Radial Magnetic Encoder U-Shaped Fixing Member Injection Molding
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Solution Overview
Problem
The manufacturing of radial-type magnetic encoders is costly and prone to yield deterioration due to the complexity of the manufacturing process and attachment errors, which can lead to breakage and reduced magnetic accuracy.
Innovation Solution
A radial-type magnetic encoder design featuring an annular fixing member with a U-shaped sectional shape and an annular plastic magnet that covers the sensor opposed portion, allowing for injection molding using the fixing member as an insert object, reducing the number of manufacturing steps and enhancing attachment reliability without bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the fixing member and plastic magnet are manufactured separately and fitted together using adhesive agents, then the manufacturing process can be simplified, but the number of steps increases and manufacturing cost increases
Solution Approach 1:
The patent combines the fixing member and plastic magnet into a single integrated component through injection molding. The fixing member serves as a mold insert during injection molding, allowing the plastic magnet material to be molded directly onto the fixing member, thereby merging two separate manufacturing processes into one and eliminating the need for separate fitting and adhesive application steps.
Solution Approach 2:
The fixing member is prepared in advance as a mold insert before the injection molding process. By pre-forming the fixing member with the appropriate geometry and positioning features, the subsequent injection molding can proceed directly without requiring additional assembly steps, thus reducing the overall number of manufacturing steps.
2Reliability
If the fixing member and plastic magnet are fitted together using adhesive agents, then attachment can be achieved, but the plastic magnet may break and magnetic accuracy may decrease due to attachment errors
Solution Approach 1:
By integrating the fixing member and plastic magnet into a single molded component, the patent eliminates the adhesive bonding interface that causes breakage and attachment errors. The direct injection molding process creates a unified structure where the plastic magnet material bonds inherently to the fixing member without requiring separate adhesive agents, thereby improving both attachment reliability and magnetic accuracy.
Solution Approach 2:
The fixing member acts as an intermediary during the injection molding process, serving as both the structural component and the mold insert. This intermediary role allows the plastic magnet material to be molded directly onto the fixing member surface, creating a strong mechanical and chemical bond without requiring additional adhesive agents, thus preventing breakage and attachment errors.
3Reliability
If adhesive agents are applied to both the fixing member and plastic magnet, then attachment can be achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the attachment function into the injection molding process itself, eliminating the need for separate adhesive agents. The plastic magnet material inherently bonds to the fixing member during molding through direct contact and cooling, creating a strong attachment without requiring additional adhesive materials or application steps, thereby reducing manufacturing cost while maintaining attachment strength.
Solution Approach 2:
The injection molding process itself provides the attachment function without requiring external adhesive agents. The plastic magnet material self-bonds to the fixing member through the molding process, utilizing the mold insert geometry and cooling mechanism to create a strong mechanical and chemical bond, thereby eliminating the need for separate adhesive application and reducing manufacturing cost.
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 design reduces manufacturing costs, eliminates breakage and attachment errors, and improves yield by ensuring a strong and reliable magnetic encoder with improved magnetic accuracy.
Implementation Method 1
an annular plastic magnet attached to the annular fixing member and magnetized in a multipole form so as to have N poles and S poles at regular intervals in a circumferential direction
Data Source
AI summary
A radial-type magnetic encoder includes: an annular fixing member; and an annular plastic magnet attached to the annular fixing member. The annular fixing member includes the cylindrical portion, an outward flange portion extending outward in a radial direction from an edge of the cylindrical portion, and a sensor opposed portion bent from an edge of the outward flange portion and opposed to a magnetic sensor which detects rotation of the magnetic encoder, and the annular fixing member has a substantially U-shaped sectional shape along a plane including the radial direction and an axial direction. The annular plastic magnet has a shape that covers a front surface, a back surface, and an end edge of the sensor opposed portion, and an outer-diameter-side part of the outward flange portion.