Integrated Wheel Speed Sensor Bearing Assembly
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Solution Overview
Problem
Existing wheel speed sensor systems are bulky and difficult to mount correctly, leading to challenges in accurately determining wheel speed, particularly in applications like anti-lock braking systems where precise speed measurement is crucial.
Innovation Solution
A compact wheel speed sensor assembly incorporating a bearing with a tone wheel and a magnetoresistive sensor, where the tone wheel is coupled to the bearing's carrier and a spacer, allowing for precise detection of rotational speed without the need for bulky mechanical couplings or complex sensor positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic ring is frictionally coupled to the wheel with a Hall sensor, then wheel speed can be detected, but the system becomes bulky and difficult to mount
Solution Approach 1:
The patent combines the tone wheel, carrier, and bearing into a single integrated assembly that mounts directly to the wheel hub. The tone wheel is press-fit onto the carrier which is then press-fit into the bearing, creating a compact unified structure that eliminates the need for separate magnetic rings and complex mounting brackets required by traditional Hall sensor systems.
Solution Approach 2:
The patent replaces the mechanical frictional coupling of a magnetic ring with the magnetic field interaction between the tone wheel and Hall sensor. The tone wheel's magnetic poles interact with the Hall sensor through magnetic field lines rather than requiring physical frictional contact, eliminating the need for friction-based mechanical coupling and associated mounting complexity.
2Measurement precision
If a magnetic ring is frictionally coupled to the wheel, then wheel speed can be measured, but the system becomes bulky in size
Solution Approach 1:
The patent merges the tone wheel, carrier, and bearing into a compact integrated assembly that fits within the wheel hub structure. This consolidation eliminates the need for separate magnetic rings and external mounting hardware, significantly reducing the overall volume of the speed detection system while maintaining measurement accuracy.
Solution Approach 2:
The patent employs a nested structure where the tone wheel is press-fit onto the carrier, which is then press-fit into the bearing. This nested arrangement allows multiple components to occupy the same spatial envelope, creating a compact assembly that minimizes the volume required for the speed sensor system.
3Measurement precision
If traditional sensor systems are used with magnetic rings, then wheel speed can be detected, but mounting difficulty increases
Solution Approach 1:
The patent combines the tone wheel, carrier, and bearing into a single integrated assembly that mounts directly to the wheel hub as one unit. This consolidation eliminates the need for multiple separate mounting steps and alignment procedures required by traditional magnetic ring systems, significantly simplifying the manufacturing and installation process while maintaining detection accuracy.
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 provides a small, reliable, and easily installable wheel speed sensor that accurately measures rotational speed, even in harsh environments, with minimal impact from vibrations and contaminants, effectively addressing the limitations of previous systems.
Implementation Method 1
a Hall sensor to detect the magnetic field from the ring and determine the speed of the wheel
Data Source
AI summary
A speed sensor assembly includes a bearing having a first race, a second race, a plurality of ball bearings separating the first race from the second race, and a tone wheel coupled to the second race. The speed sensor assembly also includes a spacer abutting the first race and a sensor positioned adjacent the tone wheel.