Contactless Displacement Sensor with Data-Bus Magnetic Sensing

Solution Overview

Problem

Existing displacement sensors using Hall-effect sensors are cumbersome and prone to faults when separate control and calculating units are required, limiting their practicality and reliability, especially in applications requiring extended measuring ranges.

Innovation Solution

A magnetic field sensor arrangement comprising a first magnetic field sensor as a master and multiple second sensors as slaves, connected via a data bus, which autonomously detect and communicate to cover extended measuring ranges without the need for external control units, utilizing Hall-effect or magnetoresistive sensors and integrated evaluation units.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If separate control and calculating units are used to extend measuring range, then measurement capability is improved, but device complexity increases and reliability decreases

Engineering Contradiction:

Improvemeasuring rangeVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the control unit, calculating unit, and multiple Hall-effect sensors into a single integrated sensor system. The sensor arrangement includes multiple sensors (first sensor, second sensor, third sensor) that are integrated with evaluation and control functions, eliminating the need for separate external control and calculating units. This integration extends the measuring range while reducing device complexity and improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

2Measurement precision

If separate control and calculating units are used to extend measuring range, then measurement capability is improved, but reliability worsens

Engineering Contradiction:

Improvemeasuring rangeVSAvoidreliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent merges the control unit, calculating unit, and multiple Hall-effect sensors into a single integrated sensor system. The sensor arrangement includes multiple sensors (first sensor, second sensor, third sensor) that are integrated with evaluation and control functions, eliminating the need for separate external control and calculating units. This integration extends the measuring range while reducing device complexity and improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If multiple sensors and separate control units are used, then measuring range is extended, but production cost increases

Engineering Contradiction:

Improvemeasuring rangeVSAvoidproduction cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent merges the control unit, calculating unit, and multiple Hall-effect sensors into a single integrated sensor system. The sensor arrangement includes multiple sensors (first sensor, second sensor, third sensor) that are integrated with evaluation and control functions, eliminating the need for separate external control and calculating units. This integration extends the measuring range while reducing device complexity and improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

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 a compact, reliable, and robust sensor system capable of covering large measuring ranges with reduced parts, lower production costs, and enhanced reliability by eliminating the need for separate control units and printed circuit boards.

Implementation Method 1

utilizing Hall-effect or magnetoresistive sensors

Methodology Applied

Scientific EffectHall-effect: Hall Effect

Implementation Method 2

utilizing Hall-effect or magnetoresistive sensors

Methodology Applied

Scientific EffectMagnetoresistive effect: Magnetoresistance

Data Source

PatentUS12442663B2Displacement sensor for contactless measurement of a relative position, production method for a magnetic field sensor arrangement and magnetic field sensor

Publication Date: 2025.10.14 TE CONNECTIVITY GERMANY GMBH

AI summary

A displacement sensor comprises a magnetic field source generating a magnetic field and a magnetic field sensor arrangement adapted to contactlessly detect a relative position of the magnetic field source with respect to the magnetic field sensor arrangement. The magnetic field sensor arrangement includes a first magnetic field sensor adapted to generate a first position signal and a second magnetic field sensor adapted to generate a second position signal. Each of the first magnetic field sensor and the second magnetic field sensor has a magnetic field probe adapted to detect a magnetic flux density of the magnetic field, an evaluation unit for evaluating an output signal of the magnetic field probe, and a communication interface for emitting and receiving a plurality of communication signals. The first magnetic field sensor and the second magnetic field sensor are connected to each other via a data bus for transmitting the communication signals.