Valve Magnet Fixing via Detent Hooks and Spring Preload
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Solution Overview
Problem
Existing valve designs with magnet-based position sensors for determining the angle of rotation of a flap in throttle valves face challenges in securing the magnet effectively, especially under high temperatures and vibrations, leading to costly and complex injection mold configurations.
Innovation Solution
The use of detent hooks and spring elements to preload and securely fix the magnet within a toothed segment, eliminating the need for additional fixing methods like gluing and allowing for tolerance compensation, with the option of integral or separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the magnet is molded around with plastic in an injection mold to ensure play-free fixing, then the magnet is securely fixed under high temperatures and vibrations, but the injection mold configuration becomes complex and cost-intensive
Solution Approach 1:
The toothed segment is divided into functional parts: the main body and integral detent hooks. This segmentation allows the magnet to be secured by mechanical engagement with the detent hooks rather than requiring complex mold cavities, simplifying the injection mold while maintaining secure fixation.
Solution Approach 2:
The detent hooks are formed integrally with the toothed segment, allowing the toothed segment itself to provide the fixing function without requiring separate fixing components or complex mold configurations. The spring element provides automatic preload, making the system self-regulating.
2Reliability
If additional fixing methods like gluing or spray molding are used to secure the magnet, then the magnet is securely fixed, but the production process becomes more complex and costly
Solution Approach 1:
The fixing function is extracted from the molding process and implemented through integral detent hooks on the toothed segment. This eliminates the need for additional gluing or spray molding steps, simplifying production while maintaining secure magnet fixation.
Solution Approach 2:
The detent hooks are merged with the toothed segment as integral components, combining the gear function and magnet retention function into a single part. This integration eliminates separate fixing operations and reduces production complexity.
3Measurement precision
If the magnet is tightly fixed to avoid play, then measurement precision is improved, but the structure becomes more complex requiring additional components
Solution Approach 1:
The spring element provides dynamic preload to the magnet, maintaining constant contact pressure between the magnet and detent hooks. This dynamic compensation ensures play-free positioning and high measurement precision without requiring overly complex rigid fixing structures.
Solution Approach 2:
The spring element allows for parameter adjustment of the preload force on the magnet. By optimizing the spring constant and preforce, the magnet is held firmly against the detent hooks to eliminate play, ensuring precise angular position detection without complex mechanical constraints.
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 solution provides a reliable, play-free magnet arrangement that maintains stability under all operating conditions, simplifies production, and reduces costs by eliminating the need for complex mold configurations and additional components.
Implementation Method 1
at least one spring element is arranged that preloads the magnet against the detent hooks
Data Source
AI summary
A valve having a housing, a flap rotatably arranged in the housing and connected to a drive shaft mounted in the housing, an electric motor for driving the drive shaft, having a gearing which has at least one toothed segment and which is arranged between the electric motor and the drive shaft, and a sensor, which has a magnet, for determining the angle of rotation of the flap. The toothed segment has at least two detent hooks that engage around the magnet. Furthermore, at least one spring element is provided which preloads the magnet against the detent hooks.