Integrated Angle Measuring System with Merged Bearing and Sensor
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Solution Overview
Problem
Conventional angle measuring systems lack high accuracy, robustness, and compactness due to limitations in bearing assembly design, leading to insufficient precision and increased space requirements.
Innovation Solution
A compact angle measuring system design featuring a first component group with a ring and angle scaling, and a second component group with a sensor and printed circuit board, where the rings have non-cylindrical recesses for enhanced stability, and rolling elements between the rings, allowing for precise scanning and robust construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate bearing assembly with cylindrical recess is used for the sensor unit, then the angle measuring system can be manufactured with conventional methods, but the system does not achieve highest accuracies and requires relatively great space
Solution Approach 1:
The bearing assembly and angle measuring device are merged into a single integrated component. The sensor unit is no longer inserted into a separate bearing assembly but is directly integrated into the bearing structure, eliminating the need for a separate bearing assembly and reducing overall space requirements while improving measurement accuracy through eliminated interface errors
Solution Approach 2:
The integrated bearing assembly serves multiple functions simultaneously: it provides mechanical support for rotation, ensures precise positioning through its geometric design, and houses the angle measuring device. This multi-functionality eliminates the need for separate components and reduces the overall volume of the angle measuring system
2Reliability
If a separate bearing assembly is used for the angle measuring device, then the system is easier to manufacture with conventional methods, but the system lacks robustness for many applications
Solution Approach 1:
The bearing assembly and angle measuring device are combined into one integrated component, eliminating interfaces between separate parts that could lead to misalignment or loosening. This integration significantly improves robustness and reliability for demanding applications while the modular design of the integrated unit keeps manufacturing feasible
3Measurement precision
If conventional angle measuring systems with separate bearing assemblies are used, then the components can be manufactured separately, but the system exhibits wobble errors and radial runouts affecting accuracy
Solution Approach 1:
The bearing assembly and angle measuring device are merged into a single integrated component with a unified reference axis. This eliminates radial runouts and wobble errors that occur in conventional systems due to misalignment between separate bearing assemblies and the measurement axis, as there is now only one reference axis for the entire assembly
Solution Approach 2:
The integrated bearing assembly features an asymmetric design where the sensor unit is positioned at a specific offset from the rotation axis, creating a well-defined geometric relationship that eliminates alignment ambiguities and ensures consistent measurement reference throughout operation
Data Source
AI summary
An angle measuring system includes a first component group and a second component group, the first component group being mounted so as to be rotatable relative to the second component group. The first component group includes a ring having a running surface and an angle scaling. The second component group has a sensor for scanning the angle scaling as well as a printed circuit board having an electronic circuit for evaluating sensor signals producible by the scanning. The second component group furthermore includes a solid ring, on which another running surface is situated and which has a first recess for accommodating the circuit board and a second recess for accommodating an electrical conductor. The conductor connects the sensor electrically to the electronic circuit situated at a distance from the sensor.