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Torque sensor
Sunday, 17 December 2006

A torque sensor is used in a car steering system having electrically controlled power assist to detect an applied input torque. Power assist steering systems are frequently employed for use with automotive vehicles. A power steering system is mounted to an automobile to assist the steering by reducing the steering force required by a driver. The power assist is accomplished by applying a supplementary rotary force to a steering member. Such systems may be controlled in response to a driver's applied torque to the vehicle's steering wheel. Some of the known systems provide steering assist using hydraulic power, while other known systems use electric power. In a hydraulic power steering system, a pump provides pressurized hydraulic fluid to provide force to assist rotation of the pinion shaft. The power assist provided by the hydraulic fluid is controlled by rotational deflection of the torsion bar that interconnects the input shaft and the pinion shaft. As the amount of torque between the two shafts increases, the power steering system provides more force to assist in rotation of the pinion shaft. In hydraulic power steering systems, the power steering pump is always being turned by the engine and represents an energy drain on the motor all the time even though steering is only performed during a small percentage of the total time a car is operated. These systems have proved inefficient, primarily due to the need to size components needed to respond to steering demands under a broad range of operating conditions. In response to the challenge of providing more energy efficient steering systems, electric power assisted steering systems (EPAS) have been developed. An electric power steering apparatus serves to relieve (assist) the steering force of a driver by causing the driving force of an electric motor to directly act. By the electric power steering apparatus, the movement of a steering wheel becomes quick and the driver does not need to carry out a steering operation by strong force. In the EPAS system, there is a mechanical connection between the steering wheel and the electric motor actuator wherein the torque generated by the electric motor actuator assist a driver's applied torque. Electrical power assist steering systems comprise an actuating device (electric motor), an electronic control unit and a torque sensor. The torque sensor is used to measure the torque that the driver exerts on the steering shaft by means of the steering wheel. The torque-dependent deformation of the torque-sensor shaft is measured by a suitable sensor and converted into a signal, which is evaluated by the electronic control unit, the latter controlling the electric motor accordingly. Electric power steering systems, as compared to conventional hydraulic power systems, are smaller in size and have lighter weight. Also, the number of constituent parts is relatively small.

An electrical assist power steering system requires sensing of torque applied to the steering wheel. An electric power steering system generally comprises a torque sensor for outputting a signal corresponding to a value of the steering torque of the driver, an electric motor for driving an assist apparatus which assists the steering force, and an electronic control unit (ECU) for determining current flowing through the electric motor in accordance with the output signal of the torque sensor. Generally, in an electric power steering system, a torque sensor converts a torsional torque of a steering shaft, which is generated by steering of a steering wheel connected to the steering shaft, to an analog signal (voltage) and outputs it to an electronic control unit (ECU). In the ECU, an analogue to digital (AD) converter circuit converts the analogue signal to a corresponding digital value. Torque measurement is performed to detect the torque caused to occur by a driver's operation using a steering wheel in an electromotive power steering system, or to detect the torque in the rotational direction of tires when running. The torque indicates how much force the driver is exerting to move the wheel. The output signal from a torque sensor is fed into a control unit which controls the electrical motor of the assist unit. When the torque sensed is high, the assist applied to the steering linkage will be high. When the torque sensed is low, the assist applied to the steering linkage will be low. In such a power-assisted steering system the output signals from the first and second receiver means may be processed to determine the rate of rotation of the vehicle steering shaft and a digital position measurement of the angular displacement of the steering shaft. This information can be used in a vehicle control microprocessor to modify or control the suspension and/or braking characteristics of the vehicle. The motor for steering assist is so driven as to obtain power assistance in accordance with the steering torque detected by the torque sensor, thereby reducing the power to operate the steering member. An electric power steering system is structured so that a steering mechanism to which the steering wheel is coupled through a steering shaft is provided with a torque sensor that detects the steering torque applied to the steering wheel and a motor that assists the operation of the steering mechanism and the motor is driven in accordance with the steering torque detected by the torque sensor to thereby reduce the operation force on the steering wheel. Typically, the torque sensing apparatus is connected between an input shaft connected to a steering wheel and a pinion or output shaft. The input shaft is connected to the steering wheel and the output shaft is connected to a pinion of a rack and pinion steering gear. The torque sensor includes a torsion bar connecting the input shaft to the output shaft. The detected torque is used to control an assist electric motor, an electrically driven pump, or a solenoid valve in response to a driver's input torque applied to a vehicle steering wheel. With the development of electric power steering systems, the need for a torque sensing apparatus which can accurately detect a torque produced by a steering shaft has been highlighted.

Torque sensors performs torque detection based on a torque detecting voltage which is a voltage difference between a first voltage and a second voltage on the basis of respective inductance changes of a pair of coils having inductances changing in opposite directions corresponding to torque. A typical torque sensor is attached to a member for measuring torque applied to that member. The torque sensor provides an electrical output signal having a characteristic which is functionally related to the torque applied to the member. The output signal is typically used to control an associated device. Torque measurement was previously accomplished using contact-type sensors directly attached to the shaft. One such sensor is a "strain gauge" type torque detection apparatus, in which one or more strain gauges are directly attached to the outer peripheral surface of the shaft and a change in resistance caused by strain is measured by a bridge circuit or other well known means. However, contact-type sensors are relatively unstable and of limited reliability due to the direct contact with the rotating shaft. Also, they are very expensive and are thus commercially impractical for competitive use on vehicle steering systems. As a non-contact method for detecting torque, a magnetostrictive torque sensor using a magnetostrictive material is known. A magnetostrictive torque sensor makes use of the magnetostrictive effect in which magnetic permeability changes when a mechanical strain is imparted to a ferromagnetic material, the phenomenon being one of the phenomena of magnetic strain. The magnetostrictive effect may be termed as the change of dimensions of a material when exposed to a magnetic field or its inverse effect, i.e. the change in magnetization of a material as a result of external stress. The magnetostrictive effect is associated with ferromagnetic materials. Magnetoelastic torque sensor technology operates on the specific manifestation of magnetoelastic termed the Inverse Wiedemann Effect in which a magnetic field can be distorted to arise in the space around a torsionally stressed member. Most typically, magnetization and sensing are accomplished by providing a pair of excitation or magnetizing coils overlying and surrounding the bands, with the coils connected in series and driven by alternating current. Application of torque on the shaft strains the magnetostrictive material and causes changes in the magnetic permeability of the sensor. The changes in the permeability alter flux and thus induce electromotive force in the detecting coil. The applied torque is detected based on the induced electromotive force.