Lightweight Sensor Member for Camshaft with Angular Protrusions
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Solution Overview
Problem
Existing sensor members for engine camshafts face challenges in maintaining performance and assembly accuracy due to reduced thickness, which can lead to increased crack occurrence and signal detection deterioration, while also complicating production and assembly processes.
Innovation Solution
A lightweight sensor member with a fastening hole and angularly shaped detecting protrusions, made from a metal plate with specific tensile strength, is designed to prevent cracks and improve assembly, featuring a strength reinforcing groove and varying groove widths for position detection, manufactured using a bending and rolling process to maintain accuracy and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the size of the sensing protrusion is reduced for easy mounting of the sensor member, then the mounting ease is improved, but the thickness of the sensor member is reduced and production and assembly deteriorate
Solution Approach 1:
The sensor member is divided into a body portion and a sensing protrusion portion, allowing independent optimization of each part. The sensing protrusion can be made smaller for easy mounting while the body portion maintains sufficient thickness for manufacturability and assembly.
Solution Approach 2:
The sensor member transitions from a traditional sintered iron-based powder structure to a plate-shaped structure with dimensional precision, enabling thin-profile design while maintaining manufacturing quality through controlled plate thickness and precise dimensional tolerances.
2Weight of moving object
If the thickness of the sensor member is small due to the characteristics of iron-based powder after sintering, then the weight is reduced, but the occurrence of cracks is largely increased in an assembly process
Solution Approach 1:
The material structure changes from sintered iron-based powder to a plate-shaped structure with controlled thickness parameters. This parameter change enables achieving reduced weight while maintaining sufficient structural integrity to prevent cracks during assembly.
Solution Approach 2:
The sensor member combines a plate-shaped structural material with magnetic material properties, creating a composite structure that achieves both weight reduction and crack prevention through optimized material distribution and structural design.
Data Source
AI summary
A lightweight sensor member may include a fastening hole formed through a center thereof to be fastened to a camshaft, and a plurality of detecting protrusions formed on an external peripheral surface thereof, each having a certain angular shape to the fastening hole.