Elastic Encoder Binding Force and Sealing via Composite Magnet
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Solution Overview
Problem
Conventional encoders face challenges in achieving a strong binding force between metallic and plastic components, leading to potential damage and infiltration of foreign substances due to material differences and protrusions, which affect the stability and sealing of wheel bearings.
Innovation Solution
An elastic encoder design featuring a reinforcing rim with a metallic flange and a plastic magnet made of synthetic resin, rubber, and magnetic powder, where the plastic magnet is bound to the flange with specific binding parts and magnetized to enhance binding force and prevent damage, while the rubber material provides elasticity and the magnetic poles ensure accurate rotation detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic back plate and plastic magnet are bound together using conventional methods, then the encoder can detect rotation, but the binding force between the different materials is insufficient leading to potential damage
Solution Approach 1:
The invention uses a composite plastic magnet made of synthetic resin, rubber material, and magnetic powder. The rubber material provides elasticity and shock absorption, while the synthetic resin provides structural integrity. This composite structure allows the magnet to withstand external impacts without damage while maintaining strong binding force to the metallic back plate, resolving the contradiction between binding strength and damage resistance.
2Stability of the object's composition
If protrusions are inserted into hole parts to bind the magnet to the back plate, then the binding is stable, but the protrusions prevent proper installation of sealing members and allow foreign substance infiltration
Solution Approach 1:
The invention extracts the protrusion structure from the binding mechanism. Instead of using protrusions that extend outward and interfere with sealing, the magnet is bound to the back plate through a flat surface configuration where the plastic magnet directly contacts the metallic back plate without protruding elements. This eliminates the harmful effect of foreign substance infiltration while maintaining binding stability through the composite material's inherent adhesion and friction.
3Volume of moving object
If the plastic magnet has small thickness to reduce size, then the encoder is compact, but the magnet becomes susceptible to damage from external impacts
Solution Approach 1:
The invention changes the material parameters of the plastic magnet by incorporating rubber material into the composite structure. The rubber provides elastic properties that allow the thin magnet to absorb external impacts through deformation and rebound, preventing permanent damage. This parameter change in material composition enables the magnet to maintain small thickness while gaining impact resistance.
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 solution improves the binding force between the plastic magnet and the reinforcing flange, prevents foreign substance infiltration, and maintains stable output characteristics and pitch deviations, even under thermal variations, enhancing the encoder's durability and performance.
Implementation Method 1
a plastic magnet which is bound to the reinforcing flange so as to surround the reinforcing flange, includes synthetic resin, rubber material, and magnetic powder, and has a plurality of magnetic poles magnetized in a circumferential direction
Implementation Method 2
the rubber material provides elasticity and the magnetic poles ensure accurate rotation detection
Data Source
AI summary
Disclosed herein are an elastic encoder and manufacturing method thereof. The elastic encoder of the present invention includes a reinforcing rim which has a reinforcing body and a reinforcing flange formed along a peripheral part of the reinforcing body and which is manufactured using a metallic material; and a plastic magnet which is bound to the reinforcing flange so as to surround the reinforcing flange, includes synthetic resin, rubber material, and magnetic powder, and has a plurality of magnetic poles magnetized in a circumferential direction.