Steering Angle Sensor Bearing Element for Compact Radial Guidance
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Solution Overview
Problem
Existing steering angle sensors are sensitive to manufacturing tolerances and require complex positioning of components, leading to a non-compact design and potential wear due to friction.
Innovation Solution
A compact bearing element with a ring-shaped web and annular groove arrangement allows for precise guidance of the gear wheel without a central axis of rotation, enabling a simple and backlash-free bearing that reduces installation space and friction, using self-lubricating materials like PTFE and an arc-shaped bridge part for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the gear wheel is fixed between the housing and circuit board with annular bearing surfaces, then the gear wheel is positioned in the axial direction, but the available manufacturing tolerances are relatively small requiring exact positioning
Solution Approach 1:
A bearing element is introduced as an intermediary component between the gear wheel and the carrier. This bearing element assumes the positioning function, allowing the gear wheel to be mounted without requiring exact positioning relative to the circuit board or housing. The bearing element bridges the tolerance gaps that would otherwise require precise manufacturing.
Solution Approach 2:
The positioning function is extracted from the carrier and housing structure and transferred to a dedicated bearing element. This separation allows the bearing element to specialize in providing precise radial guidance while the carrier and housing focus on their primary functions, reducing overall positioning complexity.
2Measurement precision
If the magnetic sensor is arranged decentrally to achieve high resolution, then the magnet must extend annularly around the pin, but this increases device complexity and is not desirable for all applications
Solution Approach 1:
The bearing element acts as a mediator that enables the magnetic sensor to be positioned at the center of the gear wheel without requiring complex annular magnet arrangements. By providing stable radial support through the bearing element, the system achieves high measurement precision with a simpler centralized magnet configuration.
3Manufacturing precision
If the gear wheel is mounted with tight tolerances to ensure exact positioning, then positioning precision is improved, but the design becomes less compact and more sensitive to manufacturing variations
Solution Approach 1:
The bearing element serves as a mediator that decouples the relationship between component positioning precision and installation space. It provides the necessary radial guidance in a compact configuration, allowing the gear wheel to be precisely positioned without requiring excessive clearance or complex positioning mechanisms that would increase the overall volume.
4Reliability
If bearing surfaces are extended over 360° to ensure complete guidance, then radial guidance is improved, but installation space and device complexity increase
Solution Approach 1:
The bearing element provides radial guidance through a bearing section that does not need to extend over the full 360° circumference. The bearing section extends over a sufficient angular range to ensure the gear wheel runs without play in the radial direction, while leaving the remaining angular space available for other components, thus optimizing space utilization while maintaining reliable guidance.
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 solution creates a tolerant chain that eliminates the need for exact positioning of components, resulting in a compact, low-friction, and wear-resistant steering angle sensor design with improved resolution and space efficiency.
Implementation Method 1
the bearing section and/or the bearing surface and/or the annular groove and/or the annular web and/or the shoulder and/or the step are made of a self-lubricating material, in particular polytetrafluoroethylene (PTFE)
Data Source
Figure 1~2
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AI summary
The sensor has a carrier (4) for arranging magnetic sensors that are arranged adjacent to a gear (14), where the gear exhibits multipolar magnets. A bearing unit (18) is arranged at the carrier, where the bearing unit bridges the gear in sections. The bearing unit has a bearing section (32) that forms a stop for the gear, where the stop works in an axial direction. The bearing unit has a bearing surface (34) for guiding the gear in radial direction.