Modular Sensor Arrangement with External Bearing Element

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Solution Overview

Problem

Existing sensor arrangements face challenges with sealing issues due to moisture ingress and complex assembly, particularly when a shaft is routed through a housing, and high replacement costs for integrated components.

Innovation Solution

The mounting of the movement sensor is reversed, with the bearing element forming a static element outside the housing, simplifying assembly and sealing, and allowing for modular replacement of components, using a bearing element that projects from the housing and is connected rigidly to it, enabling precise measurement of displacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the shaft is routed through the housing as a friction bearing, then the sensor arrangement can detect displacement, but sealing issues arise due to moisture ingress and wear to the shaft mounting

Engineering Contradiction:

Improvedetection precisionVSAvoidmoisture ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sensor arrangement is divided into separate modular components: the housing with integrated position sensor, the movement sensor as a distinct unit, and the coupling rod. This segmentation allows the housing to be sealed independently while the movement sensor can be mounted externally, eliminating the need for shafts passing through the housing and thus preventing moisture ingress paths.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The movement sensor is extracted from the housing interior and mounted externally on the housing surface. This extraction removes the shaft from the housing interior, eliminating the sealing problem while maintaining the functional relationship between the shaft rotation and position detection through the external movement sensor.

Inventive Principle:

Principle #2Taking out (Extraction)

2Device complexity

If the position transducer is integrated within the housing, then the sensor arrangement is compact, but replacement of individual components becomes costly and complex

Engineering Contradiction:

Improveintegration levelVSAvoidcomponent replacement

Core Design Contradiction:

Device complexityVSEase of repair

Solution Approach 1:

The sensor system is segmented into replaceable modules: the movement sensor can be replaced independently from the housing and position sensor. This modular architecture simplifies repair operations as only the faulty movement sensor needs to be replaced rather than the entire integrated assembly, reducing replacement costs and complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The movement sensor is designed as a universal, standardized component that can be mounted on the housing and coupled to the coupling rod. This universal design allows for easy replacement with identical or compatible units, facilitating maintenance and repair while maintaining the same functional performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If the bearing element is mounted inside the housing, then the structure is compact, but sealing measures become complex and assembly is difficult

Engineering Contradiction:

Improvestructural integrationVSAvoidassembly simplicity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

Instead of mounting the bearing element inside the housing, the invention inverts the arrangement by mounting the movement sensor externally on the housing surface. This inversion simplifies the housing structure, eliminates internal sealing requirements, and allows for straightforward assembly where the movement sensor is simply mounted on the external housing surface and coupled to the coupling rod.

Inventive Principle:

Principle #13The other way round (Inversion)

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 enhances the robustness and precision of the sensor arrangement, simplifies assembly, reduces sealing complexities, and allows for cost-effective and modular replacement of components, while maintaining precise measurement capabilities.

Implementation Method 1

The position sensor, in the form of a Hall sensor, that is integrated in the housing 4... The position sensor 10 is a Hall sensor which is perfused by current and, depending on the direction of the magnetic field of the magnetic encoder, emits a Hall voltage

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS11035696B2Sensor arrangement having a modular structure including sensor mounted on bearing element configured to project from housing

Publication Date: 2021.06.15 CONTINENTAL AUTOMOTIVE TECHNOLOGIES GMBH

AI summary

A sensor arrangement having: a housing, a movement sensor, the movement sensor, being mounted on a bearing element connected to the housing; a position sensor; and a position transducer, the position sensor and the position transducer being arranged relative to each other in such a way that the movement of the movement sensor can be measured. The bearing element protrudes from the housing, or the position sensor and the position transducer are eccentric relative to the bearing element.