Motor-Driven Throttle Valve Compact Gear Cover Design
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Solution Overview
Problem
Conventional motor-driven throttle valve devices with inductive throttle sensors face challenges in installation due to increased dimensions in the short-axis direction, making them difficult to fit in narrow engine rooms.
Innovation Solution
The design reconfigures the sensor connection conductor sections to be decentralized on both sides of retainers, allowing for a more compact gear cover by positioning the sensor circuit between the exciting coil and retainers, and aligning connector terminals horizontally to reduce thickness and improve noise immunity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the connector and sensor connection conductor sections are mounted on one lateral surface side of the circuit board, then the electrical connection is simplified, but the dimension of the cover in the short-axis direction increases
Solution Approach 1:
The patent distributes connector terminals and sensor connection conductor sections along the long-axis direction of the circuit board rather than concentrating them on one lateral surface. This dimensional redistribution allows electrical connections to be made along the length of the board, reducing the required width (short-axis dimension) of the cover while maintaining all necessary electrical connections.
Solution Approach 2:
The patent segments the electrical connection components by separating connector terminals and sensor connection conductor sections into different locations along the long-axis direction of the circuit board. This segmentation allows for a more optimized spatial arrangement that reduces the cover's short-axis dimension while preserving electrical connection functionality.
2Volume of moving object
If the cover dimension in the short-axis direction is reduced, then installation in narrow engine rooms becomes feasible, but the arrangement of connector terminals and sensor connection conductor sections becomes more difficult
Solution Approach 1:
The patent compensates for the reduced short-axis dimension by utilizing the long-axis direction of the circuit board for arranging connector terminals and sensor connection conductor sections. This dimensional shift allows sufficient spacing for assembly operations while maintaining a compact cover width suitable for narrow engine room installation.
Solution Approach 2:
The circuit board is designed with pre-defined connector terminal positions and sensor connection conductor section layouts along the long-axis direction before assembly. This preliminary configuration simplifies the assembly process by eliminating the need for complex routing and positioning operations during installation, making the compact design manufacturable.
3Length of stationary object
If the sensor circuit is positioned near the connector, then the connection length is reduced, but electrical interference from the motor increases
Solution Approach 1:
The patent introduces the gear cover as a shielding intermediary between the sensor circuit and motor. The gear cover, positioned between these components, provides electromagnetic shielding that blocks interference from the motor while allowing the sensor connection conductor to maintain a reasonable length for reliable electrical connection.
Solution Approach 2:
The patent implements localized electromagnetic shielding using the gear cover in the specific region where the sensor circuit is positioned. This localized shielding approach provides protection against motor interference at the critical sensor location without requiring comprehensive shielding throughout the entire device, maintaining a balance between interference protection and design simplicity.
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 configuration reduces the overall dimension of the gear cover in the short-axis direction, enhancing installation efficiency and reducing the risk of electrical interference, while maintaining accurate rotation angle detection.
Implementation Method 1
a sensor circuit which is mounted on the circuit board to detect a change in the inductance between the excitation conductor and the receiver coil and determine the rotation angle of the throttle shaft
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to a throttle valve device comprising: a throttle body (3) which has an intake path (1); a motor (2) which is mounted in the throttle body (3); an output gear (13) which is fastened to a rotor shaft (4) of the motor (2); a throttle shaft (4) which rotates in the intake path (1); a final stage gear (10) which is fastened to the throttle shaft (4); a rotor (17) which is fastened to the throttle shaft (4); an intermediate gear (15) which meshes with the output gear (13) and the final stage gear (10); a throttle valve (8) which is fastened to the throttle shaft (4); a gear cover (20) which covers the output gear (13), the final stage gear (10) and the intermediate gear (15) and is made by resin; a retainer (15C, 20C, 20D) which is positioned on the gear cover (20) to prevent the axial separation of the intermediate gear (15); a connector (20B) which is mounted on the gear cover (20); a plurality of connector terminals (201-206) mounted on the connector (20B); a circuit board (18) which is mounted on the gear cover (20); a sensor circuit (18B) which is mounted on the circuit board (18) and positioned to face the intermediate gear (15); a detector (TPS) that detects the rotational position of the throttle shaft (4) and is provided on the circuit board (18) and positioned to face the rotor (17); and a plurality of sensor connection conductor sections (21) which are disposed along one side of the circuit board (18) to connect the connector terminals (201-206) to the sensor circuit (18B), wherein the sensor connection conductor sections (21) are insert-molded into the gear cover (20) and are disposed on both sides of the retainer (15C, 20C, 20D).