Wheel Angle Sensor Assembly Tool-Free Mechanical Shape Coupling
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Solution Overview
Problem
The existing wheel angle sensor assemblies for work vehicles, such as agricultural vehicles, face imprecision and complexity in manual fixation, leading to erroneous phasing and high manufacturing costs due to the need for hand tools and threaded couplings, which wear out and complicate the mounting process.
Innovation Solution
A wheel angle sensor assembly that uses a mechanical shape coupling with a deformable resilient element and teeth to securely attach the steering pin to the front axle, eliminating the need for hand tools and threaded connections, ensuring precise phasing and easier installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual fixation with hand tool and threaded coupling is used, then the pin can be fixed to the front axle, but the phasing precision deteriorates due to manual measurement errors and tool wear
Solution Approach 1:
The patent replaces the manual mechanical fixation system (hand tool + threaded coupling) with a self-aligning mechanical coupling system. The coupling features a conical surface that automatically aligns the pin with the front axle during insertion, eliminating the need for manual phasing operations and threaded fastening.
Solution Approach 2:
The coupling mechanism performs self-alignment through its conical geometry. When the pin is inserted into the coupling, the conical surface automatically orients the pin at the correct angle relative to the front axle without requiring external tools or manual adjustment, making the system self-servicing for phasing.
2Strength
If threaded coupling with nut is used to fix the pin, then the connection is secure, but the mounting process becomes more complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the threaded coupling components (threads, nuts, bolt holes) from the fixation system. The connection is achieved through a simple insert-remove mechanism where the pin fits directly into the coupling with a snap-fit or friction-fit connection, removing unnecessary complexity.
Solution Approach 2:
The fixation system is segmented into separate functional elements: the coupling body with conical alignment surface and the pin with corresponding insertion geometry. This segmentation allows for independent optimization of each component and simplifies the assembly process to a single insertion motion.
3Manufacturing precision
If hand tool is used for phasing the pin, then the pin can be positioned, but the tool wears out and leads to incorrect positioning over time
Solution Approach 1:
The patent replaces the wear-prone hand tool with a tool-free mechanical coupling system. The conical surface and insertion geometry provide repeatable, wear-resistant positioning that does not deteriorate with use, ensuring consistent phasing accuracy throughout the service life of the components.
4Adaptability or versatility
If preliminary mounting of angle sensor assembly is required on steering assemblies, then the sensor can be integrated, but the manufacturing cost and complexity increase
Solution Approach 1:
The coupling mechanism serves multiple functions: it provides mechanical connection, angular alignment, and sensor assembly mounting. This multi-functionality allows the same basic structure to be used across different steering assembly configurations without requiring custom preliminary mounting operations for each application.
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 simpler, faster, and more cost-effective mounting process with improved stability and precision, allowing for the assembly to be integrated or substituted as a kit into existing steering assemblies without requiring preliminary mounting operations.
Implementation Method 1
a deformable resilient element (16) made of an elastomeric material
Data Source
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AI summary
A wheel angle sensor assembly (1) for measuring a relative rotation between a front axle (3) of a vehicle with respect to a knuckle (2) to be coupled to a wheel of the vehicle, the wheel angle sensor assembly (1) comprising a steering pin (8) to be coupled via a mechanical shape coupling (13) with a first member (2, 3) between the front axle (3) and the knuckle (2), an angle sensor (7) to be coupled with a second member (2, 3) defined by the other one of the front axle (3) and the knuckle (2), and a resilient element (16) of deformable material, in which one between the steering pin (8) and the first member (2, 3) defines a groove (14) for seating the resilient element (16) and in which the mechanical shape coupling (13) is realized within the groove (14) by interference between the resilient element (16) seated in the groove (14) and a protrusion (15) carried by the other one between the steering pin (8) and the first member (2, 3) and inserted in a portion (17) of the groove (14) left free by the resilient element (16).