Torque Sensor Housing Alignment and Shielding Design
Solution Overview
Problem
Existing torque sensors with individually formed sensor assemblies and stators face alignment errors, increased manufacturing costs due to separate coupling members, and size issues from separating the sensor assembly and electronic control unit to avoid high current interference.
Innovation Solution
A torque sensor design with a housing that includes a protrusion and groove for alignment, a slot for substrate fixation without additional coupling members, and a back yoke to block high currents, reducing product size and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensor assembly and stator are individually formed, then the manufacturing flexibility is improved, but the alignment precision between the stator and collector deteriorates
Solution Approach 1:
The housing serves as an intermediary component that integrates both the sensor assembly and stator, ensuring precise alignment between the collector and stator through the housing's structural design. This eliminates alignment errors while maintaining the individual formation benefits of sensor assembly and stator.
Solution Approach 2:
The housing merges the sensor assembly and stator into a single integrated structure, ensuring that the collector and stator are precisely aligned through the housing's inherent design. This combining approach maintains manufacturing flexibility while achieving accurate alignment.
2Reliability
If the substrate and housing are fixed using a separate coupling member, then the fixation reliability is improved, but the device complexity increases
Solution Approach 1:
The substrate fixing structure is merged with the housing, eliminating the need for separate coupling members. The housing itself provides the fixing function through its structural design, thereby maintaining fixation reliability while reducing device complexity.
Solution Approach 2:
The housing performs multiple functions: it provides structural support, ensures alignment between components, and fixes the substrate in place. This multi-functionality eliminates the need for separate coupling members, reducing complexity while maintaining reliability.
3Reliability
If the sensor assembly and ECU are spaced apart and connected through a wire harness, then the high current interference is avoided, but the product size increases
Solution Approach 1:
The ECU is merged with the sensor assembly into a single integrated unit. The housing provides physical separation and shielding between the high current ECU components and the sensitive sensor components, allowing close integration without wire harnesses while maintaining signal accuracy and reducing product size.
Solution Approach 2:
The housing acts as an intermediary that provides physical separation and electromagnetic shielding between the ECU and sensor assembly. This allows the components to be integrated closely without direct connection, eliminating the need for wire harnesses while maintaining signal integrity and minimizing product size.
4Volume of moving object
If the ECU and sensor assembly are integrated closely, then the product size is reduced, but the high current negatively affects sensor performance
Solution Approach 1:
The housing serves as an intermediary that provides physical separation and electromagnetic shielding between the high current ECU and the sensitive sensor assembly. This allows close integration for compact size while the housing structure blocks harmful electromagnetic interference from affecting sensor performance.
Solution Approach 2:
The sensitive sensor components are extracted and placed in a separate compartment within the housing, isolated from the high current ECU components. This spatial extraction allows close integration while protecting the sensor from electromagnetic interference through the housing's structural design.
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
Improves torque measurement accuracy, simplifies manufacturing, reduces defects, and minimizes product size by securing alignment and blocking high current interference.
Implementation Method 1
a sensor assembly configured to measure a magnetic field generated between the rotor and the stator
Implementation Method 2
the housing includes a protrusion which faces the stator, wherein the stator includes a groove, wherein the protrusion is disposed in the groove
Implementation Method 3
a back yoke to block high currents, reducing product size and manufacturing complexity
Data Source
AI summary
The present invention may provide a torque sensor comprising, a rotor, a stator disposed outside the rotor; a sensor assembly configured to measure a magnetic field generated between the rotor and the stator; and a housing, the rotor and the stator are disposed outside the housing, the sensor assembly is disposed inside the housing, wherein the housing includes a protrusion which faces the stator, wherein the stator includes a groove, wherein the protrusion is disposed in the groove.