Modular Rotary Encoder Architecture for Lower Qualification Effort
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Solution Overview
Problem
Rotary encoders for motor vehicles, construction machinery, and agricultural machinery face high qualification costs due to varying dimensions and interfaces, necessitating repeated functional tests for each configuration.
Innovation Solution
A modular rotary encoder design featuring a torsionally resistant rotor with a rotor carrier and adapter, allowing for a central unit to be qualified once, with snap-fit connections for customizable interfaces and a sensor unit that can be configured for specific applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rotary encoder is designed with customized dimensions and interfaces for specific applications, then the encoder can be optimized for the respective application, but the qualification effort and cost increase due to repeated functional tests
Solution Approach 1:
The rotary encoder is divided into a standardized base unit (housing, sensor unit, rotor carrier) and a variable rotor adapter that can be exchanged. This segmentation allows the core functional unit to be qualified once while enabling application-specific adaptations through different rotor adapters, thereby reducing repeated qualification efforts.
Solution Approach 2:
The standardized base unit with universal mounting interfaces and sensor system can serve multiple applications by simply changing the rotor adapter. This multi-functionality approach allows a single qualified core unit to be used across different applications, reducing the need for repeated qualification while maintaining application-specific optimization.
2Adaptability or versatility
If a rotary encoder is designed with customized dimensions and interfaces for specific applications, then the encoder can be optimized for the respective application, but the manufacturing cost increases due to repeated testing
Solution Approach 1:
By segmenting the encoder into a standardized base unit and a variable rotor adapter, the manufacturing process can qualify the expensive base unit once and then produce different rotor adapters at lower cost, thereby reducing overall manufacturing costs while maintaining application-specific customization.
Solution Approach 2:
The modular design allows the standardized base unit to be recovered and reused across multiple applications after initial qualification, while only the rotor adapters need to be changed for different applications, thereby reducing repeated testing and manufacturing costs.
3Adaptability or versatility
If a rotary encoder is designed as a modular system with rotor adapter and rotor carrier, then the configurability is improved, but the device complexity increases
Solution Approach 1:
The modular segmentation into standardized base unit and rotor adapter increases configurability but introduces additional assembly complexity. The snap-fit connection simplifies the interface between segments, partially offsetting the complexity increase from modularity.
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
Reduces qualification efforts by allowing a single central unit to be tested, enabling flexible and efficient adaptation to various applications with reduced testing and customization costs.
Implementation Method 1
a sensor unit (2) designed to determine an angular position of the rotor element (12)
Data Source
AI summary
A rotary encoder for a motor vehicle, construction machinery, agricultural machinery or special machinery, at least having a rotor with a rotor element mounted on it in a torsionally resistant manner, a sensor unit designed to determine an angular position of the rotor element, and a housing, wherein the sensor unit is mounted in the housing and the rotor is rotatably mounted on the housing, wherein the rotor element is arranged in a nominal position relative to the sensor unit, in such a way that a rotational movement of the rotor can be detected via the sensor unit. The rotor is designed in several parts and comprises a rotor carrier as well as a torsionally resistant rotor adapter mounted thereon, wherein the rotor carrier is mounted on the housing in a rotatable manner, and wherein the rotor element is torsionally mounted on the rotor carrier.