Fluid Actuator Sensor Module for Easy Replacement
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Solution Overview
Problem
Fluid-powered actuators face issues with position sensor failure due to harsh environments, leading to equipment downtime and costly replacements, as existing solutions either require full actuator disassembly or increase component costs and complexity.
Innovation Solution
A fluid-powered actuator design with a position sensor mounted internally on a removable cover, allowing for easy replacement without disassembling the actuator, using a draw wire transducer for accurate position measurement and incorporating a sealable sensor module with optional signal conversion and digital discrete switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the position sensor is installed inside the cylinder on the bottom cap or head cap and connected to the piston, then the position sensor is protected from harsh environment, but the whole actuator needs to be replaced in case of sensor failure
Solution Approach 1:
The actuator is segmented into separable components: the cylindrical body, the removable cover, and the position sensor. The cover can be detached from the base, allowing the position sensor to be accessed and replaced without removing the entire actuator from its installation location. This segmentation enables independent maintenance of the sensor while preserving the actuator body.
Solution Approach 2:
The position sensor is extracted from the internal environment of the actuator by mounting it on the removable cover rather than permanently integrating it into the cylindrical body. This extraction allows the sensor to be removed and replaced through the opening in the base, eliminating the need to replace the entire actuator assembly.
2Ease of repair
If the position sensor is fixed to the exterior of the cylinder bottom cap, then the sensor is accessible for replacement, but the magnets may become contaminated requiring disassembly of the actuator
Solution Approach 1:
The removable cover serves as an intermediary structure that separates the position sensor (with magnets) from the harsh internal environment of the actuator. The cover acts as a protective barrier, allowing the sensor to be mounted in a position that is both accessible for replacement and protected from contaminants such as hydraulic fluid or debris.
3Measurement precision
If magneto-restrictive sensors are used with magnets mounted on the piston, then the position can be measured, but the operational temperature range is limited and the actuator price increases
Solution Approach 1:
The removable cover design provides a universal mounting platform that can accommodate various types of position sensors (magnetic, mechanical, optical) without requiring specific modifications to the actuator body or piston. This multi-functional approach allows selection of sensors based on temperature requirements and cost considerations rather than being constrained by a single sensor type.
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
Enables protected and easily replaceable position sensing within fluid-powered actuators, reducing downtime and maintenance costs by allowing sensor module replacement without actuator removal, while maintaining accuracy and operational reliability.
Implementation Method 1
using a draw wire transducer for accurate position measurement
Data Source
AI summary
A fluid-powered actuator comprises a cylindrical body having a base proximate one extremity and a head proximate another extremity, a piston-rod assembly and a sensor module made of a removable cover and a position sensor. The piston-rod assembly is slidably mounted inside the cylindrical body. The base is provided with an opening adapted to accommodate the sensor therethrough. In operation, the cover seals the opening. The position sensor is mounted to an internal face of the cover so that the position sensor is operatively located inside the cylindrical body when the cover is in place. The position sensor is operative to measure a position of the piston-rod assembly. A sensor module adapted to sealably close the opening in the base comprises the position sensor mounted to an internal face of a cover structure. In operation, the position sensor is operatively located inside the actuator when the cover structure closes the opening.