Angle Sensor Delta Wheel Backlash Elimination
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Solution Overview
Problem
Existing angle sensors with measuring pinions and a drive pinion face hysteresis issues due to backlash, leading to measurement errors and safety concerns, particularly when the measuring pinions are indirectly coupled, and previous solutions either increase hysteresis or introduce measurement errors.
Innovation Solution
A delta wheel with coaxially arranged toothed rims is inserted between the measuring pinions, pre-tensioned using a spring or friction clutch, to constantly press the teeth against the drive pinion, eliminating backlash and hysteresis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If measuring pinions are indirectly coupled to the drive pinion, then the structure is more flexible and easier to manufacture, but backlash occurs leading to hysteresis and measurement errors
Solution Approach 1:
A resilient bearing is introduced as an intermediary element between the measuring pinion and the drive pinion. This resilient bearing absorbs backlash while maintaining a reliable mechanical connection, thereby eliminating measurement errors without complicating the manufacturing process
2Reliability
If resilient bearing is used to eliminate backlash, then hysteresis is reduced, but measurement error increases due to displacement of measuring pinion axis
Solution Approach 1:
The measurement function is segmented between two independent measuring pinions with different tooth counts. Both pinions engage with the same drive pinion teeth, and their relative positional differences are evaluated to determine the drive pinion's angular position, thereby compensating for any displacement errors
3Measurement precision
If two measuring pinions with different tooth counts are used, then measurement range exceeds 360° with high precision, but the structure becomes more complex
Solution Approach 1:
The drive pinion serves multiple functions: it is engaged by both measuring pinions simultaneously, and its teeth are used by both pinions for measurement. This multi-functional design allows the system to achieve multi-revolution measurement capability with high precision while keeping the overall structure relatively simple
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 reduces hysteresis and measurement errors by ensuring consistent tooth engagement, maintaining accuracy and safety across multiple revolutions without the risk of tooth skipping or jamming.
Implementation Method 1
The gear rims of the delta wheel are connected to one another using a viscous, friction or magnetic clutch or a tensionable spring
Implementation Method 2
The gear rims of the delta wheel are connected to one another using a viscous, friction or magnetic clutch or a tensionable spring
Implementation Method 3
The gear rims of the delta wheel are connected to one another using a viscous, friction or magnetic clutch or a tensionable spring
Data Source
Figure 1~2
AI summary
Disclosed is an angle sensor that has an angle measuring range exceeding one full rotation and is used especially for a motor vehicle. Said angle sensor comprises a drive pinion and two driven measuring pinions, the number of full rotations of the drive pinion being determined from the position of the two measuring pinions. A delta wheel encompassing two coaxially arranged gear rims is inserted between the measuring pinions. The two gear rims mesh with one respective measuring pinion while being movable towards each other only by applying force.