Capacitive Position Sensor Assembly for Linear Actuator Wear Reduction
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Solution Overview
Problem
Existing position sensors for linear actuators, such as incremental encoders, are complex, costly, and prone to losing position information during power failures, requiring reinitialization upon restart.
Innovation Solution
A capacitive position sensor system comprising two sensor components, where one component is a passive electrode arrangement along the sheath tube and the other is a reading unit on the movable carriage, allowing for contactless, precise position determination through capacitive signal evaluation and transmission, eliminating the need for mechanical contact and additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If incremental encoders are used for position feedback, then position information can be obtained, but the system becomes complex and expensive requiring multiple sensors, calculating units, and backup units
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the incremental encoder system. By using a single sensor component instead of two sensors, a calculating unit, and a backup unit, the invention retains position determination functionality while removing complex auxiliary components. The capacitive sensor system directly provides position information without requiring separate calculation and backup units.
Solution Approach 2:
The patent replaces the mechanical contact-based incremental encoder system with a capacitive sensing system. The capacitive sensor detects position through electrical field interaction rather than mechanical contact, eliminating the need for physical encoders, multiple sensors, and associated mechanical components while maintaining measurement precision.
2Measurement precision
If incremental encoders are used for position feedback, then position information can be obtained, but the system becomes expensive due to the large number of components required
Solution Approach 1:
The patent extracts and eliminates expensive auxiliary components from the incremental encoder system. By using a single sensor component instead of two sensors, a calculating unit, and a backup unit, the invention retains position determination functionality while removing costly elements, thereby reducing overall manufacturing cost.
Solution Approach 2:
The patent employs a simpler, more cost-effective capacitive sensor design that replaces expensive incremental encoder components. The capacitive sensor system uses basic electrical components rather than complex mechanical encoders, making the system more affordable while maintaining functional equivalence for position determination.
3Measurement precision
If incremental encoders are used for position feedback, then position information can be obtained, but position information is lost during power failure requiring reinitialization
Solution Approach 1:
The capacitive sensor system continuously monitors position through electrical field interaction, maintaining position information actively rather than relying on periodic updates or backup storage. The system self-refreshes position data through continuous capacitive coupling, ensuring position information is always current and retained during power interruptions.
Solution Approach 2:
The patent implements continuous position monitoring through capacitive coupling that persists during power failures. The capacitive sensor maintains electrical field interaction with the target object throughout the power interruption, continuously preserving position information without requiring periodic updates or backup storage mechanisms.
4Measurement precision
If mechanical contact-based sensors are used for position determination, then position information can be obtained, but wear occurs reducing reliability
Solution Approach 1:
The patent replaces mechanical contact-based sensing with capacitive sensing that operates through electrical field interaction. The capacitive sensor detects position changes without physical contact with the target object, eliminating mechanical wear while maintaining measurement precision through electrical coupling.
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 and enhances the reliability of position determination in linear actuators by providing a compact, precise, and contactless method for determining the position of the carriage relative to the sheath tube, reducing wear and the need for reinitialization after power failures.
Implementation Method 1
at least one signal generated through a capacitive interaction of two or more electrodes can be evaluated
Data Source
AI summary
A position sensor includes first and second sensor components. The second sensor component has a reading unit that is configured to evaluate a capacitive signal in relation to the position of the second sensor component relative to the first sensor component. The position sensor is in addition configured to provide the result of the evaluation at an interface of the first sensor component. A method for ascertaining a position of a second sensor component of a position sensor relative to a first sensor component of the position sensor as well as a linear actuator, are provided.