Flap position sensing device of active air flap system and method of manufacturing the same

A flap position sensing device of an active air flap system comprising a housing having an air inlet which allows outside air entering through a radiator grille to pass, at least one flap which rotates to reciprocate between a position for opening the air let of the housing and a position for closing the air inlet of the housing, and a flap actuator for rotating the flap, the flap position sensing device comprising:

• a rotating body which is formed of a resin material, and rotates the flap by receiving torque while the rotating body is coaxially fixed to a rotation shaft of the flap;
• a sensor casing which is formed of a resin material, and is fixed to the housing to rotatably support the rotating body;
• a first hall sensor and a second hall which are integrally formed with the sensor casing by insert injection molding, and are disposed corresponding to an open position and a closed position, respectively, of the flap;
• and
• a first permanent magnet and a second permanent magnet which are integrally formed with the rotating body by insert injection molding, are spaced apart from each other by an opening and closing angle of the flap, and are disposed to interact with the first hall sensor and the second hall sensor according to opening and closing of the flap, so as to sense the open position, the closed position, and other positions of the flap.