TORQUE SENSOR HAVING INDUCTIVELY COUPLED, INTERMESHING COMPONENTS

Abstract

A torque sensor can measure torque introduced into an upper shaft that is rotatable around a longitudinal axis and is connectable to a lower shaft via a torsion rod. A first component is connectable to the upper shaft, and a second component is connectable to the lower shaft. The components have surfaces that protrude in a longitudinal direction and at least partially overlap. A sensor coil that can generate a high-frequency alternating magnetic field is arranged on one of the surfaces of one component, and a metallic element is arranged on one of the surfaces of the other component. A torque introduced into the upper shaft causes a change in distance between the sensor coil and the metallic element. A device can measure a frequency change of the alternating magnetic field caused by the change in distance and determine the torque introduced into the upper shaft.

Claims

1.-13. (canceled)

14. A torque sensor for measuring a torque introduced into an upper shaft of a motor vehicle, wherein the upper shaft is rotatable around a longitudinal axis and is connectable to a lower shaft via a torsion rod, wherein the torque sensor comprises: a first component intermeshing in a longitudinal direction of the longitudinal axis with a second component, wherein the first component is connectable to the upper shaft and the second component is connectable to the lower shaft, wherein the first and second components each have a surface that protrudes in the longitudinal direction, wherein the surfaces of the components at least partially overlap in the longitudinal direction; and a pair of sensors with a sensor coil configured to generate a high-frequency alternating magnetic field, wherein the sensor coil is arranged on the surface of one of the first or second components and a metallic element is arranged on the first surface of the other of the first or second components, wherein a torque introduced into the upper shaft causes a change in distance between the sensor coil and the metallic element; and a device configured to measure a frequency change of the high-frequency alternating magnetic field caused by the change in distance and determine the torque introduced into the upper shaft.

15. The torque sensor of claim 14 wherein each of the first and second components includes at least two surfaces that protrude in the longitudinal direction, wherein with respect to each of the first and second components a sensor coil is disposed on a first of the at least two surfaces and a metallic element that points away from the sensor coil is disposed on a second of the at least two surfaces.

16. The torque sensor of claim 15 wherein the sensor coil of one of the first or second components is spaced apart from and faces the metallic element of the other of the first or second components, wherein the metallic element of one of the first or second components is spaced apart from and faces the sensor coil of the other of the first or second components.

17. The torque sensor of claim 14 wherein the first component is substantially cylindrical and concentrically surrounds the upper shaft, wherein the second component is substantially cylindrical and concentrically surrounds the lower shaft.

18. The torque sensor of claim 14 wherein each of the first and second components includes a circular base plate from which a protrusion extends over a circular sector, wherein the protrusion and/or a lateral surface thereof forms the surface of each component and extends in the longitudinal direction and along a radius of the circular base plate.

19. The torque sensor of claim 18 wherein electronics of the device required for measuring the frequency change are disposed on a surface of the circular base plate.

20. The torque sensor of claim 18 comprising a WPT coil that is disposed on a surface of the circular base plate remote from the protrusion, with the WPT coil being configured to receive electrical energy inductively from a primary coil connected to a sensor housing.

21. The torque sensor of claim 18 comprising signal coupling coils disposed on a circumferential surface of the circular base plate, with the signal coupling coils being configured to transmit digital output signals of the pair of sensors to a secondary coil that is attached to a stationary sensor housing.

22. The torque sensor of claim 14 wherein the surface of the first and second components are flat.

23. The torque sensor of claim 14 comprising two protrusions that have a same design, wherein the two protrusions are disposed along a circumference symmetrically around the longitudinal axis.

24. The torque sensor of claim 14 wherein the first component is identical to the second component.

25. The torque sensor of claim 14 wherein power supply and transmission of measurement signals of the pair of sensors are wireless.

26. An electromechanical power steering system for a motor vehicle, comprising: an upper shaft connected to a steering wheel; a lower shaft connected to the upper shaft via a torsion rod; the torque sensor of claim 1; and an electric motor configured to support a steering movement introduced into the steering wheel by a driver based on a torque measured by the torque sensor.

Description

[0018] A preferred embodiment of the invention is explained in more detail below on the basis of the drawings. Identical or functionally identical components are provided with the same reference signs in the figures. In the figures:

[0019] FIG. 1: shows a schematic representation of an electromechanical power steering system,

[0020] FIG. 2: shows a longitudinal section through a torque sensor,

[0021] FIG. 3: shows a spatial view of the two components of the torque sensor,

[0022] FIG. 4: shows a longitudinal section through a torque sensor with electronics arranged on one side,

[0023] FIG. 5: shows a longitudinal section through a torque sensor with electronics arranged on one side with concentrically arranged WPT coils.

[0024] In FIG. 1, an electromechanical motor vehicle power steering system 1 with a steering wheel 2, which is rotationally fixedly coupled to an upper shaft 3, is schematically depicted. By means of the steering wheel 2, the driver introduces a corresponding torque into the upper shaft 3 as a steering command. The torque is then transferred via the upper shaft 3 and a lower shaft 30 to a steering pinion 4. The pinion 4 meshes in a known way with a toothed segment 50 of a rack 5. The steering pinion 4 together with the rack 5 forms a steering gear. The rack 5 is connected at its free ends to tie rods 6 via ball joints which are not shown. The tie rods 6 themselves are connected to a steered wheel 7 of the motor vehicle in a known manner via steering knuckles. A rotation of the steering wheel 2 leads via the connection of the steering shafts 3,30 and the pinion 4 to a longitudinal displacement of the rack 5 and thus to turning of the steered wheels 7. The steered wheels 7 experience a retroactive effect from a road 70, which counteracts the steering movement. To turn the wheels 7, therefore, a force is required, which requires a corresponding torque on the steering wheel 2. An electric motor 8 of a servo unit 9 is provided to assist the driver in this steering movement. The servo unit 9 can be coupled as an auxiliary power supporting device 9, 10, 11 either to a steering shaft 3, the steering pinion 4 or the rack 5. The respective auxiliary power supporting device 9,10,11 introduces an auxiliary torque into the steering shaft 3, the steering pinion 4 and/or into the rack 5, which supports the driver in the steering work. The three different auxiliary power supporting devices 9,10,11 shown in FIG. 1 show alternative positions for their arrangement. Usually, only one of the positions shown is occupied by an auxiliary power supporting device. The servo unit can be arranged as superposition steering on the steering column or as an auxiliary power supporting device on the pinion 4 or the rack 5.

[0025] FIGS. 2 and 3 show a torque sensor 12 of the electromechanical motor vehicle power steering system shown in FIG. 1, which has two cylindrical intermeshing components 13,14. The upper shaft 3 is connected to the lower shaft 30 via a torsion rod 15. A first component 13 is torsionally fixedly connected to the upper shaft 3 and a second component 14 is torsionally fixedly connected to the lower shaft 30. The two components 13,14 are connected to the corresponding shafts 3,30 at the opposite ends of the torsion rod 15 in the longitudinal direction. The components 13,14 surround the associated shaft 3,30 concentrically. They have a recess 16, preferably adapted to the outer shape of the shaft, which serves to attach the components 13,14 to the associated shaft. The two components 13,14 are identical. They have a base plate 17, which extends rotation-symmetrically around the longitudinal axis 100 of the shafts and from which two protrusions 18 protrude in the longitudinal direction on the same side. The protrusions 18 are arranged evenly distanced in the circumferential direction around the longitudinal axis 100 and extend along the radius from the recess 16 to the circumferential side 19 of the base plate. The protrusions 18 each preferably occupy a circular sector of less than 90°. The protrusions 18 can be of the same shape. At their two ends in the circumferential direction, the protrusions 18 each have flat surfaces 20,21 (end faces), which extend along the radius, over the entire height of the protrusions h.sub.v. On one of the two flat surfaces 20 of a respective protrusion, a metallic element 22, in particular a conductive material forming a conductive sensor surface, is arranged, and a sensor coil 23 is arranged on the other flat surface 21. Each component 13,14 thus has two sensor coils 23 and two conductive sensor surfaces 22. In the circumferential direction, a conductive sensor surface 22 of one of the protrusions 18 and a sensor coil 23 of the other protrusion 18 of a single component 13,14 are spaced apart from each other. The components 13,14 intermesh in the mounted state. The protrusions 18 of the first component 13 are arranged in the circumferential direction between the protrusions 18 of the second component 14, so that a sensor coil 23 of the first component is arranged directly opposite a conductive sensor surface 22 of the second component 14 in the circumferential direction and facing each other and vice versa. A conductive sensor surface 22 and a sensor coil 23 arranged in the immediate vicinity each form a sensor pair, so that a total of four such sensor pairs are present. The overlapping of a sensor coil 23 and a conductive sensor surface 22 of a sensor pair in the longitudinal direction 100 is preferably at least 80% in each case.

[0026] The two components 13,14 are attached at the two ends of the torsion rod to the upper and lower shaft 3,30, so that with increasing torque the components 13,14 turn relative to each other, wherein the distance between the conductive sensor surface 22 and the sensor coil 23 of two sensor pairs becomes larger and the distance between the conductive sensor surface 22 and the sensor coil 23 of the other two sensor pairs becomes smaller. If the conductive sensor surface 22 is closer to the sensor coil 23, the inductance of the sensor coil decreases. The magnetic field of the sensor coil 23 induces eddy currents in the conductive sensor surface 22, and these currents form their own magnetic field, which weakens the field of the sensor coil 23, as a result of which the mutual inductance decreases. If, on the other hand, the conductive sensor surface 22 is further away from the sensor coil 23, the inductance increases. The sensor pairs form an inductive sensor, which preferably has three main elements—an oscillator, which is a system oscillating by itself, a frequency measuring unit which both compares and evaluates the data and an output unit which converts the values into an electrical signal. During operation, the inductive sensors generate a high-frequency alternating magnetic field with the help of the sensor coil. The fact that induced eddy currents are produced causes a change in the impedance of the sensor coil. This impedance counteracts the magnetic field and is electronically converted into a switching signal. If a metallic object (conductive sensor surface) moves in the resulting magnetic field, an eddy current is induced in the object, which counteracts the magnetic field and thus withdraws energy. The frequency change caused by a changing inductance is measured using a sensor unit based on a reference oscillator.

[0027] The sensor coil is therefore preferably arranged in a parallel oscillating circuit with a loopback inverter, the output signal of which has a rectangular shape. The sensor coil excitation is preferably sinusoidal and allows a better frequency design with regard to the multiplexing of multiple channels. The frequency of this signal is the resonance frequency of the parallel LC oscillating circuit.

[0028] The movement of the two components 13,14 of the torque sensor relative to each other allows a simple distance measurement in differential form, which is a robust measurement and allows a direct measurement of the torque. All four sensor pairs are preferably evaluated for the measurement.

[0029] The electronics required for the frequency measurement 24 sit on the surface of the base plate 19. Since the components 13,14 rotate with a steering movement, the power supply and the transmission of the measuring signals are wireless. On the base plate 19, therefore, a WPT coil (secondary coil) 25 is provided on the end face away from the protrusion, which receives electrical energy inductively and thus contactlessly from a primary coil 27 connected to the sensor housing 26 and thus supplies the electronics of the associated component with power.

[0030] The circumferential surface of the base plate 19 carries signal coupling coils (primary coils) 28 for transmitting the digital output signals of the sensor pairs from the corresponding component 13,14 to a secondary coil 29, which is attached to the stationary sensor housing 26. The connection is preferably made via a serial interface, in particular by means of UART on the component side and an RX receiving unit 31 on the secondary coil side.

[0031] In another embodiment, it may be provided that the signal transmission and power transmission take place via a single common coil. It may also be generally provided that the wireless transmission of the output signals is carried out by means of capacitive elements.

[0032] FIG. 4 shows an exemplary embodiment in which the sensor coils 23 are arranged on a first of the two components 14 and the conductive sensor surfaces 22 are arranged on the second component 13. The first component 14 is thus an active element that requires a power supply and the second component 13 is a passive element that does not require a power supply. The electronics required for frequency measurement 24 sit on the surface of the base plate 19 of the first component 14. The power supply of the first component 14 is carried out by means of two WPT coils (secondary coils) 25. The first component 14 is preferably pot-shaped and the protrusion 18 described in the other exemplary embodiments sits inside a jacket 32 on the base plate 19. The second component 13 is designed as described above. It is completely surrounded circumferentially by the first component 14. A first WPT coil 25 is arranged on the end face of the jacket surface 32 of the first component 14 and a second WPT coil 25 is arranged on the end face of the base. The WPT coils 25 accordingly receive power from two primary coils 27 connected to the sensor housing 26 and associated with the WPT coils 25 and can thus supply the electronics of the first component with power.

[0033] The circumferential surface of the jacket 32 of the first component 14 carries two signal coupling coils (primary coils) 28 for the transmission of the digital output signals of the sensor pairs from the first component 14 to a respective secondary coil 29, which is attached to the stationary sensor housing 26.

[0034] FIG. 5 shows a further embodiment with which the sensor coils 23 are arranged on a first of the two components 14 and the conductive sensor surfaces 22 are arranged on the second component 13. Unlike the previous example, the two components 13,14 have essentially the same geometry. The power supply of the first component 14 is carried out by means of two WPT coils (secondary coils) 25, which are arranged in a concentric arrangement on the outer end face of the first component away from the protrusion. The WPT coils 25 receive power from two primary coils 27 connected to the sensor housing 26 and also concentrically arranged and can thus supply the electronics of the first component 14 with power.

[0035] The circumferential surface of the base plate 19 of the first component 14 carries two signal coupling coils (primary coils) 28 for the transmission of the digital output signals of the sensor pairs from the first component 13 to two secondary coils 29 attached to the stationary sensor housing 26. The connection is preferably made via a serial interface, in particular by means of RX receiving units 31 on the secondary coil side.

[0036] The exemplary embodiments shown in the figures comprise a total of four pairs of sensors. However, the principle is generally also applicable to the presence of at least two pairs of sensors. The more sensor pairs are provided, the higher the resolution of the torque measurement.