Steering Sensor Assembly Single Carrier Magnetic Coding
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Solution Overview
Problem
Existing motor vehicle steering systems face challenges in providing reliable, compact, and cost-effective sensor data for steering torque and angle, particularly in cramped spatial conditions, where traditional solutions require multiple carrier members and complex initialization processes.
Innovation Solution
A sensor assembly that integrates a torque sensor and a rotational angle sensor using a single magnetically coded carrier member, allowing for compact and cost-effective design, with a counting mechanism to determine absolute steering angles beyond 360 degrees without continuous power supply, enabling efficient data collection and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple carrier members with magnetic coding are used for torque and angle sensing, then measurement reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple carrier members with magnetic coding into a single integrated carrier member that serves both torque sensing and absolute angle sensing functions. This merging reduces the number of components while maintaining the reliability of sensor data through redundant magnetic coding patterns on the same carrier structure.
Solution Approach 2:
The single carrier member is designed with multiple magnetic coding patterns that serve different sensing purposes simultaneously - one pattern for torque determination and another for absolute angle determination. This multi-functionality allows one component to replace what would traditionally require multiple separate components.
2Reliability
If multiple carrier members with magnetic coding are used for torque and angle sensing, then measurement reliability is improved, but manufacturing cost increases
Solution Approach 1:
By merging multiple carrier members into one, the patent reduces manufacturing steps, assembly operations, and material costs. The single carrier member can be manufactured as one integrated component rather than requiring separate manufacturing and assembly of multiple identical components.
Solution Approach 2:
The universal carrier member design allows a single manufacturing process to produce a component that performs multiple sensing functions, eliminating the need for separate manufacturing lines or assembly steps for different carrier members, thereby reducing overall manufacturing cost.
3Measurement precision
If traditional sensor systems are used, then absolute steering angle can be determined, but initialization processes become complex and time-consuming
Solution Approach 1:
The magnetic coding patterns on the carrier member are pre-configured to provide reference information that enables immediate determination of absolute steering angle without requiring runtime initialization. The counting mechanism is pre-programmed with the magnetic coding structure, allowing direct calculation of absolute position from the measured angle and segment count.
Solution Approach 2:
The sensor system uses the magnetic coding on the carrier member to self-determine absolute steering angle without external initialization signals or complex calibration procedures. The counting mechanism automatically tracks angular segments and calculates absolute position based on the predefined magnetic pattern, making the system self-sufficient.
4Volume of moving object
If compact sensor design is implemented, then spatial requirements are reduced, but sensor reliability may deteriorate
Solution Approach 1:
By merging torque sensing and angle sensing into a single integrated sensor assembly with one shared carrier member, the patent achieves compact design while maintaining reliability through the redundant magnetic coding patterns that provide multiple measurement pathways within the compact structure.
Solution Approach 2:
The patent implements a nested structure where the magnetic coding patterns are integrated into the carrier member itself, and the sensing elements are positioned within the magnetic field generated by the rotating carrier. This nesting allows multiple sensing functions to occupy overlapping spatial volumes, achieving compactness without sacrificing measurement reliability.
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
The solution provides precise and reliable sensor data for steering systems, ensuring high failure safety and reduced manufacturing costs, with the ability to determine absolute steering angles accurately and efficiently, even in de-energized conditions, without the need for complex initialization or continuous power.
Implementation Method 1
a torque sensor for magnetically determining a steering torque
Implementation Method 2
a rotational angle sensor for magnetically determining an absolute steering angle, in particular relating to an absolute angular position
Data Source
AI summary
A sensor assembly for motor vehicle steering systems, having a torque sensor for magnetically determining a steering torque, and a rotational angle sensor for magnetically determining an absolute steering angle, precisely one carrier member being provided which has a magnetic coding for determining the steering torque and the absolute steering angle and which is shared by the torque sensor and the rotational angle sensor.