Limited Rotation Rotary Actuator with Rectangular Coil
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Solution Overview
Problem
Conventional limited-angle electromechanical rotary actuators used in optical scanning are costly to manufacture due to complex coil winding and bonding processes, leading to sub-optimal performance and reliability issues, particularly in consumer-grade applications where low cost is paramount.
Innovation Solution
A limited rotation electromechanical rotary actuator design featuring a stator, a bidirectionally operable rotor assembly, and a single rectangular coil that surrounds a solid cylindrical magnet, with apertures allowing the coil to pass through the output and position sensor shafts, reducing manufacturing complexity and costs while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional coil winding and bonding processes are used, then torque production is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The coil is divided into multiple discrete segments or sections, each independently wound and positioned around the rotor magnet. This segmentation allows for simplified manufacturing of individual coil sections that can be assembled without complex bonding processes, reducing overall manufacturing complexity while maintaining torque production capability through the combined effect of all coil segments
Solution Approach 2:
The coil is configured to extend in the axial dimension of the rotor magnet, creating a three-dimensional coil structure rather than a simple planar winding. This dimensional change allows the coil to wrap around and engage with the rotor magnet in a manner that simplifies the winding process while effectively distributing the torque-generating force across multiple spatial dimensions
2Reliability
If conventional actuators are used, then reliable torque production is achieved, but manufacturing cost increases
Solution Approach 1:
The coil is designed as a simplified, potentially disposable component that can be manufactured at low cost using straightforward winding and assembly processes. Rather than requiring expensive precision bonding and complex multi-step manufacturing, the coil can be produced economically and replaced if necessary, reducing overall system manufacturing cost while maintaining adequate reliability for the application
Solution Approach 2:
The coil configuration allows for self-alignment and self-securing to the rotor magnet through its three-dimensional structure and geometric features. This self-service characteristic eliminates the need for complex bonding processes and precision alignment procedures during assembly, reducing manufacturing cost and improving ease of manufacture while maintaining reliable torque transmission
3Power
If complex coil arrangements are used, then performance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The coil is configured with an asymmetric three-dimensional structure that is specifically tailored to match the geometry of the rotor magnet and the desired torque characteristics. This asymmetric design allows the coil to achieve optimal performance through its geometric form rather than requiring precise positioning and alignment during manufacturing, as the asymmetry itself provides the necessary torque distribution and mechanical coupling
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 reduces manufacturing costs and improves reliability by simplifying coil winding and bonding, enabling efficient torque production over a limited range of angles, making it suitable for consumer-grade applications like point-of-purchase displays and self-driving vehicles while maintaining performance comparable to conventional galvanometer scanners.
Implementation Method 1
an electrical coil surrounding a rotor magnet on top, bottom, and two sides thereof
Implementation Method 2
When the coil is energized, a Lorentz Force is imposed on both the coil and the magnet
Implementation Method 3
a solid cylindrical diametral-magnetized magnet
Implementation Method 4
The rotor assembly may include an output shaft, a solid cylindrical diametral-magnetized magnet
Data Source
AI summary
A limited rotation electromechanical rotary actuator includes a stator having an aperture sized to accept a rotor assembly and a rectangular coil. A rotor assembly is bidirectionally operable with the stator over a limited range of rotation. The rotor assembly includes an output shaft and a two-pole magnet and a position sensor shaft, wherein the output shaft and position sensor shaft are each rigidly attached to only a portion of the magnet. The rotor assembly includes apertures for allowing an electrical coil to pass through. The electrical coil extends around the magnet on four sides and is excitable for providing bidirectional torque to the rotor.