Multi-Turn Angle Sensing With Embedded Gear Magnets
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Solution Overview
Problem
Existing multi-turn angle measurement devices face issues with complex and non-compact designs due to the use of transmission gears with play and the need for adhesive fastening of permanent magnets, leading to high installation costs and potential loss of magnets over time.
Innovation Solution
The integration of permanent magnets directly into the transmission design through overmolding, secured with a snapping mechanism, eliminates play and adhesive bonds, allowing for a compact and cost-effective design with consistent magnetic force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If permanent magnets are fastened with adhesive bonds on transmission gears, then the design allows for magnet attachment, but the design becomes non-compact and magnets risk loss over time
Solution Approach 1:
The patent merges the permanent magnet attachment function with the transmission gear structure itself. The magnets are integrated directly into the gear bodies, eliminating separate mounting mechanisms and adhesive bonds. This integration achieves both compact design and secure magnet retention without the drawbacks of external mounting methods.
2Ease of manufacture
If adhesive bonds are used to fasten permanent magnets, then magnet attachment is achieved, but play cannot be minimized due to machine processing limitations
Solution Approach 1:
The patent segments the transmission gear into multiple parts during manufacturing - specifically creating a gear body with an integrated magnet recess. This segmentation allows precise positioning of the permanent magnet within the gear structure through mechanical features rather than relying on adhesive bonds, thereby minimizing axial play caused by machine processing tolerances.
3Ease of manufacture
If permanent magnets are arranged with separate mounts above transmission gears, then magnet attachment is possible, but the design becomes non-compact and total height increases
Solution Approach 1:
The patent applies the nesting principle by placing the permanent magnets directly within the transmission gear structure itself. The magnets are positioned in recesses or cavities formed as part of the gear manufacturing process, eliminating the need for separate mounts above the gears. This nested arrangement maintains a compact overall device height while securing the magnets in their required positions.
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 approach results in a more compact, cost-effective, and reliable multi-turn angle measurement device with reduced wear and no axial play, ensuring consistent magnetic force application and improved durability.
Implementation Method 1
a magnetically working multi-turn angle scanning function
Data Source
AI summary
The invention relates to a multi-turn angle measurement device for measuring multiple revolutions of a shaft (4), consisting of a first code carrier (31) with an optical single-turn scanning function (34) for detecting the absolute position of the shaft and a second code carrier for measuring the number of revolutions of the shaft (4). A reduction gear (2) is arranged between the first code carrier (31) and the second code carrier, and the second code carrier consists of a number of permanent magnets (22), the position of which is detected by an assembly of Hall sensors (16a-16b) fixed to the housing. Each of the permanent magnets (22) is embedded into the plastic material of the transmission gears (20) of the reduction gear (2).