Integrated Rotary Scale Positioning for Precise Angle Detection
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Solution Overview
Problem
Existing rotational positioning devices face issues with precision due to center deviations during assembly, which affect the accuracy of angle change detection and target angle positioning. Additionally, externally installed encoders increase device size and cost, and obstruct the passage of cables and hydraulic parts through the hollow roller gear.
Innovation Solution
A rotational positioning device with a housing, a rotational member rotatable within the housing, and sensors installed in the housing. The rotational member has a graduated scale integrally formed along its circumferential direction, allowing the sensors to detect angle changes with high precision and position the rotational member at a target angle with improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an encoder is externally installed to detect rotation angle, then angle detection function is achieved, but device size increases and cost increases
Solution Approach 1:
The graduated scale is integrally formed with the rotational member, merging the scale into the rotational member itself rather than being a separate external component. This eliminates the need for a separate encoder housing and reduces overall device size while maintaining angle detection capability.
Solution Approach 2:
The scale is extracted from being a separate encoder component and integrated directly onto the rotational member. This extraction allows the scale to be formed as a simple circumferential marking on the rotational member, reducing the need for additional encoder housing and mounting structures.
2Measurement precision
If an encoder is externally installed to detect rotation angle, then angle detection function is achieved, but manufacturing cost increases
Solution Approach 1:
The graduated scale is merged with the rotational member through integral formation, eliminating the need for separate encoder components and reducing part count. This simplification directly reduces manufacturing cost while maintaining angle detection functionality.
Solution Approach 2:
The scale is formed as a simple circumferential marking on the rotational member using cost-effective methods such as laser marking or printing, replacing expensive commercial encoder assemblies with a simpler, cheaper marking solution that achieves the same functional purpose.
3Measurement precision
If an encoder is externally installed, then angle detection is achieved, but cables and hydraulic parts cannot pass through the hollow roller gear
Solution Approach 1:
The scale is extracted from being a separate encoder component and integrated directly onto the rotational member. This allows the hollow roller gear to remain hollow and functional, enabling cables and hydraulic parts to pass through while the scale markings are applied directly to the outer surface of the rotational member.
Solution Approach 2:
The scale markings are placed on the outer circumferential surface of the rotational member in a different dimensional location than the hollow interior. This allows the hollow interior to remain open for cable passage while the outer surface provides the scale markings for angle detection.
4Measurement precision
If the encoder input shaft is connected to the roller gear shaft, then angle detection is achieved, but center deviation occurs during assembly
Solution Approach 1:
The scale is extracted from being a separate encoder component and integrated directly onto the rotational member. This eliminates the need to connect a separate encoder input shaft to the roller gear shaft, thereby eliminating the source of center deviation and assembly accuracy problems.
Solution Approach 2:
The scale and rotational member are merged into a single integrated component. This ensures that the scale rotates exactly with the rotational member without any relative movement or misalignment, eliminating center deviation issues that would occur with separate connected components.
Data Source
AI summary
Provided is a rotational positioning device capable of positioning a rotational angle at a target angle position with high precision. A rotational positioning device is provided with: a housing; a rotational member which is rotatable about a rotational member axial line and at least a part of which is accommodated in the housing; and at least one sensor installed in the housing. A graduated scale with a plurality of scale marks is formed integrally with the rotational member along the circumferential direction of the rotational member. The at least one sensor detects an angle change amount due to rotation of the rotational member on the basis of the plurality of scale marks. The rotational member is positioned at the target angle position on the basis of the angle change amount.