Flexible PCB for Inductive Angle Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inductive angle-measuring devices face challenges in achieving precise angular measurements due to manufacturing and assembly tolerances, which can result in errors such as eccentricity and wobble, affecting the accuracy of relative position determination between rotating machine parts.
Innovation Solution
A scanning element with a flexible printed circuit board is designed to be inserted into a housing with a guideway, allowing for elastic deformation and precise positioning, featuring exciter and receiver lines that extend over a significant arc length to enhance immunity to errors and tolerate greater manufacturing and assembly variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the printed circuit board is made stiff to maintain uniform circular shape, then measurement precision is improved, but ease of assembly deteriorates due to difficulty in insertion into guideway
Solution Approach 1:
The printed circuit board transitions from a static rigid structure to a dynamic flexible structure that can adapt its shape. The board is inserted in a flattened state and then elastically deforms into a uniform circular shape after insertion, allowing easy assembly while achieving precise measurement geometry.
Solution Approach 2:
The physical state of the printed circuit board changes from a flexible insertion state to a rigid operational state. The board's flexibility during assembly allows insertion, while its elastic memory enables it to assume and maintain the precise circular shape required for accurate angular measurements during operation.
2Measurement precision
If manufacturing and assembly tolerances are reduced to improve measurement precision, then angular measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The printed circuit board performs self-alignment and self-positioning through its elastic deformation into the guideway. The form-locking mechanism automatically ensures the board assumes the correct circular shape and position without requiring complex external alignment procedures or high-precision assembly fixtures.
Solution Approach 2:
The natural elastic deformation of the printed circuit board, which could be seen as a manufacturing challenge, is converted into a beneficial self-aligning mechanism. The board's flexibility allows it to accommodate tolerances during assembly while automatically achieving the precise circular geometry needed for accurate measurements.
3Measurement precision
If the air gap between printed circuit board and graduation element is reduced to improve measurement precision, then signal quality is improved, but reliability deteriorates due to sensitivity to manufacturing tolerances
Solution Approach 1:
The printed circuit board's elastic flexibility creates a dynamic air gap that can accommodate manufacturing tolerances and assembly variations. The board can elastically deform to maintain optimal spacing, ensuring reliable operation even with variations in component dimensions or assembly precision.
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 solution provides precise measuring signals and allows for relatively large manufacturing and assembly tolerances, ensuring high accuracy in angular position determination by minimizing errors from eccentricity and wobble, thus improving the reliability of inductive angle-measuring devices.
Implementation Method 1
by being inserted into the guideway, the printed circuit board is deformed—especially elastically—along a circle line that is curved about the axis
Implementation Method 2
When an electric excitation current changing or alternating over time is applied to the exciter lines or excitation coils, signals which are a function of the angular position are generated in the receiver lines or receiver coils during the relative rotation between rotor and stator
Data Source
AI summary
A scanning element for an inductive angle-measuring device includes a printed circuit board which has exciter lines and receiver lines, and an electronic circuit. The printed circuit board is arranged in a housing, the housing having a guideway into which the printed circuit board is inserted. The guideway is formed such that the printed circuit board is positioned with form locking in a direction parallel to an axis, and by being inserted into the guideway, the printed circuit board is deformed along a circle line which is curved about the axis.