Rotation Detector Rotor Machining
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Solution Overview
Problem
Conventional rotation detectors require precise machining of gears and rings to maintain high precision, resulting in low working efficiency and limited applicability to materials like steel, where sintering methods are not feasible.
Innovation Solution
A rotor design with a first cylindrical portion and a second cylindrical portion, where teeth are formed on both portions in a single operation by machining, allowing for efficient production and detection of rotational position and speed using a magnetic field generator and detector unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gears and rings are precisely machined to maintain high precision, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent merges the gear and ring into a single integrated rotor structure where both components are formed simultaneously in one machining operation. The rotor includes a first cylindrical portion with gear teeth and a second cylindrical portion with a single tooth, both machined together from the same workpiece. This eliminates the need for separate machining and assembly operations, achieving high concentric alignment precision while significantly improving productivity.
2Manufacturing precision
If multiple teeth are formed and then ground leaving only one tooth, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent applies preliminary action by forming the single tooth on the second cylindrical portion directly during the initial machining operation, rather than forming multiple teeth and then removing them through grinding. The machining process is designed to create the exact final tooth configuration in one step, eliminating unnecessary preliminary and subsequent operations.
3Productivity
If sintering method is used to form gear and single tooth as unitary structure, then productivity is improved, but adaptability deteriorates
Solution Approach 1:
The patent replaces the sintering process with a mechanical machining process. Instead of using powder metallurgy and sintering to form the rotor, the invention uses conventional machining methods to machine the rotor blank directly. This substitution maintains the productivity benefits of integrated formation while restoring the ability to use various materials including steel, aluminum, and other metals that can be machined.
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
Enables efficient production and accurate detection of rotational position and speed, reducing the need for precise machining and expanding material options beyond sinterable materials.
Implementation Method 1
a magnetic field generator fixed to face the rotor and generates a magnetic field
Implementation Method 2
a detector unit arranged between the rotor and the magnetic field generator to detect signals that vary responsive to changes in the magnetic field caused the rotation of the rotor
Data Source
AI summary
A rotor (1b) includes a first cylindrical portion (10), and a second cylindrical portion (20) including a first partial circumferential surface (21) having a width narrower than that of the first cylindrical portion (10) in the circumferential direction, and a second partial circumferential surface (22) having a radius smaller than a radius of the first partial circumferential surface; the rotor, further, including a first to-be-detected portion having a plurality of teeth (15), and a second to-be-detected portion having at least one tooth (25), and wherein the at least one tooth of the second cylindrical portion and the tooth of the first cylindrical portion corresponding to the at least one tooth are formed in one operation by machining.