Non-Contact Position Sensor for Two-Speed Transfer Case
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Solution Overview
Problem
Current power transfer systems in four-wheel drive vehicles rely on contact-type position sensors, which may not offer the desired level of reliability and functionality without increasing packaging space or component count, necessitating the development of alternative contactless position sensing configurations.
Innovation Solution
A two-speed transfer case equipped with a non-contact position sensor, such as a Hall Effect sensor, is integrated to detect the rotated position of a rotary sector plate or the axial position of a moveable range fork or shift rail, enhancing sensing accuracy and reliability without additional space or components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact-type position sensors are used in power transfer systems, then the sensing function is provided, but the reliability and functionality are insufficient without increasing packaging space or component count
Solution Approach 1:
The patent replaces contact-type position sensors with a contactless position sensing system that uses a rotor-mounted magnet and a stator-mounted sensor. This substitution eliminates mechanical contact, thereby improving reliability by removing wear and contact failure modes while maintaining the position sensing function without increasing overall system complexity.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the moving component ( rotor) and the stationary sensor (stator). The magnet mounted on the rotor creates a magnetic field that the stator sensor detects, enabling contactless position detection. This intermediary approach allows reliable position sensing without direct mechanical contact between sensor components.
2Reliability
If contactless position sensors are implemented, then reliability and functionality are improved, but packaging space and component count must be maintained
Solution Approach 1:
The patent merges the position sensing function into the existing motor structure by integrating the magnet into the rotor and the sensor into the stator of the motor assembly. This consolidation allows the contactless position sensing system to be implemented within the existing packaging space of the power transfer system without requiring additional dedicated sensor housing or mounting space.
Solution Approach 2:
The motor serves multiple functions: it provides the driving force for the power transfer system and simultaneously houses the position sensing system through its rotor and stator components. This multi-functionality allows the contactless sensor to be implemented without increasing packaging space, as the motor structure is utilized for both actuation and sensing purposes.
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 contactless position sensing arrangement provides improved reliability and functionality by accurately detecting the position of moveable components, enabling precise control of drive modes and torque distribution in four-wheel drive vehicles, thus enhancing the overall performance and efficiency of the power transfer system.
Implementation Method 1
A two-speed transfer case equipped with a non-contact position sensor, such as a Hall Effect sensor, is integrated to detect the rotated position of a rotary sector plate or the axial position of a moveable range fork or shift rail
Data Source
AI summary
A two-speed active transfer case is disclosed having a range shift mechanism with a moveable range shift component and a contactless position sensing arrangement for detecting the position of said moveable range shift component.