Sensor Assembly

Tools

  • Holoseat Test Stand with computer to operate it
  • Soldering iron with stand
  • Helping hands
  • Exhaust fan
  • Sensor assembly jig (3D printed tool - provide link)
  • Flush snips
  • Small scissors
  • Safety glasses

Materials

  • Instant/super glue (prefer Loctite Super Glue Ultragel Control)
  • Solder
  • Isopropyl alcohol
  • Cotton balls
  • (1) WSSM-01: TRRS Audio Connector PCB
  • (1) WSSM-02: TLE4966L Infineon Technologies High Precsn Hall / Board Mount Hall Effect/Magnetic Sensor
  • (1) WSSM-03: Sensor Housing Lower Half
  • (1) WSSM-04: Sensor Housing Upper Half
  • (1) WSSM-05: 3M 9472LE Tape 5/8" x 1" piece

Safety Issues

  • Care must be taken when using the soldering iron, the tip is very hot
  • Always wear safety glasses while working with soldering irons
  • Avoid breathing in the soldering fumes, use a vent or hood if needed to provide adequate ventilation

Product

HS-04: Wheel Speed Sensor Module

Procedure

1. Place sensor on TRRS Audio Connector PCB

  1. Place WSSM-02: TLE4966L Sensor in jig with label facing “out” (toward window in jig)
  2. Slide TLE4966L Sensor into jig until its label aligns can be seen through the window in jig
  3. Bend TLE4966L Sensor leads down along jig
  4. Place TLE4966L Sensor pins through holes in WSSM-01: TRRS Audio Connector PCB with the jack facing up
  5. Align TRRS Audio Connector PCB with lip on jig
  6. Bend TLE4966L Sensor leads over to fix position of sensor relative TRRS Audio Connector PCB
  7. Remove TLE4966L Sensor/TRRS Audio Connector PCB sub-assembly from jig

2. Solder TLE4966L Sensor to TRRS Audio Connector PCB

  1. Place TLE4966L Sensor/TRRS Audio Connector PCB sub-assembly in helping hands
  2. Solder all 4 TLE4966L Sensor leads to their pins on the TRRS Audio Connector PCB
  3. Trim back excess leads from TLE4966L Sensor

3. Verify sensor

  1. Place TLE4966L Sensor/TRRS Audio Connector PCB sub-assembly in WSSM-03: Sensor Housing Lower Half
  2. Connect sensor cable from test stand to Wheel Speed Sensor sub-assembly
  3. Place Wheel Speed Sensor sub-assembly in sensor mount on test stand
    step3.3-sm.jpg
  4. Run tests - see test stand for API calls/application used for these tests (there is a CLI tool to run these tests automatically)
    1. Verify direction
      1. it should report cw when wheel turns 20 rpm cw
      2. it should report ccw when wheel turns 20 rpm ccw
    2. Verify cadence (using average cadence)
      1. it should report 30 +/- 2 when wheel turns cw at 30 rpm
      2. it should report 50 +/- 2 when wheel turns cw at 50 rpm
      3. it should report 45 +/- 2 when wheel turns cw at 45 rpm
      4. it should report 25 +/- 2 when wheel turns cw at 45 rpm

4. Finish assembly

  1. Take Wheel Speed Sensor sub-assembly off test stand
  2. Place WSSM-04: Sensor Housing Upper Half on top of WSSM-03: Sensor Housing Lower Half
  3. Press Sensor Housing Upper Half into Sensor Housing Lower Half until it clicks into place and sits flush on the Sensor Housing Lower Half
  4. Add 9472LE Tape
    1. Clean the bottom of the Wheel Speed Sensor Module with isopropyl alcohol using a cotton ball
    2. Wait for the alcohol to dry
    3. Cut 5/8" long piece of 9472LE Tape
    4. Apply 9472LE Tape to the bottom of the Wheel Speed Sensor Module
    5. Press Wheel Speed Sensor Module firmly onto a flat surface for 60 seconds
    6. Trim excess tape off of Wheel Speed Sensor Module

step2.1-sm.jpg (49 kB) J. Simmons, 05/02/2018 08:39 pm

step2.3-sm.jpg (25.4 kB) J. Simmons, 05/02/2018 08:39 pm

step3.1-sm.jpg (29.7 kB) J. Simmons, 05/02/2018 08:39 pm

step3.3-sm.jpg (55.4 kB) J. Simmons, 05/02/2018 08:39 pm

step4.2-sm.jpg (27.6 kB) J. Simmons, 05/02/2018 08:39 pm

step4.3-sm.jpg (29.1 kB) J. Simmons, 05/02/2018 08:39 pm

step4.4.4-sm.jpg (30.9 kB) J. Simmons, 05/05/2018 02:29 am

step4.4.6-sm.jpg (30.3 kB) J. Simmons, 05/05/2018 02:29 am

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