Encoder Sensor Mounting Body With Pressing Contact Part

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Solution Overview

Problem

Existing encoder sensor mounting methods require soldering, making them difficult to detach, time-consuming, and not lead-free, which is environmentally unfriendly and complicates assembly.

Innovation Solution

An encoder sensor mounting body with a base that uses a pressing contact part to attach to the motor's electrode terminal, allowing for detachable and adjustable attachment without soldering, utilizing a relay connector for signal and power lines, and a fitting part for secure positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering is used to fix the substrate and encoder sensor to the electrode terminal, then the fixing strength and reliability are improved, but the ease of manufacture deteriorates due to time-consuming assembly and lead usage

Engineering Contradiction:

Improvefixing strengthVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the soldering process (thermal/chemical joining) with a mechanical pressing connection system. The base includes a pressing contact part that mechanically connects to the electrode terminal through pressing force, eliminating the need for soldering while providing reliable electrical connection and mechanical fixation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent divides the encoder assembly into separable components: the base with pressing contact part and the encoder sensor mounted on it. This segmentation allows the encoder sensor to be easily attached and detached from the base, and the base to be connected to the motor without permanent soldering, thus reducing assembly time and enabling lead-free construction.

Inventive Principle:

Principle #1Segmentation

2Reliability

If soldering is used to fix the encoder sensor, then the reliability of the connection is improved, but the ease of operation deteriorates because the encoder becomes difficult to remove and reattach

Engineering Contradiction:

Improveconnection stabilityVSAvoiddetachability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent implements a dynamic connection system where the base can be pressed onto and detached from the electrode terminal multiple times. The pressing contact part maintains reliable electrical connection during operation while allowing easy removal and reattachment when needed, providing both stability and flexibility.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The base is designed with a pressing contact part that pre-establishes a reliable mechanical and electrical connection when pressed onto the electrode terminal. This preliminary mechanical connection ensures stable operation while inherently allowing easy detachment without requiring solder melting, thus solving both reliability and detachability requirements.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If soldering is used for fixing the encoder sensor, then the electrical connection reliability is improved, but the environmental friendliness deteriorates due to lead usage

Engineering Contradiction:

Improveelectrical connectionVSAvoidlead contamination

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the soldering process (which uses lead) with a mechanical pressing connection system. The electrical connection is established through direct metal-to-metal contact via the pressing contact part, eliminating the need for solder and lead entirely, thus achieving lead-free and environmentally friendly construction while maintaining reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If the encoder sensor is mounted on a substrate at the end surface of the motor, then the wiring is simplified, but the device complexity increases due to the cubic shape and multiple components

Engineering Contradiction:

Improvewiring structureVSAvoidassembly complexity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent merges the base structure with the pressing contact part and the encoder sensor mounting function into a single integrated component. This consolidation reduces the number of separate parts and assembly steps compared to the conventional substrate-based approach, simplifying both the overall device structure and the manufacturing process while maintaining simplified wiring.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9464923B2Encoder sensor mounting body, drum disk encoder, and motor with encoder using same

Publication Date: 2016.10.11 KODENSHI CORP

AI summary

In order to make it possible to be readily attachable and detachable with respect to a motor and capable of realizing a lead-free encoder sensor mounting body, an encoder sensor is detachably or fixedly attached on a base, the base being pressedly in contact with an electrode terminal of the motor and including a pressing contact part that is electrically connected to a power line, and thus the base is detachably fixed to an end surface of the motor by a pressing force of the pressing contact part.