Flap Position Sensing Device with Integrated Hall Sensors
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Solution Overview
Problem
The active air flap system in vehicles faces challenges in accurately sensing the position of the flap, leading to potential overheating issues when the flap fails to open or close properly, necessitating a reliable method to detect open, closed, and intermediate positions.
Innovation Solution
A flap position sensing device incorporating a rotating body with integrated permanent magnets and Hall sensors, housed in a resin sensor casing, which interacts with the flap to sense its position through the Hall effect, eliminating the need for a printed circuit board and reducing the device's size by integrating sensors and magnets during injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensing methods are used for flap position detection, then the device structure becomes complex and size increases, but measurement precision is insufficient for accurate position sensing
Solution Approach 1:
The patent combines multiple sensing elements (first Hall sensor and second Hall sensor) into a single integrated sensing device housing. The sensors are mounted on the same housing structure, and their outputs are processed together to determine flap position, merging multiple detection functions into one compact unit that accurately detects open, closed, and intermediate positions without complex separate sensing systems
Solution Approach 2:
The patent replaces complex mechanical sensing mechanisms with magnetic field-based Hall sensors. Instead of using mechanical linkages, switches, or physical contact-based position detection, the system uses non-contact magnetic field sensing to detect flap position, thereby reducing mechanical complexity while improving measurement precision and reliability
2Ease of manufacture
If separate mounting of sensors and magnets is used, then manufacturing precision is difficult to maintain, but assembly ease is improved
Solution Approach 1:
The patent integrates the mounting structures for both Hall sensors and permanent magnets into a single housing component. The housing contains dedicated mounting features for sensors and magnets that are manufactured as one piece, ensuring precise relative positioning between sensing elements and magnetic elements while simplifying the manufacturing process through single-component fabrication
3Ease of operation
If a printed circuit board is used for sensor mounting, then ease of operation is improved, but device size and manufacturing complexity increase
Solution Approach 1:
The patent extracts and eliminates the printed circuit board from the sensing device structure. Instead of mounting Hall sensors on a PCB, the sensors are directly mounted on the housing structure with direct electrical connections, removing the unnecessary intermediary PCB layer and reducing overall device volume while maintaining ease of installation and operation
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
Accurately detects the flap's position, enabling timely action to prevent engine overheating and reducing manufacturing complexity and size by integrating sensors and magnets, thus enhancing operational reliability.
Implementation Method 1
The first hall sensor and the second hall sensor are integrally formed with the sensor casing by insert injection molding, and are disposed corresponding to an open position and a closed position, respectively, of the flap... disposed to interact with the first hall sensor and the second hall sensor according to opening and closing of the flap, so as to sense the open position, the closed position, and other positions of the flap
Data Source
AI summary
A flap position sensing device of an active air flap system, and a method of manufacturing the same are described. The flap position sensing device includes a rotating body, a sensor casing, a first hall sensor and a second hall sensor, and a first permanent magnet and a second permanent magnet. The rotating body is formed of a resin material, and rotates the flap by receiving torque while the rotating body is coaxially fixed to a rotation shaft of the flap. The sensor casing is formed of a resin material, and is fixed to the housing to rotatably support the rotating body. The first hall sensor and the second hall sensor are integrally formed with the sensor casing by injection molding, and are disposed corresponding to an open position and a closed position, respectively, of the flap.