GB2570004A

GB2570004A - Sensor apparatus

Info

Publication number: GB2570004A
Application number: GB1800339.2A
Authority: GB
Inventors: Willis Mark; Vinamata Xavier; Hooi Tan You; Redfern Luke
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2018-01-09
Filing date: 2018-01-09
Publication date: 2019-07-10
Anticipated expiration: 2038-01-09
Also published as: GB2570004B; GB201800339D0

Abstract

The present disclosure relates to a sensor module (2,fig 1) including a housing (3) and a sensor (4). The housing (3) has a first abutment surface (6, fig 3) for abutting a mounting surface (13, 21, fig 9). A first housing axis (Z1) extends perpendicular to said first abutment surface (6). The sensor (4) has at least a first sensing axis (SZ). The sensor (4) is disposed in said housing (3) such that the first sensing axis (SZ) is inclined at an acute angle (a3) to the first housing axis (Z1). The present disclosure also relates to a sensor assembly (1) including a sensor module (2) and an inclined mount (20). The sensor module (2) and the sensor assembly (1) have particular application in a vehicle (V), such as a motor vehicle. The present disclosure also relates to a method of installing a sensor module (2) and/or a sensor assembly (2).

Description

SENSOR APPARATUS

TECHNICAL FIELD

The present disclosure relates to a sensor apparatus. In particular, but not exclusively, the present disclosure relates to a sensor apparatus for configuring the orientation of a first sensing axis. The sensor apparatus has particular application in a vehicle, such as a motor vehicle. The present disclosure also relates to a vehicle incorporating the sensor apparatus. The present disclosure also relates to a method of installing a sensor module and/or a sensor assembly.

BACKGROUND

Sensors, such as accelerometers, are typically mounted in a particular orientation to improve performance. In the automotive industry, the vehicle body and major components like sub-frames are designed in advance of knowing the location or mounting angle of accelerometers. The location and/or mounting angle required to improve performance of the sensors may only be determined at a late stage in the design cycle. This can result in the need to change designs in order to provide a suitable mounting location for the sensor and/or to orientate the sensor appropriately. Rather than modify the design of the vehicle components, the sensor could be modified, for example to change the orientation of one or more sensing axis. However, this approach may necessitate the design and manufacture of different sensors for different applications in the same vehicle.

At least in certain embodiments, the present invention seeks to provide a sensor apparatus which overcomes or ameliorates at least some of the shortcomings of prior art arrangements.

SUMMARY OF THE INVENTION

Aspects of the present invention relate to a sensor module, a sensor assembly and a vehicle as claimed in the appended claims. Aspects of the present invention also relate to a method of installing a sensor module and/or a sensor assembly as claimed in the appended claims.

According to a further aspect of the present invention there is provided a sensor module comprising: a housing having a first abutment surface for abutting a mounting surface, the housing having a first housing axis extending perpendicular to said first abutment surface; and a sensor having at least a first sensing axis; wherein the sensor is disposed in said housing such that the first sensing axis is inclined at an acute angle to the first housing axis. The sensor is mounted in a fixed orientation in said housing. Since the first sensing axis is inclined relative to the first abutment surface, the orientation of the first sensing axis is dependent on the angular orientation of the housing about said first housing axis. The orientation of the first sensing axis may be set by defining the angular orientation of the housing. The orientation of the housing may, for example, be defined by appropriate positioning of locating means which cooperate with the housing. The position of the locating means may be more readily changed than the orientation of the mounting surface on which the housing is mounted. Thus, at least in certain embodiments, the orientation of the first sensing axis may be defined later in a design cycle. The orientation of the sensor module may be adjusted to change the orientation of the first sensing axis in two or three dimensions. At least in certain embodiments, this may enable the sensor to capture more relevant information. This has particular application in monitoring vibrations which may occur in three dimensions. By adjusting the orientation of the first sensing axis in two or three dimensions, the sensor may be configured to sense more information about the vibrations. The sensor module is suitable for installation in a vehicle to sense vibrations, for example in a section of the vehicle body.

At least in certain embodiments, the sensor may be mounted in a plane which is inclined at an acute angle relative to the first abutment surface and the mounting surface. The effective angle of the sensor can be changed to by changing the orientation of the sensor. By way of example, if the first abutment surface and the mounting surface are inclined at 25° to a reference plane, a total of up to 50° of adjustment in the orientation of the first sensing axis can be achieved by simple rotation of the sensor about the first housing axis. The sensor module may comprise means for fixing the angular orientation of the housing at a precise orientation within 360° of rotation. The orientation of the sensor module may be defined to tune vehicle systems with reduced or minimal changes in manufacturing and/or production of the body-in-white.

The first abutment surface may form a lower surface of the housing.

The first abutment surface may comprise part or all of a surface having rotational symmetry about the first housing axis. The first abutment surface may, for example, comprise a part-spheroidal surface or a part-spherical surface. Alternatively, the first abutment surface may be substantially planar.

It will be understood that the mounting surface is configured substantially to match the profile of the first abutment surface to mount the housing. The mounting surface may have rotational symmetry about a first axis, the first axis being coincident with the first housing axis. The mounting surface may, for example, comprise a part-spheroidal surface or a part-spherical surface. Alternatively, the mounting surface may be substantially planar.

The sensor may have only one sensing axis. The sensor may consist of said first sensing axis. Alternatively, the sensor may have more than sensing axis. For example, the sensor may also have a second sensing axis and optionally also a third sensing axis.

The first sensing axis may be a vertical sensing axis. In use, the first sensing axis may be at least substantially parallel with a vertical axis of the vehicle. The first housing axis may be a vertical axis.

The housing may have a second housing axis extending perpendicular to said first housing axis. The second housing axis may be a longitudinal axis.

The housing may be configured to be mounted in a first angular orientation about said first housing axis. The first angular orientation may be predefined. In a variant, the housing may be configured to be mounted in one of a plurality of angular orientations which are predefined.

The housing may comprise first locating means for locating the housing in said first angular orientation. The first locating means may be configured to inhibit rotation of the housing. The first locating means may comprise anti-rotation means for inhibiting rotation of the housing about said first housing axis. The first locating means may comprise one or more projection and/or one or more aperture. The one or more projection and/or the one or more aperture may be formed in the first abutment surface.

The housing may have a sidewall. Alternatively, or in addition, the one or more projection and/or the one or more aperture may be formed in the sidewall of the housing.

The one or more projection and/or the one or more aperture may be configured to engage a cooperating feature on the mounting surface. For example, an aperture or a projection may be formed in said mounting surface.

The sidewall may be configured to engage a cooperating feature to fix the housing in said first angular orientation. The sidewall may have a keyed profile for cooperating with the mounting surface to fix the housing in said first predefined angular orientation. The sidewall may comprise a regular polygon for positioning in multiple predefined angular orientations. Alternatively, the sidewall may comprise an irregular polygon for positioning in a single predefined angular position.

The sensor module may comprise a first bore for receiving a mechanical fastener to mount the sensor module to the mounting surface. The first bore may have a central longitudinal bore axis coincident with the first housing axis.

The sensor assembly may comprise a mechanical fastener for mounting the sensor assembly to the mounting surface. The mechanical fastener may have a central longitudinal axis coincident with the first housing axis.

The housing may comprise first and second mounting means for mounting the housing in said first angular orientation. The first and second mounting means may comprise first and second bores for receiving mechanical fasteners. In use, first and second mechanical fasteners may locate in said first and second bores to mount the housing.

Alternatively, the first and second mounting means may comprise first and second mechanical fasteners. The first and second mechanical fasteners may, for example, be formed integrally with the housing. The first and second fasteners may each comprise a clip or a projection for locating in a corresponding aperture formed in a body panel or other structural member.

The first sensing axis may be a vertical sensing axis. The vertical sensing axis may be configured, in use, to extend substantially parallel to a vertical axis of the vehicle.

According to a further aspect of the present invention there is provided a sensor assembly comprising a sensor module as described herein and an inclined mount. The inclined mount is configured to mount the sensor module. The inclined mount may comprise an inclined mounting surface for abutting the first abutment surface, and a second abutment surface for abutting a second mounting surface. The inclined mounting surface and the second abutment surface may be inclined relative to each other. The orientation of the inclined mount may be adjustable independently of the housing. Thus, the angular orientation of the inclined mount may be configurable independently of the angular orientation of the housing.

At least in certain embodiments, the angular orientation of the sensor module and/or the angular orientation of the inclined mount may be adjusted independently of each other to alter the orientation of at least the first sensing axis of the sensor. A direction of the first sensing axis and/or a magnitude of an angle defined between the first sensing axis and a reference axis may be adjusted.

The housing described herein may be configured to be mounted to the inclined mounting surface in said first angular orientation.

The first locating means may cooperate with the first surface of the inclined mount to inhibit rotation of the housing about said first housing axis.

The inclined mount may have a first inclined mount axis extending substantially perpendicular to said second abutment surface. The angular orientation of the inclined mount relative to the second mounting surface may be adjustable about said first inclined mount axis.

The inclined mounting surface may have rotational symmetry about a first axis, the first axis being coincident with the first housing axis. The inclined mounting surface may, for example, comprise a part-spheroidal surface or a part-spherical surface. Alternatively, the inclined mounting surface may be substantially planar.

The second abutment surface may comprise part or all of a surface having rotational symmetry about the first inclined mount axis. The second abutment surface may, for example, comprise a part-spheroidal surface or a part-spherical surface. Alternatively, the second abutment surface may be substantially planar.

The inclined mount may be configured to be mounted in a second angular orientation about said first inclined mount axis. The second angular orientation may be predefined. The inclined mount may comprise second locating means for locating the inclined mount in said second angular orientation. The second locating means may comprise anti-rotation means for inhibiting rotation of the inclined mount about said first inclined mount axis. The second locating means may comprise one or more projection and/or one or more aperture. The one or more projection and/or the one or more aperture may be formed in the second abutment surface. Alternatively, or in addition, the one or more projection and/or the one or more aperture may be formed in a sidewall of the inclined mount.

The one or more projection and/or the one or more aperture may be configured to engage a cooperating feature on the second mounting surface.

The inclined mount may comprise a sidewall having a non-circular profile. The sidewall may be configured to engage a cooperating feature to fix the inclined mount in said second angular orientation. The second sidewall may have a keyed profile for cooperating with the second mounting surface to fix the inclined mount in said second angular orientation.

The inclined mount may comprise first and second mounting means for mounting the inclined mount in said second angular orientation.

The inclined mount may comprise a second bore for receiving a mechanical fastener to mount the inclined mount to the second mounting surface. The second bore may have a central bore axis coincident with the first inclined mount axis.

The second assembly may comprise a second mechanical fastener for mounting the inclined mount to the second mounting surface. The second mechanical fastener may have a central longitudinal axis coincident with the first inclined mount axis.

The sensor may be any type of sensor which is direction sensitive. The sensor may, for example, comprise one or more accelerometer; and/or one or more gyroscope. The one or more accelerometer may be configured to measure acceleration along said first sensing axis and/or about said first sensing axis. One or more accelerometer may be provided to measure acceleration along and/or about a second sensing axis and optionally also a third sensing axis.

According to a further aspect of the present invention there is provided a vehicle comprising one or more sensor module as described herein; and/or one or more sensor assembly as described herein, wherein the sensor module and/or the inclined mount is mounted to a body member of the vehicle. The body member may, for example, form part of a vehicle body.

The body member may define the mounting surface. The mounting surface may be inclined relative to a longitudinal axis of the vehicle, for example at an acute angle. By inclining the mounting surface, the orientation of the housing and/or the inclined mount may be set so as to achieve the desired orientation of the first sensing axis.

The body member may comprise means for cooperating with the first locating means to define the angular orientation of the housing; or means for cooperating with the second locating means to define the angular orientation of the inclined mount. The cooperating means may comprise one or more aperture and/or one or more projection. The cooperating means may be configured to inhibit rotation of the housing; or the inclined mount.

According to a further aspect of the present invention there is provided a method of mounting a sensor module as described herein. The method comprises adjusting the orientation of the housing about the first housing axis to change the orientation of the first sensing axis of the sensor. The method may comprise fastening the sensor module such that the housing is mounted in a predetermined orientation about said first housing axis.

According to a further aspect of the present invention there is provided a method of mounting a sensor assembly described herein. The method comprises adjusting the orientation of the housing about said first housing axis; and/or adjusting the orientation of the inclined mount. The method may include fastening the sensor module to the inclined mount such that the housing is in a predetermined orientation about said first housing axis. Alternatively, or in addition, the method may include fastening the inclined mount in a predetermined orientation. The orientation of the inclined mount may be adjusted about a first inclined mount axis extending substantially perpendicular to the second abutment surface.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which:

Figure 1 shows a schematic reference of a vehicle incorporating a sensor assembly in accordance with an embodiment of the present invention;

Figure 2 shows a plan view of the sensor assembly in accordance with the embodiment shown in Figure 1;

Figure 3 shows a side view of the sensor assembly in accordance with the embodiment shown in Figure 1;

Figure 4 shows an end view of the sensor assembly in accordance with the embodiment shown in Figure 1;

Figure 5 shows the sensor assembly in accordance with the embodiment shown in Figure 1 in a first mounting configuration on a body member;

Figure 6 shows the sensor assembly in accordance with the embodiment shown in Figure 1 in a second mounting configuration on a body member;

Figure 7 shows a plan view of the sensor assembly in accordance with the embodiment shown in Figure 1 mounted to a body member;

Figure 8 illustrates the possible orientations of the vertical sensing axis of the sensor assembly in accordance with the embodiment shown in Figure 1;

Figure 9 shows a schematic reference of a sensor assembly in accordance with a further embodiment of the present invention;

Figure 10 shows a plan view of the sensor assembly in accordance with the embodiment shown in Figure 9 mounted to an inclined mount;

Figure 11 illustrates the different orientations of the vertical sensing axis of the sensor in accordance with the embodiment shown in Figure 9;

Figure 12 shows a side view of the sensor assembly in accordance with a further embodiment of the present invention;

Figure 13 shows a plan view of the sensor assembly shown in Figure 12; and Figure 14 shows a plan view of an embodiment of the sensor assembly in accordance with a further embodiment of the present invention.

DETAILED DESCRIPTION A sensor assembly 1 in accordance with an aspect of the present invention will now be described with reference to the accompanying figures. As shown schematically in Figure 1, the sensor assembly 1 has particular application in a vehicle V, such as a motor vehicle. The sensor assembly 1 may be used in other applications.

As shown in Figures 2, 3 and 4, the sensor assembly 1 includes a sensor module 2. The sensor module comprises a sensor housing 3 and a sensor 4. The sensor 4 in the present embodiment comprises an accelerometer 5 having three axis of measurement. The accelerometer 5 is configured to measure acceleration along a first sensing axis SZ, a second sensing axis SY and a third sensing axis SX. The first, second and third sensing axes SZ, SY, SX are arranged substantially perpendicular to each other. Other types of sensor may be incorporated into the sensor assembly 1. For example, the sensor 4 may comprise one or more gyroscope for measuring rotation about said first, second and third sensing axes SZ, SY, SX. The one or more gyroscope may replace the accelerometer 5, or may be provided in addition to the accelerometer 5. In an alternative embodiment, the sensor 4 may comprise an accelerometer 5 having one axis of measurement, for example along the first sensing axis SZ.

The sensor 4 is mounted in the sensor housing 3 which is composed of a plastics material. Other materials may be used to form the sensor housing 3. The sensor 4 is fixedly mounted in the sensor housing 3. The sensor housing 3 comprises a first abutment surface 6, a sidewall 7 and a first upper surface 8. The first abutment surface 6 is configured to abut a mounting surface to mount the sensor assembly 1. In the present embodiment the first abutment surface 6 is substantially planar. The sensor housing 3 comprises a first bore 9 having a first central bore axis B1 extending substantially perpendicular to the first abutment surface 6. The first bore 9 is a cylindrical bore and is configured to receive a first fastener 10 to mount the sensor assembly 1. The first fastener 10 is illustrated as a bolt having an external thread 11, but other types of fasteners may be used. The sensor housing 3 comprises first locating means for locating the sensor housing 3 in a predefined angular position. The first locating means comprises a first projection 12 extending from the first abutment surface 6 of the sensor housing 3. Rather than use a mechanical fastener, an adhesive could be used to fasten the sensor housing 3.

The sensor housing 3 is described herein with reference to a virtual reference frame comprising a first housing axis Z1, a second housing axis Y1 and a third housing axis X1. The first housing axis Z1, the second housing axis Y1 and the third housing axis X1 are arranged perpendicular to each other. The first housing axis Z1 is coincident with the first central bore axis B1 and extends perpendicular to the first abutment surface 6. The sensor housing 3 is rotatable about the first housing axis Z1. The second housing axis Y1 extends in a transverse direction; and the third housing axis X1 is coincident with a longitudinal centreline of the sensor housing 3. The second housing axis Y1 and the third housing axis X1 define a first reference plane P1 which is substantially parallel to the first abutment surface 6. The first housing axis Z1 and the third housing axis X1 define a second reference plane P2 which is substantially perpendicular to the first abutment surface 6.

The sensor 4 is mounted in the sensor housing 3 such that at least one of the first, second and third sensing axes SZ, SY, SX is offset from the first housing axis Z1, the second housing axis Y1 and the third housing axis X1. In the present embodiment, the first sensing axis SZ and the third sensing axis SX are offset from the first housing axis Z1 and the third housing axis X1. The second sensing axis SY is parallel to the second housing axis Y1. The sensor 4 is arranged such that the first sensing axis SZ is inclined at a sensor incline angle a3 relative to the first housing axis Z1. The sensor incline angle a3 is an acute angle in the range 0°to 90° exclusive. In the present embodiment, the sensor incline angle a3 is 25°. It will be understood that the sensor 4 may be mounted in the sensor housing 3 such that one or more of the first, second and third sensing axis SZ, SY, SX is inclined at an angle relative to the corresponding first housing axis Z1, second housing axis Y1 and third housing axis X1. The sensor 4 may be rotated about the third housing axis X1 and/or the second housing axis Y1, for example. The angular offset about the third housing axis X1 or the second housing axis Y1 may be the same or different.

As shown in Figure 5, the first abutment surface 6 abuts a first mounting surface 13 defined by a first body member 14 of the vehicle body. In the present embodiment, the first mounting surface 13 is substantially planar. The first mounting surface 13 is inclined at a mounting angle a1 relative to the longitudinal axis X of the vehicle V. The mounting angle a1 is an acute angle and may be the same as or different from the sensor incline angle a3. In the arrangement illustrated in Figure 5, the first mounting surface 13 is inclined upwardly towards a front F of the vehicle V. The mounting angle a1 is approximately 25° in the present embodiment. A first mounting aperture 16 is formed in the first body member 14 to receive the first fastener 10. A lock nut 17 having a female thread is provided to cooperate with the first fastener 10 to fasten the sensor housing 3 to the first body member 14. A first locating aperture 18 is formed in the first body member 14 to receive the first projection 12. The sensor assembly 1 is mounted to the first body member 14 such that the first projection 12 locates in said first locating aperture 18 at least substantially to inhibit rotation of the sensor housing 3. The first locating aperture 18 is profiled to match the first projection 12. In the present embodiment, the first locating aperture 18 comprises a hole extending through the first body member 14. In a variant, the first locating aperture 18 may comprise a recess or depression for receiving the first projection 12. A plan view of the sensor assembly 1 mounted to the first mounting surface 13 of the first body member 14 is shown in Figure 7.

The first sensing axis SZ and the third sensing axis SX are disposed in said second reference plane P2; and the second sensing axis SY is disposed in the first reference plane P1. The first sensing axis SZ is inclined at said sensor incline angle a3 relative to the first housing axis Z1. Since the first sensing axis SZ and the first housing axis Z1 are not parallel, the angular orientation of the sensor housing 3 about the first housing axis Z1 determines the orientation of the first sensing axis SZ. When the sensor assembly 1 is installed in the vehicle V, the orientation of the first sensing axis SZ relative to the vertical axis Z is dependent on the orientation of the sensor housing 3 about the first housing axis Z1. In use, the orientation of the sensor housing 3 about the first housing axis Z1 is defined by the position of the first locating aperture 18. The first locating aperture 18 may be located at any angular position relative to the first mounting aperture 16 in the range 0° to 360°. The relative position of the first locating aperture 18 defines the angular orientation of the third housing axis X1 of the sensor housing 3 relative to the longitudinal axis X of the vehicle V. The relative position of the first locating aperture 18 and the first mounting aperture 16 are defined at the design stage. The third housing axis X1 is used herein as a datum to define the angular orientation of the sensor housing 3. The angular offset between the longitudinal axis X and the third housing axis X1 about the vertical axis Z is referred to herein as a sensor housing offset angle φ2. The sensor housing offset angle φ2 is in the range 0° to 360°. In the present embodiment, the third sensing axis SX is disposed in the second reference plane P2 such that the sensor housing offset angle φ2 also defines an angular orientation of the third sensing axis SX relative to the longitudinal axis X of the vehicle V. It will be understood that the orientation of the first sensing axis SZ is a function of the sensor incline angle a3, the sensor housing offset angle φ2 and the mounting angle a1. The mounting of the sensor assembly 1 will now be described.

The sensor assembly 1 is illustrated in a first mounting position in Figure 5; and a second mounting position in Figure 6. As described herein, the sensor assembly 1 has a sensor incline angle a3 which is 25°; and the mounting angle a1 of the first mounting surface 13 is 25°. In the first mounting position, the sensor housing offset angle φ2 is 0°. The sensor incline angle a3 and the mounting angle a1 give a combined orientation of the first sensing axis SZ as 90° to the longitudinal axis X of the vehicle V. Thus, the first sensing axis SZ is oriented vertically, parallel to the vertical axis Z of the vehicle V. In the second mounting position, as illustrated in Figure 6, the sensor housing offset angle φ2 is 180° such that the orientation of the sensor 4 is reversed. In this configuration, the sensor incline angle a3 and the mounting angle cri give a combined orientation of the first sensing axis SZ as 140° to the longitudinal axis X of the vehicle V. As shown in Figure 6 this corresponds to an arrangement in which the first sensing axis SZ is inclined at 50° to the vertical axis Z of the vehicle V. The first and second mounting positions correspond to the maximum angular range of the first sensing axis SZ for the present configuration of the sensor housing 3 and first body member 14.

It will be appreciated that the angular orientation of the first sensing axis SZ may be changed by adjusting the sensor housing offset angle φ2 between 0°and 360°. The positioning of the first locating aperture 18 can be changed with relative ease during the design process to define the required sensor housing offset angle φ2. At least in certain embodiments, the sensor assembly 1 according to aspects of the present invention facilitates adjustment of the orientation of the sensor 4. The adjustability of the first sensing axis SZ afforded by the sensor assembly 1 described with respect to Figures 1 to 7 is shown schematically in Figure 8 for variants of the sensor assembly 1 disposed in a range of different mounting configurations. The mounting angle a1 is shown increasing from a1=0° to a1=30° in increments of 10°from left to right; and the sensor incline angle a3 is shown increasing from a3=0° to a3=30° from top to bottom. The orientation of the first sensing axis SZ for sensor housing offset angles φ1 in the range 0° and 360° are plotted in the vehicle reference frame having a longitudinal axis X, a transverse axis Y and a vertical axis Z. Arrangements in which the mounting angle a1 is 0° correspond to mounting the sensor assembly 1 on a flat surface. Arrangements in which the sensor incline angle a3 is 0° correspond to an arrangement in which the first sensing axis SZ is aligned with the first housing axis Z1; this arrangement is outside the scope of the present invention. A further embodiment of the sensor assembly 1 in accordance with an aspect of the present invention is shown in Figures 9, 10 and 11. Like reference numerals are used for like components.

As shown in Figure 9, the sensor assembly 1 comprises a sensor module 2 and an inclined mount 20. The arrangement of the sensor module 2 is unchanged from the previous embodiment. In this embodiment, the sensor module 2 is fastened to the inclined mount 20, and the inclined mount 20 is fastened to a second mounting surface 27 defined by a second body member 28. As described herein, the angular orientation of the first sensing axis SZ is dependent on the relative orientation of the sensor housing 3 and the inclined mount 20. The sensor housing 3 comprises first locating means for locating the sensor housing 3 in a predefined angular position. The first locating means in the present embodiment comprises a first projection 12 which projects downwardly from a first abutment surface 6 of the sensor housing 3. In the illustrated arrangement, the second mounting surface 27 is substantially horizontal. It will be appreciated that in certain applications the second mounting surface 27 may be inclined relative to the longitudinal axis X of the vehicle V

The inclined mount 20 comprises an inclined mounting surface 21 for mounting the sensor module 2; and a second abutment surface 22. The inclined mounting surface 21 is configured to cooperate with the first abutment surface 6 of the sensor housing 3 to mount the sensor module 2. The second abutment surface 22 is configured to abut the second mounting surface 27 of the second body member 28 to mount the sensor assembly 1. In the present embodiment the inclined mounting surface 21 and the second abutment surface 22 are substantially planar. The inclined mounting surface 21 and the second abutment surface 22 are inclined relative to each other and define the mounting angle a1. The inclined mount 20 is described with reference to a virtual reference frame comprising a first inclined mount axis Z2, a second inclined mount axis Y2 and a third inclined mount axis X2. The first inclined mount axis Z2, the second inclined mount axis Y2 and the third inclined mount axis X2 are arranged perpendicular to each other. The first inclined mount axis Z2 extends substantially perpendicular to the second abutment surface 22. The inclined mount 20 is rotatable about the first inclined mount axis Z2. In the present embodiment, the inclined mount 20 has a circular profile in plan form and the first inclined mount axis Z2 is coincident with a central axis of the inclined mount 20, as shown in Figure 10. The inclined mount 20 may have different profiles which may be symmetrical or asymmetrical. The inclined mount 20 may, for example, have a polygonal profile. A first mounting aperture 23 is formed in the inclined mounting surface 21. The first mounting aperture 23 has an internal thread to cooperate with the first fastener 10 to fasten the sensor housing 3 to the inclined mount 20. The first mounting aperture 23 has a second central bore axis B2 which extends substantially perpendicular to the inclined mounting surface 21. When the sensor module 2 is mounted to the inclined mount 20, the first and second central bore axes B1, B2 are arranged co-axially. The inclined mount comprises first locating means for fixing the angular orientation of the sensor housing 3 relative to the inclined mount 20. The first locating means in the present embodiment comprises a first locating aperture 25 formed in the inclined mounting surface 21 to engage the first projection 12 of the sensor housing 3.

In use, the inclined mount 20 is fastened to the second body member 28. A third bore 24 is formed in the inclined mount 20 to receive a second mechanical fastener to fasten the inclined mount 20 to the second body member 28. The third bore 24 has a third central bore axis B3 which is coincident with the first inclined mount axis Z2. The second fastener may comprise a bolt having an external thread for cooperating with a captive nut or the like to fasten the inclined mount 20 to the second body member 28. A second mounting aperture 30, for example comprising a circular bore, is formed in the second body member 28 to receive the second fastener. A lock nut having a female thread is provided to cooperate with the second fastener to fasten the inclined mount 20 to the second body member 28. The inclined mount 20 comprises second locating means for locating the inclined mount 20 in a predefined angular position about the first inclined mount axis Z2. The second locating means in the present embodiment comprises a second projection 26 which projects downwardly from the second abutment surface 22. The second body member 28 comprises a second locating aperture 29 for cooperating with the second projection 26 to fix the inclined mount 20 in a predefined angular orientation.

The angular orientation of the sensor housing 3 relative to the inclined mount 20 is defined by the relative position of the first locating aperture 25 and the first mounting aperture 23. The first locating aperture 25 may be located at any angular position relative to the first mounting aperture 23 in the range 0° to 360°. The relative position of the first locating aperture 25 and the first mounting aperture 23 are defined at the design stage. The third housing axis X1 is used herein as a datum to define the angular orientation of the inclined mount 20. The relative position of the first locating aperture 25 defines the angular orientation of the third housing axis X1 of the sensor housing 3 relative to the third inclined mount axis X2 of the inclined mount 20. The angular offset between the third housing axis X1 and the third inclined mount axis X2 about the vertical axis Z corresponds to the sensor housing offset angle φ2. The sensor housing offset angle φ2 is in the range 0°to 360°. In the present embodiment, the third sensing axis SX is disposed in the second reference plane P2 such that the sensor housing offset angle φ2 also defines an angular orientation of the third sensing axis SX relative to the third inclined mount axis X2.

The angular orientation of the inclined mount 20 relative to the second body member 28 is defined by the relative position of the second locating aperture 29 and the second mounting aperture 30. The second locating aperture 29 may be located at any angular position relative to the second mounting aperture 30 in the range 0° to 360°. The relative position of the second locating aperture 29 and the second mounting aperture 30 are defined at the design stage. The third inclined mount axis X2 is used herein as a datum to define the angular orientation of the inclined mount 20. The relative position of the second locating aperture 30 defines the angular orientation of the third housing axis X1 of the sensor housing 3 relative to the longitudinal axis X of the vehicle V. The angular offset between the longitudinal axis X and the third inclined mount axis X2 about the vertical axis Z is referred to as the inclined mount offset angle φ1. The inclined mount offset angle φ1 defines an angular orientation of the inclined mount 20 relative to the longitudinal axis X of the vehicle V and is in the range 0° to 360°.

The orientation of the first, second and third sensing axes SZ, SY, SX are dependent on the sensor housing offset angle φ2 and the inclined mount offset angle φ1. As the first sensing axis SZ is inclined relative to the first central bore axis B1, the orientation of the first sensing axis SZ relative to the vertical axis Z is dependent on the sensor housing offset angle φ2. Rotating the inclined mount 20 about said first inclined mount axis Z1 changes the inclined mount offset angle q>1, thereby altering the orientation of the sensor 4 and changing the orientation of the first sensing axis SZ. Adjusting the sensor housing offset angle φ2 and the inclined mount offset angle φ1 independently of each other allows the magnitude of the angle defined between the first sensing axis SZ and a reference axis, such as the vertical axis Z of the vehicle V, to be adjusted. Alternatively, or in addition, the direction of the first sensing axis SZ may also be adjusted. In the illustrated arrangement, the second mounting surface 27 is horizontal and, therefore, changes to the inclined mount offset angle φ1 alter the direction of the first sensing axis SZ but the angular orientation relative to the vertical axis Z remains substantially constant. Adjusting the angular orientation of the sensor housing 3 and the inclined mount 20 relative to each other alters the magnitude of the angle formed between the first sensing axis SZ and the vertical axis Z. In arrangements in which the second mounting surface 27 is inclined relative to the longitudinal axis X of the vehicle V, the orientation of the sensor housing 3 and/or the inclined mount 20 also alter the magnitude of the angle defined between the first sensing axis SZ and the vertical axis Z. The inclined mount 20 therefore provides additional adjustment of the orientation of the third sensor axis SZ. It will be understood that the sensor housing offset angle φ2 and the inclined mount offset angle φ1 may be adjusted independently of each other.

The adjustability of the first sensing axis SZ afforded by the sensor assembly 1 is shown schematically in Figure 11 for discrete configurations of the sensor assembly 1 and the inclined mount 20 disposed in different configurations. The mounting angle a1 defined by the inclined mount 20 is shown increasing from a1=0°to a1=30°in increments of 10° from left to right; and the sensor incline angle a3 is shown increasing from a3=0°to a3=30°from top to bottom. The orientation of the first sensing axis SZ for sensor housing offset angles φ1 in the range 0° and 360° are plotted in the vehicle reference frame having a longitudinal axis X, a transverse axis Y and a vertical axis Z. The first sensing axis SZ in the present embodiment can be oriented in a broader range than the previous embodiment. Arrangements in which the mounting angle a1 is 0° correspond to mounting the sensor assembly 1 on a flat surface. Arrangements in which the sensor incline angle a3 is 0° correspond to an arrangement in which the first sensing axis SZ is aligned with the first housing axis Z1; this arrangement is outside the scope of the present invention.

The embodiments described herein have defined the orientation of the first sensing axis SZ relative to the vertical axis Z of the vehicle V. In certain applications, the first sensing axis SZ may be aligned with the vertical axis Z. However, the first sensing axis SZ may be aligned with an axis other than the vertical axis Z. The sensor assembly 1 described herein may, for example, be configured to monitor vibrations occurring in a body members. These vibrations may occur in one dimension or more than one dimension. By adjusting the orientation of the first sensing axis SZ, the sensor 4 may collect information which is more relevant to, or which better characterises the vibrations in the body member. In this scenario, the first sensing axis SZ may be oriented more closely to align with one or more axis for characterising the vibrations in the body member. The sensor assembly 1 may, for example, be used to measure vibrations in a body member and to output a vibration signal for controlling an electromechanical actuator to modify the vibrations in the body member. A sensor assembly 1 in accordance with a further embodiment is illustrated in Figures 12 and 13. This embodiment is a modification of the embodiment described herein with reference to Figures 2 to 7. Like reference numerals are used for like components.

The sensor module 2 comprises a sensor housing 3 and a sensor 4. The sensor 4 in the present embodiment comprises an accelerometer 5 having three axis of measurement. The operation of the sensor 4 is unchanged from the other embodiments described herein. The accelerometer 5 is configured to measure acceleration along a first sensing axis SZ, a second sensing axis SY and a third sensing axis SX. The first, second and third sensing axes SZ, SY, SX are arranged substantially perpendicular to each other. The sensor 4 is fixedly mounted in the sensor housing 3 such that the first sensing axis SZ is inclined at said sensor incline angle a3 relative to the first housing axis Z1, as shown in Figure 12. As described herein, the sensor module 2 is configured to be mounted to a mounting surface of a body member.

The sensor housing 3 comprises a first abutment surface 6, a sidewall 7 and a first upper surface 8. The first abutment surface 6 is configured to abut the mounting surface of the body member to mount the sensor assembly 1. In the present embodiment, the sensor housing 3 comprises first and second bores 9-1, 9-2 for receiving first and second mechanical fasteners to mount the sensor assembly 1. The first and second mechanical fasteners locate in corresponding mounting apertures formed in the first body member. The first and second bores 9-1, 9-2 extend substantially perpendicular to the first abutment surface 6. In this arrangement, one of said first and second fasteners forms a locating means. The relative positioning of the mounting holes in the body member determines the angular orientation of the sensor module 2. It will be understood that the spacing between the first and second mounting apertures is fixed. However, the relative positioning of the first and second mounting apertures determines the angular orientation of the sensor housing 3. Since the first sensing axis SZ and the first housing axis Z1 are not parallel, the angular orientation of the sensor housing 3 about the first housing axis Z1 determines the orientation of the first sensing axis SZ.

When the sensor assembly 1 is installed in a vehicle V, the orientation of the first sensing axis SZ relative to the vertical axis Z is dependent on the orientation of the sensor housing 3 about the first housing axis Z1. In use, the orientation of the sensor housing 3 about the first housing axis Z1 is defined by the position of the mounting holes in the first body member 14. The first locating aperture 18 may be located at any angular position relative to the first mounting aperture 16 in the range 0° to 360°. The relative position of the first and second mounting holes defines the angular orientation of the third housing axis X1 of the sensor housing 3 relative to the longitudinal axis X of the vehicle V. The angular offset between the longitudinal axis X of the vehicle V and the third housing axis X1 about the vertical axis Z defines a housing offset angle φ2. The housing offset angle φ2 is in the range 0°to 360°. It will be understood that the orientation of the first sensing axis SZ is a function of the actuator incline angle a3, the housing offset angle φ2 and the mounting angle a1.

It will be appreciated that the sensor module 2 shown in Figures 12 and 13 could be mounted to an inclined mount 20. The inclined mount 20 in this embodiment would be modified to incorporate first and second mounting apertures 23-1,23-2 for alignment with the first and second bores 9-1, 9-2. The relative positioning of the first and second mounting apertures 23-1,23-2 in the inclined mount 20 would define the housing offset angle φ2. This embodiment is illustrated in Figure 14. In the present embodiment, the inclined mount 20 has a circular profile in plan form and the first inclined mount axis Z2 is coincident with a central axis of the inclined mount 20. In the illustrated arrangement, the sensor module 2 and the inclined mount 20 are arranged coaxially such that the relative position of the sensor module 2 remains substantially fixed irrespective of the housing offset angle φ2.

In a further variant, the inclined mount 20 may be modified to incorporate first and second bores 24 for mounting the inclined mount 20 in a predetermined orientation to define the inclined mount offset angle φ1.

It will be appreciated that various modifications may be made to the embodiment(s) described herein without departing from the scope of the appended claims. For example, the sensor assembly 1 may comprise more than one inclined mount 20. For example, multiple inclined mounts 20 may be stacked on each other to provide additional degrees of freedom.

The sensor 4 could be movably mounted in the sensor housing 3. For example, the sensor 4 may be rotatable about a second longitudinal axis extending parallel to the first inclined mount axis Z2. A movable mounting would allow the orientation of the first and second sensing axes SX, SY to be adjusted independently of the angular orientation of the sensor housing 3 about the first inclined mount axis Z2. For example, the sensor 4 could be rotated within the sensor housing 3 to align the first and second sensing axes SX, SY with the longitudinal and transverse axis X, Y of the vehicle V. The sensor 4 may be fixed in a desired rotational position, for example by a locking mechanism or an adhesive.

Claims

CLAIMS:

1. A sensor module comprising: a housing having a first abutment surface for abutting a mounting surface, the housing having a first housing axis extending perpendicular to said first abutment surface; and a sensor having at least a first sensing axis; wherein the sensor is disposed in said housing such that the first sensing axis is inclined at an acute angle to the first housing axis.

2. A sensor module as claimed in claim 1, wherein the housing is configured to be mounted in a first angular orientation about said first housing axis, the first angular orientation being predefined.

3. A sensor module as claimed in claim 2, wherein the housing comprises first locating means for locating the housing in said first angular orientation.

4. A sensor module as claimed in claim 3, wherein the first locating means comprises one or more projection and/or one or more aperture.

5. A sensor module as claimed in claim 4, wherein the one or more projection and/or the one or more aperture is formed in the first abutment surface.

6. A sensor module as claimed in claim 4 or claim 5, wherein the one or more projection and/or the one or more aperture is/are configured to engage a cooperating feature on the mounting surface.

7. A sensor module as claimed in any one of the preceding claims comprising a first bore for receiving a mechanical fastener to mount the sensor module to the mounting surface, the first bore having a central longitudinal bore axis coincident with the first housing axis.

8. A sensor module as claimed in any one of claims 1 to 6 comprising a mechanical fastener for mounting the sensor module to the mounting surface, the mechanical fastener having a central longitudinal axis coincident with the first housing axis.

9. A sensor module as claimed in claim 2, wherein the housing comprises first and second mounting means for mounting the housing in said first angular orientation.

10. A sensor module as claimed in any one of the preceding claims, wherein the first sensing axis is a vertical sensing axis.

11. A sensor module as claimed in any one of the preceding claims, wherein the sensor comprises one or more accelerometer; and/or one or more gyroscopes.

12. A sensor assembly comprising a sensor module as claimed in any one of the preceding claims, the sensor assembly comprising: an inclined mount comprising an inclined mounting surface for abutting the first abutment surface, and a second abutment surface for abutting a second mounting surface; wherein the inclined mounting surface and the second abutment surface are inclined relative to each other.

13. A sensor assembly as claimed in claim 12 when dependent directly or indirectly on claim 2, wherein the housing is configured to be mounted to the inclined mounting surface in said first angular orientation.

14. A sensor assembly as claimed in claim 13 when dependent directly or indirectly on claim 3, wherein the first locating means cooperates with the inclined mount to inhibit rotation of the housing about said first housing axis.

15. A sensor assembly as claimed in any one of claims 12, 13 or 14, wherein the inclined mount has a first inclined mount axis extending substantially perpendicular to said second abutment surface.

16. A sensor assembly as claimed in claim 15, wherein the inclined mount is configured to be mounted in a second angular orientation about said first inclined mount axis, the second angular orientation being predefined.

17. A sensor assembly as claimed in claim 16, wherein the inclined mount comprises second locating means for locating the inclined mount in said second angular orientation.

18. A sensor assembly as claimed in claim 17, wherein the second locating means comprises one or more projection and/or one or more aperture.

19. A sensor assembly as claimed in claim 18, wherein the one or more projection and/or the one or more aperture is formed in the second abutment surface.

20. A sensor assembly as claimed in claim 18 or claim 19, wherein the one or more projection and/or the one or more aperture is/are configured to engage a cooperating feature on the second mounting surface.

21. A sensor assembly as claimed in any one of claims 12 to 20 comprising a second bore for receiving a mechanical fastener to mount the inclined mount to the second mounting surface, the second bore having a central bore axis coincident with the first inclined mount axis.

22. A sensor assembly as claimed in any one of claims 12 to 20 comprising a second mechanical fastener for mounting the inclined mount to the second mounting surface, the second mechanical fastener having a central longitudinal axis coincident with the first inclined mount axis.

23. A vehicle comprising one or more sensor module as claimed in any of claims 1 to 11; and/or one or more sensor assembly as claimed in any one of claims 12 to 22, wherein the sensor module and/or the inclined mount is mounted to a body member of the vehicle.

24. A vehicle as claimed in claim 23, wherein the body member defines the mounting surface.

25. A vehicle as claimed in claim 23 or claim 24, wherein the body member comprises means for cooperating with the first locating means to define the first angular orientation of the housing; and/or means for cooperating with the second locating means to define the second angular orientation of the inclined mount.

26. A vehicle as claimed claim 25, wherein the cooperating means comprises one or more aperture and/or one or more projection.

27. A method of mounting a sensor module as claimed in any one of claims 1 to 11, comprising adjusting the orientation of the housing about said first housing axis to change the orientation of the first sensing axis of the sensor.

28. A method as claimed in claim 27 comprising fastening the sensor module such that the housing is mounted in a predetermined orientation about said first housing axis.

29. A method of mounting a sensor assembly as claimed in any one of claims 12 to 22, the method comprising adjusting the orientation of the housing about said first housing axis; and/or adjusting the orientation of the inclined mount.

30. A method as claimed in claim 29 comprising fastening the sensor module to the inclined mount such that the housing is in a predetermined orientation about said first housing axis; and fastening the inclined mount in a predetermined orientation.

31. A method as claimed in claim 29 or claim 30 when dependent directly or indirectly on claim 14, wherein the orientation of the inclined mount is adjusted about the first inclined mount axis extending substantially perpendicular to the second abutment surface.