Integrated Driven Gear Rotor for Throttle Assembly
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Solution Overview
Problem
The existing electronically controlled throttle devices face inefficiencies in the assembly process due to the separate and complex fixing methods of the driven gear and rotor, leading to cumbersome operations and reduced operability during manufacturing.
Innovation Solution
The driven gear, which transmits rotation from the motor, is integrated to function as the rotor, allowing for a single manual fixing operation and simplifying the insert-molding process, thereby improving assembly efficiency and operability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the driven gear and rotor are individually fixed to the throttle shaft with different fixing methods, then the functional requirements are met, but the assembly process becomes cumbersome and operability decreases
Solution Approach 1:
The patent combines the driven gear and rotor into a single integrated component that is fixed to the throttle shaft as one unit. This merging eliminates the need for separate fixing operations for the driven gear and rotor, reducing assembly steps and improving operability while maintaining all necessary functions.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it acts as both the driven gear for transmitting motor rotation and the rotor for the throttle sensor. This multi-functionality reduces the number of separate parts and fixing operations required, directly addressing the operability issue.
2Reliability
If the driven gear is fixed first and then the rotor is insert-molded onto the protruding end of the throttle shaft, then both components are secured, but the mold structure becomes complicated and handling becomes difficult
Solution Approach 1:
By merging the driven gear and rotor into a single component, the patent eliminates the need for sequential fixing operations. The integrated component can be fixed in one operation, simplifying the mold structure and making handling easier during the molding process while ensuring reliable fixation.
3Productivity
If separate fixing methods are used for driven gear and rotor, then functional requirements are satisfied, but assembly time and operational steps increase
Solution Approach 1:
The integration of driven gear and rotor into one component allows for a single fixing operation instead of multiple sequential operations. This merging directly reduces assembly time and increases productivity by eliminating redundant assembly steps.
Solution Approach 2:
The driven gear and rotor are designed as a pre-integrated unit before assembly, with all necessary connections established in advance. This preliminary integration means that during final assembly, only one fixing operation is needed rather than multiple separate operations, reducing assembly time.
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 configuration enables efficient assembly of the driven gear and exciting conductor to the throttle shaft, enhancing manufacturing operability and simplifying the mold structure, resulting in a more streamlined and reliable throttle device assembly process.
Implementation Method 1
an inductive throttle sensor is provided to detect a throttle position. The inductive throttle sensor as a whole comprises a rotor provided with an exciting conductor, and a substrate provided with an excitation conductor and a signal detection conductor
Data Source
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AI summary
Provided is an electronically controlled throttle device for an engine driving to open and close a throttle valve (8) of a valve body (3) to which rotation of a motor (15) is transmitted from a driven gear (14) via a throttle shaft (6), and disposing a substrate (22) on which an excitation conductor (23) and a signal detection conductor (24) are arranged to face an exciting conductor (21) rotating together with the throttle shaft (6). The driven gear (14) comprises an embedded core metal (25), and has one side surface to which an exciting conductor (21) is exposed, the core metal (25) and the exciting conductor (21) being insert-Molded of a synthetic resin material and prepared, and a caulked portion (6a) of the throttle shaft (6) is inserted and fixed into a shaft hole (25a) extending through the core metal (25).