Sensor Arrangement for a Vehicle and Corresponding Method for Producing such a Sensor Arrangement
A sensor arrangement for a vehicle includes a sensor element and a connection cable at least partially encased with plastic by means of injection moulding in order to form a sensor housing. The sensor housing is connected to a fastening tab which comprises a base body having fastening means. The fastening tab includes an insertion sleeve which is connected to the base body and into which a sensor housing body of the sensor housing is inserted. The sensor housing and the insertion sleeve each comprise fixing means which are designed in such a manner that there are different angular positions for fixing the sensor housing and the fastening tab. The sensor housing and the fastening tab are fixed in one of the different angular positions with respect to one another.
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The invention is based on a sensor arrangement for a vehicle of the generic type of independent patent claim 1 and on a corresponding method for producing such a sensor arrangement of independent patent claim 7.
German Laid-Open Patent Application DE 10 2008 042 091 A1 describes a method for producing a magnetic field sensor and a corresponding magnetic field sensor, in particular for use as a rotational speed sensor and/or direction of rotation sensor for the rotation of the wheel or for the drive train of a motor vehicle. The described magnetic field sensor comprises an electrical assembly for sensing and evaluating magnetic field signals and a connecting cable, which are together encased in plastic in an injection molding process. At the same time, a fastening tab is integrally molded on, which fastening tab has a base body with a fastening bush. The described production method uses fabrication methods which are proven for the production of sensors with an axial cable outlet, and fabrication devices for producing sensors with a bent cable outlet, which devices have only to be combined with one assembly station in which the connecting cable is then also fully automatically bent and locked in the bent position by suitable means. A positioning means which is embodied as a latching contour and/or riveting contour is expediently provided for the locking process. The latching contour and/or riveting contour can be integrally injection molded onto the connecting cable and, after the bending of the cable into its predetermined angular position, said latching contour and/or riveting contour can be latched or riveted with a positioning means which is also embodied as a latching contour and/or a riveting contour on the fastening tab.
In order to bend the cable into the predetermined angular position, the cable no longer has to be removed from the work piece carrier, since the type of connection permits immediate locking. As a result, the process times are reduced. Regardless of the desired angular position (radial or axial) of the cable relative to the sensor, this concept permits recourse to just one single fabrication line. However, in order to produce different positions of the fastening tab and different functional lengths, it is necessary to make changes to the injection molding molds of the rotational speed sensors. It is therefore possible, for example, for new mold inserts and/or adjustment of mold inserts to be necessary, as a result of which the molds become very complex and high-maintenance.
DISCLOSURE OF THE INVENTIONThe sensor arrangement according to the invention for a vehicle having the features of independent claim 1 and a corresponding method for producing such a sensor having the features of independent claim 7 have the advantage that a sensor element and a connecting cable are at least partially encased with plastic by injection molding in order to form a sensor housing, and the sensor housing is subsequently connected to a fastening tab which comprises a base body with fastening means. The fastening tab can also be produced, for example, as a plastic injection molded part in a separate work step. According to the invention, the fastening tab comprises an insertion sleeve which is connected to the base body and into which a sensor housing body of the sensor housing is inserted, wherein the sensor housing and the insertion sleeve each comprise securing means which are embodied in such a way that various angular positions for securing the sensor housing and the fastening tab are present, wherein the sensor housing and the fastening tab are secured with respect to one another in one of the various angular positions. By means of the various angular positions it is possible to select the optimum angular position of the fastening tab in relation to the sensor housing with respect to the installation position in the vehicle. As a result, the shape of the sensor arrangement can be matched in an optimum way to the installation space in the vehicle. The sensor arrangement according to the invention is essentially produced by mounting the sensor housing in the fastening tab. Embodiments of the invention advantageously permit sensor arrangements whose fastening tabs and sensor housings can have different angular positions with respect to one another to be produced without changes being necessary to the injection molding molds. The various sensor arrangements are produced by means of the assembly process, wherein the flexibility of the angular position of the fastening tab with respect to the sensor housing is brought about, for example, by means of a plurality of latching possibilities.
As a result of the measures and developments specified in the dependent claims, advantageous improvements of the sensor arrangement for a vehicle, which is disclosed in independent patent claim 1, and of the method for producing such a sensor arrangement, disclosed in independent patent claim 7, are possible.
It is particularly advantageous that a star contour is integrally formed onto the sensor housing body as a securing means, which star contour interacts with a corresponding star contour which is arranged on the insertion sleeve. The sensor housing is therefore inserted into the insertion sleeve of the fastening tab and the angular position of the fastening tab with respect to the sensor housing is advantageously secured by means of the star contour provided on both parts.
In a refinement of the sensor arrangement according to the invention, the star contour of the sensor housing body is hot caulked with the corresponding star contour of the insertion sleeve. The hot caulking can advantageously ensure a desired functional dimension and a durable connection between the components.
In a further refinement of the sensor arrangement according to the invention, positioning means, which are embodied as latching contours, are arranged on the connecting cable and on the fastening tab, for the purpose of locking the connecting cable which is bent into an angular position with respect to the sensor element and/or with respect to the fastening tab. For the purpose of locking, for example, a first latching contour is arranged as a sleeve-shaped contour on the connecting cable, and at least one second latching contour is embodied as a cut-out with integrally formed-on latching projections as part of the fastening tab. The latching contour is of relatively small design, with the result that the expenditure on material is reduced compared to the prior art. In order to bend the cable into the predetermined angular position, the cable no longer has to be removed from the work piece carrier after the caulking process since the method of connecting permits immediate securing. As a result, the process times are reduced. If a plurality of second latching contours are arranged on the fastening tab, the connecting cable can be bent over radially in various directions, of which directions a preferred bending direction is selected as a function of the installation space in the vehicle in order to permit optimum guidance of the connecting cable in the vehicle. After the locking of the position elements, the positioning means which are integrally formed onto the fastening tab absorb the axial tensile forces from the connecting cable.
In a further refinement of the sensor arrangement according to the invention, a cap with at least one cut-out for the connecting cable is provided. In this context, the cap covers the bent region of the connecting cable and is fitted over the fastening tab and latched. In order to secure all the parts, the cap is pushed onto the fastening tab and latched. In this context, the radial forces from the connecting cable are not absorbed by the latched connection but rather by an encompassing geometry. The cap advantageously serves as a fastening element and as a heat protection for the bending point of the connecting cable.
The positioning means for the connecting cable are advantageously integrally injection molded on at least partially to the connecting cable and/or to the sensor unit and/or to the fastening tab, with the result that loose positioning means and fastening means can be at least largely dispensed with. In particular, the positioning means are integrally injection molded onto the connecting cable and to the fastening tab of the sensor arrangement. The sensor element and/or an electronic assembly sense/senses a magnetic field to be monitored and evaluate/evaluates the sensor signals. This determines the orientation of the sensor element and the fastening tab as well as the routing of the connecting cable.
Exemplary embodiments of the invention are illustrated in the drawings and will be explained in more detail in the following description.
In the drawings:
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In order to secure all the parts, the cap 40 is pushed over the upper end 34.1 of the insertion sleeve 34, and over the two lateral surfaces 36.4 of the second positioning means 36 which are embodied as an angular element. For this purpose, the cap 40 has a cut-out 42 which corresponds to the bend in the connecting cable and whose upper opening 42.1 is matched to the contour of the annular collar 24 and has a stop (not denoted in more detail) for the annular collar 24. The lower edge of the cut-out 42 is embodied as a reinforcement bar 44 with which the cap 40 rests on the edge of the insertion sleeve 34. A bearing surface 48 and a latching projection 46 are integrally formed onto each end of the reinforcement bar 44 of the cap 40, which bearing surface 48 and latching projection 46 latch with correspondingly embodied latching edges 36.7 on the lateral surfaces 36.4 of the second positioning means 36 which are embodied as an angular element. After the latching the bearing surfaces 48 of the cap lie on the side surfaces 36.4 of the second positioning means 36 which are embodied as an angular element. This means that in the cap 40 the radial forces which come from the connecting cable 16 are not absorbed by the latching connection but rather by the geometry engaging around in the form of the bearing surfaces 48 and the lateral surfaces 36.4. The cap 40 therefore serves as a fastening element and as a heat protection for the bending point of the connecting cable 16. The configuration of the first and second positioning means 20, 36 and of the cut-out 42 in the cap 40 are selected in the illustrated exemplary embodiment in such a way that right-angled deflection of the connecting cable 16 with respect to the sensor housing body 12 takes place. Where necessary, any other desired deflection angle for the connecting cable 16 can also be implemented by corresponding configurations of the first and second positioning means 20, 36 and of the cut-out 42 in the cap 40.
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In order to secure all the parts, the cap 40′ is fitted onto the second positioning means 36′, which are embodied as a spherical shell, and latched. For this purpose, the cap 40′ has a cut-out 40 which corresponds to the bend in the connecting cable 16′ and has two main openings 42.1′, 42.2′. A first main opening 42.1 is matched to the outer contour of the sleeve-shaped contour 22 and has a bearing surface 48.2 for the annular collar 24′ of the sleeve-shaped contour 22′. A second main opening 42.2′ has a larger clear width than the first main opening 42.1′ and is matched to the contour of the annular collar 24′ in such a way that the second main opening 42.2′ can be pushed over the annular collar 24′, the upper edge of which second main opening 42.2′ is matched to the contour of the annular collar 24. The lower edge of the cut-out 42′ is formed by two clamping bars 44′ which downwardly bound two further cut-outs 49′ which are matched to the contour of the outer wall 36.4′ of the second positioning means 36′ which are embodied as a spherical shell, in such a way that in the latched state of the cap 40′, two bearing surfaces 48.1′ which bound the cut-out 49′ bear on the outer wall 36.4′ of the second positioning means 36′ which are embodied as a spherical shell. In the latched state of the cap 40′, the two latching projections 46′ which are integrally formed onto the clamping bars 44′ engage around the contour of the second positioning means 36′ which are embodied as a spherical shell. This means that in the cap 40′ the radial forces which come from the connecting cable 16 are not absorbed by the latched connection but rather by the geometry which engages around in the form of the bearing surfaces 48.1′ and the outer wall 36.4′ of the second positioning means 36′ which are embodied as a spherical shell. The cap 40′ therefore also serves as a fastening element and as a heat protection for the bending point of the connecting cable 16′. The configuration of the first and second positioning means 20′, 36′ and that of the cut-out 42′ in the cap 40′ are selected in the illustrated exemplary embodiment in such a way that right-angled deflection of the connecting cable 16 is possible at three different angular positions with respect to the sensor housing body 12. Where necessary, any other desired deflection can be implemented for the connecting cable 16′ and more than three can be implemented by corresponding configurations of the first and second positioning means 20′, 36′ as well as the cut-out 42′ in the cap 40.
The mode of operation of the sensor arrangement 1, 1′ is basically known and the application possibilities are very versatile. In motor vehicles, the sensor arrangement 1 serves, in particular, to determine the rotational speed, the acceleration, the acceleration gradient and/or the rotational angle of rotating parts. The use in motor vehicles is promoted here by the various angular positions which make it possible to select the optimum angular position of the fastening tab in relation to the sensor housing with respect to the installation position in the vehicle. As a result, the shape of the sensor arrangement can be matched in an optimum way to the installation space in the vehicle. The sensor arrangement according to the invention is produced essentially by mounting the sensor housing in the fastening tab.
Embodiments of the invention advantageously permit sensor arrangements to be produced whose fastening tabs and sensor housings can have different angular positions with respect to one another, without the need to make changes to the injection molding molds. The various sensor arrangements are produced by the mounting process, wherein the flexibility of the angular position of the fastening tab with respect to the sensor housing is provided, for example, by means of a plurality of latching possibilities.
Claims
1. A sensor arrangement for a vehicle, comprising:
- a sensor element; and
- a connecting cable,
- wherein the sensor element and the connecting cable are at least partially encased with plastic by injection molding in order to form a sensor housing,
- wherein the sensor housing is connected to a fastening tab which comprises a base body with fastening means,
- wherein the fastening tab comprises an insertion sleeve which is connected to the base body and into which a sensor housing body of the sensor housing is inserted,
- wherein the sensor housing and the insertion sleeve each comprise securing means which are embodied in such a way that various angular positions for securing the sensor housing and the fastening tab are present, and
- wherein the sensor housing and the fastening tab are secured with respect to one another in one of the various angular positions.
2. The sensor arrangement as claimed in claim 1, characterized in that further comprising:
- a star contour is integrally formed onto the sensor housing body as a securing means, which
- wherein the star contour interacts with a corresponding star contour which is arranged on the insertion sleeve.
3. The sensor arrangement as claimed in claim 2, characterized in that wherein the star contour of the sensor housing body is hot caulked with the corresponding star contour of the insertion sleeve.
4. The sensor arrangement as claimed in claim 1, further comprising:
- positioning means, which are embodied as latching contours, arranged on the connecting cable and on the fastening tab,
- wherein the positioning means lock the connecting cable which is bent into an angular position with respect to the sensor element and/or with respect to the fastening tab.
5. The sensor arrangement as claimed in claim 4, wherein:
- a first latching contour is arranged as a sleeve-shaped contour on the connecting cable, and
- at least one second latching contour is embodied as a cut-out with integrally formed-on latching projections as part of the fastening tab.
6. The sensor arrangement as claimed in claim 4, further comprising:
- a cap with at least one cut-out for the connecting cable,
- wherein the cap covers the bent region of the connecting cable and is fitted over the fastening tab and latched.
7. A method for producing a sensor arrangement, comprising:
- at least partially encasing with plastic a sensor element and a connecting cable, are at least partially encased with plastic by injection molding in order to form a sensor housing;
- connecting the sensor housing to a fastening tab which has a base body;
- inserting a sensor housing body of the sensor housing into an insertion sleeve which is connected to the base body;
- respectively arranging a securing means on the sensor housing and on the insertion sleeve; and are erred
- embodying the securing means in such a way that various angular positions for securement between the sensor housing and the fastening tab are made available; and
- securing the sensor housing and the fastening tab with respect to one another in one of the various angular positions.
8. The method as claimed in claim 7, further comprising:
- hot caulking the securing means of the sensor housing body are hot caulked to the corresponding securing means of the insertion sleeve.
9. The method as claimed in claim 7, wherein:
- positioning means, which are embodied as latching contours and which lock the connecting cable which is bent into an angular position with respect to the sensor element and/or to the fastening tab are integrally injection-molded on to the connecting cable and onto the fastening tab,
- a first latching contour is integrally injection molded onto the connecting cable as a sleeve-shaped contour, and
- at least one second latching contour is integrally injection molded onto the fastening tab as a cut-out with integrally molded-on latching projections.
10. The method as claimed in claim 7, wherein:
- a cap having at least one cut-out for the connecting cable, is fitted onto the fastening tab and latched, and
- the cap covers the bent region of the connecting cable.
Type: Application
Filed: Oct 29, 2010
Publication Date: Aug 23, 2012
Applicant: Robert Bosch GmbH (Stuttgart)
Inventors: Ronald Steinbrink (Erfurt), Daniel Matthie (Eisenach), Jan Beyersdorfer (Foertha)
Application Number: 13/505,221
International Classification: G01D 11/24 (20060101); B23P 11/00 (20060101);