Ultrasonic transducer, ultrasonic sensor and method for operating an ultrasonic sensor

An ultrasonic transducer has an integrated memory for storing a post-pulse oscillation time of the ultrasonic transducer in the uninstalled state.

FIELD OF THE INVENTION

The present invention relates to an ultrasonic transducer, an ultrasonic sensor and to a method for operating an ultrasonic sensor.

BACKGROUND INFORMATION

Ultrasonic sensors use an ultrasonic transducer to convert an electrical excitation signal to an ultrasonic pulse. Based on the mechanical inertia of the ultrasonic transducer, an ultrasonic transducer continues to oscillate even after the end of an electrical excitation signal, and emits an ultrasonic pulse that is extended compared to the electrical excitation. This additional duration is denoted as post-pulse oscillation time.

Ultrasonic transducers are also used to receive echos of ultrasonic pulses. Since an echo cannot be distinguished from a post-pulse oscillation, no electrical signal is evaluated during the post-pulse oscillation time.

The post-pulse oscillation time is subject to a multitude of influences, such as contamination, aging, icing in winter, material fatigue, damage by broken rock, later paint work.

A method is discussed in Japanese patent document JP 2003-248050 which newly determines the post-pulse oscillation time of the ultrasonic transducers in a learning mode, during the operation of an ultrasonic sensor. From the post-pulse oscillation response ascertained, one is able to conclude that there was a malfunction.

SUMMARY OF THE INVENTION

The ultrasonic transducer according to the exemplary embodiments and/or exemplary methods of the present invention includes an integrated memory for storing at least one post-pulse oscillation time of the uninstalled ultrasonic transducer.

This post-pulse oscillation time is independent of influences that act later, such as painting, installation in a bumper, installation in a vehicle, temperature fluctuations, aging. Based on the knowledge of the pure post-pulse oscillation time conditioned by the construction of the ultrasonic transducer, one is able to determine the effects of the environment and of the installation. The storage may take place before or/and after the paint work and/or additional assembly steps. If necessary, a corresponding number of memories is provided, in which the individual post-pulse oscillation times are able to be stored.

The post-pulse oscillation time is able to be read out individually for each ultrasonic transducer. An ultrasonic sensor or the evaluation system (the system could read out the memory and, in the light of the time, release the reception window in a matched manner) is able to set a beginning of the distance measurement after the emission of an ultrasonic pulse, individually for each ultrasonic transducer. The shortest detectable distance may be reduced thereby. The evaluation system is able to read in the post-pulse oscillation time once only, or anew on a regular basis, for instance, at a system start or at the start of the measurement. Alternatively, the reading in of the post-pulse oscillation time is able to take place by a new installation of an individual ultrasonic transducer, for example, during an exchange of a defective ultrasonic transducer. This makes possible a steady adaptation of the evaluation system to the post-pulse oscillation time of the currently installed sensors. Thus, the adaptation takes into account both the sensor-related changes (environmental influences, etc.) and the sensor exchange.

One additional aspect of the exemplary embodiments and/or exemplary methods of the present invention relates to an ultrasonic sensor. It includes at least one ultrasonic transducer, which has an integrated memory, in which a first post-pulse oscillation time of the ultrasonic transducer in the uninstalled state is stored. A readout device is used for reading out the first post-pulse oscillation time from the memory. A measuring device is used for determining a second post-pulse oscillation time of the ultrasonic transducer installed in the ultrasonic sensor, and an evaluation device is used to deactivate the ultrasonic transducer if the second post-pulse oscillation time deviates from the first post-pulse oscillation time by more than one tolerance range, and/or is used to set a flag in the memory if the second post-pulse oscillation time deviates from the first post-pulse oscillation time by more than one tolerance range.

The post-pulse oscillation time of the ultrasonic transducers may be permanently increased by a number of influences. Since the post-pulse oscillation time of a portion of a series of ultrasonic transducers is only able to be stated using a tolerance, conclusions concerning a possible worsening can be drawn only conditionally from current measurements of the post-pulse oscillation time in operation. The comparison of the individual value of the post-pulse oscillation time of the ultrasonic transducer and a current measurement make possible a more accurate detection of a degradation.

The post-pulse oscillation time of the ultrasonic transducers may also be reduced by effects such as broken rock. Since the post-pulse oscillation time of a portion of a series of ultrasonic transducers is only able to be stated using a tolerance, conclusions concerning a possible worsening can be drawn only conditionally from current measurements of the post-pulse oscillation time in operation. The comparison of the individual value of the post-pulse oscillation time of the ultrasonic transducer and a current measurement make possible a more accurate detection of a relevant change. The result of the broken rock may lead to a loss in sensor sensitivity up to total failure.

One further aspect of the exemplary embodiments and/or exemplary methods of the present invention relates to a method for operating an ultrasonic sensor, having the steps: Reading out a first post-pulse oscillation time from an integrated memory of ultrasonic transducers of the ultrasonic sensor; determining a second post-pulse oscillation time of the ultrasonic transducers installed in the ultrasonic sensor; and deactivating the ultrasonic transducers, whose second post-pulse oscillation time deviates from the first post-pulse oscillation time by more than one tolerance range.

The exemplary embodiments and/or exemplary methods of the present invention are explained in the following with reference to specific embodiments and the attached figures.

DETAILED DESCRIPTION

FIG. 1shows a specific embodiment of an ultrasonic transducer1in cross section. A diaphragm pot2is formed, for instance, by a tube that is open at the top, whose one opening is spanned by a diaphragm3.

Diaphragm3is mechanically connected to an electromechanical transducer4, which converts an electrical signal to a mechanical motion. Examples of an electromechanical transducer4are piezoactive ceramic piles or a coil in the magnetic field of a permanent magnet.

The interior of diaphragm pot2may be spray-filled using a foam material5. Foam material5leads to a mechanical connection of electromechanical transducer4to diaphragm pot2. Foam material5acts in a damping manner on the oscillating motion of diaphragm. Instead of foam material5, other damping filler materials may also be used.

Electromechanical transducer4may be excited using an electrical periodic signal, whereby diaphragm3is set into oscillation of a corresponding frequency. After the switching off of the electrical periodic signal, diaphragm3keeps oscillating for a post-pulse oscillation time. The duration of the post-pulse oscillation time is specified by the inertia of diaphragm3, electromechanical transducer4and the damping properties of foam material5, as well as the (damping) properties of connected electrical circuit20to transducer4. Electrical circuit20provides the signal for exciting electromechanical transducer4, and evaluates the ultrasonic signals of the diaphragm. Electrical circuit20is made up at least of an interface15and a measuring device13. In one embodiment it may also include memory6. There is at least one electrical circuit20which is able to excite and evaluate one or more transducers4.

After the completion of ultrasonic transducer1, the post-pulse oscillation time is able to be measured in a checking environment or under other known conditions. The post-pulse oscillation time is able to be ascertained individually for each ultrasonic transducer1inclusively or exclusively of the associated electronic system20, or one may take random samples for a portion of ultrasonic transducers1with/without electronic system. If transducer4is installed as a unit together with electrical circuit20, the post-pulse oscillation time is yielded for the overall unit. In the case of separately situated units of transducer4and electrical circuit20, the post-pulse oscillation time refers to transducer4. The combination of transducer4and separate electrical circuit20yields a greater scatter of the overall post-pulse oscillation time.

The following explanations refer, for the purpose of a simpler description, only to one of the combinations mentioned above, namely a transducer4having a separate electronic system20.

In ultrasonic transducer1, for instance, a memory6is integrated inside diaphragm pot2or in electromechanical transducer4or in electronic system20. Examples of memory6are EEPROM's and flash memories. The post-pulse oscillation time, ascertained before, of individual, uninstalled ultrasonic transducer1is stored in memory6of ultrasonic transducer1, for instance, as post-pulse oscillation time21.

The post-pulse oscillation time stored in memory6(measured, for instance, in the painted state, having decoupling rings, . . . ) is a characteristic property of ultrasonic transducer1. It is not influenced by further processing, or only negligibly so. The installation of the sensor in the bumper may change the post-pulse oscillation time. This should take place only slightly, however, provided the installation is performed correctly. When the mounting is faulty, the influences may become greater, and may lead to significant deviations of ultrasonic transducers1from their uninstalled properties and also with respect to one another. Just on this point, based on the individual post-pulse oscillation time, checking during the first mounting, or even in the case of making repairs, makes it possible to exchange a transducer. The post-pulse oscillation time of transducer4may be stored alternatively after the first correct installation, such as in the bumper, again under defined measuring conditions, at a second location in memory6, as post-pulse oscillation time22. A comparison of post-pulse oscillation time21and22takes place using a current measured value. An evaluation may take into account the effect of the temperature on the oscillating behavior. A change over time, an aging, may be ascertained from long-term measurements. A model is able to establish the typical aging as a function of an operating duration and/or the kilometer coverage of a vehicle. This model may be taken into account when comparing a current measurement to stored post-pulse oscillation time21,22.

FIG. 2shows an ultrasonic sensor10in a partial section. In ultrasonic sensor10, a plurality of ultrasonic transducers1, such as two, is installed. The respective post-pulse oscillation time of ultrasonic transducer1is stored in a memory6of ultrasonic transducers1.

Ultrasonic transducers1are connected, via decoupling rings, to a housing12of ultrasonic sensor10. The housing of ultrasonic sensor10may be partially formed by a bumper. Housing12may be assembled from several parts, e.g. a housing for accommodating transducer1and a second part in the form of the bumper.

Decoupling rings11are intended to prevent a cross feed of the oscillation of diaphragm3to housing12. The material properties and the geometry of housing12influence, among other things, the post-pulse oscillation time of ultrasonic transducer1. Housings12may be embodied differently for each sensor position. The cross feed is dependent on the embodiment of the installation of ultrasonic transducer1and on decoupling rings11. Therefore, the post-pulse oscillation time for identical ultrasonic transducers1may be different after installation in ultrasonic sensor10and housing12.

Paint work later carried out on the transducer is able to change the post-pulse oscillation time. In this instance, both the additional mass of the paint on the diaphragm and the heat treatment for drying the paint have an effect on the post-pulse oscillation time.

Ultrasonic sensor10has a measuring device13. In standard operation, measuring device13is used to determine a distance with the aid of the running time of ultrasonic pulses. Measuring device13is able to emit an electrical excitation pulse to ultrasonic transducers1, whereupon diaphragm3is excited to oscillation. Furthermore, measuring device13records electrical signals of diaphragm3when the latter is mechanically excited by an incoming ultrasonic echo. Using an addressing device and a multiplexer device, measuring device13is able to address a plurality of transducers4. Alternatively, each transducer has assigned to it its own measuring device13. This measuring device13may also be integrated into the housing of transducer4, for example.

In a test operation for ascertaining the post-pulse oscillation time of ultrasonic transducers1, measuring device13may be used installed in ultrasonic sensor10. The measuring method carried out provides essentially the following steps. Ultrasonic transducer1is excited by an electrical excitation pulse. Directly after the ending of the electrical excitation pulse, an electrical signal is recorded that is emitted by ultrasonic transducer1. Initially, ultrasonic echos are not yet to be expected, for which reason it is assumed that the electrical signal originates with the post-pulse oscillation of diaphragm3. This should be confirmed by the measuring device or the measuring point in time. What is evaluated is the duration between the end of the electrical excitation pulse and the point in time when the electrical signal of the ultrasonic transducer1is below a recording threshold. The evaluation may be repeated several times, particularly when the vehicle is or was moved meanwhile, so as to avoid faulty measurements based on close-by reflecting objects. The duration is assigned to a post-pulse oscillation time of ultrasonic transducer1in the installed state.

An evaluation device14reads out from memory6of ultrasonic transducer1, for instance, the latter's post-pulse oscillation time in the uninstalled state. For this purpose, appropriate interfaces15are provided. The two post-pulse oscillation times in the uninstalled and the installed state are compared to each other. If there is a difference that is greater than the tolerance value, evaluation device14detects that ultrasonic transducer1is defective or is installed in a faulty manner. Ultrasonic transducer1is deactivated or alternatively, measuring device13is informed that this ultrasonic transducer1is defective, so that, if further distance measurements are made, it is no longer taken into account. Alternatively or in addition, a flag may be set in memory6that stores the detection of the defectiveness. A later change in the flag may advantageously be prevented by an appropriate measure. A later repair or a cover-up of a faulty installation may thus be prevented. Measures for preventing a later correction include a once writable storage location, coded storage, etc.

The tolerance value may be specified to evaluation device14in a fixed manner.

Alternatively, the tolerance value may be ascertained by evaluation device14. To do this, evaluation device14determines for each ultrasonic transducer1the deviation of the post-pulse oscillation time of ultrasonic transducer1in the installed and the uninstalled state. The deviation may be ascertained, for example, as the difference or the quotient. The median of the deviation is ascertained as the standard value. If the deviation of an ultrasonic transducer1differs from the median by more than one tolerance factor, this ultrasonic transducer1is detected as being defective.

In addition, the environmental temperature may also be drawn upon for the evaluation. The continually determined post-pulse oscillation time in the installed state may, in one specific embodiment, be stored in memory6as post-pulse oscillation time23,24, . . . of ultrasonic transducer1. This makes it possible to track the long-term behavior of the individual ultrasonic transducers1. In one further specific embodiment, the storage may be made as a function of the kilometer coverage and/or the temperature (weather conditions).

One embodiment ascertains the tolerance value from the long term behavior. The post-pulse oscillation time in the installed state is determined during a first operating time, for instance, the first 100 operating hours or the first 1000 km of the motor vehicle. The value ascertained is stored and is regarded as the guidance quantity for the post-pulse oscillation time and the tolerance value. The tolerance value or the guidance quantity may be stored in memory6. In light of this guidance quantity, minor damage by broken rock, for example, may be ascertained by comparison.

One embodiment ascertains the tolerance value from the long term behavior, for instance, during one annual cycle. The post-pulse oscillation is recorded over the typical course of an environmental cycle (summer/winter). The ascertainment of the post-pulse oscillation time over the time period is induced by evaluation unit14and electric circuit20. The shortest and the longest post-pulse oscillation time, along with the appertaining conditions, such as temperature, are stored in memory6. In addition, the minimum and maximum temperature, at which the post-pulse oscillation test was carried out, may also be stored. (Low or high temperatures do not necessarily have to produce minimum or maximum post-pulse oscillation times). The evaluation device is able to ascertain the expected post-pulse oscillation time from these values. Using the comparison of current post-pulse oscillation time to stored values, one is able to detect the influencing of the measuring device (soiling, icing, damage, . . . ) when a limit is exceeded or undershot.

Memory6may be a permanent memory, whose values can no longer be changed. This makes possible a later checking of the individual ultrasonic transducer1, to see whether it has been installed properly.

The post-pulse oscillation time of uninstalled ultrasonic transducer1may be ascertained for different temperatures, emitting performance, etc. The dependencies of the post-pulse oscillation time that is ascertained may also be stored in memory6, in the form of correction quantities or as a table having corresponding post-pulse oscillation times. Evaluation device14of ultrasonic sensor10is able to determine the post-pulse oscillation time corresponding to the operating conditions. The time intervals between the emitting of the ultrasonic pulse and the receiving of the echos may be adjusted appropriately. Moreover, an error diagnosis of the individual ultrasonic transducers1may be carried out with increased reliability.