SENSING ASSEMBLY FOR DICHOTOMIC SENSING

Embodiments herein are directed to a position sensor. The position sensor includes an inductive sensor assembly, a secondary sensor, and a coupler member. The inductive sensor assembly includes a transmitter coil and at least one receiver coil located proximate to the transmitter coil. The at least one receiver coil generating a receiver signal when the transmitter coil is excited. The receiver signal being sensitive to a position of a part. The secondary sensor is positioned within an inner diameter of the transmitter coil. The coupler member is coupled to the part and configured to move with a movement of the part. The coupler member overlies at least a portion of the at least one receiver coil. The coupler member including a body, at least one projecting portion extending from the body and at least one magnet concentrically positioned with the body.

TECHNICAL FIELD

The present disclosure relates to sensor assemblies, and, more specifically to inductive sensing and Hall Effect sensing assembly.

BACKGROUND

Conventional rotary inductive sensing coil interferes with conductors placed over the sensing coil. Therefore, it is not feasible to establish low impedance connection through the coil in circumstances such as placing another electronic sensor at the center of the coil. Using arc-linear sensing coil, offsetting the inductive sensing target from the pivot, allows placement of a secondary sensor at the pivot of the target object without electrical connections thereof and sensing coil interfering with each other. However, an unintended lateral offset of the target pivot results in sensed angle error since it effectively results overall change in conductor target shift comparable to angle change. Further, because of the interference between sensing coil and conductor placement, conventional rotary sensing coils inhibit use of concentric secondary electronic sensor within one circuit board despite it being a desired inexpensive option.

SUMMARY

In one embodiment, a position sensor assembly is provided. The position sensor assembly includes an inductive sensor assembly, a secondary sensor, and a coupler member. The inductive sensor assembly includes a transmitter coil that has an inner diameter and at least one receiver coil located proximate to the transmitter coil. The secondary sensor is positioned within the inner diameter of the transmitter coil. The coupler member is coupled to the part and configured to move with a movement of the part. The coupler member overlies at least a portion of the at least one receiver coil. The coupler member includes a body that has an area defined by an outer edge, at least two projecting protrusions extending beyond the outer edge and at least one target positioned within the area of the body. The at least one receiver coil is configured to generate a receiver signal when the transmitter coil is excited due to a change in an inductive coupling between the transmitter coil and the at least one receiver coil caused by the movement of the at least two projecting protrusions, the receiver signal being sensitive to a position of the part.

In another embodiment, a sensor assembly that has a multi-layered circuit board is provided. The sensor assembly includes an inductive sensor assembly, a secondary sensor, and a coupler member. The inductive sensor assembly includes a transmitter coil that has an inner diameter and a plurality of receiver coils located proximate to the transmitter coil. Each of the plurality of receiver coils having a pair of terminating ends that terminate spaced apart to define a gap therebetween in at least one layer of the multi-layered circuit board. The secondary sensor is positioned within the inner diameter of the transmitter coil. The secondary sensor has at least one electrically conductive trace extending therefrom and though the gap. The coupler member is configured to move. The coupler member overlies at least a portion of the plurality of receiver coils. The coupler member includes a body having an area defined by an outer edge, at least two projecting protrusions extending beyond the outer edge, and at least one target positioned within the area of the body. Movement of the coupler member modifies an inductive coupling between the transmitter coil and the plurality of receiver coils to generate a first receiver signal and the movement of the coupler member moves the at least one target detected by the secondary sensor to generate a second receiver signal, the second receiver signal indicative of a different change caused by movement of the coupler member than the first receiver signal.

In yet another embodiment, a position sensor assembly is provided. The position sensor assembly includes an inductive sensor assembly, a secondary sensor, and a coupler member. The coupler member is configured to move. The coupler member includes a body having an area defined by an outer edge, three projecting protrusions extending beyond the outer edge of the body, and at least one target positioned within the area of the body. The inductive sensor assembly includes a transmitter coil having an inner diameter and a plurality of receiver coils located proximate to the transmitter coil. Each of the plurality of receiver coils have a pair of terminating ends spaced apart to define a gap therebetween. Each of the plurality of receiver coils are arranged in a sinusoidal shape with five periods that spans 300 degrees. The plurality of receiver coils are separated into three independent inductive coil segments and two unused segments in which the plurality of receiver coils are configured to, in the three independent inductive coil segments, sense changes to the inductive coupling between the transmitter coil and the plurality of receiver coils caused by the three projecting protrusions passing through the respective three independent inductive coil segments. A secondary sensor positioned within the inner diameter of the transmitter coil, the secondary sensor having at least one electrically conductive trace extending therefrom and though the gap.

DETAILED DESCRIPTION

Embodiments presented herein are directed to a position sensor assembly that includes a radial multi-pole arc-linear inductive sensing assembly. The position sensor described herein includes redundant sensing utilizing both inductive sensing techniques and a secondary sensing technique, such as Hall Effect sensing techniques, with a single circuit board, such as a four-layer circuit board. Further, the position sensor described herein combines arc-linear sensing techniques and multi-pole rotary sensing techniques to overcome disadvantages of conventional sensor assemblies. For example, conventional sensor assemblies cannot include both Hall Effect and inductive sensing on the same board in close proximity because the metal and magnet for the Hall Effect sensing interfere with the inductive sensing. One solution is offsetting the sensing techniques with offset pivot axes and using mechanical devices such as links, gears, levers, and the like, to space apart of separate the two sensing techniques. Such solutions introduce slack, misalignment, mechanical failure, and the like.

A solution to these undesirable conditions described above may be arc-linear sensing with a concentric pivot axis. However, arc linear sensing is known to be less accurate compared to rotary sensing. Further, in arc linear sensor assemblies, an XY-offset causes output errors such as when a coupler is offset. When the coupler offsets, arc-linear coil confuses this with rotation. This result in deviation of signals from the sensing coils that is difficult to distinguish from a target rotated to achieve similar change in coverage. However, in another example for conventional sensor assembly, in a multi-pole rotary coil sensor assemblies, a coupler XY-offset is cancelled out. That is, conventional sensor assemblies with multiple poles within a rotary sensing coil incur a sensed angle error due to lateral shift in pivot can be avoided since lateral offset in one pole effectively results in counteracting lateral offset in the other poles. However, these multiple poles sensing application require the offsetting of the sensing techniques with offset pivot axes and using mechanical devices, as discussed above.

The position sensor assembly described herein includes a sensor arrangement that permits concentric secondary electronic sensor(s) and reduced susceptibility to sensed angle error caused by lateral pivot shift. For example, the position sensor described herein places multiple arc-linear inductive sensing coils radially, concentrically, and symmetrically and connecting the receiver coils in series. Such an arrangement creates an opening or gap between the sensing coils within a circuit board where the electrical connection to the concentric secondary electronic sensor can be placed without causing interference with the components for the Hall Effect sensing. Further, the lateral pivot shift in one direction results in counteracting signal changes in the coils, which can negate each other due to the series connection. Accordingly, the arrangement of the position sensor assembly described herein is advantageous compared to conventional sensor assemblies.

As used herein, the term “communicatively coupled” means that coupled components are capable of exchanging data signals and/or electric signals with one another such as, for example, electrical signals via conductive medium, electromagnetic signals via air, optical signals via optical waveguides electrical energy via conductive medium or a non-conductive medium, data signals wirelessly and/or via conductive medium or a non-conductive medium and the like.

As used herein, the term “longitudinal direction” refers to the forward-rearward direction of the assembly (i.e., in the +/−X direction depicted inFIG.1). The term “lateral direction” refers to the cross-direction (i.e., in the +/−Y direction depicted inFIG.1), and is transverse to the longitudinal direction. The term “vertical direction” refers to the upward-downward direction of the assembly (i.e., in the +/−Z-direction depicted inFIG.1).

Now referring toFIGS.1-2and3C, a simplified example environmental arrangement of a position sensor assembly is schematically depicted inFIG.1. The position sensor assembly100described herein includes a circuit board102(FIG.3C), a coupler member104coupled or otherwise attached to a part106, such as a shaft or other member that moves, an inductive sensor assembly108and a secondary sensor assembly110(FIG.3C). The inductive sensor assembly108may include a transmitter coil112(e.g., the outer rings), at least one receiver coil, depicted as a plurality of receiver coils114, and a pair of inductive sensing interface integrated circuits118a,118b(FIG.3C). In the depicted embodiments, the plurality of receiver coils114are six receiver coils116a,116b,116c,116d,116e,116fare utilized. Each of the plurality of receiver coils114are generally in a sinusoidal shape using inductive coils. This is non-limiting, and they may be more or less than six receiver coils utilized in the inductive sensor assembly.

As discussed in greater detail herein, the coupler member104overlies at least a portion of the inductive sensor assembly108and a portion of the secondary sensor assembly110. Further, rotation of the coupler member104modifies the inductive coupling between the transmitter coil112and the plurality of receiver coils114. Each of the plurality of receiver coils114may be configured to produce no signal in the absence of the coupler member104, due to self-cancellation of various induced potentials. As an example, in some embodiments, each of the plurality of receiver coils114(e.g., six receiver coils116a,116b,116c,116d,116e,116f) may each include first and second loop structures configured so as to tend to cancel each other's induced potential. Each loop structure may have circumferential segments at the outer diameter alternating with circumferential segments at the inner diameter, corresponding to an overlay and/or underlay of the two loop structures.

Now referring toFIGS.1-4B and7A-7F, the positioning of the coil arrangement of the inductive sensor assembly108will be described in more detail. In some embodiments, each of the plurality of receiver coils114are arc-linear. Each of the plurality of receiver coils114may be configured to span five complete periods along an arcuate path or shape. Such an arrangement maximizes the balance between positively and negatively ‘coupled areas’, as discussed in greater detail herein. In the depicted embodiment, each of the plurality of receiver coils114may span 300 degrees to form or define a generally “C” shape. Further, each of the plurality of receiver coils114include terminating ends120a,120b, respectively. The terminating ends120a,120bare spaced apart from one another to define a gap122that extends the last 60 degrees. As such, none of the plurality of receiver coils114extend in or through the gap122within the circuit board102, as discussed in greater detail herein. Further, each of the plurality of receiver coils114are electrically connected in a series arrangement.

It should be understood that the spanning 300 degrees in a generally “C” shape is non-limiting and it should be understood that the gap122may be larger or smaller than 60 degrees. For example, the gap122may be 40 degrees, 25 degrees, 75 degrees, and the like, which may change the span of each of the plurality of receiver coils114. As such, the span of each of the plurality of receiver coils114is not limited to 300 degrees and may be any degrees such that the sum of the gap122and the span of the plurality of receiver coils114is 360 degrees to create a general circular arrangement to detect or sense movement of the coupler member104, as discussed in greater detail herein.

Each of the plurality of receiver coils114include an innermost portion130a, and an outermost portion130b. Further, in some embodiments, the outermost portion130bof each of the plurality of receiver coils114may be equal to or extend beyond the size of the coupler member104, as discussed in greater detail herein. Additionally, in some embodiments, the outermost portion130bof each of the plurality of receiver coils114may be equal to the outer diameter OD1of the transmitter coil112. In other embodiments, the outermost portion130bof each of the plurality of receiver coils114extend beyond the outer diameter OD1of the transmitter coil112.

Still referring toFIGS.1-4Band now toFIG.8, in the depicted embodiment, there are two unused segments124a,124b, or blind areas that are not used. It should be understood that for purposes of coil manufacturing, the plurality of receiver coils114, may be continuous connected through the two unused segments124a,124b, but this is an unused area or blind area, as best depicted inFIG.8. That is, each of the plurality of receiver coils114may be depicted as a single coil extending through the unused segments124a,124b, but may be separated or broken in the unused segments124a,124bseparating or defining three independent arc linear sections of coils162a,162b,162c, as best illustrated inFIG.8, and as discussed in greater detail herein. Each of the unused segments124a,124bmay amount to be one pole such that the plurality of receiver coils114is utilized as three-pole arc-linear coils (e.g., each of the independent arc linear sections of coils162a,162b,162care a pole for a three-pole receiver) for a three-pole sensor. Each of the independent arc linear sections of coils162a,162b,162cinclude portions of the plurality of receiver coils114(e.g., some of the periods of the generally sinusoidal shape pass through each of the independent arc linear sections of coils162a,162b,162c). Further, each of the independent arc linear sections of coils162a,162b,162cmay be symmetrical in shape (e.g., angularly symmetrical), a same distance from the axis128(e.g., center point that the axis128transverses), have the same span, and are symmetrically spaced apart or separated.

The unused segments124a,124bare depicted at the four and eight o'clock positons of the plurality of receiver coils114and the gap122is depicted at the 6 o'clock position. This is non-limiting and the gap122and/or the unused segments124a,124bmay be at different areas of the plurality of receiver coils114. The unused segments124a,124bpermit various electrical connections to other components of the inductive sensor assembly108.

That is, the blind areas, or unused segments124a,124b, and the gap122allow for the placement of electrical connections without placing undesired conductors within the plurality of receiver coils114, which can interfere with the sensing of the inductive sensor assembly108and/or the secondary sensor assembly110, such as by changing or otherwise manipulating various fields, such as magnetic and/or electric fields, in an undesirable manner. This is non-limiting and there may be more or less blind areas or unused segments. In some embodiments, the number of blind areas or unused segments may be to match the number of targets (e.g., projecting protrusions) of the coupler member104such as, four pole, five pole, six pole, two pole, and the like, as appreciated by those skilled in the art. Further, each of the three independent arc linear sections of coils162a,162b,162cpermit for the sensing angle error to be reduced or eliminated due to the shape and arrangement of each of the three independent arc linear sections of coils162a,162b,162c. That is, the shape and arrangement of each of the three independent arc linear sections of coils162a,162b,162cpermit for the shift of the pivot (coupler member104) to change while each of the three independent arc linear sections of coils162a,162b,162caccount for the shift by sensing or detecting the coverage changes of the pivot (e.g., coupler member104), in which the arrangement partially cancels each other.

Now referring toFIGS.7A-7F, schematically depicted is an example arrangement of the plurality of receiver coils114. In the depicted embodiments, the plurality of receiver coils114may be generally in a continuous sinusoid shape. Such an arrangement and/or shape eliminates the demarcation between each of the plurality of receiver coils114and maximizes the balance between positively and negatively ‘coupled areas’. That is, each coil of the plurality of receiver coils114are arranged with alternating positive and negative loops such that various induced potentials of adjacent loops are cancelled or zero unless the coupler member104is introduced to modify the induced potentials. In the depicted embodiments, each of the plurality of receiver coils114span over 5 periods (e.g.5complete sinusoidal waves) with the span of 300 degrees. This is non-limiting, each span may be less than or more than five complete sinusoidal waves. As such, depending on the span, the number of periods (e.g. 5 sinusoidal waves) may change.

Now referring back toFIGS.1-4B, the transmitter coil112may be generally circular and includes at least one circular loop formed substantially concentrically around an axis128of the inductive sensor assembly108. In some embodiments, the transmitter coil112includes several loops formed substantially concentrically around the axis128and all windings or loops of the transmitter coil112may be oriented in the same rotational direction. The transmitter coil112may include an inner diameter ID1and an outer diameter OD1in a conventional circular coil design, as best depicted inFIG.4A. This is non-limiting and other shapes and designs may be used.

The transmitter coil112, which may also be referred to as an exciter coil, is excited by a source of alternating current126by an exciter signal. The exciting source or alternating current may be a high frequency alternating current source. Examples include, without limitation, a Colpitts oscillator, or other electronic oscillator. When excited by electrical energy, the transmitter coil112may radiate electromagnetic radiation. There is inductive coupling between the transmitter coil112and any other proximate coils, which induces a receiver signal in that coil (e.g., the plurality of receiver coils114). That is, the transmitter coil112may be printed on or within the102circuit board so that, when energized by the high frequency alternating current source126, the transmitter coil112generates a high frequency electromagnetic field. The outer diameter of the transmitter coil112may be positioned to be between the innermost portion130aof each of the plurality of receiver coils114and the outermost portion130bof each of the plurality of receiver coils114.

Now referring toFIGS.3A-3C and4A-4B, the circuit board102may be a printed circuit board, single-sided, double-sided, multilayer, rigid, flexible, rigid-flexible, combinations thereof, and the like. In the depicted embodiment, the circuit board102includes an inner surface154aand an outer surface154bthat is opposite to and spaced apart from the inner surface154ato define a thickness. Further, in the depicted embodiment, the circuit board102has four layers156a,156b,156c,156d, as best depicted inFIG.4B.

In the depicted embodiment, the transmitter coil112may be positioned on one layer of the circuit board102. Each of the each of the plurality of receiver coils114may have portions that are positioned in separate layers (e.g., layers156a,156bin the depicted embodiment ofFIG.4B) of the circuit board102and/or alternate between layers in the axial direction or in the vertical direction (i.e., in the +/−Z-direction) such that a difference in the distance or airgap from the coupler member104is created, as discussed in greater detail herein. In some embodiments, portions of each of the each of the plurality of receiver coils114may be positioned in adjacent or adjoining layers. In other embodiments, portions of each of the plurality of receiver coils114may be positioned in layers that are spaced apart or separated by another layer that may be unoccupied or may contain other coils (i.e., a portion of the transmitter coil112, components for the secondary sensor assembly110, and the like).

As such, in some embodiments, portions of each of the plurality of receiver coils114overlap and underlap other portions of each of the plurality of receiver coils114. It should be appreciated that the overlap portions are not connected with the path of the coil above and/or below, and that this coil arrangement permits sensing of the coupler member104from different distances or air gaps and permits for each of the plurality of receiver coils (e.g., the six receiver coils116a,116b,116c,116d,116e,116fdepicted individually inFIGS.7A-7F) to act as independent coils. In yet other embodiments, portions some or each of the each of the plurality of receiver coils114are disposed within the same layer of the circuit board102so to have the same depth in the vertical direction (i.e., in the +/−Z-direction) or airgap from the coupler member104.

Further, as discussed in greater detail herein, the arrangement of the transmitter coil112and the plurality of receiver coils114permits for components of the secondary sensor assembly110(e.g. electrically conductive traces138and other electrical connections) to extend within any layer of the circuit board102with the exception, in some embodiments, of the layer occupied by the transmitter coil112. In the depicted embodiment, the components of the secondary sensor assembly110(e.g., the electrically conductive traces138and other electrical connections) may extend through layers156a,156b,156dand not have interference between components of the inductive sensor assembly108and components of the secondary sensor assembly110. As such, the circuit board102may only include four layers.

Now referring back toFIGS.3A-3C, the pair of inductive sensing interface integrated circuits118a,118bof the inductive sensor assembly108may be configured to utilize the RF frequency magnetic field. The pair of inductive sensing interface integrated circuits118a,118bmay each be positioned to be coupled to the circuit board102. In some embodiments, each of the pair of inductive sensing interface integrated circuits118a,118bmay be positioned outside of, or beyond the outer diameter of the transmitter coil112and the outermost portions of each of the plurality of receiver coils114. The inductive sensing interface integrated circuits118a,118bmay be communicatively coupled to each of the plurality of receiver coils114via a plurality of traces132a,132b, respectfully. It should be understood that other conductive mediums may be used in addition to the plurality of traces132a,132band/or instead of the plurality of traces132a,132b, as appreciated by those skilled in the art.

The pair of inductive sensing interface integrated circuits118a,118bmay be communicatively coupled to a microcontroller134. The microcontroller134may be an electronic control unit, a central processing unit (CPU), and the like, for performing the functions as described herein. As such, the microcontroller134may be configured to receive, analyze and process sensor data, perform calculations and mathematical functions, convert data, generate data, control system components, transmit data (e.g., to a vehicle side controller or electronic control unit), and the like. The microcontroller134may include one or more processors, and other components, for example one or more memory modules that stores logic that is executable by the one or more processors and a database based on, for example, received signal data from the inductive sensor assembly108and the secondary sensor assembly110. Each of the one or more processors may be a controller, an integrated circuit, a microchip, central processing unit or any other computing device. The one or more memory modules may be non-transitory computer readable medium and may be configured a RAM, ROM, flash memories, hard drives, and, or any device capable of storing computer-executable instructions, such that the computer-executable instructions can be accessed by the one or more processors.

The computer-executable instructions may include logic or algorithms, written in any programming language of any generation such as, for example machine language that may be directly executed by the processors, or assembly language, object orientated programming, scripting languages, microcode, and the like, that may be compiled or assembled into computer-executable instructions and storage on the one or more memory modules. Alternatively, the computer-executable instructions may be written in hardware description language, such as logic implemented via either a field programmable gate array (FPGA) configuration or an application specific integrated circuit (ASIC), all their equivalents. Accordingly, the assemblies and/or systems described herein may be implemented in any conventional computer programming language, as preprogrammed hardware elements, or as a combination of hardware and software components.

The secondary sensor assembly110may include be magneto, optical, potentiometer, Hall Effect, and/or the like. For each of these, a secondary sensor136that corresponds to the type of the at least one target148may be used to sense or detect the at least one target148of the coupler member104, as discussed in greater detail herein. The at least one target148may be multiple differing targets such that the secondary sensor assembly110includes a combination of sensors configured to sense or detect the corresponding at least one target148. In a non-limiting example, the sensor assembly110may include sensors for detecting at least one target that changes a magnetic field (Hall Effect) and another target that changes optics (e.g., mirrors). As such, the secondary sensor assembly110may include more than one type of sensor that corresponds to the at least one target148.

Further, the secondary sensor136is communicatively coupled to the microcontroller134. In some embodiments, the secondary sensor136may be positioned anywhere within the inner diameter ID1of the transmitter coil112and may be positioned inside of the innermost portion130aof each of the plurality of receiver coils114. In other embodiments, the secondary sensor136may be positioned to be concentric with the transmitter coil112and the plurality of receiver coils114. The electrically conductive traces138or other electrical connections extend from the secondary sensor136through the gap122to other components of the position sensor assembly100, such as, without limitation, to the microcontroller134, a power source139, and the like.

In a non-limiting example, in the depicted embodiments, the secondary sensor assembly110may utilize Hall Effect techniques to sense or detect the position of the at least one target148. As such, the secondary sensor136may be a Hall Effect sensor136. The Hall Effect sensor136is communicatively coupled to the microcontroller134and may be configured to utilize the DC frequency. The Hall Effect sensor136may be positioned on the circuit board102within the inner diameter of the transmitter coil112and inside of the innermost portion130aof each of the plurality of receiver coils114. In some embodiments, the Hall Effect sensor136may be positioned to be concentric with the transmitter coil112and the plurality of receiver coils114. The Hall Effect sensor136may be utilized as a primary or a secondary, or redundant, sensor and may be configured to sense changes in the magnetic field intensity. The electrically conductive traces138or other electrical connections extend from the Hall Effect sensor136through the gap122to other components of the position sensor assembly100, such as, without limitation, to the microcontroller134, a power source139, and the like.

It should be appreciated that the arrangement of the position sensor assembly100(e.g., the inductive sensor assembly108) permits for the secondary sensor136of the secondary sensor assembly110to be positioned within the same circuit board and proximate to the transmitter coil112and the plurality of receiver coils114.

Now referring back toFIGS.1-2and toFIGS.5A-5C, the coupler member104is coupled or otherwise attached to the part106such that when the part106moves (e.g., changing position), the coupler member104also moves. The coupler member104includes a body140that includes an exterior surface142aand an interior surface142b, which is opposite from and spaced apart from the exterior surface142ato define a thickness. In some embodiments, the interior surface142bmay be coupled or otherwise attached to the part106via at least one fastener. The at least one fastener may include, without limitation, bolt and nut, screw, rivet, epoxy, weld, adhesive, hook and loop, and/or the like. In other embodiments, the part106may be received within a portion of the coupler member104such as in a snap-fit configuration to attach or otherwise couple the part106to the coupler member104.

In the depicted embodiments, the coupler member104is a three-pole target. As such, in the depicted embodiment, three projecting protrusions144a,144b,144c, or lobes, extend from an outer edge158of the body140. That is the body140has an outer diameter OD4defined by the outer edge158. Each of the three projecting protrusions144a,144b,144c, or lobes, extend outwardly from the outer edge158and beyond the outer diameter OD4of the body140. This is non-limiting and there may be less than or more than three projecting protrusions extending from the body140. In some embodiments, there may be one or two projecting protrusions. In other embodiments, there may be five, six, eight, and many more projecting protrusions.

Further, in some embodiments, each of the projecting protrusions144a,144b,144cmay be integrally formed as a monolithic structure with the body140such that the body140and the projecting protrusions144a,144b,144care stamped together from the same piece of material to form a single piece without any coupling between the outer edge158and each of the projecting protrusions144a,144b,144c. In other embodiments, some or all of the projecting protrusions144a,144b,144care coupled or otherwise attached to the outer edge158of the body140via fasteners such as, without limitation, a bolt and nut, a screw, a rivet, epoxy, weld, adhesive, hook and loop, and/or the like. Further, each of the projecting protrusions144a,144b,144care illustrated as a general frustum shape and are configured to act as a target for the inductive sensor assembly108, as discussed in greater detail herein. This is non-limiting, and other shapes may be used, such as, without limitation, truncated pyramid, triangular, square, hexagonal, octagonal, parallelepiped, and/or the like. As such, any regular or irregular shape may be contemplated to include an edge that modifying the inductive coupling, as appreciated by those skilled in the art.

In some embodiments, each of the projecting protrusions144a,144b,144cmay be uniformly spaced apart so to have a rotational symmetric shape, as illustrated inFIGS.5A and5B. In some embodiments, each of the projecting protrusions144a,144b,144cmay not be uniformly spaced apart (e.g., non-uniform spacing), which creates or generates a non-symmetric rotational shape, as illustrated inFIG.5C. In the non-symmetric rotational shape examples, the projecting protrusions144a,144b,144care not equally spaced apart such that there are differing angular distances (in degrees) between each of the projecting protrusions144a,144b,144c, as illustrated inFIG.5C. For example, the angular distance AD1between the projecting protrusion144aand projecting protrusion144bis different from the angular distance AD2extending between the projecting protrusion144band the projecting protrusion144c(e.g., offset by a predetermined amount of degrees), resulting in a non-symmetric rotational shape. Further, in some embodiments, the angular distance AD3extending between the projecting protrusion144cand the projecting protrusion144amay be also be different from the angular distance AD2(e.g., offset by a predetermined amount of degrees), resulting in a non-symmetric rotational shape.

In some embodiments, at least one of the projecting protrusions144a,144b,144cmay extend radially from the body140(e.g., from the outer edge158) a greater length compared to the other projecting protrusions144a,144b,144c. For example, as best illustrated inFIG.5A, the projecting protrusion144aextends radially from the body140a length, illustrated by arrow L1, a greater distance or length than the other projecting protrusions144b,144cextend radially from the body140(e.g., from the outer edge158) illustrated by arrow L2. As such, in this embodiment, the projecting protrusion144ais longer or extends radially outward from the body140(e.g., from the outer edge158) a greater distance compared to the projecting protrusions144b,144cresulting in a non-symmetric rotational shape. In other embodiments, any one of the projecting protrusions (e.g.,144b,144c) may extend radially from the body140(e.g., from the outer edge158) a greater distance or length than the other projecting protrusions (e.g.144a,144c) resulting in the non-symmetric rotational shape. As such, at least one of the projecting protrusions144a,144b,144cmay extend radially from the body140(e.g., from the outer edge158) a different distance outwardly than the other projecting protrusions144a,144b,144c.

In other embodiments, any two of the projecting protrusions144a,144b,144cmay extend radially from the body140(e.g., from the outer edge158) a greater distance or length than the other projecting protrusion. Further, in some embodiments, all three of projecting protrusions144a,144b,144cmay extend radially from the body140(e.g., from the outer edge158) at different distances or lengths resulting in a non-symmetric rotational shape, as best illustrated inFIG.5B. InFIG.5B, the length or distance of the projecting protrusion144c, depicted by arrow L3, is less than the length or distance of the projection protrusion144b, depicted by arrow L2, which in turn is less than the length or distance of the projection protrusion144a, depicted by the arrow L1.

It should be appreciated that the shape of the coupler member104negates the gap122and the unused segments124a,124bof the plurality of receiver coils114. As such, each of the projecting protrusions144a,144b,144cmay act as an individual target for the inductive sensor assembly108indicative of, and/or sensitive to the movement and/or positioning of the part106. As such, movement of the projecting protrusions144a,144b,144cmay be sensed by the inductive sensor assembly108via detecting eddy currents changes in the three independent arc linear sections of coils162a,162b,162c(FIG.8) to generate a first receiver signal, which correlates to a position of the part106, without the sensor errors described herein. That is, each edge of each of the projecting protrusions144a,144b,144cmay act as an individual target by changing an eddy current, which is detected by at least one of the plurality of receiver coils114in the three independent arc linear sections of coils162a,162b,162c(FIG.8) and is converted as an electronic or electromagnetic signal (e.g., the first receiver signal).

In some embodiments, the body140and/or the projecting protrusions144a,144b,144cmay be formed from a metallic material. For example, and without limitation, each of the projecting protrusions144a,144b,144cand/or the body140may be formed from aluminum, copper, gold, silver, zinc, brass, steel, chrome, nickel, alloys, combination thereof, and/or the like. In other embodiments, the body140, portions of the body140, and the like, may also include, or in addition to the projecting protrusions144a,144b,144c, may also be formed from different metallic materials described above.

This is non-limiting and the body140may be merely a second circuit board (e.g., separate and independent from the circuit board102) or some other device, apparatus, assembly, or the like, that may not be molded or manufactured with the three projecting protrusions144a,144b,144c, or lobes, and in which the three projecting protrusions144a,144b,144c, or lobes, are coupled or otherwise attached therefrom and configured to extend therefrom. As such, in this embodiment, the three projecting protrusions144a,144b,144c, may be coupled to the part106and/or to the second circuit board via fasteners such as, without limitation, a bolt and nut, a screw, a rivet, epoxy, weld, adhesive, hook and loop, and/or the like. As such, the outer edge158is not limited to edges of the metallic coupler, but may be outer edges to any device, apparatus, assembly, or the like, such that the outer edges of the second circuit board, a housing, and the like, in which the three projecting protrusions144a,144b,144c, or lobes, may be coupled or otherwise attached and configured to extend therefrom. As such, the body140may be formed of any material, including conductive or non-conductive materials, and/or have portions of each, combinations of each, and/or the like.

In some embodiments, at least one of the projecting protrusions144a,144b,144cmay include at least one opening154configured as a mounting hole for the manufacturing processes such as a stamping hole.

In embodiments, the body140of the coupler member104may further include a an area145positioned within the outer edge158and in which a central portion146may be concentrically positioned in the area145of the body140to be concentrically positioned between each of the projecting protrusions144a,144b,144c. In some embodiments, the central portion146are the area145may be synonymous and defined by the outer edge158and may include an inner diameter ID3and an outer diameter OD4. In some embodiments, the body140may further include an annular portion150that is positioned to be concentric with the central portion146and/or the body140. That is, the annular portion150is optionally based on the type of the at least one target148. For instance, when the at least one target is magnetic, the annular portion150may be used. The annular portion150may have an outer diameter OD2, which may be less than the inner diameter ID3of the central portion146. As such, the annular portion150may be larger in diameter than the at least one target148, but is smaller in diameter compared to the central portion146of the body140.

The annular portion150may be made of a non-ferrous or non-conductive material. For example, and without limitation, the annular portion150may be formed from Acrylic or Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PETE or PET), Polyvinyl Chloride (PVC), Acrylonitrile-Butadiene-Styrene (ABS), and/or the like. As such, the annular portion150and the projecting protrusions144a,144b,144cand/or the body140may be formed from different materials.

In some embodiments, the annular portion150may be molded with the body140of the coupler member104to form a monolithic structure. That is, in some embodiments, the annular portion150may be molded with the body140in a same manufacturing process such that the annular portion150is part of or formed with the body140. In other embodiments, the annular portion150may be a member that is mounted or coupled to the body140. That is, the annular portion150may be coupled, or otherwise attached, to the exterior surface142aat or near the central portion146of the body140via at least one fastener. The at least one fastener may include, without limitation, bolt and nut, screw, rivet, epoxy, weld, adhesive, hook and loop, and/or the like.

In some embodiments, the annular portion150may include a recess152. The recess152may be configured to receive at least one target148. In some embodiments, the at least one target148may be received within the recess152in a snap-fit configuration. In other embodiments, the at least one target148may be mounted or coupled to the recess152. That is, the at least one target148may be molded, coupled, or otherwise attached to the annular portion150at or near the central portion146of the body140via at least one fastener. The at least one fastener may include, without limitation, bolt and nut, screw, rivet, epoxy, weld, adhesive, hook and loop, and/or the like. As such, the recess152is configured to receive the at least one target148such that the annular portion150circumferentially surrounds the at least one target148.

In other embodiments, the at least one target148may be mounted, coupled, or otherwise attached to the exterior surface142aat or near the central portion146of the body140via at least one fastener. The at least one fastener may include, without limitation, bolt and nut, screw, rivet, epoxy, weld, adhesive, hook and loop, and/or the like. In this embodiment, the annular portion150be mounted or coupled to the exterior surface142aat or near the central portion146of the body140via at least one fastener. The at least one fastener may include, without limitation, bolt and nut, screw, rivet, epoxy, weld, adhesive, hook and loop, and/or the like.

In other embodiments, the annular portion150may include an opening160that is configured to receive the at least one target148. In some embodiments, the at least one target148may be received within the opening160in a snap-fit configuration. In other embodiments, the at least one target148may be mounted or coupled to the opening160. That is, the at least one target148may be molded, coupled, or otherwise attached to the opening160of the annular portion150via at least one fastener. The at least one fastener may include, without limitation, bolt and nut, screw, rivet, epoxy, weld, adhesive, hook and loop, and/or the like. As such, the opening160is configured to receive the at least one target148such that the annular portion150circumferentially surrounds the at least one target148.

It should be understood that in some embodiments, the annular portion150, the at least one target148, and the at least three projecting protrusions144a,144b,144cmay be formed from different materials.

The annular portion150may be configured as an insulator to provide a barrier between the magnetic force and/or magnet field and may direct the magnetic force and/or the magnet field perpendicular to the annular portion150. In some embodiments, the at least one target148may generally be circular in shape with an outer diameter OD2that is less than an inner diameter ID2of the recess152or the opening160. The annular portion150and the at least one target148may each be configured to move with the movement of the coupler member104. In other embodiments, the at least one target148may be any shape or design such as, without limitation, square, triangular, octagonal, hexagonal, elliptical, irregular shaped, and/or the like. As such, in some embodiments, the recess152and the opening160of the annular portion150may have a corresponding shape to the at least one target148.

The at least one target148may be configured to act or function a second target. That is, the movement of the at least one target148may be sensed by the components of the secondary sensor assembly110to determine the position of the coupler member104, which ultimately is indicative of the part106. The at least one target148may be a redundant sensing target and is utilized in the secondary sensor assembly110.

In some embodiments, the movement of the at least one target148is sensed or otherwise detected by the secondary sensor assembly110configured to detect or sense various changes, outputs, and the like, that may be influenced by movement of the at least one target148, such as changes in the magnetic field, optics, resistance, current, inductance, electric field, magnetic field, and/or the like, dependent on the type of the at least one target148. As such, the detection or sensing of the various changes, outputs, and the like, may be used as the signal itself (e.g., to generate a second receiver signal to correlate to, and/or indicative of, a position of the part106) or may be sensed data that the microcontroller134uses to correlate to a position of the part106to generate the second receiver signal. That is, the at least one target148of the coupler member104may be used for the detection of various changes or outputs (e.g., optics, resistance, current, inductance, electric field, magnetic field, and/or the like, depending on the type of the at least one target148), to convert a displacement or angular measurement to an electronic or electromagnetic signal (e.g., the second receiver signal). Further, the secondary sensor assembly110may sense different changes or outputs (e.g., optics, resistance, current, inductance, electric field, magnetic field, and/or the like, depending on the type of the at least one target148) than the sensed or detections by the inductive sensor assembly108.

In some embodiments, the at least one target148is a magnet148a, as best depicted inFIGS.5A-5C. In this embodiment, the movement of the at least one magnet148aand the sensing of the movement by the secondary sensor assembly110via detecting changes in the magnetic field to generate the second receiver signal, which correlates to the position of the part106. That is, the at least one magnet148aof the coupler member104may be used for the Hall Effect detection of magnetic change, to convert a displacement or angular measurement to an electronic or electromagnetic signal (e.g., the second receiver signal).

In operation, the part106may move, such as rotationally. In response, the coupler member104also moves with the part106. The movement of the coupler member104changes or modifies the inductance or the electric field between the at least one of the plurality of receiver coils114and the transmitter coil112. Further, because each of the plurality of receiver coils114are connected in series and the edges of the each of the projecting protrusions144a,144b,144cchange or modify the inductance or the electric field between the at least one of the plurality of receiver coils114and the transmitter coil112, a lateral shift of pivot will result in each of the plurality of receiver coils114having coverage changes, which partially cancel each other such that a sensing angle error is reduced for lateral shift of pivot, as discussed in greater detail herein. Such a change or modification of eddy currents and/or the electric field may be determined, calculated, or otherwise received by the microcontroller134as the first receiver signal, which is correlated to, or may be indicative, of the current position of the coupler member104. As such, the position of the part106may be known by knowing the position of the coupler member104with the sensing angle error is minimized with respect to the lateral shift of pivot of the part106.

Additionally, movement of the coupler member104also moves the at least one target148. Such a movement of the at least one target148may change the various measured outputs (e.g., optics, resistance, current, inductance, electric field, and/or the like, depending on the type of the at least one target148), which may be detected or sensed by the secondary sensor assembly110. Such a change or modification of the various outputs (e.g., optics, resistance, current, inductance, electric field, and/or the like, depending on the type of the at least one target148) may be determined, calculated, or otherwise received by the microcontroller134as the second receiver signal, which is correlated to, or may be indicative, of the current position of the coupler member104.

Now referring to back toFIG.1and toFIG.6A, which graphically depicts an example simulation of an XYZ offset performance of the inductive sensor assembly108of the position sensor assembly100. In the simulation, the sensor is programmed to output 5˜95% output within 20-degree span in terms of coupler member104rotation. As illustrated, at the various offsets in the X-direction (e.g., X=−1.0 mm to X=1.0 mm), the data is correlated with similar output and the same degrees. As such, the XYZ offset performance of the inductive sensor assembly108of the position sensor assembly100behaves as expected for the various offsets as illustrated.

Still referring toFIG.1and now toFIG.6B, which graphically depicts an example simulation of an X, Y, Z offset from nominal position and measured a shift in an output of the inductive sensor assembly108of the position. As illustrated, the sensed angle error due to lateral shift in pivot is reduced to be similar or comparable to rotary inductive sensors

It should now be understood that the embodiments described herein are directed to a radial multi-pole arc-linear inductive sensing coil assembly, with multiple poles within a rotary sensing coil, configured to avoid a sensed angle error due to a lateral shift in pivot since the lateral offset in one pole effectively results in counteracting lateral offset in the other poles. As such, the present multi-pole inductive sensing coil assembly combines the advantages of arc-linear sensing coil and multi-pole rotary sensing coil.