Torque-Angle Sensor Top Cover Integration
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Solution Overview
Problem
Existing torque-angle sensors for vehicles require complex mounting processes due to multiple components, increasing costs and reducing assembly efficiency.
Innovation Solution
A torque-angle sensor design featuring a top cover with a second fitting part that integrates with the system casing, eliminating the need for a separate system top cover and transfer connector, thereby simplifying the mounting process and reducing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate system top cover and transfer connector are used to protect the torque-angle sensor and transmit signals, then the sensor is protected and signals are transmitted, but the number of components increases and the mounting process becomes complex
Solution Approach 1:
The patent combines the system top cover and transfer connector into a single integrated top cover assembly. The top cover includes an input transfer connector and an output transfer connector that are built-in, eliminating the need for separate protective covers and connectors. This merging reduces the number of components while maintaining the protection and signal transmission functions.
Solution Approach 2:
The top cover serves multiple functions simultaneously: it protects the torque-angle sensor, provides electrical connection through built-in connectors, and transmits signals. By making the top cover multi-functional, the patent eliminates the need for separate dedicated components for each function, thereby reducing overall system complexity.
2Reliability
If multiple separate components are used for mounting the torque-angle sensor, then the sensor is protected and connected, but the mounting process time increases and assembly efficiency decreases
Solution Approach 1:
The patent merges the protective cover and signal transmission connectors into a single integrated top cover assembly that can be installed in one step. This reduces the number of assembly operations required while ensuring both protection and electrical connection are achieved simultaneously, thereby improving assembly efficiency without compromising reliability.
3Adaptability or versatility
If multiple separate components are used in the torque-angle sensor system, then the functions are fulfilled, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple functional components (protective cover, input connector, output connector) into a single integrated top cover assembly. This reduces the total number of parts that need to be manufactured, stored, and assembled, thereby lowering manufacturing costs while maintaining all necessary functional capabilities of the sensor system.
Solution Approach 2:
The top cover is designed to perform multiple functions (protection, signal input, signal output) simultaneously. By making a single component multi-functional, the patent reduces the total component count and associated manufacturing costs while preserving the full functional capability of the system.
Data Source
AI summary
A torque-angle sensor is mounted on a steering column with a system casing and configured to detect a steering torque and angle of steering wheel steering of a vehicle. The torque-angle sensor includes a top cover, a torque sensing unit, an angle sensing unit, a PCB, a signal output terminal, and a sensor casing. The top cover includes a body, a first fitting part, and second fitting part. The first fitting part is a flange extending from the body towards the sensor casing, and fitted to the sensor casing. The second fitting part is a flange extending in a radial direction and/or axial direction of the body, and fitted to the system casing. In a radial direction of the body, a distance between the second fitting part and a center of the body is greater than a distance between the first fitting part and the center of the body.