Pinion Sensor Assembly Torque Error Reduction
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Solution Overview
Problem
Conventional electric power steering apparatuses experience increased manufacturing costs and measurement errors due to the accumulation of assembly errors from multiple constitutional components during assembly, leading to potential malfunctions.
Innovation Solution
A pinion sensor assembly and cover assembly that includes an input shaft connected to a steering shaft, a pinion shaft inserted into a rack housing, and a torque sensor with a wire harness connector, along with a cover featuring a through-hole for the input shaft, a sealing member, and a support member to prevent foreign matter and facilitate rotation, reducing assembly errors and enhancing assemblability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple constitutional components are assembled to form the torque sensor assembly, then the functional capabilities are enhanced, but assembly errors accumulate leading to measurement errors and potential malfunctions
Solution Approach 1:
The patent combines the torque sensor, pinion shaft, and housing into an integrated assembly where the torque sensor is directly mounted on the pinion shaft within the housing. This merging of components reduces the number of separate assembly interfaces, thereby minimizing cumulative assembly errors while maintaining all necessary functional capabilities of sensing and transmission.
2Adaptability or versatility
If multiple constitutional components are assembled to form the torque sensor assembly, then the functional capabilities are enhanced, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent segments the steering system into distinct functional modules: the torque sensor assembly (comprising the torque sensor, pinion shaft, and housing as an integrated unit) and the rack mechanism. This segmentation allows the torque sensor assembly to be pre-assembled and tested independently, then installed as a single unit, thereby simplifying the overall assembly process and improving productivity while maintaining functional capabilities.
3Adaptability or versatility
If traditional assembly methods are used with multiple separate components, then design flexibility is maintained, but assembly errors accumulate causing malfunctions
Solution Approach 1:
The patent merges the torque sensor, pinion shaft, and housing into a integrated assembly that reduces the number of assembly interfaces. This merging maintains design flexibility through modular construction while significantly improving reliability by eliminating multiple potential failure points from component interfaces and reducing cumulative assembly errors.
Data Source
AI summary
Disclosed are a pinion sensor assembly and an electric power steering apparatus having the same. According to the present invention, it is possible to substantially reduce the number of constitutional elements to be assembled when assembling a torque sensor and neighboring elements, to reduce an error in change of torque caused by accumulation of assembling errors of the constitutional elements, thereby preventing a malfunction, and to enhance assemblability.