Coil body, inductive rotational speed sensor, and method for producing the same

Patent metadata

Field	Value
Publication number	US-12504439-B2
Application number	US-201917312356-A
Country	US
Kind code	B2
Filing date	Dec 3, 2019
Priority date	Dec 18, 2018
Publication date	Dec 23, 2025
Grant date	Dec 23, 2025

Abstract

A coil body for an inductive rotational speed sensor, including: a base body having at least one winding region for coil windings about an axial axis and an opening for receiving a pole assembly along the axial axis; and two current rails, each of which run parallel to the axial axis and include a contact region for electrical connection cables to connect the coil in the winding region to the electrical connection cables, in which each of the contact regions includes at least one bendable section to guide the electrical connection cables at least in some sections parallel to the axial axis or, perpendicular thereto, in a radial manner. Also described are a related inductive rotational speed sensor, and related methods.

First claim

The invention claimed is:

1 . A coil body for an inductive rotational speed sensor, comprising:
a base body having at least one winding region for coil windings about an axial axis and an opening for receiving a pole assembly along the axial axis; and two current rails, each current rail of the current rails runs parallel to the axial axis and includes a respective contact region for a respective electrical connection cable to connect at least one coil winding of the coil windings in the at least one winding region to the respective electrical connection cable, wherein each of the current rails is formed from a flat metal sheet and has a main surface, each current rail being bent, about a longitudinal direction, in the respective contact region to form a respective contact surface perpendicular to the main surface; wherein each current rail of the two current rails includes a respective connection region and a respective intermediate region, the respective intermediate region being situated between the respective connection region and the respective contact region, the respective connection region being at a first end of the current rail and the respective contact region being at a second end of the current rail, the first and second ends being opposite ends of the current rail relative to each other; wherein each of the respective contact regions includes a bendable section in the respective contact surface and is configured to guide the respective electrical connection cable, at least in some sections, (i) parallel to the axial axis for an axial variant or, (ii) perpendicular thereto in a radial manner for a radial variant, wherein each bendable section of each of the respective contact regions has a reduced cross-sectional area by way of two material cut-outs, so that a defined bend of the bendable section can be realized in a manner in which an end section of the respective contact region can be bent about an axis that is perpendicular to the main surface, at the material cut-outs, away from the axial axis and perpendicular to a remaining part of the respective contact region; wherein the two current rails are formed identically and fastened to opposite lying sides on the base body, wherein each respective current rail of the two current rails includes a respective tab fixed to the base body and which by a positive-locking or a non-positive locking fixing arrangement on the base body, the respective tabs prevent displacement of the current rails relative to the base body, and wherein for each respective current rail of the two current rails, the respective tab is formed as a vertically upwards bent section of the respective intermediate section of the respective current rail, and wherein each respective current rail of the two current rails is bent in the respective connection region of the respective current rail, toward the respective contact region of the respective current rail, in a U-shape, and a protruding limb of each of the U-shapes has a slit which receives at least one wire of the coil, the protruding limb extending in a direction toward the respective contact region of the respective current rail.

2 . The coil body of claim 1 , further comprising:
at least one anti-rotation device that is embodied as a radial protrusion on the base body by virtue of retaining the coil body in the encapsulation tool to prevent the coil body from rotating during an encapsulation process.

3 . The coil body of claim 1 , wherein the base body includes at least one latching hook that is embodied so as to fix a pole assembly that is inserted in the opening of the base body so as to prevent an axial movement of the inserted pole assembly.

4 . The coil body of claim 1 , wherein the base body includes at least one venting opening for connecting an inner region of the base body, which is accessible through the opening, to an outer region to equalize the pressure between the inner region of the base body and the outer region as the pole assembly is inserted.

5 . The coil body of claim 1 , wherein each of the two current rails includes a barrier that is embodied to divert, during an encapsulation procedure, an encapsulating mass in the encapsulation tool to protect an electrical contact to the coil.

6 . The coil body of claim 1 , wherein the contact regions of the two current rails each include a surface area for welding or soldering or crimping the respective electrical connection cable, or a further contacting arrangement to fasten the respective electrical connection cable to the respective contact region.

7 . The coil body of claim 1 , wherein each current rail of the current rails includes a respective notch to facilitate a bending of the current rail along the axial axis.

8 . The coil body of claim 1 , wherein the end section of the respective contact region of each respective current rail of the two current rails is bent about the axis that is perpendicular to the main surface of the respective contact rail, at the material cut-outs of the bendable section of the contact region of the respective current rail, away from the axial axis and perpendicular to the remaining part of the contact region of respective current rail.

9 . An inductive rotational speed sensor, comprising:
a coil body for an inductive rotational speed sensor, including:
a pole assembly;
a base body having at least one winding region, which includes coil windings about an axial axis and an opening that receives along the axial axis the pole assembly, wherein the pole assembly includes a magnet and a pole core in the opening of the base body; and
two current rails, each of current rail of the current rails runs parallel to the axial axis and includes a respective contact region for a respective electrical connection cable to connect at least one coil winding of the coil windings in the at least one winding region to the respective electrical connection cable, wherein each of the current rails is formed from a flat metal sheet and has a main surface, each current rail being bent, about a longitudinal direction, in the respective contact region to form a respective contact surface perpendicular to the main surface;
wherein each current rail of the two current rails includes a respective connection region and a respective intermediate region, the respective intermediate region being situated between the respective connection region and the respective contact region, the respective connection region being at a first end of the current rail and the respective contact region being at a second end of the current rail, the first and second ends being opposite ends of the current rail relative to each other;
wherein each of the respective contact regions includes a bendable section in the respective contact surface and is configured to guide the respective electrical connection cable, at least in some sections, (i) parallel to the axial axis for an axial variant or, (ii) perpendicular thereto in a radial manner for a radial variant,
wherein each bendable section of each of the respective contact regions has a reduced cross-sectional area by way two material cut-outs so that a defined bend of the bendable section can be realized in a manner in which an end section of the respective contact region can be bent about an axis that is perpendicular to the main surface, at the material cut-outs, away from the axial axis and perpendicular to a remaining part of the respective contact region;
wherein the two current rails are formed identically and fastened to opposite lying sides on the base body;
a casing, which is made from a synthetic material, that encases at least in part the coil body, which has the coil windings and the pole assembly; wherein each respective curre

Assignees

• Knorr Bremse Systeme Fuer Nutzfahrzeuge Gmbh

Inventors

• Lechner Klaus
• Kluftinger Andre
• Huber Christoph
• Palzer Stefan
• Buettner Martin
• Fruhstorfer Ines

Classifications

• H01F27/29

  Terminals; Tapping arrangements {for signal inductances} · CPC title

• G01P3/488

  delivered by variable reluctance detectors · CPC title

• G01D11/245

  Housings for sensors · CPC title

• G01P1/026 Primary

  for speed measuring devices, e.g. pulse generator · CPC title