Crankshaft Torque Sensor Integrated Cavity
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Solution Overview
Problem
Current methods for measuring engine torque during vehicle powertrain development are expensive, require significant design effort, and often rely on algorithmic calculations that may not be available early in the development process, and they must contend with high g-forces, vibration, and temperatures, necessitating a solution that does not modify the flex plate or flywheel.
Innovation Solution
An engine crankshaft with a rear bearing journal featuring a substantially cylindrical cavity and integrated torque sensors that measure torque exerted on the rear bearing journal, allowing for direct measurement of engine torque without modifying the flex plate or flywheel, and providing a signal indicative of the engine's torque output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If torque sensors are integrated into the crankshaft, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The torque sensor is integrated directly into the crankshaft structure, merging the measurement function with the existing rotating component. This eliminates the need for separate torque measurement devices and reduces overall system complexity while maintaining high measurement precision through direct coupling with the torque transmission path.
Solution Approach 2:
The crankshaft serves dual functions: it continues to perform its primary role of converting piston motion to rotational motion while simultaneously housing and transmitting torque sensor signals for measurement. This multi-functionality reduces the need for additional dedicated measurement components.
2Ease of manufacture
If the rear bearing journal is modified with a cavity, then ease of manufacture is improved, but strength deteriorates
Solution Approach 1:
The cavity is created only in the non-load-bearing portion of the rear bearing journal, leaving the load-bearing areas intact and fully strengthened. This localized modification allows sensor integration while preserving the structural integrity and strength of the critical load-bearing regions of the journal.
Solution Approach 2:
The rear bearing journal is segmented into load-bearing and non-load-bearing zones, with the cavity confined to the non-critical section. This segmentation allows manufacturing modifications in safe zones without compromising the strength of the load-bearing zones.
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
Enables accurate and cost-effective measurement of engine torque without altering existing powertrain components, reducing design complexity and avoiding reliance on algorithmic calculations, while withstanding high g-forces and temperatures.
Implementation Method 1
The at least one torque sensor is configured to generate a torque signal corresponding to a torque exerted on the rear bearing journal
Data Source
AI summary
In various embodiments, an engine crankshaft is disclosed. The engine crankshaft comprises a rear bearing journal. The rear bearing journal has an output end. The rear bearing journal defines a substantially cylindrical cavity extending from the output end into the rear bearing journal. The engine crankshaft may further comprise at least one torque sensor operatively coupled to the rear bearing journal. The at least one torque sensor is configured to generate a torque signal corresponding to a torque exerted on the rear bearing journal. The torque exerted on the rear bearing journal is indicative of a torque output of an engine.