Wheel Speed Sensor Pulsar Ring Mounting Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wheel speed sensor mounting structures face challenges in maintaining accurate positional relationships between the sensor body portion and the pulsar ring during thermal expansion of the brake disc, especially under special braking conditions, leading to potential deformation and loss of detection accuracy.
Innovation Solution
A wheel speed sensor mounting structure that includes a pulsar ring with radially outward projecting mounting portions and a seat portion arranged on the same plane, along with a rib structure on the portion to be detected, which are fastened together with the brake disc using a bolt, and a sensor body positioned between the fork and brake caliper, ensuring minimal deformation and maintaining the predetermined distance between the portion to be detected and the sensor body portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brake disc and pulsar ring are rigidly mounted together using bolts, then the number of parts is reduced and manufacturing cost is lowered, but the pulsar ring deforms due to thermal expansion of the brake disc during braking, causing loss of detection accuracy
Solution Approach 1:
The mounting structure is segmented into three distinct components: the brake disc, the pulsar ring, and the wheel hub. Each component is fastened independently to the wheel hub, allowing the pulsar ring to maintain its own thermal expansion characteristics separate from the brake disc, thereby preventing deformation while still achieving a compact multi-component mounting arrangement.
Solution Approach 2:
The wheel hub serves as an intermediary mounting surface that receives both the brake disc and pulsar ring separately. By fastening both components to the hub rather than fastening them to each other, the hub mediates the thermal expansion differences between the brake disc and pulsar ring, preventing the pulsar ring from deforming while maintaining stable mounting positions for both components.
2Volume of moving object
If the brake disc and pulsar ring are fastened together to the wheel using bolts, then both components can be mounted on the wheel in a compact size, but the pulsar ring deforms when the brake disc thermally expands during braking
Solution Approach 1:
The mounting structure is segmented into three distinct components: the brake disc, the pulsar ring, and the wheel hub. Each component is fastened independently to the wheel hub, allowing the pulsar ring to maintain its own thermal expansion characteristics separate from the brake disc, thereby preventing deformation while still achieving a compact multi-component mounting arrangement.
Solution Approach 2:
The mounting structure allows the pulsar ring to dynamically expand and contract with temperature changes independently from the brake disc. By not rigidly coupling the pulsar ring to the brake disc, the structure accommodates thermal dynamics while maintaining stable mounting positions through separate fastening to the wheel hub.
3Measurement precision
If a floating mount structure is used to maintain stable positional relationship between sensor and pulsar ring, then detection accuracy is maintained, but the structure becomes more complex with additional components
Solution Approach 1:
The wheel hub serves a dual function: it acts as both the mounting surface for the brake disc and the mounting surface for the pulsar ring. This self-service approach eliminates the need for separate mounting brackets or floating mount structures, achieving stable positioning and accurate detection while minimizing structural complexity.
Solution Approach 2:
The wheel hub is designed as a universal mounting surface that can accommodate both the brake disc and pulsar ring simultaneously. This multi-functional design eliminates the need for additional specialized mounting structures, achieving both compactness and stability without increasing overall device complexity.
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 configuration effectively suppresses twisting and deformation of the pulsar ring, maintaining the positional relationship and detection accuracy even under extreme thermal conditions, while also reducing the number of parts and costs by adopting a rigid mount structure.
Implementation Method 1
the brake disc is raised to high temperature due to friction generated between the brake disc and a brake caliper at the time of braking a vehicle so that the brake disc is thermally expanded
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A pulsar ring (20) includes a portion to be detected (21) and a pulsar ring mounting portions (23) which project in the radially outward direction from an outer peripheral portion of the portion to be detected (21). The portion to be detected (21) and a pulsar ring mounting portion (23) are arranged so as to form continuous planar surfaces, and the pulsar ring (20) is rigidly mounted on a mounting boss (50) of a wheel (1b) using a bolt (10) by fastening a brake disc (4) and the pulsar ring (20) together in a state where the pulsar ring (20) overlaps with the brake disc mounting portion (4b). Even when the brake disc (4) thermally deforms at the time of braking so that the pulsar ring mounting portion (23) is pulled radially outwardly, the portion to be detected (21) and the pulsar ring mounting portion (23) are arranged on the same plane thus forming the continuous planar surfaces and hence, the portion to be detected (21) is hardly twisted and thereby the deformation of the portion to be detected (21) is hardly generated as a whole.