Torque Sensor with Resin Bobbin for Oil Resistance
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Solution Overview
Problem
Existing magnetostrictive torque sensors, particularly those using flexible circuit boards, face challenges with oil resistance, which is crucial for applications where they may be exposed to lubricant oil or high temperatures.
Innovation Solution
A torque sensor design featuring a resin bobbin with inclined grooves for winding insulated detection coils, utilizing a polyphthalamide, polyether ether ketone, or polyphenylene sulfide resin for the bobbin and fixing ring, providing improved oil and heat resistance, and a magnetic ring to enhance sensitivity and prevent magnetic flux leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flexible circuit board is used for the detection coil substrate, then the device complexity is reduced and ease of manufacture is improved, but the oil resistance and reliability deteriorate
Solution Approach 1:
The patent changes the material parameter of the substrate from flexible circuit board (film-shaped resin) to resin bobbin. This material substitution fundamentally improves oil resistance while maintaining ease of manufacture, as the resin bobbin can be molded directly into the required shape with grooves for the detection coils.
Solution Approach 2:
The patent employs composite material construction by combining resin bobbin substrate with detection coils wound around it. The resin bobbin provides oil-resistant structural support while the detection coils provide sensing functionality, creating a composite structure that achieves both reliability and manufacturing efficiency.
2Adaptability or versatility
If the torque sensor is exposed to lubricant oil or high temperatures, then the application versatility is improved, but the reliability of film-shaped resin components deteriorates
Solution Approach 1:
The patent changes the thermal and chemical resistance parameters of the substrate material by replacing film-shaped resin with resin bobbin made from oil-resistant and heat-resistant materials. This enables the torque sensor to operate reliably in environments with lubricant oil and high temperatures.
Solution Approach 2:
The patent replaces the short-living film-shaped resin components with durable resin bobbin structures that can withstand harsh environments. The resin bobbin is designed to be long-lasting and resistant to degradation from oil and heat exposure.
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 design enhances oil resistance and reliability, enabling accurate torque detection in environments with lubricant oil exposure and high temperatures, while maintaining high sensitivity and avoiding the need for processing the rotating shaft.
Implementation Method 1
a magnetostrictive rotating shaft (2) to which a torque is applied
Implementation Method 2
a rotating shaft having a magnetostrictive characteristic that a magnetic permeability varies according to an applied torque
Implementation Method 3
a detection coil, wherein the detection coil can detect a variation in magnetic permeability of the rotating shaft under the applied torque as a variation in inductance thereof
Data Source
AI summary
A torque sensor for being attached around a magnetostrictive rotating shaft includes a bobbin that is provided coaxially with the rotating shaft, wherein the bobbin includes a resin, a hollow cylindrical shape, and first inclined grooves and second inclined grooves formed on an outer peripheral surface thereof, wherein the first inclined grooves are inclined at a predetermined angle relative to an axial direction, and wherein the second inclined grooves are inclined at a predetermined angle relative to the axial direction in an opposite direction of the first inclined grooves, a first detection coil including an insulated wire wound around the bobbin along the first inclined grooves, a second detection coil including the insulated wire wound around the bobbin along the second inclined grooves, and a measurement portion that detects a inductance variation of the first and second detection coils so as to measure a torque applied to the rotating shaft.