Angled PCB Rotary Angle Sensor for Compact Motor Installation
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Solution Overview
Problem
Rotary angle measuring systems in limited installation spaces, such as electric motors, face challenges with both radial and axial space constraints, requiring a more compact design.
Innovation Solution
The rotary angle measuring system is designed with a printed circuit board arrangement where the second board section is angled relative to the first, overlapping partially in projection, and connected via a flexible third board section, allowing for reduced radial and axial space usage, along with a shielding element to protect sensors from external fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the printed circuit board sections are arranged at an angle to reduce radial extent, then the radial installation space is reduced, but the axial extent increases
Solution Approach 1:
The patent applies dimensionality change by arranging the printed circuit board sections at an angle (specifically 45 degrees) relative to each other and to the shaft axis. This angular arrangement transforms the spatial configuration from a conventional planar layout to a three-dimensional angled structure, allowing the sensor system to fit within a smaller radial envelope while distributing the axial footprint across multiple sections connected by flexible circuits.
2Area of stationary object
If the printed circuit board sections are arranged at an angle to reduce radial extent, then the radial installation space is reduced, but both radial and axial installation spaces are constrained
Solution Approach 1:
The patent segments the printed circuit board into multiple sections (first, second, and third printed circuit board sections) that are arranged at different angles and positions. Each section houses specific components (excitation unit, sensor unit, evaluation electronics) and is connected via flexible printed circuit boards. This segmentation allows the system to navigate complex installation space constraints by distributing components across multiple angled sections rather than requiring a single large planar board.
Solution Approach 2:
The patent employs flexible printed circuit boards to connect the rigid printed circuit board sections. These flexible connections allow the system to adapt to varying installation conditions and maintain electrical connectivity while accommodating the angled arrangement of board sections. The flexibility enables the structure to be installed in constrained spaces where rigid connections would be impossible.
3Area of stationary object
If the second printed circuit board section is arranged to overlap in projection with the excitation unit, then the radial extent is minimized, but the axial arrangement becomes more complex
Solution Approach 1:
The patent implements a nested arrangement where the second printed circuit board section is positioned such that its parallel projection onto a longitudinal plane overlaps with the projection of the excitation unit. This nesting allows the sensor section to be radially aligned with the excitation magnet, minimizing the overall radial extent of the measuring system. The flexible printed circuit board connects these nested sections, allowing the sensor unit to be positioned in radial proximity to the excitation unit while maintaining electrical connectivity through the flexible intermediary.
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
This configuration results in a compact rotary angle measuring system with precise and reliable detection capabilities, minimizing installation space requirements while maintaining accuracy and protection from external interference.
Implementation Method 1
an excitation unit which is co-rotatably connected to the shaft and which comprises at least one permanent magnetic excitation magnet
Implementation Method 2
a first magnetic field sensor which is arranged on the first printed circuit board section and via which an excitation magnetic field generated by the excitation unit can be detected
Data Source
AI summary
A rotary angle measuring arrangement includes a shaft, and a rotary angle measuring system which detects a rotary shaft movement. The rotary angle measuring system includes an excitation unit connected to the shaft which generates a magnetic field, a magnetic field sensor, a PCB arrangement, and an evaluation electronics arranged on the PCB arrangement and electrically connected to the magnetic field sensor. The PCB arrangement includes a first PCB section arranged perpendicular to a longitudinal axis of the shaft, and a second PCB section angled with respect to the first PCB section and electrically connected thereto. The magnetic field sensor is arranged on the first PCB section. The magnetic field is detectable via the magnetic field sensor. A parallel projection of the second PCB section onto a longitudinal plane parallel to the longitudinal axis and a parallel projection of the excitation unit onto the longitudinal plane at least partially overlap.