The present application claims the benefit under 35 U.S.C. § 119 of German Patent Application No. DE 102016201851.5 filed on Feb. 8, 2016, which is expressly incorporated herein by reference in its entirety.
Conventional sensors often sense at least one rotation characteristic of rotating elements. Rotating characteristics generally describe characteristics that at least partially describe the rotation of the rotating element. For instance, this may involve angular velocities, rotary frequencies, angular accelerations, angles of rotation, angular position or other characteristics which may characterize a continuous or discontinuous, regular or irregular rotation or revolution of the rotating element. Examples of such sensors are described in Konrad Reif (Publ.): Sensoren im Kraftfahrzeug [Automotive Sensors], 2nd edition, 2012, pages 63-74 and 120-129.
For instance, a position of a camshaft of an internal combustion engine relative to a crankshaft can be ascertained with the aid of what is generally referred to as a phase sensor employing a Hall-effect sensor. Typically, a trigger wheel is mounted on the rotating axis. Teeth may be situated on the trigger wheel which are sampled by the Hall-effect sensor when the camshaft is rotating. In German Patent Application No. DE 10 2012 213 539 A1, for instance, a method is described for ascertaining a phase position of an adjustable camshaft of an internal combustion engine which includes a trigger wheel and a camshaft adjuster. The phase position of the camshaft is ascertained on the basis of phase flank interrupts triggered by the trigger wheel, and a model that is a function of at least one operating variable of the camshaft adjuster.
However, methods of this kind do not allow continuous position sensing. Absolute angle sensing in a measuring range of 360° is not possible. Also, the resolution is limited due to the small diameters of the used trigger wheels. These small diameters result in minimal gap sizes that must be taken into account. In addition, an absolute position determination is possible only in a dynamic case, when the trigger wheel is rotating. An instantaneous availability of the absolute positional value when switching on the voltage supply, i.e. a true power-on function, is therefore not provided. Especially in a startup of an engine of the internal combustion engine, a precise position is not known. Apart from that, such methods are highly sensitive with regard to magnetic interference fields.
U.S. Pat. No. 7,499,878 B2 describes an inductive linear and rotary position sensor. A device having an excitation coil and a receiver coil is described. The excitation coil is excited by an excitation source and generates a magnetic flux. The receiver coil generates a receive signal through an inductive coupling between the excitation coil and the receiver coil.
Despite the improvements brought about by such sensor devices, there is still room for improvement. Sensor devices of this type may have a complex structure, which particularly means that a simple installation and de-installation are not possible.
Therefore, a sensor device and a method for ascertaining at least one rotation characteristic of a rotating element are provided, which may avoid the aforementioned problems of conventional devices and methods at least for the most part; in particular, they allow for high-resolution sensing of a rotation characteristic, especially an absolute angle, of a rotating element in a measuring range of 360°, and are represented in the claims.
In a first aspect of the present invention, a sensor device for ascertaining at least one rotation characteristic of a rotating element is proposed. In general, a rotation characteristic may be understood to refer to a characteristic that at least partially describes the rotation of the rotating element. This, for instance, may be angular velocities, rotary frequencies, angular accelerations, angles of rotation, angular positions or other characteristics, which are able to characterize a continuous or non-continuous, regular or irregular rotation or revolution of the rotating element. For instance, the rotation characteristic may be a position, especially an angular position. In principle, a rotating element may describe an arbitrary element which has an axis of rotation and rotates about said axis. The rotating element, for example, may be a shaft of a drive machine such as a camshaft. For instance, an angular position of a camshaft is able to be ascertained. An angular position of a camshaft may describe an angle of rotation of the camshaft in relation to an axis that is positioned at a right angle to the axis of rotation.
The sensor device includes at least one trigger wheel which is able to be connected to the rotating element. The rotating element and the trigger wheel have an axis of rotation, especially a shared axis of rotation. The trigger wheel may be situated concentrically about the rotating element and have a cylindrical basic form. The axis of rotation may be an axis of symmetry parallel to a height of the cylinder. The trigger wheel may be connected to the rotating element. The trigger wheel may be mounted on the rotating element, for instance with the aid of at least one fastening element. The trigger wheel may be fastened to the rotating element in a concentric manner. In response to a rotary motion of the rotating element, the trigger wheel is able to rotate along with the rotating element. A position, in particular an angular position, of the trigger wheel may correspond to a position of the rotating element, in particular an angular position.
The sensor device includes at least one coil array. In principle, a coil array may describe a device of arbitrary shape which includes at least one coil. A coil may be understood as a component that is set up to generate or detect a magnetic field. The coil array includes at least one excitation coil and at least one receiver coil. The excitation coil and the receiver coil may have at least one winding. For example, the excitation coil and the receiver coil may be developed as circuit traces made from metal, for instance. An excitation coil may be understood as a coil which generates a magnetic flux when excited. The excitation is able to be brought about by a source, in particular a current source. The coil array may include an excitation coil having at least one winding. The excitation coil and the receiver coil are able to be coupled in an inductive manner. A receiver coil may describe a coil which is set up to generate a signal as a result of the inductive coupling between excitation coil and receiver coil, the signal being a function of the inductive coupling. The inductive coupling may be dependent upon a position of the trigger wheel. The trigger wheel can be produced from a metal and during a rotary motion, may sweep a region of the coil array and change the inductive coupling between the excitation coil and receiver coil. The receiver coil may include at least one sensor coil. The receiver coil may be made up of two partial windings of a coil that are oriented in an opposite direction. This means that during a current flow through the coil, current is flowing through the partial windings in a clockwise direction and in a counter-clockwise direction respectively. The coil array may have a multiplicity of receiver coils such as a receiver coil system, in particular a sine/cosine system or a multi-phase system. Other coil systems are conceivable as well in principle. The sensor device may be designed to represent a sine system, a cosine system or a multiphase system for the detection.
The coil array is situated on at least one circuit carrier. A circuit carrier may be understood to describe a device which is set up to accommodate electronic components. The circuit carrier may be a planar circuit carrier such as a circuit board, a circuit card, a wafer or a printed circuit, in particular a printed circuit board (PCB), and the coil array may be printed onto the PCB, for example.
The trigger wheel has a trigger-wheel profile. The trigger wheel may have a cylindrical basic shape. In principle, a trigger-wheel profile may be understood to describe an arbitrarily shaped development of a cylinder jacket of the trigger wheel. For instance, the cylinder jacket may have at least one bulge and/or at least one notch. The trigger wheel profile may include at least one profile element which can be a tooth, for instance. The profile element may be a track contoured in a width of the trigger wheel. A width of the trigger wheel may be understood as a height of the cylinder jacket. The trigger wheel may include a multiplicity of profile elements which may be distributed across a circumference of the trigger wheel, in particular. For example, the trigger wheel may have a plurality of teeth and/or at least one contoured track. The profile elements may be periodically disposed across the circumference of the trigger wheel. The profile elements are able to be disposed equidistantly across the circumference but other developments are also conceivable in principle, such as developments in which the profile elements are not situated equidistantly.
The sensor device is designed to ascertain a change in the inductive coupling between the excitation coil and the receiver coil as a function of a position of the trigger wheel. The sensor device may be set up for ascertaining an absolute position of the rotating element from the change in the inductive coupling. An ascertainment of an absolute position of the rotating element may describe an ascertainment of a position, in particular an angular position, relative to the sensor device. The inductive coupling may be dependent upon a position of the trigger wheel. During a rotary motion, the trigger wheel may sweep a region of the coil array, which may lead to a change in the magnetic flux and to a change in the inductive coupling between the excitation coil and receiver coil. The inductive coupling may change as a function of the trigger-wheel profile. For instance, the inductive coupling may change at a beginning of a profile element and/or at an end of a profile element. The receiver coil is able to generate a signal that is a function of the inductive coupling. The sensor device may be designed to provide an availability, in particular an instantaneous availability, of an absolute positional value of the rotating element when a voltage supply is switched on, for instance during a start of an engine of an internal combustion engine (true power-on function).
The sensor device may include an evaluation unit. The evaluation unit may include at least one evaluation circuit which can be situated together with the coil array on a shared circuit carrier, or which may be disposed separately from the coil array on a further circuit carrier. The evaluation unit may include a data-processing device and be designed to receive the signal from the receiver coil and to ascertain a position of the trigger wheel, in particular an angular position.
The circuit carrier is situated coaxially with the axis of rotation of the trigger wheel. “Situated coaxially with the axis of rotation of the trigger wheel” may be understood to mean that that the circuit carrier is situated on a cylinder jacket around the trigger wheel, in a radial position relative to the camshaft. The circuit carrier surrounds the trigger wheel at least partially in a circular manner. “At least partially in a circular manner” may be understood to mean that the circuit carrier does not surround the trigger wheel completely but covers a subregion, in particular a circle segment of the trigger wheel. For example, the circuit carrier may have an opening angle. The circuit carrier may cover a subsection of the circumference of the trigger wheel according to the opening angle. An absolute measuring range of the sensor device may depend on the opening angle of the circuit carrier. This system is particularly advantageous from the aspect of an installation and de-installation of the sensor device. In principle, other developments are conceivable as well such as developments in which the circuit carrier surrounds the trigger wheel completely.
The circuit carrier may include a multiplicity of coil arrays. For instance, the circuit carrier may have a first region in which a first coil array is situated, and a second region in which a second coil array is disposed.
The circuit carrier may have a flexible design. For example, the circuit carrier may be a planar circuit carrier which is developed to be flexible, especially bendable. The circuit carrier may include a flexible material and, for instance, be a flexible circuit board. The circuit carrier, for example, may be a rigid-flex circuit board, particularly a bent rigid-flex circuit board. The circuit carrier may have at least two planar surfaces, and the planar surfaces may be situated at an angle with respect to one another. The circuit carrier may be a rigid circuit carrier. The circuit carrier may have at least one connection element, such as a material preweakening and/or a notch, which is designed to connect the planar surfaces to each other.
The circuit carrier may be situated in an injection-molded housing. For the mechanical stabilization, the circuit carrier, which includes a sensor wafer and an evaluation unit, for example, can be situated in an injection-molded housing.
The sensor device may have at least two trigger wheels. In addition, the sensor device can have at least two coil arrays; a first coil array may be situated coaxially with a first trigger wheel, and a second coil array may be situated coaxially with a second trigger wheel. For instance, the two coil arrays, e.g., a first coil array and a second coil array, are able to be placed on a shared circuit carrier. The first coil array may include a multiplicity of receiver coils such as a first receiver-coil array. The second coil array may include a multiplicity of receiver coils such as a second receiver-coil array.
The first trigger wheel and the second trigger wheel are able to have trigger wheel profiles that differ from one another. For example, the first trigger wheel may have a trigger wheel profile in which profile elements having a first periodicity are situated on the first trigger wheel. The second trigger wheel may have a trigger wheel profile in which profile elements having a second periodicity that differs from the first periodicity are situated. The first trigger wheel and the second trigger wheel are able to have identical trigger wheel profiles and be situated at an offset from one another. The first trigger wheel and the second trigger wheel may be connected to one another; for example, the first trigger wheel and the second trigger wheel may be designed as one part. An evaluation and position determination is able to take place with the aid of a Vernier (Nonius) method in which in particular an interpolation of a multiplicity of signals to a measuring value takes place, especially a positional value. In this way the measuring range of the sensor device is able to be expanded to a measuring range of 360° through the use of two trigger wheels or two trigger wheel profiles that differ in their periodicity, and two coil arrays.
In one further aspect of the present invention, a method for ascertaining at least one rotation characteristic of a rotating element is proposed. With regard to definitions and specific embodiments of the method, reference can be made to the above comments with regard to the sensor device proposed in a first aspect of the present invention. A sensor device according to the present invention is used in the method. The sensor device includes at least one trigger wheel which is able to be connected to the rotating element. The rotating element and the trigger wheel have an axis of rotation. The sensor device includes at least one coil array, which encompasses at least one excitation coil and at least one receiver coil. The coil array is situated on at least one circuit carrier. The trigger wheel has a trigger wheel profile. In the method, a change of an inductive coupling between the excitation coil and the receiver coil is ascertained as a function of a position of the trigger wheel. The circuit carrier is situated coaxially with the axis of rotation of the trigger wheel. The circuit carrier surrounds the trigger wheel at least partially in a circular manner. An absolute position of the rotating element is able to be ascertained from the change in the inductive coupling. The method may allow for an instantaneous availability of an absolute positional value when a voltage supply is switched on (true power-on function).
Additional optional details and features of the present invention result from the following description of preferred exemplary embodiments which are schematically shown in the figures.
Sensor device 110 includes at least one trigger wheel 116 which is able to be connected to rotating element 112. Rotating element 112 and trigger wheel 116 have an axis of rotation such as a shared axis of rotation 114. Trigger wheel 116 may be situated concentrically around rotating element 112 and have a cylindrical basic shape. Trigger wheel 116 is able to be connected to rotating element 112. During a rotary motion of rotating element 112, trigger wheel 116 is able to rotate together with rotating element 112 so that a position, in particular an angular position, of trigger wheel 116 corresponds to a position of rotating element 112, in particular an angular position.
Sensor device 110 includes at least one coil array 118. A schematic representation of a coil array 118 according to the present invention is shown in
Circuit carrier 128 is disposed coaxially with axis of rotation 114 of trigger wheel 116. As shown in
Circuit carrier 128 may include a multiplicity of coil arrays 118.
Circuit carrier 128 may be situated in an injection-molded housing. For the mechanical stabilization, the circuit carrier, which includes a sensor wafer and an evaluation unit, for example, may be disposed inside an injection-molded housing.
Trigger wheel 116 has a trigger wheel profile 140.
Sensor device 110 is designed to ascertain a change in the inductive coupling between excitation coil 120 and receiver coil 122 as a function of a position of trigger wheel 160. Sensor device 110 may be developed to determine an absolute position of rotating element 112 from the change in the inductive coupling. The inductive coupling may be a function of a position of trigger wheel 116. During a rotary motion, trigger wheel 116 may sweep a region of coil array 118. This may lead to a change in the magnetic flux and to a change in the inductive coupling between excitation coil 120 and receiver coil 122. The inductive coupling may change as a function of trigger wheel profile 140. For instance, the inductive coupling may change at a beginning of a profile element 142 and/or at an end of a profile element 142. Receiver coil 122 may generate a signal which is a function of the inductive coupling. Such a development of sensor device 110 may enable an availability of an absolute positional value when a voltage supply is switched on (true power-on function).
Sensor device 110 may have an evaluation unit. The evaluation unit may include at least one evaluation circuit which may be situated together with coil array 118 on a shared circuit carrier 128, or may be situated separately from coil array 118 on a further circuit carrier 128. The evaluation unit may encompass a data processing device. The evaluation unit may be designed to receive the signal from receiver coil 122 and to ascertain a position of trigger wheel 116, in particular an angular position.
Sensor device 110 may have at least two trigger wheels 116. For instance, sensor device 110 may have a first trigger wheel 144 and a second trigger wheel 146.
Number | Date | Country | Kind |
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10 2016 201 851 | Feb 2016 | DE | national |
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Entry |
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Konrad Reif, “Sensoren im Kraftfahrzeug [Automotive Sensors]”, 2nd edition, 2012, p. 63-74 and 120-129. |
Number | Date | Country | |
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20170227379 A1 | Aug 2017 | US |