Rotary Encoder Trigger Signal Generation Using Wiegand Effect
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Solution Overview
Problem
Existing rotary encoders are complex and expensive to manufacture, limiting their cost-effectiveness and ability to function independently without an external power source.
Innovation Solution
A rotary encoder design featuring a stator and rotor with specific magnetic sensor configurations, including pulse wires and magnets, that allow for energy self-sufficiency and cost-effective production by generating trigger signals from specific magnetic interactions, enabling accurate angular position measurement even without external power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional magnetic scanning principles with multiple magnetic pole segments and flux concentrators are used, then the rotary encoder can determine angular position, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent extracts and eliminates the complex flux concentrators and multiple magnetic pole segments from the traditional design. Instead, it uses a single magnet with simple polarity segments on the rotor and corresponding sensors on the stator, removing unnecessary components while maintaining the essential magnetic field detection function for angular position measurement.
Solution Approach 2:
The patent inverts the traditional approach by placing the magnetic field source (magnet with polarity segments) on the rotor and the detection elements (sensors) on the stator, rather than having multiple magnets and flux concentrators. This inversion simplifies the overall structure and reduces manufacturing complexity while achieving the same measurement function.
2Reliability
If the rotary encoder is equipped with multiturn gears and magnetic measuring principles for emergency operation, then it can count revolutions without external power, but the device complexity and cost increase
Solution Approach 1:
The patent makes the primary magnetic sensing system serve dual functions: it accurately measures angular position during normal powered operation and simultaneously counts revolutions during emergency unpowered operation. The same magnets and sensors perform both functions, eliminating the need for separate multiturn gear mechanisms.
Solution Approach 2:
The patent merges the angular position measurement function and the revolution counting function into a single integrated magnetic sensing system. The magnets with polarity segments and the sensors work together to provide both precise angular measurement and revolution tallying, combining what were previously separate functions into one unified system.
3Measurement precision
If multiple magnetic pole segments and flux concentrators are arranged over the shaft circumference, then angular position can be determined, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent applies segmentation to the magnet itself by creating distinct polarity segments (N and S poles) on the rotor magnet rather than using multiple separate magnets or complex flux concentrator arrangements. This segmentation of the magnetic field source simplifies the overall structure while maintaining the ability to determine angular position through the varying magnetic field patterns detected by the sensors.
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 cost-effective production and operation of rotary encoders that can accurately measure angular position independently, reducing manufacturing complexity and operational reliance on external power sources.
Implementation Method 1
A magnetically sensitive unipolar element, for example a pulse wire or a Hall element, can be used as the trigger sensor
Implementation Method 2
The magnetic sensors detect the respective magnetic field of the first magnet and the third magnet when the two components rotate relative to each other by at least one full revolution
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a rotary encoder and a method for its operation, comprising two component groups (1, 2) arranged to be rotatable relative to each other about an axis (A), wherein the first component group (1) comprises a trigger sensor (1.1) and several magnetic sensors (1.3, 1.4). The second component group comprises a first magnet (2.1, 2.4), a second magnet (2.2, 2.5), and a third magnet (2.3, 2.6). The component groups (1, 2) are configured such that the magnetic field of the first magnet (2.1, 2.4) and the third magnet (2.3, 2.6) can be detected by the magnetic sensors (1.3, 1.4) during one full rotation. The second magnet (2.2, 2.5) and the third magnet (2.3, 2.6) can generate a trigger signal through the trigger sensor (1.1), while the first magnet (2.1, 2.4) prevents the trigger sensor (1.1) from generating a trigger signal.