Torque Sensor Rotor Assembly Mechanical Interlocking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing torque sensors face challenges in manufacturing complexity and cost due to welding processes, and they suffer from reduced durability and wear resistance due to the use of separate components and frequent rotor rotation.
Innovation Solution
A rotor assembly for a torque sensor that uses a simple structure with hooks and hook grooves, and press-fit ribs to firmly fix the rotor to the gear, reducing the number of components and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to fix the rotor to the gear, then the rotor is firmly fixed, but the manufacturing process becomes complex and manufacturing cost increases
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical interlocking system consisting of protrusions on the rotor that fit into grooves on the gear. This mechanical substitution eliminates the complex welding process while achieving firm fixation through geometric interlocking, thereby reducing manufacturing process complexity while maintaining fixing strength.
2Reliability
If separate components are used to fix the rotor to the gear, then the rotor is secured, but the number of components increases and productivity decreases
Solution Approach 1:
The patent merges the rotor and gear into a single integrated assembly by forming protrusions directly on the rotor body that interlock with grooves on the gear. This merging eliminates the need for separate fixing components such as retainers or fasteners, reducing the total component count while maintaining fixing reliability through the integrated interlocking structure.
3Ease of operation
If the rotor rotates frequently during driving, then the steering function is achieved, but severe wear occurs between the rotor and housing
Solution Approach 1:
The patent introduces a bearing as an intermediary element between the rotor and the housing. This bearing mediates the relative rotation, allowing the rotor to rotate freely for steering operation while the bearing absorbs the wear through its rolling contact mechanism. This protects the rotor and housing from direct contact wear, thereby maintaining durability and wear resistance despite frequent rotation.
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 improves the durability and wear resistance of the rotor assembly by enlarging the area for relative rotation between the gear and housing, while also reducing manufacturing costs and increasing productivity.
Implementation Method 1
each of the first coupling portion may include a hook bent from the rotor and being elastically deformable, and a hook groove penetrating the gear or being depressed from the gear in a radial direction
Implementation Method 2
Each of the second coupling portion may include a supporting rib protruding inward from the inner circumferential surface of the gear, and a pair of press-fit ribs provided in the rotor and being in close contact with both sides of the supporting rib
Data Source
AI summary
A rotor assembly of a torque sensor includes: a rotor having a through hole formed along an axial direction so that a steering shaft can be inserted in the through hole; a gear having substantially a ring shape and coupled to the rotor; and a fixing portion configured to fix the rotor to the gear. The fixing portion includes at least one first coupling portion configured to fix the rotor to the gear with respect to the axial direction, and at least one second coupling portion configured to fix the rotor to the gear with respect to a rotation direction. Each of the first coupling portion includes an elastically deformable hook bent from the rotor, and a hook groove penetrating the gear or being depressed from a surface of the gear in a radial direction, such that the hook is inserted in and caught by the hook groove.