Bimetallic Sensor Mount for Axle Corrosion
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Solution Overview
Problem
Conventional speed sensor assemblies in motor vehicles are prone to corrosion at the mounting interface, leading to a change in sensor position and loss of wheel speed sensing capability over time.
Innovation Solution
A bimetallic sensor mount with a corrosion-resistant material for the sensor region and a weldable material for the mounting structure, reducing corrosion and maintaining sensor position accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a steel boss is used for mounting the sensor to the axle housing, then the sensor can be securely mounted, but corrosion occurs at the mounting interface leading to sensor position changes
Solution Approach 1:
The sensor mount is constructed as a composite structure with a corrosion-resistant material (such as aluminum or aluminum alloy) and a weldable material (such as steel). The weldable material is attached to the corrosion-resistant material, allowing the assembly to be welded to the steel axle housing while the sensor contacts only the corrosion-resistant portion, thereby preventing galvanic corrosion at the mounting interface.
2Stability of the object's composition
If the sensor position changes due to corrosion, then the mounting structure remains intact, but wheel speed sensing capability is lost
Solution Approach 1:
The composite sensor mount maintains the structural integrity needed for stable mounting while the corrosion-resistant material portion ensures that the sensor position remains stable relative to the axle housing, preserving measurement precision throughout the service life of the component.
3Object-affected harmful factors
If a corrosion resistant material is used for the sensor mount, then corrosion is reduced, but the material may not be weldable to the mounting structure
Solution Approach 1:
The sensor mount comprises a corrosion-resistant material substrate with a weldable material layer or attachment. The weldable material (such as steel) is bonded to the corrosion-resistant material (such as aluminum) through various methods including mechanical fastening, brazing, or specialized welding techniques, enabling attachment to steel axle housings while maintaining corrosion resistance at the sensor interface.
Solution Approach 2:
The weldable material acts as an intermediary between the corrosion-resistant sensor mount and the steel axle housing. This intermediary layer allows welding to the steel housing without exposing the sensor to corrosive environments, as the sensor contacts only the corrosion-resistant material portion of the mount.
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 bimetallic sensor mount effectively reduces corrosion, ensuring accurate wheel speed detection over extended periods by maintaining the sensor's position relative to the target surface.
Implementation Method 1
a bimetallic sensor mount having a first region of a first metallic material that is adapted to support the sensor and a second region of a second metallic material that is adapted for attachment to the mounting structure
Data Source
AI summary
An axle assembly for a vehicle includes an axle housing having a tubular portion. A bimetallic sensor mount having a first region of corrosion resistant material and a second region of weldable material is welded to the tubular portion. A differential unit including a side gear is disposed in a central cavity of the axle housing. An axleshaft having a shaft portion and a target portion with a plurality of teeth is disposed in the tubular portion of the axle housing. The shaft portion is coupled to the side gear. A sensor is coupled to the sensor mount and extends through an aperture in the mount and the tubular portion to locate an end portion of the sensor a predetermined distance from the teeth of the target portion. A method of making an axle assembly having a sintered bimetallic sensor mount is also disclosed.