Dual-Encoder Substrate Layout for Thinner Rotation Sensing
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Solution Overview
Problem
Existing encoder configurations with separate substrates for optical and magnetic sensors face challenges in thickness reduction due to the need for multiple substrates, limiting downsizing possibilities.
Innovation Solution
The encoder unit integrates magnetic and optical encoders on a single substrate, with magnetic sensors mounted on one surface and an optical sensor on another, allowing for reduced substrate count and thickness, while maintaining accurate rotation angle and number detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If optical sensor and magnetic sensor are mounted on separate substrates, then each sensor can be independently positioned, but the encoder thickness increases and downsizing becomes difficult
Solution Approach 1:
The patent merges the optical sensor and magnetic sensor onto a single substrate, eliminating the need for multiple separate substrates. This integration directly reduces the encoder thickness while maintaining the independent positioning capability of each sensor type through appropriate mounting arrangements on the unified substrate.
2Ease of operation
If multiple substrates are used for optical and magnetic sensors, then sensor positioning is flexible, but the overall encoder structure becomes more complex
Solution Approach 1:
By combining multiple sensor mounting functions into a single substrate, the patent reduces structural complexity while preserving positioning flexibility through designed mounting configurations on the integrated substrate.
3Volume of moving object
If substrates are placed close together for compact design, then encoder size is reduced, but electrical coupling becomes more difficult
Solution Approach 1:
The integration of optical and magnetic sensors on a single substrate eliminates the need for electrical coupling between separate substrates, simplifying the manufacturing process while achieving compact encoder dimensions.
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 enables thinner encoder units with reduced substrate count, preventing sensor interference and offering design flexibility, while ensuring accurate rotation detection and easier electrical coupling, contributing to downsized encoder and robot systems.
Implementation Method 1
an optical sensor receiving light reflected by the optical scale
Implementation Method 2
a plurality of magnetic sensors on which magnetic fields of the corresponding magnets act
Data Source
AI summary
An encoder unit includes a magnetic encoder having a main gear fixed to a rotation shaft, a plurality of auxiliary gears meshing with the main gear, magnets placed in the respective auxiliary gears, and a plurality of magnetic sensors on which magnetic fields of the corresponding magnets act, an optical encoder placed apart from the magnetic encoder in an axial direction of the rotation shaft and having an optical scale fixed to the rotation shaft and an optical sensor receiving light reflected by the optical scale, and a substrate placed between the magnets and the optical scale and having one surface with the magnetic sensors mounted thereon and another surface with the optical sensor mounted thereon.