Flexible Sensor Gear Teeth to Prevent Lash and Splitting
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Solution Overview
Problem
Bifurcated anti-lash teeth in rotatable sensor gears can split, leading to erroneous sensor readouts in steering systems, particularly in power steering systems where precise position data is critical.
Innovation Solution
A rotatable sensor gear with a central base and radially extending teeth featuring closed tips and inner pockets, allowing for flexibility to prevent lash and splitting, thereby enhancing precision and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bifurcated anti-lash teeth are used in the sensor gear, then lash between the sensor gear and driving component is reduced, but the teeth are prone to splitting which causes erroneous sensor readouts
Solution Approach 1:
The patent applies this principle by making the sensor gear teeth flexible rather than rigid. The teeth are designed with material properties and structural features that allow them to flex and deform elastically under load, absorbing stress without splitting. This flexibility prevents the tooth splitting problem while maintaining lash reduction benefits, as the flexible teeth can conform to the driving component teeth during engagement.
Solution Approach 2:
The patent applies this principle by changing the material parameters and structural parameters of the teeth. The teeth are made from flexible materials with specific elastic properties, and their geometry is optimized to allow controlled deformation. By adjusting these parameters, the teeth can withstand operational stresses without splitting, thereby improving reliability while maintaining the anti-lash function.
2Strength
If rigid teeth are used in the sensor gear, then manufacturing precision is easier to achieve, but the teeth cannot accommodate misalignment and are prone to splitting
Solution Approach 1:
The patent applies this principle by designing the teeth as flexible structures rather than rigid ones. The flexible teeth can deform to accommodate manufacturing tolerances and alignment variations, reducing the stringency of manufacturing precision requirements while preventing tooth splitting through elastic deformation.
Solution Approach 2:
The patent applies this principle by changing the material parameters from rigid to flexible, and adjusting geometric parameters to allow controlled deformation. This enables the teeth to tolerate broader manufacturing tolerances while maintaining structural integrity under load, effectively resolving the contradiction between manufacturing precision and tooth strength.
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
The solution effectively prevents lash between the sensor gear and mating components, ensuring accurate position sensing and reducing errors in steering system operations by maintaining tooth integrity and flexibility.
Implementation Method 1
wherein each of the plurality of teeth define an inner pocket to allow the plurality of teeth to be flexible
Data Source
AI summary
A sensor gear assembly for a steering system includes a driving component having a plurality of teeth extending therefrom. The sensor gear assembly also includes a rotatable sensor gear having a plurality of teeth extending radially away from an outer diameter of the rotatable sensor gear, wherein at least a portion of the plurality of teeth of the rotatable sensor gear are flexible.