Dual Camshaft Sensor Housing for VVT Engine Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing camshaft sensing systems for dual overhead camshaft engines require multiple separate sensor assemblies, leading to increased complexity, engineering hours, and potential inaccuracies due to the need for precise positioning and sealing of multiple sensor elements, which also result in longer engine head lengths and increased wiring requirements.
Innovation Solution
A dual sensor element system is integrated into a common housing, sharing a single mounting on the engine structure, with a common power and ground lead and individual signal leads for each sensor, reducing the number of required leads and mounts, and allowing precise positioning between the intake and exhaust camshafts to enhance accuracy and reduce the need for larger target wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate sensor assemblies are used for each camshaft, then each camshaft can be sensed independently, but the device complexity and wiring requirements increase significantly
Solution Approach 1:
The patent combines two separate sensor assemblies into a single integrated sensor assembly that senses both camshafts. The sensor assembly includes a first sensor element for the first camshaft and a second sensor element for the second camshaft, both mounted in the same housing and connected through common wiring harnesses for power and ground, reducing the overall complexity while maintaining independent sensing capability.
2Measurement precision
If multiple separate sensor assemblies are mounted on the engine, then each sensor can be positioned independently, but the engineering hours and mounting complexity increase
Solution Approach 1:
The patent integrates multiple sensor elements into a single pre-assembled unit with a common housing and mounting structure. This allows the entire sensor assembly to be mounted as one unit on the engine, reducing the number of separate mounting operations and engineering hours required while maintaining precise positioning through the integrated design.
3Reliability
If separate wiring harnesses are used for each sensor, then each sensor has dedicated connections, but the number of leads, pins, and sockets increases
Solution Approach 1:
The patent combines the wiring connections for multiple sensors into shared common wiring harnesses. The sensor assembly uses common power leads and common ground leads that serve multiple sensor elements, significantly reducing the total number of leads, pins, and sockets required compared to separate wiring for each sensor.
4Measurement precision
If target wheels are mounted on the front or rear of camshafts, then camshaft position can be sensed, but the overall head length increases
Solution Approach 1:
The patent repositions the sensor elements and target wheels from the traditional front/rear axial position to a lateral position where sensors are mounted on opposite sides of the camshaft. This dimensional change allows the sensing function to be achieved without increasing the overall head length in the axial direction.
5Reliability
If multiple holes are formed in the engine head for sensor mounting, then each sensor can be secured, but sealing requirements and manufacturing complexity increase
Solution Approach 1:
The patent consolidates multiple separate mounting holes into a single mounting location for the integrated sensor assembly. This reduces the number of sealing interfaces required in the engine head, simplifying the manufacturing process and sealing requirements while maintaining secure mounting of the sensor elements.
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
This configuration simplifies the mounting process, reduces engineering time, and improves the accuracy of camshaft position sensing by allowing precise control of the sensor gap and using smaller target wheels, while minimizing the number of required leads and mounts, thus enhancing overall system efficiency.
Implementation Method 1
Hall Effect transducers are commonly used as the camshaft position-sensing element in the sensor assembly
Data Source
AI summary
A position sensing system uses two sensing elements to sense the rotary position of target wheels mounted on two camshafts. The two sensing elements are mounted in a common sensor housing and preferably the two sensor elements share power and ground wires, and each sensor element has its own signal wire. The wires preferably are contained within a common conduit that extends from the housing to a location outside of the rocker cover. The end of the conduit may support one-half of an electrical connector that terminates the wires from the sensors. Mounting the two sensing elements in a common housing simplifies mounting the sensors on the engine, and reduces the number of wires required to power and derive signals from the two sensors. The target wheels are mounted directly on the camshafts and are positioned along the axis of the camshaft, spaced from the camshaft ends.