Cylinder Control Unit Hall IC Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional piston position detecting devices fail to specify the motion range of a piston with high accuracy due to incorrect descriptions of magnetic flux density and reliance on gradual changes in the isogauss line, leading to inaccurate on/off switching of Hall ICs.
Innovation Solution
A cylinder control unit with a cavity for the Hall IC in a resin or frame, featuring a positioning section that prevents movement during resin hardening, and a through opening for improved insulation and productivity, using polyamide or polybutylene terephthalate resin with glass fibers, allowing precise positioning and sealing of the Hall IC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Hall IC is placed in a required position to detect piston position with high accuracy, then measurement precision is improved, but manufacturing precision deteriorates due to incorrect magnetic flux density description and reliance on gradual isogauss line changes
Solution Approach 1:
The patent applies preliminary action by pre-positioning the Hall IC at a specific location (5mm from the magnet surface) during the molding process. The mold cavity is designed to automatically position the Hall IC at the optimal detection point before the resin hardens, ensuring both high measurement precision and manufacturing precision without requiring post-assembly adjustments.
Solution Approach 2:
The patent introduces a mold cavity as an intermediary structure that mediates between the Hall IC and the final assembled position. The cavity serves as a positioning fixture during manufacturing, ensuring the Hall IC is placed at the correct location relative to the magnet, thereby resolving the contradiction between detection accuracy requirements and manufacturing precision limitations.
2Ease of manufacture
If resin is used to cover Hall IC for positioning, then ease of manufacture is improved, but reliability deteriorates due to potential movement during resin hardening
Solution Approach 1:
The mold cavity performs preliminary positioning of the Hall IC before the resin completes its hardening process. By designing the cavity to contact and constrain the Hall IC at critical points, the system ensures the component cannot shift during the transition from liquid to solid resin, maintaining both ease of manufacture and position stability.
Solution Approach 2:
The mold cavity acts as an intermediary constraint mechanism between the Hall IC and the resin. It provides physical support and positioning during the vulnerable hardening phase, preventing movement that would compromise reliability, while still allowing for simple resin-based assembly.
3Reliability
If terminal insulation is improved, then reliability is improved, but device complexity increases due to additional insulation structures
Solution Approach 1:
The patent merges the insulation function with the existing resin material and mold cavity structure. The resin itself serves as the insulating medium, and the mold cavity design inherently provides terminal insulation through its geometry, eliminating the need for separate insulation components and reducing overall device complexity while maintaining high reliability.
Solution Approach 2:
The resin material performs multiple functions simultaneously: it provides structural support, electrical insulation, and positional constraint for the Hall IC. This multi-functionality reduces the need for additional dedicated insulation structures, simplifying the device while improving terminal insulation reliability.
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 enables accurate specification of the piston's motion range by ensuring the Hall IC is securely positioned and insulated, enhancing the accuracy and productivity of the position detecting device, allowing precise control of the piston's motion.
Implementation Method 1
setting a differential Hall integrated circuit in the casing and separately setting 2 Hall elements in the direction same as the magnetic pole of the magnet
Implementation Method 2
A cavity for containing the Hall IC is provided in the resin, or, a frame for positioning the Hall IC inside it may be provided in the resin
Data Source
Figure 1(a)~2(b)
Figure 3
Figure 4
AI summary
[PROBLEM TO BE SOLVED] To specify motion range of piston 110 in air cylinder 100 with high accuracy. [MEANS FOR SOLVING THE PROBLEM] Position detecting devices 1a and 1b respectively comprise Hall IC switching on/off of output of electrical signal depending on relative position to magnet 140 placed so that moving direction of piston 110 crosses at right angle to the boundary of magnetic poles and resin covering said Hall IC while positioning it inside, Hall IC of the first position detecting device switches on/off of the output by magnetic force from a first magnetic pole and Hall IC of the second position detecting device switches on/off of the output by magnetic force from a second magnetic pole. The position detecting device 1b is mounted on the north pole side of the magnet 140 and the position detecting device 1a is mounted on the north pole side of the magnet 140.