Solenoid Actuator Sensor Integration for Driveline Assembly
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Solution Overview
Problem
The complexity of tolerances in electromagnetically actuated driveline components, such as differentials, makes accurate sensor positioning challenging, leading to increased costs and labor in assembly and calibration.
Innovation Solution
An actuator assembly with an integrated sensor target that allows direct sensing of the sensor target's position relative to the frame, eliminating the need for precise alignment and simplifying the assembly process by pre-programming the sensor assembly before installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is mounted via bracket to a stationary structure with multiple tolerance-influenced elements, then the sensor can identify the position of the axially translating member, but the assembly complexity and calibration labor increase significantly
Solution Approach 1:
The sensor assembly is merged with the actuator assembly by directly coupling the sensor to the actuator frame, eliminating the need for separate bracket mounting structures. This integration reduces the number of components and assembly steps while maintaining positioning accuracy.
Solution Approach 2:
The sensor is pre-positioned and pre-programmed during actuator assembly fabrication, allowing the sensor target to be accurately positioned relative to the sensor before the actuator is installed in the driveline component. This preliminary action eliminates the need for complex field calibration.
2Reliability
If multiple tolerance elements are involved in the sensor positioning path, then the sensor can detect the actuated state, but the manufacturing and assembly precision requirements increase
Solution Approach 1:
The sensor assembly is extracted from the complex bracket mounting system and directly coupled to the actuator frame, removing multiple intermediate tolerance-influenced elements from the positioning path. This simplifies the manufacturing precision requirements while maintaining reliable state detection.
Solution Approach 2:
The actuator frame serves multiple functions: it provides structural support for the coil assembly, serves as the mounting structure for the sensor, and defines the positioning reference for the sensor target. This multi-functionality reduces the need for separate precision-machined mounting structures.
3Strength
If a bracket member with sensor bracket is used to retain the electromagnetic actuator and hold the sensor, then the actuator can be securely mounted, but the number of parts and assembly steps increase
Solution Approach 1:
The mounting function and sensor-holding function are merged into a single integrated actuator frame structure. The frame directly retains the electromagnetic actuator through its structural design while simultaneously providing the mounting interface for the sensor, eliminating the need for separate bracket members.
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 approach reduces the complexity and cost of assembly, allows for efficient installation, and eliminates the need for further calibration, enabling accurate state identification of driveline components without additional programming or calibration.
Implementation Method 1
these electromagnetically-actuated driveline components typically include a sensor, such as a Hall-effect sensor, that is employed to identify a position of an axially translated member
Implementation Method 2
an electromagnetic actuator to translate members of an assembly into/out of engagement with one another
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
An electromagnetic actuator assembly that includes an annular frame (20), a coil assembly (22), an annular armature (24), a plunger (26) and a sensor. The coil assembly is coupled to the frame and includes an annular core (66) and an annular coil (64). The annular armature is received in the frame and abutted against the plunger. A sensor target (122) can be coupled to the armature or the plunger and includes a radially outwardly extending sensor target. The sensor is coupled to the frame and configured to sense a position of the sensor target. A method for operating an electromagnetic actuator is also provided.