Segmented Stator Teeth for Torque Sensor Cost Reduction
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Solution Overview
Problem
The existing EPS system for vehicle steering stability faces challenges in manufacturing cost due to the integral stator structure, which results in material waste and limited design applicability for varying motor sizes.
Innovation Solution
A torque sensor module with a stator formed by coupling multiple unit stator teeth, allowing for separate manufacturing and assembly, enabling versatile design adaptations and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an integral stator structure is used, then manufacturing simplicity is maintained, but material waste increases and design flexibility decreases
Solution Approach 1:
The stator is divided into multiple independent stator teeth that can be manufactured separately and then assembled together. This segmentation allows each tooth to be optimized individually, reduces material waste by only producing needed components, and maintains manufacturing simplicity through standardized production processes for each segment.
2Strength
If an integral stator structure is used, then structural integrity is maintained, but design adaptability for varying motor sizes is reduced
Solution Approach 1:
The stator teeth are designed as separate modular units that can be independently configured and assembled. This allows the same basic tooth design to be adapted for different motor sizes by varying the number of teeth, their arrangement, or their dimensions, while maintaining structural integrity through standardized connection methods.
Solution Approach 2:
The modular stator tooth design creates universal components that can be used across different motor configurations and sizes. The same basic tooth structure can be adapted for various applications by changing assembly patterns, making the design versatile while maintaining structural reliability.
3Ease of manufacture
If an integral stator structure is used, then manufacturing process is simplified, but production efficiency decreases
Solution Approach 1:
By dividing the stator into separate teeth, each tooth can be manufactured using optimized processes suitable for its specific geometry, and multiple teeth can be produced simultaneously or in parallel. This increases production efficiency while the standardized segmentation maintains process simplicity through repeatable assembly procedures.
Solution Approach 2:
Stator teeth can be pre-manufactured, pre-magnetized, or pre-assembled with other components before final stator assembly. This preliminary preparation of modular units streamlines the overall manufacturing process and increases productivity by enabling parallel production steps.
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 approach reduces manufacturing costs and enhances design flexibility by allowing for various motor sizes and improved magnetization characteristics, promoting efficient and cost-effective production.
Implementation Method 1
a first magnet disposed at a periphery of the rotor holder
Data Source
AI summary
The disclosure relates to a torque sensor module comprising: a rotor (including a rotor holder and a first magnet); and a stator formed by a plurality of unit stators to be divided. Each of the unit stators separately includes a head part and a tooth that extends in a bent direction from the corresponding head part.