Camshaft Sensor Support Structure for Engine Cylinder Head
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Solution Overview
Problem
The existing sensor support structures for camshafts in internal combustion engines face challenges in maintaining precise positioning due to deformation of resin-made cylinder head covers and inaccuracies in connection angles, leading to decreased positional accuracy of the cam angle sensor.
Innovation Solution
A sensor support structure with a connection portion contacting the cylinder head, an arm portion extending radially, a sensor support portion for the sensor, and a restriction portion to prevent movement in the circumferential direction, enhancing mounting accuracy and allowing for precise orientation and assembly of the sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensor is fixed to the bracket with a fixing bolt, then the sensor can be mounted on the cam cap, but the positional accuracy decreases due to connection angle changes at the fixing portion
Solution Approach 1:
The support structure is divided into separate functional portions: a connection portion that interfaces with the cylinder head, an arm portion that extends radially, and a sensor support portion that holds the sensor. This segmentation allows each portion to be optimized independently, with the connection portion providing stable positioning and the sensor support portion ensuring precise sensor placement, thereby resolving the contradiction between ease of manufacture and manufacturing precision
Solution Approach 2:
The arm portion acts as an intermediary element between the connection portion and the sensor support portion. It transmits positional stability from the connection portion to the sensor support portion while maintaining the required orientation, thus preserving sensor positional accuracy without complicating the mounting process
2Measurement precision
If the cam cap is used as the support portion for the sensor, then the sensor can be positioned relative to the camshaft, but the positional constraint is limited because the cam cap is not provided over the whole area of the camshaft in the axial direction
Solution Approach 1:
The support structure extends the positioning capability from the limited cam cap area to the broader cylinder head area by utilizing the connection portion that contacts the cylinder head. This dimensional extension allows the sensor to be positioned with high precision while accommodating the full axial coverage requirements, as the cylinder head provides a larger mounting surface than the cam cap alone
3Manufacturing precision
If the connection portion is positioned to contact the cylinder head, then the mounting accuracy is enhanced, but the structure becomes more complex compared to direct cam cap mounting
Solution Approach 1:
The connection portion, arm portion, and sensor support portion are merged into a single integrated support structure. This combining of functions into one component achieves high mounting accuracy through the cylinder head contact while avoiding the complexity of multiple separate parts, as the integrated design simplifies assembly and reduces the number of fastening operations required
Data Source
AI summary
A sensor support structure includes a connection portion positioned in the cylinder head cover of an internal combustion engine from an outer surface of the cylinder head cover to a position where the connection portion comes in contact with a cylinder head of the internal combustion engine, an arm portion extending from an outer end side of the connection portion toward an outer side of the connection portion in a radial direction, a sensor support portion provided at an extending end of the arm portion, the sensor support portion being formed to protrude in a direction away from a side where the cylinder head is positioned, the sensor support portion supporting a sensor that detects a rotation of a camshaft of the internal combustion engine; and a restriction portion restricting a movement of the arm portion relative to the cylinder head cover in a circumferential direction about the connection portion.