Non-Contact Steering Torque Sensor Modular Rotor Design
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Solution Overview
Problem
Conventional torque sensors for vehicle steering systems have complex configurations with numerous components, leading to increased production costs, labor-intensive assembly, and reduced durability due to frequent rotor rotation, as well as requiring the replacement of all parts when one component fails.
Innovation Solution
A non-contact angle/torque sensor design featuring a separable upper and lower rotor configuration with magnet pockets and extensions, allowing for independent servicing and replacement of components like flux collectors without affecting the entire system, reducing customer support costs and simplifying maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate retention features with fasteners are provided between the rotor and gear to fix them, then the rotor and gear can be securely fixed, but the number of components increases and production cost is increased
Solution Approach 1:
The rotor and gear are merged into a single integrated component, eliminating the need for separate retention features and fasteners. This integration reduces the number of components while maintaining secure fixing through the unified structure of the rotor gear assembly.
2Strength
If separate retention features with fasteners are provided between the rotor and gear, then the rotor and gear can be fixed together, but the assembly operation becomes inconvenient and difficult, requiring additional labor and assembly time
Solution Approach 1:
By integrating the rotor and gear into one component, the assembly process is simplified as fewer parts need to be installed and secured. This eliminates the labor-intensive process of installing multiple fasteners and retention features, thereby improving assembly efficiency and productivity.
3Strength
If fasteners and retention features are provided between the rotor and gear, then the rotor and gear can be fixed, but the fasteners can be easily damaged due to frequent rotor rotation, reducing the durability of the sensor
Solution Approach 1:
The integration of rotor and gear eliminates fasteners and retention features that are susceptible to damage from frequent rotation. The unified structure has no separate joining elements to fail, thereby improving the overall durability and reliability of the sensor under continuous operational conditions.
4Reliability
If replacement of one component requires removal of all parts ( rotor, stator, sensor package), then the components can be replaced as a unit, but additional repair expense and labor requirements are incurred
Solution Approach 1:
The sensor is divided into separable modules ( rotor assembly, stator assembly, sensor package) that can be independently removed and replaced. This modular segmentation allows replacement of individual components without requiring removal of all parts, reducing repair complexity and labor requirements while maintaining system 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 design enhances maintenance efficiency, reduces production costs, and improves durability by enabling the replacement of specific components rather than the entire sensor, thus lowering repair expenses and increasing productivity.
Implementation Method 1
an upper rotor of the non-contact angle/torque sensor which is formed in an annular shape having a central axis, and in which magnets are located
Data Source
AI summary
A non-contact angle/torque sensor comprises an upper rotor in an annular shape having a central axis, and in which magnets are located, the magnets positioned within the annular shape around the central axis with the north and the south poles of adjacent magnets being oriented opposite to one another, and a lower rotor in an annular shape and sharing the central axis of the upper rotor, and located spaced outwardly from an outer circumferential surface of the upper rotor. The lower rotor has upper and lower stators spaced apart along the central axis. The upper stator has upper and lower backplanes and a series of upper and lower extensions extending from the respective backplanes. The upper extensions and the lower extensions are not intermeshed or overlapped.