Position Detecting Apparatus Using Variable Magnetic Field Intensity

This invention is in the field of position sensors, and specifically relates to magnetic position sensors for use with automotive suspension systems.

Position sensors of all types are commonly known in the art, especially in the automotive and industrial environments. Position sensors determine the location of a movable part with respect to a reference. Such sensors range from complex electrical devices to simple mechanical devices. The prior art includes position sensing devices adapted for many different applications as well as position sensors specifically adapted for automotive suspension systems. Adjustable suspension systems typically utilize one or more sensors for detecting the position of one or more parts of the suspension system with respect to either another part of the suspension system or another part of the chassis of the vehicle.

There are many problems with the sensors available today. Sensors which provide only discrete signals can resolve a desired position into only a relatively small number of possibilities. Analog position sensing devices usually have a relatively short stroke or measuring distance.

A position sensing device using a magnetic sensor is disclosed in European Patent No. 0215454. The device of European Patent No. 0215454 has a relatively long stroke or measuring range, but the device is inadequate for use as a position sensing device in today's automotive suspension systems. The device consists of a closed magnetic circuit including at least one permanent magnet or electro-magnet, a yoke and a magnetic sensor. The sensor moves along an inside surface of the yoke and senses a magnetic field intensity of leakage flux emanating from the inside surface of the yoke. The sensor being transferred along the yoke surface makes the sensor vulnerable to a bumpy and harsh environment of an automobile. Furthermore, the design is too expensive and complex for use in an automotive suspension system that would use up to three or four sensors in one suspension system.

Another position sensor that measures magnetic field intensities is a device disclosed in European Patent No. 0368687A2. The device disclosed in European Patent No. 0368687A2 includes a magnetic tape which produces a magnetic field that varies sinusoidally along a longitudinal axis of the tape. The device includes a cursor acting as a pick up head and comprising two identical detectors each including a magnetic core shaped as a half torus and a magnetic flux to voltage transducer. The position of the cursor is a function of the distance between the two transducers and the magnetic field intensity detected. The use of two transducers and two magnetic cores each shaped as a half torus makes the device cumbersome and impractical in an automotive suspension system environment.

Today's automotive components are focusing on active and semiactive suspension systems that are safe, reliable and provide smooth transitions responsive to rough driving conditions and roads. One of the first attempts at such powerful suspension systems include complicated sensors that are expensive and require a significant amount of extra horsepower drained from the automobile's engine system. Such suspension systems add additional weight and intricate electronics to existing suspension systems. The systems are not practical for most car models especially the lower cost models.

Simple, low cost sensors that are being produced today are typically digital sensors. The digital devices simply gives a discrete high, medium and low signal, or a small number of discrete possible states, and the suspension system adjusts accordingly. Unfortunately, since the signal is simply a high or low signal or a discrete state, the signal is not representative of how far off the error is from an equilibrium position. There is the constant problem of over correcting or under correcting and a number of corrections will have to be made before equilibrium is found.

Thus, there is a need in the market for a simple, low cost position sensor that can be adapted for the automotive environment especially to provide suspension position information and other types of information for adjustable suspension systems.

A principal object of the invention is a simple, low cost position sensor that can be adapted for an automotive suspension system environment.

Another object of the present invention is a magnetic position sensor that provides a linear output over a relatively long stroke.

Another object of the present invention is a position sensor that provides instantaneous error correction and thus smooth response period.

These and other objects are achieved by the present invention which includes, a position sensor system comprising magnetic medium divided into a plurality of areas of magnetization for producing a magnetic field with a variable intensity along a longitudinal axis of the magnetic medium. The magnetic medium is movable with respect to a sensing device which scans along the longitudinal axis of the magnetic medium in order to detect the intensity of the magnetic field produced by the magnetic medium. The sensing device produces an electric signal which corresponds to the magnetic field intensity detected at any given point along the longitudinal axis. The intensity of the magnetic field along the longitudinal axis of the magnetic medium varies monotonically, that is, it varies in one direction.

The areas of magnetization are arranged so that the magnetic field detected by the sensor along a longitudinal axis of the magnetic medium is linear. Thus, the present invention provides a linear output over a relatively long stroke.

A linear output over a long stroke allows for instant error correction and position alliance. Thus, the present invention allows for instant computation of how much compensation is needed and in what direction in order to correct and arrive at an equilibrium position.

The present invention is particularly suitable for an automotive suspension system. An automotive suspension sensor system for a vehicle can be constructed with the magnetic position sensor of the present invention. The sensor includes a magnetic medium of predetermined length made up of a plurality of longitudinally extending magnetic strips. The strips have respective geometries which vary with position along the length of the magnetic medium. Adjacent magnetic strips have opposite polarities. The magnetic field produced by the magnetic medium is linear along a longitudinal axis of the magnetic medium. The sensor further includes a Hall cell as the sensing device for producing an electrical signal representative of a magnetic field intensity produced by the magnetic medium at any given point along the longitudinal axis of the magnetic medium. The magnetic medium is movable with respect to the sensing device. Thus, either the magnetic medium or the sensing device actually moves so that the sensing device scans along the longitudinal axis of the magnetic medium and detects the variable magnetic intensity produced by the magnetic medium. The signal representing the position of the magnetic medium relative to the magnetic field sensing device along the longitudinal axis of the magnetic medium is linear.

Flux guides are placed in close proximity to the Hall cell to guide the flux of the magnetic field through the Hall cell. An iron back up piece is located behind the magnetic medium in order to enhance the magnetic field. The sensor system is connected at one end to a stationary member of the suspension system and at another end to a movable part of the suspension system. The sensor is also connected to a central processing unit for calculations and error correction.

The magnetic sensor of the present invention is simple and inexpensive to produce. It is adaptable for automotive suspension systems of most car models, especially inexpensive models.

The present invention allows for smooth transitions for reactions to bumps and manuvering of a vehicle for most road and traffic conditions.

The sensor according to the present invention is useful in providing suspension position information and ride height information for vehicle leveling systems or adjustable suspension systems.

Other objects, features and advantages of the invention will become apparent from the following detailed description, appended claims and accompanying drawing.

The invention will now be described in detail with respect to several preferred embodiments with reference to the accompanying drawing, wherein;

FIG. 1 is a plan view of a housing for a vehicle sensor system in accordance with the invention;

FIG. 2 is a side view of the housing of the sensor system of FIG. 1;

FIG. 3 is a plan view of the system shown in FIG. 1 with a movable part retracted within a stationary part shown in phantom;

FIG. 4 is a plan view of the sensor system of FIG. 1 with the movable part extended;

FIG. 5 is a cross-sectional side view of the movable part of the sensor system of FIG. 1;

FIG. 6 is a perspective view of the Hall cell between the flux guides as arranged within the housing of the system of FIG. 1;

FIGS. 7a-7c are cross-sectional front views taken across the line 7--7 of FIG. 5 for different magnetic field intensities;

FIGS. 8a-8c are plan views of a magnetizing fixture at different angles in accordance with the invention;

FIG. 9 is a circuit diagram for the sensor system of FIG. 1; and

FIG. 10 is a chart that shows the linear output of the circuit diagram of FIG. 9 for the present invention.

FIG. 1 shows a top view of a housing of a sensor system 10 in accordance with the present invention. The housing includes a stationary part 12 and a telescopically movable part 18. The telescopically movable part 18 is located in a first end 14 of the stationary part and is extendable as shown by the dotted lines of FIG. 1.

FIG. 2 shows a side view of the housing of FIG. 1. One end of the movable part 18 has a connection portion 22 for connection to a movable part of a suspension system (not shown). One end 16 of the stationary part 12, shown opposite to the first end 14, has a connection portion 24 for connection to a stationary part of the suspension system. The positioning of the connection means in regard to the sensor system 10 and the suspension system can vary as long as the movable part 18 of the sensor system is connected to a movable part of the suspension system and the stationary part 12 of the sensor system is connected to a stationary part of the suspension system.

A magnetic medium 20 is located on the movable part 18 as shown in FIG. 4 and by dotted lines in FIG. 3. The magnetic medium 20 can be a plastic bonded magnet adaptable for automotive applications. FIG. 3 shows the magnetic medium 20 and most of the movable part 18 retracted within the stationary part 12 of the housing and FIG. 4 shows the magnetic medium 20 and most of the movable part 18 extended outside of the housing. The movable part 18, with the magnetic medium 20, telescopically retracts in and extends out of the stationary part 12 of the housing.

A sensing device 50 is located within the first end 14 of the stationary part 12 so that the magnetic medium 20 is scanned by the sensing device 50 as it travels in and out of the stationary part 12. The sensing device 50 is a linear Hall cell but can be any other suitable type of magnetic flux to voltage transducer component. The Hall cell 50 can be of a known type which provides a change in voltage output which varies in magnitude in accordance with variations of magnetic field strength or magnetic flux detected by the Hall cell 50.

On two sides of the Hall cell 50 are flux guides 60, 65 to concentrate and guide the magnetic flux through the Hall cell 50. The flux guides 60, 65 are made of a ferrous material.

FIGS. 3 and 4 show the magnetic medium 20 divided into a plurality of areas of magnetization. Specifically, three areas of magnetization of particular geometric shapes form a magnetic field intensity that varies linearly along a longitudinal axis 25. The areas of magnetization may be different than the geometries and polarities shown in FIGS. 3 and 4 as long as the magnetic field intensity varies so that positions are measurable over a relatively long stroke. A first area 42 of magnetization and a third area 46 of magnetization are south poles with triangular shaped geometrics disposed oppositely to one another. Between the two south poles 42, 46 is an offset rectangular shaped north pole area 44. Alternatively, the pole areas could be arranged in any way in which a linearly output could be detected.

FIG. 5 shows a cross-sectional view of the movable part 18 of the sensor system 10. A thin sheet of plastic material 75 is attached on top of the magnetic medium 20 as a protective coating. Alternatively, a magnet assembly could be injection molded into the movable part 18 using the same polymer as the movable part 18. An iron sheet 70 or other ferrous material is attached behind the magnetic medium 20 so that a concentrated magnetic return path is created.

FIG. 6 shows the Hall cell 50 arranged between two flux guides 65, 60. As the magnetic medium 20 is moved in and out of the stationary part 12 the magnetic field and flux around the Hall cell 50 varies. When the magnetic medium 20 is all the way extended the magnetic flux is as shown in FIG. 7a. When the magnetic medium 20 is pushed half way into the stationary part 12 the magnetic flux at the Hall cell 50 cancels itself and there is no net magnetic flux through the Hall cell 50 as shown by FIG. 7b. When the magnetic medium 20 is pushed all the way into the stationary part 12 the magnetic flux is as shown in FIG. 7c, which is the reverse of FIG. 7a. The Hall cell 50 provides an output signal which varies in magnitude in accordance with various magnetic fields or magnetic flux detected.

The magnetic field intensity varies linearly along the longitudinal axis 25 because of the plurality of areas of magnetization arranged to have a linear output for a relatively long stroke. The area of magnetization can be polarized as shown in FIGS. 8a-8c. A magnetizing fixture 75 is placed over the magnetic medium 20 at particular angles in order to create the desired pattern of magnetic areas. The magnetic fixture 75 is placed at an angle of 1 degree from the longitudinal axis 25 as shown in FIG. 8a, at 2 degrees in FIG. 8b, and at 4 degrees in FIG. 8c. The larger the angle with respect to the longitudinal axis 25, the steeper the slope of the linear output. Alternatively, the magnetizing fixture could be modified for functions other than linear, i.e., sine, cosine, exponential, etc.

FIG. 9 shows a circuit diagram for the sensor system 10 of the present invention. A constant 5 volts is supplied the Hall cell 50 by a 5 volt line regulator. The Hall cell 50 outputs a control signal based upon the magnetic field across the Hall cell 50. The control signal is amplified and a power control signal is created to drive a 300 ohm load.

FIG. 10 shows the output from the circuit of FIG. 9. The x-axis shows the position of the Hall cell with respect to the longitudinal axis in mm and the y-axis shows the corresponding output in milliamps.

While the invention has been described and illustrated in connection with preferred embodiments, many variations and modifications as will be evident to those skilled in this art may be made therein without departing from the spirit of the invention, and the invention as set forth in the appended claims is thus not to be limited to the precise details of construction set forth above as such variations and modifications are intended to be included within the scope of the appended claims.