US 8,008,910 B2Granted

Strut position sensor including a magnet mounted on an idler gear contained in a stator portion, which is movable relative to a rotor portion connected to the strut, and a galvanomagnetic sensor in the stator portion for detecting angular position of the strut

AssigneeStrattec Power Access LLC

InventorsThomas Lawson Booth, Howard Warren Kuhlman

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Abstract

A power actuator system for a movable vehicle panel such as a lift gate assembly includes a position sensor that detects the pivotal movement of a strut mechanism of the power lift gate assembly relative to the host vehicle. A rotary sensor is coupled directly to an end component of the strut mechanism and provides signals that indicate the total amount of pivotal or rotary movement of the strut mechanism and the lift gate during the opening and closing of the lift gate. The signals provide information to determine the absolute position of the strut and the lift gate for processing in the vehicle's electronic control unit.

Claims18

Dependent claims

A position sensor assembly for sensing movement of a drive mechanism, the drive mechanism including an elongated strut having a first end connector pivotably affixed to a frame remote from the drive mechanism and a second end connector pivotably affixed to a movable panel supported on the frame, wherein at least one of the strut connectors includes a fixed portion attached to the frame and a movable portion attached to the strut, the position sensor assembly comprising:

a stator portion adapted for connection to the fixed connector portion;
a rotor portion moveable in response to rotation of the movable connector portion about an axis between first and second different connector portion positions, the stator portion supporting a galvanomagnetic sensing element;
an idler supported on the stator portion and moveable relative to each of the first end connector and the rotor portion, the idler including an idler gear, the idler supporting a magnet juxtaposed in substantially axial alignment with the galvanomagnetic sensing element when the movable connector portion is in each of the first and second positions for magnetic interaction therewith, the galvanomagnetic sensing element generating a sensor output signal indicative of the relative angular position of the movable and fixed connector portions;
the rotor portion comprising a yoke affixed to and movable with the strut, the yoke having a yoke gear integrally formed with the yoke and including a plurality of radially outwardly directed gear teeth;
and
wherein the stator portion nestingly receives an integral communication assembly including the sensing element, a communication link, and a printed circuit board,
and wherein the yoke gear continuously engages the idler gear teeth to magnify the rotation of the idler gear and the magnet.

4 more elements

A position sensor assembly operable to sense movement of an elongated strut as the elongated strut moves a panel relative to an opening in a frame, the elongated strut including a first end connector rotatably affixed to the frame remote from the moveable panel and a second end connector rotatably affixed to the movable panel, the position sensor assembly comprising:

a stator portion secured against movement relative to the frame;
and
a rotor portion moveable relative to the frame in response to movement of one of the first end connector and the second end connector;
an idler supported on the stator portion and moveable relative to each of the first end connector and the rotor portion, the idler including an idler gear;
the rotor portion comprising a yoke affixed to and movable with the strut, the yoke having a yoke gear integrally formed with the yoke and including a plurality of radially outwardly directed gear teeth;
a magnet supported on the idler;
and
a galvanomagnetic sensing element driven by the rotor portion such that rotational movement of the panel relative to the frame in a first rotational direction causes rotational movement of the rotor portion in a second rotational direction relative to the stator portion, the second rotational direction being opposite to the first rotational direction, the galvanomagnetic sensing element producing a sensor output signal indicative of the relative angular position of the magnet and the galvanomagnetic sensing element which corresponds to a relative angular position of the stator portion and the moveable portion;
wherein the sensing element, a printed circuit board, and a communication link are jointly and integrally inserted into a recess defined in the stator portion,
and wherein the yoke continuously engages the idler gear to increase the rotation of the idler gear and the magnet.

7 more elements

A position sensor assembly operable to sense movement of an elongated strut as the elongated strut moves a panel relative to an opening in a frame, the elongated strut including a first end connector pivotably affixed to the frame remote from the moveable panel and a second end connector pivotably affixed to the movable panel, the position sensor comprising:

a stator portion secured to the frame;
a rotor portion rotatable about a first axis with one of the first end connector and the second end connector relative to the frame and the stator portion;
an idler supported on the stator portion and moveable relative to each of the first end connector and the rotor portion, the idler including an idler gear;
the rotor portion comprising a yoke affixed to and movable with the strut the yoke having a yoke gear integrally formed with the yoke and including a plurality of radially outwardly directed gear teeth;
and
a magnet supported on the idler and a galvanomagnetic sensing element supported on the stator portion, the magnet and the galvanomagnetic sensing element being rotatable about a second axis relative to the galvanomagnetic sensing element, the second axis being substantially parallel to the first axis, the galvanomagnetic sensing element being operable to produce a sensor output signal indicative of the relative angular position of the magnet and the galvanomagnetic sensing element which corresponds to a relative angular position of the stator portion and the moveable portion;
wherein the sensing element, a printed circuit board, and a communication link are together integrally nested in a recess defined in the stator portion, and
wherein the yoke gear continuously engages the idler gear teeth to boost the rotation of the idler gear and the magnet.

5 more elements

Dependencies are inferred from the claim text.