Rotary Encoder Sensor Layout for Stronger Angle Signals
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary encoders face challenges in configurability due to undesirable boundary conditions affecting the geometric dimensions and positioning of the rotor element relative to the stator unit, leading to suboptimal signal strength and accuracy in rotation angle measurement.
Innovation Solution
A sensor unit design where the rotor element and stator unit are mounted on opposite flat sides of a common carrier body, allowing for improved configurability and increased rotor element diameter, reduced distance, and enhanced signal strength and accuracy through a compact inductive or magnetic measuring principle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the rotor element is mounted on a rotor carrier with specific geometric design, then the structural stability is maintained, but the configurability of rotor element dimensions and positioning is limited
Solution Approach 1:
The device is segmented into a carrier body and a separately mountable rotor element. The rotor element can be independently configured and mounted on the carrier body without being constrained by complex rotor carrier geometry, allowing flexible adaptation to different application requirements while maintaining structural stability through the carrier body design.
Solution Approach 2:
The carrier body is designed with a universal mounting interface that can accommodate rotor elements of various dimensions and configurations. This universal design eliminates the need for complex, application-specific rotor carrier geometries, enabling the same carrier body to support different rotor elements for diverse measurement tasks.
2Measurement precision
If the rotor element diameter is increased to improve signal strength, then the measurement accuracy is improved, but the device size and integration into housing becomes constrained
Solution Approach 1:
The rotor element is mounted on the carrier body in a configuration that optimizes its dimensional arrangement. By utilizing the three-dimensional space efficiently and mounting the rotor element on the carrier body rather than constraining it within a complex rotor carrier, larger rotor element diameters can be accommodated without proportionally increasing the overall device volume, thus improving signal strength while maintaining compact integration.
3Measurement precision
If the distance between rotor element and stator unit is reduced to improve measurement accuracy, then the signal strength increases, but the mechanical structural requirements become more stringent
Solution Approach 1:
The rotor element and stator unit are integrated into a unified sensor unit with the carrier body serving as a common mounting structure. This merging allows for precise positioning and minimal spacing between the rotor element and stator unit, optimizing the measurement accuracy and signal strength. The carrier body provides the necessary mechanical support, eliminating the need for additional complex structural components that would be required if the elements were separately mounted.
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 design enhances the configurability and accuracy of rotary encoders by optimizing geometric dimensions and relative arrangement, improving signal strength and measurement precision.
Implementation Method 1
which detects the angular position of the rotor element using an inductive or magnetic measuring principle
Implementation Method 2
which detects the angular position of the rotor element using an inductive or magnetic measuring principle
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a
AI summary
The invention relates to a sensor unit (10) for a rotary encoder (100), comprising at least a rotor element (11), a stator unit (12) configured to determine the angular position of the rotor element (11), and a carrier body (13). According to the invention, the rotor element (11) is rotatably mounted on a first flat side of a receiving section (13a) of the carrier body (13), with the stator unit (12) being arranged on a second flat side of the receiving section (13a) on the reverse side.