Torque Sensor Multi-Case Design for Unified Assembly
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Solution Overview
Problem
The existing torque sensors and torque angle sensors (TAS) require separate assembly lines, leading to increased manufacturing costs due to the inability to divide their structure into torque and angle sensors.
Innovation Solution
A torque sensor design that integrates a torque sensor module and an angle sensor module within a single assembly line using a multi-case configuration, where the second case features rotationally symmetrical fixing units and printed circuit boards, allowing for shared components and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If torque sensor and angle sensor are manufactured separately on different assembly lines, then each sensor can be optimized for its specific function, but manufacturing costs increase and production efficiency decreases
Solution Approach 1:
The second case is designed with rotationally symmetrical fixing units that can accommodate different sensor modules (torque sensor module or angle sensor module). This universal design allows a single assembly line to manufacture both torque sensors and angle sensors using the same case structure, thereby reducing manufacturing costs and eliminating the need for separate assembly lines while maintaining optimized functionality for each sensor type.
2Productivity
If torque sensor module and angle sensor module share the same case structure, then manufacturing efficiency improves and costs reduce, but the structural design complexity increases
Solution Approach 1:
While the overall case structure maintains rotational symmetry for universality, the fixing units are positioned asymmetrically at specific angular intervals (e.g., 0°, 120°, 240°) to accommodate the specific mounting requirements of torque and angle sensor modules. This controlled asymmetry within a symmetric framework allows efficient production on a single line while managing structural complexity through standardized positioning patterns.
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
This design enables the manufacturing of torque sensors, angle sensors, and torque angle sensors on a single line, significantly reducing personnel and manufacturing costs by minimizing the number of components and assembly lines.
Implementation Method 1
a torque magnetic element detecting a magnetic field generated between the rotor unit and the stator unit
Implementation Method 2
an angle magnetic element detecting a magnetic field generated between the rotor unit and the stator unit
Data Source
AI summary
Disclosed is a torque sensor connected with a first shaft and a second shaft, the torque sensor including a first case, a second case coupled with the first case, a third case coupled with the second case, a torque sensor module disposed between the first case and the second case and connected with the first shaft and the second shaft, and an angle sensor module disposed between the second case and the third case. The second case includes first fixing units formed on an outer circumferential surface thereof, and the first fixing units are rotationally symmetrical with respect to a longitudinal axis.