Cabling Device Motion Sensor Using Hall Effect for Cable Winding Control
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Solution Overview
Problem
Existing line guiding devices, particularly energy guiding chains, face challenges in having a simple, compact, and robust movement sensor design suitable for both vertical and horizontal applications, and require a cost-effective control system for winding and unwinding heavy cables, especially in shore power supply and civil engineering tools.
Innovation Solution
A movement sensor with a guide and a slider that can be displaced longitudinally, using non-contact proximity switches or Hall sensors to detect the direction and extent of movement, connected to a control unit for actuating motor drives, which can be integrated into the line routing device to support forward and reverse movement, and a drum drive system for winding and unwinding cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a complex sensor technology (e.g., force-measuring sensor on carrier) is used to detect movement parameters, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical force-measuring sensors with a magnetic field-based detection system. A magnet is attached to the movable component, and a Hall effect sensor or reed switch detects its position non-contactly. This substitution eliminates mechanical contact, reduces wear, and simplifies the sensor structure while maintaining measurement precision.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the moving component and the sensor. Instead of directly measuring mechanical force or displacement with complex sensors, the system uses a magnet to create a magnetic field that the Hall effect sensor or reed switch detects. This intermediary approach simplifies the direct measurement interface.
2Manufacturing precision
If a coupling device with displacement sensor is used to control drive movement, then control precision is improved, but device complexity and size increase
Solution Approach 1:
The patent extracts the sensing function from a complex coupling device and implements it as a separate, simple magnetic detection system. The magnet is attached to the moving part, and the Hall effect sensor or reed switch is positioned independently to detect position. This separation eliminates the need for a complex integrated coupling device with built-in displacement sensors.
Solution Approach 2:
The patent replaces mechanical displacement sensors within the coupling device with non-contact magnetic field detection. The Hall effect sensor or reed switch detects the magnet's position without mechanical contact, eliminating the need for complex mechanical sensor integration and reducing overall device complexity.
3Force
If motor-assisted cable routing is implemented, then force requirements are reduced, but device complexity increases
Solution Approach 1:
The patent implements a control system that automatically responds to detected movement parameters without requiring complex external control mechanisms. When the Hall effect sensor or reed switch detects magnet position changes, the system automatically activates or deactivates the drive mechanism. This self-service approach reduces force requirements while minimizing control system complexity.
4Reliability
If non-contact sensors (Hall sensor or reed switch) are used instead of contact-based sensors, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses a magnet with dimensions larger than the minimum required to generate a detectable magnetic field. This excessive magnetic field strength compensates for variations in sensor positioning and spacing, allowing the use of simple non-contact sensors without requiring extremely tight manufacturing tolerances. The magnet's field extends sufficiently to ensure reliable detection even with moderate positioning variations.
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 solution simplifies the design of line routing devices, reduces tensile and shear forces, and enables efficient control of cable routing systems, particularly for heavy cables, without the need for complex control technology, enhancing reliability and reducing operational costs.
Implementation Method 1
at least one Hall sensor or reed switch whose output signal depends on the position of the magnet
Implementation Method 2
output signal depends on the position of the magnet, in particular on the direction of movement
Data Source
Figure 1~3
Figure 4A
Figure 4B
AI summary
The invention relates to cabling devices, e.g. energy chains (31, 51), having a motion sensor. One aspect relates to a motion sensor (10; 20), comprising a bearing having a first component, e.g. a guide (11; 21) of a linear bearing, and a second component that is mobile relative thereto, e.g. a longitudinally displaceable slider (12; 22), and also at least one pickup (13, 14; 23, 24), the output signal from which is dependent on the relative position of the two components. The motion sensor (10; 20) can have the first component arranged at the connection point that is to be supplied with power and can have the second component arranged at the mobile end of the cabling device, or vice versa. A further aspect relates to an apparatus (30; 40) for winding and unwinding a cabling device. A rotatable drum (32; 42) for winding and unwinding the cabling device has a drum drive (38; 48). The load-side end region (52B) of the cabling device has a sensor unit (35; 45) arranged on it for sensing a motion quantity. A control unit (36; 46) connected to the sensor unit (35; 45) controls the drum drive.