Ignition Device Integrating Crankshaft Sensor and Transformer
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Solution Overview
Problem
The high costs and assembly complexity of cabling and plug connections in internal combustion engine ignition systems for small engines, such as lawn mowers or power generators, due to the need for multiple individual components like ignition coils, sensors, and control units, which increase both assembly effort and costs.
Innovation Solution
Integration of a crankshaft sensor and at least one ignition transformer into a shared housing with input and output ports for electrical connections, reducing the need for separate mounting and cabling, and incorporating a control unit and electromagnetic shielding to minimize interference and enhance integration density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual components (ignition coils, sensors, control units) are mounted separately in the engine, then each component can be independently serviced and replaced, but assembly effort and cabling costs increase significantly
Solution Approach 1:
The patent combines the ignition coil, crankshaft sensor, and control unit into a single integrated ignition device housing. This merging eliminates the need for separate mounting locations and reduces the number of individual cable connections required, as all components share common electrical connections through the housing's input and output ports.
Solution Approach 2:
The integrated housing serves multiple functions simultaneously: it provides structural support for all components, acts as an electromagnetic shield, provides mounting locations for spark plugs, and consolidates electrical connections. This multi-functionality reduces the overall system complexity while maintaining serviceability.
2Adaptability or versatility
If multiple individual components are used for ignition system functions, then functional versatility is maintained, but costs due to cabling and plug contacts increase
Solution Approach 1:
By consolidating the ignition coil, sensor, and control unit into one housing, the patent reduces the number of separate cable harnesses and plug contacts needed. The integrated design allows all components to share common electrical connections through the housing's input ports (for power and sensor signals) and output ports (for spark plug connections).
3Ease of manufacture
If components are integrated into a shared housing, then assembly costs are reduced, but heat dissipation and electromagnetic interference may increase
Solution Approach 1:
The patent converts the potential harmful effect of electromagnetic interference into a beneficial shielding solution by implementing electromagnetic shielding within the housing. The housing structure itself is designed to contain and redirect electromagnetic fields, protecting sensitive components while maintaining the cost benefits of integration.
Solution Approach 2:
The housing acts as an intermediary structure that provides electromagnetic shielding between components. It serves as a physical barrier that prevents direct electromagnetic coupling between the ignition coil and sensor, while still allowing necessary thermal and electrical connections.
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 significantly reduces assembly costs and effort by integrating multiple components into a single module, minimizing cabling, and providing a compact, cost-effective ignition device with reduced interference, while maintaining effective spark generation and sensor functionality.
Implementation Method 1
at least one ignition transformer (ignition coil) having a primary winding (primary coil) and a secondary winding (secondary coil) for generating an ignition spark
Implementation Method 2
a crankshaft sensor (CPS sensor, crankshaft position sensor) is accommodated for detecting the rotational speed and/or the position of a crankshaft provided with, in particular, a toothed position sensor
Data Source
AI summary
An ignition device for an internal combustion engine, having a housing in which a crankshaft sensor is accommodated for detecting the rotational speed and/or the position of a crankshaft, which is in particular provided with a toothed position sensor and in which at least one ignition transformer with a primary winding is accommodated, and a secondary winding for generating a spark for the internal combustion engine is accommodated, wherein a number of input ports, in particular for the connection of an electrical energy source for supplying the or each ignition transformer and/or for supplying sensor and/or control signals, and in which a plurality of output ports, in particular for connecting at least one spark plug and/or for emitting control signals, are provided.