Magnet-Integrated Absolute Encoder Gearing for Precise Position Detection
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Solution Overview
Problem
Conventional absolute encoders face issues with misalignment and synchronization of magnetic field generating and detecting elements, leading to inaccurate angular position detection.
Innovation Solution
The absolute encoder design includes a first driving gear with a magnet, a first driven gear, a second driving gear, and a second driven gear, with specific configurations to ensure proper alignment and synchronization, enhancing magnet holding capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic field generating element is provided at one end of the layshaft, then the absolute encoder can detect angular positions, but misalignment and synchronization issues occur between the magnetic field generating element and the magnetic detecting element
Solution Approach 1:
The patent replaces the direct mechanical coupling system with a magnetic field-based detection system. Instead of mechanically linking the magnet to the layshaft, the magnet is integrated into the first driving gear that rotates with the spindle, while the magnetic detecting element remains on the layshaft. The magnetic field transmits rotational position information without requiring mechanical synchronization, eliminating misalignment issues between rotating components.
Solution Approach 2:
The first driving gear serves multiple functions: it transmits rotational motion from the spindle to the layshaft through gear engagement, and simultaneously carries the magnetic field generating element to provide angular position detection. This multi-functionality eliminates the need for separate magnet mounting mechanisms and ensures automatic synchronization between the magnet and spindle rotation.
2Measurement precision
If the magnetic detecting element is positioned to detect the magnetic field, then angular position can be measured, but misalignment between centers causes detection errors
Solution Approach 1:
The patent replaces mechanical alignment requirements with magnetic field-based detection. The magnetic field generated by the magnet on the first driving gear can be detected by the magnetic detecting element on the layshaft without requiring precise center alignment between the two components. The magnetic field naturally follows the rotation of the first driving gear, providing accurate angular position information regardless of slight misalignments in component centers.
3Measurement precision
If rotations of the magnetic field generating element and the layshaft are not synchronized, then detection accuracy deteriorates, but mechanical coupling adds complexity
Solution Approach 1:
The patent replaces complex mechanical synchronization mechanisms with a magnetic field transmission system. The magnet on the first driving gear generates a magnetic field that directly reflects the rotational position of the spindle, which is then detected by the magnetic detecting element on the layshaft. This eliminates the need for complex mechanical coupling and synchronization mechanisms while maintaining high detection accuracy.
Solution Approach 2:
The patent merges the functions of the magnet and the first driving gear into a single integrated component. The magnetic field generating element is provided on the first driving gear, combining the drive function and the detection reference function in one component. This simplifies the overall structure by eliminating separate magnet mounting mechanisms and ensures automatic synchronization between the magnet rotation and the drive gear rotation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The improved design allows for more precise and reliable detection of angular positions, reducing misalignment and synchronization issues.
Implementation Method 1
a magnetic field generating element (magnet) is provided at one end of the layshaft, and a magnetic field generated from the magnetic field generating element is detected by a magnetic detecting element
Data Source
AI summary
An absolute encoder includes a spindle gear fixed to a motor shaft, a permanent magnet provided on the spindle gear, and a first driven gear having a center axis perpendicular to a center axis of a worm gear portion, and engaging the worm gear portion. The absolute encoder includes a second driving gear provided coaxially with the first driven gear and rotating according to a rotation of the first driven gear, and a second driven gear having a center axis perpendicular to the center axis of the first driven gear, and engaging the second driven gear. The spindle gear includes a magnet holder which is fit onto a tip end of the motor shaft, coaxially with the motor shaft, and a resin gear portion provided with the worm gear portion on an outer side in a radial direction.