Injection Molding of Signal Generators for Hallsensor-Arrays

霍尔传感器阵列信号发生器的注塑成型

• 批准号: 238855620
• 负责人: Professor Dr.-Ing. Dietmar Drummer
• 金额: --
• 依托单位: Lehrstuhl für Kunststofftechnik (LKT)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2013
• 资助国家: 德国
• 起止时间: 2012-12-31 至 2016-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/238855620?language=en
• 关键词: Injection; Molding; Signal; Generators; Hallsensor

In this project, the effects of various process parameters on the pole pitch accuracy in the production of multipolar magnets by injection molding will be investigated. The pole pitch accuracy is very important for the accurate detection of the angle with so-called "Hall-effect sensor arrays" that can be used in rotary encoders for determining the rotation angle. The Hall-effect sensor arrays reach the position resolutions that previously were reserved for optical encoders. The prerequisite, how-ever, is a high accuracy of the pole width, since the accuracy of the angular determination with the "Hall-effect sensor arrays" strongly depends on the precision of the width of each pole. For example a pole width deviation of 0.1 mm in the hall array AS 5304 causes a measurement error of approximately 0.025 mm. For the so-called "Hall-effect sensor arrays" mainly magnetically isotropic, elastic magnetic tapes are used, which are magnetized in a complex process by means of special multipolar magnetization devices within an additional manufacturing step. But it would be also possible to use an ansisotropic pole-oriented magnetic rings which can be aligned multipolar directly in injection molding. This would allow very economical "off-tool" manufacturing of signal generator for the precise angle sensors. The injection molding process also provides the opportunity to combine these magnetic rings with other functional elements, such as bushings, shafts, gears, or magnetic sensors, that can be manufactured directly in the two shot injection molding or insert molding process.The magnetic filler orientation by injection molding takes place during the injection and holding pressure. In these phases, the filler particles are in motion, and the viscosity of the polymer matrix changes very dynamically. This can lead to inaccuracies in the formation of the multi-polar structure inside the magnet. A technical requirement for the use of the injection molding magnetized magnets, is the elaboration of the factors influencing the accuracy of the pole width to achieve the the most accurate pole as a target. Since the height of the peak flux density is not relevant for the accuracy of the angle determination, the variables that determine the flux densities at peak will be not investigated under this project.The aim of this research project is the systematic investigation of the influences of material, process (gating, process parameters) and geometry on the pole pitch as well as the modeling and simulation of the process behavior and derivation of design rules for the manufacturing of precise signal generators.

在该项目中，将研究各种过程参数对通过注入成型产生多极磁体的极螺距精度的影响。杆螺距精度对于以所谓的“霍尔效应传感器阵列”的精确检测非常重要，可用于旋转编码器来确定旋转角度。霍尔效应传感器阵列达到了以前用于光学编码器的位置分辨率。但是，先决条件是极宽度的高精度，因为用“霍尔效应传感器阵列”的角度确定的准确性很大程度上取决于每个极宽度的宽度的精度。例如，霍尔阵列中的极宽度为0.1 mm，因为5304导致测量误差约为0.025 mm。对于所谓的“霍尔效应传感器阵列”，主要是磁性各向同性的，使用弹性磁磁带，这些磁带在复杂的过程中通过特殊的多极磁化设备在附加的制造步骤中磁化。但是，也可以使用面向杆子的磁环，可以直接在注射成型中对齐多极。这将允许为精确角度传感器的信号发生器的非常经济的“偏离工具”制造。注射成型过程还提供了将这些磁环与其他功能元件（例如衬套，轴，齿轮或磁性传感器）相结合的机会，这些功能元件可以直接在两次射击喷射成型或插入模制过程中直接制造。在注射压力和保持压力期间，注射型磁性填充剂取向。在这些阶段，填充颗粒正在运动中，并且聚合物基质的粘度非常动态变化。这可能导致磁铁内多极性结构形成的不准确性。使用注射成型磁化磁铁的技术要求是阐述影响极宽度的因素，以实现最精确的极点作为目标。由于峰值密度的高度与角度确定的准确性无关，因此确定峰值的磁通密度的变量将不在此项目下进行研究。该研究项目的目的是对材料，过程（Got，过程，过程参数）和几何参数的系统进行系统研究，并在杆位上进行了对工艺和启用的模型和启用的模型和仿真行为的模型和仿真。