Integrated Sensor Shaft Bearing Design for Mounting
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Solution Overview
Problem
Existing ride-height sensors face challenges in producing a shaft that can be easily integrated into a housing with precise mounting, as existing solutions require complex production methods or precise fits, making them difficult to manufacture and prone to external influences.
Innovation Solution
A sensor device with a shaft element that features a narrowing portion, allowing for easy radial and axial mounting, with bearing portions that provide support in both directions, enabling precise positioning and integration with the lever element, while minimizing friction and protecting against external influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shaft with a rotationally symmetrical collar is used, then the shaft can be mounted in the housing, but the shaft cannot be formed integrally with the lever element and production becomes more complex
Solution Approach 1:
The patent merges the shaft and lever element into a single integrally formed component, eliminating the need for separate assembly of these parts. This reduces the number of components and simplifies manufacturing while maintaining the functional requirements of the shaft structure.
2Reliability
If a spherical cap portion is used on the shaft, then the shaft can be introduced into the housing and latched in place, but production becomes relatively complicated with a precise fit requirement
Solution Approach 1:
The patent segments the mounting function into distinct bearing portions with different geometries (conical section and stepped section) rather than using a single spherical cap. This segmentation allows each portion to serve a specific mounting purpose, simplifying production while ensuring reliable positioning and latching in the housing.
3Reliability
If the shaft is mounted with a collar in a bearing chamber, then the shaft can be supported, but the mounting requires a housing with a collar receiving region of greater diameter
Solution Approach 1:
The patent applies local quality by creating specific bearing portions at defined locations on the shaft (conical section and stepped section) rather than requiring a overall collar structure. This allows the shaft to be supported locally at critical points, reducing the need for a complex housing structure with enlarged collar receiving regions.
Data Source
AI summary
A sensor device for detecting rotation, having a position transmitter with a shaft element having first and second shaft ends. The rotation to be detected is introduced via the first shaft end. The shaft element contains a magnet element at the second shaft end, a sensor element for detecting the rotation of the magnet element, and a housing part with at least two sections are separated from each other. The shaft element of the position transmitter is mounted on the first section, and the sensor element is arranged in the second section. The housing part and the shaft element each have a first bearing portion shaped so as to taper towards the shaft end in the region of the second shaft end, the shaft element supported on the housing part on the first bearing portion in order to support the position transmitter on the housing part.