Angular Position Sensor Assembly Using Intermediary Mounting Plate
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Solution Overview
Problem
The production costs and reject rates for angular position sensors, particularly those using Hall sensors, are high due to the need for precise alignment and calibration, which increases the complexity and time required for assembly.
Innovation Solution
A method for producing angular position sensors that involves using an assembly tool with a receptacle for the Hall sensor and a housing alignment device, allowing for precise alignment and fastening of the circuit board to the housing without the need for fine adjustments, thereby reducing production costs and reject rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discrete Hall sensors are used with manual alignment, then flexibility in sensor positioning is improved, but manufacturing precision and assembly time deteriorate
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component between the Hall sensor and the housing. The mounting plate features a recess that precisely receives the Hall sensor chip, ensuring accurate positioning. This mediator transfers the positioning function from manual alignment to a predefined mechanical interface, resolving the contradiction between flexibility and precision.
Solution Approach 2:
The Hall sensor chip is pre-positioned within a recess on the mounting plate during manufacturing. This preliminary action ensures that when the assembly is put together, the sensor is already in its correct position, eliminating the need for time-consuming manual alignment and calibration during final assembly.
2Measurement precision
If manual alignment and calibration procedures are used, then measurement precision is improved, but productivity and assembly time deteriorate
Solution Approach 1:
The mounting plate with its precisely engineered recess serves as a self-aligning fixture. When the Hall sensor chip is placed in the recess, it automatically assumes the correct position without requiring external alignment tools or manual adjustment. This self-service mechanism maintains measurement precision while dramatically improving assembly speed.
Solution Approach 2:
The precise positioning features are built into the mounting plate during manufacturing, performing the alignment function in advance. This preliminary preparation eliminates the need for time-consuming calibration procedures during assembly, thereby improving productivity without sacrificing measurement precision.
3Manufacturing precision
If multipart housing design with fine adjustment capability is used, then alignment precision is improved, but device complexity deteriorates
Solution Approach 1:
The patent combines the positioning and support functions into a single integrated mounting plate component. The mounting plate features a recess that simultaneously provides precise positioning and mechanical support for the Hall sensor chip. This merging of functions eliminates the need for complex multipart housing designs with multiple adjustment mechanisms.
Solution Approach 2:
The mounting plate acts as an intermediary between the circuit board and the housing, providing a simplified interface that ensures precise positioning without requiring complex housing structures. The plate's recess precisely receives the sensor chip, while the overall plate geometry ensures correct positioning relative to the housing, thereby simplifying the housing design.
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 method reduces production costs and reject rates by simplifying the assembly process, improving the alignment precision of the Hall sensor, and eliminating the need for extensive calibration, while also enhancing the robustness and quality of the angular position sensors.
Implementation Method 1
the angular position sensor includes a circuit board with a Hall sensor... the Hall sensor interacts with a magnet that is rotatably fastened to the rotor
Data Source
AI summary
A method for producing an angular position sensor, in which a Hall sensor fastened to a printed circuit board is inserted into a receptacle of an assembly tool. A housing is arranged around the printed circuit board, wherein the housing is aligned with the assembly tool, and the printed circuit board is fastened to the housing. The invention also relates to an assembly tool and an angular position sensor.