Sensor Mounting Structure for Electric Power Steering
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Solution Overview
Problem
Conventional electric power steering apparatuses face challenges in packaging and increased total length due to the separation distance required for sensor installation, which complicates assembly and affects product design.
Innovation Solution
A sensor mounting structure with a housing having open and communicating accommodation parts, a sensing unit positioned at a predetermined distance from the worm wheel, and a fastening mechanism using a coupling part and fastening member with elastic elements for secure fixation without the need for a separate assembly tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate assembly tool is used to install the sensor, then the sensor can be securely fixed, but a separation distance must be maintained between the tool and housing, increasing the total length
Solution Approach 1:
The sensor is nested within the housing structure, with the sensor holder positioned inside the housing cavity. The sensor is inserted through the opening in the housing cover and secured within the housing, eliminating the need for external assembly tools and reducing the overall length of the apparatus.
Solution Approach 2:
The sensor holder and sensor assembly are pre-positioned within the housing structure during manufacturing. The housing is designed with pre-formed openings and mounting features that prepare the sensor for installation, eliminating the need for separate assembly tools and reducing the separation distance requirement.
2Manufacturing precision
If a separate assembly tool is used for sensor installation, then the sensor can be positioned accurately, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The housing structure is merged with the sensor mounting function. The housing includes integrated features such as the sensor holder, mounting openings, and positioning structures, combining multiple functions into a single component and simplifying the assembly process while maintaining positioning accuracy.
Solution Approach 2:
The housing serves multiple functions: it protects internal components, provides structural support, and integrates the sensor mounting mechanism. The housing cover with its opening and the internal sensor holder work together as a universal assembly that simplifies installation while ensuring accurate sensor positioning.
3Object-affected harmful factors
If the sensor is installed with a separation distance from the housing, then tool interference is prevented, but packaging efficiency is reduced
Solution Approach 1:
The sensor assembly is nested within the housing cavity, utilizing the internal space of the housing for sensor placement. This eliminates the need for external separation distance while preventing tool interference, as the sensor is accessible through the housing cover opening during assembly but protected within the housing during operation.
Solution Approach 2:
The sensor installation approach transitions from a linear external mounting (requiring separation distance) to a three-dimensional internal placement within the housing cavity. The sensor is positioned in the internal volume of the housing, allowing compact packaging while maintaining assembly accessibility through the housing cover opening.
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 solution reduces the total length of the electric power steering apparatus, enhances packaging efficiency, and simplifies the assembly process by eliminating the need for a separate assembly tool, thereby improving overall design and functionality.
Implementation Method 1
an elastic member which is formed on any one side surface of two side surfaces of the coupling body and is provided to be elastically deformed when the pair of supports are coupled to the coupling body
Data Source
AI summary
Disclosed herein are a sensor mounting structure of an electric power steering apparatus and an electric power steering apparatus having the same. The sensor mounting structure of an electric power steering apparatus includes a housing having a first accommodation part of which one side surface is open to accommodate a worm wheel and a second accommodation part which communicates with the first accommodation part and accommodates a worm shaft, a sensing unit disposed such that the sensing unit is spaced a predetermined distance from and faces the worm wheel, and a fastening means which fixes the sensing unit to the housing.