Throttle Actuator Force Sensing for Cable Sticking Verification

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Solution Overview

Problem

Vehicles operating in harsh conditions, such as snowmobiles, ATVs, and watercrafts, face issues with throttle systems becoming stuck due to environmental interactions, leading to unintended throttle operation and potential safety hazards.

Innovation Solution

A throttle articulation verification system integrated with a throttle lever, including sensors to verify operator presence and force application, which sends signals to the engine control unit (ECU) to confirm intended throttle movement, and includes a spring mechanism to detect cable sticking, triggering a limp mode if necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a throttle system is operated in harsh environments, then the vehicle can function in various conditions, but the throttle components may stick leading to unintended operation

Engineering Contradiction:

Improvevehicle operation in harsh conditionsVSAvoidthrottle operation reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The verification system performs preliminary detection of throttle actuator position and operator presence before allowing engine operation. This prevents unintended throttle operation by verifying the system state in advance, addressing the reliability issue while maintaining adaptability to harsh environments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors throttle actuator position via sensors and provides feedback to the control unit. This closed-loop feedback mechanism detects sticking conditions and verifies intended operation, resolving the contradiction between operating in harsh environments and maintaining reliable throttle control.

Inventive Principle:

Principle #23Feedback

2Reliability

If a verification system with multiple sensors is added, then throttle operation safety is improved, but device complexity increases

Engineering Contradiction:

Improvethrottle operation safetyVSAvoidverification system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The verification system uses a multi-functional approach where sensors serve multiple purposes: detecting operator presence, verifying throttle actuator position, and monitoring for sticking conditions. This consolidates safety functions into a unified system, improving reliability without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The control unit acts as an intermediary that processes signals from multiple sensors and coordinates the verification logic. This centralizes the complexity in a single processing unit rather than distributing it across multiple independent systems, making the overall system more manageable while maintaining high safety standards.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If force sensors are integrated into the throttle actuator, then cable sticking detection is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecable sticking detection accuracyVSAvoidthrottle actuator manufacturing

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The force sensors are integrated directly into the throttle actuator assembly, merging the sensing function with the actuator structure. This consolidation improves manufacturing efficiency compared to separate sensor installations, while maintaining high measurement precision for detecting cable sticking conditions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Traditional mechanical cable tension indicators are replaced with electronic force sensors that provide precise digital measurements. This substitution improves detection accuracy while the integration into the actuator assembly minimizes the increase in manufacturing complexity through standardized sensor mounting procedures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Ensures safe and reliable throttle operation by detecting cable sticking and adjusting engine performance to prevent unintended throttle positions, enhancing vehicle safety and control.

Implementation Method 1

A spring plate is disposed between the carrier and the circuit board. The spring plate is adjacent to and extends between the first force sensor and the second force sensor.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20260015063A1Throttle actuator position verification

Publication Date: 2026.01.15 POLARIS IND INC

AI summary

A throttle actuator includes a base, a carrier and a circuit board coupled between the base and the carrier. The circuit board has a first force sensor and a second force sensor. A spring plate is disposed between the carrier and the circuit board. The spring plate is adjacent to and extends between the first force sensor and the second force sensor. A cover is coupled to the base enclosing the carrier, the spring plate and the circuit board between the cover and the base.