the nonlinearity of the magnetic field is less than 1.5 °. It is true that the distance of the sensitive element of the switch-Hall sensor to the magnetic ring should be less than 2.5 mm. On the other hand, the distance between the analog Hall sensor and the magnetic ring with greater than 3.5 mm is to design. For this reason, the three digital Hall sensors are mounted on the front of the board and the two analog sensors on the back of the board.

Another problem solved by the invention is that the sensor exceeds a certain strength due to the resolution and the disturbance by the geomagnetic field. That The distance between the magnetic surface and the sensitive element of the analog Hall sensor is not too large. Furthermore, when used in an EZA, the magnetic field should be stronger than 20mT.

On the other hand, the entire assembly has a large tolerance and the height of the sensors and the board can not be reduced. Therefore, the two analog Hall sensors are installed in the board so that the side closer to the sensitive element faces the inside of the board.

The sensor according to the invention has a combined strain relief system. Due to the miniaturization, a single strain relief is not sufficient. The strain relief block consists of the narrowing of the cable channel through an upper and a lower side and the adhesion of the cable to the plastic end extrusion. The narrowing of the cable channel creates a greater pressure on the cable sheath and it increases the frictional or deformation energy to prevent greater slippage.

In one embodiment, all sensors have a relative angular error to the stator, this can be determined by a Back EMF test. They are stored in the Control Unit and read out during motor control in order to shift the commutation table accordingly.

Thus, in summary, that according to the invention a rotor bearing sensor assembly is disclosed, which is interchangeable without much effort. Thus, a maintenance is inexpensive to carry out. In addition, the rotor position sensor assembly disclosed herein is characterized by a high degree of reliability in rotor position determination. Also part of the inventive concept is an electric clutch actuation system / clutch release system incorporating such a rotor bearing sensor assembly.

The rotor position sensor assembly preferably includes three digital switch Hall sensors, and preferably two analog Hall sensors. The digital switch Hall sensors are hereby rigidly mounted on a first side of a board, preferably soldered. The analogue Hall sensors are also rigidly attached to a second side of the board, preferably soldered. The first and / or the second side of the board preferably has insert bushings for centering a position of the sensors. The board preferably has a curved / curved shape to allow reliable electrical connection to an external circuit. The connection between the individual circuits is a cable. The rotor position sensor assembly according to the invention is encased by a housing / a sensor end encapsulation, which is constructed from a thermosetting / thermosetting material.

The invention will be explained in more detail by means of drawings. Show it:

1 a sectional perspective view through a clutch actuation system;

2 a perspective view of a rotor position sensor assembly according to the invention;

3 a perspective view of a Sensorendumspritzung; and

4 a perspective view of a board, which is equipped with sensors.

The figures are merely schematic in nature and are for the sole purpose of understanding the invention. The same elements are provided with the same reference numerals. The features of the individual embodiments can be interchanged.

In 1 is a rotor bearing sensor assembly 1 as a component of a clutch release system 2 shown. An electric motor, essentially consisting of a stator 3 and a rotor 4 is composed, thereby performs a rotation, which via a transmission 23 , such as a ball screw, is converted into a translation. By means of this translation an engagement or disengagement of a clutch is effected. To the position of the rotor 4 relative to the stator 3 Being able to determine is on the rotor 4 a magnet 5 appropriate. This induces a magnetic field coming from the rotor position sensor assembly 1 is evaluated such that the position of the rotor and thus the operating state of the coupling can be determined with high precision. At a sensor section 6 the rotor position sensor assembly, the sensor is arranged such that the relative position between the stator 3 and rotor 4 is efficiently determinable.

To the rotor position sensor assembly 1 To seal them to protect them mechanically and thermally, is a Sensorendumspritzung 7 as a capsule-like housing around the rotor position sensor assembly 1 arranged around. The sensor end coating 7 protects the rotor position sensor assembly 1 in front of an entry on the sides of the electric motor. In addition, a sensor seal 8th between a shoulder of a release carrier 9 and the rotor position sensor assembly 1 arranged. The sensor seal 8th is designed for example as an O-ring and allows a precise fit of the rotor position sensor assembly 1 in the release carrier 9 , The release carrier 9 has a shaft portion and a rim portion. The shaft portion is designed substantially rotationally symmetrical and extends substantially in the axial direction, while the rim portion extends substantially in the radial direction.

In 2 is the rotor position sensor assembly 1 presented for yourself. It essentially consists of a circuit board 10 and a sensor carrier 13 together. According to the invention, the circuit board 10 designed as a bent component. It thus has a sensor section 20 and a fixing portion 21 on. On the sensor section 20 are on a first page 18 and on a second page 19 electrical sensors 11 . 12 arranged. Preferably, on the first page 18 facing the electric motor / actuator, digital switch-hall sensors 11 arranged. These are preferably three digital switch Hall sensors 11 , Alternatively, one, two, four or five digital switch-hall sensors 11 on the first page 18 mountable.

On the second page 19 are analog Hall sensors 12 arranged. These are in interaction with the digital switch Hall sensors 11 prepared so that it's the magnet 5 Induced magnetic field detect such that the position of the rotor 4 to the stator 3 is precisely determinable. All sensors 11 . 12 are on the sensor section 20 arranged. The sensor section 20 is over a bend 14 the board 10 with the attachment section 21 connected. The attachment section 21 has a predefined interface to a cable 16 like that with the board 10 to connect that on this a voltage can be applied. The cable 16 is by means of a connection 17 like that with the board 10 coupled, that these are preferably connected to each other via a plug-in mechanism. The attachment section 21 extends substantially in an axial direction of the clutch release system 2 , The axial offset created thereby causes the rotor-blade sensor assembly 1 designed optimized space. Because by means of the offset are the electrical sensors 11 . 12 both on the first page 18 , as well as on the second page 19 attachable, which causes the rotor position sensor assembly 1 in a circumferential direction, that is, a direction about an axis of rotation of the release carrier 9 in an angular range in the range between 50 ° and 120 °, preferably 90 °, is trained. This angle span is taken from the board 10 together with the sensor carrier 13 filled.

With regard to their geometry, the sensor section 20 and the attachment section 21 freely adaptable to their respective environment, since the bending point 14 makes a corresponding connection between the sections. To the rotor position sensor assembly 1 in a predefined position in the release carrier 9 to attach are in the sensor carrier 13 Einsetzbuchsen 15 arranged. These are preferably designed as passage openings and allow the attachment of the rotor position sensor assembly 1 using fasteners, such as screws or rivets. That the cable 16 to its interface with the attachment section 21 the board 10 extends exclusively in the circumferential direction is a further advantage of the invention. Thus, the cable 16 secured against kinking, which leads to faster wear.

In 3 is a perspective view of the rotor sensor layer assembly according to the invention 1 with the sensor end coating 7 shown. This encapsulates all components of the sensor layer assembly 1 , and thus protects them from mechanical and / or thermal stress. The tangential course of the cable 15 relative to the rotor sensor layer assembly 1 is in 3 as well as the angular span between 50 ° and 120 °. The extending in the axial direction width of the sensor carrier 13 is smaller in magnitude than the axial direction offset from the mounting portion 21 the board 10 is defined.

4 represents the attachment section 21 enlarged there. An inside of the bending point 14 is configured such that the sensor section 20 runs in the circumferential direction. On the second page 19 the board 10 are inventively insertion pockets 22 arranged so that the electrical sensors 11 . 12 in a predefined position following the poka-yoke principle in these can be used. The pockets 22 are preferably in the sensor section 20 milled. According to the invention, the analog Hall sensors are on the second side 19 appropriate.

LIST OF REFERENCE NUMBERS

1

 Rotor position sensor assembly

2

 clutch release

3

 stator

4

 rotor

5

 magnet

6

 sensor section

7

 Sensorendumspritzung

8th

 sensor seal

9

 clutch release

10

 circuit board

11

 Digital switch-hall sensor

12

 Analog Hall sensor

13

 sensor support

14

 bend

15

 insert sleeve

16

 electric wire

17

 connection

18

 First page

19

 Second page

20

 sensor section

21

 attachment section

22

 insert pocket

23

 transmission

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102014218544 A1 [0002]

Claims (10)

Rotor bearing sensor assembly ( 1 ) for a clutch release system ( 2 ) with a stator ( 3 ) and a rotor rotatable relative thereto ( 4 ), wherein the rotor position sensor assembly ( 1 ) a board ( 10 ), on which electrical sensors ( 11 . 12 ) for the magnetic field-dependent position determination of at least one rotor-fixed magnet ( 5 ) are arranged, characterized in that on a first side ( 18 ) of the board ( 10 ) and on a second page ( 19 ) of the board ( 10 ) at least one electrical sensor ( 11 . 12 ) is attached. Rotor bearing sensor assembly ( 1 ) according to claim 1, characterized in that the at least one electrical sensor ( 11 ) on the first page ( 18 ) of the at least one electrical sensor ( 12 ) on the second page ( 19 ) differs in terms of its type and / or control. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 or 2, characterized in that the at least one electrical sensor ( 11 ) on the first side and the at least one sensor ( 12 ) are configured on the second side as Hall sensors. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 to 3, characterized in that the at least one electrical sensor on the first side ( 18 ) as a digital switch hall sensor ( 11 ) and / or the at least one electrical sensor on the second side ( 19 ) as an analog Hall sensor ( 12 ) is configured. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 to 5, characterized in that in a state in which the rotor position sensor assembly ( 1 ) is integrated into a drive train, the first side ( 18 ) is facing an actuator and / or the second side ( 19 ) faces a dual mass flywheel. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 to 5, characterized in that the board ( 10 ) has a sensor section extending in a circumferential direction (US Pat. 20 ) and an axially extending mounting portion ( 21 ), wherein the sensor section ( 20 ) and the attachment section ( 21 ) over a bending point ( 14 ) are interconnected. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 to 6, characterized in that in the sensor section ( 20 ) at least one insertion pocket ( 22 ) is introduced, in which at least one electrical sensor can be used. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 to 7, characterized in that the board ( 10 ) to a sensor carrier ( 13 ), which is configured as a separate component, is rigidly coupled. Rotor bearing sensor assembly ( 1 ) according to one of claims 1 to 8, characterized in that the magnet ( 5 ) in its rotational position relative to at least one electrical sensor ( 11 . 12 ) is prepared to be calibrated for its location by software. Coupling release system ( 2 ) of a motor vehicle, with a rotor ( 3 ), a stator ( 4 ) and a disengaging element, characterized in that a position of the rotor ( 3 ) relative to the stator ( 4 ) by means of a rotor bearing sensor assembly ( 1 ) is realized according to one of claims 1 to 9.

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