Ball Screw Recirculation Cover Integrated Sensor Detection
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Solution Overview
Problem
Existing ball screw systems experience excessive vibration and potential damage due to high-speed operation, and current detection methods require additional sensors and complex configurations that increase the overall length and complexity of the nut, compromising movement and requiring external components.
Innovation Solution
A ball screw structure with a microcontroller and sensor integrated into the recirculation cover, which includes a recirculation passage for the ball assembly, allowing direct detection of the screw shaft's rotation state and transmitting signals through a buzzer, light-emitting diode, or wireless communication to a receiver unit, reducing the need for external sensors and minimizing space occupation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If a sensor element is additionally installed to detect rotation state, then detection function is improved, but the overall length of the nut increases
Solution Approach 1:
The sensor element and microcontroller are merged into the recirculation cover, which is an existing component of the ball screw system. This integration allows the detection function to be added without increasing the overall length of the nut, as the sensor is housed within the existing recirculation cover structure rather than being added as a separate external component.
Solution Approach 2:
The recirculation cover is given multiple functions: it continues to serve its original purpose of recirculating balls while simultaneously housing the sensor element and microcontroller for rotation state detection. This multi-functionality eliminates the need for additional space-consuming components dedicated solely to detection.
2Difficulty of detecting and measuring
If a detection device is arranged in a recess of the nut, then detection function is improved, but the overall length of the nut increases
Solution Approach 1:
The detection device is merged with the recirculation cover rather than being arranged in a recess of the nut. The recirculation cover already occupies the necessary space near the nut, and by integrating the sensor and microcontroller into this existing structure, the detection function is achieved without modifying the nut's dimensions or adding to its overall length.
3Difficulty of detecting and measuring
If a sensor and controller are mounted externally, then detection function is improved, but the configuration and size of the nut must vary
Solution Approach 1:
The sensor and microcontroller are merged into the recirculation cover, which is a standard component of the ball screw system. This internal integration eliminates the need for external mounting and avoids any variation in the configuration and size of the nut, maintaining the original compact design while adding detection capability.
Solution Approach 2:
The recirculation cover serves itself by housing not only the ball recirculation function but also the detection system. The microcontroller and sensor are contained within the existing structure, allowing the system to provide detection services without requiring external components or modifications to the nut's configuration.
4Device complexity
If detection components are integrated into the recirculation cover, then device complexity is reduced, but space for ball assembly movement must be maintained
Solution Approach 1:
The recirculation cover is segmented into distinct functional zones: one area houses the microcontroller and sensor elements, while another area provides the necessary space for the ball assembly to move and recirculate. This segmentation allows both the detection function and ball movement space to coexist within the same component without interference.
Solution Approach 2:
The detection components are arranged in a different spatial dimension within the recirculation cover, utilizing the vertical or radial space rather than the axial space required for ball assembly movement. This dimensional arrangement allows the sensor and microcontroller to be housed without encroaching on the movement space of the ball assembly.
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 solution effectively detects the rotation state of the screw shaft, reduces vibration-related damage, and simplifies the configuration by integrating detection components within the recirculation cover, enabling efficient diagnosis and inspection without extending the nut's length or increasing complexity.
Implementation Method 1
the sensor being directly provided in the inside thereof with a recirculation channel to allow a ball assembly to move therethrough for recirculation and is removably mounted to a flattened portion of the nut with occupying an additional space so as to directly detect a rotation state of the screw shaft
Implementation Method 2
indicating the detected screw shaft state in the form of a signal of sound (with a buzzer) and lighting (with a light-emitting diode)
Implementation Method 3
indicating the detected screw shaft state in the form of a signal of sound (with a buzzer)
Data Source
AI summary
A ball screw structure with detection function includes a screw shaft having an external screw groove; a nut mounted to the screw shaft to be movable in an axial direction of the screw shaft and having an internal screw groove, which corresponds to the external screw groove of the screw shaft to define a loading channel between the internal screw groove of the nut and the external screw groove of the screw shaft; a ball assembly movable, through rolling, in the loading channel; and a recirculation member directly mounted to the nut and provided thereon with a microcontroller and a sensor to detect a rotation state of the screw shaft inside the nut and further formed with a recirculation passage in communication with the nut to allow the ball assembly to move and recirculate therethrough.