Sensor Assembly Magnet Fixation via Segmented Grooves
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Solution Overview
Problem
Existing motor designs face challenges in accurately sensing the rotation of a rotor due to detachment issues of the sensing magnet, which affects the reliability and precision of rotation detection.
Innovation Solution
A sensor assembly is developed with a holder and sensor cap that securely fixes the sensing magnet using a nonmagnetic material, featuring a first insertion groove, a ring-shaped wing portion, and a sensor cap with a fastening mechanism to prevent detachment and maintain magnetic sensitivity, allowing for accurate rotation sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensing magnet is directly fixed to the rotation shaft using adhesive, then the sensing magnet can be attached to the rotation shaft, but the sensing magnet may become detached and the bonding process is difficult to manage accurately
Solution Approach 1:
The invention divides the sensing magnet into multiple segments with recesses formed at opposing sides. These recesses allow insertion grooves to be formed, enabling the sensing magnet to be securely fixed to the rotation shaft through mechanical interlocking rather than relying solely on adhesive bonding. This segmentation approach makes the bonding process easier to manage while preventing detachment.
Solution Approach 2:
The invention uses insertion grooves that fit into recesses of the sensing magnet, creating a nested structure. The holder is inserted into the recesses of the sensing magnet segments, forming an interlocking assembly that securely attaches the sensing magnet to the rotation shaft. This nested design provides reliable fixation without adhesive while improving ease of manufacture.
2Reliability
If a holder and sensor cap structure is used to secure the sensing magnet, then detachment is prevented and sensing accuracy is maintained, but the device complexity increases
Solution Approach 1:
The invention combines the holder and sensor cap into an integrated assembly that works together to secure the sensing magnet. The holder with insertion grooves and the sensor cap with fastening portions function as a unified structure, simplifying the overall design while maintaining reliability. This merging reduces the number of separate components needed.
Solution Approach 2:
The sensing magnet segments with recesses are designed to self-align and self-lock with the holder through the insertion groove mechanism. The fastening portions of the sensor cap automatically engage with the holder structure, providing self-service fixation without requiring additional complex fastening mechanisms or assembly steps.
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 prevents sensing magnet detachment and maintains sensitivity, ensuring reliable and precise rotation detection while allowing for miniaturization and improved magnetic flux management.
Implementation Method 1
a detection unit that senses a rotation of the sensing magnet. The detection unit may include a magnetic element that faces the bottom portion of the sensor cap
Data Source
AI summary
Disclosed herein are a sensor assembly including a holder that includes a first insertion groove formed at one side and a second insertion groove formed at the other side, a sensing magnet disposed at the first insertion groove, and a sensor cap that covers the sensing magnet, and a motor including the same.