Dual Rotor Position Sensor for Multi-Control Sensing
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Solution Overview
Problem
Conventional rotary position sensors are limited to sensing the position of a single control in vehicular systems and cannot provide position information for multiple controls in close proximity, requiring separate sensors for each control.
Innovation Solution
A rotary position sensor design featuring two independently rotatable rotors with magnets and Hall-effect sensors within a shared housing, allowing simultaneous sensing of multiple control positions by utilizing a ferromagnetic ring for magnetic field separation and o-rings for environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single conventional rotary position sensor is used, then the device complexity is low, but it cannot provide position information for multiple controls in close proximity
Solution Approach 1:
The sensor is divided into multiple independent sensing channels, each with its own rotor, magnet, and Hall-effect sensor. Each channel can independently sense the position of a different control, allowing a single sensor housing to provide position information for multiple controls simultaneously while maintaining relatively simple individual channel structures
Solution Approach 2:
The sensor housing and internal components are designed to support multiple sensing functions within a single device. The universal structure can accommodate multiple rotors and sensing channels, making the sensor capable of monitoring various vehicular controls (accelerator pedal, brake pedal, clutch pedal, etc.) with a single unit
2Adaptability or versatility
If multiple conventional rotary position sensors are used to sense multiple controls, then the measurement precision for each control is maintained, but the device complexity and quantity of components increase
Solution Approach 1:
Multiple sensing channels that would traditionally require separate sensor units are merged into a single integrated sensor housing. The housing contains multiple rotors, magnets, and Hall-effect sensors that operate simultaneously in close proximity, enabling one sensor unit to replace multiple individual sensors and reduce the total quantity of components
Solution Approach 2:
The sensor structure employs a nested arrangement where multiple rotors are positioned within the same housing space, each rotor associated with its own magnet and Hall-effect sensor. This nested configuration allows multiple sensing functions to coexist in a compact arrangement, reducing the overall space and component quantity compared to using separate sensor units
3Adaptability or versatility
If rotors are positioned in close proximity to sense multiple controls, then the adaptability to monitor multiple controls is improved, but magnetic field interference between channels increases
Solution Approach 1:
Ferromagnetic materials are introduced as intermediary elements to manage and direct magnetic flux between adjacent rotors and sensing channels. These ferromagnetic components act as flux guides or shields, channeling magnetic fields along desired paths and preventing magnetic field leakage into adjacent channels, thereby reducing magnetic field interference while allowing rotors to be positioned in close proximity
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 the simultaneous detection of position data for multiple vehicular controls, such as brake pedal arms, reducing the need for multiple sensors and enhancing reliability while maintaining environmental protection.
Implementation Method 1
A sensor, such as a Hall-effect sensor, may be disposed within the sensor housing and positioned adjacent to the magnets. The Hall-effect sensor or sensors is adapted to sense the magnitude and direction of the magnetic field associated with the first and second magnets and generate an electrical signal in response to the magnetic fields sensed by the Hall-effect sensor.
Data Source
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AI summary
A rotary position sensor (102) includes a sensor housing (202) defining an interior cavity. A first rotor (206) may be positioned and rotatable within the interior cavity, and the first rotor (206) may at least partially define a bore (214) to receive a shaft (112) and include a first magnet (326). Furthermore, the rotary position sensor (102) may include a second rotor (208) positioned and rotatable within the interior cavity, and the second rotor (208) may at least partially define the bore (214) to receive the shaft (112) and include a second magnet (328). A ring element (304) may be disposed in the sensor housing (202), and the ring element (304) may be arranged between the first rotor (206) and the second rotor (208).