Modular Rotary Angle Sensor PCB Architecture for Flexible Integration
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Solution Overview
Problem
Existing rotary angle sensor devices are not easily adaptable to different applications, lacking flexibility in configuration and functionality.
Innovation Solution
A modular system comprising a carrier assembly, rotor assembly, and multiple printed circuit board assemblies with varying configurations, including different sensor technologies and interfaces, allowing for easy adaptation to diverse applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rotary angle sensor device is designed with fixed configuration, then the manufacturing process is simple, but the adaptability to different applications is poor
Solution Approach 1:
The rotary angle sensor device is divided into separate modular components: a carrier assembly, a rotor assembly, and at least one printed circuit board assembly. Each component can be independently configured and selected, allowing the device to be customized for different applications without redesigning the entire system. The modular architecture enables easy reconfiguration by selecting different combinations of components.
Solution Approach 2:
The carrier assembly serves as a universal base that can accommodate different types of rotor assemblies and printed circuit board assemblies. The standardized interface design allows the same carrier assembly to support multiple sensor technologies and application requirements, making the overall system multi-functional and highly adaptable.
2Adaptability or versatility
If multiple configurations of sensor devices are produced, then the adaptability to different applications improves, but the manufacturing complexity increases
Solution Approach 1:
By segmenting the device into standardized modular components, the manufacturing process becomes more efficient. Each component can be manufactured independently using optimized processes, and then assembled through standardized interfaces. This reduces the complexity of producing multiple configurations compared to manufacturing complete custom devices for each application.
Solution Approach 2:
The system allows for parameter changes in configuration by selecting different components with varying parameters (sensor technologies, interfaces, etc.) while maintaining the same standardized physical interface. This enables flexibility without requiring changes to the fundamental manufacturing process or assembly methodology.
3Adaptability or versatility
If the sensor device is customized for specific applications, then the functionality meets specific requirements, but the device complexity increases
Solution Approach 1:
The device is segmented into functional modules where each module can be independently selected based on application requirements. This allows customization of specific functions while keeping the overall structure organized and manageable. The modular approach prevents structural complexity from increasing uncontrollably, as each addition is a discrete unit with defined interfaces.
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
Enables easy customization and adaptation of rotary angle sensor devices to meet specific application requirements, enhancing flexibility and functionality without complex modifications.
Implementation Method 1
The connecting device typically comprises several connecting elements made of an electrically conductive material, preferably a metal, which are electrically insulated from one another
Implementation Method 2
In the case of a contactless inductive sensor technology, for example, the rotor assembly has a short-circuit winding designed in a known manner
Implementation Method 3
In the case of a magnet-based sensor technology, the rotor assembly comprises one or more permanent magnets which, in a known manner, generate a defined sequence of at least one magnetic north pole and at least one magnetic south pole
Data Source
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AI summary
The present invention relates to a rotary angle sensor device (100) comprising: a carrier assembly (1) with a carrier assembly base body (1.1) forming a rotor chamber (1.2), a rotor assembly (2) rotatably arranged relative to the carrier assembly (1) in the rotor chamber (1.2), a first and second printed circuit board assembly (3), each attached to the carrier assembly (1), wherein the first printed circuit board assembly (3) comprises a detection device (3.2) which cooperates with the rotatable rotor assembly (2) for rotary angle detection, wherein the second printed circuit board assembly (4) comprises a connection contact device (4.2), and wherein the carrier assembly (1) comprises a connecting device (1.5) which is attached to the carrier assembly base body (1.1) and establishes an electrical connection between the first printed circuit board assembly (3) and the second printed circuit board assembly (4).The present invention further relates to a modular system for manufacturing such a rotary angle sensor device (100).