Angular Position Sensor Mounting on Rotating Shafts
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Solution Overview
Problem
Existing methods for mounting angular position sensors on rotating shafts, such as motor shafts, face challenges when the shaft diameter is larger than the sensor, the end face is not orthogonal, or the motor has a non-solid shaft, leading to unreliable mounting due to angular inertia affecting the coupling.
Innovation Solution
A device comprising an alignment plate with a central aperture and a coupling shaft with a spherical joint, which is affixed to the rotating shaft using bolts and adjustment screws to ensure rotational alignment and balance, allowing for secure attachment even on large diameter motor shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single screw or attachment means is used to mount the angular position sensor, then the device complexity is reduced, but the reliability of the sensor mounting is diminished over time due to angular inertia causing over-tightening or loosening
Solution Approach 1:
The mounting structure is divided into multiple independent components: an alignment plate with multiple mounting holes, multiple screws distributed across the plate, and a coupling shaft. This segmentation allows the mounting system to distribute mechanical stresses across multiple attachment points rather than relying on a single screw, preventing over-tightening or loosening of individual fasteners while maintaining secure sensor attachment.
2Adaptability or versatility
If the rotating shaft diameter is larger than the shaft of the sensor, then the sensor can be mounted on larger motor shafts, but the alignment and mounting reliability become more difficult to achieve
Solution Approach 1:
The alignment plate serves as an intermediary component between the large diameter rotating shaft and the smaller sensor shaft. The plate is affixed to the rotating shaft with multiple screws, providing a stable mounting surface. The coupling shaft then connects this plate to the sensor, creating a reliable mechanical transmission path that accommodates the diameter difference while maintaining precise rotational alignment through the plate's rigid structure and multiple attachment points.
3Adaptability or versatility
If the end face of the rotating shaft is not orthogonal to the shaft axis, then various motor designs are accommodated, but the mounting and alignment of the sensor becomes unreliable
Solution Approach 1:
The alignment plate incorporates adjustment screws that enable dynamic adjustment of the plate's position and orientation relative to the rotating shaft. This allows the mounting system to compensate for non-orthogonal end faces by adjusting the plate's angular orientation, ensuring that the coupling shaft remains properly aligned with the sensor axis while accommodating various motor designs with different shaft geometries.
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 provides reliable and durable mounting and alignment of angular position sensors by minimizing stress and maintaining shaft balance, ensuring accurate rotational alignment and stability over time.
Implementation Method 1
a spherical joint coupled to first end of the coupling shaft and centrally disposed in contact with the end face of the rotating shaft
Data Source
AI summary
An adjustable device for mounting an angular position sensor such as an encoder to a large diameter rotating shaft such as a motor shaft is provided. The adjustable device includes a specially configured alignment plate, a coupling shaft, a spherical joint, and a plurality of fixing bolts and adjustment screws that are disposed symmetrically on the adjustment plate and radially offset from the shaft rotation axis. The fixing bolts and adjustment screws are generally disposed the same radial distance from the central rotation axis.