Magnet Sensor Means for Electric Drive Shafts
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Solution Overview
Problem
Existing magnetic encoder attachments to shafts or roller bearings in harsh environments, such as oil pump engines, face challenges with adhesive reliability, environmental toxicity, and high production costs, particularly in ensuring secure and vibration-resistant connections.
Innovation Solution
A magnetic transducer system comprising a plastic-bound magnetic encoder and an adapter with peg-like projections or recesses for a non-positive fit, utilizing sintered materials for chemical resistance and durability, allowing for simple and reliable assembly without requiring specialized shaft designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bonds are used to attach magnetic encoders to shaft ends, then the connection can be simple to implement, but the reliability and resistance to harsh environmental conditions deteriorates
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (non-positive connection via peg-like projections). The adapter features peg-like projections that are pressed into corresponding cavities in the shaft end, creating a mechanical interlock that provides reliable attachment without requiring adhesives. This mechanical substitution resolves the contradiction by maintaining ease of manufacture through simple press-fitting while dramatically improving connection reliability and environmental resistance.
2Reliability
If form-fitting connections are used to ensure security against twisting, then the connection reliability improves, but the device complexity and production effort increases
Solution Approach 1:
The patent divides the connection system into two separate components: the magnetic encoder itself and the adapter. The adapter contains the peg-like projections that engage with cavities in the shaft end. This segmentation allows the complex form-fitting features to be contained in the adapter rather than requiring complex contours on the shaft, thereby maintaining torsion resistance while reducing overall device complexity and production effort.
Solution Approach 2:
The adapter serves as an intermediary component between the magnetic encoder and the shaft end. It provides the mechanical interlocking features (peg-like projections) that ensure torsion resistance, while the magnetic encoder remains a simple cylindrical component. This intermediary approach allows form-fitting connections to be implemented without requiring complex shaft modifications.
3Ease of manufacture
If adhesives are used to attach magnetic encoders, then the attachment process is simple, but harmful factors and environmental pollution increase
Solution Approach 1:
The patent eliminates adhesive chemicals by replacing chemical bonding with mechanical bonding. The peg-like projections in the adapter are pressed into cavities in the shaft end, creating a secure mechanical connection without requiring any adhesives. This substitution completely eliminates the harmful factors and environmental pollution associated with adhesive chemicals while maintaining simple attachment procedures.
4Reliability
If combinations of form-fitting and adhesive connections are used, then the connection reliability improves, but the manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the adhesive component from the connection system, relying solely on the mechanical form-fitting connection through peg-like projections. By removing the adhesive step entirely, the patent reduces manufacturing complexity and cost while maintaining connection security through the engineered mechanical interlock. The adapter's peg-like projections are designed to provide sufficient mechanical strength without requiring additional adhesive bonding.
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3d
AI summary
The invention relates to a magnet sensor means of an electric drive, which is mounted on a shaft end of a shaft or on an inner ring of a rolling element bearing secured to said shaft. The aim of the invention is to devise a magnet sensor means which allows as simple a connection as possible to be produced between a magnet sensor and a shaft end of a shaft or an inner ring of a rolling element bearing secured to said shaft, for which simple manufacturing and mounting methods may be used which are reliable and for which a large body of experiential knowledge is available. In addition, said magnet sensor means should be resistant to harsh environmental conditions, including chemical resistance, vibratory strength, and large fluctuations in temperature. According to the invention, this problem is solved using the features of claim 1.