Throttle Control Cartridge Double Cam Redundant Stop
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Solution Overview
Problem
Existing throttle control systems for vehicles face challenges in achieving a balanced feel for throttle operation while ensuring a redundant stop mechanism for safety, particularly in confined spaces, where traditional stops provide a limited safety factor and require a fine-tuned balance between spring force and cam angle.
Innovation Solution
A throttle control cartridge with a Hall-effect sensor and magnet configuration, featuring unique cam and cam follower surfaces at different helix angles, and axially extending splines for a redundant stop mechanism that limits maximum angular rotation, providing enhanced safety and control through spline engagement members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional stop mechanism is used for throttle control, then the structure is simple, but the safety factor is limited and the throttle feel cannot be balanced with the off-throttle position
Solution Approach 1:
The stop mechanism is segmented into a primary stop and a redundant stop positioned at different locations. The primary stop provides the main throttle limiting function, while the redundant stop engages only if the primary stop fails, thereby increasing the safety factor without requiring complete redesign of the entire stop mechanism.
Solution Approach 2:
The redundant stop is positioned to engage before the throttle can exceed safe limits in the event of primary stop failure. This beforehand cushioning ensures that even if the primary stop fails, the throttle cannot reach dangerous positions, providing a safety buffer that increases reliability.
2Reliability
If a cam with steep angle is used to stop throttle return force, then the off-throttle position is achieved, but the off-throttle force becomes too high making it difficult to control
Solution Approach 1:
Different segments of the cam profile have different angles optimized for different functions. The cam has a first portion with a steeper angle for effective off-throttle positioning and a second portion with a gentler angle for smoother throttle control during normal operation, allowing each local region to optimize for its specific function.
Solution Approach 2:
The cam profile is designed with dynamically varying angles rather than a uniform steep angle. The cam transitions between different angular sections depending on the throttle position, providing high stopping force only when needed for off-throttle control while maintaining ease of operation during normal throttle manipulation.
3Volume of moving object
If the packaging area is reduced for compact design, then the device size is minimized, but the space for redundant stop mechanism is constrained
Solution Approach 1:
The redundant stop mechanism is nested within the existing cartridge structure, utilizing space within the hollow shaft or internal cavities. The redundant stop components are positioned concentrically or adjacently to primary stop elements, allowing both stop mechanisms to coexist within the compact cartridge volume without significantly increasing overall dimensions.
Solution Approach 2:
The redundant stop mechanism utilizes a different spatial dimension or orientation compared to the primary stop. Instead of extending the cartridge lengthwise, the redundant stop is positioned radially or axially within the existing footprint, effectively using three-dimensional space efficiently to accommodate both stop mechanisms in a compact arrangement.
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 enables precise throttle control and safety by ensuring a redundant stop mechanism that maintains control even if primary stops fail, while providing a balanced feel and improved safety in compact designs.
Implementation Method 1
A throttle control cartridge includes a first member carrying a Hall-effect sensor; a second member carrying a magnet
Data Source
AI summary
A throttle control cartridge has a circuit board carrying a Hall-effect sensor, the position of which is fixed in a housing carrying a cam. A shaft carrying a magnet is rotatably and translatably disposed with respect to the housing and carries a cam follower that engages the cam and translates the shaft with respect to the housing when the shaft is rotated with respect to the housing in at least one of two opposed angular directions. The cam and the cam follower have at least first and second pairs of cam surfaces in which a first cam surface is disposed at a different cam or helix angle then the second cam surface. A redundant stop is cooperatively formed between the cam follower and splines on the shaft to limit axial translation of the cam follower in one direction of rotation of the shaft relative to the housing.