Segmented Encoder Carrier Ring for Large Shaft Alignment
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Solution Overview
Problem
Conventional encoders face challenges in installation on large shafts with complex mounting requirements, inaccessibility, and thermal expansion issues, leading to alignment and stress problems, especially in space-constrained environments like wind turbines, where lightweight materials are desired.
Innovation Solution
A carrier ring with suspension means and resilient members, allowing for adjustable attachment without heating, using a slightly larger inner dimension than the shaft, and featuring protrusions and adjustment elements to ensure secure mounting on shafts with different material coefficients of thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a unseparated carrier ring is heated and mounted on a steel shaft, then the ring can be installed on the shaft, but subsequent alignment and straightening difficulties occur due to different coefficient of thermal expansion between the light metal ring and steel shaft
Solution Approach 1:
The patent changes the installation method from thermal expansion-based (heating) to mechanical expansion-based (resilient members). The resilient members allow the ring to be expanded mechanically to fit over the shaft, then contract to secure the ring without thermal cycling that causes misalignment. This resolves the contradiction by eliminating thermal expansion differences while maintaining ease of installation.
Solution Approach 2:
The carrier ring is divided into segments or sections connected by resilient members, allowing independent adjustment of each segment. This segmentation enables the ring to adapt to shaft form defects and maintain alignment precision while keeping the installation process simple and tool-free.
2Weight of moving object
If a carrier ring is made from lightweight materials to reduce weight, then weight is reduced, but stress and alignment issues worsen when mounted on steel shafts using conventional heating methods
Solution Approach 1:
The patent changes the mounting mechanism from thermal-based to mechanical-based using resilient members. This allows lightweight materials to be used without the thermal stress and alignment problems associated with heating, as the mechanical expansion/contraction process generates no thermal stress that could compromise the lightweight structure or cause misalignment.
3Reliability
If conventional encoders are used on large diameter shafts, then encoding function is achieved, but complex and expensive specialized mounting such as toothed belt concepts are required
Solution Approach 1:
The carrier ring design provides a universal mounting solution that works on shafts of various diameters and materials without requiring specialized mounting concepts like toothed belts. The resilient member mechanism adapts to different shaft sizes and materials, simplifying the overall encoder system while maintaining reliability across applications.
4Manufacturing precision
If a carrier ring is adjusted to compensate for shaft form defects and eccentricity, then alignment precision is improved, but the adjustment process becomes time-consuming and troublesome
Solution Approach 1:
The carrier ring is segmented with resilient members that allow independent adjustment of each section. This enables quick compensation for shaft form defects and eccentricity by simply adjusting individual segments rather than requiring complex realignment of the entire ring, significantly reducing adjustment time while maintaining precision.
Solution Approach 2:
The resilient members provide dynamic adjustability, allowing the ring to be easily adjusted to compensate for shaft imperfections. The resilient connection enables simple positional adjustments without requiring complex tools or procedures, reducing adjustment time while achieving the necessary alignment precision.
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
Facilitates easy, uncomplicated installation and adjustment of the carrier ring, reducing stress and alignment issues, enabling the use of lightweight materials and eliminating the need for specialized mounting or heating, thus simplifying the assembly process and reducing costs.
Implementation Method 1
suspending means with resilient members... The resilient members are adjustable in the direction towards the central axis of the ring
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The present invention relates to a carrier ring (2) for an encoder (1). The carrier ring (2) comprises suspension means with resilient members (6; 6'; 7; 7'; 8; 8'). The carrier ring is radially divided and is demountable in at least two sections such that the carrier ring is attachable around a shaft, and the inner periphery (11) of the carrier ring (2) comprises protrusions (10) which are fixed or adjustable in the direction (R1) towards the central axis (C) of the ring (2) and are intended as contact surfaces towards the shaft.