Steering Angle Sensor Gearbox With Integrated Over-Rotation Stop
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Solution Overview
Problem
Existing angular position sensor assemblies and steering systems for vehicles are complex and prone to over-rotation, requiring a more simplified and robust design that prevents over-steering while efficiently detecting shaft rotations.
Innovation Solution
A gearbox is integrated into the angular position sensor assembly, serving as a fixed mechanical stop and rotational encoder, allowing for a simplified structure that prevents over-rotation and efficiently detects shaft rotations, using diverse sensor principles for enhanced safety and space efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional angular position sensor assembly is used, then the shaft rotation can be detected, but the structure is complex and over-rotation cannot be prevented
Solution Approach 1:
The patent combines the gearbox and mechanical stop functions into a single integrated component. The gearbox serves dual purposes: transmitting rotational motion while simultaneously providing mechanical stops at predetermined angular positions to prevent over-rotation of the shaft, thereby reducing the number of separate components needed.
Solution Approach 2:
The gearbox is designed to perform multiple functions: it transmits rotational motion from the shaft to the encoder while also serving as a mechanical stop device. This multi-functionality eliminates the need for separate over-rotation prevention mechanisms, simplifying the overall structure.
2Reliability
If multiple separate components are used for rotation detection and over-rotation prevention, then functionality is achieved, but space consumption increases
Solution Approach 1:
The encoder and mechanical stop functions are merged into a single integrated assembly. The gearbox housing contains both the encoding mechanism and the mechanical stop elements, allowing rotation detection and over-rotation prevention to occur within the same spatial envelope rather than requiring separate component volumes.
Solution Approach 2:
The encoder components are nested within the gearbox structure. The coding element is positioned inside the gearbox housing, and the mechanical stops are integrated into the same housing, creating a compact nested arrangement that minimizes overall assembly volume.
3Ease of manufacture
If a simplified structure is used, then production efficiency improves, but measurement precision may be compromised
Solution Approach 1:
The encoder is divided into a stationary housing and a rotating coding element. This segmentation allows the coding element to be a simple, easily manufactured component with discrete angular markings, while the stationary housing contains the sensing mechanism. The simplified segmented structure improves manufacturability while maintaining measurement precision through the clear geometric relationship between segments.
Data Source
AI summary
An angular position sensor assembly for determining an angular position of a shaft when the shaft rotates about an axis of rotation of the shaft. A rotational encoder is connected to the shaft in force transmission and a rotational sensor detects a movement of the rotational encoder. On the shaft, a non-rotatable first gear part of a gearbox of the angular position sensor assembly is arranged and the rotational encoder is formed as a second gear part of the gearbox engaged with the first gear part. The gearbox simultaneously forms a fixed mechanical stop of the shaft on a first end of an angular position range of the shaft when the shaft rotates counterclockwise and on a second end of the angular position range of the shaft when the shaft rotates clockwise.