Sensor Module Polygonal Protrusion Anti-Slip Design
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Solution Overview
Problem
Existing sensor modules in motors face issues with accurate rotor position detection due to slip between the sensing magnet and sensing plate, caused by weakened adhesive strength from heat or impact.
Innovation Solution
A sensor module design featuring a sensing plate with a polygonal protrusion and a corresponding polygonal-shaped sensing magnet with segmented magnets, where the sensing magnet is fixedly inserted into the plate, preventing slip and enhancing bonding strength through a magnetic interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to fix the sensing magnet to the sensing plate, then the sensing magnet can be attached to the sensing plate, but the adhesive strength weakens due to heat or impact causing slip between the sensing magnet and sensing plate
Solution Approach 1:
The patent replaces the adhesive bonding system with a mechanical interference fit system. The sensing magnet includes a protrusion that fits into a corresponding recess in the sensing plate, creating a mechanical connection that prevents slip. This mechanical system is more reliable under heat and impact conditions compared to adhesive bonding.
Solution Approach 2:
The sensing magnet is divided into multiple segmented magnets arranged around the protrusion. This segmentation allows each magnet to be precisely positioned and secured by the mechanical interference fit, ensuring accurate rotor position detection while maintaining strong bonding without adhesive.
2Ease of manufacture
If adhesive bonding process is used to attach the sensing magnet, then the sensing magnet can be fixed to the sensing plate, but the manufacturing process becomes more complex
Solution Approach 1:
The patent eliminates the adhesive bonding process entirely by using a mechanical interference fit. The protrusion-recess mechanism allows the sensing magnet to be attached through simple assembly operations without requiring adhesive application, curing time, or complex bonding equipment, thereby simplifying the manufacturing process.
Solution Approach 2:
The protrusion and recess features are pre-formed during the molding or machining of the sensing magnet and sensing plate respectively. This preliminary formation of the mechanical connection features eliminates the need for separate bonding operations, reducing manufacturing steps and improving ease of manufacture.
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 ensures accurate rotor position detection by preventing slip between the sensing magnet and plate, while simplifying the manufacturing process by eliminating the need for an adhesive bonding process.
Implementation Method 1
The magnetic device identifies a current position of the rotor by sensing a magnetic force of a sensing magnet installed to be interlocked with rotation of the rotor
Implementation Method 2
The sensor module may include a magnetic device which detects a change in magnetic flux according to rotation of the sensing magnet
Data Source
AI summary
Disclosed is a sensor module, comprising: a protrusion part of a polygonal shape formed at one side; a sensing plate including a first insertion hole, formed in the protrusion part, to which a rotational shaft is coupled; and a sensing magnet including a second insertion hole, formed to correspond to the polygonal shape, in which the protrusion part is inserted and fixed.