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，将研究通过注射成型生产多极磁体时各种工艺参数对极距精度的影响。极距精度对于通过所谓的“霍尔效应传感器阵列”精确检测角度非常重要，该阵列可用于旋转编码器以确定旋转角度。霍尔效应传感器阵列达到了以前为光学编码器保留的位置分辨率。然而，先决条件是极宽度的高精度，因为使用“霍尔效应传感器阵列”确定角度的精度很大程度上取决于每个极的宽度的精度。例如，霍尔阵列 AS 5304 中 0.1 mm 的磁极宽度偏差会导致大约 0.025 mm 的测量误差。对于所谓的“霍尔效应传感器阵列”，主要使用磁各向同性的弹性磁带，这些磁带在额外的制造步骤中通过特殊的多极磁化装置在复杂的过程中被磁化。但也可以使用各向异性磁极定向磁环，该磁环可以在注塑成型中直接多极排列。这将允许非常经济地“脱离工具”制造用于精确角度传感器的信号发生器。注塑工艺还提供了将这些磁性环与其他功能元件（例如衬套、轴、齿轮或磁性传感器）相结合的机会，这些元件可以直接在二次注塑或嵌件注塑工艺中制造。注塑成型的磁性填料定向发生在注射和保压过程中。在这些阶段中，填料颗粒处于运动状态，聚合物基质的粘度变化非常动态。这可能导致磁体内部多极结构的形成不准确。注塑充磁磁体的使用技术要求，是对影响磁极宽度精度的因素进行详细阐述，以达到最精确的磁极作为目标。由于峰值磁通密度的高度与角度确定的准确性无关，因此本项目不会研究决定峰值磁通密度的变量。本研究项目的目的是系统研究材料、工艺（选通、工艺参数）和几何形状对极距的影响，以及工艺行为的建模和仿真以及精密信号发生器制造的设计规则的推导。