Rotation Sensor Assembly With Spacer-Based Precise Positioning
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Solution Overview
Problem
Existing sensor attachment methods fail to provide precise positioning for rotation sensors due to clearance between bolts and bolt holes, leading to decreased precision and increased costs from complex bracket shaping and potential deformation during tightening.
Innovation Solution
A sensor assembly that includes a bracket fixed to a fixing subject member, a spacer contacting the member, and a rotation sensor sandwiched between the spacer and bracket, ensuring precise positioning and cost reduction by eliminating the need for complex shaping and cutting of the bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bracket is formed simply by pressing a metal plate, then manufacturing cost is reduced, but shape precision of the bracket deteriorates
Solution Approach 1:
A positioning pin is introduced as an intermediary component between the bracket and the sensor assembly. The positioning pin has a cylindrical shape with a diameter smaller than the through-hole in the bracket, allowing it to fit through the hole and provide precise positioning. This mediator component enables accurate sensor positioning without requiring complex bracket shaping or cutting operations, thus maintaining low manufacturing cost while achieving high positioning precision.
2Ease of operation
If a clearance is provided between the bolt and bolt hole for assembly purposes, then ease of assembly is improved, but positional precision of the rotation sensor deteriorates
Solution Approach 1:
The positioning pin acts as a mediator that decouples the assembly clearance from the final positioning accuracy. The pin fits through the bolt hole with appropriate clearance for easy assembly, but its cylindrical geometry and engagement with the sensor assembly ensure that once assembled, the sensor is precisely positioned. The positioning pin transfers the positioning function from the bolt-bolt hole interface to the pin-sensor interface, where precision is achieved through the pin's geometry rather than tight tolerances.
3Manufacturing precision
If the bracket is subjected to cutting processing to improve shape precision, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The positioning pin serves as a mediator that eliminates the need for complex cutting processing of the bracket. Instead of precisely cutting the bracket to achieve accurate sensor positioning, the positioning pin is simply inserted through a through-hole in the bracket. This approach replaces expensive precision cutting operations with a simple insertion operation, significantly reducing manufacturing cost while maintaining high positioning precision.
4Ease of operation
If the bracket is deformed by the tightening force of the bolt, then assembly is simplified, but positional precision of the rotation sensor deteriorates
Solution Approach 1:
The positioning pin acts as a mediator that protects the sensor positioning from bracket deformation. The pin is inserted through the bracket's through-hole and engages with the sensor assembly, creating a rigid positioning reference. Even when the bracket deforms under bolt tightening forces, the positioning pin maintains the sensor's position because the pin's cylindrical geometry and engagement with the sensor assembly provide a stable reference that is independent of bracket deformation.
Data Source
AI summary
A sensor assembly that is fixed to a fixing subject member includes a bracket that is fixed to a fixing subject member, a spacer that is attached to the bracket and contacts the fixing subject member, and a rotation sensor that is held by the bracket and is sandwiched between the spacer and the bracket.