Rotation angle detector having sensor cover integrating magnetic sensing element and outside connection terminal

• US 6,756,780 B2
• Filed: 05/09/2002
• Issued: 06/29/2004
• Est. Priority Date: 11/01/1999
• Status: Expired due to Term

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Kondo, Tomokazu, Kono, Yoshiyuki, Kubota, Takamitsu, Hamaoka, Takashi, Hagio, Hirofumi
• Primary Examiner(s): Le, N.
• Assistant Examiner(s): Aurora, Reena
• Application Number:
  US10/140,936
• Publication Number:
  US 20020130656A1
• Time in Patent Office: 782 Days
• Field of Search: 324/207.2, 324/207.21, 324/207.25, 324/207.15, 324/207.16, 324/174, 123/617, 123/612
• US Class Current: 324/207.25
• CPC Class Codes: B60K 35/60 Instruments characterised by their location or relative disposition in or on vehicles arrangements of lighting devices on dashboards B60Q3/10
• CPC Class Codes: F02D 11/106 Detection of demand or actuation
• CPC Class Codes: F02D 2200/0404 Throttle position
• CPC Class Codes: F05C 2201/021 Aluminium
• CPC Class Codes: F16K 1/221 specially adapted operating means therefor operating means per se F16K31/00
• CPC Class Codes: F16K 31/041 for rotating valves F16K31/055 takes precedence
• CPC Class Codes: F16K 31/535 for rotating valves F16K31/54 takes precedence
• CPC Class Codes: F16K 37/0033 using a permanent magnet, e.g. in combination with a reed relays
• CPC Class Codes: G01D 11/30 Supports specially adapted for an instrument; Supports specially adapted for a set of instruments
• CPC Class Codes: G01D 2205/40 Position sensors comprising arrangements for concentrating or redirecting magnetic flux
• CPC Class Codes: G01D 5/145 influenced by the relative movement between the Hall device and magnetic fields see G01R33/06

Abstract

Non-contact type Hall ICs detecting an rotation angle of a throttle valve, a stator core strengthening a magnetic field around the Hall ICs, a lead frame connecting the Hall ICs to an outside ECU are integrated in a sensor cover by resin molding. Thus, the Hall ICs, the stator core, and the lead frame are accurately positioned in the sensor cover. As a result, the Hall ICs are accurately positioned with respect to a permanent magnet disposed in a shaft side of the throttle valve, thereby improving an accuracy of detecting the rotation angle of the throttle valve.

Claims

1. A throttle position sensor comprising:

a housing forming an outer casing, said housing defining an opening;

a throttle valve provided in said housing, said throttle valve including a shaft;

a bearing provided in said housing to rotatably support said shaft;

a generally cylindrical rotor core rotating with said shaft, said rotor core including a pair of magnets, each of which generates a magnetic force, said magnets being circumferentially spaced from each other, an end surface of a north pole end of one of said magnets circumferentially facing and being connected through the rotor core to an end surface of a north pole end of the other one of said magnets, an end surface of a south pole end of said one of said magnets circumferentially facing and being connected through the rotor core to an end surface of a south pole end of said other one of said magnets, said rotor core being positioned at one end of said shaft;

a non-contact type magnetic sensing element receiving the magnetic force of at least one of said magnets to detect the rotation angle of said shaft, said non-contact type magnetic sensing element being positioned radially inward of said magnets;

an output terminal connected to said non-contact type magnetic sensing element to output an output signal of said non-contact type magnetic sensing element;

a stator core being positioned radially inward of said magnets and strengthening the magnetic force around said non-contact type magnetic sensing element; and

a sensor cover made of resin, said sensor cover integrating and supporting said non-contact type magnetic sensing element and said output terminal by resin molding, said sensor cover covering the opening of said housing.

2. The throttle position sensor according to claim 1, wherein said stator core is radially positioned between said magnets and said non-contact type magnetic sensing element.

3. The throttle position sensor according to claim 1, wherein said stator core forms a magnetic circuit in cooperation with said rotor core.

4. The throttle position sensor according to claim 1, wherein said non-contact type magnetic sensing element includes two element parts, which are disposed side by side in parallel at a 180 degree interval to face in opposite directions.

5. The throttle position sensor according to claim 1, wherein said non-contact type magnetic sensing element includes a plurality of element parts, which are disposed in series and are oriented in a common direction.

6. The throttle position sensor according to claim 1, wherein said magnets generate two magnetic fluxes, which flow in opposite directions.

7. The throttle position sensor according to claim 1, wherein:

said rotor core include a pair of recesses, which are recessed in an inner circumferential surface of said rotor core;

said magnets are positioned in said recesses, respectively; and

each of said recesses defines a substantial air space between a corresponding one of said magnets and said stator core.

8. The throttle position sensor according to claim 1, wherein said end surface of said north pole end and said end surface of said south pole end of each magnet are entirely covered by said rotor core.

9. A throttle position sensor comprising:

a housing forming an outer casing, said housing defining an opening;

a throttle valve provided in said housing, said throttle valve including a shaft;

a bearing provided in said housing to rotatably support said shaft;

a rotor core rotating with said shaft, said rotor core including a magnet generating a magnetic force, said rotor core being positioned at one end of said shaft;

a non-contact type magnetic sensing element receiving the magnetic force of said magnet to detect the rotation angle of said shaft, said non-contact type magnetic sensing element being positioned radially inward of said magnet;

an output terminal connected to said non-contact type magnetic sensing element to output an output signal of said non-contact type magnetic sensing element;

a stator core strengthening the magnetic force around said non-contact type magnetic sensing element; and

a sensor cover made of resin, said sensor cover integrating and supporting said non-contact type magnetic sensing element and said output terminal by resin molding, said sensor cover covering the opening of said housing,

wherein said stator core includes;

a first stator core portion provided by stacking a first plurality of magnetic plates in a thickness direction thereof;

a second stator core portion provided by stacking a second plurality of magnetic plates in a thickness direction thereof; and

a non-magnetic plate connecting an end surface of said first stator core portion to an end surface of said second stator core portion; and

said first stator core portion and said second stator core portion define a magnetic sensing gap having a predetermined width therebetween.

10. The throttle position sensor according to claim 9, wherein:

said first plurality of magnetic plates are semi-disk magnetic plates; and

said second plurality of magnetic plates are semi-disk magnetic plates.

11. The throttle position sensor according to claim 9, wherein:

said magnet includes first and second half arc portions;

said first arc portion includes;

a north pole located on a radially inner side of said first arc portion, and

a south pole located on a radially outer side of said first arc portion; and

said second arc portion includes;

a south pole located on a radially inner side of said second arc portion, and

a north pole located on a radially outer side of said second arc portion.