Torque Sensor Assembly With Flux Conductors for Magnetic Interference
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing torque sensor devices for steering shafts in motor vehicles are susceptible to magnetic interference from external fields, leading to inaccurate torque measurements and are cumbersome to assemble, particularly when flux conductors with additional collecting surfaces are involved.
Innovation Solution
A torque sensor device with pre-assembled housing parts that include the stator arrangement and magnetic sensor, allowing for easy assembly and reduced risk of damage to flux conductors, while incorporating a design that compensates for interference flux using flux conductors with collecting surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flux conductors with additional collecting surfaces are used to compensate for interference flux, then measurement precision is improved, but device complexity increases and assembly becomes more cumbersome
Solution Approach 1:
The device is divided into two pre-assembled modules: a first module containing the housing part, stator arrangement, and magnetic sensor, and a second module containing the flux conductors. This segmentation allows the complex flux conductor assembly to be prepared separately and then integrated, reducing overall assembly complexity while maintaining the interference compensation functionality.
Solution Approach 2:
The flux conductors are pre-assembled with the housing part and stator arrangement before final integration. This preliminary assembly ensures proper positioning and reduces the risk of damage during final assembly, while maintaining the complex geometry needed for interference flux compensation.
2Measurement precision
If flux conductors with additional collecting surfaces are used to compensate for interference flux, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
By separating the flux conductor assembly into a distinct second module that can be pre-assembled and then integrated with the first module, the manufacturing process is simplified. Each module can be manufactured and quality-checked independently before final assembly.
Solution Approach 2:
The housing part serves as an intermediary component that facilitates the integration of the flux conductors. The housing provides a structured interface that simplifies the connection between the pre-assembled modules, making the overall assembly process easier despite the complex geometry of the flux conductors.
3Device complexity
If traditional assembly methods are used, then device complexity is reduced, but risk of damage to flux conductors increases
Solution Approach 1:
The flux conductors are pre-assembled with the housing part and stator arrangement in a controlled manner before final integration. This preliminary assembly allows for careful positioning and securing of the flux conductors, reducing the risk of damage during the final assembly step while maintaining overall assembly simplicity.
Solution Approach 2:
The flux conductor assembly is extracted as a separate second module that can be prepared independently. This extraction allows the flux conductors to be handled and positioned separately from other components, reducing the risk of damage during assembly while keeping the overall device design simple.
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 solution enables precise and easy assembly of the torque sensor device, reducing the impact of external magnetic interference and ensuring accurate torque measurements with a simple, cost-effective design.
Implementation Method 1
the magnet arrangement and the stator arrangement can be moved relative to each other in the circumferential direction about a central axis of the torque sensor device by applying a torque such that a magnetic flux can be generated in the stator arrangement by a relative movement between the magnet arrangement and the stator arrangement in the circumferential direction
Implementation Method 2
the flux conductor arrangement comprises at least one first flux conductor and one second flux conductor and the first flux conductor and the second flux conductor each have at least one transmission surface, wherein the at least one transmission surface of the first flux conductor and the at least one transmission surface of the second flux conductor are positioned opposite each other such that they form an axial gap between them
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a torque-sensor device (10) for sensing a torque applied to a shaft about an axis of rotation of the shaft and also relates to a method for at least partially assembling a torque-sensor device (10), wherein the torque-sensor device (10) has a magnet arrangement (33), a stator arrangement (21, 22, 23, 31, 32), a flux-conductor arrangement (19, 20) and a magnet-sensor arrangement with at least one magnet sensor (16, 17), wherein the magnet arrangement (33) is designed for generating at least one magnetic field and the flux-conductor arrangement (19, 20) has a first flux conductor (19) and a second flux conductor (20), and the first flux conductor (19) and the second flux conductor (20) each have at least one transmission area (26, 26'), which lie opposite one another in such a way that they form an axial gap (S) between them, wherein the torque-sensor device (10) has at least a first subassembly (12, 12') with a first housing part (13) and a second subassembly (11) with a second housing part (18), wherein the first pre-assembled subassembly (12, 12') comprises at least the first housing part (13), the stator arrangement (21, 22, 23, 31, 32) and at least one magnet sensor (16, 17) of the magnet-sensor arrangement, and the second pre-assembled subassembly (11) comprises at least the second housing part (18), the first flux conductor (19) and the second flux conductor (20), and the second housing part (18) can be pushed onto the first housing part (13) and, while it is being pushed on, a magnet sensor (16, 17) can be introduced into the gap (S).