Encoder Floating Connector Design for Assembly
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Solution Overview
Problem
Conventional encoders require time-consuming soldering processes for fixing sensor parts, increasing manufacturing time and cost, while flexible connectors compromise strength, and optical adjustments are complex and labor-intensive.
Innovation Solution
An encoder design featuring a movable part, a sensor part, a flange, and floating connectors that eliminate the need for soldering by allowing optical positional adjustments and using a rigid connector for increased strength and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to fix the sensor part, then the encoder strength and reliability are improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent replaces the soldering process (thermal/mechanical joining method) with a connector-based mechanical connection system. The sensor part is fixed to the case via a connector that can be attached through simple insertion or snap-fit mechanisms, eliminating the need for soldering irons, flux, and reflow ovens, thereby drastically reducing manufacturing time while maintaining structural integrity through proper connector design
Solution Approach 2:
The patent divides the encoder into modular components: the sensor part, the case, and the connector as a separate element. This segmentation allows the sensor part to be independently mounted to the case using the connector, enabling rapid assembly without committing the sensor part to permanent soldered joints, thus reducing manufacturing complexity and time
2Ease of operation
If a flexible connector is used to allow optical positional adjustment, then the ease of operation is improved, but the connector strength is reduced
Solution Approach 1:
The patent incorporates a floating connector design that allows dynamic positional adjustment. The connector can move or flex within certain limits to accommodate optical alignment requirements while maintaining sufficient structural strength. This dynamic capability enables the connector to adapt to positional variations without requiring excessive flexibility that would compromise strength
Solution Approach 2:
The patent modifies the connector's physical parameters (such as material selection, cross-sectional geometry, or structural configuration) to achieve an optimal balance between flexibility for optical adjustment and sufficient strength for mechanical support. By carefully controlling these parameters, the connector provides just enough compliance for alignment while maintaining the necessary load-bearing capacity
3Measurement precision
If optical positional adjustment is performed manually, then the measurement precision is improved, but the productivity is reduced
Solution Approach 1:
The patent designs the connector and sensor part mounting structure to enable self-alignment or automatic positioning. The floating connector naturally positions the sensor part relative to the case through mechanical guidance features (such as ribs, slots, or tapered surfaces), eliminating the need for manual optical adjustment while maintaining sufficient positioning accuracy for functional operation
Data Source
AI summary
An encoder and a manufacturing method thereof, by which the encoder can be manufactured by a few processes at a low cost. The encoder has a rotating slit rotatable about an axis, a printed circuit board for measuring a rotational displacement of the rotating slit, a flange to which the printed circuit board is fixed after positioning the printed circuit board, a first connector fixed to the flange, and a second connector mounted on the printed circuit board and connected to the first connector. At least one of the first connector and the second connector is a floating connector having a structure configured to absorb a displacement at least in a direction perpendicular to the axis 12.