Steering Angle Sensing With Integrated Pinion Magnet Assembly
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Solution Overview
Problem
Existing electric power steering systems require multiple components such as sub-gears, magnets, and sensors, leading to increased manufacturing costs and structural complexity, as well as limited installation space.
Innovation Solution
A simplified apparatus for detecting steering angle using a pinion shaft with a pinion gear, a magnet, a magnetic sensor, and a printed circuit board, eliminating the need for conventional main gears, sub-gears, and sensors, and incorporating a magnet holder and sealing mechanism to secure the magnet and sensor components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional EPS with main gear, sub-gears, magnets and sensors are used, then steering angle detection function is achieved, but manufacturing cost increases and structure becomes complicated
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the conventional EPS system. Specifically, it removes the main gear and sub-gears, retaining only the pinion gear that is inherently present in the steering system. This extraction principle reduces component count and structural complexity while preserving the essential steering angle detection function through the use of a single magnet and sensor assembly.
Solution Approach 2:
The patent merges multiple functions into fewer components. The magnet and sensor are integrated into a compact assembly that rotates with the pinion gear, combining the magnetic field generation and detection functions in a unified structure. This merging eliminates the need for separate main gear and sub-gear assemblies, thereby simplifying the overall structure.
2Reliability
If conventional EPS with multiple gears and sensors are used, then steering angle detection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates expensive components such as the main gear and additional sub-gears from the system. By retaining only the essential pinion gear and using a simplified magnet-sensor assembly, the manufacturing cost is reduced while the steering angle detection function remains intact.
Solution Approach 2:
The patent employs simpler, more cost-effective components in place of complex mechanical assemblies. The use of a single magnet and sensor instead of multiple gears and sensors reduces material costs and manufacturing complexity, aligning with the principle of using simpler, more economical components when possible.
3Reliability
If conventional EPS with multiple components are used, then steering angle detection function is provided, but installation space is limited
Solution Approach 1:
The patent merges the magnet and sensor into a compact integrated assembly that rotates with the pinion gear. This consolidation significantly reduces the space required for the steering angle detection mechanism, allowing for more efficient use of installation space within the vehicle's steering system.
Solution Approach 2:
The magnet is positioned within or adjacent to the pinion gear structure, and the sensor is integrated into the same rotational assembly. This nesting arrangement allows multiple components to occupy overlapping or adjacent spatial volumes, minimizing the overall footprint of the detection system.
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 apparatus reduces manufacturing costs and simplifies the structure while providing precise steering angle detection, enhancing design freedom and installation space utilization.
Implementation Method 1
a magnetic sensor for detecting a rotation angle of a steering wheel connected to the pinion shaft
Data Source
AI summary
An apparatus for detecting a steering angle includes a pinion shaft coupled to a rack housing in which a rack bar is installed, the pinion shaft on which a pinion gear meshing with a rack gear is formed; a magnet disposed at one end of the pinion shaft and configured to rotate together with the pinion shaft; a printed circuit board (PCB) disposed at a predetermined distance from the magnet and including a magnetic sensor for detecting a rotation angle of a steering wheel connected to the pinion shaft; and a connector connected to the PCB to transmit a detected value measured by the magnetic sensor to an electronic control unit (ECU).