Rotary Encoder Plug-in Shaft Conical Interface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current rotary angle sensors face challenges in flexibility and cost-effectiveness due to slippage issues in coupling mechanisms, leading to increased assembly complexity and costs, especially when adapting to various customer-specific shaft diameters and lengths.
Innovation Solution
The design incorporates a plug-in solid or hollow shaft with a cone for centering, featuring a positive connection with the angle encoder main shaft through oversized form fits and adhesive grooves, preventing slippage and allowing for customizable metric and imperial dimensions, enabling direct torque transmission without axial movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a plug-in shaft system is used to adapt to various shaft diameters, then adaptability is improved, but slippage occurs which deteriorates reliability
Solution Approach 1:
The patent employs conical surfaces (tapers) on both the plug-in shaft and the receiving bore. These conical geometries create friction-based mechanical interference that prevents slippage while allowing the shaft to be inserted and removed. The conical shape converts axial insertion force into radial clamping force, ensuring reliable torque transmission without slippage across different shaft diameters.
Solution Approach 2:
The conical surfaces are pre-configured with specific geometric parameters (angles and dimensions) during manufacturing. When the shaft is inserted, the conical surfaces automatically self-align and create the necessary mechanical interference fit without requiring additional adjustment or assembly steps, preventing slippage from the outset.
2Reliability
If custom shaft designs are used for each application, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent creates a universal plug-in shaft system where a single base shaft design with a standardized conical interface can accommodate multiple shaft diameters and configurations. The conical receiving bore serves as a universal interface that works with different shaft sizes, eliminating the need for custom-designed shaft assemblies for each application while maintaining reliable torque transmission.
Solution Approach 2:
The shaft system is divided into modular components: a base shaft, interchangeable conical inserts or adapters, and a universal receiving bore. This segmentation allows different shaft configurations to be achieved by combining standard components rather than designing entirely custom assemblies, reducing overall system complexity.
3Adaptability or versatility
If multiple bearing assemblies are used for different shaft configurations, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs a universal bearing assembly design with a standardized conical receiving bore that can accommodate multiple shaft diameters. This single bearing assembly type replaces multiple specialized bearing assemblies, allowing the same bearing component to serve different shaft configurations through the interchangeable conical interface system.
Solution Approach 2:
The system allows dynamic reconfiguration of shaft assemblies by enabling the insertion and removal of different conical shaft inserts or adapters within the universal bearing assembly. This dynamic adaptability eliminates the need for multiple static bearing assembly designs, simplifying manufacturing while maintaining versatility.
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 solution enhances flexibility and cost-effectiveness by ensuring precise, slippage-free rotation transmission, reducing assembly complexity and enabling standardization across different shaft diameters, thus meeting a wide range of customer requirements efficiently.
Implementation Method 1
adhesive grooves, preventing slippage
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention relates to a rotary angle encoder with a detection electronics and an angle encoder main shaft (2), wherein the angle encoder main shaft (2) is a tube, wherein the angle encoder main shaft (2) has an insertion opening (20) at one end and an angle encoder coupling (16) at the other end, wherein the angle encoder coupling (16) can be force-fitted/form-fittedly connected to a square coupling (9) of an insertable solid shaft (3) or a hollow shaft coupling (14) of an insertable hollow shaft (10).