Onboard Detector Wire Bending for Resin Size Reduction
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Solution Overview
Problem
Existing vehicle detectors face challenges in downsizing and improving on-vehicle mountability due to wire protrusions that can contact vehicle components, leading to increased resin member size when bending wires to prevent contact.
Innovation Solution
An onboard detector design featuring a cable with insulated wires and a sheath, where the wires are bent between the sheath and lead wires, allowing the cable to be arranged such that the sheath's axial direction intersects with the lead wire's longitudinal direction, thereby preventing contact with vehicle components and reducing the detector's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire is arranged to extend out of the resin member along the axial direction of the Hall IC, then the connection is simple, but the wire comes into contact with vehicle body or other components mounted on a vehicle
Solution Approach 1:
The patent changes the wire arrangement from a linear axial extension to a three-dimensional configuration where the wire extends along the axial direction and then bends in a radial direction. This dimensional transition allows the wire to avoid contact with vehicle components while maintaining connection simplicity.
Solution Approach 2:
The patent introduces a curved portion with a specific radius of curvature in the wire path. This curvature enables the wire to bend smoothly from axial to radial direction, preventing contact with vehicle body or components while maintaining ease of manufacture and installation.
2Object-affected harmful factors
If the wire is bent inside the resin member to prevent contact with vehicle components, then contact prevention is achieved, but the size of the resin member increases
Solution Approach 1:
Instead of bending the wire inside the resin member in a single direction, the patent utilizes both axial and radial dimensions. The wire extends axially then bends radially, distributing the bending space efficiently and avoiding excessive increase in resin member volume.
Solution Approach 2:
The patent pre-configures the wire path with a calculated bending radius during the design stage. This preliminary action ensures that the wire naturally follows a path that prevents contact with vehicle components without requiring additional space for ad-hoc bending adjustments.
3Object-affected harmful factors
If the wire extends perpendicular to the axis of the Hall IC, then contact with vehicle components is prevented, but the resin member size increases due to the arc angle requirement
Solution Approach 1:
The patent transitions the wire arrangement from a single-plane perpendicular extension to a two-dimensional path combining axial and radial directions. This allows the wire to achieve perpendicular orientation for contact prevention while minimizing the arc angle and corresponding resin member volume.
Solution Approach 2:
The patent calculates and pre-determines the optimal bending radius and arc angle during design. This preliminary calculation ensures that the wire achieves the necessary perpendicular orientation with minimal bending space, thereby reducing the resin member size while maintaining contact prevention.
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 enables the downsizing of the fixing member and enhances on-vehicle mountability by preventing wire contact with vehicle components, while maintaining accurate detection of steering torque and wheel rotation.
Implementation Method 1
a Hall IC for detecting magnetic field strength
Implementation Method 2
a torsion bar coupling the input shaft to the output shaft... the multipole magnet and the pair of multipolar yokes are relatively rotated by twist of the torsion bar caused by torque applied to the steering
Implementation Method 3
the multipole magnet and the pair of multipolar yokes are relatively rotated by twist of the torsion bar caused by torque applied to the steering. A pair of magnetism collecting rings having an annular shape is arranged on the outer peripheral side of the pair of multipolar yokes and a magnetism collecting portion is provided on each magnetism collecting ring at a circumferential position so as to radially protrude. The magnetic sensor is sandwiched between the magnetism collecting portion of one of the magnetism collecting rings and the magnetism collecting portion of the other magnetism collecting ring. when the multipole magnet and the pair of multipolar yokes are relatively rotated, magnetic field strength to be detected by the magnetic sensor varies according to the relative rotation angle
Data Source
AI summary
An onboard detector includes a cable including an insulated wire including a center conductor and an insulation covering the center conductor and a sheath covering the insulated wire, a sensor including a sensor main body including a detecting element and a lead wire extending from the sensor main body and connected to the center conductor, and a fixing member to fix the sensor to the cable. The fixing member is configured to fix the insulated wire exposed from the sheath while being bent between the sheath and the lead wire. The insulated wire fixed while being bent allows the cable to be arranged such that an axial direction of the sheath inside the fixing member intersects with a direction parallel to a longitudinal direction of the lead wire.