EPS Motor Sensing Magnet Anti-Separation Coupling
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Solution Overview
Problem
The existing coupling structure between the sensing magnet and the plate in EPS motors is prone to separation due to adhesive failure, especially under varying temperature conditions, making it difficult to maintain a stable connection and increasing the risk of motor malfunction.
Innovation Solution
A coupling structure that includes a disk-shaped plate with a ring-shaped sensing magnet and magnet grips, where the plate is coated with adhesive and features a caulking process to physically grip the sensing magnet, providing additional support through a holder member and fixing unit, such as screws or rivets, to prevent separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive coupling is used to attach the sensing magnet to the plate, then the structure is simple and easy to manufacture, but the coupling reliability deteriorates under high temperature and alternating temperature conditions causing magnet separation
Solution Approach 1:
The coupling structure is segmented into multiple functional elements: a plate with protrusions, a sensing magnet with corresponding recesses, and an adhesive layer. This segmentation allows each component to perform its specific function - the protrusions and recesses provide mechanical interlocking while the adhesive provides chemical bonding, thereby resolving the contradiction between manufacturing simplicity and coupling reliability under temperature variations
Solution Approach 2:
The coupling mechanism uses a composite approach combining mechanical interlocking (through protrusions and recesses) and chemical adhesion (through adhesive). This composite coupling method maintains both ease of manufacture and high reliability under high temperature and alternating temperature conditions, preventing magnet separation while keeping the manufacturing process simple
2Ease of manufacture
If adhesive coupling is used to attach the sensing magnet to the plate, then the manufacturing process is simple, but the adhesion precision deteriorates making it difficult to control the adhesion process
Solution Approach 1:
The plate is pre-formed with protrusions and the sensing magnet is pre-formed with corresponding recesses before the adhesive bonding step. This preliminary mechanical interlocking structure ensures proper alignment and positioning, making the subsequent adhesive application easier to control and achieving both simple manufacturing and precise adhesion
3Reliability
If a high price adhesive is selected to improve coupling strength, then the coupling reliability improves, but the manufacturing cost increases
Solution Approach 1:
The coupling function is segmented between the mechanical interlocking structure (protrusions and recesses) and the adhesive layer. The mechanical structure provides the primary coupling strength and positional stability, allowing the use of a lower-cost adhesive that only needs to provide supplementary bonding, thereby reducing manufacturing cost while maintaining high coupling reliability
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 solution enhances the reliability of the motor by maintaining a stable connection between the sensing magnet and plate, even under extreme temperature conditions, eliminating the need for additional parts and reducing material costs.
Implementation Method 1
the sensing magnet is fixed to an upper surface of a plate mounted at an upper side of the rotor using an adhesive
Data Source
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AI summary
Disclosed is an anti-separating structure of a sensing magnet for EPS motor, the structure being a coupling structure between the sensing magnet and a plate of the EPS motor, the structure including a disk-shaped plate formed with a magnet accommodation unit protrusively formed near at a rotation shaft, a ring-shaped sensing magnet centrally formed with a through hole having a diameter corresponding to the magnet accommodation unit, and magnet grip units each formed at a predetermined gap along a circumferential surface of the magnet accommodation unit.