U.S. patent application number 11/183777 was filed with the patent office on 2005-11-10 for magnetic torque sensor including integral sub-unit.
Invention is credited to Fukaya, Shigetoshi, Nakane, Naoki, Sugimura, Kiyoshi, Takeda, Kenji.
Application Number | 20050247139 11/183777 |
Document ID | / |
Family ID | 27767214 |
Filed Date | 2005-11-10 |
United States Patent
Application |
20050247139 |
Kind Code |
A1 |
Sugimura, Kiyoshi ; et
al. |
November 10, 2005 |
Magnetic torque sensor including integral sub-unit
Abstract
A pair of magnetic flux collecting rings and a magnetic sensor
are integrally covered by a molded resin to form a sub unit of a
torque sensor. The pair of rings and sensors are integrated and are
in contact with each other, i.e., the magnetic sensor is held in
between respective magnetic flux collecting portions of the rings
without any air gap formed therebetween. Magnetic flux collected by
the rings can be detected by the magnetic sensor to a maximum
degree, whereby the signal output of the magnetic sensor is
enhanced and made stable.
Inventors: |
Sugimura, Kiyoshi;
(Toyoake-city, JP) ; Nakane, Naoki; (Toyota-city,
JP) ; Fukaya, Shigetoshi; (Toyota-city, JP) ;
Takeda, Kenji; (Okazaki-city, JP) |
Correspondence
Address: |
POSZ LAW GROUP, PLC
12040 SOUTH LAKES DRIVE
SUITE 101
RESTON
VA
20191
US
|
Family ID: |
27767214 |
Appl. No.: |
11/183777 |
Filed: |
July 19, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11183777 |
Jul 19, 2005 |
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11043074 |
Jan 27, 2005 |
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11043074 |
Jan 27, 2005 |
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10374104 |
Feb 27, 2003 |
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6868744 |
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Current U.S.
Class: |
73/862.331 ;
310/257 |
Current CPC
Class: |
G01L 3/104 20130101;
G01L 5/221 20130101 |
Class at
Publication: |
073/862.331 ;
310/257 |
International
Class: |
H02K 001/12 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 7, 2002 |
JP |
2002-61260 |
Sep 27, 2002 |
JP |
2002-283425 |
Claims
1-9. (canceled)
10. A torque sensor comprising: a torsion bar having a first end
connected to a first shaft and a second end connected to a second
shaft for converting a torque applied between the first shaft and
second shafts into a torsional displacement; a multi-pole magnet
fixed to one of the first and second shafts and the first end of
the torsion bar; a multi-pole yoke fixed to one of the first and
second shafts and the second end of the torsion bar for forming a
magnetic circuit within a magnetic field generated by the
multi-pole magnet; a pair of magnetic flux collecting members for
collecting a magnetic flux from the multi-pole yoke; a magnetic
sensor in magnetic communication with said pair of magnetic flux
collecting members for detecting an intensity of the magnetic field
generated by the multi-pole magnet; a first molded part formed to
integrally include at least a portion of the magnetic sensor; and a
second molded part formed to integrally include at least a portion
of the pair of magnetic flux collecting members and including a
holder portion holding the first molded part.
11. The torque sensor according to claim 10, wherein the holder
portion of the second molded part includes a guide groove receiving
at least a portion of the first molded part.
12. The torque sensor according to claim 10, wherein the second
molded part further includes a snap fit portion securely retaining
the first molded part within the holder portion of the second
molded part.
13. The torque sensor according to claim 10, wherein the first
molded part includes a back portion supporting a lead wire for
connecting the magnetic sensor to an electric control unit and
engaging the holder portion of the second molded part.
14. The torque sensor according to claim 13, wherein the first
molded part further includes a seat portion supporting the magnetic
sensor in a hole of the second molded part.
15. The torque sensor according to claim 10, wherein the magnetic
sensor includes two magnetic sensors located side by side.
16. The torque sensor according to claim 10, wherein the pair of
magnetic flux collecting members are formed in one of a ring shape
and a semi-circular shape.
17. A torque sensor comprising: a torsion bar having a first end
connected to a first shaft and a second end connected to a second
shaft for converting a torque applied between the first shaft and
second shafts into a torsional displacement; a multi-pole magnet
fixed to one of the first and second shafts and the first end of
the torsion bar; a multi-pole yoke fixed to one of the first and
second shafts and the second end of the torsion bar for forming a
magnetic circuit within a magnetic field generated by the
multi-pole magnet; a first resin-molded part that includes a pair
of magnetic flux collecting members for collecting a magnetic flux
from the multi-pole yoke; a second resin-molded part that includes:
a magnetic sensor in magnetic communication with said pair of
magnetic flux collecting members for detecting an intensity of the
magnetic field generated by the multi-pole magnet; a holder portion
that holds the first molded part in engagement with the second
molded part.
18. The torque sensor according to claim 17, wherein the holder
portion includes a guide groove that receives a mating portion of
the first molded part.
19. The torque sensor according to claim 17, wherein the second
molded part further includes a snap fit portion that securely
retains the first molded part within the holder portion of the
second molded part.
20. The torque sensor according to claim 17, wherein the first
molded part includes a back portion that supports a lead wire for
connecting the magnetic sensor to an electric control unit and that
engages the holder portion of the second molded part.
21. The torque sensor according to claim 20, wherein the first
molded part further includes a seat portion that supports the
magnetic sensor in a hole of the second molded part.
22. The torque sensor according to claim 17, wherein the magnetic
sensor includes two magnetic sensors located side by side.
23. The torque sensor according to claim 17, wherein the pair of
magnetic flux collecting members are formed in one of a ring shape
and a semi-circular shape.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon, claims the benefit of
priority of, and incorporates by reference the contents of prior
Japanese Patent Application No. 2002-61260 filed on Mar. 7, 2002,
and No. 2002-283425 filed on Sep. 27, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a torque sensor for
detecting torque applied to a rotating shaft based on measurement
of changes in magnetic flux density or magnetic field
intensity.
[0004] 2. Description of the Related Art
[0005] The present inventors have filed a prior patent application
relating to a torque sensor (Japanese Patent Application No.
2001-316788, U.S. Patent Application Publication No. 2002-189371).
This torque sensor generally includes a torsion bar connecting an
input shaft and an output shaft, a multi-pole magnet fixed to one
end of this torsion bar, a pair of multi-pole yokes fixed to the
other end of the torsion bar and disposed inside a magnetic field
generated by the multi-pole magnet, a pair of magnetic flux
collecting rings for introducing magnetic flux from the multi-pole
yokes, and a magnetic sensor for detecting magnetic field intensity
via the rings.
[0006] The pair of magnetic flux collecting rings are each provided
with portions that have the function of collecting magnetic flux
directed from the multi-pole yokes, and these portions are arranged
opposite to each other. The magnetic sensor is interposed between
these mutually opposing magnetic flux collecting portions of the
rings. When the torsion bar is twisted, magnetic flux is generated
between the pair of multi-pole yokes due to a change in the
relative positional relationship between the multi-pole magnet and
multi-pole yokes in the circumferential direction. The magnetic
flux is collected by the pair of rings, and the magnetic sensor
detects the density of the magnetic flux.
[0007] It is crucial, in this torque sensor, to utilize the
magnetic flux collected by the rings as much as possible. However,
because the magnetic sensor is interposed between the magnetic flux
collecting portions of the rings, there exists a problem of
magnetic flux leakage through the inevitable air gaps between the
magnetic sensor and magnetic flux collecting portions. This leakage
causes a decrease in signal output from the sensor.
[0008] Another problem is that, since the air gaps in each and
every product cannot possibly be made constant because of slight
variations resulting from assembling tolerances, the signal output
from the sensors tends to be slightly different.
SUMMARY OF THE INVENTION
[0009] The present invention has been devised taking into
consideration the above circumstances, its object being to provide
a torque sensor capable of enhanced and stable signal output, which
is achieved by minimizing magnetic flux leakage.
[0010] To achieve the above object, the present invention provides
a torque sensor including a torsion bar coaxially connected at
opposite ends to a first shaft and a second shaft for converting
torque applied between both shafts into a torsional displacement.
Also provided are: a multi-pole magnet fixed to the first shaft or
one end of the torsion bar, a multi-pole yoke fixed to the second
shaft or the other end of the torsion bar for forming a magnetic
circuit within a magnetic field generated by the multi-pole magnet,
a pair of magnetic flux collecting members for collecting magnetic
flux from the multi-pole yoke, and a magnetic sensor for detecting
magnetic field intensity via the pair of magnetic flux collecting
members. The characteristic feature of this torque sensor is that
the magnetic sensor and the pair of magnetic flux collecting
members are assembled as one piece.
[0011] This construction enables the air gaps between the magnetic
flux collecting members and magnetic sensor to be minimal, whereby
the magnetic sensor can maximally detect collected magnetic
flux.
[0012] In the above torque sensor, the magnetic sensor and the pair
of magnetic flux collecting members may integrally be covered by a
molded resin, and a signal cable from the magnetic sensor and a
terminal connected to the signal cable may be embedded in the
molded resin. This construction integrates the magnetic sensor, the
pair of magnetic flux collecting members, and the terminal by the
molded resin, thereby facilitating assembly of these components to
a housing or the like. In the molded resin, a connector for holding
the terminal may also be integrally provided, thereby facilitating
assembly.
[0013] Alternatively, the torque sensor may have a lead wire for an
external electrical connection of the terminal, one end of which
lead wire is embedded in the molded resin and connected to the
terminal inside the molded resin. A reduction in cost can be
achieved by the omission of the connectors.
[0014] The pair of magnetic flux collecting members may be formed
either in a ring shape or in a semicircular shape. Ring-shaped
magnetic flux collecting members will prevent a displacement of
their axial centers relative to the multi-pole yokes, and thus can
reduce detecting errors of the magnetic sensor. The semicircular
design will offer better and easier assembly, since it allows
assembly along a radial direction.
[0015] The pair of magnetic flux collecting members and the
magnetic sensor may separately be molded of resin and assembled as
one piece. This construction will facilitate the positioning of the
magnetic flux collecting members and magnetic sensors relative to
each other.
[0016] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0018] FIG. 1A is a cross-sectional view of a sub unit of a torque
sensor according to a first embodiment of the present
invention;
[0019] FIG. 1B is a cross-sectional view of a sub unit of a torque
sensor according to a first embodiment of the present
invention;
[0020] FIG. 2A is a diagram for explaining the operation of the
torque sensor;
[0021] FIG. 2B is a diagram for explaining the operation of the
torque sensor;
[0022] FIG. 2C is a diagram for explaining the operation of the
torque sensor;
[0023] FIG. 3 is a cross-sectional view of the entire torque
sensor;
[0024] FIG. 4 is a schematic illustration of an electric power
steering system;
[0025] FIG. 5A is a cross-sectional view of a sub unit of a torque
sensor according to a second embodiment of the present
invention;
[0026] FIG. 5B is a cross-sectional view of a sub unit of a torque
sensor according to a second embodiment of the present
invention;
[0027] FIG. 6A is a cross-sectional view of an assembly of a
magnetic sensor and a pair of magnetic flux collecting rings
integrated with each other according to a third embodiment of the
present invention;
[0028] FIG. 6B is a cross-sectional view of an assembly of a
magnetic sensor and a pair of magnetic flux collecting rings
integrated with each other according to a third embodiment of the
present invention,
[0029] FIG. 6C is a plan view of the assembly as viewed from the
side of the magnetic sensor;
[0030] FIG. 7A is a cross-sectional view of a resin molded magnetic
sensor;
[0031] FIG. 7B is a front view of a resin molded magnetic
sensor;
[0032] FIG. 7C is a cross-sectional view of resin molded magnetic
flux collecting rings according to the third embodiment;
[0033] FIG. 7D is a front view of resin molded magnetic flux
collecting rings according to the third embodiment; and
[0034] FIG. 8 is a cross-sectional view of the entire torque sensor
according to the third embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] Preferred embodiments of the present invention will be
hereinafter described with reference to the accompanying drawings.
The following description of the preferred embodiments is merely
exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0036] (First Embodiment)
[0037] FIG. 1A and FIG. 1B are cross-sectional views of a sub unit
4 used in a torque sensor 1 including a magnetic sensor 2 and a
pair of magnetic flux collecting rings 3 according to a first
embodiment of the present invention.
[0038] The torque sensor 1 of this embodiment is employed, for
example, in an electric power steering system for a vehicle shown
in FIG. 4, for detecting steering power or torque applied to the
shaft of the steering 5, and outputting the detected torque to an
electric control unit (ECU) 6. The ECU 6 controls output of an
electric motor 7 according to the steering power detected by the
torque sensor 1.
[0039] As shown in FIG. 3, the torque sensor 1 is disposed between
an input shaft 8 and an output shaft 9 that constitute the steering
shaft. The torque sensor 1 is comprised of a torsion bar 10, a
multi-pole magnet 11, a pair of multi-pole yokes 12, a pair of
magnetic flux collecting rings 3, and a magnetic sensor 2.
[0040] The torsion bar 10 is a bar-like resilient member, and its
opposite axial ends are fixed to the input shaft 8 and output shaft
9 by pins 13, respectively. Application of steering torque to the
steering shaft produces a torsional displacement in the torsion bar
10 according to the torque. The multi-pole magnet 11 is formed in a
ring shape and composed of North and South poles alternately
arranged in a circumferential direction. The multi-pole magnet 11
is press-fitted and fixed to an outer circumference of either the
input shaft 8 or the output shaft 9.
[0041] The pair of multi-pole yokes 12 are ring-shaped and made of
a soft magnetic material. They each have a plurality of
circumferentially, equally spaced claws 12a, and are arranged such
that their respective claws 12a engage with each other with an air
gap between them, as shown in FIG. 2B. The pair of multi-pole yokes
12 are disposed close to the outer circumference of the multi-pole
magnet 11, and fixed to either of the input shaft 8 or the output
shaft 9 by a holder 14.
[0042] The multi-pole yokes 12 (12A, 12B) are positioned relative
to the multi-pole magnet 11 such that, when the torsion bar 10 is
not twisted, each axial center of the claws 12a of the multi-pole
yokes 12 (12A, 12B) coincides with a boundary between immediately
adjacent North and South poles of the multi-pole magnet 11 as shown
in FIG. 2B. Thus, the output voltage of the magnetic sensor 2 is
zero when no steering power is applied between the input shaft 8
and output shaft 9.
[0043] The pair of magnetic flux collecting rings 3 are made of the
same soft magnetic material as the multi-pole yokes 12 and are
disposed close to the outer circumference of the multi-pole yokes
12. The rings 3 have the function of collecting magnetic flux from
the multi-pole yokes 12. They are provided with respective
plate-like magnetic flux collecting portions 3a at one location in
the circumferential direction, which are arranged opposite to each
other. The magnetic sensor 2 is interposed between these magnetic
flux collecting portions 3a of the pair of rings 3 for detecting
the density of magnetic flux generated therebetween.
[0044] The magnetic flux collecting rings 3 and magnetic sensor 2
are integrally covered by a molded resin 15 to form the sub unit 4
as shown in FIG. 1A and FIG. 1B, which is assembled to a column
housing 16 that supports the steering shaft from an axial direction
(see FIG. 3). The rings 3 and sensor 2 are integrated such that the
magnetic sensor 2 is interposed between the magnetic flux
collecting portions 3a of the rings 3 without any gap therebetween,
i.e., they are in close contact with each other.
[0045] The sub unit 4 includes a terminal 17 that is connected to a
signal cable 2a of the magnetic sensor 2 and embedded in the molded
resin 15. A connector 18 for holding the terminal 17 is also
provided integrally in the molded resin 15.
[0046] The torque sensor of this embodiment operates as
follows:
[0047] When no steering torque is applied to the torsion bar 10,
there is no torsional displacement in the torsion bar 10. In this
state, each axial center of the claws 12a of the multi-pole yokes
12 coincides with each boundary between immediately adjacent North
and South poles of the multi-pole magnet 11, as shown in FIG. 2B.
The number of magnetic force lines extending from each of the North
poles of the multi-pole magnet 11 to each of the claws 12a of the
multi-pole yokes 12 is equal to that of the magnetic force lines
extending from each of the South poles to each of the claws 12a.
These magnetic force lines form closed loops, respectively, inside
each of the pair of multi-pole yokes 12A, 12B, and do not leak into
the air gap between both yokes. Thus the output of the magnetic
sensor 2 is zero at this time.
[0048] When steering torque is input to the steering shaft, causing
a torsional displacement in the torsion bar 10, the relative
positions of the multi-pole magnet 11 and the pair of multi-pole
yokes 12 are changed in a circumferential direction. The
circumferential displacement between each of the axial centers of
claws 12a and the boundary between adjacent North and South poles
of the multi-pole magnet 11 causes an increase in the number of
magnetic force lines of opposite polarity in each of the multi-pole
yokes 12A, 12B. Magnetic fluxes of opposite polarity are thus
generated between both yokes, which are directed by the rings 3
into their magnetic flux collecting portions 3a, and the sensor 2
detects the density of magnetic flux between the magnetic flux
collecting portions 3a.
[0049] As described above, the torque sensor 1 of this embodiment
has a sub unit 4 made up of a magnetic sensor 2 and a pair of
magnetic flux collecting rings 3 integrated therewith. Since the
sensor 2 is interposed between the magnetic flux collecting
portions 3a of the rings 3 in contact therewith, there is no air
gap formed between the sensor 2 and magnetic flux collecting
portions 3a. Therefore, the collected magnetic flux can maximally
be detected by the magnetic sensor 2. The sub unit 4 thus
contributes to more stable and enhanced signal output of the
magnetic sensor 2.
[0050] The sub unit 4 also provides a design for ease of assembly
to the column housing 16 or the like as compared to a conventional
torque sensor, because it enables the pair of magnetic flux
collecting rings 3 and magnetic sensor 2 to be readily assembled to
the column housing 16 from an axial direction as shown in FIG.
3.
[0051] Another advantage of the sub unit 4 is that, since it
includes the terminal 17 and the connector 18 for retaining the
terminal 17 that are both embedded in the molded resin 15, it
enables several relevant components such as rings 3, sensor 2,
terminals 17, and connectors 18 to be handled as one component,
thus facilitating management of components.
[0052] (Second Embodiment)
[0053] FIG. 5A and FIG. 5B are cross-sectional views of a sub unit
4 of a torque sensor according to a second embodiment of the
present invention. The magnetic flux collecting rings 3 in this sub
unit 4 are formed in a semicircular shape as can be seen from the
drawings. This configuration enables the sub unit 4 to be assembled
to the column housing 16 not only from an axial direction but also
from a radial direction. It offers even better assembly of the sub
unit 4 and allows more freedom of design for the column housing 16
and surrounding components.
[0054] The rings 3, even in their semicircular form, can exhibit
equal magnetic flux collecting properties for directing magnetic
flux from the multi-pole yokes 12. The sub unit 4 of this
embodiment employs a lead wire 19 instead of the connector 18 in
the previous embodiment. One end of the lead wire 19 is embedded in
the molded resin 15 and is connected to the terminal 17 inside the
molded resin 15. This results in a cost reduction because the
connectors 18 are omitted.
[0055] (Third Embodiment)
[0056] FIG. 6A and FIG. 6B are cross-sectional views of an assembly
of a magnetic sensor 2 and a pair of magnetic flux collecting rings
3 integrated therewith according to a third embodiment of the
present invention. FIG. 6C is a top, plan view of the assembly
viewed from the side of the magnetic sensor 2.
[0057] In this embodiment, the magnetic sensor 2 and the pair of
magnetic flux collecting rings 3 are each resin molded before being
assembled into one piece. Two sensors 2 are arranged side by side
and the portions connected to their respective lead wires 19 are
resin molded as shown in FIG. 7B. The sensor mold 20, which is the
resin molded portion of the sensors, is formed in an L-shape in
cross section and has a seat portion 20a and a back portion 20b as
shown in FIG. 7A. The two magnetic sensors 2 project from a bottom
face of the seat portion 20a, and the ends of the lead wires 19
extend from a top end face of the back portion 20b.
[0058] The pair of rings 3 are arranged such that their magnetic
flux collecting portions 3a face each other as shown in FIG. 7C,
and the outer circumferential sides of the rings are resin molded.
The mold 21 covers only the outer side and their inner
circumferential side is exposed. The mold 21 includes a holder
portion 21a and a snap fit portion 21b for holding the sensor mold
20 and a hole 21c for accommodating the magnetic sensors 2.
[0059] The holder portion 21a consists of a pair of extended bars
spaced apart a certain distance on an outer circumference of the
mold 21. In an inner face of the mutually facing bars of the holder
portion 21a are formed guide grooves 21d for guiding the back
portion 20b of the sensor mold 20.
[0060] The snap fit portion 21b also consists of a pair of bars
similarly to the holder portion 21a, that protrude on an outer
circumference of the mold 21. They are given a certain resiliency,
and provided with hooks 21e as shown in FIG. 7D at their distal
ends, for engaging with the seat portion 20a of the sensor mold 20
when the ring component is assembled to the sensor component.
[0061] The hole 21c communicates to a space between the mutually
facing magnetic flux collecting portions 3a of the pair of rings 3,
as shown in FIG. 7C. The distance between the mutually facing
magnetic flux collecting portions 3a is designed such as to give a
certain clearance between these portions and the magnetic sensors
2.
[0062] When the ring component and sensor component are assembled
into one piece, the magnetic sensors 2 are accommodated in the
space between the opposing magnetic flux collecting portions 3a of
the pair of rings 3, with the back portion 20b of the sensor mold
20 held by the holder portion 21a and the seat portion 20a of the
sensor mold 20 retained by the snap fit portion 21b, as shown in
FIG. 6B and FIG. 6C. This assembly, made up of the integrated rings
3 and sensors 2, is inserted and tightly held, as shown in FIG. 8,
between a column housing 16a supporting the input shaft 8 and
another column housing 16b supporting the output shaft 9.
[0063] According to the construction of this embodiment, since the
pair of rings 3 and magnetic sensors 2 are integrated into a
one-piece assembly, they can readily be positioned relative to each
other. That is, the magnetic sensors 2 can be arranged at a
predetermined location in the space between the two mutually facing
magnetic flux collecting portions 3a of the rings 3 simply by
inserting them into the hole 21c formed in the mold 21 covering the
rings 3.
[0064] Similar to the first embodiment, there is practically no air
gap formed between the magnetic sensors 2 and the magnetic flux
collecting portions 3a of the rings 3. Therefore, the collected
magnetic flux can be detected by the magnetic sensors 2 to a
maximum degree.
[0065] The description of the invention is merely exemplary in
nature and, thus, variations that do not depart from the gist of
the invention are intended to be within the scope of the invention.
Such variations are not to be regarded as a departure from the
spirit and scope of the invention.
* * * * *