Shaft-Integrated Angle Sensor Shielding
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Solution Overview
Problem
Magnetic sensors in harsh environments, such as automotive systems, are susceptible to disturbances that lead to faulty measurements and sensor failures due to magnetic field interference from mechanical and electrical components, and existing solutions fail to effectively mitigate these disturbances while maintaining precision and accuracy.
Innovation Solution
An integrated sensor system that incorporates a sensor module and a magnet module within a shaft, where the shaft acts as a shield to protect the sensor element from external disturbances, using a soft magnetic material with high permeability to minimize interference and maintain accurate magnetic field measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic sensors are used in harsh environments with mechanical and electrical components, then angle sensing capability is provided, but measurement accuracy deteriorates due to magnetic field disturbances
Solution Approach 1:
A magnetic shield made of soft magnetic material is introduced as an intermediary component between the magnetic sensor and the external environment. This shield selectively guides magnetic field lines, allowing the sensor's own magnetic field to pass through while blocking external magnetic disturbances, thereby protecting measurement accuracy without compromising sensor operation in harsh environments
Solution Approach 2:
The magnetic shield is positioned specifically around the sensor element and magnet module within the shaft, providing localized magnetic field management. This targeted shielding approach ensures that only the critical sensing区域 is protected from external magnetic disturbances, maintaining measurement precision where it matters most
2Object-affected harmful factors
If additional shielding components are added to protect the sensor, then protection from disturbances is improved, but device complexity increases
Solution Approach 1:
The magnetic shield is integrated with the existing shaft structure, merging the shielding function with the mechanical support structure. This combination eliminates the need for separate, extensive encapsulation components, reducing device complexity while maintaining effective protection from magnetic disturbances
Solution Approach 2:
The shaft itself serves dual purposes: providing mechanical support and housing the magnetic shield. The structure performs multiple functions simultaneously, reducing the need for additional components and simplifying the overall device architecture
3Object-affected harmful factors
If extensive encapsulation is used to shield the sensor, then protection from disturbances is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The magnetic shield is designed as a modular component that can be separately manufactured and then assembled into the shaft structure. This segmentation allows for specialized manufacturing of the shield using appropriate soft magnetic materials, followed by straightforward integration, simplifying the overall manufacturing process compared to extensive encapsulation
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 system provides robust and accurate angle sensing over 360 degrees by shielding the sensor and magnet modules from disturbances, enhancing the reliability and precision of magnetic field measurements in harsh environments without the need for extensive encapsulation or additional space.
Implementation Method 1
The shaft is configured to shield the magnet module and the sensor element from one or more disturbances
Implementation Method 2
using a soft magnetic material with high permeability to minimize interference and maintain accurate magnetic field measurements
Data Source
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AI summary
A sensor arrangement includes a sensor element and a magnet module. The sensor element is configured to measure a magnetic field and is positioned within a shaft. The shaft is configured to shield the magnet module and the sensor element. The magnet module is configured to generate the magnetic field. The sensor element is at least partially positioned within the shaft.