Encoder PCB Reinforcement for Vibration and Shock Durability
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Solution Overview
Problem
Encoders attached to electric motors or driven apparatuses face malfunctions or damage due to excessive vibration or shock, as the center portion of the printed board vibrates widely, leading to electronic part failures, and existing solutions like acceleration sensors or vibration-proof springs are costly and complex.
Innovation Solution
A simple reinforcing member is used to contact the printed board at a non-peripheral portion, forming a vibration node to reduce resonance, with a structure that includes a rod or plate member extending radially and upwardly, and an auxiliary member contacting the center of the printed board, made from materials like engineering plastic, ceramic, or metal, to minimize vibration displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the printed board is fixed only at peripheral portions to the housing, then the encoder structure remains simple and cost-effective, but the center portion of the printed board vibrates widely under excess vibration or shock, causing malfunction or breakage of electronic parts
Solution Approach 1:
The encoder housing serves dual functions: it provides the structural enclosure and simultaneously acts as the vibration reduction member that contacts the printed board at the center portion. This self-service approach eliminates the need for separate vibration reduction components, maintaining structural simplicity while improving reliability against vibration and shock.
Solution Approach 2:
The housing is designed to perform multiple functions: it encloses the encoder components, provides mounting surfaces for the printed board at peripheral portions, and simultaneously contacts the center portion of the printed board to reduce vibration. This multi-functionality resolves the contradiction by improving vibration resistance without adding device complexity.
2Reliability
If acceleration sensors or vibration-proof spring members are arranged in the encoder to reduce vibration, then the vibration resistance improves, but the encoder becomes expensive and difficult to make compact
Solution Approach 1:
The vibration reduction function is extracted from separate components (acceleration sensors, spring members) and integrated directly into the housing structure through strategic contact points on the printed board. This extraction eliminates the need for complex vibration sensing and compensation mechanisms while maintaining vibration resistance.
Solution Approach 2:
The housing structure itself provides vibration reduction by contacting the printed board at specific locations, eliminating the need for separate vibration-proof components. This self-service approach maintains encoder compactness and simplicity while improving vibration resistance.
3Reliability
If resin is used to harden the center portion of the printed board to improve vibration resistance, then the durability against vibration improves, but a huge amount of effort and cost is required, increasing encoder cost and decreasing production efficiency
Solution Approach 1:
The housing structure provides vibration reduction through mechanical contact at the printed board center, eliminating the need for resin hardening processes. This approach maintains manufacturing simplicity and efficiency while improving vibration resistance, as it requires only standard assembly operations without additional coating or curing steps.
Solution Approach 2:
The vibration reduction function is extracted from material modification (resin hardening) and implemented through structural design of the housing. This extraction maintains ease of manufacture by using standard mechanical assembly rather than requiring complex coating or curing processes.
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 reinforcing member effectively reduces vibration at the contact point, increasing the resonant frequency and minimizing adverse effects on electronic parts, while maintaining a compact and cost-effective design without the need for complex circuits or resin reinforcement.
Implementation Method 1
a vibration node is formed at the portion of the printed board where the reinforcing member contacts, in order to reduce vibration due to resonance of the printed board
Data Source
AI summary
A reliable encoder capable of reducing vibration of a printed board when the encoder is subjected to vibration or shock, by means of a simple structure. The encoder has a housing, a rotating code plate arranged in the housing and configured to rotate in synchronization with an object to be measured, a printed board attached to the housing and positioned above the rotating code plate, wherein the encoder has a reinforcing member configured to contact a portion of the printed board where the displacement of the printed board is large while the printed board is resonated due to vibration or shock applied to the encoder.