Annular Rotary Encoder Wiring Layout for Narrow Shaft Spaces
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Solution Overview
Problem
Existing rotary encoders face challenges in efficiently routing and hard-wiring inter-substrate wiring cables in narrow annular spaces, leading to signal quality deterioration, poor usage efficiency, and increased costs due to non-standardized cable lengths for motors of different sizes.
Innovation Solution
The rotary encoder employs an annular printed wiring substrate with a wiring pattern for power supply and signal transfer, interconnected with mounting substrates via radial bridging inter-substrate wiring cables, eliminating the need for extensive cable routing and allowing for standardized components across different motor sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inter-substrate wiring cables are routed around the edges of encoder substrates in a narrow annular space, then the substrates can be connected, but the signal quality deteriorates and additional routing space is required
Solution Approach 1:
The patent changes the routing dimension from circumferential (around the edges) to radial (across the width of the annular space). Wiring cables are routed radially between adjacent encoder substrates rather than circumferentially around their edges, utilizing the unused radial dimension of the narrow annular space. This resolves the contradiction by providing adequate cable routing space without compromising signal quality, as the radial path is shorter and does not require additional circumferential routing space.
2Ease of operation
If cable connectors are mounted on substrates facing in the circumferential direction to draw out wiring cables, then cables can be connected, but adjacent substrates must be set apart reducing space utilization
Solution Approach 1:
The patent inverts the conventional approach by mounting cable connectors to face radially inward or outward instead of circumferentially. Wiring cables are drawn out radially between adjacent substrates rather than circumferentially from facing connectors. This inversion eliminates the need to set adjacent substrates apart, maximizing the utilization of the narrow annular space while maintaining ease of wiring operations.
3Adaptability or versatility
If standard encoder substrates are assembled in motors of different sizes, then substrate standardization is achieved, but inter-substrate wiring cable lengths must be changed for each motor size increasing costs
Solution Approach 1:
The patent makes the inter-substrate wiring cables universal by routing them radially between adjacent substrates. This radial routing configuration allows the same cable length and connector configuration to be used across different motor sizes, as the cables connect adjacent substrates regardless of the overall encoder diameter. This resolves the contradiction by enabling both substrate standardization and cable standardization, reducing manufacturing costs while maintaining adaptability to different motor sizes.
Data Source
AI summary
A rotary encoder is incorporated in an annular space formed between a hollow rotating shaft and an encoder case. The rotary encoder has an annular printed wiring substrate, a plurality of mounting substrates that are outward from the printed wiring substrate in the radial direction and are arranged in the circumferential direction, and inter-substrate wiring cables bridged between the printed wiring substrate and each of the mounting substrates in the radial direction. Power supply to the mounting substrates and signal transmission and reception between the mounting substrates can be accomplished without routing around the wiring cables. It is possible to achieve a rotary encoder that is suitable for being incorporated in a narrow annular space.