Inductive Sensor Valve Gear Assembly for Fragile Target Handling
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Solution Overview
Problem
Existing valve devices with inductive sensors face challenges in handling and assembly due to the small, thin detection targets, which are prone to bending or damage, and require effort and attention to prevent damage during storage and assembly.
Innovation Solution
A valve device design that integrates a plate-shaped gear made of resin with a metal support member and a detection target of a non-contact sensor through insert molding, where the detection target is exposed on one side surface and the support member is exposed on the other side, allowing for easy handling and assembly by welding the support member and shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin metal plate detection target is used in the valve shaft, then the detection function is achieved, but the detection target is prone to bending or damage and requires careful handling during assembly and storage
Solution Approach 1:
The detection target is integrated with the gear through insert molding, combining the thin metal plate detection target with a larger structural component. This merging allows the detection target to be handled as part of the robust gear assembly rather than as a separate fragile component, eliminating the need for special handling precautions while maintaining detection functionality.
2Reliability
If a thin metal plate detection target is used, then the detection function is achieved, but the assembly process requires special attention and effort to prevent damage
Solution Approach 1:
The detection target is pre-integrated with the gear through insert molding during gear manufacturing. This preliminary action of combining components before final assembly eliminates the need for separate handling and assembly of the fragile detection target, simplifying the overall manufacturing process and reducing assembly complexity.
3Ease of operation
If the detection target is integrated into the gear through insert molding with exposed support member, then handling is facilitated, but additional welding process is required to attach the shaft
Solution Approach 1:
The support member is designed with an exposed portion that separates the detection target integration function from the shaft attachment function. This segmentation allows the detection target to be integrated through insert molding while the exposed support member provides a dedicated interface for shaft attachment via welding, distributing manufacturing complexity across distinct functional zones.
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
Facilitates easier handling and assembly of the detection target, reduces the risk of damage, and simplifies the manufacturing process by integrating the detection target into the gear through insert molding and welding the shaft unit.
Implementation Method 1
generate high-frequency magnetic fields by causing currents to flow through sensor coils
Implementation Method 2
detect inductance of the sensor coils changing due to the detection targets moving in the magnetic fields
Implementation Method 3
a rear side of an abutting part of the support member is irradiated with laser light through the exposure hole from the side of the other side surface of the gear to weld the support member and the shaft
Data Source
AI summary
In a valve device including: a plate-shaped drive gear provided at an end of a valve shaft made of metal; and, at the drive gear, a detection target of an inductive sensor detecting a rotation angle of the valve shaft, the drive gear has a lever member made of metal and integrated through insert molding in which a part thereof is exposed in the inner surface, the detection target is integrated along with the lever member through the insert molding on a side of the outer surface of the drive gear, and an exposure portion of the lever member at the drive gear including the lever member and the detection target and the end of the valve shaft are caused to abut each other, and a rear side of the abutting part is laser-welded from the side of an outer hole and is fixed thereby to configure a shaft unit.