U.S. patent application number 09/758922 was filed with the patent office on 2001-06-07 for hall effect rotation sensor for a throttle valve unit.
This patent application is currently assigned to AB Elektronik GMBH. Invention is credited to Apel, Peter, Wilczek, Klaus.
Application Number | 20010002599 09/758922 |
Document ID | / |
Family ID | 27512677 |
Filed Date | 2001-06-07 |
United States Patent
Application |
20010002599 |
Kind Code |
A1 |
Apel, Peter ; et
al. |
June 7, 2001 |
Hall effect rotation sensor for a throttle valve unit
Abstract
A Hall-effect angular rotation sensor device for a throttle
valve unit. The sensor includes a housing unit, a stationary unit,
and a moving unit moveable relative to the stationary unit. The
stationary and the moving units are at least partially enclosed by
the housing unit. The stationary unit includes a first and a second
partial ring stator segment that are at least partially retained in
the housing unit, leaving a stator distancing gap in which at least
one Hall-effect IC switch is positioned. The moving unit includes
(a) a partial ring magnet segment that is at least partially
distanced from the first and the second partial ring stator
segments by an air gap and (b) a third partial ring stator segment
positioned behind and opposite the air gap.
Inventors: |
Apel, Peter; (Sudkirchen,
DE) ; Wilczek, Klaus; (Werne, DE) |
Correspondence
Address: |
Michael C. Barrett
FULBRIGHT & JAWORSKI L.L.P.
Suite 2400
600 Congress Avenue
Austin
TX
78701
US
|
Assignee: |
AB Elektronik GMBH
|
Family ID: |
27512677 |
Appl. No.: |
09/758922 |
Filed: |
January 19, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09758922 |
Jan 19, 2001 |
|
|
|
09493406 |
Jan 28, 2000 |
|
|
|
Current U.S.
Class: |
137/554 ;
251/129.12; 251/248 |
Current CPC
Class: |
Y10T 137/8242 20150401;
H02K 29/08 20130101; F02D 9/105 20130101; G01D 5/145 20130101; F02D
11/106 20130101; F02D 2009/0294 20130101 |
Class at
Publication: |
137/554 ;
251/129.12; 251/248 |
International
Class: |
F16K 037/00; F16K
031/02; F16K 031/44; F17D 003/00; E03B 007/07 |
Foreign Application Data
Date |
Code |
Application Number |
May 27, 1999 |
DE |
299 09 201.1 |
May 17, 1999 |
DE |
299 08 409.4 |
Jan 29, 1999 |
DE |
199 03 490.7 |
Jan 29, 1999 |
DE |
199 03 653.5 |
Jan 29, 1999 |
DE |
299 01 516.5 |
Claims
What is claimed is:
1. A position device for a throttle valve unit, comprising: a
throttle valve; a throttle valve shaft configured to hold the
throttle valve; a housing unit configured to contain the throttle
valve; and a Hall-effect angular rotation sensor adjacent the
throttle valve shaft, the Hall-effect angular rotation sensor
comprising: a stationary unit; a moving unit moveable relative to
the stationary unit; a drive unit; and a transmission positioned
between the moving unit and the drive unit; wherein the housing
unit is configured to at least partially enclose the stationary
unit and the moving unit; wherein the stationary unit includes a
first and a second partial ring stator segment that are at least
partially retained in the housing unit, leaving a stator distancing
gap in which at least one Hall-effect IC switch is positioned; and
wherein the moving unit includes (a) a partial ring magnet segment
that is at least partially distanced from the first and second
partial ring stator segments by an air gap and (b) a third partial
ring stator segment positioned behind and opposite the air gap, and
wherein the moving unit is at least partially retained in a toothed
gear segment of the transmission.
2. The device of claim 1, wherein the throttle valve and the
throttle valve shaft are retained in a throttle valve housing of
the housing unit.
3. A Hall-effect angular rotation sensor device, comprising: a
housing unit; a stationary unit; and a moving unit moveable
relative to the stationary unit; wherein the stationary and the
moving units are at least partially enclosed by the housing unit;
wherein the stationary unit includes a first and a second partial
ring stator segment that are at least partially retained in the
housing unit, leaving a stator distancing gap in which at least one
Hall-effect IC switch is positioned; and wherein the moving unit
includes (a) a partial ring magnet segment that is at least
partially distanced from the first and the second partial ring
stator segments by an air gap and (b) a third partial ring stator
segment positioned behind and opposite the air gap, and wherein the
moving unit is at least partially retained in a rotatable
element.
4. The device of claim 3, wherein the rotatable element comprises a
toothed gear segment of a transmission that is retained on a
throttle valve shaft of a throttle valve.
5. The device of claim 3, wherein the first and the second partial
ring stator segment, the partial ring magnet segment, and the third
partial ring stator segment lie in a plane at least partially side
by side.
6. The device of claim 3, wherein the first and the second partial
ring stator segments, the partial ring magnet segment, and the
third partial ring stator segment are positioned side by side.
7. The device of claim 3, wherein the rotatable element is
configured to rotate from a zero position to an end position, and
wherein the partial ring magnet segment and the third partial ring
stator segment assume a position relative to the first and second
partial ring stator segments in which they are positioned at least
partially overlapping each other in the zero position and almost
completely overlapping each other in the end position.
8. The device of claim 3, wherein the lengths of the first and the
second partial ring stator segments as well as the partial ring
magnet segment and the third partial ring stator segment comprise a
circle segment between about 80.degree. and about 180.degree..
9. The device of claim 3, wherein the partial ring magnet segment
comprises a magnet with opposite polarity.
10. The device of claim 3, wherein the partial ring stator
segments, the partial ring magnet segments, the Hall-effect IC
switch, and the rotatable element are at least partially enclosed
by a sensor housing element of the housing unit.
11. The device of claim 10, wherein the sensor housing element is
constructed from a plastic material into which the first and the
second partial ring stator segments are at least partially
molded.
12. The device of claim 10, wherein the sensor housing element is
configured to be placed on a throttle valve housing and the
rotatable element is configured to be plugged onto a throttle valve
shaft.
13. The device of claim 12, wherein the sensor housing element is
configured as a cap housing element.
14. The device of claim 12, wherein the sensor housing element is
configured to be closed with a cap into which the first and the
second partial stator ring elements are at least partially
molded.
15. The device of claim 3, wherein the rotatable element is coupled
to a spring element contained in the housing.
16. The device of claim 3, wherein the rotatable element is
constructed from a plastic material into which the third partial
ring stator segment and the partial ring magnet segment are at
least partially molded.
17. The device of claim 3, wherein the first, the second, and the
third partial stator ring elements comprise a ferrous material.
18. The device of claim 3, wherein the third partial ring stator
segment and the partial ring magnet segment are integral and
wherein the partial magnet ring element is manufactured by a
magnetizing process.
19. The device of claim 3, wherein the rotatable element comprises:
a toothed gear segment; a motor bevel gear coupled to a drive unit;
an intermediate bevel gear; and an adjusting bevel gear coupled to
the intermediate bevel gear.
20. An adjusting device for a throttle valve unit, comprising: a
throttle valve; a throttle valve shaft; a throttle valve housing;
and a Hall-effect angular rotation sensor device coupled with the
throttle valve shaft, the Hall effect angular rotation sensor
device comprising: a stationary unit; a mobile unit moveable in
relation to the stationary unit; a drive unit; a transmission
positioned between the mobile unit and the drive unit; and a
housing element that at least partially encloses the stationary
unit, the mobile unit, and the transmission; wherein the
transmission, the stationary unit, and the mobile unit are
contained in a cap housing element; wherein the stationary unit
includes at least two partial stator ring segments positioned at a
distance from each other to leave an air gap and at least one
stator distancing gap between them; and wherein the mobile unit
includes a ring magnet contained in a toothed wheel segment of the
transmission, the ring magnet being configured to move at least
partially in the air gap.
21. The device of claim 20, wherein the partial stator ring
segments and the ring magnet are positioned in the same plane at
least partially side-by-side.
22. The device of claim 20, wherein the partial stator ring
segments and the ring magnet are positioned vertically one on top
of the other.
23. The device of claim 20, wherein the stator distancing gap and
the air gap are integral.
24. The device of claim 20, wherein the toothed wheel segment is
constructed from plastic material into which the ring magnet is at
least partially molded.
25. The device of claim 20, wherein the cap housing element is
constructed from plastic material into which the partial stator
ring segments are at least partially molded.
26. The device of claim 20, wherein the toothed wheel segment is
coupled to a spring element.
27. The device of claim 20, wherein the cap housing element is
configured to be plugged onto the throttle valve housing, and
wherein the toothed wheel segment is configured to engage the
throttle valve shaft.
28. The device of claim 20, wherein the transmission comprises: a
toothed wheel segment; a motor sprocket wheel coupled with the
drive unit; an intermediate sprocket wheel; and an adjusting
sprocket wheel coupled to the intermediate sprocket wheel.
29. The device of claim 20, wherein the drive unit comprises a
motor that is at least partially enclosed by the cap housing
element.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of
position devices. More particularly, it concerns a position device
for a throttle valve unit, in which a throttle valve held by a
throttle valve shaft is arranged adjustably in a housing unit that
includes at least one Hall-effect angular rotation sensor unit that
is arranged on the throttle valve unit. The sensor unit includes a
stationary unit, a moving unit that can be moved relative to the
stationary unit, a drive unit, and a transmission that is arranged
between the moving unit and the drive unit. The housing unit
encloses, at least partially, the stationary unit and the moving
unit. Even more particularly, the invention concerns a Hall-effect
angular rotation sensor device that includes a stationary unit and
a moving unit that can be moved relative to the stationary unit.
The housing unit encloses, at least partially, the stationary unit
and the moving unit.
[0003] The present invention also relates generally to the field of
adjusting devices. More particularly, it concerns an adjusting
device for a throttle valve unit with a throttle valve, which is
adjustably contained with a throttle valve shaft in a throttle
valve housing. That housing contains at least a Hall-effect angular
rotation sensor unit that is coupled with the throttle valve unit
including: a stationary unit, a mobile unit that can be moved in
relation to the stationary unit, a drive unit, a transmission that
is positioned between the mobile unit and the drive unit, and a
housing element that encloses at least partially the stationary and
the mobile units and the transmission.
[0004] 2. Description of Related Art
[0005] An adjusting device of particular interest is described in
WO 95 14 911 A1. It consists of a throttle valve that is enclosed
by a throttle valve housing. The throttle valve with a throttle
valve shaft is arranged rotatably in the throttle valve housing. An
angular rotation sensor, a transmission unit, and a motor unit
(that are connected to each other) are arranged in a sensor
housing. A specially-configured housing for electronic components
contains a circuit unit separately. The individual housings can be
stacked together. The angular rotation sensor consists of a
stationary element, relative to which a rotating element can be
moved. The stationary element is a stator element consisting of two
partial, half-moon shaped stator elements, between which there is a
distancing gap in which a Hall sensor is located. The rotating
element is a ring magnet element that is retained by a magnet
retaining unit connected to a shaft.
[0006] Although this adjusting device has exhibited at least a
degree of utility, its assembly expense may be very high. In
addition, it is not possible to mount the angular rotation sensor,
the motor, and the transmission easily on different types of
throttle valve units.
[0007] In WO 98 55 828 A1 an angular rotation sensor is described
in which stator elements and a magnet element are configured in the
shape of partial ring segments. While this configuration reduces
the quantity of material needed to produce these parts,
manufacturing and assembly costs may be very high.
[0008] Accordingly, and in view of the shortcomings listed above,
it would be advantageous to develop an adjusting device and an
angular rotation sensor device that are easy to manufacture, easy
to assemble, and easy to connect. This task is solved by a position
device and by an angular rotation sensor device according to the
present disclosure.
SUMMARY OF THE INVENTION
[0009] Certain advantages accomplished by the invention reside in
that stator elements may be configured as partial ring stator
segments, and a ring magnet element may be configured as a partial
ring magnet segment. Such a design advantageously saves material.
The integration of these parts into units of an angular rotation
sensor makes subsequent adjustments unnecessary, saving valuable
assembly time. The special configuration of the partial ring magnet
segment and a three-piece division of the stator into three partial
ring stator segments (and their special correlation with each
other) constitutes an advantageous design of an angular rotation
sensor. Such a design makes highly precise measurements
possible.
[0010] In an angular rotation sensor device according to one
embodiment of the present disclosure, the moving element may be a
toothed gear segment of a transmission. This toothed gear segment
may be mounted on a throttle valve shaft of a throttle valve. The
movable element, however, may also be configured in a different way
and may be part of another device (e.g., part of a belt tightener
or the like). The variable configuration of the rotatable element
makes it possible to combine it with a multitude of different
systems used to measure an angle of rotation.
[0011] In one embodiment, the first and the second partial ring
stator segments, as well as the partial ring magnet segment and the
third partial ring stator segment, may be positioned in one plane
at least partially side by side. In another embodiment, they may be
positioned at least partially on top of each other. With the
benefit of the present disclosure, it will be apparent to those
having skill in the art that other configurations may also be
utilized.
[0012] In one embodiment, when the toothed gear segment rotates
from a zero position to an end position, the partial ring magnet
segment and the third partial ring stator segment may assume a
position relative to the first and the second partial ring stator
segments in which they are positioned at least partially
overlapping each other in a zero position and almost completely
overlapping each other in an end position. With partial segments
that lie in one plane, the partial ring magnet segment and the
third partial ring stator segment move like a sickle past the first
and second partial ring stator segments (that also act like a
sickle), starting at the tips, and past each other either side by
side or one underneath the other, until they reach the ends of the
two sickles. In this embodiment, the Hall-effect IC switch is
positioned at the most effective point of movement of these two
sickle-shaped partial elements.
[0013] The first and the second partial ring stator segments, as
well as the partial ring magnet segment and the third partial ring
stator segment, feature sickles that are as long as a segment of a
circle between about 80.degree. and about 180.degree.. In one
embodiment, a circle segment of about 115.degree. was found to be
the variant that is optimum for measuring.
[0014] In one embodiment, the partial ring magnet segment may be
configured as a magnet of opposite polarity. This reduces the total
height of the angular rotation sensor device by about one-half. In
one embodiment, the angular rotation sensor device with its parts
and transmission may be enclosed, at least partially, by a sensor
housing element of the housing unit. The toothed gear segment may
be coupled in the sensor housing element to a spring element that
is also contained in the sensor housing element. This guarantees a
well-defined end position.
[0015] In order to be able to better adjust individual parts,
plastic material may be used. If the sensor housing element is
molded out of plastic material, the first and the second partial
ring stator segments may be molded into it during the same molding
process. When forming the toothed gear segment out of plastic
material, the partial ring magnet segment and the third partial
ring stator segment may be molded into the plastic material as
well. Molding into plastic saves additional adjusting effort and
facilitates the main assembly of the basic elements of the angular
rotation sensor device.
[0016] In one embodiment, the throttle valve with the throttle
valve shaft may be contained in a throttle valve housing of the
housing unit. The sensor housing element may be placed on the
throttle valve housing, and the toothed gear segment may be plugged
onto the throttle valve shaft. Such a two-piece configuration makes
it possible to manufacture an angular rotation sensor with a
transmission, etc. at a different site than the site where the
throttle valve unit is produced. The prefabricated units may then
be assembled at the site of the throttle valve manufacturer or at a
different site. In this fashion, it is possible to manufacture
large quantities and to optimize the final unit cost.
[0017] In one embodiment, the sensor housing element may be
configured as a housing cap. Such a housing cap element may be put
on the throttle valve housing as a sealing element. In another
embodiment, the sensor housing element itself may feature a cap
that may be used to close it. In an embodiment in which the first
and second partial stator ring elements are positioned on top of
each other, those elements may also be molded into a cap, at least
partially.
[0018] In one embodiment, the sensor housing element and the
throttle valve housing may be coupled to each other. The coupling
may be realized through any methodology known in the art including,
but not limited to, screws, an additional bar, or the like.
[0019] In one embodiment, the first, second, and third partial ring
stator segments may include a ferrous material. Select steels or
any other suitable material may also be used. In this embodiment,
the partial ring magnet segment and the third partial ring stator
element may be shaped as a single piece. Subsequently, the partial
ring magnet segment may be configured as a magnet of opposite
polarity using magnetizing procedures as known in the art.
[0020] In one embodiment, the transmission may be configured
conventionally or with magnetic gearing. The transmission may
include the following components: a toothed gear segment, a motor
bevel gear coupled to the drive unit, an intermediate bevel gear,
and an adjusting bevel gear that may be coupled to the intermediate
bevel gear and which may be held rotatably in the sensor housing
element. The toothed gear segment may engage the adjusting bevel
gear, and the motor bevel gear may engage the intermediate bevel
gear.
[0021] In one embodiment, the drive unit may be a motor that is at
least partially enclosed by the sensor housing element. However, it
is also possible that the motor, which may be enclosed by an
external housing, may be coupled to the cap housing element. In
both embodiments, a configuration results that may be coupled in an
easy manner to a separately manufactured throttle valve unit.
[0022] Further advantages accomplished through the present
invention reside in particular in that the transmission, the
stationary, and the mobile unit may be contained together in a
housing cap element. This makes it possible to pre-assemble and
manufacture this component independently from the location of the
manufacturer of the throttle valve unit. The fully equipped cap
housing element may be easily adapted and coupled to a wide variety
of different throttle valve units. Another rather significant
advantage is that the mobile unit may be retained in the toothed
wheel segment of the transmission. This saves space and simplifies
the adjustment of the mobile unit. The ring magnet that is
configured in the shape of a partial ring may be easily retained in
the toothed wheel segment, and a positive interaction between these
ring magnets and partial stator ring segments is guaranteed. The
toothed wheel segment, which can be used instead of a fully
circular toothed wheel, secures the firm position and the function
of the sensor.
[0023] The partial stator ring segments and the partially
ring-shaped ring magnets may be partially arranged side-by-side in
the same plane. The ring magnet segment moves like a sickle into
the air gap opening between the two partial stator ring segments,
and at the same time at least one Hall-IC probe is positioned in
the stator distancing gap.
[0024] The partial stator ring segments and the ring magnet segment
may also be arranged to be positioned one on top of the other. In
this configuration, the ring magnet segment moves within the air
gap opening between the two partial stator ring segments. One of
the two partial stator ring segments is subdivided into two
subdivisions, leaving the distancing gap open between them in which
at least one Hall-IC probe is positioned. In the stator distancing
gap one, two, or more Hall-IC probes may be positioned. Providing
several Hall-IC probes, on the one hand, increases functional
reliability through redundant systems, and on the other hand,
potential gradients of the Hall-IC probes that are offset from each
other by a certain angle may be registered and displayed.
[0025] The toothed wheel segment may be made from plastic material
into which the ring magnet may be molded. The cap housing element
may also be made from plastic material into which the partial
stator ring segments or the subdivided partial stator ring segments
may be at least partially molded. This secures the structural
integration of these parts that are very important for the function
and measuring precision of the angular rotation sensor. In this
manner, production effort is reduced to a minimum. These elements
may be precisely adjusted, making subsequent adjustments
superfluous.
[0026] The toothed wheel segment may be connected inside the cap
housing element by a spring element that is also contained in the
cap housing element. This guarantees that when the drive unit is
switched off or if the throttle valve shaft does not move, the
sensor is moved to a well defined end position.
[0027] The connection between the housing cap element and the
throttle valve housing may be accomplished in at least two ways,
although other ways will be apparent to those having skill in the
art with the benefit of the present disclosure. In one embodiment,
the housing cap element may be put on top of the throttle valve
housing, thus forming a complete housing. When putting the cap down
simultaneously, the toothed wheel segment is plugged onto the
throttle valve shaft. The completely equipped, readily supplied
housing cap element thus requires only one assembly manipulation in
order to attach it to the throttle valve unit, producing in this
manner a functional whole. In another embodiment variant, the
housing cap element encloses all functional units, i.e., the
transmission, the partial stator ring segments, the subdivided
partial stator ring segments (if these are used), one or several
Hall-IC probes, and the ring-segment-shaped ring magnet. This
housing cap element is coupled to the throttle valve housing by a
bracket or other device, so both parts form a unit.
[0028] The transmission may be realized as a conventional
transmission or as a planetary gear. In one embodiment, the
transmission includes a the toothed wheel segment, a motor sprocket
wheel that is coupled with the drive unit, an intermediate sprocket
wheel, and an adjusting sprocket wheel coupled to the intermediate
sprocket wheel that can be rotatably retained in the cap housing
element, with the toothed wheel segment engaging the adjusting
sprocket wheel, and with the motor sprocket wheel engaging the
intermediate sprocket wheel.
[0029] In one embodiment, the drive unit may be a motor that is at
least partially enclosed by the cap housing element. However, it is
also possible to couple the motor, which is enclosed in an external
housing, with the cap housing element. In both cases, a structural
unit results that can be connected in a simple way with a
separately manufactured throttle valve unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The following drawings form part of the present
specification and are included to further demonstrate certain
aspects of the present invention. The invention may be better
understood by reference to one or more of these drawings in
combination with the detailed description of specific embodiments
presented herein. In the figures below, like reference numerals
have been applied to like elements. However, the use of different
reference numerals should not be interpreted as necessarily
implying dissimilar elements.
[0031] FIG. 1a shows a first embodiment of an angular rotation
sensor device with an open sensor housing element coupled to a
throttle valve unit in a schematic perspective view.
[0032] FIG. 1b shows a detailed view of an angular rotation sensor
device according to FIG. 1a.
[0033] FIG. 2a shows a second embodiment of an angular rotation
sensor device with an open sensor housing element connected to a
throttle valve unit in a schematic perspective view.
[0034] FIG. 2b shows a detailed view of an angular rotation sensor
device according to FIG. 2a.
[0035] FIG. 3 shows a first embodiment of a throttle valve angular
rotation sensor that is firmly coupled to a throttle valve unit
with an open cap housing element in a schematic perspective
view.
[0036] FIG. 4 shows a second embodiment of a throttle valve angular
rotation sensor that is coupled with a throttle valve unit with an
open cap housing element in a schematic perspective view.
[0037] FIG. 5 shows a throttle valve angular rotation sensor
according to FIG. 3 in a schematic side view.
[0038] FIG. 6 shows a throttle valve angular rotation sensor
according to FIG. 3 in a schematic bird's eye view.
[0039] FIG. 7 shows a throttle valve angular rotation sensor
according to FIG. 3 in a schematic rear view.
[0040] FIG. 8 shows an enlarged detail of a throttle valve angular
rotation sensor according to FIGS. 3 and 5-7 in a schematic bird's
eye view.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0041] In FIG. 1a, a throttle valve angular rotation sensor is
shown with an angular rotation sensor device 100. It includes an
angular rotation sensor device and a throttle valve unit including
a throttle valve housing 7 and a throttle valve 8 that is retained
in the throttle valve housing 7 and can be adjusted via a throttle
valve shaft 10. A sensor housing element 6, which carries a motor
9, is arranged on the throttle valve housing 7. The sensor housing
element 6 may, in one embodiment, be manufactured as an enclosed
component but it will be understood that it may be manufactured in
many different manners. For instance, in another embodiment, it may
be manufactured as an open component, as shown in FIG. 1a, that may
be subsequently closed with a separate cap.
[0042] The sensor housing element 6 contains a transmission 1, a
stationary unit 2, 3, 4, and a rotating unit 3', 5 of an angular
rotation sensor. The transmission 1 may be configured as a
conventional transmission or as a planetary gear. It includes a
motor bevel gear 13 that is coupled to a shaft of the motor 9. The
motor bevel gear 13 engages the intermediate bevel gear 12, below
which an adjusting bevel gear 14 is positioned. The adjusting bevel
gear 14 engages a toothed gear segment 11 that is coupled to the
throttle valve shaft. The toothed gear segment may be configured as
a circular disc that features toothing 17 (See FIG. 2a for a better
view) in one segment.
[0043] The configuration of the stationary and the moving units is
important. As shown in FIG. 1b in particular, the stator unit is
formed by two opposing partial ring stator segments 2 and 3. The
partial ring stator segments 2 and 3 are retained in a sensor
housing element 6. Between the two partial ring stator segments 2
and 3, there is a distancing gap 16 at the end of which, as FIG. 1a
shows, there is a Hall-effect IC switch (ASIC) 4.
[0044] The partial toothing 17 of toothed gear segment 11 engages
the adjusting bevel gear 14. The toothed gear segment 11 is coupled
to a spring that is retained in the sensor housing element 6. This
guarantees that the toothed gear segment 11 always rotates to a
defined end position. By rotating the toothed gear segment 11 to
the given end position, it is guaranteed that the angular rotation
sensor device 100 also assumes a defined end position.
[0045] A partial ring magnet segment 5, and behind it a partial
ring stator segment 3', are molded into the toothed gear segment 11
in an appropriate and precise position. The partial ring magnet
segment 5 and the partial ring stator segment 3' may be shaped as
one piece out of a ferrous material. The section containing the
partial ring magnet segment 5 is then formed by means of a
magnetizing process as is known in the art. The partial ring magnet
segment 5 may be magnetized with opposite polarity. In this manner,
the total height of construction of the angular rotation sensor
device may be reduced by approximately half. The toothed gear
segment 11 itself may be made from plastic material so that both
segments 3' and 5' may be molded with great precision and in the
exact position.
[0046] The two partial ring stator segments 2 and 3, and the
partial ring stator segment 3' and the partial ring magnet segment
5, are configured as segments of a circle. In one embodiment, the
segment of a circle has an angle that may be between about
80.degree. and about 180.degree. although other ranges of angles
may be suitable as well. As a result of tests, it has been
established that a greater than about a quarter circle segment of
about 115.degree. produces the most accurate measuring results.
This produces two opposing, sickle-shaped configurations.
[0047] When rotating the toothed gear segment 11, the sickle-shaped
configuration formed by the two partial ring stator segments 2 and
3, beginning with the tip of its sickle, and the sickle-shaped
configuration formed by the partial ring magnet segment 5 and the
third partial ring stator segment 3', move past each other leaving
an air gap 15 between them. The zero position of the toothed gear
segment 11 is shown in FIG. 1a. In this position, the tips of the
two sickles 2 and 3, and 3' and 5, overlap each other only
minimally. When the toothed gear segment rotates into its end
position, the two partial ring stator segments 2 and 3 rotate
enough to assume an almost completely overlapping position with the
partial ring magnet segment 5 and the partial ring stator segment
3' located behind it. The Hall-effect IC switch (ASIC) 4 is
positioned at the end of the movement, as FIG. 1a illustrates.
Rotating the two sickle-shaped units against each other from the
zero position to the end position generates a variable Hall voltage
that corresponds to the various angle positions.
[0048] In an angular rotation sensor device shown in FIGS. 2a and
2b, the transmission 1 and also the toothed gear segment 11 of the
transmission are configured in a way similar to that in FIG. 1a.
Also, the toothed gear segment is coupled to the sensor housing
element with a spring that also guarantees a defined end
position.
[0049] The difference between the angular rotation sensor device
200 and the angular rotation sensor device 100 is clarified by FIG.
2b. Here, it becomes clear that the individual segments 2, 3, 3', 4
and 5 are positioned in a vertical arrangement, one above the
other.
[0050] In one embodiment, the partial ring stator segment 2 and the
partial ring stator segment 3 are at least partially molded into
the sensor housing element 6. Between them, there is the stator
distancing gap 16, in which the Hall-effect IC switch (ASIC) 4 is
positioned. As in device 100, not only one, but two Hall-effect IC
switches 4 may be positioned in the stator distancing gap 16. This
makes it possible to measure two angularly-offset voltages. The
second probe 4, however, may also be installed for reasons of
redundancy, thus significantly increasing reliability and measuring
precision. If the sensor housing element 6 features a separate cap,
the two partial ring stator segments 2 and 3 may be molded into
this cap.
[0051] The partial ring stator segment 3', and above it the partial
ring magnet segment 5, may be molded into the toothed gear segment
11 and retained in this manner. There is an air gap 15 between the
partial ring stator segment 5 and the two partial ring stator
segments 2 and 3. Here too, the two partial ring stator segments 2,
3, and 3' may be made out of ferrous material, which has been
labeled with the designation Fe, the symbol for iron. The partial
ring stator segment 3' and the partial ring magnet segment S may be
molded as one piece, as is also the case in the angular rotation
sensor device 100. The partial ring magnet segment 5 may be
magnetized with opposite polarity, which has the positive effect of
reducing the entire height by approximately half.
[0052] FIG. 2a shows that here too, two sickle-shaped
configurations are generated that move more than a quarter of a
circle with a length that can be between about 80.degree. and about
180.degree. (or other ranges) but is here advantageously about
115.degree..
[0053] When these two sickle-shaped formations are rotated, the tip
of the sickle formed by the ring magnet segment 5 and the partial
ring stator segment 3' rotates underneath the sickle formed by the
two partial ring stator segments 2 and 3. When the toothed gear
segment rotates from a zero position to an end position, the two
sickles 3' and 5, and 2 and 3, are at least partially opposite
(i.e. their tips overlap somewhat) allowing the measurement of a
starting value. When the toothed gear segment 11 rotates into its
end position, the lower sickle formed by the partial ring stator
segment 3' and the partial ring magnet segment 5 is positioned
completely underneath the other sickle (i.e. almost completely
overlapping).
[0054] The motor 9 may either be enclosed in the sensor housing
element 6 or it may be coupled to it separately. The sensor housing
element 6 that contains either the angular rotation sensor device
100 or the angular rotation sensor device 200 may be formed in the
following way: the sensor housing element may be a complete housing
that is closed separately with a cap. This housing may be attached
directly to the throttle valve housing 7, as shown in FIGS. 1a and
2a. The sensor housing element 6 configured in this way, however,
may also be coupled to the throttle valve housing 7 by means of
connecting elements. When setting it on the throttle valve housing
in this manner, the toothed gear segment 11 may be plugged onto the
throttle valve shaft 10.
[0055] In another embodiment, the sensor housing element may be
configured like a cap that can close the throttle valve housing 7.
In such an embodiment, the toothed gear segment may be plugged onto
the throttle valve shaft 10.
[0056] The two embodiments mentioned above have the advantage that
the angular rotation sensor devices 100 or 200 (with and without
accessories such as a transmission, a motor unit, etc.) may be
assembled at a site that is different from the site where the
throttle valve unit with the throttle valve housing 7 and the
throttle valve 8, which is held rotatably by the throttle valve
shaft 10 in the housing 7, is assembled. In addition, another
important advantage is that the total height of the angular
rotation sensor device may be reduced by nearly half due to its
configuration. In this manner, the space that is available in a
motor compartment may be optimized. Molding the essential parts of
the angular rotation sensor device into the sensor housing element
6 or into the toothed gear segment 11 reduces the assembly effort
and the assembly time in comparison to conventional devices.
[0057] In FIG. 3, a throttle valve angular rotation sensor 120 is
shown. It includes a throttle valve unit including a throttle valve
housing 27 and a throttle valve 28 that is adjustably retained via
a throttle valve shaft 30 in a throttle valve housing 27.
[0058] As FIGS. 3-7 show, a cap housing element 26 carrying a motor
29 is positioned on top of the throttle valve housing 27. The cap
housing element 26 may be manufactured as a closed component. It
can also be manufactured in an open configuration that is then
closed by a separate cap. In the cap housing element are contained
a transmission 21, a stationary unit 22, 23, 24 and a rotating unit
25.
[0059] The transmission 21 may be configured as a conventional
transmission or as a planetary gear. It includes a motor sprocket
wheel 33 that is coupled to the shaft of the motor 29. The motor
sprocket wheel operates in conjunction with an intermediate
sprocket wheel 32 to the bottom side (see also FIG. 8) of which an
adjusting sprocket wheel 34 is positioned. The adjusting sprocket
wheel 34, on its part, operates in conjunction with a toothed wheel
segment 31 that is coupled with the throttle valve shaft.
[0060] The configuration of the stationary and the mobile units is
very important. As FIG. 8 shows, the stationary unit is formed by
two partial stator ring segments 22 and 23 that are positioned
opposite from each other. The partial stator ring segments 22 and
23 are retained in the housing element 26. An air gap 35 exists
between the two partial stator ring segments 22 and 23 that is
simultaneously a stator distancing gap and at the end of which a
Hall-IC probe (ASIC) 24 is positioned.
[0061] The toothed wheel segment 31 engages the adjusting sprocket
wheel 34 over approximately one third of its circumference with
both toothed wheels having toothing 37. The toothed wheel segment
31 is coupled by a spring that is retained in the cap housing
element 26. This guarantees that the toothed wheel segment 31 is
always rotated into a defined end position. When rotating the
toothed wheel segment 31 into the end position, it is made sure
that the throttle valve angular rotation sensor 120 also assumes a
defined end position.
[0062] Opposite from the toothed segment of the toothed wheel
segment 31, another circular segment is positioned that maintains a
distance to the partial stator ring segment 23. Into one side of
this segment, a ring magnet 25 is molded that is configured in the
shape of a segment of a circle. Since the toothed wheel segment 31
may be made out of plastic material, the ring magnet 25, that is
configured in the shape of a segment of a circle, may be molded in
precisely the correct position. When the toothed wheel segment 31
rotates the ring magnet, configured in the shape of a half circle,
it moves like a sickle into the gap marked with designations 35 and
36, and in this manner generates a variable Hall voltage.
[0063] In a throttle valve angular rotation sensor 220, shown in
FIG. 4, the transmission 21 and also the toothed wheel segment 31
of the transmission are configured as shown in FIG. 3. However,
here the partial stator ring segments 22 and 23, and the ring
magnet 25, are not positioned in the same plane, but vertically on
top of each other. Specifically, the partial stator ring segment 22
is subdivided into two sub-partial stator ring segments 22.1 and
22.2 (not shown). Between the two sub-partial stator ring segments
22.1 and 22.2, the stator distancing gap 36 opens up into which the
Hall-IC probe (ASIC) 24 is inserted. It is also possible to create
two gaps 36 by further subdividing the partial stator ring segment
22, and in this manner to be in a position to register two output
potential gradients of the Hall-IC probe that are offset by a
certain angle.
[0064] An air gap 35 opens between the two sub-partial stator ring
segments 22.1 and 22.2 and the partial stator ring segment 23,
positioned below them. The ring magnet 25 moves in this air gap and
is retained by the toothed wheel segment 27. By molding the ring
magnet 25 into the toothed wheel segment 31 that is made out of
plastic material, and by molding the sub-partial stator ring
segments 22.1 and 22.2 and the partial stator ring segment 23 into
the cap housing element 6 that is also molded from plastic
material, the precise adjustment of the parts of the sensor that
are important for the exactness of measurements may be secured.
[0065] The cap housing element 26 may be configured like the
housing cap that contains the described parts of the sensor 120 or
220. In addition, the cap housing element 26 may also contain the
motor 29. However, it is also possible to enclose the motor 29 in a
separate housing which is then flanged to the throttle valve
housing 27. A throttle valve angular rotation sensor 120 or 220
with such a throttle valve housing 27 may be manufactured in a
location that is different from that where the throttle valve unit
is manufactured, and can be subsequently put on the throttle valve
unit. When putting the cap housing element 26 on the throttle valve
housing 27 simultaneously, the throttle valve shaft engages the
toothed wheel segment 31 or a clutch unit, permitting the sensor to
be combined with the throttle valve in a single manipulation.
[0066] In other embodiments, it is possible to manufacture the cap
housing element 26 as a flat cylindrical box that may be closed
with a separate cap, as shown in FIGS. 3 and 4, and that also
contains the described elements of the throttle valve angular
rotation sensor 120 or 220. In this case, it is possible to connect
the cap with the throttle valve housing by plugging one onto the
other while at the same time engaging the throttle valve shaft of
the throttle valve. But it is also possible to prefabricate the
throttle valve housing and the cap housing element as a unit and
subsequently equip them as required.
[0067] All of the methods and apparatus disclosed and claimed
herein can be made and executed without undue experimentation in
light of the present disclosure. While the techniques of this
invention have been described in terms of specific embodiments, it
will be apparent to those of skill in the art that variations may
be applied to the techniques described herein without departing
from the concept, spirit and scope of the invention. All such
modifications apparent to those skilled in the art are deemed to be
within the spirit, scope and concept of the invention as defined by
the appended claims.
* * * * *