As a key component controlling vehicle power output, the precision and reliability of a motorcycle's throttle sensing system directly impact riding safety and user experience. Traditional throttle sensing systems often use mechanical or conventional magnetic components, which suffer from issues such as rapid wear, insufficient signal stability, and weak environmental adaptability. Leveraging its technical expertise in the field of plastic magnetic components, Ningbo Buer Magnetoelectric Technology Co., Ltd. has proposed an integrated solution using high-performance plastic magnetic components for throttle sensing systems and has validated its application value through practical cases.

I. Technical Pain Points in Throttle Sensing Systems and Advantages of Plastic Magnetic Components

• Limitations of Traditional Technology:

Mechanical Wear: Mechanical contact parts in throttles are prone to wear due to frequent use, leading to signal drift or failure.

Temperature Sensitivity: Conventional magnets experience magnetic performance degradation in high-temperature environments, affecting signal accuracy.

Structural Complexity: Multi-component assembly methods increase failure risks and assembly costs.

• Core Advantages of Plastic Magnetic Components:

High Precision and Consistency: Utilizing injection molding processes, plastic magnetic components can achieve dimensional accuracy of ±0.05mm, ensuring uniform magnetic field distribution and meeting the throttle system's requirements for signal stability.

Environmental Resistance: Plastic magnetic components using PPS or PA binders can withstand a temperature range of -40°C to 150°C, adapting to the high-temperature and high-vibration environment of a motorcycle's engine compartment.

Integrated Design: Plastic magnetic components can be molded integrally with other structural parts, reducing assembly steps and enhancing system reliability.

II. Ningbo Buer Magnetoelectric's Solutions and Technical Features

Material Selection and Magnetic Circuit Design:

Magnetic Material: Selected based on throttle sensing requirements. Neodymium Iron Boron (NdFeB) or ferrite magnetic powder is chosen. The former offers high magnetic energy product (can exceed 45 MGOe), while the latter provides cost advantages and corrosion resistance.

Binder Optimization: For motorcycle operating conditions, PPS engineering plastic binder is used to enhance the component's heat resistance and mechanical strength.

Precision Injection Molding and Multi-pole Magnetization:

Molding Process: Fully automated injection molding production lines control runner and cooling parameters to reduce internal stress and ensure component dimensional stability.

Multi-pole Magnetization Technology: Custom magnetization tooling is employed to achieve precise magnetic pole positioning (inter-pole error ≤ 0.5°), ensuring the linearity of angle sensing signals.

Component Integration and Testing Verification:

Structural Innovation: Integrates the plastic magnetic component with the sensor chip and protective housing to form a sealed module, preventing interference from oil, dirt, and dust.

Performance Testing: Ensures stable signal output under extreme operating conditions through high/low-temperature cycling tests, vibration tests, and full inspection of magnetic flux.

III. Typical Case Analysis: Throttle System Upgrade for a Branded Scooter

Requirement Background: A motorcycle manufacturer reported frequent signal jitter in their scooter's throttle system under high temperatures, causing acceleration hesitation. The failure rate of the original mechanical sensor was 12%, leading to high after-sales costs.

Solution Implementation:

Customized Design: Based on the throttle structure's space, Ningbo Buer Magnetoelectric designed a ring-shaped multi-pole plastic magnetic component (pole count: 32 poles) to be directly embedded into the handlebar axle core, replacing the original mechanical contacts.

Parameter Optimization: Adopted an NdFeB-PPS material system with a magnetic energy product of 10 MGOe and an operating temperature range of -40°C to 150°C.

Application Results:

Signal Stability: After the upgrade, signal linearity improved to 99.5%, with no degradation in high-temperature environments.

Extended Lifespan: Enhanced wear and corrosion resistance of the components increased the system lifespan by over 3 times compared to the original solution.

Cost Optimization: The integrated design reduced assembly time by 30%, lowering the customer's overall costs by approximately 20%.

IV. Industry Outlook and Technological Evolution

With the development of motorcycle electrification and intelligence, throttle systems need to meet higher precision and multi-functional integration requirements. In the future, plastic magnetic component technology is expected to evolve in the following directions:

Integrated Smart Sensing: Embedding microchips within plastic magnetic components to enable dual output of angle and temperature signals.

Lightweighting and Miniaturization: Further reducing component size and weight through thin-wall injection molding processes.

Sustainable Materials: Developing bio-based binders to enhance the environmental performance of components.

Conclusion

Ningbo Buer Magnetoelectric Technology Co., Ltd., leveraging its profound technical expertise in plastic magnetic components, has provided a high-reliability solution for motorcycle throttle sensing systems through material innovation, precision processes, and integrated design. Practical applications demonstrate that this solution significantly improves signal accuracy, environmental adaptability, and product lifespan, offering effective support for motorcycle manufacturers in reducing costs and enhancing efficiency. In the future, the company will continue to deepen research in plastic magnetic technology, promoting the development of throttle systems towards greater intelligence and efficiency.