Clutch Cam Angle Sensor Segmentation for Cost Reduction
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Solution Overview
Problem
Conventional cam mechanisms require expensive angle sensors with large detection ranges to accurately detect cam member rotation over a wide angular range, leading to increased manufacturing costs and limited applicability.
Innovation Solution
A control apparatus for a clutch driving mechanism using two angle sensors with non-overlapping dead zones, where one sensor detects the first cam face and the other the second cam face, allowing for accurate detection of cam member rotation over a wide range without the need for expensive sensors, and a decision unit determines which sensor to use based on the cam member's position and direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single angle sensor with large detection range is used to detect cam member rotation over a wide angular range, then detection coverage is improved, but manufacturing cost increases
Solution Approach 1:
The detection task is segmented into two separate angle sensors, each responsible for a specific cam face (first cam face and second cam face). Each sensor has a limited detection range optimized for its specific cam face, avoiding the need for a single expensive sensor with a large detection range. This segmentation allows using multiple low-cost sensors instead of one high-cost sensor.
Solution Approach 2:
Each angle sensor is configured with local detection capabilities tailored to its specific cam face. The first angle sensor detects the first cam face within its detection range, and the second angle sensor detects the second cam face within its detection range. This local optimization allows each sensor to be designed with appropriate detection range for its specific task, reducing overall system cost.
2Reliability
If the cam member rotates in one direction only to facilitate shock moderation, then clutch connection quality is improved, but the detection system becomes more complex due to large angular range requirements
Solution Approach 1:
The cam member is segmented into two distinct cam faces (first cam face for connection, second cam face for disconnection), each detected by a dedicated angle sensor. This segmentation allows the detection system to handle the large angular range of one-directional rotation without requiring a single complex sensor, instead using two simpler sensors with non-overlapping detection ranges.
Solution Approach 2:
The control unit acts as an intermediary that manages the switch between the first angle sensor and the second angle sensor based on the cam member's rotational position. This intermediary control logic enables the system to seamlessly transition between sensors, effectively handling the large angular range detection requirement without increasing individual sensor complexity.
3Ease of manufacture
If two angle sensors with non-overlapping dead zones are used to cover the wide angular range, then detection cost is reduced, but the system requires additional control logic to switch between sensors
Solution Approach 1:
The angular detection range is segmented between two angle sensors with non-overlapping dead zones. The first angle sensor covers the first cam face detection range, and the second angle sensor covers the second cam face detection range. This segmentation allows using inexpensive sensors with limited ranges rather than expensive sensors with large ranges, accepting the trade-off of needing sensor switching control logic.
Solution Approach 2:
The control unit uses feedback from the cam member's rotational position to determine which angle sensor should be active. By monitoring the current angular position and comparing it with the detection ranges of the two sensors, the control unit dynamically switches between sensors to ensure continuous accurate detection throughout the entire rotational range.
Data Source
AI summary
A control apparatus for a clutch driving mechanism can include a clutch driving mechanism which connects and disconnects a clutch. An angle sensor can detect the angle of rotation of a cam member. A cam face can include a first cam face for connecting the clutch through the linear motion of the operating member. A second cam face, formed continuously to the first cam face, can disconnect the clutch through the linear motion of the operating member. The angle sensor 21 can include a first angle sensor which can detect an angular range of the first cam face, and a second angle sensor which can detect an angular range of the second cam face. The dead zones E of the angle sensors are disposed in such a manner as not to overlap with each other.