Torque Sensor Device with Integrated Magnet Assembly
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Solution Overview
Problem
Conventional contactless torque sensors for electric power steering systems have complex assembly processes and high manufacturing costs due to numerous constituent elements, which can lead to erroneous operations and reduced durability.
Innovation Solution
A torque sensor device with a simplified structure, comprising a housing, a magnet unit, a collector unit, and a sensing unit, where the collector unit focuses a magnetic field generated by the magnet unit, allowing for accurate detection of torque between input and output shafts through relative rotation displacement, with a collector unit arranged to improve assemblability and reduce material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional contactless torque sensor uses multiple constituent elements (permanent magnet, detection ring with gear structure, sensor), then torque detection function is achieved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines the permanent magnet and detection ring into a single integrated magnet assembly. The magnet assembly includes a permanent magnet and a detection ring with gear structure that are formed as one piece, eliminating the need for separate components and reducing assembly complexity while maintaining the torque detection function through magnetic flux changes.
Solution Approach 2:
The magnet assembly serves multiple functions simultaneously: it generates the magnetic field for detection, provides the gear structure for mechanical coupling, and acts as the detection ring for magnetic flux sensing. This multi-functionality reduces the number of separate components needed in the torque sensor.
2Measurement precision
If a conventional contactless torque sensor uses numerous constituent elements, then torque detection is enabled, but assembly process becomes complicated and manufacturing cost increases
Solution Approach 1:
The permanent magnet and detection ring are merged into a single magnet assembly that can be manufactured as one component. This integration simplifies the assembly process by reducing the number of parts that need to be assembled while preserving the precise magnetic flux detection capability needed for accurate torque measurement.
3Reliability
If a conventional contactless torque sensor uses excessive constituent elements, then detection function is achieved, but durability is reduced due to more potential failure points
Solution Approach 1:
By merging the permanent magnet and detection ring into a single integrated magnet assembly, the patent reduces the number of potential failure points. Fewer separate components mean fewer interfaces and connections that could fail, thereby improving overall sensor durability and reliability.
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 torque sensor device enhances assemblability, reduces manufacturing costs, and achieves more accurate torque detection with a simpler structure, improving sensitivity and reliability.
Implementation Method 1
a magnet unit (200) including a magnet block (220) accommodated in the housing (100) in such a manner as to be fixed in position to the housing; a collector unit (300) including a collector (310, 320, 330) at least partially disposed between the input shaft (2) and the magnet block (220) and between the output shaft (3) and the magnet block (220) in such a manner as to be partially rotatably connected to each of the input shaft (2) and the output shaft (3), the collector (310, 320, 330) being configured to focus a magnetic field generated from the magnet unit (200); and a sensing unit (400) including a torque sensor (410, 420) disposed at the outer circumference of the collector unit (300) and configured to detect the magnetic field focused by the collector unit (300)
Data Source
AI summary
Provided is a torque sensor device to detect a torque between an input shaft and an output shaft through a relative rotation displacement therebetween. The torque sensor device includes: a housing to accommodate an end of the input shaft and an end of the output shaft: a magnet unit including a magnet block fixed in position to the housing; a collector unit including a collector disposed between the input shaft and the magnet block and between the output shaft and the magnet block in the radial directions of the input shaft and the output shaft to be partially rotatably connected to each of the input shaft and the output shaft, the collector focusing a magnetic field generated from the magnet unit; and a sensing unit including a torque sensor disposed at the outer circumference of the collector unit and detecting the magnetic field focused by the collector unit.