Magnetic Sensor Compression Terminals Positioning
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Solution Overview
Problem
Existing magnetic sensor devices face challenges in accurately positioning sensors relative to a rotary shaft during the fabrication of rotation sensing devices, often due to misalignment during soldering and substrate attachment steps.
Innovation Solution
The magnetic sensor device employs compression terminals and sensor securing portions with fasteners, allowing for secure electrical connection and easy adjustment of sensor positions relative to the rotary shaft, eliminating the need for precise soldering and reducing misalignment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic sensors are soldered to the substrate, then electrical connection is achieved, but positioning accuracy deteriorates due to misalignment during soldering
Solution Approach 1:
The patent replaces the soldering process with a mechanical compression terminal system. The compression terminal applies mechanical pressure to establish electrical connection between the sensor and substrate, eliminating the need for soldering. This substitution resolves the contradiction by avoiding the misalignment issues inherent in soldering while maintaining reliable electrical connection through controlled mechanical pressure.
Solution Approach 2:
The patent changes the connection method from thermal/chemical (soldering) to mechanical (compression). By changing the parameter of connection mechanism, the system achieves both reliable electrical connection and positioning accuracy. The compression terminal allows for adjustable pressure and precise positioning without the constraints of soldering processes.
2Ease of manufacture
If substrate is attached to housing, then structural assembly is completed, but sensor positioning accuracy deteriorates due to misalignment during attachment
Solution Approach 1:
The patent implements preliminary positioning features on the substrate that are established before the substrate is attached to the housing. Positioning holes, alignment marks, or reference features are pre-configured on the substrate to ensure accurate sensor placement. This preliminary action allows the sensor to be correctly positioned relative to the rotary shaft before the substrate is mounted, resolving the misalignment issue while maintaining ease of assembly.
3Manufacturing precision
If compression terminals are used, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The patent merges the electrical connection function and mechanical positioning function into a single compression terminal structure. The terminal simultaneously provides electrical contact and mechanical pressure for positioning, eliminating the need for separate components. This merging approach achieves high positioning accuracy without proportionally increasing device complexity, as one component performs multiple functions.
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
This solution enables the magnetic sensors to be readily positioned according to the design specifications, improving the accuracy of rotation detection and simplifying the assembly process by eliminating the need for precise soldering and allowing for post-assembly adjustment.
Implementation Method 1
a magnetic wire rod (5) that generates a large Barkhausen effect
Data Source
AI summary
It is an object to make it possible for magnetic sensors to be readily disposed in such a manner that the position of the magnetic sensors relative to the rotary shaft corresponds to the design position. The magnetic sensor device 3 comprises a magnetic sensor 4 having a magnetic wire rod that generates a large Barkhausen effect, a yoke 21, a casing 22 in which the magnetic sensor 4 and the yoke 21 are accommodated, and sensor securing portions 28 for securing the casing 22 to a substrate. The terminals 15 of the magnetic sensor 4 are compression terminals, and, as the casing 22 is secured to the substrate by the sensor securing portions 28, the terminals 15 are pressed against conductor portions on the substrate and are electrically connected to the conductor portions.