Throttle Position Sensor Assembly Press-Fit Integration
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Solution Overview
Problem
Existing throttle position sensor systems are costly and time-consuming due to the complex and costly process of attaching detectable elements to the throttle plate shaft, which requires precise angular, radial, and axial alignment to prevent inaccurate readings or system failure, often involving difficult and expensive laser welding that can also warp materials.
Innovation Solution
A press-fit method is used to integrate a sensor element onto the throttle plate shaft, with inwardly extending members engaging recesses on the shaft, and an inductive rotary position sensor detects the sensor element's position to determine the throttle plate's position, utilizing a cold forming process to prevent deformation and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is used to attach the detectable element to the throttle plate shaft, then the attachment strength is improved, but the manufacturing cost and time increase significantly
Solution Approach 1:
The patent replaces the thermal laser welding process with a mechanical press-fit attachment system. The detectable element is attached to the throttle plate shaft through a press-fit connection where the element is pressed onto the shaft, creating a secure mechanical bond without requiring laser welding equipment or thermal processes. This substitution eliminates the complexity and cost associated with laser welding while maintaining adequate attachment strength for the application.
2Reliability
If laser welding is used to attach the detectable element, then the attachment is secure, but material warping occurs due to heat generation
Solution Approach 1:
The patent eliminates the thermal process of laser welding and replaces it with a cold mechanical press-fit attachment method. The detectable element is secured to the throttle plate shaft through mechanical pressure and interference fit, completely avoiding heat generation. This prevents thermal distortion and warping of the detectable element, throttle plate shaft, or surrounding components while still achieving reliable attachment.
3Measurement precision
If precise angular and radial alignment is ensured during detectable element attachment, then sensor reading accuracy is improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent incorporates alignment features directly into the detectable element and throttle plate shaft design before the attachment process. The detectable element includes radial alignment features such as positioning ribs or keys that mate with corresponding features in the shaft, automatically establishing the correct angular and radial orientation during the press-fit operation. This preliminary design of alignment features eliminates the need for complex post-attachment alignment procedures or specialized alignment equipment.
4Reliability
If the detectable element is securely attached to prevent positional movement, then sensor reliability is improved, but the attachment process becomes more difficult and costly
Solution Approach 1:
The patent designs the detectable element with a nested structure where an inner cylindrical portion is press-fit onto the throttle plate shaft, and an outer cylindrical portion extends radially outward to engage with the sensor. This nested configuration allows the element to be securely anchored to the rotating shaft while maintaining the proper geometric relationship with the sensor. The nested design inherently provides both radial and axial positioning, preventing movement without requiring additional complex fastening operations.
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
This method provides a reliable, cost-effective, and efficient attachment of the throttle position sensor, ensuring accurate readings without the need for expensive and complex laser welding, while maintaining sensor stability and preventing material deformation.
Implementation Method 1
an inductive rotary position sensor detects a position of the sensor element for determining a position of the throttle plate
Data Source
AI summary
Throttle body assemblies having improved throttle position sensing assemblies and a method of integrating a throttle position sensor assembly with a throttle body assembly are described. The method comprises the steps of: i) press-fitting a sensor element onto a shaft of a throttle plate of a throttle body assembly; ii) engaging one or more inwardly extending members of the sensor element with one or more recessed portions formed on the shaft of the throttle plate; and iii) disposing an inductive rotary position sensor proximate the sensor element, wherein the press-fit engagement and one or more inwardly extending members limit axial and rotational movement of the sensor element with respect to the throttle plate, and wherein the inductive rotary position sensor detects a relative position of the sensor element for the purpose of ascertaining a position of the throttle plate.