Geared Motor Absolute Encoder Reduces Start-Up Time
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Solution Overview
Problem
Conventional geared motors require the motor shaft to rotate multiple times to position a load side device within a multi-rotation operating range, leading to inefficiency and increased start-up time, especially when the positioning range corresponds to multiple rotations of the gear shaft.
Innovation Solution
A multiple-rotation absolute-value encoder system that includes a gear shaft absolute-value encoder with a two-pole magnet and magnetic sensors, a reduction mechanism using a magnetic gear to reduce rotational speed, and a load side absolute-value encoder with a two-pole magnet and sensors, allowing the load side device to be positioned within one rotation of the gear shaft, thereby reducing the motor shaft's rotation requirement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the motor shaft rotates multiple times to cover multiple rotations of the gear shaft, then the operating range of the load side device can be achieved, but the start-up time increases and the operation becomes inefficient
Solution Approach 1:
The patent replaces the conventional incremental encoder system with an absolute value encoder that uses magnetic sensors to detect the position of a magnet on the gear shaft. This substitution eliminates the need for multiple rotations to establish position, as the absolute value encoder provides immediate position information upon power-up, thereby reducing start-up time while maintaining the ability to cover multiple rotations of the gear shaft.
2Measurement precision
If the motor shaft rotates multiple times to establish the starting point, then the original position can be determined, but the operation becomes complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-configuring the absolute value encoder with a magnet positioned on the gear shaft. This allows the system to immediately determine the starting point position upon power-up without requiring the motor shaft to rotate multiple times to establish position. The magnetic sensor detects the magnet's position directly, providing immediate position information and eliminating complex startup procedures.
3Measurement precision
If a starting point sensor is attached to the load side device, then the starting point can be detected, but the device complexity increases
Solution Approach 1:
The patent merges the starting point detection function into the existing absolute value encoder system by utilizing the same magnetic sensor that detects gear shaft position. The magnet is attached to the gear shaft itself, combining the encoder's position sensing capability with starting point detection, thereby eliminating the need for a separate starting point sensor and reducing overall device complexity.
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 solution enables the determination of the load side device's original position without additional start-up operations, significantly reducing start-up time and motor shaft rotations, as the absolute position can be determined from the output of the magnetic sensors within one rotation, even for multi-rotation operating ranges.
Implementation Method 1
a magnetic sensor that detects a rotating magnetic field from the two-pole magnet
Implementation Method 2
a reduction mechanism that reduces the rotational speed of the gear shaft
Data Source
AI summary
A multiple-rotation absolute-value encoder of a geared motor, wherein the geared motor (10) reduces the rotational speed of a motor shaft (12) and takes it out from a gear shaft (14) to drive a machine device (15) in an operating range corresponding to two rotations of the gear shaft (14). The multiple-rotation absolute-value encoder (20) fitted to the geared motor (10) is made up of a gear shaft absolute value encoder (30) for detecting the absolute position of the gear shaft (14) and a load side absolute value encoder (50) having a two-pole magnet (51) and a magnetic sensor (52) rotating at a rotational speed reduced to half the rotational speed of the gear shaft (14) through the magnetic gear (40).