Rotary Encoder Without Stopping Structure for 360-Degree Rotation
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Solution Overview
Problem
Conventional encoders have limited channel numbers due to a stopping structure that restricts the rotating angle, leading to instability in electrical brush contact and reduced service life due to insecure riveting and thermal expansion issues.
Innovation Solution
An encoder design without a stopping structure, featuring a rotating shaft with a 360-degree or greater rotation angle, elongated elastic arms for stable brush contact, and a secure connection between the electric brush and circuit plate using a plastic covered part, bent part, and elastic arm integrated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stopping structure is used to limit the rotating angle of the rotating shaft, then the encoder structure is simple and easy to manufacture, but the number of channels is limited and cannot be increased
Solution Approach 1:
The patent removes the stopping structure (stop blocks and stopping base) from the encoder system. By extracting this limiting component, the rotating shaft can rotate more than 360 degrees, enabling the number of channels to be increased to 32 or more while maintaining ease of manufacture for the remaining components.
2Strength
If the electrical brush is riveted with the circuit plate at high temperature, then the connection is strong, but thermal expansion and contraction loosen the electrical brush reducing service life
Solution Approach 1:
The patent changes the connection method from high-temperature riveting to a press-fit or snap-fit structure. The electrical brush is inserted into the movable arm with a fitted connection that does not require high-temperature processing, thereby avoiding thermal expansion and contraction issues while maintaining strong connection strength and extending service life.
3Reliability
If the electrical brush is riveted with the movable arm, then the electrical brush is secured, but the riveting process causes the brush head height to decrease by 50% resulting in unstable contact
Solution Approach 1:
The patent removes the riveting process from the electrical brush assembly. By eliminating this manufacturing step, the brush head height is preserved without the 50% reduction caused by riveting, ensuring stable contact with the circuit plate while maintaining security through the fitted connection structure.
4Device complexity
If the elastic arm of the electrical brush is too short, then the structure is compact, but the angle between the elastic arm and arm seat changes greatly loosening the electrical brush
Solution Approach 1:
The patent changes the length parameter of the elastic arm, making it longer than in conventional designs. This increased length reduces the angular change between the elastic arm and arm seat during operation, preventing loosening of the electrical brush and ensuring stable contact, while the overall structure remains compact through optimized component arrangement.
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
Increases channel numbers to 32 or more, enhances signal stability by ensuring a secure and stable connection between the electric brush and circuit plate, and improves contact reliability by reducing thermal expansion effects.
Implementation Method 1
an elastic arm of the electrical brush is too short... the length of the electrical brush is too short, then an angle between the elastic arm and the arm seat changes greatly to loosen the electric brush
Data Source
AI summary
An encoder without a stopping structure comprises a rotating shaft (1), an axis sleeve (2), a stopping base (4), a positioning elastic trip (5), a spacer (6), a partition plate (7), at least one movable arm (8), at least one electric brush (9) and at least one main body (11), and they are sequentially arranged from bottom to top. There is not any stopping structure on the rotating shaft (1) and the stopping base (4). The rotating shaft (1) can be rotated 360 degrees or more. The electric brush (9) has a plastic covered part (91), a bent part (92), an elastic arm (93) and a brush head (94) forming an integrated structure. The plastic covered part (91) is covered in a movable arm (8). The bent part (92) connects the plastic covered part (91) and the elastic arm (93) and bends the elastic arm (93) toward the plastic covered part (91). The elastic arm (93) comprises a main arm (931) with long strip ring body and a branch arm (932). Said brush head (94) is pressed at the free ends of the main arm (931) and the branch arm (932). The number of channels of the encoder increases to 32 or more, so that the programming and operating control can be conveniently realized. The electric brush is connected steadily with the circuit plate of the encoding circuit because of the electric brush without any loose situations.