Hydraulic Cylinder Sensor Mounting for Tool-Free Service Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing designs for magnetostrictive length sensors in hydraulic cylinders require disassembly of the cylinder to access or replace the sensor, and the electrical connectors are prone to thread damage, leading to costly repairs.
Innovation Solution
A cylinder length sensor mounting and retaining assembly that includes a casing attachable to the blind end of the cylinder, a sensor retention cap, and a locking pin system, allowing access to the sensor without disassembly and using an over-molded cordset for connector removal, which reduces the risk of thread damage and maintains the sensor seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor is incorporated into the hydraulic cylinder using existing designs, then the sensor can accurately measure the linear position of the cylinder rod, but access to the sensor requires complete disassembly of the cylinder
Solution Approach 1:
The cylinder assembly is segmented into distinct components: the main cylinder body and a separate sensor mounting assembly. The sensor mounting assembly includes a sensor receiving channel with a closed end that accepts the sensor, allowing the sensor to be accessed and replaced by removing only the sensor mounting assembly rather than the entire cylinder. This segmentation resolves the contradiction by maintaining sensor measurement accuracy while improving accessibility.
2Ease of repair
If the electrical connector uses a two-piece construction with separate fasteners, then the connector can be disassembled for sensor removal without soldering, but the threads are prone to damage and require excessive repair costs
Solution Approach 1:
The electrical connector is designed as a disposable component rather than a repairable one. The connector includes an integrated cordset with conductors that are permanently attached to the sensor, eliminating the need for threaded fasteners that can be damaged. When the sensor needs replacement, the entire connector assembly is removed and replaced as a single unit, avoiding thread damage issues while maintaining ease of repair through simple replacement rather than complex repair procedures.
3Ease of operation
If the sensor retention cap is positioned to allow easy sensor removal, then sensor access is improved, but exterior moisture can more easily reach the mounting interface
Solution Approach 1:
The sensor retention cap incorporates a tortuous path feature that extends in the dimensional direction along the mounting interface. This tortuous path forces moisture to travel a longer, more complex route to reach the mounting interface between the sensor and the sensor receiving channel, effectively blocking moisture ingress while maintaining easy sensor removal capability through the retention cap's design.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A cylinder length sensor mounting and retaining assembly for a hydraulic cylinder includes a casing attachable to a blind end of the cylinder, a sensor retention cap affixable to the casing adjacent the blind end of the cylinder, and a locking pin extendable through the casing and positioned adjacent the sensor retention cap. The assembly facilitates sensor removal without requiring disassembly of the cylinder.