The invention is based on a fastening assembly for a sensor assembly of the generic type of independent patent claim 1, and on a corresponding sensor assembly of the generic type of independent patent claim 10.
Active and passive safety systems such as, for example, restraint systems such as, for example, airbags, seat belt pretensioners etc. as well as systems for controlling the vehicle movement dynamics such as, for example, ESP, ABS etc. are used in modern motor vehicles. An essential component of such systems are inertial sensors which are used to measure accelerations and/or yaw rates and/or rotation rates of the motor vehicle and are preferably embodied as micro-mechanical or micro-electromechanical sensors. During operation, such sensors are made to move in an oscillating fashion by suitable mechanical excitation, and forces and/or accelerations which occur are measured and evaluated.
German laid-open patent application DE 10 2007 058 965 A1 describes, for example, a motor vehicle sensor housing for a motor vehicle sensor having an insertion part. The described motor vehicle sensor housing is manufactured from polypropylene in a region of the insertion part in order to damp a sensor module which is arranged in/on the motor vehicle sensor housing. The motor vehicle sensor is preferably embodied as a micro-mechanical or micro-electromechanical sensor such as, for example, an inertial sensor which is preferably constructed as a rotation rate sensor or airbag-triggering sensor. The sensor module can be embodied in one piece with the sensor housing, or the two components can be permanently connected to one another by means of a mechanical connection. The insertion parts can be embodied, for example, as at least one metallic supporting bush which serves to support fastening forces acting on the sensor housing, which sensor housing is fastened to a fastening means on the bodywork.
A problem which frequently occurs when inertial sensors in motor vehicles are used is that of interference accelerations which can occur depending on the installation location of the sensor. These interference accelerations have a particularly large influence on the output signals of the sensor if they have frequencies in the region of an excitation frequency of the sensor or a natural frequency of the sensor assembly. On the basis of oscillation measurements and FEM analyses (FEM: Finite Element Method) it is possible to demonstrate that overshoot factors, which arise owing to eigenmodes of the housing, can interfere massively with signals of the inertial sensors. A particularly destructive influence is caused by the first eigenmodes in the frequency range from 30 Hz to 4 kHz. Within this frequency range, a relatively high degree of sensitivity of the inertial sensors, in particular of a two-axle acceleration element, can be detected.
The inventive fastening assembly for a sensor assembly, which comprises at least one sensor module, having the features of independent patent claim 1, has, compared with the above, the advantage that a metal bush comprises a sleeve as a single-point fixing means and a disk as a carrier unit for a carrier plate, on which the at least one sensor module is arranged, wherein the sleeve is led through a central passage in the carrier plate. In this context, the sensor assembly can be connected to the metal bush via a fastening assembly according to the invention, and suitable fastening means can be connected to a vehicle bodywork. The essential difference from the previous approaches is that the sensor assembly is now only fastened to a fastening assembly which is embodied as a central fixing means in the form of a single-point fixing means. For this purpose, the metal bush, which serves both for fixing and as a function carrier, is used as a central element.
As a result of the proposed inventive design, resonances can be shifted into uncritical frequency ranges above approximately 4 to 5 kHz, and influences of the carrier plate resonances and of other components which are connected to the carrier plate can be reduced by virtue of the fact that the sensor module is positioned on a region of the carrier plate which is not susceptible to interference. As a result, embodiments of the present invention permit housing designs which are optimized in terms of vibration to be made available. This means that the natural frequencies of a housing which encloses the sensor assembly can advantageously be shifted into a frequency range which is above approximately 4 to 5 kHz. Since the eigenmodes of the housing constitute the main cause of interference in the sensor signal, it becomes clear how advantageous it is to decouple the eigenmodes of the housing. Embodiments of the invention not only permit natural resonances of the housing to be decoupled but also the overshoots on the carrier plate to be significantly reduced. Therefore, in particular the installation location of the at least one sensor module on the carrier plate can be decoupled from the eigenmodes of the housing. In addition, the dimensions of the housing can be reduced by virtue of the single-point fixing means.
The inventive approach to a solution provides a multiplicity of configuration possibilities which are optimized in terms of vibration and fabrication thanks to the versatile geometry parameters and material parameters. Thanks to the effective decoupling of the eigenmodes of the housing by the metal bush, the designer is therefore no longer reliant on a housing material which has a high modulus of elasticity, since the material no longer has to be selected in accordance with vibration criteria. For the housing, it is advantageously possible to use a cost-effective plastic which only has to satisfy the motor vehicle-specific requirements. Furthermore, the freedom in terms of design and materials permits targeted shifting of the eigenmodes of the carrier plate and of the overshoots associated therewith.
A further advantage of the novel housing concept is the dimensioning of the housing. As a result of the central fixing means, the overall dimensions of the sensor assembly depend directly on the diameter of the fastening means. A relatively small diameter therefore not only means a decrease in the overall dimensions, since a relatively small metal bush, a relatively small carrier plate and a relatively small housing are produced, but also a reduction in the weight and in the material costs. Apart from this, the miniaturization allows a greater degree of rigidity and therefore additional shifting of the natural frequencies.
As a result of the measures and developments specified in the dependent claims, advantageous improvements of the fastening assembly for a sensor assembly, specified in independent patent claim 1, are possible.
It is particularly advantageous that the metal bush is embodied as an insertion part and is inserted at least partially into a floor of a housing which surrounds the sensor assembly. The metal bush can therefore, for example, be particularly easily at least partially encapsulated using an injection-molding method.
In one refinement of the fastening assembly according to the invention, the carrier plate is coupled to the metal bush via a plurality of securing elements and/or at least one central support element. In this context, the carrier plate can be bonded to the securing elements and/or to the at least one central support element. A particularly simple embodiment is obtained if the securing elements and/or the at least one central support element are integrally molded onto the housing floor. This embodiment allows the number of parts to be advantageously reduced and the oscillation behavior to be improved further.
In a further refinement of the fastening assembly according to the invention, the carrier plate rests on the at least one central support element in the region of the passage. The central support element can, for example, be integrally formed on the housing floor as an annular collar which bears on the sleeve of the metal bush.
In a further refinement of the fastening assembly according to the invention, the plurality of securing elements are arranged between the carrier plate and the disk of the metal bush at predefined positions in such a way that the installation location of the at least one sensor module which is arranged on the carrier plate is decoupled in terms of vibration from the eigenmodes of the sensor assembly. As a result, the interference influences acting on the at least one sensor module can be advantageously reduced further.
In a further refinement of the fastening assembly according to the invention, the fastening means act on a support surface at the upper edge of the sleeve. Alternatively, the fastening means act on a support surface within the sleeve. This means that the support surface for the fastening means is arranged either in the region of the housing cover or in the region of the housing floor. From the point of view of vibration, the two embodiments behave very similarly. The fastening means is embodied, for example, as a screw with a screw head. Through skillful positioning of the securing elements it is possible to minimize very satisfactorily the overshoots on the carrier plate in the positioning area of the sensor module in both embodiments. Furthermore, it was possible to shift the eigenmodes of the design to higher frequencies by using the metal bush. Apart from the configuration which is optimized in terms of vibration, material costs and fabrication costs also played a decisive role for the practical implementation. Additional objectives in the development of sensor concepts are therefore the reduction in the mass and in the geometric dimensions. Since a large cutout is required for the screw head when the support surface is arranged in the sleeve, this embodiment has overall larger dimensions than the embodiment in which the support surface is arranged at the edge of the sleeve. Due to the relatively large bush dimensions, a relatively high mass and relatively large overall dimensioning occur. When the support surface is arranged outside the sleeve, the sensor assembly has a relatively large overall height. For this reason, the embodiment of the inventive fastening assembly is selected as a function of the installation space available.
In a further refinement of the inventive fastening assembly, the at least one sensor module is arranged on a first side of the carrier plate with respect to the sleeve and at least one further component is arranged on a second side of the carrier plate with respect to the sleeve. Arranging the components on various sides of the carrier plate prevents the natural resonances of the further components, which comprise, for example, a capacitor and/or a plug socket, from propagating to the sensor module side by virtue of the central fixing means of the carrier plate.
As a result, the interference effects of the further components are advantageously decoupled in an effective way. In addition, corresponding electronic evaluation circuits in the sensor module can be integrated or arranged on the carrier plate.
In a further refinement of the fastening assembly according to the invention, the metal bush is embodied in two parts, wherein the sleeve is inserted into a corresponding opening in the disk. This advantageously permits mass production of the metal bush with relatively low expenditure on fabrication and costs.
The two parts can be joined, for example, by welding or pressing. A circular shape or a rectangular shape can be selected for the geometry of the disk, which entails additional savings in terms of material and weight.
The fastening assembly according to the invention can be used for a sensor assembly having at least one sensor module which is arranged on a carrier plate.
The exemplary embodiments of the invention are illustrated in the drawings and are explained in more detail in the following description.
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The two-part embodiment of the metal bush 20′, 20″ advantageously permits mass production of the metal bush 20′, 20″ with relatively low expenditure on fabrication and costs. For the geometry of the disk 24, 24′, 24″, a circular shape or a rectangular shape can be selected, which entails additional savings in terms of material and weight.
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Furthermore, the plurality of securing elements 15 between the carrier plate 32 and the disk 24 of the metal bush 20 are arranged at predefined positions in such a way that the installation location of the sensor module 34 which is arranged on the carrier plate 32 is decoupled in terms of vibration from eigenmodes of the sensor assembly 1, 1′, 1″. The optimum positions may be determined, for example, on the basis of trial structures with corresponding oscillation measurements and by simulations and/or FEM analyses. In order to advantageously effectively decouple the interference effects of the further component 36, the sensor module 34 is arranged on the left-hand side of the carrier plate 32 with respect to the sleeve 22, and the further component 36 is arranged on the right-hand side of the carrier plate 32 with respect to the sleeve 22. Arranging the components on various sides of the carrier plate 32 prevents the natural resonances of the further component 36 from propagating to the sensor module side by virtue of the central fixing of the carrier plate.
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The previously described embodiments of the sensor assembly 1, 1′, 1″ according to the invention without a housing can be expanded, for example, by installing a second sensor module. The additional sensor module can be positioned, for example, on the underside of the carrier plate 32. Both sensor modules are therefore located in the region of the carrier plate 32 which is not susceptible to vibration. Since the dimensions increase only slightly, it is appropriate to design a universal housing for both concepts. The use of a universal housing not only entails an enormous saving potential but also provides a decisive customer advantage. The customer can use the existing mount when this system is expanded, saving the development costs for a new mount. The previously described embodiments of the sensor assembly 1, 1′, 1″ according to the invention without a housing can be used, for example, within a control unit, with the result that an additional housing for the sensor assembly 1, 1′, 1″ is not necessary.
Two exemplary embodiments of a sensor assembly 5, 105 with a housing, which can be installed at any desired locations in the vehicle, are also described below.
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In the second exemplary embodiment, the sensor module 134 is also attached to the opposite side of the capacitor 136, with the objective of minimizing possible feedback of the natural resonances of the capacitor 136 to the sensor module 134. Furthermore, the eigenmodes of the sensor assembly 105 can be shifted to relatively high frequencies in a region above approximately 4 to 5 kHz by the use of the metal bush 120. Electrical contact is made by means of the plug socket 111 which is integrally molded onto the floor 118 which is embodied as a housing body. The housing cover 12 is also designed as an injection-molded component and can be welded to the housing floor 118 by means of, for example, laser welding technology, in order to seal the electronic assembly 130 off from the outside with respect to sprayed water. In addition, the housing 110 generates a damping effect, which acts positively on the signal behavior of the sensor module 134.
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In a further embodiment (not illustrated) of a sensor assembly according to the invention with a housing, the influence of the plug-type contacting process can be reduced further by virtue of the fact that the plug socket and the press-in pins for the plug-type contacting process are arranged as the capacitor on the side of the carrier plate lying opposite the sensor module. As a result, owing to the central fixing of the carrier plate by means of the metal bush virtually complete coupling of the plug vibrations can be achieved. A further aspect, which has not been mentioned hitherto, is the correct orientation of the sensor assembly when installation occurs in the vehicle. In conventional housings, correct adjustment during installation is ensured by two-point fixing. By eliminating the second fastening screw, the obligatory condition no longer arises. However, it can be implemented, for example, by a plastic mandrel in the housing floor. Said mandrel is plugged through a hole, provided for this purpose, at the installation location during mounting. The plastic mandrel provides the further advantage over two-point fixing of the sensor assembly being prevented from being mounted in an inverted fashion.
The embodiments of the invention advantageously permit, by virtue of the metal bush which serves as a central fixing unit and carrier unit and permits the “single-point fixing”, resonance frequencies to be shifted into uncritical frequency ranges above approximately 4 to 5 kHz and a reduction in the influence of carrier plate resonances and of other components which are arranged on the carrier plate.
Number | Date | Country | Kind |
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10 2009 045 557.4 | Oct 2009 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2010/062782 | 9/1/2010 | WO | 00 | 8/1/2012 |