Rotation Sensor Holder Eliminates Filling Resin
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Solution Overview
Problem
The high manufacturing cost of rotation sensors due to the use of expensive internal filling resin to fix the magnetic detection section within the case.
Innovation Solution
A rotation sensor design that incorporates a holder with a holder main body and rib to surround and fix the magnetic detection section, eliminating the need for internal filling resin, thereby reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal filling resin is used to fix the magnetic detection section, then the magnetic detection section is securely fixed to the case, but manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the internal filling resin from the sensor structure. Instead of using resin to fix the magnetic detection section, the lead frames themselves are designed to provide mechanical support and positioning through their folded configurations and contact with the case, thereby removing the need for expensive internal filling resin while maintaining fixing reliability
Solution Approach 2:
The lead frames perform multiple functions: they provide electrical connections, mechanical support, and positioning for the magnetic detection section. The folded portions of the lead frames create abutment surfaces that directly support the magnetic detection section, allowing the component to serve itself rather than requiring additional fixing materials
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 effectively reduces manufacturing costs by simplifying the assembly process and enhancing workability while maintaining the sensor's functionality and accuracy.
Implementation Method 1
a magnetic detection section arranged inside the case so as to extend over the distal end of each of the pair of lead frames, and configured to detect a change in magnetic field caused by a magnetic body arranged on the rotating body
Data Source
AI summary
To obtain a rotation sensor capable of reducing manufacturing cost, provided is a rotation sensor including: a case including: a bottom surface portion; a side surface portion; and an opening; a pair of lead frames each including a distal end inserted into the case through the opening; a magnetic detection section arranged inside the case, and configured to detect a change in magnetic field caused by a magnetic body; and a holder surrounding the magnetic detection section in cooperation with the case, the holder including: a holder main body, which has an outer peripheral surface formed along an inner peripheral surface of the side surface portion and is configured to sandwich the pair of lead frames between the outer peripheral surface and the side surface portion; and a rib formed along a forming portion of the lead frame so as to be brought into contact with the forming portion.