Piezoelectric Flexible Element Mechanical Encoder for High Precision
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Solution Overview
Problem
Existing mechanical encoders face challenges in providing high-precision position and direction signals due to limitations in sensing accuracy and noise generation, particularly in rotary motion detection.
Innovation Solution
A mechanical encoder design featuring a flexible element with piezoelectric layers and a signal sensing module, where poking structures deform the flexible element to generate active sensing signals, enabling precise position and direction signal generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sliding contact blocks are used in mechanical encoders, then the structure is simple, but the sensing accuracy is limited and noise generation increases
Solution Approach 1:
The patent replaces traditional sliding contact blocks with a flexible element that generates electrical signals through mechanical deformation. The flexible element is deformed by the scale strip'spoke structures' to directly generate sensing signals, eliminating the need for sliding contacts and associated noise while improving sensing accuracy through active signal generation rather than passive contact detection
Solution Approach 2:
The patent changes the physical state and properties of the sensing element from rigid sliding contacts to a flexible deformable element. By utilizing the flexibility and elastic deformation characteristics of the flexible element, the system achieves higher measurement precision through controlled deformation that generates electrical signals, while the material properties are optimized to balance flexibility and signal generation capability
2Measurement precision
If optical encoders with photolithography processes are used, then encoder counts increase rapidly and accuracy improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces complex optical systems with photolithography patterns with a mechanical-flexible hybrid system. The flexible element with piezoelectric or capacitive sensing generates position signals through mechanical deformation, eliminating the need for intricate optical components, light sources, and photolithography manufacturing processes while achieving comparable or superior accuracy
Solution Approach 2:
The flexible element serves multiple functions: it acts as both the mechanical coupling element between the scale strip and the sensing mechanism, and as the active sensor that generates electrical signals through its deformation. This self-service capability eliminates the need for separate sensing components and complex manufacturing processes, simplifying both the device structure and manufacturing
3Reliability
If mechanical encoders with sliding contact blocks are used, then the structure is simple, but noise generation increases and reliability decreases
Solution Approach 1:
The patent eliminates sliding contact blocks that generate noise through friction and electrical contact instability. Instead, the flexible element generates electrical signals through mechanical deformation of piezoelectric materials or capacitive changes, which inherently produces cleaner signals with less noise and higher reliability
Solution Approach 2:
The patent converts the mechanical deformation that would traditionally be considered a disturbance or harm into a useful signal generation mechanism. The deformation of the flexible element, which could be seen as a disturbance to the system, is instead harnessed to generate the position and direction signals needed for encoder operation, eliminating noise while maintaining simplicity
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
The design achieves high-precision movement signals with reduced noise, allowing for accurate position detection and direction determination in rotary motion applications.
Implementation Method 1
The flexible element includes a first piezoelectric layer and a second piezoelectric layer, wherein the first piezoelectric layer and the second piezoelectric layer are stacked on each other via an attach material
Data Source
AI summary
A mechanical encoder including an assembly, a flexible element, and a signal sensing module is disclosed. The assembly has a plurality of poking/stiring structure that provides poking/stirring function. The flexible element includes a first piezoelectric layer and a second piezoelectric layer. The first piezoelectric layer and the second piezoelectric layer are stacked on each other via an attach material. The flexible element is set up so that the poking/stiring structures stir/poke a first end of the flexible element, so as to output an electrical signal responsive to deformation of the flexible element. The signal sensing module receives the electrical signal to generate a position signal and a direction signal corresponding to the movement of the poking structures.