Conduction Cross-Over for Cylinder Distance Measurement
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Solution Overview
Problem
Conventional distance measuring apparatuses for piston position detection in linear drives, such as pneumatic or hydraulic cylinders, face challenges including high installation costs, structural complexity, and susceptibility to external disruptions due to externally fitted sensors, which can lead to errors and assembly line stoppages.
Innovation Solution
A distance measuring apparatus that integrates a transmitting and receiving device with a conduction cross-over for coaxially inductive coupling and decoupling of electromagnetic waves within the cylinder, allowing for continuous and precise distance measurement between a reflection body and an injection point, without the need for external sensors, and enabling adjustment of switch distances electronically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If externally fitted sensors are used for discrete piston position detection, then the detection function is achieved, but the structural complexity increases and reliability decreases due to susceptibility to external disruptions
Solution Approach 1:
The sensor system is merged with the cylinder structure itself. The cylinder tube serves as both the mechanical component and the waveguide for electromagnetic waves. The conduction cross-over integrates the electrical connection directly into the cylinder assembly, eliminating externally fitted sensors and their mounting structures, thereby reducing structural complexity while improving reliability.
Solution Approach 2:
Electromagnetic waves serve as an intermediary to transmit position information through the non-conductive piston rod to the conduction cross-over. This intermediary approach allows detection without direct electrical contact or externally fitted sensors, protecting the system from external disruptions while maintaining simple structure.
2Adaptability or versatility
If multiple sensors are fitted externally to detect additional positions, then more position detection points are achieved, but installation costs and structural complexity increase
Solution Approach 1:
The integrated sensor system with conduction cross-over serves multiple detection points along the cylinder stroke. By utilizing the entire cylinder tube as the waveguide and the piston rod as the reflector, the system can detect positions at multiple points without requiring separate external sensors for each location, thereby reducing installation costs while maintaining versatility.
Solution Approach 2:
The cylinder structure itself provides the sensing function through its interaction with electromagnetic waves. The conduction cross-over and piston rod combination automatically detects positions along the stroke without requiring additional external components, making the system self-sufficient and cost-effective for multiple detection points.
3Reliability
If externally fitted sensors are used, then position detection is achieved, but the sensors are susceptible to foreign influences and mechanical failure
Solution Approach 1:
Electromagnetic waves act as an intermediary that can penetrate non-conductive materials (piston rod) without being affected by external mechanical disruptions. The wave-based detection method is immune to foreign influences that would affect externally fitted sensors, as the waves travel through the cylinder tube and reflect off the piston rod internally, isolated from external environmental factors.
4Measurement precision
If continuous piston position measurement systems are used, then continuous position data is achieved, but the structural complexity and logistical complexity increase
Solution Approach 1:
The patent replaces complex mechanical or magnetostrictive continuous measurement systems with an electromagnetic wave-based detection system. By using electromagnetic waves that travel through the cylinder tube and reflect off the piston rod, continuous position data is obtained through simple phase or time measurement, eliminating the need for complex mechanical structures, hollow piston rods, or external fitting while maintaining measurement precision.
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 provides a cost-effective, robust, and integrated distance measurement system that is independent of cylinder length, pressure, oil, and humidity, with high precision and minimal reconstruction required, ensuring reliable operation and reduced logistical complexity.
Implementation Method 1
conduction cross-over provided at the injection point for the coaxially inductive coupling of the transmitting and receiving device to the conducting structure in order to inject an electromagnetic wave into the conducting structure
Implementation Method 2
to decouple the electromagnetic wave reflected on the reflection body from the conducting structure
Implementation Method 3
an analysis device for calculating a distance between the injection point and the reflection body from the phase difference between the injected electromagnetic wave and the decoupled electromagnetic wave
Data Source
AI summary
A distance measuring apparatus and method for calculating a distance in a conducting structure are provided. One distance measuring apparatus provides for calculating a distance between a reflection body in a conducting structure and an injection point provided on an end section of the conducting structure for electromagnetic waves is provided. The distance measuring apparatus includes a transmitting and receiving device with a conduction cross-over provided at the injection point for the coaxially-inductive coupling of the transmitting and receiving device to the conducting structure in order to inject an electromagnetic wave into the conducting structure and to decouple the electromagnetic wave reflected on the reflection body from the conducting structure. The distance measuring apparatus also includes an analysis device for calculating a distance between the injection point and the reflection body from the phase difference between the injected electromagnetic wave and the decoupled electromagnetic wave.