Motor Sensor Carrier Structure to Prevent Metallic Interference
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Solution Overview
Problem
Existing electric motors in motor vehicle ancillary units face challenges in maintaining robustness and reliability, particularly in the positioning and operation of sensors for rotor speed detection, which can be affected by interference from metallic components and require complex assembly processes.
Innovation Solution
The design incorporates a sensor support with arms that securely fasten the sensor to a bearing shield, maintaining it at a safe distance from metallic components and stabilizing it to prevent interference, while also simplifying assembly through a robust and compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is positioned close to the rotor for accurate detection, then measurement precision is improved, but the sensor is affected by interference from metallic components
Solution Approach 1:
The patent introduces a non-metallic support structure (arm) as an intermediary between the sensor and the metallic rotor components. This arm holds the sensor at a safe distance from metallic parts while maintaining proper positioning for accurate detection, thus eliminating interference without sacrificing measurement precision
Solution Approach 2:
The sensor is positioned in a different spatial dimension (radially outward on the bearing shield) rather than being placed directly adjacent to the rotor. This dimensional repositioning allows the sensor to detect rotor position accurately while being physically separated from interfering metallic components
2Reliability
If the sensor is secured firmly to prevent interference, then reliability is improved, but assembly complexity increases
Solution Approach 1:
The sensor support arm is integrated with the bearing shield to form a single structural unit. This merging eliminates the need for separate mounting brackets or complex fastening mechanisms, achieving reliable sensor positioning while simplifying the overall assembly structure
Solution Approach 2:
The bearing shield serves multiple functions: it provides mechanical support for the rotor, acts as a mounting structure for the sensor support arm, and shields the sensor from metallic interference. This multi-functionality reduces the number of separate components and simplifies assembly
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 design enhances the robustness and reliability of the electric motor by preventing sensor interference and reducing assembly complexity, leading to improved accuracy and reduced production costs.
Implementation Method 1
The sensor comprises, for example, an encoder wheel which is co-rotationally fastened to a rotor shaft and is of a partially magnetic design. The position of the magnetic blades of the encoder wheel is detected by means of a co-rotationally held circuit board of the sensor
Implementation Method 2
an electric voltage which depends on the position/rotating speed of the encoder wheel relative to the circuit board is induced
Data Source
AI summary
An electric motor of an auxiliary unit of a motor vehicle, in particular an electromechanical brake booster, contains a bearing shield and a sensor carrier manufactured from a plastic. The sensor carrier has a body arranged perpendicularly to an axis of rotation, to which a sensor is mounted and to which arms extending at least partly parallel to the axis of rotation are connected on the edge side. The arms are fastened to the bearing shield.