Rotating Sensor Metallic Patterns on Plastic Substrate
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Solution Overview
Problem
Existing sensing technologies for rotating bodies, particularly in miniature forms, face challenges in accurately detecting minute displacements and efficiently calculating rotation information due to limitations in pattern design and material usage.
Innovation Solution
The apparatus incorporates a cylindrical supporting member with first and second pattern portions, each comprising metallic patterns with specific shapes and angle differences, coupled with sensing coils to detect rotation information, including rotation angle and angular velocity, while being formed from plastic with thin patterns to minimize profile and enhance mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If metallic patterns are used on a plastic supporting member, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by combining metallic patterns (for electromagnetic sensing) with a plastic supporting member (for structural support and insulation). This composite structure enables precise rotation detection through the metallic patterns while the plastic material simplifies manufacturing compared to fully metallic constructions, resolving the contradiction between measurement precision and manufacturing complexity
Solution Approach 2:
The metallic patterns are applied locally on specific surfaces of the plastic supporting member rather than throughout the entire structure. This localized application provides the necessary electromagnetic properties for accurate detection only where needed, while maintaining the manufacturing advantages of plastic for the bulk structure, thus balancing precision requirements with manufacturing simplicity
2Volume of moving object
If thin patterns with thickness of 8 μm to 12 μm are used, then volume of moving object is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a precise thickness range of 8 μm to 12 μm for the metallic patterns, optimizing this parameter to achieve miniaturization while maintaining manufacturability. This parameter optimization allows the thin patterns to provide sufficient electromagnetic signal for detection while remaining within achievable manufacturing tolerances for thin-film deposition processes
Solution Approach 2:
The use of thin metallic film patterns (8-12 μm) on the plastic supporting member enables miniaturization of the rotating component. The thin-film construction reduces the overall profile thickness while the film deposition process on plastic provides a manufacturable approach to achieving consistent thin dimensions across production
3Measurement precision
If multiple pattern portions with angle differences are used, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The detection system is segmented into multiple pattern portions (first pattern portion and second pattern portion) with different angular orientations. Each pattern portion provides detection information for specific angular ranges, and by combining the outputs from these segmented patterns, the system achieves comprehensive and precise rotation detection while keeping each individual pattern relatively simple in design
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 enables precise detection of rotation information with reduced profile and cost, suitable for miniature applications, by utilizing metallic patterns on a plastic supporting member with sensing coils, improving accuracy and manufacturability.
Implementation Method 1
a sensor module including a first sensor disposed opposite to the first pattern portion and a second sensor disposed opposite to the second pattern portion, wherein the first patterns and the second patterns are formed of a metallic material, and each of the first sensor and the second sensor comprises a sensing coil
Data Source
AI summary
An apparatus for sensing a rotating body includes a cylindrical supporting member being connected to a rotating shaft, a unit to be detected including a first pattern portion provided in a first height region of the supporting member, and the first pattern portion including first patterns extended in a rotation direction of the rotating shaft and a second pattern portion provided in a second height region of the supporting member, extended in a rotation direction of the rotating shaft, and the second pattern portion including second patterns having an angle difference with the first patterns, and a sensor module including a first sensor disposed opposite to the first pattern portion and a second sensor disposed opposite to the second pattern portion, the first patterns and the second patterns are formed of a metallic material, and each of the first sensor and the second sensor includes a sensing coil.