Encoder Stepped Shoulder Axial Alignment
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Solution Overview
Problem
Existing encoders for detecting rotation angle require complex alignment processes and additional assembly devices, making them costly and difficult to install, especially in restricted spaces.
Innovation Solution
The encoder design features a stator with a bearing surface having a stepped shoulder that maintains the required axial distance, allowing for simplified mounting by rotating the stator into a recessed receptacle on the motor attachment surface, eliminating the need for additional assembly devices and enabling alignment without additional space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the stator is mounted in a mounting auxiliary position using elastic spring rings, then the axial alignment between rotor and stator is ensured, but the device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the elastic spring ring from the mounting structure. Instead of using spring rings to hold the stator in the mounting auxiliary position, the patent uses a simple shouldered shaft that directly positions the stator at the correct axial distance during mounting, thereby simplifying the device structure while maintaining precise axial alignment.
Solution Approach 2:
Instead of using an elastic element (spring ring) to maintain the mounting auxiliary position, the invention inverts the approach by using a rigid shouldered shaft that inherently defines the axial position. The shoulder on the shaft directly abuts the stator, eliminating the need for elastic mounting elements and simplifying the overall structure.
2Manufacturing precision
If additional assembly devices are used for mounting, then the alignment precision is improved, but the ease of manufacture and installation deteriorates
Solution Approach 1:
The invention merges the alignment function and mounting function into a single integrated structure. The shouldered shaft combines the positioning function (defining axial distance) with the mounting function (providing the mounting surface), eliminating the need for separate assembly devices and simplifying the installation process while maintaining precise alignment.
Solution Approach 2:
The shouldered shaft performs the alignment function automatically during the mounting process. As the stator is mounted onto the shaft, the shoulder automatically positions the stator at the correct axial distance without requiring additional alignment tools or procedures, making the system self-aligning and simplifying installation.
3Reliability
If the stator is fixed at a defined axial distance using complex mounting mechanisms, then the scanning signal quality is improved, but the ease of operation and installation deteriorates
Solution Approach 1:
The shouldered shaft is designed with the axial distance pre-defined by the shoulder height. This preliminary action of pre-positioning the stator at the correct axial distance during manufacturing eliminates the need for complex mounting mechanisms during installation, while ensuring the optimal scanning signal quality is achieved from the outset.
Data Source
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AI summary
Encoder for detecting measured values which are dependent on the rotation angle of the shaft (42) of a motor or the like, comprising a rotor (28), which can be fixed on the shaft (42), and comprising a stator housing (10), which can be fixed by a bearing surface (54) on an attachment surface (46) of the motor and has a scanning means (18, 20) for detecting the relative rotational position of rotor (28) and stator, wherein, in the mounted state, the rotor (28) is fixed on the shaft (42) and the housing (10) is fixed on the attachment surface (46) in such a way that the rotor (28) and the scanning means (18, 20) have a defined axial distance (h), and wherein, for mounting purposes, firstly the encoder is pushed onto the shaft (42) until the housing (10) is held in a mounting auxiliary position with its bearing surface (54) at an axial distance from the attachment surface (46), said axial distance corresponding to the defined distance (h), then the rotor (28), in this mounting auxiliary position of the housing (10), is brought axially to bear against the scanning means (18) and is fixed on the shaft (42) and, finally, the housing (10) of the stator is moved by its bearing surface (54) by the defined distance (h) towards the attachment surface (46) into a mounting end position and is fixed on the attachment surface (46). The bearing surface (54) of the housing (10) of the stator has a shoulder (60) projecting beyond the plane of the bearing surface (54) by the height of the defined distance (h), wherein, in the mounting auxiliary position, the housing (10) bears against the attachment surface (46) by said shoulder (60), and wherein, in a mounting end position rotated about the axis of the encoder relative to the mounting auxiliary position, the shoulder (60) descends into a recessed receptacle (48) of the attachment surface (46), such that the housing (10) is displaced with the scanning means (18, 20) by the defined axial distance (h) axially relative to the rotor (28) fixed on the shaft (42).