Torque Sensor Unit Pressed-In Housing Frictional Connection
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Solution Overview
Problem
Conventional torque sensors for electromechanical power steering systems are complex to manufacture due to the need for multiple parts and machining operations, such as screw fixing, which complicates the production process.
Innovation Solution
A torque sensor unit is designed with a frictional connection between a ring magnet and a magnetic flux conductor, where the sensor unit is pressed into a housing to form a connection without screws, allowing for simplified assembly and potentially reinforced with adhesives for added stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw fixing is used to connect the sensor unit to the holder, then the connection is secure and reliable, but the number of parts increases and the manufacturing process becomes complicated
Solution Approach 1:
The sensor unit housing and holder are merged into a single integrated component. The sensor unit is directly mounted within the holder housing, eliminating the need for separate screw fixing components. This integration reduces the total part count while maintaining connection reliability through the unified structural design.
2Reliability
If screw fixing is used to connect the sensor unit to the holder, then the connection is secure, but the manufacturing process requires machining operations and tightening steps
Solution Approach 1:
The holder and sensor unit housing are combined into a single integrated part that can be manufactured as one piece using injection molding or similar processes. This eliminates the need for separate machining operations for thread cutting and screw tightening, significantly simplifying the manufacturing process while ensuring reliable connection through the integrated structure.
3Adaptability or versatility
If multiple individual parts are used for sensor assembly, then the design is modular and flexible, but the production method becomes complicated
Solution Approach 1:
The holder and sensor unit housing are merged into a single integrated component that maintains design flexibility through modular sensor cartridge insertion. The integrated housing provides structural support and mounting features, while the sensor unit can still be independently selected and replaced, preserving adaptability while simplifying production to a single molding operation.
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 approach simplifies the production process, reduces the number of parts required, and enables automated assembly, making the torque sensor easier to manufacture and more cost-effective while maintaining accurate torque measurement capabilities.
Implementation Method 1
a magnetic flux conductor (16) which can be connected to a second partial shaft (31), wherein the two axially opposite partial shafts (30, 31) are connected to each other via a torsion bar (32)
Implementation Method 2
two shaft parts (30, 31) that can be rotated relative to another to a limited extent are elastically coupled to each other via a torsion spring
Implementation Method 3
The sensor unit (17) is pressed into a housing opening (212) of the second housing (21)
Data Source
AI summary
A torque sensor unit may include a ring magnet that can be connected to a first partial shaft for conjoint rotation, a magnetic flux conductor that can be connected to a second partial shaft, a sensor unit having a first housing, wherein the sensor unit detects a change in rotational angle between the partial shafts, a second housing that surrounds the ring magnet and the magnetic flux conductor and is fixedly connected to the first housing of the sensor unit. The second housing of the torque sensor unit may have a housing opening into which the first housing of the sensor unit is pressed to form a frictional connection.