Actuator Sensor Assembly with Segmented Magnet
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Solution Overview
Problem
Current actuator and non-contacting position sensor (NPS) assemblies are costly and require high-cost magnetic materials, limiting their affordability and durability in applications with mechanical vibrations and thermal extremes.
Innovation Solution
The actuator and sensor assembly incorporates a magnet with stacked portions of different magnetic materials, including NdFeB and iron or steel, to generate a magnetic field sensed by a Hall Effect device, which is housed in a durable and cost-effective design with a flexible diaphragm and spring mechanism, allowing precise position measurement without physical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-cost magnetic materials are used in the magnet assembly, then measurement precision and reliability are improved, but manufacturing cost increases
Solution Approach 1:
The magnet assembly is divided into multiple segments or portions, allowing different magnetic materials to be used in different regions. This segmentation enables the system to achieve high measurement precision in critical areas while using cost-effective materials in less critical areas, thereby resolving the contradiction between measurement precision and manufacturing cost.
Solution Approach 2:
Different portions of the magnet assembly are assigned different material qualities based on their functional requirements. High-cost magnetic materials are used only where necessary for precise position measurement, while lower-cost materials are used in other portions, optimizing the balance between measurement precision and manufacturing cost.
2Measurement precision
If contacting position sensors are used, then measurement precision is improved, but durability deteriorates due to wear and friction
Solution Approach 1:
The patent replaces the mechanical contacting sensor system with a non-contacting magnetic field-based sensor system. The Hall Effect sensor detects position changes through magnetic field variations without physical contact, eliminating wear and friction while maintaining measurement precision, thus resolving the contradiction between measurement precision and durability.
3Reliability
If non-contacting position sensors with high-cost magnetic materials are used, then durability is improved, but manufacturing cost increases
Solution Approach 1:
The magnet assembly is segmented to use different materials in different portions, achieving durability through the non-contacting magnetic field design while controlling costs by using lower-cost materials where possible and high-performance materials only where necessary for optimal magnetic field generation.
Solution Approach 2:
The magnet assembly employs composite construction with different magnetic materials (including both high-cost and lower-cost materials) combined in a single assembly. This composite approach maintains the durability benefits of non-contacting sensors while reducing overall manufacturing cost through strategic material selection.
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
This design enhances the durability and cost-effectiveness of the actuator and sensor assembly by maintaining precision and accuracy under mechanical and thermal stress while reducing material costs through the use of lower-cost ferromagnetic materials for the magnet assembly.
Implementation Method 1
A non-contacting position sensor utilizes one or more magnets to generate magnetic fields that vary as a function of position, and devices to detect varying magnetic fields to measure the position of the component to be monitored. Often, a Hall Effect device is used to produce an electrical signal that is dependent upon the magnitude, polarity, or direction of the magnetic flux incident upon the device.
Data Source
AI summary
An actuator and sensor assembly comprising respective sensor and actuator housings defining an interior chamber. Clips on the sensor housing engage the actuator housing for coupling the sensor and actuator housings together. The sensor housing includes a wall defining a pocket. A connector with a sensor couples to the sensor housing in a relationship wherein the sensor extends into the sensor housing pocket. A movable piston is located in the interior chamber and a tube thereon defines a receptacle for a magnet located adjacent the pocket. The piston is seated on a flexible diaphragm. An actuator shaft includes one end coupled to the piston and an opposite end coupled to a movable object. A plurality of pins in the actuator housing mount the assembly to a support bracket. The sensor senses changes in the magnetic field in response to changes in the position of the magnet relative to the sensor.