Rotation Detector Wiring Bend Positioning
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Solution Overview
Problem
Conventional rotation detectors for tires face challenges such as wire interference with vehicle components and asymmetrical sensor arrangements due to assembly errors, leading to increased complexity and reliability issues when detecting tire rotation.
Innovation Solution
A rotation detector design that uses a case-shape housing with position marks to align sensors correctly, forming resin parts to secure wiring in a reliable bent position without additional parts, allowing for symmetrical and reliable assembly for both right and left tires using the same mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire extends in the axial direction from the sensor body, then the wiring is simple and easy to manufacture, but the wire interferes with vehicle components such as suspension arms and brake dust covers
Solution Approach 1:
The wire extension direction is changed from the axial direction to a radial direction perpendicular to the axial direction. This dimensional change allows the wire to extend away from the sensor body in a direction that does not interfere with vehicle components while maintaining manufacturing simplicity through the molding process.
2Measurement precision
If the magnetic sensor arrangement is adjusted to accommodate assembly errors, then the measurement precision improves, but the device complexity increases due to different sensor arrangements for right and left tires
Solution Approach 1:
The sensor body is designed with an asymmetric sensor side position mark that, when combined with the symmetric mold side position mark, creates different effective arrangements for right and left tires. This asymmetric design allows the same mold to produce sensors with different orientations, accommodating assembly errors while maintaining manufacturing simplicity.
Solution Approach 2:
The position marks are pre-designed into the sensor body and mold during manufacturing, establishing the correct angular relationship before assembly. This preliminary positioning action ensures that even with assembly variations, the sensors will be correctly oriented relative to the rotation direction of the gear rotor.
3Reliability
If additional parts are used to secure the bent wiring, then the reliability of the bent wire position improves, but the device complexity and number of parts increases
Solution Approach 1:
The function of securing the bent wire is merged into the resin molding process itself. The resin material serves both as structural support and as the securing medium that holds the wire in its bent position, eliminating the need for separate fastening parts while maintaining reliability.
Solution Approach 2:
The resin molding process automatically secures the bent wire during manufacturing. The wire is positioned and fixed by the same molding process that creates the sensor body housing, making the system self-sufficient without requiring additional dedicated fastening components.
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 solution ensures reliable and symmetrical sensor arrangements for both right and left tires, reducing assembly complexity and increasing the reliability of the bent wiring, thus enhancing the overall performance of the rotation detector.
Implementation Method 1
forming a second resin part of the resin molding by pouring resin into the hollow space defined by the mold, wherein the second resin part includes an outer periphery of the sensor body and a bent portion that fixes the wiring extending from the sensor body
Implementation Method 2
The magnetism (direction of magnetic flux) from the magnet changes as teeth on the gear rotor J3 are driven by rotation of the gear shaft J2, because the teeth of the rotor J3 run through the magnetic flux that flows from the magnet toward the magnetic sensor
Data Source
AI summary
A rotation detector having a Hall IC in a case-shape housing includes a wiring extending therefrom in a direction of a bent portion of a detector body in accordance with one of plural predetermined directions of a position pin defined by pin receivers when the detector body is molded by using a mold having the position pin.