A dual-brush conductive angular displacement sensor

Abstract

This invention provides a dual-brush conductive plastic angular displacement sensor, comprising: a housing and a rotating shaft. The housing houses a conductive plastic sensing mechanism, which includes a first conductive plastic substrate, a second conductive plastic substrate, a first brush, and a second brush. Both the first and second brushes are fixedly connected to the rotating shaft and are connected via conductive connectors. The first brush is disposed on one side of the first conductive plastic substrate, and the second brush is disposed on one side of the second conductive plastic substrate. The first conductive plastic substrate is an annular, unbroken substrate. This invention's dual-brush conductive plastic angular displacement sensor utilizes two conductive plastic substrates in conjunction with two brushes for measurement, eliminating the need for components such as current collector rings and current collector wires, reducing production costs, avoiding poor contact, resulting in more stable and reliable signal output, and a longer service life.

Description

Technical Field

[0001] This invention relates to the field of sensor technology, and in particular to a dual-brush conductive angular displacement sensor. Background Technology

[0002] Currently, displacement sensors convert linear or circular mechanical displacement into electrical signals. By fixing a variable conductive plastic resistive slide rail at a fixed point on the sensor, the displacement of the brush on the slide rail measures different resistance values. The voltage between the brush and the sensor's starting point is proportional to the angle of the brush's movement. Conductive plastic angular displacement sensors, through the uniform rotation of the brush, provide high-precision output signals, offering stable and reliable performance and a long service life.

[0003] In some existing plastic-coated angular displacement sensors, the brushes are fixedly mounted on the brush arm assembly. The brush arm assembly includes components such as the collector wire and the collector ring, which has a complex structure and is prone to problems such as poor contact between the parts and poor measurement stability, thus affecting the accuracy of the measurement; moreover, the collector wire, collector ring and other components are made of copper, alloys and other materials, which results in high production costs. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] The problem to be solved by this invention is to provide a long-life dual-brush conductive angular displacement sensor that eliminates the need for components such as current collector rings and current collector wires, reduces production costs, avoids poor contact, and provides a more stable and reliable signal output.

[0006] (II) Technical Solution

[0007] To address the aforementioned technical problem, this invention provides a dual-brush conductive plastic angular displacement sensor, comprising: a housing and a rotating shaft. The housing houses a conductive plastic sensing mechanism, which includes a first conductive plastic substrate, a second conductive plastic substrate, a first brush, and a second brush. Both the first and second brushes are fixedly connected to the rotating shaft and are connected via conductive connectors. The first brush is disposed on one side of the first conductive plastic substrate, and the second brush is disposed on one side of the second conductive plastic substrate. The first conductive plastic substrate is an annular, unbroken substrate with an annular, unbroken, low-resistance conductive region. During measurement, the rotating shaft is driven to rotate by an external power device. The rotating shaft drives the second brush to slide uniformly on the surface of the second conductive plastic substrate. This linearly changing, high-precision signal is then transmitted via the first brush to the first conductive plastic substrate and finally output through a signal output terminal.

[0008] This invention relates to a dual-brush conductive plastic angular displacement sensor. A shim is fitted onto the rotating shaft, positioned on one side of the first high-speed ball bearing. The axial clearance of the product can be adjusted by increasing or decreasing the thickness of the shim to prevent vertical movement of the rotating shaft, thus ensuring smooth and stable brush operation and increasing the stability and accuracy of the signal output. The use of two conductive plastic substrates in conjunction with the dual brushes eliminates the need for components such as current collector rings and current collector wires, reducing production costs, avoiding poor contact, and resulting in a more stable and reliable signal output and a longer service life. A brush arm is fixedly fitted onto the rotating shaft, with a conductive connector fixedly connected to the brush arm. The brush arm is an injection-molded part, ensuring insulation between the brush component and the rotating shaft, preventing short circuits and other abnormalities, thus enhancing reliability. A first high-speed ball bearing and a second high-speed ball bearing are located between the rotating shaft and the housing, supporting the rotating shaft and brush arm, reducing friction during shaft movement, and ensuring rotational accuracy, thereby improving measurement accuracy.

[0009] Furthermore, the first conductive plastic substrate is correspondingly disposed above the second conductive plastic substrate, and both the first brush and the second brush are positioned between the first conductive plastic substrate and the second conductive plastic substrate. The first brush is positioned upwards, and the second brush is positioned downwards, resulting in a reasonable structural design.

[0010] Furthermore, the housing is provided with a signal output terminal that is electrically connected to the first conductive plastic substrate, which facilitates the output of angular displacement signals.

[0011] Furthermore, a brush arm is fixedly mounted on the rotating shaft, and the conductive connector is fixedly connected to the brush arm. The brush arm is an injection-molded part, and the brush component is insulated from the rotating shaft, so that short circuits or other abnormalities will not occur, making it more reliable in use.

[0012] Furthermore, the housing has a positive power connection terminal and a negative power connection terminal on one side, and a slotted groove on one end of the rotating shaft. The housing also has a servo mounting slot and a positioning mounting hole, allowing for easy installation and wide applicability by selecting a suitable mounting method. The groove is used to adjust the starting zero position of the rotating shaft, making adjustment more convenient.

[0013] Furthermore, the housing includes an upper housing and a lower housing, with the first conductive plastic substrate fixedly mounted on the upper housing and the second conductive plastic substrate fixedly mounted on the lower housing.

[0014] Furthermore, a first high-speed ball bearing and a second high-speed ball bearing are provided between the rotating shaft and the housing to support the rotating shaft and the brush arm, reduce the friction during the rotation of the rotating shaft, and ensure its rotational accuracy, thereby improving the measurement accuracy.

[0015] Furthermore, a shim is fitted on the rotating shaft, and the shim is placed on one side of the first high-speed ball bearing; the axial clearance of the product can be adjusted by increasing or decreasing the thickness of the shim to prevent the rotating shaft from moving up and down, thereby making the brush run smoothly and increasing the stability and accuracy of the signal output.

[0016] Furthermore, the low-resistance conductive area is coated with low-resistance silver paste, and the first conductive plastic substrate is provided with a first pin electrically connected to the low-resistance conductive area, and the first pin is electrically connected to the signal output terminal.

[0017] Furthermore, the second conductive plastic substrate is provided with a second pin and a third pin for connecting to a power source. The second pin is electrically connected to the positive terminal of the power source, and the third pin is electrically connected to the negative terminal of the power source. The second pin is connected to the third pin through a resistive paste. The second conductive plastic substrate is a conventional conductive plastic substrate in the prior art, and will not be described in detail here.

[0018] (III) Beneficial Effects

[0019] This invention relates to a dual-brush conductive plastic angular displacement sensor. It utilizes two conductive plastic substrates with dual brushes for measurement, eliminating the need for components such as current collector rings and current collector wires, reducing production costs, avoiding poor contact, resulting in more stable and reliable signal output, and a longer service life. A brush arm is fixedly mounted on the rotating shaft, with a conductive connector fixedly connected to the brush arm. The brush arm is an injection-molded part, ensuring insulation between the brush components and the rotating shaft, preventing short circuits and other abnormalities, thus enhancing reliability. A first high-speed ball bearing and a second high-speed ball bearing are located between the rotating shaft and the housing, supporting the rotating shaft and brush arm, reducing friction during shaft movement, and ensuring rotational accuracy, thereby improving measurement accuracy. A shim is mounted on the rotating shaft, positioned on one side of the first high-speed ball bearing. The axial clearance of the product can be adjusted by increasing or decreasing the thickness of the shim to prevent vertical movement of the rotating shaft, ensuring smooth and stable brush operation and increasing the stability and accuracy of the signal output. Attached Figure Description

[0020] Figure 1 This is a top view of the dual-brush conductive angular displacement sensor of the present invention;

[0021] Figure 2 This is a cross-sectional view of the dual-brush conductive angular displacement sensor of the present invention;

[0022] Figure 3 This is a schematic diagram of the structure of the first conductive plastic substrate of the dual-brush conductive angular displacement sensor of the present invention;

[0023] Figure 4 This is a schematic diagram of the structure of the second conductive plastic substrate of the dual-brush conductive angular displacement sensor of the present invention;

[0024] The component names corresponding to the various reference numerals in the figure are as follows: 1 is the housing, 101 is the servo mounting slot, 102 is the positioning mounting hole, 103 is the upper housing, 104 is the lower housing, 2 is the rotating shaft, 201 is the groove, 3 is the first conductive plastic substrate, 301 is the first pin, 4 is the second conductive plastic substrate, 401 is the second pin, 402 is the third pin, 5 is the first brush, 6 is the second brush, 7 is the low-resistance conductive area, 8 is the conductive connector, 9 is the signal output terminal, 10 is the brush arm, 11 is the positive power supply connection terminal, 12 is the negative power supply connection terminal, 13 is the first high-speed ball bearing, 14 is the second high-speed ball bearing, 15 is the resistance paste, and 16 is the gasket. Detailed Implementation

[0025] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0026] See Figures 1-4 This invention provides a dual-brush conductive plastic angular displacement sensor, comprising: a housing 1 and a rotating shaft 2. The housing 1 houses a conductive plastic sensing mechanism, which includes a first conductive plastic substrate 3, a second conductive plastic substrate 4, a first brush 5, and a second brush 6. Both the first brush 5 and the second brush 6 are fixedly connected to the rotating shaft 2 and connected via a conductive connector 8. The first brush 5 is disposed on one side of the first conductive plastic substrate 3, and the second brush 6 is disposed on one side of the second conductive plastic substrate 4. The first conductive plastic substrate 3 is an annular, unbroken substrate with an annular, unbroken, low-resistance conductive region 7. During measurement, the rotating shaft is driven to rotate by an external power device. The rotating shaft drives the second brush to slide uniformly on the surface of the second conductive plastic substrate. This linearly changing, high-precision signal is then transmitted to the first conductive plastic substrate 3 via the first brush and finally output through a signal output terminal. Both the first brush 5 and the second brush 6 are hexavalent alloy brushes. Two conductive plastic substrates are bonded to the inside of the housing using high-strength, high-temperature resistant adhesive. A brush rotates uniformly on their surface, providing a high-precision output signal with stable, reliable performance and a long service life. Both housing 1 and shaft 2 are rotating parts.

[0027] See Figure 2 The first conductive plastic substrate 3 is positioned above the second conductive plastic substrate 4, and the first brush 5 and the second brush 6 are both placed between the first conductive plastic substrate 3 and the second conductive plastic substrate 4. The first brush 5 is positioned upwards, and the second brush is positioned downwards, resulting in a reasonable structural design.

[0028] See Figures 1-3The housing 1 has a signal output terminal 9 electrically connected to the first conductive plastic substrate 3 for facilitating the output of angular displacement signals. The low-resistance conductive area 7 is coated with low-resistance silver paste. The first conductive plastic substrate 3 has a first pin 301 electrically connected to the low-resistance conductive area 7, and the first pin 301 is electrically connected to the signal output terminal 9. The second conductive plastic substrate 4 acts as a conductive ring for transmitting signals, resulting in lower production costs, greater reliability, and reduced likelihood of short circuits and poor contact.

[0029] See Figure 2 A brush arm 10 is fixedly mounted on the rotating shaft 2. A conductive connector 8 is fixedly connected to the brush arm 10. The brush arm 10 is an injection molded part. The brush components are insulated from the rotating shaft, preventing short circuits and other abnormalities, making it more reliable in use. The brush arm and the rotating shaft are bonded together with high-strength, high-temperature resistant adhesive. The injection molded brush arm is made of PA66 plastic.

[0030] See Figure 1 , Figure 2 and Figure 4 The housing 1 has a positive power connection terminal 11 and a negative power connection terminal 12 on one side. One end of the rotating shaft 2 has a slotted groove 201. The housing 1 has a servo mounting slot 101 and a positioning mounting hole 102, allowing for easy installation and wide applicability. The groove 201 is used to adjust the starting zero position of the rotating shaft 2, making adjustment more convenient. (See reference...) Figure 1 The second conductive plastic substrate 4 is provided with a second pin 401 and a third pin 402 for connecting to a power source. The second pin 401 is electrically connected to the positive terminal 11 of the power source, and the third pin 402 is electrically connected to the negative terminal 12 of the power source. The second pin 401 is connected to the third pin 402 through a resistive paste 15. The second conductive plastic substrate 4 is a conventional conductive plastic substrate in the prior art, and will not be described in detail here.

[0031] See Figure 1 and Figure 2 The housing 1 includes an upper housing 103 and a lower housing 104. A first conductive plastic substrate 3 is fixedly installed on the upper housing 103, and a second conductive plastic substrate 4 is fixedly installed on the lower housing 104. A first high-speed ball bearing 13 and a second high-speed ball bearing 14 are provided between the rotating shaft 2 and the housing 1 to support the rotating shaft and brush arm, reduce friction during the rotation of the shaft, and ensure its rotational accuracy, thereby improving measurement accuracy. A shim 16 is fitted on the rotating shaft 2, and the shim 16 is located on one side of the first high-speed ball bearing 13. The axial clearance of the product can be adjusted by increasing or decreasing the thickness of the shim to prevent the rotating shaft from moving up and down, thereby making the brush run smoothly and increasing the stability and accuracy of the signal output.

[0032] This invention relates to a dual-brush conductive plastic angular displacement sensor. A first high-speed ball bearing and a second high-speed ball bearing are located between the rotating shaft and the housing. These bearings support the rotating shaft and brush arms, reducing friction during shaft movement and ensuring rotational accuracy, thereby improving measurement accuracy. A shim is fitted onto the rotating shaft, positioned on one side of the first high-speed ball bearing. The axial clearance of the product can be adjusted by increasing or decreasing the thickness of the shim to prevent vertical movement of the rotating shaft, thus ensuring smooth and stable brush operation and increasing the stability and accuracy of the signal output. The use of two conductive plastic substrates in conjunction with the dual brushes eliminates the need for components such as current collector rings and current collector wires, reducing production costs, avoiding poor contact, and resulting in more stable and reliable signal output and a longer service life. The brush arms are fixedly fitted onto the rotating shaft, and conductive connectors are fixedly connected to the brush arms. The brush arms are injection-molded, ensuring insulation between the brush components and the rotating shaft, preventing short circuits and other abnormalities, thus enhancing reliability.

[0033] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A dual-brush conductive angular displacement sensor, comprising: The housing (1) and the rotating shaft (2) are characterized in that the housing (1) is provided with a conductive plastic sensing mechanism, the conductive plastic sensing mechanism including a first conductive plastic substrate (3), a second conductive plastic substrate (4), a first brush (5) and a second brush (6), the first brush (5) and the second brush (6) are fixedly connected to the rotating shaft (2), the first brush (5) and the second brush (6) are connected by a conductive connector (8), the first brush (5) is disposed on one side of the first conductive plastic substrate (3), the second brush (6) is disposed on one side of the second conductive plastic substrate (4), the first conductive plastic substrate (3) is an annular unbroken substrate, the annular unbroken substrate is provided with an annular unbroken low resistance conductive area (7); The first conductive plastic substrate (3) is correspondingly disposed above the second conductive plastic substrate (4), and the first brush (5) and the second brush (6) are both placed between the first conductive plastic substrate (3) and the second conductive plastic substrate (4); the housing (1) is provided with a signal output terminal (9) electrically connected to the first conductive plastic substrate (3); a brush arm (10) is fixedly mounted on the rotating shaft (2), and the conductive connector (8) is fixedly connected to the brush arm (10), and the brush arm (10) is an injection molded part.

2. The dual-brush conductive angular displacement sensor as described in claim 1, characterized in that, The housing (1) has a positive power connection terminal (11) and a negative power connection terminal (12) on one side, and the rotating shaft (2) has a groove (201) in the shape of a line at one end. The housing (1) has a servo mounting groove (101) and a positioning mounting hole (102).

3. The dual-brush conductive angular displacement sensor as described in claim 1, characterized in that, The housing (1) includes an upper housing (103) and a lower housing (104). The first conductive plastic substrate (3) is fixedly installed on the upper housing (103), and the second conductive plastic substrate (4) is fixedly installed on the lower housing (104).

4. The dual-brush conductive angular displacement sensor as described in claim 1, characterized in that, A first high-speed ball bearing (13) and a second high-speed ball bearing (14) are provided between the rotating shaft (2) and the housing (1).

5. The dual-brush conductive angular displacement sensor as described in claim 4, characterized in that, A shim (16) is fitted on the shaft (2), and the shim (16) is placed on one side of the first high-speed ball bearing (13).

6. The dual-brush conductive angular displacement sensor as described in claim 1, characterized in that, The low-resistance conductive area (7) is coated with low-resistance silver paste, and the first conductive plastic substrate (3) is provided with a first pin (301) electrically connected to the low-resistance conductive area (7), and the first pin (301) is electrically connected to the signal output terminal (9).

7. The dual-brush conductive angular displacement sensor as described in claim 2, characterized in that, The second conductive plastic substrate (4) is provided with a second pin (401) and a third pin (402) for connecting to a power source. The second pin (401) is electrically connected to the positive terminal (11) of the power source, and the third pin (402) is electrically connected to the negative terminal (12) of the power source.

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