Oxygen Sensor Socket Geometry for Single-Handed Torque Access
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Solution Overview
Problem
Existing tools for removing oxygen sensors are inefficient due to the need for two hands to operate, limited effective travel, and increased torque requirements when using offset ratcheting systems, leading to potential damage and environmental impacts from inefficient engine performance and increased emissions.
Innovation Solution
A torque tool with a circular base and hexagonal interior featuring corner relief spots and an elongated opening, allowing for single-handed operation, increased effective travel, and direct torque application over the sensor's center, reducing the risk of mechanical damage and improving accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard 7/8 inch socket with offset ratchet connection is used, then the tool can loosen/tighten the sensor, but two hands are required to operate due to side pressure on the socket
Solution Approach 1:
The patent extracts the ratchet mechanism from the socket interface, allowing the socket portion to be used independently with a single hand while the ratchet handle operates separately, eliminating the need for two-handed operation required by traditional offset ratchet connections
Solution Approach 2:
The tool is divided into separate functional components: a socket portion for engaging the sensor and a ratchet handle portion for applying torque, which can be used independently or combined, allowing flexible single-handed operation
2Ease of operation
If an offset ratcheting system is used, then torque can be applied to the sensor, but the effective degrees of travel are reduced due to play in the ratchet handle
Solution Approach 1:
The patent separates the ratchet mechanism from the socket connection, eliminating the play and wiggle inherent in offset ratchet systems by allowing direct alignment of the torque application axis with the sensor center
Solution Approach 2:
Instead of forcing the socket to accommodate offset ratcheting, the patent inverts the approach by allowing the ratchet to operate independently and transmit torque directly to the socket, maximizing effective travel degrees
3Force
If torque is applied offset from the center, then the ratchet can engage the sensor, but more energy/torque/strength is required to achieve the same results
Solution Approach 1:
The patent employs asymmetric geometry in the hexagonal socket interface and corresponding hexagonal sensor engagement surfaces, optimized for direct center-aligned torque application rather than offset ratcheting, improving mechanical efficiency
Solution Approach 2:
The patent inverts the traditional approach by having the ratchet apply force directly to the center of the socket rather than requiring offset engagement, eliminating the mechanical disadvantage of lever arm misalignment
4Ease of operation
If a 7/8 inch box end wrench is used, then the sensor can be engaged, but the electrical connector cannot slide through due to size constraints
Solution Approach 1:
The patent segments the tool into a removable socket portion and a handle portion, allowing the use of larger socket sizes (1 inch or 1 1/4 inch) that provide sufficient clearance for electrical connectors while maintaining manageable handle dimensions
Data Source
AI summary
A torque tool to remove a sensor body includes a substantially circular base, the base having a substantially hexagonal interior extending away from the circular base, the circular base having an exterior that extends into an outer hexagonal body; and an elongated opening extending from a rim of the base to the hexagonal interior, wherein each tip of the hexagon interior has a corner relief.