Lateral Cylinder-Head Position Sensor to Minimize Stroke Loss
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Solution Overview
Problem
Existing position sensors for working cylinders are space-consuming, cause significant stroke loss, and are not suitable for small cylinders, while also potentially weakening the cylinder components and requiring costly machining.
Innovation Solution
A position sensor designed like a bottle or cartridge, installed orthogonally to the piston stroke direction, using a cable drum with a piston anchor and variable sensor arm, which minimizes stroke loss and adapts to various cylinder sizes without compromising stability or requiring extensive machining, and allows for flexible installation and retrofitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a position sensor is integrated in the area of a cylinder head in the piston stroke direction, then the position can be measured, but the stroke loss is large and the cylinder is significantly extended
Solution Approach 1:
The position sensor is mounted laterally on the cylinder head in a direction orthogonal to the piston stroke direction, rather than integrating it along the stroke direction. This dimensional change allows the sensor to measure piston position without extending the cylinder length or causing stroke loss, as the sensor operates in a perpendicular plane to the motion.
2Measurement precision
If a position sensor is integrated in the area of a cylinder head, then the position can be measured, but space is consumed and the cylinder is significantly extended
Solution Approach 1:
By mounting the sensor laterally on the cylinder head perpendicular to the piston stroke direction, the sensor utilizes space in a different dimension rather than extending the cylinder volume along the stroke direction. This eliminates the need for significant cylinder extension while maintaining position measurement capability.
3Measurement precision
If the position sensor is installed in the area of a cylinder head, then the position can be measured, but cost-intensive machining of the piston and working cylinder is required
Solution Approach 1:
The position sensor is extracted from the piston and cylinder body and mounted externally on the cylinder head. This eliminates the need for cost-intensive machining of the piston and working cylinder, as the sensor is installed as a separate component on the existing cylinder head structure.
Solution Approach 2:
A lateral mounting structure is introduced as an intermediary between the cylinder head and the position sensor. This mediator allows the sensor to be mounted without direct integration into the piston or cylinder body, avoiding the need for expensive machining operations while maintaining measurement accuracy.
4Measurement precision
If the position sensor is installed in the area of a cylinder head, then the position can be measured, but the piston and piston rod are weakened
Solution Approach 1:
The position sensor is extracted from the piston and cylinder body structure and mounted externally on the cylinder head. This eliminates the need to drill holes or attach sensors to the piston and piston rod, thereby avoiding any weakening of these critical load-bearing components.
Data Source
AI summary
A position sensor (1.1, 1.2) for a working cylinder (2.1, 2.2) with a cable drum (4.1, 4.2), a cable (5) with a piston anchor (7.1, 7.2) and an interface (13.1, 13.2) for determining a position and a movement of a piston (3.1, 3.2) of the working cylinder (2.1, 2.2), the position sensor (1.1, 1.2) is to be operatively connected to the working cylinder (2.1, 2.2) from outside in the area of a cylinder head (15.1, 15.2).