Modular Rotary Encoder Mounting Jig for Precise Alignment
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Solution Overview
Problem
The complex and cumbersome process of accurately mounting modular rotary encoders, requiring high precision and technical proficiency, poses challenges for users who are not familiar with the encoder's configuration and characteristics, especially when multiple sensors are involved.
Innovation Solution
A simplified mounting method for modular rotary encoders, where the code disc is adjusted along the axial direction using a disc hub with a terminal locking device, allowing for easy positioning and height adjustment via sliding and pressure contact, eliminating the need for precise alignment and visual determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the encoder is assembled with high precision mounting requirements, then the output signal waveform accuracy is improved, but the mounting process becomes complex and difficult for users
Solution Approach 1:
A mounting jig is introduced as an intermediary tool that incorporates alignment marks and positioning features. The jig guides the relative positioning between the code disc and circuit board, ensuring precise alignment without requiring the user to perform complex manual alignment procedures. The jig acts as a mediator that translates the precision requirements into a simple follow-the-jig assembly process.
Solution Approach 2:
Alignment marks and positioning features are pre-established on the mounting surfaces of both the code disc and circuit board before assembly. These preliminary markings indicate the correct relative positions, allowing users to simply align the marks rather than perform complex measurements or adjustments during the assembly process.
2Manufacturing precision
If the code disc and circuit board are aligned using visual determination and calipers, then the positioning accuracy is improved, but the mounting time and technical skill requirements increase
Solution Approach 1:
The mounting jig serves as an intermediary that eliminates the need for calipers and visual determination. The jig's built-in positioning features and alignment marks provide tactile and visual guides that automatically ensure accurate positioning, replacing the time-consuming manual measurement and adjustment process.
Solution Approach 2:
The mounting jig is designed to be self-aligning, where the alignment marks and positioning features automatically guide the correct placement of components. The system serves itself by providing inherent alignment cues that eliminate the need for external measurement tools and complex alignment procedures.
3Adaptability or versatility
If the encoder components are disassembled and reassembled by users, then the modular functionality is maintained, but the mounting precision becomes difficult to reproduce
Solution Approach 1:
Alignment marks and positioning features are pre-established on all encoder components during manufacturing. These preliminary markings remain on the components after disassembly and guide the user to reproduce the exact same alignment when reassembling, ensuring mounting precision is maintained across multiple assembly cycles.
Solution Approach 2:
The mounting jig acts as a reusable intermediary tool that can be used both during initial assembly and during user reassembly. The jig ensures that the same precise alignment is achieved each time the encoder is assembled or disassembled, making the mounting precision reproducible without requiring specialized skills.
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 method enables easy and accurate positioning of the code disc and electrical circuit unit, reducing the complexity of the mounting process and ensuring precise alignment without requiring advanced technical skills, thus facilitating reproducible assembly even by inexperienced operators.
Implementation Method 1
The light emitted from the light emitting element is input to the light receiving elements via the slit in the fixed slit plate and the slits in the code disc
Data Source
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AI summary
A mounting method for modular rotary encoders and modular rotary encoders provide accurate location determination with a simple user alignment operation, which is easily reproduced and assembled and has also a simple configuration. The mounting method for mounting a modular rotary encoder on the object to be measured, in which the modular rotary encoder includes a code disc and an electrical circuit unit, and in which the code disc is mounted on the axis of rotation includes: disposing the code disc on the axis of rotation; adjusting the code disc along the axis of rotation so as to cause the distance from the object to be measured to correspond to a predetermined value; and (c) then fixing the electrical circuit unit to the object to be measured.