Magnetic Encoder Inward Flange Segmentation for Outer Ring Binding
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Solution Overview
Problem
Conventional axial-type magnetic encoders with a wrap-around binding part face challenges in attaching to outer rings, as the binding part interferes with the rotating body, leading to lower positioning accuracy and potential breakage, which compromises the reliability of the binding between the annular fixing member and the plastic magnet.
Innovation Solution
An axial-type magnetic encoder system with a separated inner peripheral part at the inward flange's inner diameter-side portion and a wrap-around binding part that does not extend closer to the rotating body than the outer diameter-side portion of the inward flange's back surface, allowing for improved mechanical binding and accurate positioning by abutting the outer diameter-side portion of the inward flange against the rotating body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wrap-around binding part is formed at the inner peripheral part of the annular plastic magnet to wrap around from the sensor-opposed surface to the back surface of the inward flange part, then the reliability of binding between the plastic magnet and fixing member is improved, but the binding part interferes with the outer ring when attached to outer rings, causing positioning accuracy to deteriorate and potential breakage
Solution Approach 1:
The invention divides the binding structure into two separate functional elements: (1) an inward flange part extended radially inward from the end edge of the cylindrical part, and (2) a wrap-around binding part formed at the inner peripheral part of the annular plastic magnet. This segmentation allows the flange to provide positioning contact with the outer ring while the binding part secures the magnet, eliminating interference between positioning and binding functions.
Solution Approach 2:
The invention extracts the positioning function from the binding part by providing a dedicated inward flange part that contacts the outer ring for axial positioning. This separates the positioning role from the binding role, allowing the wrap-around binding part to focus solely on securing the magnet without interfering with positioning accuracy.
2Manufacturing precision
If the inward flange part is closely attached to the end surface of the outer ring to prevent the end surface from being hidden, then the positioning accuracy is improved, but the wrap-around binding part interferes with the outer ring and may break
Solution Approach 1:
The invention segments the structure so that the inward flange part handles positioning by contacting the outer ring, while the wrap-around binding part handles magnet retention. This spatial separation prevents the binding part from interfering with the outer ring during positioning, eliminating the risk of breakage while maintaining positioning accuracy.
Solution Approach 2:
The inward flange part acts as an intermediary element between the magnetic encoder assembly and the outer ring. It provides the necessary contact surface for axial positioning, allowing the wrap-around binding part to operate independently without direct contact with the outer ring, thus preventing mechanical interference and potential breakage.
3Reliability
If the wrap-around binding part is extended to wrap around to the back surface of the inward flange part, then the mechanical binding force is improved, but the binding part comes closer to the rotating body and causes interference
Solution Approach 1:
The invention segments the binding structure into a flange component and a binding part component with distinct functions. The flange provides positioning contact, while the binding part wraps around to provide mechanical retention. This segmentation allows the binding part to achieve reliable binding without extending into the space occupied by the rotating body, preventing interference.
Solution Approach 2:
The invention extracts the positioning function into a separate inward flange part, allowing the wrap-around binding part to be optimized for binding reliability without being constrained by positioning requirements. This enables the binding part to wrap around effectively while maintaining clearance from the rotating body, eliminating interference.
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3(a)~3(b)
AI summary
Provided is a magnetic encoder that improves reliability of binding of the annular fixing member and the annular plastic magnet even when the magnetic encoder is to be attached to an outer ring. An axial-type magnetic encoder 1 includes a wrap-around binding part C wrapping around from a sensor-opposed surface A to a back surface B of an inward flange part 2B of an annular fixing member 2. A separated inner peripheral part D separated from a rotating body 10 is formed at an inner diameter-side portion of the inward flange part 2B while an outer diameter-side portion of a back surface of the inward flange part 2B is abutted against the rotating body 10. The inner peripheral part of the annular plastic magnet 3 wraps around to a back surface of the separated inner peripheral part D. The wrap-around binding part C of the annular plastic magnet 3 wrapping around to the back surface of the separated inner peripheral part D does not come closer to the rotating body 10 than the outer diameter-side portion of the back surface B of the inward flange part 2B.