Rectangular Index Magnet Torque Sensor Design
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Solution Overview
Problem
Conventional torque index sensors face challenges due to complex fabrication processes and high error probabilities from magnetic field interference, leading to increased size and manufacturing costs, which hinder productivity and economic feasibility.
Innovation Solution
A torque index sensor with a simplified index magnet structure, where the index magnet is shaped as a rectangle and arranged with opposite polarity magnets, enhancing coupling and magnetization efficiency, and utilizing a Hall element or Hall IC for impulse signal generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the torque sensor and index sensor are arranged adjacently to reduce size, then the device size is reduced, but magnetic field interference occurs between the two sensors
Solution Approach 1:
A non-magnetic partition wall is introduced as an intermediary barrier between the torque sensor and index sensor. This partition wall physically separates the two sensors while allowing the housing to maintain a compact integrated structure, thereby eliminating magnetic field interference without increasing the overall device size.
2Stability of the object's composition
If the index magnet is shaped as an arc to maintain constant magnetization, then magnetization stability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of requiring the entire index magnet to be arc-shaped, the patent applies magnetization only to the necessary portion (the index magnetizing portion) while the rest of the magnet can be简单地 shaped. This localized approach maintains the essential magnetization stability function while significantly simplifying the overall manufacturing process and reducing costs.
3Measurement precision
If multiple arc-shaped magnets are used to form the index magnet, then angular sensing efficiency is improved, but fabrication process complexity increases
Solution Approach 1:
The index magnet is divided into multiple magnetizing portions arranged around the output shaft, with each portion having a specific magnetization direction. This segmentation allows the system to achieve superior angular sensing efficiency through multiple detection points while using simple rectangular magnets that are easier to manufacture compared to a single complex arc-shaped magnet.
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 simplified index magnet structure improves productivity and economic feasibility by reducing manufacturing costs and maintaining angular sensing efficiency, while minimizing magnetic field interference and size constraints.
Implementation Method 1
utilizing a Hall element or Hall IC for impulse signal generation
Data Source
AI summary
A torque index sensor is configured to enhance productivity with excellent economic feasibility by simplifying a magnet structure of an index sensor unit. The torque index sensor is connected to an input shaft and an output shaft, and the torque index sensor includes a housing; an index magnet housed in the housing, connected to the output shaft to rotate with the output shaft and formed in the shape of a rectangle at a cross-sectional view; and a magnetic device secured to an interior of the housing to output a magnetization signal in response to rotation of the index magnet, such that the shape of the index magnet is simplified to a rectangle to enhance productivity and economic feasibility.