Torque Support for Rotary Encoder with Elastic Mounting Brackets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing torque supports for rotary encoders are large and require more installation space than the encoder itself, failing to meet high accuracy and compactness requirements due to their structural size and stiffness, which affects the service life and precision of rotational state measurement.
Innovation Solution
A torque support design with a focus on maximizing the freely deflectable area of mounting brackets, allowing forces to be introduced in a specific, non-surface area manner, achieving high torsional rigidity while maintaining softness in linear directions, using a principle similar to a double-sided clamped beam, and optimizing the force ratio factor to reduce dimensions and improve mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the torque support uses a large structural unit to ensure high torsional rigidity and accuracy, then the measurement precision is improved, but the installation space requirement increases
Solution Approach 1:
The mounting bracket is designed with non-uniform cross-section where the first region (near the encoder housing) has larger dimensions for high torsional rigidity, while the second region (mounting area) has smaller dimensions to reduce installation space. This local variation in structural properties resolves the contradiction between needing high rigidity for accuracy and minimizing overall size for compact installation.
2Strength
If the torque arm is made with high spring stiffness to transmit forces directly to bearing units, then the structural strength is improved, but the service life decreases due to increased forces on bearing units
Solution Approach 1:
The mounting bracket has varying spring stiffness along its length, with the first region having higher stiffness for structural strength and the second region having lower stiffness to reduce forces transmitted to bearing units. This local differentiation allows the structure to be strong where needed while protecting bearing units from excessive forces that would reduce service life.
3Duration of action of moving object
If the mounting bracket has a large freely deflectable area to reduce forces on bearing units, then the service life is improved, but the torsional rigidity decreases
Solution Approach 1:
The mounting bracket is designed with different regions having different properties: the first region has larger dimensions and higher stiffness to maintain torsional rigidity, while the second region has smaller dimensions and lower stiffness to reduce bearing unit forces. This spatial differentiation of properties resolves the contradiction between needing long service life and maintaining torsional rigidity.
4Area of stationary object
If the torque support uses a compact design to reduce installation space, then the area requirement is reduced, but the structural complexity increases
Solution Approach 1:
The mounting bracket is segmented into two distinct regions with different functional requirements and structural characteristics. The first region handles torsional loading with higher rigidity, while the second region provides flexible mounting with lower stiffness. This segmentation allows the single-component bracket to achieve compact dimensions while maintaining the complex mechanical properties needed for both accuracy and bearing protection.
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 enables precise rotational state measurement with reduced installation space requirements, enhancing mechanical properties and compensating for geometric and force errors, thereby extending the service life of the rotary encoder.
Implementation Method 1
elastic mounting brackets, which are each formed to absorb forces in their direction of extension and which are flexible in at least one direction transverse to their direction of extension
Implementation Method 2
a coupling part for absorbing torques, which extends in a coupling plane and which is torsionally rigid with respect to axes which are oriented transversely to the coupling plane
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a torque support for torsionally rigidly connecting a rotary encoder to a connection surface, with a coupling part for receiving torques, which extends in a coupling plane and which is torsionally rigid with respect to axes oriented transversely to the coupling plane, with elastic mounting brackets, each designed to receive forces in its direction of extension and which are flexible in at least one direction transversely to its direction of extension, wherein a first and a second mounting bracket are to be attached to the rotary encoder and a third and a fourth mounting bracket are to be attached to the connection surface, wherein the first and the second mounting brackets on the one hand and the third and the fourth mounting brackets on the other hand are arranged on opposite sides of the coupling part, and wherein the coupling plane and the mounting brackets are oriented transversely to a shaft axis of the rotary encoder in the assembled state.The torque support is characterized according to the invention in that, for the mounting brackets in the assembled state, the sum of the freely deflectable areas is at least half as large as the total linear extent of the mounting brackets.