Rotary Encoder Housing Strain Sensing for Bearing Fault Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary encoders face issues with bearing blockage or sluggishness, leading to increased driving torque and potential connection failure between the encoder shaft and the assembly shaft, which can result in severe damage and unexpected disturbances.
Innovation Solution
A rotary encoder with a flexible housing structure and strain sensor arrangement that detects tension and compression to reliably identify bearing malfunctions, allowing for early intervention and prevention of extensive damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bearing configuration is monitored using traditional methods, then device complexity is reduced, but reliability of bearing malfunction detection deteriorates
Solution Approach 1:
The patent replaces traditional mechanical monitoring methods with a strain sensor arrangement that detects tension and compression forces. This substitution enables more reliable bearing malfunction detection by measuring physical strains directly, while the sensor arrangement can be integrated into the existing housing structure, thereby not significantly increasing device complexity.
Solution Approach 2:
The housing structure serves multiple functions: it provides structural support, transmits forces from the bearing configuration to the strain sensor arrangement, and acts as part of the detection system itself. This multi-functionality reduces the need for additional separate components, maintaining device complexity at acceptable levels while improving detection reliability.
2Reliability
If strain sensor arrangement is added to detect bearing malfunctions, then reliability of malfunction detection is improved, but device complexity increases
Solution Approach 1:
The strain sensor arrangement is merged with the housing structure, where the housing itself becomes part of the force transmission path. The flexible structure of the housing is specifically designed to transmit forces from the bearing configuration to the strain sensors, combining structural and sensing functions into a single integrated system.
Solution Approach 2:
The patent employs a flexible structure of the housing that can transmit forces while maintaining structural integrity. This flexible design allows the housing to deform slightly under bearing loads, enabling effective force transmission to the strain sensor arrangement without requiring rigid additional components, thus limiting the increase in device complexity.
3Measurement precision
If flexible structure of housing is used to transmit forces, then measurement precision of bearing forces is improved, but device complexity increases
Solution Approach 1:
The flexible structure of the housing is specifically designed to transmit forces from the bearing configuration to the strain sensor arrangement. This flexible design allows the housing to deform slightly under bearing loads, enabling effective force transmission to the strain sensors without requiring rigid additional components, thus limiting the increase in device complexity.
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 solution enables efficient and reliable detection of bearing malfunctions, preventing extensive damage and maintaining high operational standards by allowing for timely interruption of assembly operations.
Implementation Method 1
A strain sensor arrangement is attached to the housing and arranged for detecting tension and/or compression associated with the housing
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
The invention relates to a rotary encoder (200) comprising a shaft (210) having a bearing configuration (220) arranged in a housing (280), the bearing configuration (220) being configured to allow rotation of the shaft (210) relative to said housing (280), a rotor (250) being attached to said shaft (210), the rotary encoder also comprises a stator (260). The rotary encoder (200) further comprising: - a strain sensor arrangement (270, 274a, 274b, 276a, 276b, 205, 600) being configured to determine malfunction of the bearing configuration (220), said strain sensor arrangement is attached to the housing (280), wherein the housing (280) has a flexible structure so as to, in connection to rotation of said shaft (210), facilitate transmitting forces associated with said bearing configuration (220) to said strain sensor arrangement (270), wherein said strain sensor arrangement is arranged to detect tension and/or compression associated with said housing (280), wherein a malfunction of the bearing configuration (220) is determined based on said detected tension and/or compression. The invention relates also to a computer program product comprising program code (P) for a computer (201; 600) for implementing a method according to the invention. The invention relates also to a method for determining malfunction of a rotary encoder.