Torque Sensor Manufacturing via Overmolded Adapter Sealing
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Solution Overview
Problem
The existing methods for manufacturing torque sensors used in power steering systems are complex, expensive, and difficult to scale for mass production, with challenges in ensuring strong and watertight sealing while maintaining the integrity and positioning accuracy of Hall effect cells.
Innovation Solution
A method involving the preparation of a sensor case with slip rings, production of a sensor beam with an adapter to subdivide the access orifice into a preservation and filling cavity, and overmolding to create a sealed plug that securely fastens the sensor beam to the case, ensuring precise positioning and controlled resin dosage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the Hall effect cells and connector technology are grouped on a common support plate and fastened by screwing, then the torque sensor becomes robust, but the assembly method becomes complex and expensive
Solution Approach 1:
The patent merges the Hall effect cells, connector technology, and sealing elements onto a single support plate structure. This integration eliminates the need for separate assembly steps and multiple components, reducing both complexity and cost while maintaining robustness through the unified design.
2Quantity of substance
If the Hall effect cells and connector technology are embedded during overmolding, then sealing is improved and cost is reduced, but manufacturing precision deteriorates due to resin shrinkage creating mechanical stresses
Solution Approach 1:
The patent segments the support plate into distinct functional zones: a first region for mounting Hall effect cells with precise positioning features, and a second region for connector technology. This segmentation allows each zone to be optimized independently, maintaining positioning precision while enabling effective sealing through the integrated overmolding process.
3Strength
If threaded inserts, fastening screws, and dedicated fastening plate are used, then the torque sensor becomes robust, but the space requirements and weight increase
Solution Approach 1:
The support plate is designed as a multi-functional component that simultaneously serves as the mounting structure for Hall effect cells, the connector technology base, and the sealing surface. This eliminates the need for separate threaded inserts, fastening screws, and dedicated fastening plates, reducing weight while maintaining structural strength through the integrated 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
This method simplifies and cost-reduces the manufacturing process, ensures robust and watertight sealing, and maintains the accuracy and integrity of Hall effect cells, making it suitable for mass production while maintaining the sensor's strength and reliability.
Implementation Method 1
Hall effect cells, fastened to the sensor case, which are placed in the air gap which axially separates the two slip rings, in order to measure said magnetic flux
Data Source
AI summary
A method for manufacturing a torque sensor includes: placing a first slip ring and a second slip ring inside a sensor case, the slip rings being distant from each other and each carrying respectively a first measuring terminal and a second measuring terminal which delimit an air gap therebetween; producing a sensor beam and a sensor beam subassembly, the sensor beam subassembly comprising a Hall effect cell configured to be placed in the air gap and measure the magnetic flux therein, and an electrical connection interface; and introducing the sensor beam into an access orifice which passes through a wall of the sensor case to open on the air gap, so as to place the Hall effect cell in the air gap, then fastening the sensor beam on the sensor case.