Elastic Sensor Holder for Motor Magnetic Sensor Alignment
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Solution Overview
Problem
Conventional magnetic sensors in motors require lengthy and risky adjustments of the distance between the sensor gear and detection portion, often resulting in damage due to the complexity and need for precise alignment, even for skilled operators.
Innovation Solution
A magnetic sensor design featuring a sensor holder with a portion to be fastened made of a material with a lower elastic modulus than the sensor mounting base and screws, allowing for fine adjustment of the distance between the sensor gear and detection portion using screws, which can be secured without adhesives, enabling quicker and safer alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between the sensor gear and detection portion is adjusted by pushing or striking the detection portion, then the distance can be modified, but the adjustment takes a long time and may cause breakage
Solution Approach 1:
The patent changes the physical state of the sensor holder by making it elastic rather than rigid, allowing distance adjustment through elastic deformation. By applying a predetermined load to the elastic sensor holder, the distance between the detection portion and sensor gear is automatically adjusted to an appropriate value, eliminating the need for manual pushing or striking operations.
Solution Approach 2:
The elastic sensor holder automatically adjusts the distance through its own elastic properties when loaded, without requiring external manual intervention. The system self-regulates the distance by utilizing the elastic deformation of the holder material under applied load, making the adjustment process automatic and eliminating time-consuming manual operations.
2Manufacturing precision
If the distance is adjusted by pushing or striking the detection portion, then the distance can be modified, but the risk of breakage increases
Solution Approach 1:
The patent changes the mechanical properties of the sensor holder from rigid to elastic, allowing controlled deformation under load. This elastic property enables distance adjustment without concentrated impact forces, significantly reducing the risk of breakage while achieving precise positioning through gradual elastic deformation under predetermined load.
Solution Approach 2:
The elastic sensor holder acts as a cushioning element that absorbs adjustment forces through elastic deformation rather than rigid impact. This beforehand cushioning effect protects the detection portion and sensor gear from breakage by distributing adjustment forces evenly throughout the elastic material structure.
3Manufacturing precision
If a skilled operator adjusts the distance while viewing the waveform, then precise alignment can be achieved, but the process remains complex and time-consuming
Solution Approach 1:
The system performs automatic distance adjustment through the elastic sensor holder's self-regulating properties under load, eliminating the need for continuous waveform monitoring and manual intervention. The elastic holder automatically achieves the appropriate distance, simplifying the adjustment process while maintaining precision without requiring complex operator skills or continuous observation.
Solution Approach 2:
The patent replaces the complex manual adjustment mechanism (involving waveform monitoring and continuous rotation) with a simpler elastic mechanical system. The elastic sensor holder's inherent elastic properties substitute for the complex feedback-controlled manual adjustment process, achieving precise alignment through material properties rather than complex operational procedures.
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 magnetic sensor allows for rapid and precise adjustment of the distance between the sensor gear and detection portion, reducing the risk of damage and enabling easier automation of the adjustment process, while eliminating the need for adhesives.
Implementation Method 1
at least the portion to be fastened of the sensor holder is made of a material having an elastic modulus lower than the materials of the sensor mounting base and the screw
Implementation Method 2
The detection portion 103 is provided with a Hall element 103a whose output voltage varies depending on a change in the magnetic field
Implementation Method 3
The sensor gear 102 is made of a magnetic material, and accordingly, the magnetic field changes with respect to the Hall element 103a in accordance with the absence or presence of the teeth 102a of the sensor gear 102 opposed to the Hall element 103a
Data Source
AI summary
A detection portion on a sensor holder attached to a sensor mounting base is arranged to be opposed to an outer periphery of a sensor gear at a predetermined distance. The sensor holder has a holder body which holds the detection portion and a portion to be fastened which is fastened to the sensor mounting base by screws. The portion to be fastened is provided integrally with one side of the holder body that is located to face opposite the sensor gear. At least the portion to be fastened of the sensor holder is made of a material having an elastic modulus lower than the materials of the sensor mounting base and the screws.