Steering Angle Sensor Gear Support for Precise Magnet Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing steering angle sensors face challenges in achieving accurate measurement precision due to misalignment of the magnet and Hall IC, leading to increased size, interference with other components, and reduced assembly reliability when using a middle case to support the sub-gear.
Innovation Solution
A sensing device design that supports the sub-gear without a middle case, utilizing a case with an upper and lower case, a stator, rotor, main gear, sub-gear, magnet, and substrate with specific protrusion parts and grooves to guide and stabilize the sub-gear's rotation, ensuring precise measurement of the steering angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a middle case is used to support the sub-gear, then measurement precision is improved, but device size increases
Solution Approach 1:
The patent merges the middle case support structure with the main case by integrating the sub-gear support function directly into the case body. The case includes a support portion that directly supports the sub-gear, eliminating the need for a separate middle case while maintaining measurement precision.
Solution Approach 2:
The case is designed to perform multiple functions: it houses the Hall IC, supports the sub-gear through an integrated support portion, and provides structural alignment. This multi-functional design eliminates the need for a dedicated middle case component.
2Measurement precision
If a middle case is used to support the sub-gear, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The support function previously requiring a separate middle case is merged into the main case structure. The case now includes an integrated support portion that directly supports the sub-gear, reducing the number of components and simplifying the overall structure while maintaining measurement precision.
3Reliability
If a middle case is used to support the sub-gear, then assembly is more stable, but productivity decreases
Solution Approach 1:
The integration of the support portion into the case eliminates the need for separate assembly of a middle case. The sub-gear is directly supported by the case structure, reducing the number of assembly steps and improving productivity while maintaining assembly stability.
4Ease of manufacture
If the magnet and Hall IC are not accurately aligned, then manufacturing is easier, but measurement precision deteriorates
Solution Approach 1:
The case is designed with a predetermined shape that pre-positions the Hall IC and support portion in correct alignment. This preliminary structural arrangement ensures accurate alignment between the magnet on the sub-gear and the Hall IC during assembly, eliminating the need for complex alignment procedures while maintaining measurement precision.
Solution Approach 2:
The case acts as an intermediary structure that provides fixed geometric relationships between the Hall IC and the sub-gear support portion. This intermediary structure ensures accurate alignment is maintained throughout assembly and operation.
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 design enhances measurement precision by minimizing movement and tilting of the sub-gear, maintaining internal space utilization, and improving assembly reliability by eliminating the need for a middle case.
Implementation Method 1
a Hall IC which detects a change in magnetic force of the magnet
Data Source
AI summary
Disclosed in an embodiment is a sensing device, comprising: a case; a rotor rotatably disposed inside the case; a stator arranged to correspond to the rotor; a main gear that rotates in conjunction with the stator; a sub-gear that rotates in conjunction with the main gear; a magnet disposed on the sub-gear; and a substrate including a sensor disposed to face the magnet, wherein the sub-gear comprises: a body having gear teeth formed on the outer circumference thereof; a first protrusion part formed on one surface of the body to protrude toward the substrate; and a second protrusion part formed to protrude from the other surface of the body, wherein an end of the first protrusion part is disposed in a groove formed in the substrate. Accordingly, the sensing device may improve measurement accuracy by guiding rotation of the sub-gear through a support structure offering rotational support and simultaneously preventing movement of the sub-gear such as tilting.