Angular Position Sensor Rotor Latching for Play-Free Mounting

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Solution Overview

Problem

Existing angular position sensors face challenges in ensuring precise alignment and secure connection between the rotor and housing, often requiring separate spring washers and welding, which complicates manufacturing and increases costs.

Innovation Solution

An angular position sensor design where the retaining ring is an integral part of the rotor assembly, featuring latching elements and axial position-securing elements that interact to secure the rotor to the housing without play, allowing for a robust, cost-effective, and simplified manufacturing process, including torque transmission and visual inspection capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate spring washers and welding are used to secure the rotor to the housing, then reliable connection is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the retaining ring and rotor latching device into a single integrated component made of plastic. This merging eliminates the need for separate spring washers and welding operations, reducing manufacturing complexity while maintaining connection reliability through the integrated design of retaining and latching functions within one piece.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical joining methods (spring washers and welding) with a plastic injection-molded integrated component. This substitution eliminates complex mechanical assembly steps and thermal processes, simplifying manufacturing while ensuring reliable connection through the inherent properties of the molded plastic structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple separate components are used for rotor assembly, then functional requirements are met, but manufacturing cost and assembly complexity increase

Engineering Contradiction:

Improvefunctional capabilityVSAvoidmanufacturing ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple functional components (retaining ring and rotor latching device) into a single plastic injection-molded part. This integration maintains all necessary functional capabilities while dramatically simplifying manufacturing and assembly, as the single-component design eliminates the need for multiple parts and their associated joining operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated plastic component performs multiple functions simultaneously: it acts as both a retaining ring and a rotor latching device. This multi-functionality ensures that all necessary mechanical functions are achieved within a single component, reducing the total part count and simplifying the overall assembly process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If traditional retaining methods are used, then connection security is achieved, but play between rotor and housing cannot be eliminated

Engineering Contradiction:

Improveconnection securityVSAvoidalignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The integration of retaining and latching functions into a single plastic component allows for precise positioning features to be molded directly into the part. This ensures that the rotor is secured without play to the housing, as the integrated design enables precise alignment features that eliminate gaps and movements between components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic injection-molded integrated component replaces traditional mechanical retaining methods with precision molded features. These features are built-in during manufacturing, ensuring consistent and precise positioning that eliminates play between the rotor and housing, unlike assembled mechanical components that may have clearance variations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12174080B2Angular position sensor for determining an angular position and/or a torque

Publication Date: 2024.12.24 HELLA GMBH & CO KGAA

AI summary

An angular position sensor may include a housing, and a rotor including a rotor assembly with a rotor latching device. The rotor and the housing are connected by the rotor latching device secured by a retaining ring. The retaining ring can be transferred into a secured position in an axial direction. The retaining ring is integral with the rotor assembly and features at least one retaining element with which the retaining ring secures the connection of rotor and housing. The retaining ring and the rotor latching device each feature corresponding latching elements. The rotor assembly features axial position-securing elements. The latching elements interact such that the retaining ring is secured in an axial direction along the rotary axis relative to the rotor. The axial position-securing elements interact so that the rotor is secured essentially free of play on the housing in an axial direction along the rotary axis.