Encoder Sensor Interval Stability via Elastic Bearing Housing
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Solution Overview
Problem
Existing encoders face challenges in maintaining the precise interval between the sensor and the code disc set, leading to unstable position detection and signal quality due to external factors and complex repair processes.
Innovation Solution
The use of bearings, bearing housing, and an elastic assembly to maintain a fixed interval between the sensor and the code disc set, allowing axial displacement and limiting rotational motion, while enabling easy replacement of faulty components and reducing vibration through a spring and damping element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the code disc and sensor are integrated into a module, then the relative position between them is easier to ensure, but the volume of the module becomes large and repair or replacement becomes complicated
Solution Approach 1:
The encoder is divided into separate functional modules: the code disc mounted on the rotating shaft, the sensor mounted on the rear end cover, and the bearing housing with elastic assembly. This segmentation allows each component to be independently manufactured, assembled, and replaced, reducing overall system complexity while maintaining precise relative positioning through the bearing support structure.
2Device complexity
If the code disc and sensor are separated structures, then the volume of the encoder becomes smaller, but the relative position between them is more likely to change due to external factors
Solution Approach 1:
The bearing housing with elastic assembly acts as an intermediary structure between the code disc and sensor. The bearing supports the rotating shaft with high precision, while the elastic assembly (spring and damping element) compensates for external disturbances, maintaining the precise interval between the code disc and sensor despite their separated locations.
3Manufacturing precision
If rigid connection is used between bearing housing and fixing end, then the interval stability is improved, but the vibration of the encoder increases
Solution Approach 1:
The connection between the bearing housing and fixing end changes from rigid to elastic by introducing a spring and damping element. This parameter change allows the system to maintain stable interval positioning while reducing vibration transmission, as the elastic assembly can absorb and dampen vibrational forces.
4Measurement precision
If the interval between sensor and code disc is not maintained, then the position detection performance deteriorates, but the device complexity increases with additional maintenance mechanisms
Solution Approach 1:
The elastic assembly with spring and damping element provides self-compensating functionality, automatically maintaining the interval between the sensor and code disc through elastic deformation and damping forces. This self-service mechanism eliminates the need for complex active control systems or frequent manual adjustments, achieving stable position detection with minimal maintenance.
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
This configuration ensures stable and accurate position detection with reduced vibration, allowing for easy maintenance and improved signal quality by maintaining the interval between the sensor and the code disc set, and facilitating the repair and replacement of components.
Implementation Method 1
By disposing the elastic assembly including the spring and the damping element, the rotational freedom of the bearing housing can be limited without affecting the axial displacement thereof, and the vibration of the encoder can be reduced
Implementation Method 2
The elastic assembly is connected with the second end of the bearing housing and the fixing end of the rotatable device
Data Source
AI summary
An encoder applied to a rotatable device including a code disc set, at least one bearing, a bearing housing, a main housing, a sensor and an elastic assembly. The code disc set is disposed on a rotation end of the rotatable device. The bearing is disposed around the rotation end, and the bearing housing is disposed around the bearing. The main housing is connected with a first end of the bearing housing. The sensor is disposed on the main housing and corresponds to the disc wheel set, and there is an interval between the sensor and the code disc set. The elastic assembly is connected with a second end of the bearing housing and a fixing end of the rotatable device. Therefore, the interval between the sensor and the code disc set is maintained to be fixed, and the good position detection performance and stable signals are obtained.