Position Sensor Cable Routing Support for Automated Magnetic Bearing Assembly

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Solution Overview

Problem

Existing methods for producing magnetic bearing modules with position sensors are laborious, unreliable, and costly, lacking automation and flexibility, and require complex chemical processes.

Innovation Solution

A cable routing support with protuberances and serigraphs forms a track for routing cables, using insulation displacement contacts, eliminating the need for manual soldering and overmoulding, and enabling modular production with automated assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual splice connections with soldering and impregnation are used, then electrical insulation and circuit creation are achieved, but the process is laborious, unreliable, and cannot be automated

Engineering Contradiction:

Improveconnection reliabilityVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical operations (soldering, impregnation, positioning) with an automated insulation displacement contact system. The routing support with guide tracks mechanically guides cables through openings directly into contact with electrical contacts, eliminating the need for soldering and chemical impregnation processes while enabling robotic automation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The routing support structure provides self-alignment and self-positioning features through its guide tracks and openings. The cable routing path is predetermined by the physical structure of the support itself, allowing the system to automatically position cables correctly without manual intervention for alignment or positioning steps.

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If PCB wiring with soldering and overmoulding is used, then electrical connections and mechanical protection are achieved, but the method is costly and lacks modular production flexibility

Engineering Contradiction:

Improveproduction flexibilityVSAvoidproduction tool complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent divides the wiring system into separate modular components: the routing support structure, the cable assembly, and the insulation displacement contacts. This segmentation allows each component to be manufactured independently using standardized processes and enables modular assembly, eliminating the need for complex integrated PCB designs and specialized production tools for each variant.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The routing support serves multiple functions simultaneously: it provides mechanical structure, cable routing guidance, positioning alignment, and support for insulation displacement contacts. This multi-functionality replaces the need for separate PCB, overmoulding, and positioning mechanisms, simplifying the overall production system while maintaining manufacturing flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If manual positioning and chemical impregnation steps are used, then mechanical positioning precision and electrical insulation are achieved, but production time increases and environmental impact worsens

Engineering Contradiction:

Improvepositioning precisionVSAvoidproduction cycle time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The routing support is pre-designed with integrated guide tracks and openings that predetermined the exact cable routing path and positioning locations. This preliminary structuring of the positioning system eliminates the need for subsequent manual positioning adjustments and chemical impregnation steps, achieving precision through the pre-configured mechanical guidance system alone.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If complex production tools and chemical processes are used, then electrical insulation and mechanical protection are achieved, but production costs increase and ecological impact worsens

Engineering Contradiction:

Improveelectrical insulationVSAvoidchemical environmental impact

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces chemical insulation processes (impregnation with varnish) with a mechanical insulation displacement contact system. The insulation is achieved through the physical structure of the routing support and the contact design itself, which provides electrical insulation through material selection and geometric configuration rather than chemical coatings, eliminating harmful chemical substances from the production process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250377017A1Position sensor routing support, magnetic bearing module and production method

Publication Date: 2025.12.11 SKF MAGNETIC MECHATRONICS SAS

AI summary

A routing support (3) for a cable (14) for a position sensor for a magnetic bearing module (1). The position sensor for said magnetic bearing module (1) includes an arrangement of coils (11) wound on spools and an insulation displacement contact (12). The routing support (3) includes a track for routing said cable (14) and openings (4) allowing the insertion of said cable (14) in the insulation displacement contact (12) through some of the openings (4) when the routing support (3) is positioned facing said position sensor for said magnetic bearing module (1). A magnetic bearing module (1) includes such a routing support (3). A method of producing such a magnetic bearing module (1).