Annular Gear Sensor Unit With Single-Interface PCB Integration
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Solution Overview
Problem
The existing design of sensor units for mechanical systems, such as gears, is costly and time-consuming due to the complex wiring of sensor devices and printed circuit boards, which complicates their integration and connection to external voltage and signal evaluation units.
Innovation Solution
A sensor unit with a pre-fitted annular base body that houses various sensor components and a printed circuit board, featuring a single interface for external connections, allowing for rapid and cost-effective installation by positioning measurement variable pickups on one end and the voltage supply and signal transmission interface on the opposite end, with the printed circuit board protected within the base body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor devices and printed circuit boards are separately installed and wired in mechanical systems, then measurement functionality is achieved, but installation time and cost increase significantly
Solution Approach 1:
The patent combines multiple sensor devices (temperature, vibration, torque sensors) and their corresponding printed circuit boards into a single integrated sensor unit. This merging eliminates the need for separate installation and wiring of each sensor, directly reducing installation time while maintaining all measurement functionalities.
Solution Approach 2:
The sensor devices and printed circuit boards are pre-assembled and pre-wired into a complete sensor unit before installation in the mechanical system. This preliminary assembly ensures that all connections are already established, allowing for rapid installation without time-consuming on-site wiring.
2Reliability
If multiple sensor devices are installed at various points on the gear, then comprehensive measurement coverage is achieved, but wiring complexity and cost increase
Solution Approach 1:
Multiple sensor devices for different measurement variables (temperature, vibration, torque) are merged into a single sensor unit with integrated printed circuit boards. This consolidation maintains comprehensive measurement coverage while dramatically reducing wiring complexity by providing a single interface instead of multiple separate connections.
Solution Approach 2:
The sensor unit is designed as a multi-functional device that can measure multiple variables (temperature, vibration, torque) simultaneously through a single installation. This universality eliminates the need for separate single-function sensors and their associated wiring for each measurement type.
3Reliability
If printed circuit boards are connected to external voltage supply and signal evaluation units through multiple wiring points, then electrical connectivity is achieved, but installation cost and time increase
Solution Approach 1:
The complex internal wiring and printed circuit board connections are extracted and pre-assembled within the sensor unit housing. This extraction leaves only a single external interface that needs to be connected to the voltage supply and signal evaluation units, dramatically simplifying installation and reducing costs.
Solution Approach 2:
All electrical connections between sensor devices and printed circuit boards are pre-established during sensor unit manufacturing. This preliminary wiring action transfers the complexity from the installation phase to the manufacturing phase, where it can be efficiently handled, resulting in simple field installation.
Data Source
AI summary
A sensor unit includes sensor constituent parts of various sensor devices and at least one printed circuit board that has voltage supply and signal transmission components for the sensor constituent parts and to which the sensor constituent parts are connected. The sensor unit has an annular base body that receives the sensor constituent parts and the at least one printed circuit board. A gear having such a sensor unit is also provided. A drive train having such a gear, a wind power installation having such a drive train, and an industrial application having such a gear are provided.