Stator Tooth Fixation Structure for Stable Torque Sensing
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Solution Overview
Problem
The existing EPS system's sensor assembly faces issues with stator teeth separation due to external impacts, requiring manual welding, which decreases productivity and leads to variations in collector gaps, affecting sensor performance.
Innovation Solution
A sensing device design featuring stator teeth with protruding tips and bosses for secure fixation, along with a cover to maintain consistent collector spacing, enhancing assembly efficiency and preventing separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stator teeth are fixed to stator body by welding, then fixing force is provided, but stator teeth separate from stator body when external impact is applied
Solution Approach 1:
The stator teeth are divided into multiple segments (first stator teeth and second stator teeth) that can be separately fixed to the stator body. Each segment has its own fixing structure (first tips with first bosses, second tips with second bosses), allowing independent fixation that distributes stress and prevents complete separation under external impact.
Solution Approach 2:
The fixing structure extends in the axial direction of the stator with tips protruding toward the central shaft and bosses disposed on the stator body surface. This three-dimensional arrangement creates multiple fixation points distributed in different spatial dimensions, enhancing resistance to separation under external impact forces.
2Strength
If multiple teeth are fixedly welded, then fixing force is increased, but manpower is required and productivity is lowered
Solution Approach 1:
The stator teeth are designed with pre-formed tips and the stator body includes pre-formed bosses and holes. These features can be manufactured in advance during stator body production, eliminating the need for manual welding operations during final assembly. The components are prepared beforehand with integrated fixing structures that simplify the assembly process.
Solution Approach 2:
The welding process is replaced with a mechanical fixing system where tips are inserted into holes and secured with bosses. This substitution eliminates the need for welding operations, reducing manual labor requirements and increasing productivity while maintaining sufficient fixing force through the mechanical interlocking structure.
3Strength
If collectors are welded to housing, then fixing force is provided, but collectors deform and gap variations occur affecting sensor performance
Solution Approach 1:
The collectors are divided into first collector and second collector, each with its own fixing structure (protrusions fitting into grooves). This segmentation allows independent positioning and fixation of each collector, preventing deformation that would occur with welding while maintaining consistent gaps between collectors and with the stator teeth.
Solution Approach 2:
The welding process for fixing collectors to the housing is replaced with a mechanical insertion system where protrusions on the collectors fit into corresponding grooves in the housing. This mechanical fixing method avoids the heat and stress of welding that cause collector deformation, thereby maintaining consistent gap dimensions and preserving sensor performance.
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 design ensures stable fixation of stator teeth, improves manufacturing efficiency, and maintains sensor performance by preventing collector deformation and gap variations.
Implementation Method 1
a first sensor disposed between the first collector and the second collector
Data Source
AI summary
The present invention provides a sensing device comprising: a rotor; and a stator in which the rotor is disposed, wherein the stator comprises a stator tooth and a stator body, the stator tooth comprises a first stator tooth and a second stator tooth disposed inside the first stator tooth, at least one of the first stator tooth and the second stator tooth includes a tip protruding toward the center axis of the stator, and the tip is disposed at one surface of the stator body.