Cylinder-Integrated Distance Measurement for Accurate Piston Position
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Solution Overview
Problem
Conventional distance measuring devices for piston position detection in linear drives face challenges such as high installation costs, mechanical adjustments, and reduced accuracy due to external sensor mounting, which is prone to damage and logistical complexities, especially when dielectric properties of the medium fluctuate.
Innovation Solution
A distance measuring device that integrates a transmitting and receiving device with a line transition within the cylinder cover, using a measuring line to couple electromagnetic waves and evaluate the complex reflection factor, allowing for continuous, absolute distance measurement with high accuracy, and adjustable switching distances via an electronic interface, without external components or mechanical changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external magnetic sensors are mounted on the cylinder tube, then piston position detection is achieved, but installation costs and logistical effort increase due to mechanical adjustment and additional assembly requirements
Solution Approach 1:
The sensor device is integrated directly into the cylinder tube, merging the sensor mounting structure with the cylinder itself. This eliminates the need for separate external mounting brackets and reduces the number of assembly steps, while maintaining the ability to detect piston position through the cylinder wall
Solution Approach 2:
The cylinder tube itself serves as an intermediary structure that both contains the pneumatic/hydraulic medium and provides the mounting substrate for the sensor. This dual-function design eliminates the need for separate mounting structures and reduces overall system complexity
2Adaptability or versatility
If additional sensors are installed to detect different positions, then more measurement points are available, but material, assembly, and installation costs increase
Solution Approach 1:
The integrated sensor device is designed to detect multiple piston positions through a single mounting structure. The sensor can identify different positions by detecting the piston's location at various points along its stroke, eliminating the need for multiple separate sensors while providing the same versatility
Solution Approach 2:
The sensor system is designed to dynamically track the piston's continuous movement and identify different positions along the stroke. This dynamic detection capability allows a single sensor to replace multiple static sensors, reducing assembly complexity while maintaining adaptability
3Reliability
If sensors are externally mounted on the cylinder, then accessibility and robustness can be ensured, but additional installation space is required and design effort increases
Solution Approach 1:
The sensor device is nested within the cylinder tube structure, utilizing the existing cylindrical space for sensor housing. This nested design eliminates the need for additional external mounting space while maintaining sensor accessibility through the cylinder wall for signal transmission
4Measurement precision
If conventional distance measuring devices are used, then piston position can be detected, but accuracy decreases when dielectric properties of the medium fluctuate due to temperature, pressure, or contamination
Solution Approach 1:
The system incorporates a feedback mechanism that continuously monitors the dielectric properties of the medium and adjusts the measurement calculations accordingly. By measuring the change in dielectric properties and compensating for their effect on electromagnetic wave propagation, the system maintains accurate piston position measurements even when temperature, pressure, or contamination levels change
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
Enables precise, continuous piston position measurement with reduced logistical effort and cost, integrating sensors within the cylinder cover, and accounts for changing dielectric properties of the medium, enhancing measurement accuracy and robustness.
Implementation Method 1
couple an electromagnetic wave into the line structure and to couple out the electromagnetic wave reflected on the reflection body from the line structure
Implementation Method 2
measuring line for detecting material properties of the medium in the coupling area into the line structure to determine the distance
Implementation Method 3
evaluate the complex reflection factor between the coupled electromagnetic wave and the coupled out electromagnetic wave
Data Source
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AI summary
The invention relates to a distance-measuring device for determining a distance between a reflection body in a conducting structure and a coupling region for electromagnetic waves, which region is provided on an end section of the conducting structure, said measuring device comprising a transmitting and receiving device, and a conduction junction (1) provided on the coupling region, for coupling the transmitting and receiving device to the conducting structure containing a medium, in order to couple an electromagnetic wave into the conducting structure, and to decouple the electromagnetic wave, reflected on the reflection body, from the conducting structure. Said measuring device also comprises an evaluation device for determining the distance between the coupling region and the reflection body from the complex reflection coefficient between the coupled electromagnetic wave and the decoupled electromagnetic wave. The invention also relates to a corresponding method.