JP4851963B2 - Manufacturing method of rotation sensor - Google Patents

Description

The present invention relates to a rotation sensor for detecting a rotation position and a rotation speed of a rotating body such as an engine crankshaft, a camshaft, and an automobile wheel, and in particular, a front end portion is opposed to a detected rotating body such as a pulsar plate or a gear. in the synthetic resin holder that is, the Hall element from the front end side, related to the rotation sensor disposed the bias magnet and an electronic circuit unit, in particular a method for producing the same.

Such a rotation sensor is already known as disclosed in Patent Document 1 below.
JP 2003-307523 A

  In such a conventional rotation sensor, small chambers are arranged in front and back with a partition between the holders, and the Hall element and the bias magnet are respectively accommodated in these small chambers. It will be arranged with a partition between both small rooms.

  By the way, in order to improve the sensitivity of the rotation sensor, it is necessary to reduce the distance between the Hall element and the non-detection rotating body as much as possible. Since it is adsorbed by the partition wall and is recessed from the front end surface of the holder, it is difficult to close the space sufficiently by being obstructed by the front end portion of the holder. In addition, the presence of a partition wall integral with the holder between the Hall element and the bias magnet is not preferable for increasing the sensitivity of the rotation sensor.

The present invention has been made in view of such circumstances, and it is possible to sufficiently close the gap between the Hall element and the non-detection rotating body while bringing the Hall element into contact with the bias magnet, and in addition to the bias element. It is an object of the present invention to provide a method of manufacturing a rotation sensor with high sensitivity and high mass productivity that can cope with a change in the thickness of a magnet without changing its adjacent members.

To achieve the above object, the present invention is placed in a holder made of synthetic resin to be facing the front end portion to be detected rotating body, the Hall element from the front end side, a bias magnet and an electronic circuit unit, before Symbol An IC module is constituted by a Hall element and the electronic circuit unit and a lead frame connecting them, and a support surface and a sensing part protruding from the support surface are formed on the front surface of the Hall element. The bias magnet is brought into contact with the rear surface of the Hall element, and a first housing for housing the Hall element and the bias magnet is formed in the holder, and an opening for disposing a sensing unit at a front end portion of the first housing. parts and the supporting surface will be provided and abutted to the support wall, and a plurality of types of rotation sensors having different thickness of the bias magnet with the holder in common In producing,
An elastically deformable adjustment member that urges the bias magnet toward the support wall is interposed between the rear wall of the first housing and the bias magnet. The first feature is to absorb the thickness change of the bias magnet.

In addition to the first feature, the present invention uses, as the adjustment member , an elastic cylinder having a hollow portion open at both ends, and the opposite side walls of the elastic cylinder are provided as the rear wall of the first housing. said Ru is respectively resiliently abuts on the bias magnet and a second said.

Furthermore, in addition to the second feature, the present invention provides a pair of abutting walls that abut against the opposing surfaces of the rear wall of the first housing and the bias magnet, and the abutting walls. thereby connecting both ends to each other integrally, respectively, to a third feature of be composed of a pair of elastic connecting wall to exert an elastic force to bending possible extension direction.

Furthermore, in addition to any of the first to third features, the present invention further includes forming a second housing for housing the electronic circuit unit and a plurality of protrusions surrounding the electronic circuit unit in the holder , A fourth feature is that the electronic circuit unit is held in the second housing and the pressing state of the support surface against the support wall is held by a caulking portion formed by heat caulking of these protrusions .

According to the first aspect of the present invention, in manufacturing a plurality of types of rotation sensors having different thicknesses of the bias magnet while using a common holder, the rear wall of the first housing and the bias magnet are An elastically deformable adjusting member that biases the bias magnet toward the support wall is interposed, and the elastic deformation of the adjusting member absorbs changes in the thickness of multiple types of bias magnets. Multiple types of rotation sensors with different magnet thickness dimensions can be manufactured, and mass productivity can be improved.

In addition, in the manufactured plural types of rotation sensors, the bias magnet is biased forward by the elastic action of the adjusting member interposed between the rear wall of the first housing and the bias magnet, so that the hall The support surface of the element abuts and is held on the support wall of the holder, and the sensing part of the Hall element can be held at a fixed position of the opening. Can be sufficiently closed without being obstructed by the front end of the holder, and the sensitivity of the rotation sensor can be increased. In addition, since the bias magnet is brought into contact with the rear surface of the Hall element, it contributes to further improvement of the sensitivity and can stabilize the characteristics .

  According to the 2nd characteristic of this invention, an adjustment member can be comprised with an inexpensive elastic cylinder.

  According to the third feature of the present invention, by bending both elastic connecting walls of the elastic cylinder, the space between the two abutting walls is narrowed, and the elastic cylinder is placed between the rear wall of the housing and the bias magnet. Can be mounted easily and the assembly is good. After the mounting, the support surface of the Hall element can be brought into contact with and held by the support wall of the holder by the elastic force in the extending direction of both elastic connecting walls.

According to a fourth aspect of the present invention, by holding the electronic circuit unit to the second housing by crimping unit, it is firmly retain the contact between the supporting surface and the formal Da of the support wall of the Hall element it can.

  Embodiments of the present invention will be described below on the basis of preferred embodiments of the present invention shown in the accompanying drawings.

  1 is a side view showing a use state of the rotation sensor of the present invention, FIG. 2 is a perspective view showing the rotation sensor in a state before forming a resin mold protective layer, FIG. 3 is an exploded perspective view of the rotation sensor, and FIG. 1 is a plan view of FIG. 1, FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 4, and FIG. 6 is a view corresponding to FIG.

  First, in FIG. 1, for example, a pulsar plate P attached to an engine crankshaft or axle has a large number of protrusions Pa, such as gear teeth, formed on the outer peripheral surface thereof, and the front end thereof is closely opposed to the outer peripheral surface. The rotation sensor S of the present invention arranged as described above is attached to a crankcase or a fixed structure C of a vehicle body.

  In the description of the rotation sensor S, the front side refers to the pulsar plate P side, and the rear side refers to the side opposite to the pulsar plate P.

  As shown in FIGS. 2 to 4, the rotation sensor S includes a holder 1 made of synthetic resin, a hall element 2 sequentially arranged from the front end side of the holder 1, and a bias that abuts and attracts the hall element 2. A magnet 3, an adjustment member 15 for elastically biasing the bias magnet 3 forward and an electronic circuit unit 4 are provided. The electronic circuit unit 4 is formed by integrally integrating electronic components that control the Hall element 2 and process the detection signal of the Hall element 2. The electronic circuit unit 4 and the Hall element 2 are biased. The IC module 6 is configured by being connected via a plurality of front lead frames 5 passing through the upper side of the magnet 3. Coupled to the plurality of rear lead frames 7 protruding from the rear end of the electronic circuit unit 4 are a plurality of coupler terminals 8 bent in an L shape.

  On the front surface of the Hall element 2, a pair of left and right support surfaces 2a and a convex sensing portion 2b protruding from between the support surfaces 2a are formed.

  More specifically, the holder 1 includes a first housing 11 that houses the Hall element 2, the bias magnet 3, and the adjusting member 15, and a second housing 12 that houses the electronic circuit unit 4. It is provided side by side across the wall. The upper surface of the first housing 11 is open. In addition, the front portion of the first housing 11 abuts the opening 13 where the sensing portion 2b of the Hall element 2 is disposed, and the support surface 2a of the Hall element 2 side by side so as to sandwich the opening 13 between the left and right. The supporting wall 14 is formed. At this time, the thickness of the support wall 14 is set to be approximately equal to the protruding length of the sensing unit 2b.

  The bottom wall of the first housing 11 is provided with a mounting port 16 for mounting the adjusting member 15 between the rear wall 10 of the first housing 11, that is, between the partition wall 10 and the bias magnet 3. The adjustment member 15 includes an elastic cylinder 15 made of an elastic material such as rubber or synthetic resin. This elastic cylinder 15 has a hollow part open at both ends, and biases the bias magnet 3 forward by a repulsive force generated when the elastic cylinder 15 is compressed so as to crush the hollow part. The support surface 2 a of the element 2 is brought into contact with and held by the support wall 14.

  The elastic cylinder 15 is preferably configured as follows. That is, a pair of abutting walls 15a that abut each of the opposing surfaces of the rear wall 10 of the first housing 11 and the bias magnet 3, and a pair of elastic couplings that integrally connect the left and right ends of the abutting walls 15a. The length of the elastic connecting wall 15b in the front-rear direction is such that when the support surface 2a of the Hall element 2 is brought into contact with the support wall 14, the rear wall 10 of the first housing 11 and the bias magnet 3 Is set sufficiently larger than the gap formed between the two. Both connecting walls 15b can bend and stretch, and when bent, they exhibit elastic force in the extending direction.

  When the elastic cylinder 15 is mounted between the rear wall 10 of the first housing 11 and the bias magnet 3, the middle part of the left and right elastic connection walls 15b is brought close to each other by, for example, radio pliers. When the both elastic connecting walls 15b are bent in the shape of "<", the distance between the two abutting walls 15a is the distance between the rear wall 10 of the first housing 11 and the bias magnet 3. Narrower. Therefore, after the elastic cylinder 15 is inserted between the rear wall 10 of the first housing 11 and the bias magnet 3 from the mounting opening 16 of the holder 1, the two elastic connecting walls 15b in the bent state are released from the radio pliers. Both elastic connecting walls 15b are extended by their own elastic force, and are stretched between the rear wall 10 of the first housing 11 and the bias magnet 3, and eventually bias the bias magnet 3 forward, so that the Hall element 2 The support surface 2a is brought into contact with and held by the support wall 14.

  As shown in FIGS. 3 and 4, the electronic circuit unit 4 has a rectangular shape that is long in the front-rear direction in plan view, and is provided with cutouts 17 at right angles at the four corners. The second housing 12 of the holder 1 that accommodates the electronic circuit unit 4 has a rectangular shape with an open upper surface, and is formed integrally with the holder 1 at four corners of the second notch of the electronic circuit unit 4. Four protrusions 18 that are loosely engaged with 17 are arranged. These protrusions 18 are formed by pressing the support surface 2a of the Hall element 2 against the support wall 14 of the holder 1 with the repulsive action of the elastic cylinder 15 and then by heat caulking or punching, that is, around the periphery. The electronic circuit unit 4 is held by the enlarged caulking portion 18a.

  Thus, after the IC module 6, the bias magnet 3 and the adjustment member 15 are all assembled in the holder 1, the resin mold protective layer 20 covering the whole is formed (see FIGS. 2 and 6). At that time, the resin mold protective layer 20 covering the sensing portion 2b of the Hall element 2 and the front surface of the support wall 14 of the holder 1 is formed as thin as possible. A coupler 21 that accommodates and holds the coupler terminal 8 and a bracket 22 for mounting the rotation sensor S are integrally formed in the resin mold protective layer 20, and a metal collar 23 is embedded in the bracket 22. . The bracket 22 is bolted to the fixed structure C as shown in FIG.

  Next, the operation of this embodiment will be described. When the rotation sensor S is assembled, the bias magnet 3 is first brought into contact with and attracted to the rear surface of the Hall element 2 of the IC module 6, and the Hall element 2 and the bias magnet 3 are attached to the holder 1. The electronic circuit unit 4 is accommodated in the second housing 12 while being inserted into the first housing 11 and carrying the sensing portion 2 b of the Hall element 2 to the front opening 13 of the holder 1.

  Next, the adjusting member 15, that is, the elastic cylinder 15 is inserted between the rear wall 10 of the first housing 11 and the bias magnet 3 from the mounting opening 16 on the bottom wall of the first housing 11 as described above. If the two abutting walls 15a are stretched, the bias magnet 3 is urged forward to abut and hold the support surface 2a of the Hall element 2 against the support wall 14, and also the sensing portion 2b of the Hall element 2 Can be held at a fixed position of the opening 13. Therefore, the sensing unit 2b is substantially flush with the front end surface of the holder 1 without being inclined, and the sensing unit 2b is sensed when the front end of the rotation sensor S is brought close to the outer periphery of the pulsar plate P and the bracket 22 is attached to a fixed structure (not shown). The portion 2b can increase the sensitivity of the rotation sensor S by sufficiently filling the gap with the pulsar plate P without being obstructed by the front end portion of the holder 1 while maintaining an appropriate posture. In addition, the bias magnet 3 being in contact with and attracted to the rear surface of the Hall element 2 contributes to further improvement in sensitivity and can also stabilize the characteristics. In addition, since the Hall element 2, the bias magnet 3, and the adjusting member 15 are accommodated in the common first housing 11, the structure of the holder 1 is simplified, which contributes to improving the moldability and quality of the holder 1. obtain.

  Moreover, since both elastic connecting walls of the elastic cylindrical body 15 can bend and stretch, even if the thickness of the bias magnet 3 is changed by changing the specification of the rotation sensor S, the change in the thickness is changed by the both elastic connecting walls. Since it is absorbed by the bending degree of the wall 15b, the supporting surface 2a of the Hall element 2 can be brought into contact with and held by the supporting wall 14 without changing the shape of the holder 1, and thus the thickness of the bias magnet 3 can be maintained. In a plurality of types of rotation sensors having different dimensions, the holder 1 can be shared, and mass productivity can be improved.

  After the adjustment member 15 is mounted, the projection 18 projecting from the upper surface of the holder 1 is subjected to heat caulking or punch caulking around the electronic circuit unit 4 in the second housing 12, and the enlarged deformed caulking portion 18a is used. Since the corner portion of the electronic circuit unit 4 is firmly held, the contact state between the support surface 2a of the Hall element 2 and the support wall 14 of the holder 1 can be firmly held.

  Furthermore, the resin mold protective layer 20 that covers the entire rotation sensor S not only protects the entire rotation sensor S from impacts from other objects, but also fills in the gaps between the respective component members to bond the component members. In particular, the holding of the contact state between the support surface 2a of the Hall element 2 and the support wall 14 of the holder 1 can be strengthened.

  The present invention is not limited to the above embodiment, and various design changes can be made without departing from the scope of the invention. For example, the hollow elastic cylinder 15 can also be constituted by a cylindrical one.

The side view which shows the use condition of the rotation sensor of this invention. The perspective view which shows the same rotation sensor in the state before resin mold protective layer formation. The exploded perspective view of the rotation sensor. The top view of FIG. FIG. 5 is a sectional view taken along line 5-5 of FIG. FIG. 6 is a view corresponding to FIG. 5 showing a state of forming a resin mold protective layer.

P ・ ・ ・ ・ Non-detection rotating body (Pulsar plate)
S ... Rotation sensor 1 ... Holder 2 ... Hall element 2a ... Support surface 2b ... Sensing unit 3 ... Bias magnet 4 ... Electronic circuit unit 5 ... ..Lead frame (front lead frame)
6 ··· IC module 10 · · · Rear wall of the first housing (partition wall)
DESCRIPTION OF SYMBOLS 11 ... 1st housing 12 ... 2nd housing 13 ... Opening part 14 ... Support wall 15 ... Adjustment member (elastic cylinder)
15a ... Contact wall 15b ... Elastic connecting wall 18 ... Projection 18a ... Caulking part

Claims (4)

The front end portion in the synthetic resin holder that is opposed (1) to be detected rotating body (P), the Hall element (2) from the front end side, to place the bias magnet (3) and an electronic circuit unit (4) a front Symbol Hall element (2) and the electronic circuit unit (4), constitute the IC module (6) out with the lead frame for connecting between them (5), in front of the Hall element (2), A support surface (2a) and a sensing portion (2b) projecting from the support surface (2a) are formed, and the bias magnet (3) is brought into contact with the rear surface of the Hall element (2), while the holder In (1), a first housing (11) for accommodating the Hall element (2) and the bias magnet (3) is formed, and a sensing part (2b) is arranged at the front end of the first housing (11). The opening (13) and the support surface (2a) Be provided with contact and thereby support wall (14), and when manufacturing a plurality of types rotation sensors having different thickness of the bias magnet (3) with the holder (1) into a common,
An elastically deformable adjustment member that biases the bias magnet (3) toward the support wall (14) between the rear wall (10) of the first housing (11) and the bias magnet (3). 15) A method for manufacturing a rotation sensor, characterized in that a thickness change of a plurality of types of bias magnets (3) is absorbed by elastic deformation of the adjustment member (15) through 15). In the manufacturing method of the rotation sensor according to claim 1,
As the adjustment member , an elastic cylinder (15) having a hollow part open at both ends is used, and both opposite side walls (15a) of the elastic cylinder (15) are connected to the rear wall of the first housing (11). method of manufacturing a rotation sensor, characterized in that Ru is respectively resiliently abutting in said bias magnet (3). In the manufacturing method of the rotation sensor according to claim 2,
A pair of abutting walls (15a) for abutting the elastic cylinder (15) against the opposing surfaces of the rear wall of the first housing (11) and the bias magnet (3), and the abutting walls (15a) both end portions with each integrally connecting the) method of the rotation sensor, characterized in that to be constituted out of a pair of elastic connecting wall to exert an elastic force to bending possible extension direction (15b). In the manufacturing method of the rotation sensor in any one of Claims 1-3,
A second housing (12) for accommodating the electronic circuit unit (4) and a plurality of protrusions (18) surrounding the electronic circuit unit (4) are formed on the holder (1), and these protrusions (18) The electronic circuit unit (4) is held in the second housing (12) by the caulking part (18a) formed by heat caulking, and the pressing state of the support surface (2a) to the support wall (14) is maintained. A method for manufacturing a rotation sensor , comprising: holding the rotation sensor.

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