Soft Magnetic Intermediate Layer for Induction Encoder Scale
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Solution Overview
Problem
Existing scales used in electromagnetic induction encoders face challenges in signal detection accuracy due to eddy current losses and uneven signal generation caused by non-uniform mounting surfaces and conductive base materials, which cannot be miniaturized without increasing thickness or attenuating the signal.
Innovation Solution
A scale design featuring a base material with a soft magnetic intermediate layer having a roughened surface and a conductor scale pattern, which suppresses magnetic flux leakage and reduces eddy current loss, maintaining accuracy without thickness increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conductive base material is used to improve mechanical strength and electrical conductivity, then the structural integrity is improved, but eddy current loss increases and signal detection accuracy deteriorates
Solution Approach 1:
The base material is segmented into a non-conductive substrate and a separate conductive intermediate layer. This segmentation allows the non-conductive base to prevent eddy currents while the conductive intermediate layer provides necessary electrical conductivity and mechanical strength, resolving the contradiction between structural integrity and eddy current loss.
Solution Approach 2:
A non-conductive intermediate layer is introduced between the conductive base material and the scale pattern. This intermediary layer acts as a barrier that prevents eddy currents from forming in the base material while still allowing magnetic flux to pass through, thereby reducing eddy current loss without compromising the overall structural integrity.
2Measurement precision
If the scale thickness is increased to improve signal detection accuracy, then the signal detection accuracy is improved, but the device size increases
Solution Approach 1:
The invention changes the material parameters of the intermediate layer, specifically using a non-conductive material with appropriate magnetic properties. This parameter change allows for reduced thickness while maintaining signal detection accuracy, as the non-conductive material prevents eddy currents that would otherwise require greater thickness to compensate for.
Solution Approach 2:
The scale employs a composite structure combining non-conductive base material with conductive intermediate layer and scale pattern. This composite material approach achieves both compact thickness and high signal detection accuracy by leveraging the complementary properties of different materials rather than relying on increased thickness alone.
3Ease of manufacture
If a non-uniform mounting surface is used to simplify manufacturing, then the manufacturing complexity is reduced, but signal generation becomes uneven and measurement precision deteriorates
Solution Approach 1:
The invention extracts the mounting surface requirements from the base material itself and transfers them to a separate intermediate layer. By placing a non-conductive intermediate layer with a controlled mounting surface over the base material, the uniformity requirement is removed from the base material manufacturing process, allowing simpler fabrication while maintaining signal generation uniformity through the intermediate layer's controlled surface.
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 enhances signal detection accuracy by minimizing eddy current loss and maintaining a compact scale design, improving the reliability of displacement measurements in electromagnetic induction encoders.
Implementation Method 1
signal detection accuracy due to eddy current losses
Implementation Method 2
electromagnetic induction encoders
Data Source
AI summary
A scale includes a base material, an intermediate layer of soft magnetic material formed on one surface of the base material and roughened on face thereof opposite to the base material, and a scale pattern of a conductor formed on the intermediate layer.