Modular Rotary Encoder With Qualified Core and Snap Interfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rotary encoders require extensive functional testing for each design variation, leading to high operational effort due to variations in dimensions and interfaces for different applications.
Innovation Solution
A modular rotary encoder design featuring a central qualified unit comprising a rotor carrier, sensor unit, and housing, which can be combined with various rotor adapters and housing seats through snap connections, allowing for customizable configurations without repeated testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rotary encoder is designed with variations in dimensions and interfaces for different applications, then adaptability to diverse applications is improved, but the testing burden and operational effort increase significantly
Solution Approach 1:
The rotary encoder is divided into a central qualified unit and interchangeable interface components. The central unit includes the rotor carrier, sensor unit, and housing that are pre-qualified and tested. The interface components (rotor adapter and housing seat) can be exchanged without retesting the central unit, allowing adaptation to different applications while maintaining testing efficiency.
Solution Approach 2:
The central qualified unit is designed with universal interfaces that can accommodate different rotor adapters and housing seats through standardized snap connections. This multi-functionality allows a single qualified unit to serve multiple applications by simply changing the interface components, eliminating the need to requalify the entire encoder for each application variant.
2Ease of manufacture
If a rotary encoder uses a modular design with snap connections for rotor adapter and housing seat, then ease of manufacture and adaptability are improved, but device complexity increases
Solution Approach 1:
The encoder is segmented into distinct modular components (central unit, rotor adapter, housing seat) that can be manufactured separately and assembled through snap connections. This segmentation simplifies manufacturing processes and allows for easier assembly while maintaining structural integrity through the snap-fit design.
Solution Approach 2:
The rotor adapter is received in a bush-shaped receiving section through a snap connection, creating a nested structure. The rotor carrier, sensor unit, and housing form the central qualified unit that encapsulates the sensor functionality. This nesting approach organizes the modular components in a compact, hierarchical manner that reduces overall structural complexity.
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 the testing burden by qualifying a central unit, enabling efficient adaptation to diverse applications with reduced effort.
Implementation Method 1
a sensor unit (2) for determining an angular position of the rotor element (12)
Implementation Method 2
The rotor adapter (11) is held on the rotor carrier (10) by means of a snap connection
Data Source
Figure 1a
Figure 1b~1e
Figure 2
AI summary
The invention relates to a rotary encoder (100) for a motor vehicle, construction machine, agricultural machine, or special-purpose machine, comprising at least a rotor (1) with a rotor element (12) rotatably mounted thereon, a sensor unit (2) designed to determine the angular position of the rotor element (12), and a housing (3), wherein the sensor unit (2) is received in the housing (3) and the rotor (1) is rotatably mounted on the housing (3), the rotor element (12) being arranged in a target position relative to the sensor unit (2) such that a rotational movement of the rotor (1) can be detected by means of the sensor unit (2). According to the invention, the rotor (1) is formed in multiple parts and comprises a rotor carrier (10) and a rotor adapter (11) rotatably mounted thereon, wherein the rotor carrier (10) is rotatably mounted on the housing (3), and wherein the rotor element (12) is rotatably mounted on the rotor carrier (10).