Cam Angle Sensor Mounting Structure for Engine Cylinder Head
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Solution Overview
Problem
Existing cam angle sensor mounting structures face challenges in achieving a compact and lightweight design while maintaining high precision, particularly due to space constraints in internal combustion engines and concerns about sensor fouling by foreign matter, and they often require rigid metal head covers that increase weight and cost.
Innovation Solution
A cam angle sensor mounting structure featuring a metal sensor bracket rigidly attached to the cylinder head and a lightweight synthetic resin head cover non-rigidly mounted via gaskets, allowing for resilient movement and improved vibration characteristics, with the sensor bracket supporting the cam angle sensor in a manner that faces downward to avoid contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the cam angle sensor is mounted on a cylinder head in the lower region, then the mounting space is constrained by the head cover, but the sensor reading precision is maintained
Solution Approach 1:
The invention divides the mounting structure into separate components: a sensor mounting plate rigidly attached to the cylinder head, and a head cover non-rigidly mounted via vibration isolating members. This segmentation allows the sensor to be mounted in the lower region with precise positioning while the head cover is separated to avoid interference with mounting space.
Solution Approach 2:
The invention introduces vibration isolating members (such as rubber mounts or elastomeric materials) as intermediaries between the head cover and the sensor mounting structure. These intermediaries allow the head cover to be non-rigidly mounted, providing vibration isolation while maintaining the rigid connection needed for sensor precision through the separate sensor mounting plate.
2Adaptability or versatility
If the cam angle sensor is mounted with upward-facing sensing part, then the mounting flexibility is improved, but the sensing part is fouled by foreign matter such as dust and oil
Solution Approach 1:
The invention inverts the conventional upward-facing sensor orientation by mounting the cam angle sensor with its sensing part facing downward toward the signal plate on the camshaft. This inversion protects the sensing part from fouling by foreign matter while the sensor mounting plate provides the necessary flexible mounting options on the cylinder head.
3Strength
If the head cover is made of metal to ensure rigidity for supporting the cam angle sensor, then the structural strength is improved, but the weight and cost increase
Solution Approach 1:
The invention introduces vibration isolating members as intermediaries between the head cover and the sensor mounting structure. This allows the head cover to be made of lightweight materials such as resin or aluminum alloy while still providing adequate support for the cam angle sensor through the isolated rigid connection at the sensor mounting plate.
Solution Approach 2:
The invention changes the mounting rigidity parameter by using vibration isolating members with specific elastic properties. This allows the head cover to be made of lighter materials while maintaining the necessary structural strength for sensor support through the controlled rigidity of the vibration isolation system.
4Measurement precision
If the head cover is rigidly mounted to the cylinder head, then the sensor reading precision is maintained, but the vibration and noise increase
Solution Approach 1:
The invention uses vibration isolating members (such as rubber mounts, elastomeric materials, or foam) as intermediaries between the head cover and the sensor mounting structure. These intermediaries provide vibration isolation to reduce noise and vibration while maintaining the rigid connection needed for sensor precision through the separate sensor mounting plate rigidly attached to the cylinder head.
Solution Approach 2:
The invention changes the mounting rigidity parameter by using vibration isolating members with specific elastic properties. This allows the head cover to be non-rigidly mounted to reduce vibration and noise, while the sensor mounting plate maintains the necessary rigidity for precise sensor readings through its rigid attachment to the cylinder head.
5Area of stationary object
If the cam angle sensor is mounted on a cam bracket, then the mounting space is utilized, but the reading precision is reduced due to deformation from load
Solution Approach 1:
The invention extracts the sensor mounting function from the load-bearing cam bracket by providing a separate sensor mounting plate rigidly attached to the cylinder head. This separation eliminates the deformation issues caused by cam shaft and cover loads on the bracket, while still utilizing the available mounting space on the cylinder head.
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
This configuration enhances detection precision, reduces weight and cost, and minimizes noise by using a full floating soft mounting structure for the head cover, while maintaining sensor rigidity and avoiding contamination of the sensing part.
Implementation Method 1
a head cover non-rigidly mounted on the cylinder head and the sensor bracket via at least one gasket to cover a top opening of the cylinder head with a space being formed around the at least one gasket
Data Source
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AI summary
A cam angle mounting structure includes a cylinder head, a sensor bracket and a head cover. The cylinder head is configured and arranged to rotatably support a camshaft. The sensor bracket is configured and arranged to support a cam angle sensor. The sensor bracket is mounted on the cylinder head with the sensor bracket contacting the cylinder head. The head cover is non-rigidly mounted on the cylinder head and the sensor bracket via at least one gasket to cover a top opening of the cylinder head with a space being formed around the at least one gasket between the head cover and the cylinder head and between the head cover and the sensor bracket.