External Encoder Bearing Mount for Reliable Wheel Speed Sensing
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Solution Overview
Problem
Power machines, especially those without transaxles or with conventional transaxles lacking built-in sensor technology, face challenges in accurately and reliably sensing wheel speed, which is crucial for control and operation, particularly in autonomously operated and electrically powered machines.
Innovation Solution
A mountable sensor apparatus comprising an encoder bearing sensor with an inner and outer race, bearings allowing rotation, a bearing carrier, and a bracket to prevent rotation, coupled to a support structure, providing output signals for rotational speed and direction, which can be secured to the axle using set screws or press-fit methods, allowing external mounting on various power machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor is integrated into the transaxle, then wheel speed sensing is built-in and reliable, but the device complexity and manufacturing cost increase
Solution Approach 1:
The sensor system is segmented from the transaxle into a separate mounting structure. The encoder bearing sensor is mounted externally on the transaxle housing rather than being integrated inside, allowing the transaxle to remain simple while still achieving reliable wheel speed sensing through the external sensor assembly that reads signals from the rotating inner race.
2Device complexity
If an external sensor mount is used, then the transaxle remains simple, but the sensor mounting precision and reliability may be compromised
Solution Approach 1:
The mounting structure merges multiple functions into a single integrated assembly: the bracket provides structural support and positioning, the bearing carrier houses the encoder bearing sensor, and the set screws secure the entire assembly to the transaxle housing. This unified structure ensures precise sensor positioning and reliable mounting without complicating the transaxle itself.
3Ease of operation
If the sensor is mounted externally, then installation and removal become easier, but the sensor may be more susceptible to vibration and environmental factors
Solution Approach 1:
The design incorporates vibration resistance through the rigid bracket structure and secure set screw fastening system that pre-complies with mounting stresses. The encoder bearing sensor is positioned to read signals from the inner race in a manner that maintains measurement accuracy despite external vibrations, cushioning the system against environmental harmful factors before they can affect performance.
4Reliability
If a robust mounting structure with multiple fasteners is used, then sensor stability improves, but the ease of installation and removal decreases
Solution Approach 1:
The mounting system is segmented into modular components: the bracket attaches to the transaxle housing with set screws, the bearing carrier mounts to the bracket, and the encoder bearing sensor secures to the bearing carrier. This segmentation allows each component to be independently installed and removed, maintaining ease of operation while achieving robust overall mounting stability through the multi-point fastening system.
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 precise and reliable wheel speed measurement external to the transaxle, applicable to multiple power machine types, including electric machines, without requiring substantial modifications to existing vehicles, providing consistent and vibration-resistant data for control systems.
Implementation Method 1
an encoder bearing sensor comprising an inner race configured to be secured to the axle of the power machine, an outer race, and bearings positioned between the inner race and the outer race and configured to allow rotation of the inner race relative to the outer race
Data Source
AI summary
Disclosed are mountable sensor apparatus configured to measure a rotational speed of an axle of a power machine, as well as power machines including the sensor apparatus. The apparatus includes an encoder bearing sensor comprising an inner race configured to be secured to the axle of the power machine, an outer race, and bearings positioned between the inner race and the outer race and configured to allow rotation of the inner race relative to the outer race. A bearing carrier of the apparatus is connected to the outer race of the encoder bearing sensor, and a bracket is connected to the bearing carrier and mountable to a support structure of the power machine to prevent the bearing carrier and the outer race from rotating with the inner race and the axle. A sensor output line provides output signals indicative of rotational speed and direction of the axle.