Torque Sensor Axial Insertion for Surface-Mount Magnetic Sensors
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Solution Overview
Problem
The existing torque sensor technology, as described in PTL 1, faces challenges in disposing a surface-mount magnetic sensor between adjacent magnetic collection rings due to terminal extensions and magnetic sensor configurations, which restricts the placement of the sensor between the rings.
Innovation Solution
A torque sensor design that includes a rotational member with a torsion bar connecting two shafts, featuring circular-arc shaped magnetic collection mechanisms and surface-mount magnetic sensors with Hall elements, allowing the sensors to be inserted between the collection mechanisms along the rotational axis, enabling accurate torque detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a surface-mount magnetic sensor is used, then the sensor can be mounted on a substrate with terminals extending in both directions, but the sensor cannot be disposed between the magnetic collection rings due to terminal extension constraints
Solution Approach 1:
The patent changes the insertion direction from radial (between magnetic collection rings) to axial (through the input shaft). The magnetic sensor is inserted along the rotational axis direction, allowing the substrate to pass through a through-hole in the input shaft and position the sensor between the magnetic collection rings without being constrained by radial terminal extensions
2Adaptability or versatility
If the terminal extends from the detection portion to one side only, then the sensor can be disposed between magnetic collection rings, but a surface-mount magnetic sensor with bidirectional terminals cannot be used
Solution Approach 1:
The patent utilizes the axial dimension by extending terminals in both directions perpendicular to the detection portion surface, allowing the substrate to be inserted axially through the input shaft. This bidirectional terminal configuration enables surface-mount sensors to be mounted on the substrate and positioned between magnetic collection rings via axial insertion rather than radial placement
3Measurement precision
If the magnetic sensor is disposed between adjacent magnetic collection rings, then torque detection is enabled, but the sensor substrate size and complexity increase
Solution Approach 1:
The patent reduces substrate complexity by changing the insertion approach from radial to axial. The substrate is inserted through a through-hole in the input shaft along the rotational axis, allowing a more compact substrate design that positions the magnetic sensor between magnetic collection rings without requiring complex radial terminal extensions or large substrate areas
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 allows for precise detection of torque by minimizing magnetic resistance and improving the accuracy of magnetic field strength measurement, while also reducing the size and complexity of the sensor substrate, preventing short-circuiting, and enhancing assembly strength.
Implementation Method 1
a surface-mount first magnetic sensor and second magnetic sensor inserted between the first magnetic collection mechanism and the second magnetic collection mechanism and including a Hall element configured to detect a change in a magnetic field between the first magnetic collection mechanism and the second magnetic collection mechanism
Data Source
AI summary
Provided is a torque sensor that allows a surface-mount magnetic sensor to be disposed between magnetic collection rings adjacent to each other in a radial direction with respect to a rotational axis. A torque sensor includes a rotational member including a first shaft and a second shaft connected to each other via a torsion bar, a first magnetic collection mechanism and a second magnetic collection mechanism each formed into a circular-arc shape along a direction around a rotational axis of the rotational member with use of a magnetic material and disposed so as to face each other in a radial direction of the rotational member, a surface-mount first magnetic sensor and second magnetic sensor inserted between the first magnetic collection mechanism and the second magnetic collection mechanism and each including a Hall element configured to detect a change in a magnetic field between the first magnetic collection mechanism and the second magnetic collection mechanism, and a sensor substrate on which the first magnetic sensor and the second magnetic sensor are mounted. The torque sensor detects a torque generated on the rotational member based on an output signal of the first magnetic sensor or the second magnetic sensor.