Steering Sensor Cover Integration for Corrosion Resistance
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Solution Overview
Problem
Existing torque sensor devices for vehicle steering systems face issues with corrosion and complex installation processes due to recesses in metal steering housings, which can lead to electrical connection failures and increased assembly complexity.
Innovation Solution
A sensor device with an integrated sensor cover that houses both inner and outer contact units, eliminating the need for recesses and using a plastic cover for mechanical stability and corrosion resistance, featuring axial or radial connector designs and optional cable connections for flexible mounting and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If recesses are made in the metal steering housing for electrical connections, then electrical connection is enabled, but corrosion risk increases and assembly complexity increases
Solution Approach 1:
The contact units are extracted from the metal steering housing and integrated into a separate sensor cover component. This separation removes the electrical connection interfaces from the metal housing, eliminating the corrosion risk associated with recesses in the steering housing while maintaining reliable electrical connections through the plastic sensor cover.
2Reliability
If recesses are made in the metal steering housing for electrical connections, then electrical connection is enabled, but assembly complexity increases
Solution Approach 1:
The inner contact unit and outer contact unit are merged into a single sensor cover component. This integration eliminates the need for separate mounting operations for individual contact units, reducing assembly complexity while ensuring reliable electrical connections between the sensor element and external systems.
3Object-affected harmful factors
If the sensor cover is made of plastic, then corrosion resistance is improved, but mechanical strength may be reduced
Solution Approach 1:
The sensor cover is made of plastic material that provides both corrosion resistance and sufficient mechanical strength. The plastic material serves as a composite solution that eliminates corrosion risks associated with metal housing while maintaining the structural integrity needed to house and protect the electrical contact units and sensor element.
Data Source
AI summary
A sensor device for a steering system of a vehicle includes a sensor housing accommodated within a housing pot and including a first central recess defining an axis and receiving a shaft of the steering system so as to mount the sensor housing on the shaft. A sensor element is coupled to the shaft and a sensor cover is mounted on the housing pot. The sensor cover includes a second central recess receiving the shaft so as to mount the sensor cover on the shaft. An inner contact unit firmly connected to the sensor cover and electrically contacting the sensor element, the inner contact unit arranged on an inside of the sensor cover and including a connector part axially oriented along the axis. An outer contact unit is firmly connected to the sensor cover on an outside of the sensor cover and electrically connected to the inner contact unit.