Rotation Detector Using Multilayer Substrates and High Frequency Signals
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Solution Overview
Problem
Existing rotation detectors are heavy and costly due to the use of magnetic materials, which limits their weight reduction and manufacturing efficiency, and struggle with detection precision and cost-effectiveness.
Innovation Solution
A rotation detector configuration using multilayer substrates for both the rotor and stator, with detection coils on the stator substrates, and setting the excitation signal frequency higher than typical magnetic material frequencies to enhance electromagnetic coupling and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic materials (iron) are used to increase electromagnetic coupling between stator and rotor, then detection precision is improved, but weight increases significantly
Solution Approach 1:
The patent extracts and removes the magnetic material (iron) from the stator and rotor structures, replacing them with non-magnetic substrates. This extraction eliminates the weight penalty while maintaining electromagnetic coupling through alternative means (air gap magnetic field), directly resolving the contradiction between detection precision and weight.
Solution Approach 2:
The patent changes the operating parameters by using high-frequency excitation signals and optimizing the coil winding patterns (rectangular waveform) to compensate for the absence of magnetic materials. This parameter change allows the system to achieve sufficient electromagnetic coupling without relying on high-permeability magnetic materials, thus reducing weight while maintaining detection precision.
2Measurement precision
If magnetic materials and multiple insulating sheets are used to ensure electromagnetic coupling, then detection precision is maintained, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the expensive insulating sheets (stator insulating sheet and rotor insulating sheet) from the conventional structure. By using substrates with inherent insulation properties and simplified coil mounting methods, the patent reduces the number of assembly steps and material costs while maintaining electrical insulation and detection precision.
Solution Approach 2:
The patent replaces expensive, precisely manufactured insulating sheets with simpler, cheaper alternative insulation methods that are easier to manufacture and assemble. This substitution reduces manufacturing complexity and cost while achieving the same functional outcome of electrical insulation and magnetic field coupling.
3Measurement precision
If conventional processing and assembly methods are used for coils and insulating sheets, then electromagnetic coupling is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the coil winding process directly onto the substrate surface, eliminating the need for separate insulating sheet assembly steps. The coils are formed and mounted in an integrated manner on the substrate, simplifying the manufacturing process while maintaining the necessary electromagnetic coupling between stator and rotor coils.
Solution Approach 2:
The substrate itself provides the insulation function that previously required separate insulating sheets. By designing the substrate with inherent insulating properties, the patent makes the structure self-sufficient, eliminating the need for additional insulating components and reducing assembly 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 results in a lightweight rotation detector with improved detection precision and reduced manufacturing costs, while maintaining or exceeding the electromagnetic coupling and signal quality of magnetic material-based detectors.
Implementation Method 1
a relative angle of rotation between the rotor substrate and the stator substrates is detected based on detection signals induced in the detection coils when the rotor coil is excited with an excitation signal
Implementation Method 2
detection signals induced in the detection coils when the rotor coil is excited with an excitation signal
Data Source
AI summary
A rotation detector includes the following: a rotor and stators comprising a rotor substrate and stator substrates, each of which is a multilayer substrate; a rotor coil provided on the rotor substrate; and detection coils provided on the stator substrates. The frequency of an excitation signal used by said rotation detector is set so as to be higher than a prescribed frequency that would be required if the rotor and the stators were each made of a magnetic material.