Integrated Torque Sensor Module with ECU Shielding
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Solution Overview
Problem
Existing torque sensor systems for steering devices are prone to torque sensing errors due to external magnetic fields and require external cables that are vulnerable to damage and interference, complicating the integration of Electronic Control Units (ECUs) and torque sensors.
Innovation Solution
An integrated torque sensor module where the ECU and torque sensor are combined on a single printed circuit board within a housing, featuring an electromagnetic field shielding unit and a control unit that calibrates signals to correct torque offsets caused by external magnetic fields, using a Hall effect IC sensor and separate power for magnetic field intensity change rate measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the ECU is disposed outside the steering device with an external cable for signal transfer, then the integration complexity is reduced, but the reliability deteriorates due to cable damage and external magnetic field interference
Solution Approach 1:
The patent integrates the ECU and torque sensor into a single housing, eliminating the external cable connection. The ECU is mounted on a circuit board that is integrated with the torque sensor assembly, creating a unified module that prevents cable damage and external interference while maintaining manageable complexity through modular design
2Ease of operation
If the external cable and ECU protrude to the outside, then the ease of operation is improved for maintenance, but the reliability worsens due to vulnerability to damage and interference with surrounding parts
Solution Approach 1:
The ECU is nested within the torque sensor housing, with both components integrated into a single protected assembly. The circuit board carrying the ECU is mounted inside the housing that also contains the torque sensor, creating a nested structure that protects components while maintaining a compact form factor
3Device complexity
If no electromagnetic field shielding is implemented, then the device complexity is reduced, but the measurement precision deteriorates due to torque sensing errors from external magnetic fields
Solution Approach 1:
An electromagnetic field shielding unit is introduced as an intermediary component between the external environment and the torque sensor. The shielding unit, positioned within the housing, blocks external magnetic fields from reaching the sensitive torque sensing components, ensuring accurate measurements without requiring complex external shielding structures
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 effectively prevents torque sensing errors by integrating the ECU and torque sensor, reducing external cable requirements, and optimizing performance through magnetic field calibration, enhancing the robustness and accuracy of steering feel adjustments in EPS systems.
Implementation Method 1
a torque sensor electric device, which senses torsion of a steering shaft and converts the sensed torsion into an electrical signal, that is, a Hall effect IC sensor (Hall IC)
Data Source
AI summary
A torque sensor module for a steering device may include: a stator fixed to a designated position of a steering shaft and configured to detect a steering angle; a rotor rotatably fixed in the stator; a signal transmitter configured to transmit torsion information between the stator and the rotator to a Hall effect IC sensor (Hall IC); a printed circuit board having the signal transmitter and the Hall IC mounted thereon; and an ECU (Electronic Control Unit) of an EPS (Electronic Power Steering), mounted on the printed circuit board.