Rotation Sensor Assemblies and Methods of Use

This application claims the benefit of and priority to Danish Application No. PA 2024 30313, filed Jun. 11, 2024, which is hereby incorporated by reference in its entirety.

The present invention relates to rotation sensor assemblies suitable for being used in construction vehicles.

Excavators are digging machines, typically mounted on tracks or wheels. A typical excavator has a bucket mounted to the end of a two-member linkage or a three-member linkage. When the excavator has a bucket mounted to the end of a two-member linkage, one of the links, called a boom (swing arm), is pivotally mounted to a mounting structure of the excavator and extends outward in an upward direction. The other link, typically referred to as a stick, is pivotally mounted at one end to the outer end of the boom and extends downward from the boom pivot.

When the excavator has a bucket mounted to the end of a three-member linkage, a first boom is pivotally mounted to a mounting structure of the excavator and extends outward in an upward direction. A second boom is rotatably mounted to the distal end of the first boom and extends between the first boom and a stick being pivotally mounted at the distal of the second boom. In some constructions, the stick is provided as a telescopic arm.

To control the boom, stick and bucket in an accurate manner, it is required to be able to detect the relative rotational motion and/or angle (angular position) between the boom and the cap in an accurate manner.

EP3884114A1 discloses a position detection device for detecting the position of a bucket of an excavator having a cab and an arm comprising one or more booms, wherein the arm comprises a first boom being rotatably attached to the cab by a mounting structure that is rotatably attached to the cab by a shaft having a longitudinal axis extending basically vertically during normal use. A wire sensor is used to detect the rotation of the first boom about the longitudinal axis of the shaft. It is, however, challenging to calibrate the wire sensor.

WO2024090014A1 discloses a swing angle calibration method and a swing angle calibration system. The swing angle calibration system comprises a swing angle sensor connected to a swing bracket by a link mechanism. It is, however, challenging to adjust the swing angle calibration system. Accordingly, it would be advantageous to be able to provide a solution that is more flexible and easier to adjust.

Thus, there is a need for a rotation sensor assembly that is flexible and easier to adjust and is capable of detecting the relative rotational motion and/or angle (angular position) between the boom and the cap in an accurate manner without requiring a challenging calibration.

In an embodiment, a rotation sensor assembly disclosed herein comprises a first portion and a fixation member,

Hereby, it is possible to ensure that the sensor mounting member and the sensor portion are aligned and arranged sufficiently close to each other to ensure that a magnetic field with a sufficiently large amplitude can be detected when applying the rotation sensor assembly. Accordingly, the rotation sensor assembly is capable of detecting the relative rotational motion and/or angle (angular position) between the boom and the cap in an accurate manner.

The rotation sensor assembly is configured to detect the relative rotational motion and/or angle (angular position) of a boom of an excavator in an accurate manner.

The rotation sensor assembly comprises a first portion configured to be attached to the cab of an excavator. The first portion comprises one or more structures for mounting a sensor portion of the rotation sensor assembly. The first portion comprises one or more structures for attaching the first portion to the cab of the excavator.

The first portion comprises an angle bracket attached to a base bracket having a foot portion, wherein a plurality of slots is provided in an upper portion of the base bracket, each slot being configured to receive a portion of a bolt extending through the slot for detachably attaching the base bracket to a first part of the angle bracket.

The angle bracket comprises one or more slots each configured to receive a bolt extending through a slot of the base bracket and the slot of the angle bracket.

The first portion comprises a magnetic sensor base, wherein a magnetic sensor portion is attached to the fixation member, wherein the sensor base is attached to the angle bracket, wherein the rotation sensor assembly is arranged and configured to detect the angular position and/or angular motion of the sensor portion relative to the sensor base.

In an embodiment, the rotation sensor assembly comprises a protection member configured to be attached to a boom of the excavator. In an embodiment, the protection member comprises a protection top member and a protection bottom member that is detachably attached to the protection top member.

In an embodiment, the rotation sensor assembly comprises a protection member comprising a protection top member, wherein the fixation member is a protection bottom member that is detachably attached to the protection top member.

In an embodiment, the sensor portion is a transmitter whereas the sensor base is a receiver.

In an embodiment, the sensor base is a transmitter whereas the sensor portion is a receiver.

In an embodiment, the rotation sensor assembly comprises a sensor base and a sensor portion, wherein the sensor portion comprises a cavity in which cavity a male portion is rotatably mounted, wherein the rotation sensor assembly is arranged and configured to detect the angular position and/or angular motion of the sensor base relative to the male portion of the sensor portion.

In an embodiment, the angle bracket is L-shaped.

In an embodiment, a nut is fixed to each bolt to attach the base bracket and the angle bracket to each other.

In an embodiment, the slots of the base bracket extend perpendicular to the slot(s) of the angle bracket.

In an embodiment, the protection top member comprises an angled portion that is integrated to form a one-piece body having a V-shaped profile.

In an embodiment, the protection top member comprises an angled portion that is integrated to form a one-piece body having an L-shaped profile.

In an embodiment, the protection member comprises a detachably attached reinforcement member extending between the protection top member and the protection bottom member.

Hereby, the reinforcement member reinforces the protection member by enhancing the compressive strength of the protection member.

In an embodiment, the reinforcement member is U-shaped.

In an embodiment, the reinforcement member has two flange portions extending between a planar portion that is attached to the angled portion.

In an embodiment, the reinforcement member has two parallel flange portions extending between a planar portion that is attached to the angled portion.

In an embodiment, the parallel flange portions extend perpendicular to the planar portion.

In an embodiment, the planar portion is attached to the angled portion using bolts.

In an embodiment, the bolts extend through holes provided in the planar portion of the reinforcement member.

The protection member is configured to protect the sensor mounting member and the sensor portion as well as other components (e.g. a hydraulic hose and/or a hydraulic sensor) placed between the protection top member and the protection bottom member.

In an embodiment, the first portion comprises a top bracket that is detachably attached to a second part of the angle bracket.

In an embodiment, the top bracket is detachably attached to the second part of the angle bracket using bolts extending through the slots of the top bracket, wherein the slots provided in an upper portion of the base bracket and the one or more slots provided in the angle bracket are arranged in such a manner that the angle bracket can be rotated relative to the base bracket. The use of this slot configuration has the surprising effect of making it possible to rotate the angle bracket relative to the base bracket.

In an embodiment, each bolt is screwed into a threaded bore provided in the top bracket.

In an embodiment, a plurality of threaded bores is distributed along the length of the top bracket. Hereby, the second part of the (typically L-shaped) angle bracket may be attached to different threaded holes in order to achieve a desired degree of overlap between the second part of the L-shaped angle bracket and the top bracket.

In an embodiment, the first portion comprises a top bracket detachably attached to the angle bracket.

In an embodiment, the first portion comprises a sensor base that is attached to the top bracket.

In an embodiment, the sensor base is attached to the top bracket using screws or bolts extending through through-bores provided in the sensor base.

In an embodiment, the sensor base comprises a socket arranged and configured to be electrically connected to a cable provided with an electric plug.

In an embodiment, the fixation member is a sensor mounting member provided with a threaded rod or bolt protruding from a bottom surface of the sensor mounting member.

In an embodiment, the threaded rod or bolt is centrally arranged and protrudes from the bottom surface of the sensor mounting member.

In an embodiment, the threaded rod or bolt is configured to be screwed into a threaded hole of the boom of an excavator, while the sensor portion and the top bracket of the first portion is attached to the cab of the excavator. Hereby, the rotation sensor assembly can detect the angular position and/or angular motion of the boom of an excavator relative to the cab of the excavator.

In an embodiment, the threaded rod or bolt is configured to be screwed into a threaded hole of the cab of an excavator, while the sensor base and the top bracket of the first portion are attached to the boom of the excavator. Hereby, the rotation sensor assembly can detect the angular position and/or angular motion of the boom of an excavator relative to the cab of the excavator.

In an embodiment, the sensor base is attached to the top bracket. In an embodiment, the fixation member is a protection bottom member.

The excavator, according to an embodiment, is an excavator comprising a rotation sensor assembly as disclosed herein, wherein the first portion is attached to a cab of the excavator whereas the fixation member is attached to the boom of the excavator.

Alternatively, the first portion is attached to the boom of the excavator whereas the fixation member is attached to the cab of the excavator.

Hereby, the excavator can, by using the rotation sensor assembly, detect relative rotational motion and/or angular positions between the boom of an excavator and the cap of the excavator. By using an excavator provided with a rotation sensor assembly according to the present disclosure, it is possible to ensure that the fixation member and the sensor portion are aligned and arranged sufficiently close to each other to ensure that a magnetic field with a sufficiently large amplitude can be detected when applying the rotation sensor assembly.