Torque sensor

An automotive steering system comprising:

• a shaft linked to at least one of a set of road wheels and a steering hand wheel;
• a sensor connected to the shaft for sensing torque applied to the shaft and operative to provide as output a signal indicative of the applied torque;
• a controller in signal communication with the sensor and operative thereby to accept as input from the sensor the signal indicative of the torque applied to the shaft;
• and
• a motor coupled to the shaft and in signal communication with the controller and operative thereby to accept as input from the controller a command to apply torque to the shaft,
• wherein said sensor includes a first substrate operably coaxially coupled to a primary shaft of said shaft, said first substrate oriented substantially perpendicular to an axis defining said shaft;
• a second substrate operably coaxially coupled to a secondary shaft coaxially connected to said primary shaft, said second substrate oriented substantially perpendicular to said axis defining said shaft, said first and second substrates each having an aperture therethrough configured to receive an alignment pin therethrough, said first and second substrates being substantially parallel to each other defining an electrical interface therebetween, said electrical interface configured to generate a signal indicative of an amount of torque applied to said shaft;
• and
• a housing configured to enclose said first and second substrates having said electrical interface therebetween, wherein one side of said housing includes an alignment aperture therethrough positioned to align with said apertures of said first and second substrates having said alignment pin therethrough and extending outside of said housing, said alignment aperture configured to limit contact of said alignment pin with edges defining said alignment aperture in said housing while allowing said alignment pin to align said apertures of said first and second substrates with said alignment aperture.

A method to maintain a predetermined voltage offset during assembly of a torque sensor assembly, the method comprising:

• coaxially connecting a primary shaft with a secondary shaft;
• operably connecting a first substrate coaxially with said primary shaft, said first substrate oriented substantially perpendicular to an axis defining said shaft;
• operably connecting a second substrate coaxially with said secondary shaft, said second substrate oriented substantially perpendicular to said axis defining said shaft, said first and second substrates each having an aperture therethrough configured to receive an alignment pin therethrough, said first and second substrates being substantially parallel to each other defining an electrical interface therebetween, said electrical interface configured to generate a signal indicative of an amount of torque applied to said shaft;
• and
• configuring a housing to enclose said first and second substrates having said electrical interface therebetween, wherein one side of said housing includes an alignment aperture therethrough positioned to align with said apertures of said first and second substrates having said alignment pin therethrough and extending outside said housing, said alignment aperture configured to limit contact of said alignment pin with edges defining said alignment aperture in said housing while allowing said alignment pin to align said apertures of said first and second substrates with said alignment aperture.

A method to accommodate alignment between an aperture configured in each of a pair of substrates coaxially aligned in parallel and rotatable with respect to each other within a housing, the method comprising:

• positioning an alignment aperture in said housing to substantially align with each aperture in said pair of substrates;
• configuring said alignment aperture such that an alignment pin extending through and aligning each said aperture with said alignment aperture contacts edges defining each said aperture and limits contact with edges defining said alignment aperture;
• disposing said alignment pin through each said aperture via said alignment aperture;
• operably connecting a shaft to each of said pair of substrates;
• and
• removing said alignment pin extending outside said housing.