LED Encoder Assembly With Magnetic Sensing to Eliminate Brush Wear
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Solution Overview
Problem
Existing encoders in electronic products, such as stereo systems and audio/video equipment, face challenges with light emitting diodes (LEDs) integration due to height and brightness mismatch, increased manufacturing complexity and cost, and reduced service life due to brush contact wear.
Innovation Solution
An encoder with a light emitting diode that utilizes a non-contact magnetic sensor to eliminate brush contact issues, combined with a switch function, where the control shaft and pressing driving body cooperate to trigger electrical contact without interfering with the LED, enhancing service life and product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light emitting diodes are placed on the substrate to generate light, then the lighting function is achieved, but the integration in height and brightness is difficult and manufacturing complexity increases
Solution Approach 1:
The patent combines the LED module with the encoder module into a single integrated structure. The LED is mounted on the encoder's circuit board rather than separately on the substrate, merging two functions (lighting and encoding) into one component assembly. This reduces the number of separate mounting operations and simplifies the manufacturing process.
Solution Approach 2:
The encoder module is designed to serve multiple functions: it provides encoding signals through its standard function and simultaneously serves as a mounting platform for the LED to provide lighting. This multi-functional design eliminates the need for separate LED mounting on the substrate, reducing manufacturing steps.
2Ease of manufacture
If additional soldering processes are added to dispose the light emitting diodes on the substrate, then the LED can be mounted, but the process time will increase and the cost will also increase
Solution Approach 1:
By integrating the LED mounting to the encoder assembly rather than the substrate, the patent combines two mounting operations into one. The LED is soldered to the encoder's circuit board during encoder assembly, and both the encoder and LED are then mounted together as a single unit, eliminating redundant soldering processes.
Solution Approach 2:
The LED is pre-mounted to the encoder module during its assembly process, before the final installation onto the substrate. This preliminary action allows the LED and encoder to be prepared together as a complete assembly, reducing the number of separate mounting steps required during final installation.
3Reliability
If brushes are used to contact metal contacts to generate pulse signals, then the encoder can function, but wearing and tearing occurs, resulting in shortening the service life of the product
Solution Approach 1:
The patent replaces the mechanical brush contact system with a magnetic field-based sensing system. The magnetic sensor detects changes in magnetic field caused by the movement of the magnetic ring, generating encoding signals without any physical contact. This eliminates wear and tearing of brush contacts, significantly extending the product's service life.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the moving part (magnetic ring) and the sensing part (magnetic sensor). Instead of direct mechanical contact between brushes and contacts, the magnetic field transmits the motion information, enabling contactless signal generation and eliminating wear.
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 proposed encoder solution improves service life and quality by using non-contact magnetic induction technology, simplifies manufacturing, and provides a compact, thin, and lightweight design with integrated LED, switch, and encoder functions.
Implementation Method 1
the encoder module is provided with a magnetic sensor, a magnetic ring, and a rotating driving body having a penetration hole
Implementation Method 2
a light emitting diode; a switch module, including: an insulating base having a main chamber and a terminal part
Data Source
AI summary
An encoder with a light emitting diode includes: a light emitting diode, a switch module, an encoder module and a control shaft. The switch module includes an insulating base having a terminal part, a conductive elastic piece and a pressing driving body. The conductive elastic piece is disposed in the insulating base, and is disposed above the terminal part. The pressing driving body is disposed in the insulating base and is disposed above the conductive elastic piece for accommodating the light emitting diode. At least part of the encoder module is disposed in the insulating base, and the encoder module includes a magnetic sensor, a magnetic ring and a rotating driving body. The control shaft passes through a penetration hole of the rotating driving body, and is disposed above the pressing driving body.