DESCRIPTION "SENSOR"

[0001] The object of the present invention is a sensor of the type comprising a sensitive member being housed within a housing and a stem extending from outside the housing to the inside of the same where it interacts with the sensitive member for transmitting to the latter a value to be measured, such as the movement or the location of a stem outer portion protruding from the housing.

[0002] This type of sensor has a number of applications . A typical example is a linear transducer assembled to an excavator for monitoring the location of the excavator arm or a plastic injection press for monitoring the location of the half-moulds. In this cases, the housing and the outer portion of "the stem are connected to two locations on the excavator or press, respectively, of which the (variation in the) distance or relative position is measured. The sensitive member is, for example, a potentiometer accommodated within the housing and functionally operating with a stem inner portion that transmits either the location or movement of its outer portion to the potentiometer. [0003] According to the particular application, the sensor is exposed to an external environment which is more or

less aggressive and damaging for both the sensitive members and the electronic components provided for signal processing. In the case of applications on earth- moving machines, for example, the sensor is exposed to humidity and temperature changes, rain, as well as earth, dust and ice depositing on the stem. In industrial applications, the sensor is often installed in corrosive and dusty environments . [0004] In order to ensure a suitable protection to the sensitive member and electric components provided for signal processing, the opening through which the stem is inserted in the housing requires to be sealed by suitable sealing means. [0005] The sealing means of the prior art, though being satisfactory in terms of protection (for example, the standard IP67 which indicates a determined protection against humidity and dust penetration) , have the drawback of beαng subject to high wear. While the sensitive member of a linear potentiometer transducer reaches for example a duration of more than 100 million maneuvers (corresponding to more than 25 thousand kilometer movement of the stem relative to the housing) without requiring any maintenance or replacement operation, the sealing means will be worn much before, such that the degree of protection required by the

application: cannot be guaranteed over time. [0006] Accordingly, the object of the present invention is to provide a sensor having such characteristics to overcome the drawbacks mentioned with reference to prior art.

[0007] This and other objects are achieved by means of a sensor comprising:

[0008] - a housing defining an inner space and a pass- through opening; [0009] - a sensitive member accommodated within the inner space;

[0010] - a stem extending, through the pass-through opening, from outside the housing to the inner space where it interacts with the sensitive member for transmitting to the latter a value to be measured,

[0011] - means suitable to seal the gap between the pass- through opening and the stem, wherein said means comprise: [0012] - a seal in pressing contact with a seat formed in the pass-through opening, and with the stem;

[0013] - lubricating material arranged such that it wets the seal when the sensor is operating.

[0014] Due to the provision of lubricating material being arranged such that it wets the seal when the sensor is operating, a surprising wear reduction in the seal and a

consequent increase in the sensor life are achieved -when ^~ the same operates in a hard environment .

[0015] Referring particularly to those sensors being exposed to incrustations, such as dust, earth or ice, the object of the invention is further achieved by means of a sensor in which the means for sealing the gap between the pass-through opening and the stem comprise: [0016] - a seal in pressing contact with a seat formed in the pass-through opening, and with the stem; [0017] - a substantially rigid, outer scraper extending about the stem in a position between the seal and the stem outer portion protruding from the housing, the scraper being suitable to scrap deposits or incrustations from the outer portion before the same reaches the seal and has such a shape as to substantially prevent any pressing contact of the latter with the stem.

[0018] By means of the outer scraper, one obtains a considerable reduction in the deposits and incrustations to which the "pressing" seal is subjected, thereby the shelf life of the latter is increased, and further, due to the "non-pressing" interaction of the stem and the outer scraper, the wear of the outer scraper is reduced. [0019] While said solutions fulfill the object of the invention in an independent and satisfactory manner, a

versatile use of the same sensor in hard environments being very different from each other, for example humidity or corrosive substances, incrustations, fine and coarse dusts, ice, etc., can be obtained by combining both solutions, whereby the same can be mass manufactured.

[0020] In order to better understand the invention and appreciate the advantages thereof, several embodiments of the same will be described herein 'below, with reference to the figures, in which:

[0021] Fig. 1 is a front view of a sensor according to an embodiment of the invention;

[0022] Fig. 2 is a sectional view according to line II-II in Fig. 1; [0023] Fig. 3 is an enlarged view of the detail III from

Fig. 2;

[0024] Fig. 4 is an exploded view of a sensor according to an embodiment of the invention;

[0025] Fig. 5 is an enlarged sectional view of a detail of the sensor from Fig. 5;

[0026] Fig. 6 is a front view of a further detail of the sensor from Fig. 5;

[0027] Fig. 7 is a sectional view according to line VII-

VII of the detail from Fig. 6 ; [0028] Fig. 8 is a perspective view of the detail from

Fig . 6 ;

[0029] Pig. 9 is a front perspective view of a further detail of the sensor from Fig. 5;

[0030] Fig. 10 is a rear perspective view of the detail from Fig. 9;

[0031] Fig. 11 is a sectional view of the detail from Fig.

9.

[0032] The sensor according to the invention, for example a linear transducer, is overall designated with numeral 1 and comprises a housing 2 defining an inner space 3 and a pass-through opening 4. A sensitive member 5, for example a potentiometer, is accommodated within the inner space 3. A stem 10, preferably rigid, or alternatively flexible or articulated, extends through the pass-through opening 4, from outside the housing to the inner space 3 where it interacts with the sensitive member 5 to transmit to the latter a value to be measured ^" , such as a location, movement, or speed value, either translational or angular. [0033] Means sealing the gap between the pass-through opening 4 and the stem 10 are further provided such that a high degree of protection is guaranteed for the inner space relative to the outside environment, referring particularly to penetration of dirt and humidity. Besides separating the inner space 3 from the external

environment, these means -divide the stem between an inner portion 6 arranged within the housing 2, and more precisely within the inner space 3, and an outer portion 7 erecting from the housing 2 and exposed to the external environment. Of course, the length of the inner 6 and outer 7 portions will change according to the position of the stem and the housing relative to each other . [0034] The sealing means comprise a seal, preferably an O- ring 8, which is abutted, in pressing contact, against a seal seat 9 in the pass-through- opening 4 and against the stem 10 and lubricating material 11 arranged in a lubricant chamber 12 formed in the housing 2 in communication with the seal seat 9, such that the seal 8 is wetted when the sensor 1 is operating.

[0035] This" implies an increase in the degree of protection from the penetration of humidity and dust while reducing the wear of the sear, thereby the sensor is highly protected over time. [0036] In accordance with an embodiment, a first inner scraper 13 is arranged between the seal 8 and the sensitive member 5 and a second inner scraper 14 is arranged between the seal and the outer portion of the stem 10, both inner scrapers 13, 14 being in pressing contact with the stem 10 such that together with the

latter they define the lubricant chamber 12. ^" The pressing contact between the two inner scrapers and the stem can be obtained for example through an elastic preload biasing the scrapers towards the stem in the radial direction.

[0037] Advantageously, the first inner scraper 13 separates the lubricant chamber 12 from the sensitive member 5 such that any contact of the lubricating material contained in the lubricant chamber with the sensitive member is either hindered or prevented.

[0038] Besides protecting the sensitive member and any further data processing electronic device from (excessive) contact with the lubricating material, the two inner scrapers effectively avoid that the lubricating material is polluted by foreign substances, and that the lubricating material leaks out from the lubricant chamber and the seal seat .

[0039] In accordance with an embodiment, the inner scrapers 13, 14 form each a first contact area 15, 15' that provides a substantially cylindrical surface abutment against the stem and a second contact area 16, 16 ' that provides an abutment against the stem substantially following an annular line. [0040] To prevent the sensitive member from being polluted by the lubricant and the lubricant from being polluted

by the dirt from the external environment, it_ is particularly advantageous for the inner scrapers to be arranged such that the first (surface) contact area 15 of the first inner scraper 13 faces the lubricant chamber and the first (surface) contact area 15' of the second inner scraper 14 faces the outer portion of the stem.

[0041] Advantageously, the two inner scrapers are made of plastic material, preferably loaded with brass or graphite and preloaded through an elastic collar 17, such as an o-ring, preferably made of NBR material. [0042] In accordance with a further embodiment, a rigid, outer scraper 18, preferably made of metal, extends around the stem 10 in a position between the seal 8 and the outer portion 7 of the stem. When moving the stem ^" for insertion into the housing, the outer scraper 18 eliminates deposits or incrustations on the outer portion 7 before the latter reaches the seal ^" 8. The- outer scraper 18 is hold and shaped such that a pressing contact of the same with the stem 10 is substantially prevented.

[0043] Advantageously, the outer scraper 18 is held within the housing 2 in a floating manner, for example with such a clearance allowing the same to follow, to some extent, the transversal movements and inclinations of

the stem.

[0044] In accordance with the embodiment illustrated in Fig. 3, the outer scraper 18 is arranged between the second inner scraper 14 and the outer portion of the stem. Thereby, the second inner scraper 14 separates the lubricant chamber 12 from the outer scraper and either hinders or prevents that the lubricating material 11 may get in contact with the impurities from the external environment that are near the outer scraper. [0045] According to an embodiment, the outer scraper 18 has an active portion 19 with an inner cylindrical surface 20 facing the stem and a conical outer surface 21 converging in a sharp edge 22 facing the outer portion 7 of the stem. [0046] Since the outer scraper eliminates possible incrustations and impurity deposit on the stem, according to the particular embodiment, wear is reduced in the seal or second inner scraper, and their exposal to polluting substances is decreased. [0047] To further avoid an undesired decrease in the degree of protection over time, the sensor is provided with guide means, preferably at least one plain bearing 23 holding the stem such as to prevent the stem from unevenly resting on the seal 8 and/or the inner scrapers 13, 14 and/or the outer scraper 18. Preferably, at least

one bearing is arranged between the lubricant chamber 12 and the sensitive member 5.

[0048] Fig. 1 to 4 illustrate a linear transducer according to a preferred embodiment, in which the housing 2 comprises a tubular middle portion 24, preferably an aluminum extruded section with a front end 25 to be coupled with a first cover 26 defining the pass-through opening 4 and a rear end 27 opposite the front end 25 to which there may be connected a second cover 28 provided with an element 29 for securing the housing to an application first part, and preferably, with an electric connector 30 for connecting the sensor electronic board to an external data processing system

(not illustrated in the figures) . [0049] The first cover 26 comprises a front portion 31 and a rear portion 40.

[0050] The front portion 31 is substantially cylindrical with an inner surface 32 defining a middle opening with three shoulders, or more precisely, with three co-axial seats facing the rear end 27 of the sensor.

[0051] A first seat 33, preferably cylindrical, is suitable to accommodate the outer scraper 18 with clearance, i.e. in a floating manner. [0052] A second seat 34 being formed adjacent to the seat 33 for the outer scraper 18 is suitable to accommodate

the second inner scraper 14, .which forms preferably an abutment surface 35 for the outer scraper 18, thereby preventing the same from being displaced in the longitudinal direction towards the seal 8 and the inner space 3.

[0053] A third seat 36 formed adjacent to the seat 34 for the second inner scraper accommodates a separation ring 37 having a front surface 38 facing the outer portion of the stem and being an abutment for the second inner scraper 14, thereby preventing the same from being displaced in the longitudinal direction towards the seal and the inner space, as well as a rear surface 39 facing the inner space. [0054] The seat 36 for the separation ring 37 preferably further accommodates a coupling portion 41, preferably tubular and cylindrical, of the rear portion 40. [0055] The rear portion 40 of the first cover 26 defines a middle opening and comprises a front "surface 42, said coupling portion 41 protruding therefrom. Radially outside and preferably co-axial with the coupling portion 41 there is formed an annular seat 43 for a seal, such as an o-ring 44, that allows sealing coupling of the front portion 31 with the rear portion 40 of the first cover 26. [0056] Within the coupling portion 41 there is formed an

annular: shoulder 4-5 such as to define a -cup-shaped seat 46 facing the separation ring 37.

[0057] The cup-shaped seat 46 defines the seal seat 9, together with the rear surface 39 of the separation ring 37- and the stem 10.

[0058] Advantageously, the coupling portion 41, or more generally the seal seat 9, has an inner diameter such as to cause a radial compression by the seal 8 against the stem 10 and a length greater than the longitudinal extension of the seal 8, such that a space is defined adjacent to the seal 8 which acts as the lubricant chamber 12. This lubricant chamber 12 is filled with the lubricating material 11, such as a lubricating grease, when assembling the first cover 26. The separation ring 37 and the annular shoulder 45 within the coupling portion have an inner diameter greater than the section diameter of the stem 10, such as to define, together with the latter, a passageway for the lubricating material, i.e. an extension of the lubricant chamber 12 to the two inner scrapers 13 , 14.

[0059] A rear surface 47 of the rear portion 40 forms at least three shoulders or, more precisely, at least three co-axial seats facing the rear end of the sensor. [0060] A first seat 48 accommodates the first inner scraper 13.

[0061] A second seat 49 formed adjacent to the seat 48 fox the first inner scraper accommodates the bearing 23, which is preferably provided with a front surface 50 facing the outer portion 7 of the stem being an abutment for the first inner scraper 13, thereby preventing the same from being displaced in the longitudinal direction towards the inner space 3.

[0062] A third seat 51 formed adjacent to the seat 49 for the bearing accommodates the front end 25 of the tubular middle portion 24, preferably by interposing a flat seal 52 the shape of which depends on the shape of the extruded section of the middle portion 24. [0063] The front portion 31 and rear portion 40 of the first cover comprise at least one, preferably two aligned through holes 53, 54 that house respective clamping screws 55 that can be screwed in threaded holes 56 being formed in the front end 25 of the housing middle portion. Thereby, the two portions of the first cover can be tightened both to each other and the tubular middle portion such as to obtain a reliable and durable sealing of the sensor.

[0064] Different materials for the lubricating material, seal and inner scrapers have been tested within the scope of the present invention, and deemed satisfactory. [0065] By way of example, LGMT2 , LGEP2 , LGHP2 , LGET2

lubricating greases-, sold by SKF, for use as the- lubricating material, Turcon ^® Excluder ^® 2 code T46 scrapers for use as the inner scrapers and NBR o-ring for use as the seal are mentioned as being particularly advantageous .

[0066] To overcome wear problems in the seal-stem system, which may occur due to the continuous pressure of the seal and inner scrapers against the stem, it is further advantageous that the stem is formed of steel, at least surface-hardened, or plated by, for example, a layer of chrome .