Steering Position Sensor with Dual Sub-Gears for Steer-by-Wire
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Solution Overview
Problem
Existing steering apparatuses lack a reliable and stable method for detecting the position and movement of a rack bar in a vehicle, particularly in steer-by-wire systems where a mechanical connection is omitted, necessitating additional sensors for accurate position sensing.
Innovation Solution
A position sensor with a substrate featuring initial and sub-gears, rotors, and sensing coils, where the processor identifies impedance or reluctance to determine rotation angles of sub-rotors, which are then used to calculate the rotation angle of the initial shaft connected to the rack bar assembly, providing an output signal for controlling the steering motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mechanical connection between the steering wheel and rack bar is removed in a steer-by-wire system, then the steering system becomes more flexible and modern, but additional sensors are required to detect the linear motion of the rack bar, increasing device complexity
Solution Approach 1:
The patent replaces the mechanical connection between steering wheel and rack bar with an electrical connection system. The steering wheel's rotational motion is detected by sensors (angle sensor, torque sensor) and transmitted electrically to a control unit, which then controls a motor to drive the rack bar. This substitution eliminates the need for direct mechanical linkage while maintaining steering functionality.
Solution Approach 2:
The patent introduces a motor as an intermediary component between the steering wheel and rack bar. The motor converts electrical signals into mechanical motion to drive the rack bar, serving as a mediator that bridges the gap created by removing the direct mechanical connection. This intermediary enables the steer-by-wire functionality while providing a means to control rack bar position.
2Measurement precision
If additional sensors are added to detect rack bar position in steer-by-wire systems, then position detection capability is improved, but the reliability and stability of position detection remain insufficient
Solution Approach 1:
The patent implements a feedback mechanism where the position sensor continuously monitors the rack bar's position and feeds this information back to the control unit. The control unit compares the detected position with the target position and adjusts the motor's operation accordingly, ensuring accurate and reliable position detection throughout the steering range.
Solution Approach 2:
The patent replaces mechanical position detection methods with an electrical sensing system. A position sensor detects the rack bar's linear motion and converts it into electrical signals that are processed by the control unit. This electrical substitution provides more reliable and stable position detection compared to mechanical methods, as electrical sensors offer higher precision and fewer mechanical wear issues.
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
Enhances the reliability, stability, and robustness of position detection and movement detection of the rack bar, enabling precise control of the steering system without mechanical connections.
Implementation Method 1
the processor identifies impedance or reluctance to determine rotation angles of sub-rotors
Data Source
AI summary
A position sensor includes a substrate having a first surface and a second surface opposite to the first surface; an initial shaft passing through the first and the second surfaces of the substrate in a direction perpendicular to the substrate; a first initial gear mounted to the initial shaft and positioned above the first surface of the substrate; a second initial gear mounted to the initial shaft and position below the second surface of the substrate; a first sub-shaft positioned above the first surface of the substrate, and disposed perpendicular to the substrate and parallel to the initial shaft; a first sub-gear mounted to the first sub-shaft and positioned above the first surface of the substrate and rotatably engaged with the first initial gear; a first sub-rotor mounted to the first sub-shaft and positioned above the first surface of the substrate; a first sensing coil disposed on a first surface of the substrate; a second sub-shaft separated from the first sub-shaft, positioned below the second surface of the substrate, and disposed perpendicular to the substrate and parallel to the initial shaft; a second sub-gear mounted to the second sub-shaft, positioned below the second surface of the substrate, and rotatably engaged with the second initial gear; a second sub-rotor mounted to the second sub-shaft and positioned below the second surface of the substrate; and a second sensing coil disposed on the second surface of the substrate.