Position sensor

A road wheel actuator comprising:

• a position sensor comprising:
• an angle sensor;
• a sensor shaft, wherein the sensor shaft is configured to rotate relative to the angle sensor, wherein the angle sensor is configured to sense rotation of the sensor shaft;
• a first bearing, wherein the first bearing is affixed to the sensor shaft;
• and
• a sensor wheel comprising:
• a first wheel-half, wherein the first wheel-half comprises a first body and first teeth, wherein the first teeth radially extend from the first body, wherein the first wheel-half is affixed to the sensor shaft, wherein the sensor shaft is configured to rotate with the first wheel-half;
• and
• a second wheel-half, wherein the second wheel-half comprises a second body and second teeth, wherein the second teeth radially extend from the second body, wherein the second wheel-half is directly or indirectly supported by the sensor shaft, wherein the second wheel-half is configured to rotate relative to the sensor shaft and the first wheel-half, wherein the second wheel-half is torsionally preloaded to the first wheel-half;
• a housing;
• and
• a ball screw drive comprising:
• a ball screw spindle comprising external spindle-threads;
• and
• a ball screw nut comprising internal nut-threads, a nut-bearing, external nut-threads, and a drive section, wherein the ball screw nut is axially constrained to the housing by the nut-bearing, wherein the internal nut-threads couple to the external spindle-threads, wherein rotation of the ball screw nut causes translation of the ball screw spindle relative to the ball screw nut and the housing, wherein the external nut-threads engage the first teeth and the second teeth.

A method comprising:

• affixing a first bearing to a sensor shaft;
• affixing a first wheel-half of a sensor wheel to the sensor shaft, wherein the first wheel-half comprises a first body and first teeth, wherein the first teeth radially extend from the first body, wherein the sensor shaft is configured to rotate with the first wheel-half;
• inserting a second wheel-half of the sensor wheel onto the sensor shaft, wherein the second wheel-half comprises a second body and second teeth, wherein the second teeth radially extend from the second body, wherein the second wheel-half is directly or indirectly supported by the sensor shaft, wherein the second wheel-half is configured to rotate relative to the sensor shaft and the first wheel-half, wherein the second wheel-half is torsionally preloaded to the first wheel-half;
• and
• inserting the sensor shaft within an angle sensor to form a position sensor, wherein the sensor shaft is configured to rotate relative to the angle sensor, wherein the angle sensor is configured to sense rotation of the sensor shaft.