Actuator Sensor Waterproofing via Segmented Housing
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Solution Overview
Problem
Magnetoresistive sensors in electronic clutch systems are prone to malfunction when exposed to water due to their close proximity to the magnet, leading to position calculation errors.
Innovation Solution
The actuator design includes a housing with a sensor mounted inside and a magnet on a rotating shaft, with a sealing mechanism to prevent water ingress, and a mounting groove configuration that minimizes the distance between the magnet and sensor to reduce signal interference and obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is placed close to the magnet for accurate position detection, then measurement precision is improved, but the sensor becomes vulnerable to water ingress and malfunction
Solution Approach 1:
The housing is divided into a sensor chamber and a motor chamber separated by a waterproof partition. The sensor is isolated in its own sealed chamber, physically segmenting it from the magnet and motor components that may be exposed to water, thus protecting the sensor while maintaining detection accuracy through precise positioning of the magnet relative to the sensor chamber.
Solution Approach 2:
A waterproof partition acts as an intermediary barrier between the sensor and the external environment. This partition allows magnetic field penetration for position detection while blocking water ingress, serving as a mediator that enables both accurate measurement and reliable protection simultaneously.
2Measurement precision
If the air gap between the sensor and magnet is reduced for better signal strength, then measurement precision is improved, but the sensor becomes more susceptible to water contamination
Solution Approach 1:
The design transitions the protection approach from reducing the air gap (one-dimensional optimization) to adding a spatial dimension through the waterproof partition. The partition creates a protected three-dimensional space around the sensor, allowing the magnet to be positioned close for strong signal while water contamination is blocked from reaching the sensor through the partition barrier.
3Ease of manufacture
If the housing structure is simplified for ease of manufacture, then manufacturing precision requirements are reduced, but the waterproofing capability may be compromised
Solution Approach 1:
The housing is segmented into modular chambers (sensor chamber and motor chamber) connected through sealed interfaces. This segmentation allows each chamber to be manufactured and sealed independently, then assembled together. The waterproof partition creates a clear separation that simplifies the sealing design compared to creating a completely waterproof complex single structure, thus balancing ease of manufacture with waterproofing reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents water from reaching the sensor, ensuring reliable operation and accurate position calculation by maintaining the sensor's integrity and reducing signal interference.
Implementation Method 1
the magnet changes its magnetic field between the sensor and the magnet during rotating with the rotating shaft
Implementation Method 2
a magnetoresistive sensor disposed on an actuator, the magnetoresistive sensor typically includes a position-fixed sensor and a position-changeable magnet
Data Source
AI summary
An actuator includes a controller, a motor and a sensor device. The controller includes a housing, and the motor includes a rotor, and the rotor includes a rotating shaft. The motor is mounted on the outside of the housing, and the sensor device includes a magnet and a sensor, the magnet is mounted on the rotating shaft of the motor, and the sensor is mounted inside the housing. The actuator has a good waterproof performance and anti-interference ability. This disclosure also relates to an electronic clutch system having the actuator.