Angle Sensor Eccentricity Compensation via Groove Coupling
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Solution Overview
Problem
The existing angle sensor coupling structures are prone to vibration and eccentricity issues, leading to gear wear and reduced tooth strength, which can cause malfunction and damage.
Innovation Solution
An angle sensor design featuring a coupling member with a ring-shaped main gear and inner protrusions that transmit rotating force through a groove, allowing for precise force transmission and compensation of eccentricity, with a gap between the main gear and coupling member to maintain engagement and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If press-fitting or injection molding is used to couple the main gear to the coupling member, then the gear is firmly attached, but vibration and eccentricity cause gear wear and reduced tooth strength
Solution Approach 1:
The coupling structure is segmented into discrete components: the coupling member with groove, the main gear with inner protrusion, and the rotating shaft. This segmentation allows each component to perform its specific function independently while reducing stress concentration and vibration transmission throughout the assembly.
Solution Approach 2:
The coupling member acts as an intermediary between the rotating shaft and the main gear. It absorbs and compensates for eccentricity and vibration through its groove design, preventing these harmful effects from being directly transmitted to the gear teeth, thereby protecting gear tooth strength while maintaining reliable operation.
2Productivity
If the main gear is tightly coupled to the coupling member, then rotation is transmitted effectively, but eccentricity causes wear and potential damage
Solution Approach 1:
The coupling structure incorporates dynamic compensation capabilities through the groove design that allows the main gear to adjust its position relative to the coupling member. This dynamic adjustment enables effective rotation transmission while accommodating and compensating for eccentricity, preventing wear and damage.
Solution Approach 2:
The groove dimensions and shape are specifically designed to change the mechanical parameters of the coupling system. The groove width, depth, and profile are optimized to provide sufficient constraint for rotation transmission while allowing enough clearance to absorb eccentricity, thereby preventing gear wear.
3Duration of action of stationary object
If a complex coupling structure is used to compensate for eccentricity, then durability is improved, but manufacturing and assembly become more difficult
Solution Approach 1:
Instead of making the entire coupling structure complex, only specific local areas are designed with special features: the groove in the coupling member and the inner protrusion on the main gear. This localized complexity provides the necessary eccentricity compensation and durability improvements while keeping the rest of the structure simple and easy to manufacture.
Solution Approach 2:
The groove and inner protrusion are designed with asymmetric geometries that specifically address the eccentricity problem. The asymmetric shape allows the gear to self-align and compensate for eccentricity during operation, improving durability without requiring complex manufacturing processes for the entire assembly.
Data Source
AI summary
Disclosed is an angle sensor configured to compensate eccentricity of a main gear rotated by a rotating shaft, thus inhibiting abrasion of a gear and reduction in tooth strength and thereby improving operational reliability and durability, the angle sensor including a housing formed with a space for allowing a rotating shaft to pass, a coupling member disposed in the housing and coupled with the rotating shaft to rotate along with the rotating shaft, a ring-shaped main gear coupled to an outer circumference of the coupling member and rotated along with the coupling member, a subsidiary gear meshed with the main gear, an inner protrusion protruding inwards from an inner circumference of the main gear, and a groove formed in the coupling member, the inner protrusion being inserted into the groove to transmit a rotating force from the coupling member to the main gear.