Rotation Sensor Bearing Removable Substrate Groove
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotation sensor equipped bearing assemblies face challenges such as non-reusability of components, increased axial length due to sensor substrate thickness, labor-intensive assembly, and the need for multiple molds for different shaft diameters, leading to inefficiencies and increased costs in maintenance and replacement.
Innovation Solution
A rotation sensor equipped bearing assembly design featuring a removably mounted sensor substrate with a substrate mounting groove on the sensor housing, allowing for easy replacement of faulty components, reduced axial length, and simplified assembly, with a sliding bearing unit and optical sensor options for cost-effectiveness and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the encoder is fitted to the inner ring by press fitting technique, then the encoder can be securely mounted, but the encoder cannot be reused and the bearing assembly or sensor cannot be replaced independently
Solution Approach 1:
The patent divides the rotation sensor equipped bearing assembly into separable modules: the encoder unit (including encoder and first housing) and the sensor unit (including sensor, second housing, and circuit board). This segmentation allows independent replacement of faulty components while maintaining secure mounting through standardized coupling interfaces between modules.
2Ease of manufacture
If a ring shaped substrate having the sensor installed thereon is fitted to the sensor housing in coaxial relation, then the sensor can be mounted, but the axial length of the rotation sensor equipped bearing assembly increases by the thickness of the substrate
Solution Approach 1:
The patent repositions the sensor from a coaxial ring-shaped substrate configuration to a planar circuit board mounted on the second housing. The sensor detects encoder patterns through a radially extending detection window, changing the detection dimension from axial to radial, thereby eliminating the need for additional axial space equal to substrate thickness.
3Reliability
If the sensor mounting substrate is fitted to the sensor housing using insert molding, then the substrate can be securely mounted, but a substantial amount of labor and time is required to set the substrate in a mold during molding
Solution Approach 1:
The patent separates the sensor mounting from the housing manufacturing process. Instead of using insert molding to integrate the substrate into the housing, the circuit board with sensor is manufactured separately and then mounted to the second housing using standard fastening methods, eliminating complex mold setup requirements while maintaining secure mounting.
4Adaptability or versatility
If the rotation sensor equipped bearing assembly is designed to accommodate different shaft diameters by changing molds, then various shaft diameters can be supported, but the number of molds required increases and labor and time are substantially increased
Solution Approach 1:
The patent designs the encoder with a universal mounting structure that can accommodate different shaft diameters without requiring different molds. The encoder housing and mounting interface are designed to be adaptable to various shaft sizes, allowing a single mold design to serve multiple shaft diameter requirements, thereby reducing the number of molds needed and simplifying the manufacturing process.
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 easy disassembly and replacement of faulty components, reduces axial length, and simplifies assembly, while allowing for cost-effective and compact integration in business machines, enhancing maintenance efficiency and reducing component costs.
Implementation Method 1
the rotation of the encoder is detected by means of an optical sensor supported in the sensor housing
Data Source
AI summary
A bearing unit is provided in an inner peripheral portion of a sensor housing in which a sensor portion is installed. The sensor portion includes a sensor mounting substrate and a sensor fixed to this sensor mounting substrate. The sensor housing is provided with an axially extending substrate mounting groove formed in a direction of a chord which will define the circular section of the outer peripheral surface of the sensor housing. The sensor mounting substrate is mounted on this substrate mounting groove to install the sensor portion within the sensor housing.