Rotary Encoder Self-Powered Design via Integrated Magnet and Coil
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Solution Overview
Problem
Conventional rotary encoders require extensive wiring for both power supply and data transmission, leading to increased maintenance and costs due to the need for primary batteries, and their design is inflexible and expensive due to additional components.
Innovation Solution
A compact rotary encoder design with an integrated energy generation unit using a ring magnet and SMD multi-layer planar coil, allowing for autonomous energy supply and wireless communication, reducing the need for separate generators and additional components, and enabling flexible arrangement and efficient energy generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a generator and additional components are added to provide autonomous energy supply, then the rotary encoder achieves independent energy supply, but the device complexity and cost increase
Solution Approach 1:
The patent combines the energy generation unit with the signal generator unit by integrating the magnet element and coil structure into the existing encoder components. The magnet element that generates the magnetic field for position detection is simultaneously used to generate electrical energy through electromagnetic induction with the coil, merging two functions into a single integrated unit.
Solution Approach 2:
The magnet element serves dual purposes: it creates the magnetic field necessary for the signal generator to detect shaft position, and it simultaneously acts as the moving magnet in the electromagnetic induction system that generates electrical energy. This multi-functionality eliminates the need for separate energy generation components.
2Reliability
If a separate generator is integrated into the rotary encoder, then autonomous energy supply is achieved, but the rotary encoder design becomes difficult to adapt to existing installation space
Solution Approach 1:
The energy generation components are merged with the signal generator unit that is already part of the rotary encoder's standard configuration. The magnet element and coil are integrated into the existing mechanical and electrical structure, allowing the energy generation function to be added without requiring separate installation space or major design changes.
3Ease of operation
If primary batteries are used for energy supply, then the rotary encoder can operate wirelessly, but maintenance effort and costs increase due to battery replacement
Solution Approach 1:
The rotary encoder generates its own electrical energy through electromagnetic induction using the rotation of the shaft itself to move the magnet element relative to the coil. This self-generated energy is stored in a capacitor or rechargeable battery, eliminating the need for external primary batteries that would require periodic replacement.
4Reliability
If extensive wiring is used for power supply and data transmission, then the rotary encoder can be connected to the controller, but wiring effort and costs increase
Solution Approach 1:
The patent replaces extensive physical wiring with wireless communication technology. The rotary encoder uses wireless transmission (such as radio frequency communication) to send measured variables and data to the controller, eliminating the need for separate communication cables and reducing wiring 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 provides a compact, low-maintenance rotary encoder with improved voltage supply and wireless data transmission, reducing wiring efforts and operational costs while allowing adaptation to different designs.
Implementation Method 1
The rotary encoder has an energy generation unit (5) for generating electrical energy for the rotary encoder (1)... The first element (5a) of the power generation unit (5) consists of at least one axially multi-pole magnet element (2a)... the second element (5b) consists of at least one coil (6)... When the shaft (W) rotates, the first element (5a) of the power generation unit (5) induces a voltage in the second element (5b) or in the coils (6)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
In order to enable a compact and self-sufficiently powered rotary encoder, the invention provides a rotary encoder for acquiring information from a rotating shaft, comprising a signal transmitter unit attached to the shaft, a signal acquisition unit arranged axially opposite the signal transmitter unit, a signal evaluation unit comprising a printed circuit board spaced axially from the shaft, and a power generation unit for generating electrical energy for the rotary encoder, wherein the power generation unit consists of a first element provided on the signal transmitter unit and a second element arranged on the printed circuit board of the signal evaluation unit, and wherein the first and second elements are arranged opposite each other.