Encapsulated Position Sensor Functional Unit Design
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Solution Overview
Problem
Existing position sensors require customized protective housings for different measuring lengths and principles, making mass production and automation challenging, and they often need additional assembly and protection measures at customer sites.
Innovation Solution
A position sensor functional unit is designed with a tightly encapsulated, easily handable, and pre-assembled unit that includes a functional rod and evaluation electronics, which can be shipped and assembled with a protective housing, allowing for various measuring principles using a standard structure and enabling cost-effective manufacturing and easy customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If customized protective housings are designed for different measuring lengths and principles, then the position sensor can be adapted to specific applications, but the production complexity increases and mass production becomes difficult
Solution Approach 1:
The position sensor is divided into two independent parts: a standardized functional unit (containing the sensor components) and a customized protective housing. The functional unit remains constant across different applications, while only the protective housing varies. This segmentation allows the core sensor to be mass-produced efficiently while still accommodating application-specific requirements through housing customization.
Solution Approach 2:
A universal functional unit is designed that can be used across multiple applications and measuring principles. The standardized functional unit includes all essential sensor components (encoder, evaluation electronics, connection elements) and can be adapted to different measuring lengths and principles simply by changing the protective housing, thereby achieving multi-functionality without increasing production complexity.
2Productivity
If the position sensor functional unit is designed as a standardized unit for mass production, then production efficiency increases, but the ability to accommodate different measuring principles decreases
Solution Approach 1:
The sensor system is segmented into a standardized functional core and variable protective housings. The functional unit contains all measuring components and is designed universally, allowing mass production. The protective housing is the only part that varies according to specific measuring principles and applications, enabling both high productivity and adaptability.
Solution Approach 2:
The system allows dynamic adaptation through modular design. While the functional unit remains standardized for efficient production, the protective housing can be selected or customized based on specific measuring principles and application requirements, providing flexibility without compromising production efficiency.
3Reliability
If additional assembly and protection measures are implemented at customer sites, then the sensor receives adequate protection, but the assembly complexity and time increase
Solution Approach 1:
The functional unit is pre-assembled and pre-protected within a standardized housing that includes integrated protective features. Essential components are pre-positioned and secured during manufacturing, so that upon delivery to the customer, the sensor requires minimal additional assembly or protection measures, thereby maintaining both reliability and ease of installation.
Data Source
AI summary
Since the functional unit (PS-F) of a position sensor is no longer to be repaired in the event of failure, but is to be replaced completely—which is nevertheless to be canred out according to the principle of bloodless removal, especially when arranged in a piston of a working cylinder unit—according to the invention, such functional units are manufactured in different dimensions and possibly also functioning according to different measuring principles in a very simple and cost-effective manner and according to the modular principle in that a functional rod (FS) of the functional unit (PS-F) on the one hand the electronics board (2) with the evaluation unit (12) on the other hand are each inserted opposite the pot-shaped head housing (1), from which the functional rod (FS) then protrudes from the open side (1a), and are pre-fixed to the latter, and the head housing (1) is then cast from the open side, which only brings about the firm connection between the evaluation electronics (12) on the one hand and the functional rod (FS) on the other after curing. This results in a fully functional unit (PS-F), which can also be tested and programmed, but which is nevertheless housed by the customer-depending on the application in a further protective housing (100), usually made of metal.