Configurable Hall-Effect Sensor for Throttle Control
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Solution Overview
Problem
Current throttle control sensor applications require custom-designed components, leading to high development costs and limited interchangeability, and lack a configurable solution that can meet various standards and interface connections for different drive systems.
Innovation Solution
A configurable non-contact position sensor using a Hall effect sensing device that detects angle changes in a magnetic field, adaptable for both direct and non-direct drive systems, with interchangeable components and modular connector interfaces, conforming to SAE standards and providing various electrical outputs, housed in a flexible over-molded shell for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-designed sensors are used for each application, then specific requirements (drive angle, return spring torque, connector, sensor position) can be met, but development cost and lead time increase significantly
Solution Approach 1:
The sensor module is designed with universal features including a standardized housing, interchangeable connector modules, and configurable internal components (magnets, springs, rotors) that can be adjusted to meet different application requirements. This allows a single base design to serve multiple throttle control applications while maintaining customizability through component selection and configuration rather than complete redesign.
2Reliability
If custom-designed sensors are used for each application, then specific requirements can be met, but interchangeability of components is eliminated
Solution Approach 1:
The sensor assembly is divided into modular segments including a base sensor module, interchangeable connector modules, and configurable internal components. Each segment can be independently selected or replaced based on application requirements. The standardized interface between segments enables interchangeability while allowing customization of the complete assembly to meet specific drive angle, torque, and connector requirements.
3Ease of manufacture
If a single configurable sensor design is used, then development cost and lead time are reduced, but the ability to meet specific application requirements may be compromised
Solution Approach 1:
The sensor module incorporates dynamic configurability through interchangeable connector modules and adjustable internal components (magnets, springs, rotors) that can be selected and positioned to achieve specific drive angles, return spring torques, and electrical output characteristics. This dynamic adaptation allows the same base design to be precisely configured for different applications without requiring custom manufacturing, thereby maintaining manufacturing precision while reducing development costs.
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 solution reduces manufacturing costs and lead time by enabling a single sensor to fit multiple applications, ensuring compliance with standards and providing flexibility in drive systems and interface connections, while maintaining environmental sealing and reliability.
Implementation Method 1
A configurable non-contact position sensor using a Hall effect sensing device that detects angle changes in a magnetic field
Data Source
AI summary
Embodiments herein relate to the general art of motor vehicles, and to the particular field motor vehicle components, especially sensors for electronic throttle controls. Particular embodiments include configurable Hall-effect sensors for use in vehicle controls. In various embodiments, the configurable sensors may include a flexible over molding that may allow the sensor assemblies to achieve an environmental rating conforming International Protection Rating IP 67 and/or IP 66. Additionally, because the sensor assemblies are modular, a single assembly may be configured in any number of different ways, including direct drive and indirect drive applications and multiple different proprietary interface connections, while maintaining compliance with Society of Automotive Engineers (SAE) standards.