Electrostatic Sensor Array for Gauge Pin Position Detection
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Solution Overview
Problem
Existing methods for determining the shape of objects, such as Hall effect sensors and magnetic heads, are costly and require precise alignment, while electrostatic sensors that move along the gauge pin's longitudinal axis are less expensive but still cumbersome.
Innovation Solution
An array of electrostatic sensor devices on a circuit board with a dielectric substrate and conducting rings surrounding sensing holes, allowing for relative position detection of a sensor pin without moving it along its axis, providing a proportional signal indicative of the pin's position through variable electrostatic coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Hall effect sensors are used to determine object shape, then measurement precision is improved, but device cost and alignment complexity increase
Solution Approach 1:
The patent replaces the mechanical Hall effect sensor system with an electrostatic sensing system that uses capacitive coupling through a dielectric substrate. This substitution eliminates the need for precise mechanical alignment between the sensor and gauge pin, while maintaining measurement precision through electrical field detection. The sensor device uses a dielectric layer with conductive planes that create capacitive coupling, allowing position detection without direct mechanical contact or alignment.
Solution Approach 2:
The patent introduces a dielectric substrate as an intermediary between the sensor elements and the gauge pin. This dielectric layer with conductive planes serves as a mediator that transmits position information through capacitive coupling, eliminating the need for direct mechanical contact or precise alignment between the sensor and the gauge pin, thus reducing alignment complexity while maintaining measurement capability.
2Measurement precision
If electrostatic sensors are moved along the gauge pin's longitudinal axis, then measurement capability is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent inverts the traditional sensing approach by placing multiple sensor elements in a fixed array on the circuit board instead of moving a single sensor along the gauge pin. The gauge pin remains stationary while the sensor array detects position through capacitive coupling, eliminating mechanical movement mechanisms and reducing device complexity while maintaining position detection capability.
Solution Approach 2:
The patent divides the sensing function into multiple discrete sensor elements arranged in an array on the circuit board. Each sensor element corresponds to a specific position and detects capacitive coupling independently. This segmentation allows the system to achieve full position detection capability without mechanical movement, as each segment (sensor element) monitors a specific location simultaneously.
3Adaptability or versatility
If a shaped conductive zone is used on the sensor pin, then measurement range is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses a shaped conductive zone on the gauge pin with specific geometric characteristics (such as a tapered or contoured shape) that creates a characteristic capacitive coupling profile as it moves through the sensor array. This parameter change in the conductive zone geometry allows the system to detect position over a wider range by analyzing the changing capacitance values across multiple sensor elements, expanding measurement range while using standard manufacturing processes.
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 cost-effective, precise, and instantaneous indication of the gauge pin's location without mechanical movement, reducing manufacturing costs and complexity, and allowing for a wider range of measurement with differentiated output signals.
Implementation Method 1
variable electrostatic coupling to produce differentiated output signals when the first sensor element of each of the sensor device pairs are at varying positions relative to the second sensor element
Data Source
AI summary
An electrostatic sensor device including a first sensor element and a second sensor element; a dielectric substrate material formed in two layers, and a sensing hole which penetrates the dielectric substrate material from its upper surface to its lower surface. The first sensor element is receivable in the sensing hole; and second sensor element includes a first conducting ring disposed on an upper surface of said dielectric substrate and surrounding said sensing hole. The second conducting ring is disposed on a lower surface of the dielectric substrate and surrounds the sensing hole. The first sensor element and the second sensor are capable of producing a variable response when the first sensor element is disposed in the sensing hole.