Hydraulic Boom Extension Sensing With Integrated Magnetostrictive Sensor
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Solution Overview
Problem
Existing lift devices lack accurate and reliable methods for measuring the position of extension members, which can lead to operational inefficiencies and safety concerns.
Innovation Solution
The proposed lift device incorporates a hydraulic assembly with a piston and cylinder system, coupled with a magnetorestrictive position sensor. This sensor uses a magnet and a sensing element to determine the position of the piston, which is then transmitted to a control system for precise positioning of the extension member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetorestrictive position sensor is used to measure piston position, then measurement precision is improved, but device complexity increases due to the additional sensor components integrated within the hydraulic cylinder
Solution Approach 1:
The position sensor is integrated within the hydraulic cylinder, merging the measurement function with the existing hydraulic structure. The sensor housing is positioned inside the cylinder barrel, and the magnet is mounted on the piston rod, creating a compact integrated system that measures piston position without adding external components.
Solution Approach 2:
The sensor element is nested within the pressure tube, which is itself positioned within the hydraulic cylinder. The magnet is positioned between the piston head and cylinder head, with the sensor element extending through the pressure tube to detect the magnet's position, creating a nested arrangement that maximizes space utilization.
2Reliability
If a pressure tube with sensor element is integrated into the hydraulic cylinder, then reliability is improved through protected sensing, but manufacturing precision requirements increase due to tight tolerances for sensor and magnet positioning
Solution Approach 1:
The pressure tube serves as an intermediary protective structure that houses the sensor element and provides a reference framework for positioning. The tube's rigid structure maintains precise spacing between the sensor element and the magnet, compensating for manufacturing variations and ensuring consistent measurement geometry.
Solution Approach 2:
The sensor element and magnet are positioned and secured within the pressure tube and hydraulic cylinder assembly before final assembly. This preliminary positioning ensures that the critical measurement geometry is established early in the assembly process, making subsequent assembly steps simpler and more reliable.
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
The solution provides accurate and reliable position measurement of the extension member, enhancing the operational efficiency and safety of the lift device by enabling precise control and positioning.
Implementation Method 1
a magnetorestrictive position sensor comprising a sensor element and a magnet
Data Source
AI summary
A system may include a boom assembly comprising a base member and an extension member. The system may include a hydraulic assembly comprising: a cylinder housing having an internal cavity, a piston positioned partially within the internal cavity and coupled to the extension member at a distal end of the piston, a piston head coupled to the piston at a proximal end of the piston, the piston head located within the cylinder, a pressure tube coupled to the cylinder and positioned within the internal cavity, a sensor element extending within the pressure tube, and a magnet coupled to the piston and proximate at least a portion of the sensor element.