Structural Locating Sensor Module with Auxiliary PCBs Under Vibration
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Solution Overview
Problem
Existing torque sensor assemblies face challenges in maintaining precise alignment and electrical connectivity of sensors under vibrational conditions, particularly in vehicular systems like power steering systems.
Innovation Solution
A sensor assembly comprising a sensor module with a main printed circuit board (PCB) and auxiliary PCBs connected via attachment elements and a retainer, which maintains defined positions and electrical connections of sensors using retention members and press-fit pins, allowing for accurate torque measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are mounted on separate auxiliary PCBs for torque measurement, then measurement precision is improved, but maintaining precise alignment and electrical connectivity under vibrational conditions becomes difficult
Solution Approach 1:
The sensor module is divided into multiple auxiliary PCBs, each mounted on separate vibration isolation mounts. This segmentation allows independent positioning of each sensor while maintaining overall structural integrity through the common PCBA platform, resolving the contradiction between measurement precision and alignment stability.
Solution Approach 2:
Vibration isolation mounts serve as intermediary elements between the PCBA and the sensors. These mounts filter out vibrational disturbances before reaching the sensors, enabling precise torque measurement while maintaining reliable alignment under vibrational conditions.
2Measurement precision
If multiple auxiliary PCBs are used to distribute sensors, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Multiple auxiliary PCBs are merged into a single integrated sensor module assembly that functions as one cohesive unit. The auxiliary PCBs are electrically connected and mechanically integrated with the main PCBA, allowing the system to achieve high measurement precision while managing device complexity through unified design and assembly.
Solution Approach 2:
The auxiliary PCBs serve multiple functions: they mount sensors, provide electrical connections, and facilitate vibration isolation. This multi-functionality reduces the need for separate components and simplifies the overall device structure despite using multiple PCBs.
3Measurement precision
If sensors are positioned close to magnetoelastic regions, then measurement precision is improved, but electrical connectivity and alignment become sensitive to vibration
Solution Approach 1:
Vibration isolation mounts act as intermediaries between the sensor mounting structure and the magnetoelastic regions. These mounts provide mechanical isolation that maintains precise alignment and electrical connectivity even when the system experiences vibrational disturbances during operation.
Solution Approach 2:
The vibration isolation mounts are designed beforehand to compensate for expected vibrational disturbances. By pre-positioning the sensors on these isolated mounts, the system maintains measurement precision without requiring extremely tight manufacturing tolerances for alignment.
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 alignment and stable electrical connections of sensors, ensuring reliable torque measurement even under vibrational conditions, enhancing the performance of vehicular systems like power steering systems.
Implementation Method 1
The shaft comprises magnetoelastic regions, the magnetic characteristics of which change in response to the applied torque
Implementation Method 2
A plurality of sensors are disposed adjacent to the shaft, near the magnetoelastic regions, and measure the magnetic fields generated by the magnetoelastic regions
Data Source
AI summary
A sensor assembly for a vehicle including a sensor module having a main printed circuit board (PCB). A plurality of auxiliary printed circuit boards (PCBs) are coupled to the main PCB and electrically connected to the main PCB. Each of the plurality of auxiliary PCBs has at least one sensor that is configured to generate a signal. Each of the plurality of auxiliary PCBs are coupled to each other in a defined position relative to each other. A plurality of attachment elements couple the plurality of auxiliary PCBs and the main PCB to at least partially maintain the defined positions of the auxiliary PCBs relative to each other and to electrically connect the plurality of auxiliary PCBs to the main PCB. A retainer abuts the plurality of auxiliary PCBs.