Sensorised Wheel Hub Structure for Real-Time Force and Moment Sensing
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Solution Overview
Problem
Existing sensor systems in vehicles are ineffective in accurately detecting mechanical stresses on wheel hub units due to their complexity, cost, and unreliability, making them unsuitable for series production and real-time force detection.
Innovation Solution
A sensorised wheel hub unit with a rolling bearing and radially outer ring featuring longitudinal concave recesses, metal plates, and piezoresistive ceramic sensors, which are welded to ensure reliability and integrated with an electrical circuit for real-time force detection, providing accurate data on forces and moments applied to the wheel hub.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing sensor systems are used to detect mechanical stresses on wheel hub units, then detection capability is provided, but the systems are complex, costly, and unreliable making them unsuitable for series production
Solution Approach 1:
The detection system merges multiple sensing functions into a single integrated wheel hub unit. The piezoresistive ceramic sensors are embedded within the wheel hub structure itself, combining the structural component with the detection function, thereby reducing overall system complexity while maintaining high reliability for series production
Solution Approach 2:
The wheel hub unit serves itself by incorporating the detection system directly into its structure. The piezoresistive ceramic sensors are integrated within the wheel hub, allowing it to self-monitor mechanical stresses without requiring separate external sensor systems, thus reducing complexity and improving reliability
2Measurement precision
If existing sensor systems are used to detect mechanical stresses on wheel hub units, then detection capability is provided, but the cost is high making them unsuitable for series production
Solution Approach 1:
The patent employs piezoresistive ceramic sensors that are cost-effective for series production. These sensors are designed to be integrated into the wheel hub structure at a manufacturing stage, providing accurate force detection at a lower cost compared to existing sensor systems, making them economically viable for mass production
Solution Approach 2:
The invention changes the material parameter by using piezoresistive ceramic material instead of traditional sensor materials. This material choice enables accurate measurement of mechanical stresses while being more cost-effective and suitable for series production, directly addressing the cost barrier
3Measurement precision
If sensors are applied to detect rotation speed, then basic monitoring is achieved, but accurate real-time force and moment detection is not achieved
Solution Approach 1:
The patent replaces traditional mechanical sensor systems with piezoresistive ceramic sensors that directly convert mechanical stress into electrical signals. This substitution enables accurate real-time detection of forces and moments acting on the wheel hub, providing superior measurement precision compared to rotation speed sensors while maintaining manageable system complexity
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 enables accurate and reliable real-time detection of forces and moments, improving vehicle stability and autonomous driving functions, and is cost-effective for series production.
Implementation Method 1
a sensor (S) consisting of a plate (23) of piezoresistive ceramic material
Data Source
AI summary
Sensorised wheel hub unit and a method for detecting, in real time, forces and moments applied to an outer ring of the wheel hub unit in which piezoresistive ceramic plates are made of one piece with welded metal plates housed within respective recesses formed in an outer surface of the outer ring over respective races for rolling elements that there is a gap between the plates and a base wall of each recess; the temperature of the outer ring and the amplitude and frequency of first electrical signals (S1) associated with the sensors relating to the same race are analysed to determine a frequency value equal to the frequency of the first signal having the maximum amplitude and as many amplitude values (D1-Dn) as there are sensors associated with that race and each equal to the maximum amplitude of the first signal from each sensor, corrected according to temperature.