Motor Shaft Sensor Mounting for Precise Rotation Angle Detection
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Solution Overview
Problem
Existing electrically controllable drive assemblies in brake systems suffer from inaccuracies in angle of rotation acquisition due to glued connections between the signal transmitter and motor shaft, leading to errors in brake pressure regulation and increased manufacturing complexity.
Innovation Solution
A holding element realized as a hollow cylinder secures the magnetic element of the signal transmitter to the motor shaft without glued connections, using a weld connection and a clip element to maintain a constant position relative to the signal receiver, enhancing signal acquisition accuracy and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glued connections are used to fasten the magnetic element to the motor shaft, then the manufacturing process becomes simpler, but the signal acquisition accuracy deteriorates due to elasticities and relative movements under dynamic loads
Solution Approach 1:
The patent removes the glued connection from the fastening method. Instead of using adhesive, the magnetic element is fastened purely mechanically through the holding element with pressing elements that create a rigid connection, eliminating the elasticity problem while maintaining manufacturing simplicity.
Solution Approach 2:
The holding element is divided into functional segments: a body portion that interfaces with the motor shaft and pressing elements that secure the magnetic element. This segmentation allows for precise mechanical fastening without glue, improving signal accuracy while keeping assembly straightforward.
2Ease of operation
If glued connections are used to fasten the magnetic element, then assembly is simplified, but the device complexity increases due to additional manufacturing steps and quality control requirements
Solution Approach 1:
The holding element is designed to self-secure the magnetic element through its pressing elements that engage with the magnetic element's geometry. This self-fastening mechanism eliminates the need for separate gluing operations and quality control steps for adhesive bonding, reducing device complexity while maintaining assembly ease.
3Measurement precision
If the magnetic element is firmly fastened to the motor shaft, then signal acquisition accuracy improves, but the manufacturing cost increases due to additional fastening components
Solution Approach 1:
The holding element serves multiple functions: it positions the magnetic element, secures it firmly to prevent relative movement, and provides a mounting interface with the motor shaft. This multi-functionality achieves firm fastening for accurate signal acquisition without requiring multiple separate components, thereby controlling manufacturing costs.
4Reliability
If the magnetic element is firmly fastened to the motor shaft, then the reliability of signal acquisition improves, but the ease of manufacture decreases due to more complex fastening mechanisms
Solution Approach 1:
Instead of fastening the magnetic element directly to the motor shaft or using complex multi-component fastening systems, the patent inverts the approach by using a holding element that interfaces with both the shaft and magnetic element. This inverted structure achieves reliable firm fastening while maintaining manufacturing simplicity through a standardized, modular design.
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 improves the electrical controllability of the drive assembly by reducing signal inaccuracies and manufacturing costs, ensuring precise pressure medium volume control and streamlined production.
Implementation Method 1
This signal transmitter 24 is situated on the end face of motor shaft 16 facing away from rotor 14. It has a magnetic element 26 that is indirectly fastened to motor shaft 16
Implementation Method 2
A first weld connection (44) is thus produced between holding element 28 and motor shaft 16
Data Source
AI summary
An electrically controllable drive assembly including an electric motor having a rotor capable of being driven to execute a rotational movement, a motor shaft connected in rotationally fixed fashion to the rotor, and a signal transmitter of a sensor device for the electronic acquisition and evaluation of the angle of rotation of the motor shaft. The signal transmitter is indirectly anchored on the motor shaft via a holding element. The holding element is a hollow cylinder that has an open first end with which the holding element is fastened on the motor shaft and a second end, situated facing away from the motor shaft, and at least one holding element region that extends into the open cross-section of the holding element.