Magnetic Measuring Scale with Concentrated Particle Layer
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Solution Overview
Problem
Existing measuring standards for high-speed spindles in machine tools face challenges in withstanding mechanical stress and fatigue due to centrifugal forces, requiring materials that are both lightweight and mechanically robust to ensure accurate measurements and safety.
Innovation Solution
A method for producing a measuring standard involving a mixture of curable mass and magnetizable particles, where the particles concentrate in a higher ratio post-curing, forming a magnetized layer for scanning with a magnetic field sensor, and reinforced with fibers for mechanical strength, allowing for a magnetic division and improved fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a magnetic track is produced on a ring made of plastic-bonded magnetic material using conventional methods, then the measuring standard can be manufactured, but it cannot withstand the high mechanical loads and centrifugal forces at high speeds
Solution Approach 1:
The patent uses a composite material consisting of a polymer matrix (epoxy resin or polyester resin) combined with magnetizable particles (such as iron powder or ferrite). This composite structure provides both the mechanical strength needed to withstand high-speed centrifugal forces and the magnetic properties required for the measurement function. The polymer binder holds the particles together while maintaining fatigue resistance at high speeds.
2Measurement precision
If magnetizable particles are uniformly distributed in the mixture, then the material is easy to manufacture, but the magnetic division cannot be achieved for scanning
Solution Approach 1:
The patent creates a non-uniform distribution of magnetizable particles where the particle concentration varies spatially. Specifically, particles are concentrated in an outer region or surface layer of the measuring standard while the inner region has a lower particle concentration. This local variation enables the outer region to provide strong magnetic signals for scanning while the overall structure maintains manufacturability.
Solution Approach 2:
The patent transitions from a uniform three-dimensional particle distribution to a stratified or gradient distribution where particle concentration varies with position (particularly radial or depth position). This dimensional variation in particle concentration allows the outer layers to be optimized for magnetic functionality while inner layers maintain structural integrity and ease of manufacture.
3Measurement precision
If the particle concentration is increased throughout the entire mixture, then the magnetic properties improve, but the mechanical strength and fatigue resistance decrease
Solution Approach 1:
The patent applies different particle concentrations to different regions of the measuring standard. The outer region or surface layer has a high particle concentration to provide strong magnetic signals for accurate scanning, while the inner region has a lower particle concentration that maintains better mechanical properties and fatigue resistance. This spatial differentiation resolves the contradiction between magnetic performance and mechanical strength.
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 solution enables measuring standards that can withstand high-speed operations, providing accurate measurements with enhanced mechanical strength and resistance to centrifugal forces, ensuring safety and quality in high-speed applications.
Implementation Method 1
the particles are subjected to a force within the hardening period of the mass or mixture in the mold in such a way that the particles migrate into a layer of the measuring standard
Implementation Method 2
The angle scaling can, for example, have a magnetic graduation that can be scanned accordingly
Data Source
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AI summary
The method involves preparing a mixture of a hardenable mass and magnetizable particles so that the mixture has a mean particle concentration, where the particles within the hardening time period of the hardenable mass are exposed in form of a force, such that the particles migrate at a layer (L) of a measuring scale. The particles are available after hardening at a higher concentration than the mean particle concentration of the original mixture. A magnetic division is applied at located particles by magnetizing in the layer. An independent claim is included for a measuring scale, which is suitable for sensing by a magnetic field sensor.