Funnel-Shaped Sensor Cover Stabilizes PCB Position
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Solution Overview
Problem
Existing rotation angle sensor units face challenges in maintaining the stable relative position of the printed circuit board to the rotor, leading to incorrect or undetectable sensor signals due to positional loss, which is critical for accurate steering torque detection in driver assistance systems.
Innovation Solution
A rotation angle sensor unit with a funnel-shaped ring structure cover that applies a consistent holding pressure to the printed circuit board, ensuring it remains stable radially and axially within the housing volume, eliminating the need for separate holders and maintaining the simplicity and low complexity of the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If separate holders and pretensioning units are used to stabilize the printed circuit board, then the positional stability is improved, but the device complexity increases
Solution Approach 1:
The patent integrates the holding and pretensioning functions directly into the cover structure through the funnel-shaped ring structure, eliminating the need for separate holders and pretensioning units. This merging of functions maintains positional stability while reducing device complexity.
Solution Approach 2:
The cover is designed with multi-functionality, serving both as a protective enclosure and as a pretensioning element through the funnel-shaped ring structure. This universal design allows the cover to stabilize the printed circuit board without requiring additional specialized components.
2Reliability
If a complex holding mechanism is implemented to maintain printed circuit board position, then the reliability is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The patent combines the holding mechanism with the cover structure itself, creating a unified component that is both reliable and manufacturable. The funnel-shaped ring structure is integrated into the cover, allowing for simpler manufacturing processes compared to assembling multiple separate components.
Solution Approach 2:
The patent utilizes elastic deformation as a parameter change mechanism. The funnel-shaped ring structure is designed to elastically deform during assembly to engage with the printed circuit board, providing reliable holding through material property changes rather than complex mechanical mechanisms.
3Stability of the object's composition
If additional components are added to secure the printed circuit board, then the positional stability is improved, but the space utilization deteriorates
Solution Approach 1:
The patent merges the stabilization function into the existing cover structure, eliminating the need for additional space-consuming components. The funnel-shaped ring structure provides radial and axial stability without requiring separate holders or mounting elements that would occupy valuable housing volume.
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 funnel-shaped ring structure effectively stabilizes the printed circuit board during operation, preventing positional loss and ensuring accurate sensor signals, thus enhancing the reliability and safety of steering torque detection.
Implementation Method 1
the radially inner area is designed to be elastically movable in the axial direction by pressing against the printed circuit board
Data Source
AI summary
A rotation angle sensor unit for determining a rotation angle between a rotor and a stator. A housing defines a housing volume. The rotor is rotatably mounted in the housing volume. A printed circuit board has the at least one stator attached thereto. A cover for the housing encloses the printed circuit board in the housing volume. The cover has a funnel-shaped ring structure with a funnel upper side facing away from the printed circuit board and a funnel bottom side facing the printed circuit board. The funnel bottom side fixes the printed circuit board in the housing volume and presses against the printed circuit board. A cover for a rotation angle sensor unit and a method for producing a rotation angle sensor unit are also provided.