Inductive Torque Angle Sensor Without Shielding
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Solution Overview
Problem
Existing torque and angle sensors for vehicle steering systems require shielding of the sensor PCB, leading to inaccuracies in torque measurement due to non-linearity issues and difficulty in adjusting measurement ranges, especially when using multiple sensors to calculate torque from absolute angle positions.
Innovation Solution
An inductive torque sensor design featuring a stationary PCB with sensing coils, a primary target, and a secondary target with different metallic patterns, allowing for torque movement detection without shielding, and a combined inductive torque and angle sensor that integrates both sensors on the same PCB, reducing the risk of mechanical failures and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple absolute angle sensors are used to calculate torque, then torque measurement capability is achieved, but measurement precision deteriorates due to non-linearity accumulation and shielding requirements
Solution Approach 1:
The patent combines angle sensing and torque sensing functions into a single integrated sensor system. The sensing coil assembly simultaneously detects both the absolute angle position of the steering wheel and the torque applied to it, eliminating the need for multiple separate sensors. This merging approach reduces non-linearity accumulation and removes the need for shielding between sensors, thereby improving measurement precision while maintaining versatility.
Solution Approach 2:
The single sensor system performs multiple functions: it measures both the absolute angular position of the steering wheel and the torque applied to it. The sensing coil assembly is designed to detect both positional and torque information simultaneously, making the system universal and eliminating the need for separate angle and torque sensors, thus avoiding the non-linearity issues that arise from combining multiple sensors.
2Object-affected harmful factors
If shielding is added to the sensor PCB, then external interference is reduced, but device complexity increases and measurement precision deteriorates due to non-linearity
Solution Approach 1:
The patent extracts and eliminates the shielding component from the sensor PCB design. By using a single integrated sensing coil assembly that simultaneously measures angle and torque, the need for shielding between separate sensors is removed. This extraction simplifies the device structure and eliminates the non-linearity issues introduced by shielding, while the integrated design inherently provides sufficient interference protection.
3Ease of manufacture
If fixed sensor design is used, then manufacturing is simplified, but adaptability deteriorates as measurement range cannot be adjusted
Solution Approach 1:
The patent introduces dynamic adjustability to the sensor system by making the measurement range configurable through software or firmware settings rather than being fixed by hardware design. The sensing coil assembly can be calibrated to different measurement ranges and torque scales, allowing the same physical sensor to adapt to different vehicle applications and requirements. This dynamic configuration capability maintains manufacturing simplicity while providing full adaptability.
4Reliability
If separate angle and torque sensors are used, then functional reliability is improved, but device complexity increases and assembly difficulty increases
Solution Approach 1:
The patent merges separate angle sensing and torque sensing functions into a single integrated sensor unit. The sensing coil assembly is designed to simultaneously detect both the absolute angle position and the torque applied to the steering wheel, eliminating the need for multiple separate sensors. This integration reduces mechanical failure risks associated with multiple components while simplifying the overall assembly structure and installation process.
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 provides accurate torque and angle measurements without the need for shielding, allows for plausibility checks with fewer sensors, and enables easy adjustment of the mechanical torque range by modifying the target patterns, enhancing the reliability and adaptability of steering wheel position sensing.
Implementation Method 1
a transmission coil, excited by a high frequency current generates a primary magnetic field which induces a secondary voltage in a receiving coil that is proportional to its exposed area (inductive principle)
Implementation Method 2
If the metallic target is placed above one of the receiving coils, the transmitted energy of the underlying area is dissipated in the form of eddy currents and thus weakens the magnetic field in the receiving coils
Data Source
AI summary
The invention discloses an inductive torque sensor and a combined inductive torque and angle sensor for position sensing. The object of the invention to propose a torque sensor as well as a combined torque and angle sensor which does not require a shielding of the sensor PCB and which can provide a plausibility check of the torque sensor when using only three sensors will be solved by an inductive torque sensor for detection of torque movements comprising a stationary printed circuit board (PCB) with sensing coils, a primary target and a secondary target, whereas the primary target and secondary target each comprise of different metallic patterns, whereas each target covers 50% of the sensing coils and the combined coverage of both targets varies between 50% and 100% depending on the relative position between the two targets. The objective is also solved by a combined inductive torque and angle sensor comprising a primary target wheel, a secondary target wheel and a torsion beam, whereas the primary target wheel is centrally stacked on the torsion beam and comprises a metallic pattern for a steering angle 360° single-turn sensor and a first metallic pattern for the torque sensor, and the secondary target wheel comprises a second metallic pattern of the torque sensor.