Actuator and Sensor Assembly

• US 20110079138A1
• Filed: 12/08/2010
• Published: 04/07/2011
• Est. Priority Date: 12/02/2008
• Status: Active Grant

• Current Assignee: CTS Corporation
• Original Assignee: CTS Corporation
• Inventors: Storrie, Willliam D., Wolschlager, Kevin C., Newman, Robert L., Babin, Brian G.
• Granted Patent: US 8,664,947 B2
• Time in Patent Office: Days
• US Class Current: 91/1
• CPC Class Codes: G01B 7/14 for measuring distance or clearance between spaced objects or spaced apertures G01B7/30 takes precedence
• CPC Class Codes: G01D 5/145 influenced by the relative movement between the Hall device and magnetic fields see G01R33/06

Abstract

An actuator and sensor assembly comprising respective sensor and actuator housings defining an interior chamber. Clips on the sensor housing engage the actuator housing for coupling the sensor and actuator housings together. The sensor housing includes a wall defining a pocket. A connector with a sensor couples to the sensor housing in a relationship wherein the sensor extends into the sensor housing pocket. A movable piston is located in the interior chamber and a tube thereon defines a receptacle for a magnet located adjacent the pocket. The piston is seated on a flexible diaphragm. An actuator shaft includes one end coupled to the piston and an opposite end coupled to a movable object. A plurality of pins in the actuator housing mount the assembly to a support bracket. The sensor senses changes in the magnetic field in response to changes in the position of the magnet relative to the sensor.

Claims

1. An actuator and sensor assembly comprising:

a sensor housing including a wall defining a pocket;

a connector assembly including a sensor, the connector assembly being adapted for coupling to the sensor housing in a relationship wherein the sensor extends into the pocket defined by the wall of the sensor housing;

an actuator housing including a base defining an aperture, the sensor housing and the actuator housing being coupled together and defining an interior cavity;

a piston located and movable in the interior cavity and defining a receptacle;

a magnet located in the receptacle of the piston, the magnet generating a magnetic field, the sensor being adapted to sense a change in the magnetic field in response to movement of the piston and the magnet relative to the sensor; and

an actuator shaft including a first end coupled to the piston and a second end extending through the aperture in the actuator housing and into coupling relationship with a movable object.

2. The actuator and sensor assembly of claim 1 further comprising:

a flexible diaphragm located in the interior cavity, the piston being seated on the flexible diaphragm;

a spring located in the interior cavity against the piston and biasing the piston in a first position; and

a source of pressurization coupled to one of the sensor housing or the actuator housing and in fluid flow communication with the interior cavity for adjusting the pressure in the interior cavity and causing the movement of the piston.

3. The actuator and sensor assembly of claim 1 further comprising a plurality of clips on one of the sensor housing or the actuator housing and a flange on the other of the sensor housing or the actuator housing, the plurality of clips engaging against the flange for coupling the sensor housing and the actuator housing together.

4. The actuator and sensor assembly of claim 1 wherein the magnet comprises at least first and second stacked portions made of different magnetic materials.

5. The actuator and sensor assembly of claim 4 wherein the first portion is made of an NdFeB material and the second portion is made of either an iron or steel material.

6. The actuator and sensor assembly of claim 1 wherein the base of the actuator housing defines a plurality of cavities, the actuator and sensor assembly further comprising a plurality of mounting pins including respective heads extending into the plurality of cavities respectively in the base of the actuator housing.

7. The actuator and sensor assembly of claim 1 wherein the base of the actuator housing defines a central cavity, the actuator and sensor assembly further comprising a gimbal located in the central cavity and defining a central through aperture, the actuator shaft extending through the central aperture of the gimbal.

8. A sensor assembly comprising:

a sensor housing including a wall defining an opening and a pocket;

a connector including a sensor, the connector being coupled to the sensor housing in a relationship wherein the sensor extends through the opening and into the pocket defined by the wall of the sensor housing; and

a magnet located adjacent the pocket and adapted for movement relative to the sensor in the pocket, the sensor being adapted to sense a change in the magnetic field generated by the magnet in response to the movement of the magnet relative to the sensor.

9. The sensor assembly of claim 8 wherein the connector includes a plurality of terminals coupled to a substrate, the sensor being mounted on the substrate and the substrate extending into the pocket defined by the wall of the sensor housing.

10. The sensor assembly of claim 8 further comprising:

an actuator housing including a base defining an aperture, the actuator housing being coupled to the sensor housing and together defining an interior chamber;

a piston located in the interior chamber, the piston defining a carrier for the magnet;

a flexible diaphragm located in the interior chamber and including a peripheral edge wedged between the sensor housing and the actuator housing, the piston being seated against the flexible diaphragm;

an actuator shaft including a first end coupled to the piston and an opposite end extending through the aperture in the base of the actuator housing and into coupling relationship with a movable object; and

a source of pressurization coupled to the sensor housing or the actuator housing and in communication with the interior chamber for adjusting the pressure in the interior chamber and causing the movement of the piston, the magnet thereon, the actuator shaft, and the movable object coupled thereto.

11. The sensor assembly of claim 10 further comprising:

a hollow insert in the piston, the actuator shaft extending through the insert and the actuator shaft including a head seated against the top of the insert;

a first central cavity and a plurality of second peripheral cavities defined in the base of the actuator housing;

a hollow gimbal located in the first central cavity, the actuator shaft extending through the gimbal; and

a plurality of mounting pins including respective heads extending into the respective second peripheral cavities defined in the base of the actuator housing.

12. The sensor assembly of claim 8 wherein the magnet comprises at least first and second stacked portions made of different magnetic materials.

13. An actuator and sensor assembly comprising:

a sensor housing including a wall defining an opening and a pocket and a circumferentially extending skirt;

a connector assembly including a substrate having a sensor mounted thereon, the connector assembly being coupled over the top of the sensor housing in a relationship wherein the substrate and the sensor extend through the opening and into the pocket defined by the wall of the sensor housing;

an actuator housing including a base defining a central aperture and a circumferentially extending side wall, one of the skirt of the sensor housing or the side wall of the actuator housing including a plurality of clips and the other of the skirt of the sensor housing or the side wall of the actuator housing including a lip, the plurality of clips engaging against the lip for coupling the sensor housing to the actuator housing, the sensor and actuator housings together defining an interior cavity;

a flexible diaphragm located in the interior cavity and including a peripheral portion wedged between the skirt of the sensor housing and the side wall of the actuator housing;

a magnet carrier assembly located in the interior cavity and seated against the flexible diaphragm, the magnet carrier assembly including a receptacle for a magnet, the magnet carrier assembly being adapted for linear movement within the interior cavity from a first position adjacent the base of the actuator housing to a second position away from the base of the actuator housing, the magnet being located opposite, spaced, and isolated from the pocket containing the sensor;

an actuator shaft including a first end in the interior cavity coupled to the magnet carrier assembly and a second end extending through the aperture in the base of the actuator housing and coupled to a moveable object;

a spring in the interior cavity extending between the wall of the sensor housing and the magnet carrier assembly, the spring biasing the magnet carrier assembly in the first position adjacent the base of the actuator housing; and

a pressurization source coupled to one of the sensor housing or the actuator housing for adjusting the pressure in the interior cavity and causing the movement of the magnet carrier assembly, the movement of the magnet carrier causing a change in the magnetic field generated by the magnet which is sensed by the sensor.

14. The actuator and sensor assembly of claim 13 wherein the connector assembly includes a plurality of terminals extending therethrough and an arm, the plurality of terminals extending on the arm and the substrate extending from the arm and being electrically connected to the plurality of terminals, the wall of the sensor housing defining a dome and the connector assembly being seated against the dome.

15. The actuator and sensor assembly of claim 13 wherein the base of the actuator housing defines a first central cavity and a plurality of peripheral second cavities, the actuator and sensor assembly further comprising a gimbal defining a through aperture and a plurality of mounting pins including respective heads, the gimbal being located in the first central cavity defined in the base of the actuator housing and the actuator shaft extending through the aperture of the gimbal, the respective heads of the mounting pins extending into the respective peripheral second cavities defined in the base of the actuator housing.

16. The actuator and sensor assembly of claim 13 further comprising a hollow insert located in the receptacle of the magnet carrier, the first end of the actuator shaft extending through the insert and including a head abutted against the top of the insert.

17. The actuator and sensor assembly of claim 13 wherein the magnet comprises at least first and second stacked portions made of different magnetic materials.