Actuator Position Detection via Magnetic Field Comparison
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Solution Overview
Problem
Magnetic interference fields, often with a spatially static origin, disrupt magnetic limit switches in applications like welding, causing malfunctions that impair the accurate detection of actuator position and compromise system reliability, with existing solutions being costly and inadequate.
Innovation Solution
A device and method that utilize a magnetic field source attached to the actuator, allowing a control and evaluation unit to distinguish between the actuator's magnetic field and interfering fields by comparing first and second magnetic field strengths in different directions, using a comparison metric to verify the actuator's position based on the magnetic field source's properties, which change due to its movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic field sensor is used to detect the position of an actuator, then the position detection function is achieved, but magnetic interference fields cause malfunctions and reduce reliability
Solution Approach 1:
The control and evaluation unit continuously monitors the magnetic field strength and compares it against expected values. When the detected magnetic field strength deviates from the expected range, the system identifies interference and prevents erroneous position detection, thereby maintaining reliability while preserving position detection functionality
Solution Approach 2:
The control and evaluation unit acts as an intermediary between the magnetic field sensor and the position determination process. It filters out interference by evaluating whether the detected magnetic field strength corresponds to the expected field from the magnetic field source, allowing only valid position data to pass through to the control system
2Reliability
If existing approaches are used to prevent magnetic interference, then reliability may be improved, but cost and device complexity increase
Solution Approach 1:
The magnetic field sensor and control unit work together to automatically identify and filter interference without requiring additional specialized components. The system uses its existing resources (the sensor itself and the control unit's processing capability) to detect when the magnetic field strength falls outside expected ranges, eliminating the need for redundant shielding or multiple sensors
Solution Approach 2:
The system monitors changes in magnetic field strength as a parameter to distinguish between valid position changes and interference. By evaluating whether the detected field strength corresponds to expected values based on actuator position, the system can identify interference without adding hardware complexity
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
Prevents malfunctions by accurately determining the actuator's position without additional hardware, ensuring reliable operation and compact design, while distinguishing between the actuator's magnetic field and interfering fields.
Implementation Method 1
a magnetic field sensor for detecting a position of the actuator, wherein the magnetic field sensor is configured to detect a first magnetic field strength in a first direction and a second magnetic field strength in a second direction perpendicular to the first direction
Data Source
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AI summary
The invention relates to a device for carrying out a work operation, in particular a welding device, comprising: at least one actuator that performs the work operation; a magnetic field source attached to the actuator; at least one magnetic field sensor for detecting the position of the actuator, wherein the magnetic field sensor is configured to detect a first magnetic field strength in a first direction and a second magnetic field strength in a second direction perpendicular to the first direction;and a control and evaluation unit connected to the magnetic field sensor and configured to identify, based on a comparison metric relating the detected first magnetic field strength to the detected second magnetic field strength, whether the magnetic field detected by the magnetic field sensor is a magnetic field substantially generated by the magnetic field source, and, if this is the case, to determine the position of the actuator based on the detected first magnetic field strength and/or the detected second magnetic field strength, and to issue a control instruction based on the determined position of the actuator.