Molded Encoder Magnet Mounting for Reliable Shaft Position Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for joining encoder magnets to rotating components in electric vehicles and hybrid vehicles are uneconomical due to the use of adhesives, leading to increased production costs and potential detachment under high acceleration.
Innovation Solution
The encoder magnet is integrated with a support pin using a molding process, ensuring a secure connection that prevents axial and radial displacement, and optionally using a sleeve-shaped connection element for indirect molding, allowing for a force-monitored joining without additional constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to join the encoder magnet to the rotating component, then the magnet can be attached to the shaft, but the production process becomes uneconomical and the magnet may detach under high acceleration
Solution Approach 1:
The encoder magnet is integrated directly with the support pin through a molding process, combining two previously separate components (magnet and pin) into a single unified structure. This eliminates the need for separate adhesive joining steps, reducing production complexity while ensuring reliable attachment that can withstand high acceleration forces.
Solution Approach 2:
The chemical bonding method (adhesive) is replaced with a mechanical bonding method (molding process). The molding process creates a mechanical interlock between the encoder magnet and support pin, providing both reliable attachment and manufacturing efficiency without the costs and reliability issues associated with adhesive applications.
2Adaptability or versatility
If the encoder magnet is produced as loose individual parts and joined with the rotating component, then assembly flexibility is maintained, but production efforts and costs increase
Solution Approach 1:
The encoder magnet and support pin are combined into a single molded component, eliminating the need for separate assembly steps. This integration maintains design flexibility while significantly improving production efficiency by reducing the number of manufacturing operations and assembly steps required.
3Stability of the object's composition
If a secure connection is implemented to prevent axial and radial displacement, then the magnet remains fixed during operation, but the joining process becomes more complex
Solution Approach 1:
Complex multi-step mechanical assembly processes for securing the magnet are replaced with a single molding process. The molding operation inherently provides secure fixation against axial and radial displacement through the integrated structure, simplifying the joining process while ensuring position stability during high-acceleration operation.
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 reduces production costs and minimizes the risk of magnet detachment, providing a reliable and cost-effective solution for detecting angular positions of rotating components.
Implementation Method 1
an encoder magnet is fastened as a signal encoder to the shaft so as to be fixed with respect to rotation relative to it, and the magnetic field generated by the encoder magnet is detected by a sensor unit
Data Source
AI summary
An actuator for actuating a shift element in a transmission of a vehicle, particularly of a utility vehicle, includes a sensor device for detecting angular positions of a rotating component, for example, a shaft in an electric drive for a vehicle. The sensor device includes an annular encoder magnet fastened to a support pin supported on a front side of the rotating component so as to be fixed with respect to rotation relative to it such that the annular encoder magnet at least partially surrounds the support pin. The annular encode magnet is mounted on the support pin as a molded encoder magnet component.