Clutch Assembly Sensor Unit with Adjustable Mounting
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Solution Overview
Problem
Existing clutch assemblies in motor vehicle drivelines face difficulties in sensor mounting and accessibility during maintenance, leading to complex and time-consuming service procedures.
Innovation Solution
A clutch assembly design featuring a sensor unit with adjustable means that allows easy mounting and external accessibility, enabling reliable detection of the axial position of the clutch parts through a target element connected to the sensor, which can be adjusted radially and axially relative to the housing, facilitating quick and accurate sensor replacement and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is integrated into the clutch assembly housing, then the sensor mounting is secure and stable, but the sensor becomes difficult to access and replace during maintenance
Solution Approach 1:
The sensor unit is segmented from the housing as a separate, removable component. The sensor is mounted on a sensor unit that can be detached from the housing, allowing the sensor to be accessed and replaced independently without disassembling the entire clutch assembly. This segmentation resolves the contradiction by maintaining secure mounting during operation while enabling easy access during maintenance.
Solution Approach 2:
The sensor unit is designed with dynamic mounting characteristics - firmly secured during normal operation to ensure stable sensor positioning and reliable detection, but easily removable when maintenance is required. The mounting mechanism transitions from a fixed state during operation to a removable state during maintenance, resolving the contradiction between stability and accessibility.
2Reliability
If the sensor is positioned deep within the clutch assembly, then the sensor detection is stable and protected, but the sensor becomes difficult to access for service
Solution Approach 1:
The sensor unit is designed to be accessible from the exterior of the clutch assembly housing, changing the access dimension from internal to external. The sensor unit can be removed from the housing and adjusted externally, allowing service personnel to access and adjust the sensor without disassembling the clutch assembly. This dimensional change resolves the contradiction by maintaining stable detection during operation while enabling easy external access during service.
3Ease of manufacture
If the sensor position is fixed during assembly, then the manufacturing process is simple, but the sensor cannot be adjusted for accurate detection
Solution Approach 1:
The sensor unit incorporates adjustable mounting means that allow the sensor position to be modified after assembly. The mounting mechanism enables the sensor to be positioned at different locations on the sensor unit or relative to the target element, allowing accurate detection to be achieved while maintaining a relatively simple assembly process. This dynamic adjustability resolves the contradiction between manufacturing simplicity and detection accuracy.
Solution Approach 2:
The sensor unit allows for parameter changes in sensor positioning - the sensor can be adjusted to different positions and orientations on the sensor unit. This parameter adjustability enables accurate detection to be achieved while maintaining a simple assembly process, as the sensor can be positioned optimally after assembly without requiring complex precision manufacturing. The adjustable parameters resolve the contradiction between ease of manufacture and measurement precision.
4Measurement precision
If the sensor unit is designed with multiple adjustment capabilities, then the sensor detection accuracy is improved, but the device complexity increases
Solution Approach 1:
The adjustment functionality is segmented into the sensor unit rather than being distributed throughout the entire clutch assembly. The sensor unit itself is designed with integrated adjustment means, consolidating the complexity within a single removable component. This segmentation resolves the contradiction by providing multiple adjustment capabilities for accurate detection while containing the complexity within the modular sensor unit, which can be easily replaced or adjusted as needed.
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 design enhances sensor accessibility and ease of maintenance, allowing for accurate and efficient detection of clutch position, thereby improving the reliability and speed of clutch operation and maintenance processes.
Implementation Method 1
The sensor is provided in the form of a Hall sensor
Data Source
AI summary
A clutch assembly comprises a housing; a first drive part rotatingly drivable around an axis of rotation; a second drive part rotatable relative to the first drive part; a clutch which is arranged in the power path between the first drive part and the second drive part and which comprises a first clutch part which is connected to the first drive part in a rotationally fixed and axially movable way and a second clutch part which is drivingly connected to the second drive part; a controllable actuator for actuating the clutch; a sensor unit for determining a position signal which represents the axial position of the first clutch part, wherein the sensor unit comprises a target element which is at least indirectly connected to the first clutch part, and a sensor connected to the housing for recording a position of the target element; and adjusting means for adjusting the position of the sensor relative to the housing.