Steering Angle Sensor Gear Failure Detection Using Hall Angle Differences

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Solution Overview

Problem

Current steering angle sensor systems fail to effectively detect failures due to gear deformation or damage, leading to incorrect angle information and potential misalignment of meshing between the main gear and sub gears, which can result in wrong steering angle identification.

Innovation Solution

An apparatus and method that utilize a controller to identify failures by calculating angle differences between the main gear and sub gears over time, counting instances where these differences exceed preset thresholds, and summing these counts to determine if the sensor fails due to tooth damage or gear damage, thereby providing a more accurate detection of gear-related issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional failure detection methods are used, then algorithm errors and noise can be detected, but gear deformation or damage cannot be effectively detected

Engineering Contradiction:

Improvefailure detection capabilityVSAvoidgear damage detection accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical inspection methods with magnetic field-based Hall IC chip sensing to detect gear position and angle changes. By using magnetic field detection instead of mechanical measurement, the system can accurately identify gear deformation and damage through angle discrepancy analysis between main gear and sub gears.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent monitors changes in angular parameters over time by comparing the rotation angles of main gear and sub gears. By analyzing the rate of change and discrepancy in these angular parameters, the system can detect gear deformation and damage that conventional static methods would miss.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If gear meshing precision is maintained, then steering angle accuracy is improved, but gear damage cannot be detected

Engineering Contradiction:

Improvesteering angle accuracyVSAvoidgear failure detection

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent implements a feedback mechanism where the controller continuously monitors the angular relationship between main gear and sub gears, compares it against expected values, and provides feedback to detect deviations indicating gear damage. This closed-loop monitoring enables simultaneous maintenance of meshing precision and detection of failures.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary detection of gear damage by monitoring angle discrepancies before they cause complete failure. By continuously checking the rotational relationship between gears, the system can identify early signs of deformation or tooth damage and alert before catastrophic failure occurs.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If angle information is continuously monitored, then gear damage can be detected, but system complexity increases

Engineering Contradiction:

Improvegear damage detectionVSAvoiddetection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The Hall IC chips serve multiple functions: they detect both the position and rotational angle of sub gears, providing data for both normal steering operation and failure detection. This multi-functionality reduces the need for separate detection systems and minimizes overall system complexity while maintaining high reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The existing angular position data from the Hall IC chips, which is already collected for normal steering angle measurement, is reused for failure detection purposes. The system performs self-diagnosis by analyzing its own operational data, eliminating the need for additional sensors or complex external monitoring systems.

Inventive Principle:

Principle #25Self-service

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 approach allows for more effective detection of gear deformation or damage in steering angle sensors, reducing the likelihood of incorrect angle information and improving the reliability of steering systems by identifying failures based on quantifiable angle discrepancies.

Implementation Method 1

a first Hall IC chip and a second Hall IC chip each detecting a change in a magnetic field emitted to a corresponding one of the magnets

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS12172709B2Failure detection device for steering angle sensor, and control method therefor

Publication Date: 2024.12.24 HL MANDO CORP

AI summary

A failure detection device for a steering angle sensor according to an embodiment comprises: a steering angle sensor including a main gear that rotates together with a steering wheel, a first sub-gear and a second sub-gear that are each engaged with the main gear and have a constant gear ratio with the main gear, a first Hall IC chip for detecting the angle of the first sub-gear, and a second Hall IC chip for detecting the angle of the second sub-gear; and a control unit that determines failure of the steering angle sensor on the basis of a first angle difference between the current angle and a previous angle of the first sub-gear as detected by the first Hall IC chip, and a second angle difference between the current angle and a previous angle of the second sub-gear as detected by the second Hall IC chip.