Annular speed sensor

Abstract: An in-axle annular rotational speed sensor assembly (52) for drive axles (10) is provided which mounts directly to the drive axle differential bearing adjusters (36) in a relatively available and protected space (50) within the axle housing. The assembly utilizes the ferromagnetic adjuster to define a portion of the magnetic flux path (108) and maintains a large axial separation between the adjuster and the air gap (102) between the arrays of rotor and stator teeth (82, 100).

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to an in-axle rotational speed sensor assembly for mounting to a fixed metallic (magnetic) member, such as a drive axle differential bearing adjustor, having a central opening therethrough for receipt of rotatable member, such as a shaft, the rotational speed of which is to measured. Description of the Prior Art Automated vehicular systems such as brake control systems, antilock brake systems (ABS), traction control systems, differential lock-up systems and the like which utilize rotational speed sensors to provide a control input signal, usually indicative of wheel speed, to a controller, such as a microprocessor based electronic control unit (ECU), are well known in the prior art. Examples of such systems and/or sensors may be seen by reference to U.S. Patent Nos. RE 30,522; 3,961,215; 3,929,382, 3,556,610; 3,604,760; 4,585,280; 4,361,060; 3,768,840; 4,818,035 and 4,863,221. Typically, such rotational speed sensor assemblies are electromagnetic in nature and rely on the alignment of rotor teeth, or spaces between rotor teeth, rotating past a sensor to complete or break, respectively, a magnetic flux path to produce a digital or analog signal indicative of the rotational speed of the rotor. Placement of wheel-speed sensor assemblies within the axle (i.e. "in-axle") to protect same is also known as may be seen by reference to U.S. Patent Nos. 3,769,533; 4,724,935; 4,836,616, 4,862,025 and 4,862,028, The use of annular rotational speed sensor assemblies comprising an annular toothed stator/sensor which surrounds a rotating toothed rotor, or visa versa, is known in the prior art. Annular speed sensor assemblies are preferred over single or multiple point type sensor assemblies in certain situations as they provide a relatively high signal to noise ratio, tend to be self-compensating for run-out errors between the rotor and stator, and require little or no adjustment. EP-A-0 357 870 shows an example of an annular rotational speed sensor assembly. This assembly includes a coil surrounding a member the rotational speed of which is to be sensed. This coil is coaxially aligned with that member and two disk shaped stator plates each of which abuts a corresponding end face of the coil . The stator plates extends radially towards the rotational member beyond the bore of the coil such that two annular areas are provided which are in spaced relationship. Each of this annular face includes a corresponding array of radially aligned teeth extending an axial direction. The rotor of the sensor assembly is arranged between the two annular faces and comprises a ring shaped magnet carrying two rings at both end faces. This arrangement requires a non ferromagnetic support structure for coupling the rotor to the shaft since otherwise a magnetic short circuit would be provided. With another embodiment shown in EP-A-0 357 870 the annular magnet of the sensor assembly is placed around the coil whereas the rotor itself is free free from the magnet. In any case the arrangement is complicated insofar as the teeth are the ferromagnetic yoke have to be aligned as well as the teeth of the rotor since otherwise the signal to noise ratio would be pure since in the case of a misalignment a decreasing magnetic resistance at one end face could be compensated by an increasing magnetic resistance at the other end face of the rotor. It is an object of the invention to provide a simplified annular rotational speed sensor assembly. SUMMARY OF THE INVENTION The object is solved by a sensor according to claim 1 or 2. In accordance with an embodiment of the present invention, the drawbacks of the prior art have been minimized or overcome by the provision of an annular in-axle wheel speed sensor assembly for drive axles which is mounted in-axle at or adjacent to the relatively protected center of the drive axle assembly at either or both of the differential bearing adjustment members, which provides a pilot portion for axle shafts which are inserted through an opening in the bearing adjustor for driving engagement with the differential side gearing and which requires no adjustment. The above is accomplished by providing an annular in-axle wheel speed sensor for a drive axle which mounts to the drive axle differential bearing assembly adjustment member, which includes pilot means to assist assembly of the axle shafts to the drive axle differential side gearing and which requires no adjustment. Further, with relatively minor modifications, the sensor assembly may be modified for use with a wide variety of drive axles. This and other objects and advantages of the present invention will become apparent from a reading of the description of the preferred embodiment taken in connection with the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a partial sectional view of a typical prior art drive axle. Figure 2 is a perspective view of a portion of the annular wheel speed sensor assembly of the present invention. Figure 3 is a partially sectioned perspective view of the bearing adjuster of the present invention. Figure 4 is an exploded view of the annular wheel speed sensor assembly of the present invention. Figure 5 is a perspective view of the rotor member of the sensor assembly of Figure 2. Figure 6 is a perspective view of the stator member of the sensor assembly of Figure 2. Figure 7 is a perspective view of the cover member of the sensor assembly of Figure 2. Figure 8 is an enlarged partial view in section illustrating the magnetic flux path of the wheel speed sensor of Figure 2. Figure 9 is a partial schematic top view illustrating the type of assembly error that is protected against by the sensor assembly of the present invention. Figure 10 is a partial top view, in section, illustrating a drive axle with the in-axle annular speed sensors of the present invention assembled thereto. Figures 11 and 11A show exploded and assembled perspective views, respectively, of the coil bobbin and terminal block connector of the annular speed sensor assembly of the present invention. Figure 12 is an enlarged partial view, similar to Figure 8 of an alternate embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT In the following description of the preferred embodiment, certain terms will be used for convenience in reference only and are not intended to be limiting. The terms "upwardly", "downwardly", "rightwardly" and "leftwardly" will designate directions in the drawings to which reference is made. The terms "inboard", and "outboard" will refer respectively to directions towards and away from, the geometric center of the vehicle drive axle as same is conventionally mounted in a vehicle. The terms "inwardly" and "outwardly" will refer to directions towards and away from, respectively, the geometric center of the device and designated parts thereof. The above applies to the words above specifically mentioned, derivatives thereof and words of similar import. Heavy duty drive axles utilizing ring gear/pinion gear right angle gear sets are well known in the prior art. Referring to Figure 1, a typical prior art differential head assembly 10 of a single reduction drive axle utilizing a gear set 11 comprising a pinion gear 12 meshingly engaged with a ring gear 14 is illustrated. A differential assembly 16 is fixed to the ring gear for driving two axle shafts 18 and 20. Axle shafts 18 and 20 drive the left and right hand, respectively, drive wheels (not shown) as is well known in the prior art. In the axis of rotation 22 of the pinion gear 12 is substantially perpendicular to the axis of rotation 24 of ring gear 14 (and the differential 16 and drive shafts 18 and 20). Heavy duty drive axles of this, and of the two speed planetary double reduction type, are well known in the prior art. Drive axle assembly 10 also includes an axle housing 26 having a differential head portion 28. The ring gear 14 is mounted for rotation with a differential carrier 30 by means of bolt and nut assemblies 32. The differential carrier is rotationally supported in the housing portion 28 by means of tapered bearings 34 which are adjustably positioned by means of bearing adjustors 36 which are maintained in position by bearing adjustor lock members 38 and unshown bolts. The bearing adjustors 36 include outwardly extending lug members 36A which extend only partially radially inwardly from the outer periphery of the bearing adjusters to define an outboardly facing counterbore on the outboard faces of the bearing adjusters. The differential carrier 30 carries the differential spider member of 42 and which are rotatably received the differential pinion gears 44. The differential pinion gears are constantly meshed with the righthand and lefthand side gear (46 and 48), respectively, which side gears are rotatably engaged by the drive shafts 20 and 18 by means of a splined connection as is well known in the prior art. The splined connection between the inboard ends of the axle drive shafts and the hub portions of the side gears allows the axle shafts to be assembled to and disassembled from the drive axle gearing by passing same through the arm portions of the housing and centrally located openings or bores 36B in the bearing adjusters. As may be appreciated by reference to Figure 1, the spaces designated generally as 50 within the axle housing 28 which are slightly outboard and adjacent the bearing adjusters 36 are relatively well protected and unused spaces which are particularly well suited for receipt of in-axle wheel speed sensors. The annular in-axle wheel speed sensor assembly 52 of the present invention, which is adapted to be mounted to the outboard faces of one or, preferably, both of the bearing adjustors 36, and thus within space 50 within the axle housing, may be seen by reference to Figures 2, 3, 4, 8 and 10. The speed sensor assembly 52 is adapted to be received in and located by the counterbore on the outboard surface of the bearing adjusters defined by the lugs 36A thereof. Vehicular ABS and automated drive train systems are well known in the prior art and examples thereof may be seen by reference to above-mentioned U.S. Patents Nos. 3,920,284; 3,929,382; 4,168,866; 4,478,840; 4,818,035; 4,863,212; 4,361,060; 4,527,447; 4,643,048 and 4,860,861. Speed sensor assemblies for providing input signals to control units, usually microprocessor based central processing units, are well known in the prior art as may be seen by reference to above-mentioned U.S. Patents Nos. RE 30522; 3,961,215; 4,862,025; 4,862,028 and 4,893,075. Typically, such speed sensor assemblies include a magnet, a coil, a tooth ferromagnetic rotor which is keyed to a monitored shaft for rotation therewith and a stator or sensor member rotationally fixed relative to a vehicle component. Usually, rotation of the rotor tooth and tooth spaces past the stator or sensor will result in the making and then breaking of a magnetic flux path which will result in pulses of increasing and decreasing induced current in the coil, the frequency and/or voltage of the induced current being indicative of the rotational speed of the rotor and those members rotating therewith. Of course, the rotor teeth may be replaced by undulations, apertures, etc. The annular speed sensor assembly 52 of the present invention includes a ferromagnetic rotor member 54, a substantially annular permanent magnet 56, an annular coil member assembly 58, an annular ferromagnetic stator member 60 and an annular cover member 62 which is preferably of a relatively nonmagnetic flux conducting material such as stainless steel or brass or the like. A plurality of bolts or machine screws 64 are received through bolt holes 66 provided in the cover member 62 and are threadably engaged in internally threaded bores 68 provided in the adjuster members 36 to axially and rotationally mount the speed sensor assembly 52 to the outboard face of the adjuster member 36. The cover member 62 includes an axially extending wall 70 having an outer diameter surface 72 with an outer diameter just slightly less than inner diameter 74 of the counter bore defined on the outwardly facing surface of the bearing adjuster 36 by the lug members 36A whereby the assembly 52 is correctly radially positioned relative to the drive axle assembly. Preferably the bolts or machine screws 64 are of a nonferrous material and/or nonferrous spacers or sleeves are utilized therewith. The ferromagnetic rotor 54 includes an inboardly facing surface 76 for close abutment with the outboardly facing surface or face 36C of the bearing adjuster 36, and an axially extending outer diameter surface comprising an inboard portion 78, an outboard portion 80 and a radially outwardly extending array of teeth 82 interposed the inboard and outboard portions of the outer diameter surface. The radially outwardly extending teeth 82, define an outwardly facing abutment surface 84 which cooperates with the radially inwardly extending wall portion 86 of the cover member 62 to axially locate the rotor member 54. The outboard end of the rotor 54 extends axially outwardly from the other components of the speed sensor assembly 52 and defines a radially and axially inwardly tapered pilot surface 88 extending axially inwardly and radially downwardly to internal splines 90 which are intended for cooperation with external splines or projections (18A, see Fig. 10) to be provided on modified axle shafts whereby the rotor 54 will rotate with the axle shafts. The axially outwardly extending portion of the rotor 54 and the pilot or chamfer surface 88 both protects the speed sensor assembly 52 from the ends of axle shafts during assembly of the axle shafts to the differential side gears (see Fig. 9) and also pilots the ends of the axle shafts to ease such assembly. An annular coil member assembly 58 telescopically surrounds the inboard outer diameter surface 78 of the rotor. The coil assembly 58 includes a nonmagnetic bobbin member 58A which supports the coil windings 58B. To provide increased reliability of the sensor, preferably the coil is wound of a copper, nickel, plated copper or other special alloy coil wire and the outer layer of the coil may be of a heavier gauge wire. For coils of this type, 1,600 to 2,500 turns per inch is typical. A pair of terminal connectors 92 and 94 are provided for the connection to the coil member windings for purposes of providing the sensor output signal. The terminal connector assemblies 92/94 are preferably housed in a single terminal block member 95 having two openings 95A and 95B for electrical connection to blade type connectors. The terminal block is located between a pair of tabs 58C provided on the bobbin 58A (see Figs. 11 and 11A). The bobbin 58A also includes a plurality of extensions 58D which pass through openings provided in cover 62 for attaching the coil assembly 58 and stator 60 to the cover as a preassembled subassembly (see Fig. 8). An annular split ring type permanent magnet member 56 is telescopically received about the outer diameter of the annular coil member 58. Preferably, the magnet member 56 is a plastic magnet for purposes of conserving weight and for providing added reliability. The magnetic member 56 includes an inboard surface 96 for abutting engagement with the outboard surface 36C of the ferromagnetic bearing adjuster 36 and an outboardly facing surface 98 for abutting engagement with the inboard surface of the stator member 60. A generally flat washer shaped stator member 60 is axially positioned between the inboard face of the radial wall 86 of the cover member 62 and the outboard face 98 of the permanent magnet 56. The stator includes a plurality of radially inwardly extending teeth 100 which are axially aligned with portions of the radially outwardly extending teeth 82 carried by the rotor 54 and are radially spaced therefrom by an air gap 102. At its outer diameter, the stator member 60 is provided with a plurality of generally concave shaped cut outs 104 allowing passage of the bolt means 64 therethrough and a circumferentially elongated cut out portion 106 allowing passage of the connector block 92/94 axially therethrough. Preferably, the cut-outs 104 are generally radially extending and provide a relatively large clearance with screws 64 allowing the stator to move or float radially into a position of non-contact with the rotating rotor 54. The flux path 108 defined by the sensor assembly 52 of the present invention may be seen in greater detail by reference to Figure 8. In the counterclockwise direction, the flux path is from magnet member 56 through ferromagnetic adjustor member 36 into the rotor member 54 from teeth 82 of the rotor to teeth 100 of the stator across the air gap 102, also called the working gap, when the teeth of the rotor and the stator are in circumferential alignment and from the stator back into the magnet member. It is important to note, that by positioning the axially aligned portions of the teeth 82 and 100 remote from the relatively massive ferromagnetic adjuster member 36 and at a position surrounded by the relatively low permeability cover member 62, short circuiting of the magnetic flux path across from the rotor to the stator other than across the air gap 102 when the teeth are in circumferential alignment is minimized. To provide protection to the coil member 58, magnet member 56 and stator 60, the axial length 110 of surface 78, including teeth 82 is greater than the axial width 112 of the coil member 58 and magnet 56 to prevent jolts on surface 88 from being transmitted to the magnet or coil member during assembly of the axle shaft to the axle differential gearing. The cover member 62 is provided with a stamped plate 63 having a plurality of cut out portions 114 for cooperation with the locking member 38 whereby the differential adjusting member may be rotationally locked in its selected position. The cover member 62, stator member 60, coil member 58, and the connector assemblies 92/94 may be formed as a subassembly and electron beam welding of the stainless steel cover member and the coil bobbin to seal the sensor with hermetic seals at the connection points may be utilized. To increase the reliability and to minimize the requirement of servicing, bi-filar coil windings may be utilized for redundancy as may vacuum impregnated coils and soft potting material rather than a rigid epoxy to minimize stress on the coil and termination points. Referring to Figure 10 and 10A, a connector assembly 120 is provided having a cap portion 122 designed to be sealingly and threadably received in a threaded bore 124 provided in the housing and defining a socket 126. A pair of wires 128 having blade connectors 130 for receipt into openings 95A and 95B of the terminal block extend from the cap member. Figure 12 is an enlarged view, similar to Figure 8, of an alternate embodiment 252 of the annular speed sensor assembly of the present invention. Components of assembly 252 similar in structure and function to those illustrated in Figure 8 and described above will be given the same reference numerals with a "2" prefix and will not be described in great detail. The assembly 252 includes a rotor 254, a stator 260, a magnet 256 and a coil 258, all performing the same functions as their counterparts in assembly 52 described above. The assembly cooperates with a ferromagnetic bearing adjuster 236 which defines a portion of the flux path 108. Surface 276 of rotor 254 abuts surface 236(c) of the adjuster. Assembly 252 differs from assembly 52 principally in that teeth 282 are axially extending and are axially, not radially, separated from the teeth 100 of stator 260 to define an axially, not radially, extending air gap or working gap 2102. It has been found that a sensor assembly with an axially extending air gap is more tolerant of radial run out between the relatively rotating component. A spacer or thrust washer, which may be of self-lubricating material such as teflon or the like, 200 may be utilized to maintain a minimum axial separation between the rotor teeth 282 and stator teeth 100. Further advantages of the annular speed sensor are that the speed sensor is less susceptible to run out noise generation (both AM and FM), there is less noise resulting from tooth to tooth variation which allows the use of lower precision, less costly rotors and a higher output is possible due to the availability of large magnet volume and efficient magnetic circuit allowing the use of smaller diameter rotors, larger gaps, fewer turns of wire and/or less expensive magnets. It is also noted, that by utilization of the existing ferromagnetic bearing adjustor 36 as a portion of the annular speed sensor magnetic flux path 108 an additional ferromagnetic member need not be supplied with resulting savings in weight and cost. Although the preferred embodiment of the present invention has been described with a certain degree of particularity, it is understood, of course, that certain substitutions for rearrangement of the parts may be resorted to without departing from the scope of the present invention as hereinafter claimed.

Claims: An annular rotational speed sensor assembly (52) for sensing the rotational speed of a shaft (18, 20) passing through a bore (36B) in a fixed ferromagnetic member (36), said ferromagnetic member (36) defining a generally flat face (36C) surrounding said bore (36B) and generally perpendicular to the axis of rotation (28) of said shaft (18,20), said assembly comprising: a ferromagnetic rotor (54) mountable to said shaft (18,20) for joint rotation therewith, said rotor (54) defining a generally flat surface (76) parallel to and abuttable with said face (36c) and a first annular array of teeth (82) extending radially therefrom; a ferromagnetic stator (60) mountable to said ferromagnetic member (36) and defining a second annular array of teeth (100) axially aligned with said first annular array of teeth, said second array of teeth extending radially towards said first array of teeth to define a minimum average air gap (102) therebetween; the axially aligned portions of said arrays of teeth axially spaced from said surface (76) by at least a predetermined axial distance (112); a substantially annular magnet (56) axially interposed said stator and said face (36c), said substantially annular magnet (56) surrounding and radially spaced from said rotor (54) by a radial distance (116) considerably greater than said average minimum air gap (102); and an annular coil member (58) axially interposed said face and said arrays (82, 100) of teeth and radially interposed said substantially annular magnet (56) and said ferromagnetic rotor (54); wherein in use an annular magnetic flux path (108) is defined around said coil member (58), said flux path (108) defined by flux travel across the interface of said face (36C) and said surface (76), across said air gap from said first array of teeth (82) to said second array of teeth (100), from said stator (60) to said magnet (56, 256), from said magnet (56,256) to said face (36C) at an interface radially spaced from said interface of said face (36C) and said surface (76), and through said ferromagnetic member (36) to said interface of said face (36C) and said surface (76). An annular rotational speed sensor assembly (252) for sensing the rotational speed of a shaft (18, 20) passing through a bore (36B) in a fixed ferromagnetic member (236), said ferromagnetic member (236) defining a generally flat face (236C) surrounding said bore (36B) and generally perpendicular to the axis of rotation (28) of said shaft (18,20), said assembly comprising: a ferromagnetic rotor (254) mountable to said shaft (18,20) for joint rotation therewith, said rotor (254) defining a generally flat surface (276) parallel to and abuttable with said face and a first annular array of teeth (282) extending axially therefrom; a ferromagnetic stator (260) mountable to said ferromagnetic member (236) and defining a second annular array of teeth (100) radially aligned with said first annular array of teeth, said second array of teeth extending axially towards said first array of teeth to define a minimum average air gap (2102) therebetween; said arrays of teeth axially spaced from said surface by at least a predetermined axial distance; a substantially annular magnet (256) axially interposed said stator and said face, said substantially annular magnet (56,256) surrounding and radially spaced from said rotor (254) by a radial distance (116) considerably greater than said average minimum air gap; and an annular coil member (258) axially interposed said face and said arrays (282, 100) of teeth and radially interposed said substantially annular magnet (56,256) and said ferromagnetic rotor (254); wherein in use an annular magnetic flux path (108) is defined around said coil (258), said flux path (108) defined by flux travel across the interface of said face (236C) and said surface (276), across said air gap from said first array of teeth (282) to said second array of teeth (100), from said stator (260) to said magnet (256), from said magnet (256) to said face (236C) at an interface radially spaced from said interface of said face (236C) and said surface (276), and through said ferromagnetic member (236) to said interface of said face (236C) and said surface (276). The assembly of claim 1 or 2 further comprising a cover member (62,262) of magnetically nonconductive material mountable to said ferromagnetic member (36), said stator and coil member comprising a subassembly with said cover member. The assembly of claim 1 further comprising a cover member of magnetically nonconductive material mounted to said ferromagnetic member (36), said cover member comprising an axially extending portion radially surrounding said magnet (56,256) and stator and a radially extending portion extending radially inwardly from said axially extending portion at a point spaced axially more distant from said face than said arrays. The assembly of claim 1 wherein the axial separation (110) of the axially aligned portions of said arrays of teeth and said surface (76) exceeds the axial thickness (112) of said coil member. The assembly of claim 1 wherein the axial separation (110) of the axially aligned portions of said arrays of teeth and said surface (76) exceeds the axial thickness (112) of said magnet (56,256). The assembly of claims 1 or 2 wherein said rotor (54, 254) defines a rotor bore having an inner diameter for receipt of said shaft (18,20), said rotor (54,254) having an axial extension (80) extending from said first array axially away from said surface and defining a radially inwardly chamfered surface (88) to guide said shaft (18, 20) into said rotor bore. The assembly of claim 7 wherein the inner diameter of said rotor bore includes a plurality of inwardly extending projections (90) adapted to engage complementary outwardly extending projections (18A) provided on said shaft (18,20). The assembly of claim 1 wherein said stator is mounted to said ferromagnetic member (36) with a degree of relative movement in the radial direction relative to the axis of rotation (24) of said rotor (54). The assembly of claim 1 wherein said ferromagnetic member (36) is a drive axle bearing adjuster. The assembly of claim 2 wherein the axial separation (110) of the axial air gap (2102) defined between said arrays of teeth and said surface (276) exceeds the axial thickness of said magnet (56,256). The assembly of claims 2 wherein a spacer (200) is utilized to maintain a predetermined minimum axial separation between said arrays of teeth. An annular rotational speed sensor assembly (52) in accordance with one or more of the preceding claims, provided for use in a drive axle for sensing the rotational speed of an axle shaft (18, 20) passing through a bore (36B) in a ferromagnetic bearing adjuster (36) fixed to said drive axle, wherein said adjuster provides said ferromagnetic member (36) and defines a generally flat outboardly facing face (36C) surrounding said bore (36B) and extending generally perpendicular to the axis of rotation (28) of said shaft (18,20); and wherein said ferromagnetic rotor (54,254) (54) is generally tubularly shaped and mountable to said shaft (18,20) for joint rotation therewith, said rotor (54,254) defining an inboardly facing generally flat surface (76) parallel to and substantially abuttable with said face and a first annular array of teeth (82) extending outwardly from an outer surface thereof; said air gap between said arrays of teeth axially spaced from said surface by at least a predetermined axial distance (110). The assembly of claim 13 wherein said magnet (56,256) defines an inboardly facing surface (96) in abutting relation with said face and an outboardly facing surface (98) in abutting relationship with an inboardly facing surface of said stator.

Inventors: CARON LAVERNE ANDREW, PETERSON GLEN DAVID, CARON, LAVERNE ANDREW, PETERSON, GLEN DAVID
Applicants: EATON CORP, EATON CORPORATION
Application year: 1991
Main classification: G01P3
IPC codes: G01P3