Abstract:
A position sensor including at least one stator structure defining a secondary gap wherein is housed at least one Hall probe, and a mobile magnet in a main gap. The stator structure includes stator parts defining at least one first secondary gap wherein is housed at least one first Hall probe delivering a signal which is a function of the displacement of the mobile magnet relative to a first degree of freedom, and at least one second secondary gap wherein is housed at least one second Hall probe delivering a signal which is a function of the displacement of the mobile magnet relative to a second degree of freedom.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the domain of metrology, and more precisely to the domain of position sensors without contact with Hall probes. 
     2. Discussion of the Background Art 
     Hall probe sensors are known, which make it possible to determine the linear or angular position of a permanent magnet in relation to a stator structure. 
     The French patent FR2670286 is also known, relating to a magnetic sensor of position and speed with a Hall probe enabling acquisition of position or speed in a single dimension. 
     The European patent EP800055 describes a linear and angular position sensor. This sensor does not describe two gaps, and delivers analog signals which are difficult to use because they are non-linear, and low-level. Such sensors have two paths which are not independent. 
     SUMMARY OF THE INVENTION 
     Other patents such as the U.S. Pat. No. 4,639,667 or W09716736 describe sensors operating according to principles which do not permit delivery of linear and independent signals, representative of the position in two dimensions. 
     The aim of the invention is to propose a sensor making it possible to measure a position in space, according to two independent degrees of freedom. 
     To this effect, the invention concerns in its most general meaning a position sensor comprising at least one stator structure defining a secondary gap wherein is housed at least one Hall probe, and a mobile magnet in a main gap, characterised in that the stator structure is composed of stator parts defining at least one first secondary gap wherein is housed at least one main Hall probe, delivering a signal which is a function of the displacement of the mobile magnet relative to a first degree of freedom, and at least one second secondary gap wherein is housed at least one second Hall probe delivering a signal which is a function of the displacement of the mobile magnet relative to a second degree of freedom. 
     Preferably, the secondary gaps are formed of two pairs of secondary gaps. Each pair of secondary gaps contains two Hall probes arranged on either side of the intersection of the first pair of secondary gaps with the second pair of secondary gaps, and means for summation of the electric signals provided by the Hall probes placed in a same gap, to deliver a resulting signal closely proportional to the position of the magnet according t o the degree of freedom corresponding to each of the pairs of Hall probes. 
     Advantageously, the stator structure is composed of 4 poles in a magnetically soft material defining between them two pairs of secondary gaps crossing each other at a median point and in that the main gap is plane. 
     According to a first variant, the stator poles are constituted of 4 rectangular parts integral with a non-magnetic base and placed facing a support assembly and together defining two pairs of perpendicular secondary gaps. 
     According to a preferred embodiment, the L/E relation between the thickness L of the magnet and the thickness E of the gap is comprised between 1 and 2. 
     According to a second preferred embodiment, the dimensions of the secondary gaps are C 1 +E and C 2 +E, where C 1  and C 2  define the path of the mobile magnet according to the two directions of the secondary gaps. 
     According to a second embodiment variant, the magnet is in the shape of a half-tube and is mobile according to a first degree of freedom in axial translation and according to a second degree of freedom in axial rotation relative to a stator structure formed of 4 stator poles in the shape of half-rings, and in that it comprises a first pair of Hall probes placed in a first pair of secondary gaps in the median transversal plane of the stator structure, for measuring the position according to the first degree of freedom, and a second pair of Hall probes placed in a second longitudinal secondary gap constituted by longitudinal slits separating the stator half-rings. 
     According to a third embodiment variant, the magnet is in the shape of a half-tube and is mobile according to a first degree of freedom in axial translation and according to a second degree of freedom in axial rotation relative to a cylindrical stator structure formed of 4 stator poles in the shape of half-cylinders, and in that it comprises a first pair of Hall probes placed in a first pair of secondary gaps in the median transversal plane of the stator structure, for measuring the position according to the first degree of freedom, and a second pair of Hall probes placed in a second longitudinal secondary gap in the longitudinal median plane separating the stator half-cylinders. 
     According to a preferred embodiment, the longitudinal edges of the stator half-cylinders are chamfered. 
     According to a fourth embodiment of the invention, the sensor according to the invention is characterised in that the magnet is spherical or hemispherical in shape and is mobile in spherical rotation relative to a stator structure in the shape of a spherical cap formed of 4 stator poles in the shape of a cap sector, and in that it comprises a first pair of Hall probes placed in a first pair of secondary gaps in a first median plane of the stator structure, for measuring the position according to the first degree of freedom, and a second pair of Hall probes placed in a second longitudinal secondary gap in a second median plane. 
     According to a fifth embodiment variant, the sensor is characterised in that the magnet is of a spherical o r hemispherical shape and is mobile in spherical rotation relative to a stator structure formed of 4 stator poles with internal spherical shape located around the equator of the magnet, and in that it comprises a first pair of Hall probes placed in a first pair of secondary gaps in a first median plane of the stator structure, for measuring the position according to the first degree of freedom, and a second pair of Hall probes placed in a second longitudinal secondary gap in a second median plane. 
     Preferably, the main gap is spherical in shape. 
     In a sixth embodiment variant, the sensor is characterised in that the magnet is spherical or hemispherical in shape and is mobile in spherical rotation around a stator structure of spherical shape formed of 4 stator poles in the shape of a quarter of a sphere, and in that it comprises a first pair of Hall probes placed in a first pair of secondary gaps in a first median plane of the stator structure, for measuring the position according to the first degree of freedom, and a second pair of Hall probes placed in a second longitudinal secondary gap in a second median plane. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Advantageously, the stator sectors have chamfers. 
     The invention will be better understood by reading the following description, with reference to embodiment examples which are non-limiting, shown in the attached drawings where: 
     FIGS. 1 and 2 show a diagrammatic view respectively of the stator part and according to a cross-sectional view of a first embodiment variant under the form of a linear sensor XY; 
     FIGS. 3 a  and  3   b  show typical measurement results for several magnet movements; 
     FIG. 4 shows a view in perspective of a sensor XY according to the first variant; 
     FIG. 5 shows a partial view of an angular linear sensor according to the invention; 
     FIGS. 6 and 7 show partial views of an angular linear sensor according to an embodiment variant; 
     FIG. 8 shows a partial view of another embodiment variant of an angular linear sensor according to the invention; 
     FIGS.  9  and  9 ′ show respectively a view in perspective and in cross-section of a spherical sensor with two degrees of freedom in rotation; 
     FIG. 10 shows an exploded view of a magnet and its support assembly for such a spherical sensor; 
     FIG. 11 shows an embodiment of a spherical sensor simpler for industrialisation; 
     FIG. 12 shows a view of a magnet for a spherical sensor, mounted on its support assembly and alone; 
     FIG. 13 shows another embodiment of a spherical sensor; 
     FIG. 14 shows a partial view of another embodiment variant of a spherical sensor; 
     FIGS. 15 and 16 show partial and cross-sectional views of a bidirectional linear sensor with two Hall probes; 
     FIGS. 17 and 18 show views of a rotary linear sensor with two Hall probes; 
     FIGS. 19 and 20 show views of a variant of a rotary linear sensor with two Hall probes. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In general, the invention concerns a new type of sensors making it possible to detect the position of a mobile part according to two degrees of freedom. 
     The applications are aimed in particular at: 
     computer applications: mouse, joystick 
     industrial applications: pick and place 
     automobile applications: gear lever, gear assistance. 
     FIGS. 1 and 2 show respectively a schematic diagram of the stator part and a cross-section of a first embodiment variant under the form of a linear sensor XY. 
     The aim is to define the displacement of a mobile part in a plane at any instant, along a given path. 
     The sensor shown in FIGS. 1 and 2 has 4 stator poles,  1  to  4 , in a magnetically soft material, square in shape, separated from a ferromagnetic support assembly  5  by a main gap  10 . 
     A thin magnet  11 , magnetised transversally, is mobile inside the main gap. 
     The 4 stator poles moreover define between them 4 secondary gaps  6  to  9 . In each of them, a Hall probe is placed,  12  to  15 , in order to determine the magnetic induction circulating from one pole to the other through the interaction between the magnet  11  and the iron mass of the stator structure formed by the stator poles,  1  to  4 , and the support assembly  5 . 
     The sensor is thus composed of a rectangular flat magnet  11 , of 4 rectangular magnetically soft poles,  1  to  4 , of 4 Hall probes,  12  to  15 , (or any other component sensitive to magnetic induction variation), and of a rectangular ferromagnetic support assembly  5 . 
     By displacing the magnet, a variation of magnetic potential is created at each pole which modifies the induction measured in each probe. One of the points of the invention consists in the addition of the probe signals. In fact, the sum of the signals provided by the probes  12  and  14  is a linear function of the displacement relative to the X axis and the sum of the signals provided by the probes  13  and  15  is a linear function of the displacement relative to the Y axis. Thus one can obtain a signal which can easily be exploited by adding these signals by an electronic summing assembly. 
     Then one will obtain 2 independent signals, linear respectively relative to the displacements in X and Y. 
     The compensation for the variation in behaviour of the magnet with temperature can be obtained by using single probes doubled by an appropriate circuit, but it is preferable to adopt integrated circuits combining the functions of Hall probes and compensation. 
     FIGS. 3 a  and  3   b  show the typical shape of the measurement results for several magnet displacements. 
     L is the thickness of the magnet, E that of the gap and c x  and c y  the paths of the probe in two dimensions. 
     It is advisable to use a ratio L/E comprised between 1 and 2. 
     If one takes the minimum dimensions of the stators (c x +E) and (c y +E) in the measurement plane, the linearity of the signal will be effective along the two axes. 
     This design can easily be integrated into a compact system, according to FIG.  4 . 
     The magnet is then inserted into a support  31  sliding between two spacers  21  and  22 . The poles  1  to  4  are fixed on a non-magnetic base  23  and the assembly is linked by rigid fixation elements  24  to  30 , for example screws, pins etc. 
     The support  31  has fixation lugs to link it with the element whose position is to be determined. 
     One thus obtains an integrable assembly, providing easily exploitable signals. 
     FIG. 5 represents a partial diagrammatic view of a mixed sensor (x,θ), (linear+angular). 
     This system is composed of the following parts: 
     A half-ring magnet  40 , magnetised radially. Depending o n the requirements of the system, it can be stuck to the cylindrical support assembly  45  or can be mobile between the support assembly and the stators. 
     4 half-ring ferromagnetic stators  41  to  44  (the fourth stator is not shown in FIG. 5, so that the magnet is visible). 
     4 Hall probes,  46  to  49 . 
     A cylindrical ferromagnetic support assembly  45 , which can be solid or not. 
     Another embodiment of this linear-angular sensor is shown in FIGS.  6  and  7 : it consists of reversing this mechanism, that is to say of placing the support assembly  45  and the magnet  40  outside and the stators,  41  to  44 , inside. 
     The stators  41  to  44  then become half-moons and the support assembly  45  becomes a ferromagnetic tube. The magnet  40  thus remains a half-ring radially magnetised and can b e mobile between the stator  41  to  44  and the support assembly  45  or further attached to the latter. 
     In this architecture, the signals provided by probes  50  and  51  are added, that is the probes whose sensitive surface is perpendicular to the axis of rotation X, to obtain a linear signal in function of the linear displacement of the magnet according to axis X. Furthermore, one adds the signals provided by the probes  52  and  53 , that is the probes whose sensitive surface is parallel to the axis of rotation X, to obtain a linear signal in function of the rotation of the magnet according to axis X. The angular path is limited to 180°, and in practice one will obtain a linear signal over a path of the order of 160°. 
     Finally one obtains two independent signals, respectively linear relative to the rotation and the displacement according to a same axis X. 
     A variant of this solution is shown in FIG.  8 . It consists of making chamfers,  61  to  64 , on the stators  41  to  44 : then the sensitivity to rotation of the sensor is amplified by reducing its angular path. 
     In the same way as for the linear sensor XY, the sum of the signals is easily produced by a summing assembly. One can also use an integrated circuit comprising directly the element sensitive to the induction variation and the temperature compensation functions of the magnet. 
     FIG. 9 shows a diagrammatic view of a spherical sensor with two degrees of freedom in rotation. 
     The system then comprises 4 types of parts: 
     A magnet  70 , shown in FIG. 10 in an exploded view, composed of two half-magnets  76  and  77 . These two half-magnets are hemispheres, are obtained preferably by moulding and are magnetised radially. The magnet  70  can be fixed on the support assembly  75  of spherical shape or be mobile between the stators and the support assembly. 
     4 ferromagnetic stators,  71  to  74 , surrounding the magnet  70 . In the basic principle shown in FIG. 9, these have the shape of a quarter of a spherical cap. It will be seen that this shape can be modified in industrial embodiments of this type of sensor. 
     4 Hall probes,  81  to  84 , or any other element sensitive to variation in magnetic induction, placed between the stators  71  to  74 , as shown in FIG.  9 . 
     1 spherical ferromagnetic support assembly  75 . 
     By making the magnet turn relative to the two axes X and Y, one creates a modification of magnetic induction in the 4 gaps in which the probes have been placed. 
     The addition of the signals provided by the probes  81  and  82  provides a linear signal in function of the rotation of the magnet relative to the axis X. 
     The addition of the signals provided by the probes  83  and  84  provides a linear signal in function of the rotation of the magnet relative to the axis Y. 
     Finally, 2 independent and linear signals are obtained, each in function of the rotation of the magnet relative to one of the 2 axes mentioned above. 
     It is to be noted that the rotation around the 3rd axis will have no influence on the 2 signals thus obtained. 
     FIG. 11 shows an embodiment of a spherical sensor which is easier to industrialise, in particular being able to be used in the manufacture of joysticks and other levers with two degrees of freedom. 
     First of all, one can limit the angular amplitude of the stators and simplify their external shape. 
     The stators  71  to  74  then have an internal spherical shape to keep a constant distance from the external surface of the magnet and an external surface which is cylindrical here but which can be adapted according to construction requirements. 
     Furthermore, one half-magnet  76  can be pierced, or the two, according to the number of mechanical connections needed and the results desired, as shown in FIG.  12 . In this case, the hole made,  78 , must remain fairly far from the stators during the movement of the mobile part, in order to maintain the correct signals. The presence of such a cavity  78  makes it possible to fix a mechanical part on the support assembly and thus to ensure the link between this measurement device and the mechanism whose displacement is to be measured. 
     Finally, one can use only one hemispherical magnet, magnetised radially. The other can, if required, be replaced by a non-magnetic hemisphere able to serve as guide in an assembly such as that shown in FIG.  11 . It is to be noted that in this case the amplitude of each of the 2 signals will be halved. 
     A method for guiding the sphere in the gap between the stators  71  to  74  is to create a friction surface with which it will come directly into contact. The gap will then be ensured by the thickness of the material producing this guiding, a material which must evidently be non-magnetic. 
     According to the requirements of the mechanism itself, one can then choose whether to make the magnet rub directly or to cover it with a layer of an appropriate material to reduce friction, improve the lifetime of the mechanism etc. 
     FIG. 11 shows an application of this principle: the stators  71  and  73  have been enclosed in a plastic over-moulding which ensures the gap, the mechanical link between the stators and the moulding of the probes. This type of principle can also be used with any other process besides over-moulding: the plastic layer can be glued, clipped, or mounted in several different ways on the stators. 
     Another principle could consist of having only one magnetic hemisphere and of having on the complementary hemisphere a metallic spherical surface, which could be guided on a metallic cap. 
     Finally, this mechanism can be inverted, that is to say that the stators,  91  to  94 , can be arranged inside the magnet  96 . Then the support assembly becomes a hollow sphere and the stators  91  to  94  quarters of a sphere, in conformity with FIG.  13 . 
     In the same way as above, 2 independent signals are obtained, respectively linear in function of the rotation relative to the X and Y axes. 
     The first will be the sum of the signals provided by the probe  97  and the diametrically opposite probe, and the second will be the sum of the signals provided by the probe  98  and the diametrically opposite probe. 
     The possibility remains of having only one magnetised hemisphere while losing half the amplitude of the signal. 
     There is the choice of making the magnet move with the support assembly (by attaching it on top, for example) or moving independently from it, or further maintaining it immobile to make the stators move. In this case, it is possible to use the same type of assembly as that described for the preceding solution. 
     Finally, one can imagine several types of stator shapes, FIG. 14 giving an example of a possible modification. 
     The stators  91  to  94  have flat sections  100 ,  101  making it possible to concentrate the magnetic fluxes towards the Hall probes, and to facilitate the fixation of a linkage unit. 
     The invention does not only relate to the embodiments described above, but also embodiment variants. In particular, it is possible to implement not 4 Hall probes, but two Hall probes only, one per secondary gap. 
     FIGS. 15 and 16 show partial and cross-sectional views of a two-dimensional linear sensor with two Hall probes. This system comprises the following parts: 
     A flat magnet  108 , magnetised axially in the direction perpendicular to the main gap  107 . It is mobile between the stators. 
     A first pair of rectangular ferromagnetic stators,  109  and  110 , defining a first secondary gap  114 . 
     A second pair of rectangular ferromagnetic stators,  111  and  112 , defining a second secondary gap  116 , oriented perpendicularly to the first secondary gap  114 . 
     2 Hall probes  113  and  115  housed respectively in the first and second secondary gap. 
     When the magnet is displaced in its main gap, following the XY plane, it generates a magnetic induction variation in each of the 2 secondary gaps, a variation which is measured directly by the 2 probes. 
     Probe  115  then provides a linearly direct signal in function of the displacement relative to X. 
     Probe  113  then provides a linearly direct signal in function of the displacement relative to Y. 
     FIGS. 17 and 18 show views of a linear/rotary sensor with two Hall probes. This variant makes it possible to use only 2 Hall probes. The system is then composed of the following parts 
     1 half-ring magnet  120 , magnetised radially. It is mobile between the stators. 
     4 ferromagnetic stators, internal  121  and  122 , and external,  123  and  124 . The internal stators  121  and  122  are of a half-moon shape, able to be chamfered if needed. They define a plane first secondary gap  127 . The external stators  123  and  124  are rings and define the second secondary gap  128  of annular shape. 
     2 Hall probes,  129  and  130 . 
     When the magnet is displaced in its main gap, in rotation and translation relative to axis X, it generates a variation in magnetic induction in each of the 2 secondary gaps, a variation which is measured directly by the 2 probes. 
     The probe  129  will provide a directly linear signal in function of the rotation of the magnet around the axis X. 
     The probe  130  will provide a directly linear signal in function of the translation of the magnet along the axis X. 
     This principle can be inverted in relation to the magnet to obtain the drawing shown in FIGS. 19 and 20. The stators  140  and  141 , then become internal cylinders and the stators  142  and  143  become external half-rings.