Torque Sensor Collector Fixing for Accurate Hall Measurement
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Solution Overview
Problem
Existing torque sensors face issues with collector deformation during fixation to the housing, incorrect positioning, and increased part count leading to assembly complexity and cost, hindering miniaturization.
Innovation Solution
A torque sensor design with a collector having an extension portion that is fixed to the housing via a fixing portion, and a stator with integrated main gear, reducing the need for a separate middle case, ensuring accurate positioning and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the collector is fixed to the housing using thermal fusion or ultrasonic fusion, then the collector can be secured to the housing, but deformation is generated in the collector and magnetization measurement performance is degraded
Solution Approach 1:
The patent replaces thermal fusion or ultrasonic fusion with a mechanical pressing fixation method. The collector is fixed to the housing by pressing it against a pressing surface, eliminating the need for thermal or ultrasonic energy that causes deformation. This mechanical substitution preserves the collector's magnetization measurement performance while achieving reliable fixation.
2Ease of manufacture
If the collector is fixed using thermal fusion or ultrasonic fusion, then the collector can be attached to the housing, but it is not easy to mount the collector at the correct position and managing processes is difficult
Solution Approach 1:
The housing is pre-formed with a pressing surface during manufacturing that defines the exact correct position for the collector. This preliminary preparation of the mounting location eliminates positioning difficulties during assembly, as the collector naturally aligns with the pre-designed pressing surface structure.
Solution Approach 2:
The complex thermal or ultrasonic fusion processes are replaced with a simple mechanical pressing operation. The collector is fixed by pressing it against the pressing surface, which is much easier to control and manage than fusion processes, improving both ease of manufacture and positioning accuracy.
3Reliability
If a separate middle case is provided to maintain engagement between main gear and sub gear, then gear engagement is maintained, but the number of parts is increased and assembly process is added
Solution Approach 1:
The patent merges the middle case with the housing into a single integrated structure. The housing is designed to directly maintain engagement between the main gear and sub gear without requiring a separate middle case. This merging reduces the number of parts and simplifies the assembly process while maintaining reliable gear engagement through the integrated housing design.
4Stability of the object's composition
If a separate middle case is provided to maintain gear engagement, then the structure is stable, but coping with miniaturization demand is difficult
Solution Approach 1:
By merging the middle case function into the housing, the patent eliminates an additional structural layer that would increase the overall sensor size. The integrated housing design maintains structural stability for gear engagement while reducing the total volume, enabling the sensor to meet miniaturization demands.
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 design prevents collector deformation, enhances measurement performance, simplifies assembly, and enables miniaturization by integrating the main gear with the stator, improving sensing capability and reducing production costs.
Implementation Method 1
a Hall sensor disposed on the circuit board, and a collector disposed adjacent to the Hall sensor
Data Source
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AI summary
An embodiment can provide a torque sensor comprising: a housing; a rotor that is arranged inside the housing; a stator that is arranged on an outer side of the rotor; a circuit board that is arranged in the housing; a Hall-effect sensor that is arranged on the circuit board; and a collector that is arranged adjacent to the Hall-effect sensor, wherein the collector includes a body portion and an extension portion extending from the body portion, the body portion is arranged to be spaced apart from the housing, and the extension portion is directly in contact with the housing.