Rotation Sensor Spacer Reduces Resin Cost
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Solution Overview
Problem
The existing rotation sensors for detecting rotation in rotating bodies, such as engine crankshafts, face high manufacturing costs due to the use of expensive epoxy resin for internal filling and have low workability due to the need for precise handling of lead frames during the assembly of the magnetic detection section.
Innovation Solution
The rotation sensor design incorporates a spacer between the lead frames and the case's side surface to reduce the amount of internal filling resin required, thereby lowering costs, and fixes the lead frames to the spacer during assembly to minimize deformation and improve handling precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of internal filling resin is used to fill the internal space of the case, then the magnetic detection section is properly positioned and protected, but manufacturing costs increase due to the expensive epoxy resin material
Solution Approach 1:
A resin-unfilled space is introduced as an intermediary element between the magnetic detection section and the internal filling resin. This space, positioned between the lead frames and the case inner wall, reduces the volume of expensive epoxy resin needed while maintaining proper positioning through the combined support of the lead frames and the spacer structure.
Solution Approach 2:
The invention changes the spatial parameter of the internal filling resin by creating a resin-unfilled space that reduces the resin volume. By controlling the position and dimensions of this space, the patent achieves cost reduction while maintaining the functional requirements for magnetic detection section positioning and protection.
2Ease of manufacture
If the magnetic detection section is inserted into the case through the opening, then assembly is simplified, but the lead frames are prone to deformation during handling and insertion
Solution Approach 1:
The lead frames are preliminarily fixed to each other at their base portions before the insertion process. This preliminary action creates a rigid combined structure that resists deformation during subsequent handling and insertion operations, while still allowing the magnetic detection section to be inserted through the opening for simplified assembly.
Solution Approach 2:
The lead frames are merged or fixed together at their base portions to form a unified structure. This combining of multiple lead frames into a single rigid assembly reduces individual frame deformation during handling and simplifies the insertion process as a unified component.
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 design significantly reduces manufacturing costs by minimizing the use of expensive resin and enhances workability by stabilizing the lead frames during assembly, ensuring accurate placement of the magnetic detection section.
Implementation Method 1
The IC 4 generates a signal in accordance with a change in magnetic field of the in-sensor magnet 5 by the rotation of the rotary shaft 11
Implementation Method 2
The IC 4 includes a detection element such as a hall element
Data Source
AI summary
Provided is a rotation sensor capable of reducing manufacturing costs and improving workability. The rotation sensor includes: a case including: a bottom surface portion; and a side surface portion that defines a hollow internal space in cooperation with the bottom surface portion; a plurality of lead frames respectively having distal ends inserted into the case; a magnetic detection section provided to the distal ends of the plurality of lead frames arranged in parallel; a spacer provided between the plurality of lead frames and the side surface portion so as to be held in contact with an internal wall surface of the side surface portion; and an internal filling resin for filling a space portion of the hollow internal space except for the spacer, the magnetic detection section, and the plurality of lead frames.