Target Wheel Sensor Tab Groove Design
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Solution Overview
Problem
Existing target wheels in camshaft phaser assemblies are prone to deformation and have brittle or weak sensor tabs with large radii, leading to inaccurate or delayed readings by position sensors due to handling issues during installation.
Innovation Solution
A method of forming sensor tabs with a medial flange and axially extending edges, where a groove is created in the inner corner to redistribute material, reducing the outer corner radius and enhancing sensor tab thickness for improved sensor detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rolled edges are used for sensor tabs, then manufacturing is simplified, but the outer corner radius becomes large causing delayed sensor readings
Solution Approach 1:
The patent applies local quality by creating a groove at the inner corner of the sensor tab, which locally redistributes material to reduce the outer corner radius. This localized modification improves sensor reading accuracy without changing the overall manufacturing process or other parts of the sensor tab structure.
2Force
If target wheels are formed from bent sheet metal to reduce pressing forces, then pressing forces are reduced, but the target wheels become prone to deformation and handling issues
Solution Approach 1:
The patent changes the geometric parameters of the sensor tab by adding a groove at the inner corner, which redistributes material and reduces the outer corner radius. This parameter change strengthens the sensor tab structure, making it more resistant to deformation during handling while maintaining the bent sheet metal construction that reduces pressing forces.
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 results in a more reliable and accurate reading by the sensor, reducing delays in detecting the angular position of the camshaft phaser rotor, as the thicker outer corner profile provides a quicker and more precise detection.
Implementation Method 1
The groove formation results in material of the sheet metal body being forced from the inner corner to the outer corner, resulting in a smaller radius for the curvature defined by the outer corner
Data Source
AI summary
A method of forming a target wheel for a camshaft phaser assembly is disclosed. The method includes providing a sheet metal body, and stamping the sheet metal body to form a sensor tab. The sensor tab includes a medial flange positioned between first and second axially extending edges. The sensor tab includes: at least one inner corner defined between the medial flange and at least one of the first axially extending edge or the second axially extending edge, and at least one outer corner defined between the medial flange and at least one of the first axially extending edge or the second axially extending edge. The method includes forming a groove in the at least one inner corner.