Magnetostrictive Torque Sensor Assembly Using a Common Flexible Substrate
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Solution Overview
Problem
Conventional magnetostrictive torque sensors require multiple types of flexible substrates with different lengths to accommodate varying rotating shaft diameters, leading to increased manufacturing costs.
Innovation Solution
A method for assembling a magnetostrictive torque sensor using a common flexible substrate with a predetermined range of 75% to 100% of its main body portion facing the rotating shaft's outer circumference, allowing for reduced types of flexible substrates and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple types of flexible substrates with different lengths are prepared for each outer diameter of the rotating shaft, then the accuracy of torque detection is ensured, but the number of types of flexible substrates is increased, making it difficult to reduce manufacturing costs
Solution Approach 1:
The patent applies universality by designing a single flexible substrate length that can accommodate multiple rotating shaft outer diameters. The flexible substrate is configured to wrap around the bobbin portion with detection coils positioned to detect torque for shafts ranging from 10mm to 50mm in outer diameter, eliminating the need for multiple specialized substrate types and thereby reducing manufacturing costs while maintaining measurement accuracy.
2Measurement precision
If flexible substrates with different lengths are prepared for each outer diameter of the rotating shaft, then the detection accuracy for different shaft sizes is optimized, but the device complexity increases
Solution Approach 1:
The patent implements a universal flexible substrate design that serves multiple functions across different shaft sizes. The substrate includes detection coils arranged to measure torque for rotating shafts with outer diameters from 10mm to 50mm, replacing the need for multiple specialized substrates and thereby reducing device complexity while maintaining detection accuracy across the entire range.
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
Ensures accurate torque detection while significantly reducing the number of flexible substrate types needed, thereby lowering manufacturing costs.
Implementation Method 1
a magnetostrictive torque sensor that measures torque applied to a rotating shaft by utilizing an inverse magnetostrictive effect that occurs in the rotating shaft when torque is applied to the rotating shaft
Data Source
AI summary
When assembling a magnetostrictive torque sensor comprising a holder having a bobbin portion arranged around a rotating shaft to be measured, and a flexible substrate having a main body portion arranged around the bobbin portion and provided with a detection portion configured by a plurality of detection coils, a common flexible substrate having the same length in a circumferential direction of the main body portion is used when a percentage of the main body portion facing an outer circumferential surface of the rotating shaft is in a predetermined range, with a case where the main body portion of the flexible substrate faces the outer circumferential surface of the rotating shaft over an entire circumference being considered as 100%.