Flux Collector Structure for Stable Magnetic Torque Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Magnetic position sensors are prone to interference from earth's magnetic fields and electrical currents, leading to incorrect position or torque determinations, and the existing solutions to mitigate this increase production complexity and costs due to the need for two different types of flux collection elements.
Innovation Solution
A magnetic position sensor with a collector unit comprising two flux collection elements, each with a first and second collection zone in different planes, connected via a magnetically conductive portion that is mechanically reinforced with beads to prevent deformation and simplify handling, allowing for the use of structurally identical elements to reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the connection between the first collection zone and the second collection zone is mechanically reinforced with beads, then the stability and resistance to deformation is improved, but the manufacturing complexity and production time increases
Solution Approach 1:
The beads are formed as integral parts of the flux collection element during the stamping process itself, before the element is removed from the tool. This preliminary formation of reinforcement features eliminates the need for separate manufacturing steps, thereby improving stability without significantly increasing manufacturing complexity
Solution Approach 2:
The connection portion and the reinforcing beads are formed as a single integrated structure in one stamping operation. The beads are molded directly into the connection portion between the first and second collection zones, merging the structural element with its reinforcement feature, which reduces the number of discrete parts and assembly steps
2Measurement precision
If two different types of flux collection elements are produced to ensure proper arrangement of collection zones, then the measurement precision is improved, but the production costs and manufacturing complexity increase
Solution Approach 1:
The flux collection element is designed with an asymmetric connection portion that has a specific geometric configuration and magnetic conductivity profile. This asymmetric design allows a single type of element to be used in both positions (first and second collection zones) while maintaining the required spatial arrangement and measurement precision, eliminating the need to produce two different element types
Solution Approach 2:
The flux collection element is designed as a universal component that can serve both as the first collection element and the second collection element. The element incorporates both the first collection zone and the second collection zone in a single integrated structure, allowing one type of element to fulfill multiple functional roles in the magnetic field detection 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
The mechanical reinforcement of the connection between the collection zones enhances stability and reduces waste, enabling cost-effective production and handling of the flux collection elements, while ensuring accurate detection of magnetic flux by canceling out interference fields and maintaining the integrity of the magnetic field measurement.
Implementation Method 1
a connection is formed between the first collection zone and the second collection zone via a magnetically conductive connection portion
Implementation Method 2
the connection is mechanically reinforced
Data Source
AI summary
A flux collection element of a collector unit of a magnetic position sensor and a method of producing the flux collection element, wherein the flux collection element comprises a first collection zone in a first plane and a second collection zone in a second plane, and wherein there is a connection between the first collection zone and the second collection zone via a magnetically conductive connection portion between a first attachment edge of the first collection zone and a second attachment edge of the second collection zone. In particular so that the flux collection element can thus be handled as a bulk product, the connection between the first collection zone and the second collection zone is mechanically stiffened, in particular by the introduction of a bead to be used in an electromechanical steering system in which a torque acting on a steering shaft of the steering system is detected by means of such a magnetic position sensor.