Sensor Wheel Layout for Fast, Precise Engine Angle Detection

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Solution Overview

Problem

Existing encoder wheels for internal combustion engines lack precise determination of rotary angular position and have slow startup times.

Innovation Solution

A sensor wheel with six indicator elements, each having three different circumferential extensions, arranged such that any two adjacent elements share the same extension, and flanks oriented in the same direction are equidistant, allowing for rapid and accurate determination of the encoder wheel's angular position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional encoder wheels with uniform indicator elements are used, then the structure is simple, but the measurement precision of rotary angular position is insufficient

Engineering Contradiction:
Improverotary angular position determination precisionVSAvoidencoder wheel structure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The encoder wheel implements local quality by assigning different circumferential extensions to different indicator elements based on their angular positions. Specifically, indicator elements are configured with first, second, or third circumferential extensions depending on whether they are located between specific reference marks (e.g., between first and second reference marks, between second and third reference marks, etc.). This non-uniform local configuration enables the sensor to distinguish absolute angular positions more precisely while maintaining a relatively simple overall wheel structure.

Inventive Principle:
Principle #3Local quality

2Speed

If conventional encoder wheels are used, then the device is simple, but the startup time is slow

Engineering Contradiction:
Improvestartup speedVSAvoidencoder wheel structure complexity
Core Design Contradiction:
SpeedVSDevice complexity

Solution Approach 1:

The encoder wheel applies preliminary action by pre-configuring the indicator elements with specific circumferential extensions at predetermined angular positions before the engine operates. The indicator elements are arranged such that their extensions correspond to specific angular intervals defined by reference marks on the camshaft. This pre-arranged configuration allows the sensor to immediately determine absolute angular position upon startup without requiring warm-up or calibration periods, thereby achieving rapid startup while maintaining structural simplicity.

Inventive Principle:
Principle #10Preliminary action

3Measurement precision

If indicator elements have different circumferential extensions, then signal resolution is improved, but manufacturing precision requirements increase

Engineering Contradiction:
Improvesignal resolutionVSAvoidindicator element dimension precision
Core Design Contradiction:
Measurement precisionVSManufacturing precision

Solution Approach 1:

The encoder wheel applies segmentation by dividing the camshaft rotation into distinct angular intervals defined by reference marks, with each interval assigned a specific indicator element extension type (first, second, or third extension). This segmentation approach allows the manufacturing process to focus on creating discrete, well-defined extension types rather than continuously varying dimensions, thereby improving signal resolution while keeping manufacturing precision requirements manageable through standardized segment configurations.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentEP4275016B1Sensor wheel for an internal combustion engine, internal combustion engine, and method for operating an internal combustion engine
Publication Date: 2026.04.01 AUDI AG
  • EP4275016B1 patent drawingFigure 1
  • EP4275016B1 patent drawingFigure 2

AI summary

The invention relates to a sensor wheel (2) for an internal combustion engine (1), having six indicator elements (7, 8, 9, 10, 11, 12) which are arranged at a distance from each other in the circumferential direction relative to an axis of rotation of the sensor wheel on a base body (6) of the sensor wheel (2), wherein flanks (13, 14), which are arranged in the same direction, of the indicator elements (7, 8, 9, 10, 11, 12) are disposed equidistantly from each other in the circumferential direction. It is provided that the indicator elements (7, 8, 9, 10, 11, 12) have in each case one of three different indicator element extensions in the circumferential direction. The invention also relates to an internal combustion engine (1) and to a method for operating an internal combustion engine (1).