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Form Factor – Customer Examples

Rotor-stator form factor


Customer form factor examples catalog


All torque/cadence sensors are customized to fit a unique mechanical design. These rotor-stator form factor examples are solutions our customers have come up with. Each of these solutions fits into one of three major categories:

  • Radially constrained designs where the difference between outer diameter (OD) and inner diameter (ID) is restricted. Typically where the sensor fits on a shaft next to a bearing and cannot take up more radial space than the bearing.
  • Axially constrained designs where the total width of the sensor solution is limited. Typically where the sensor is working on a disk/spider surface and needs to fit between the torque-sensing disc-shaped metal and some other wall.
  • In-between where the 3D space available is constrained in both directions. This can be inside a gearbox or some other complex-shaped system.

When designing for this technology, it may help to start out with an existing example below and modify the mechanical shape from there. If you need OD < ID + 15mm, please get in touch to discuss the details.


Example 3D CAD files


These are just some examples of rotor-stator form factor. Let us know what you are looking for and we may have other examples you can use.

Silhouette
Name
ID R/S
OD|Box R/S
3D CAD
SG2Q-0831
15.2/17 mm
30/32 mm
SG2Q-0831.zip
rotor-stator-form-factor
SG2Q-0846
23.2/27 mm
41/41 mm
SG2Q-0846.zip
SG2Q-0843
24.2/24.2 mm
38.2/42.8 mm
SG2Q-0843.zip
rotor-stator-form-factor
SG2Q-0838
27/33 mm
46/46×68 mm
SG2Q-0838.zip
rotor-stator-form-factor
SG2Q-0836
29/30 mm
46/46×68 mm
SG2Q-0836.zip
rotor-stator-form-factor
SG2Q-0840
36.1/36.1 mm
50/50 mm
SG2Q-0840.zip
rotor-stator-form-factor
SG2Q-0837
38.2/39 mm
53/53×64 mm
SG2Q-0837.zip
SG2Q-0841
41/45 mm
60/70.5×73 mm
SG2Q-0841.zip
rotor-stator-form-factor
SG2Q-0839
51/68 mm
84/104 mm
SG2Q-0839.zip
SG2Q-0842
55/62 mm
80/91.5 mm
SG2Q-0842.zip
rotor-stator-form-factor
SG2Q-0845
72.5/74 mm
97.5/96 mm
SG2Q-0845.zip

Notes:
“R” = Rotor part of the sensor. The rotor is the moving/rotating part.
“S” = Stator part of the sensor. The stator is the stationary part.
“ID” = Inner diameter. The biggest shaft that can fit a given sensor set is set by the smallest ID.
“OD|Box” = Outer diameter (for some shapes indicating the bounding box makes more sense)
The air gap between rotor and stator is typically 1-2 mm and can be tuned to larger gaps as needed.
All 3D CAD files are in STEP format. The files are showing how the final sensor parts may look including the over-molding for environmental protection (grease, oil, water, etc.)

Please get in touch (below) if you need other file formats, thinner, larger, smaller, different mounting, etc. The technology is quite flexible and quick/easy to customize for a perfect fit.


FAQ


What is a form factor?
Form factor refers to the specific physical design and layout of a device or component, including its size, shape, and mounting points. In e-bikes, the form factor refers to the size, shape, and physical specifications of the rotor and stator and how they fit into the mechanical design of the e-bike.

How is torque, cadence, and angle sensors customized to fit different mechanical designs?
There are so many different mechanical designs, and you will need to have your sensor system designed in a way that secures the optimal measurements for your specific project. You may need customization of the physical size and shape, the range of electrical connections, for accuracy, resolution, and response time, and for environmental protection.
It is important that you consider the sensor requirements during the early stages of the mechanical design process in order to ensure seamless integration of the components into the overall design.

Can I use existing examples of form factors as a starting point for my own design?
Yes, you can use existing examples of form factors as a starting point for your own design. This is a common practice as it can save time and resources compared to starting from scratch. By using existing form factors, to begin with, you can benefit from already existing design solutions and take advantage of the gained knowledge and experience.However, it is important to keep in mind that you may still need to make modifications to the form factor in order to fit your specific requirements. For your mechanical design in your e-bike, you might have unique requirements in terms of size, performance, or resilience to the environment.

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