Integrated Sense Magnet Flange for Compact Motor Position Sensing
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Solution Overview
Problem
Existing electric brake systems face challenges in efficiently packaging electromechanical actuators due to size constraints and complex electrical connections, which hinder their integration into limited vehicle spaces.
Innovation Solution
A flange with a magnetically charged element over-molded onto a body surrounding the motor rotation shaft, integrated with a drive belt or gear, and a clearance portion to prevent strain on the magnetically charged elements, allowing for reduced packaging size and simplified electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electromechanical actuator is packaged in a compact design, then the installation space in vehicle is reduced, but the signal integrity and motor position sensing may be compromised
Solution Approach 1:
The flange and magnetically charged element are merged into a single integrated component. The magnetically charged element is over-molded directly onto the flange body, eliminating the need for separate mounting brackets or additional fastening hardware. This integration maintains compact packaging while preserving motor position sensing capability through the embedded magnetic elements.
Solution Approach 2:
The magnetically charged element is nested within the flange structure through over-molding. The magnetic elements are embedded into the flange body, allowing the sensing function to be contained within the compact flange assembly without increasing overall packaging volume.
2Volume of moving object
If the magnetically charged element is positioned close to the motor rotation shaft for compact packaging, then the packaging size is reduced, but strain on the magnetically charged elements increases
Solution Approach 1:
The flange is constructed as a composite structure with the magnetically charged element over-molded onto the flange body. This composite design provides mechanical support and strain relief to the magnetic elements while maintaining a compact overall size. The flange material absorbs and distributes mechanical stresses, protecting the embedded magnetic elements from excessive strain.
3Device complexity
If the flange is made as a single integrated piece with the magnetically charged element, then the assembly complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The flange and magnetically charged element are combined into a single integrated component through over-molding. This merging eliminates the need for separate assembly steps involving fasteners, brackets, or additional mounting hardware, thereby reducing assembly complexity. The integrated design achieves this simplification while managing manufacturing precision through the over-molding process.
Solution Approach 2:
The flange serves multiple functions simultaneously: it provides structural support, positions the magnetically charged element, and integrates the motor position sensing capability. This multi-functionality reduces the number of separate components needed, simplifying assembly while consolidating precision requirements into a single manufacturing process.
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 enables a compact electromechanical actuator package with improved signal integrity and reduced assembly complexity, facilitating installation in tight vehicle spaces while maintaining effective motor position sensing.
Implementation Method 1
a magnetically charged element that surrounds the body of the flange
Data Source
AI summary
A flange is provided. The flange may include: a body having an interface portion, an inner diameter, and an outer diameter, the body surrounding a motor rotation shaft of a motor of an electromechanical actuator package and the interface portion interfaces with a drive belt or drive gear of a drive mechanism of the electromechanical actuator package; and a magnetically charged element that surrounds the body of the flange.