Encapsulated Spindle Sensor Ring for Multi-Axis Displacement Accuracy
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Solution Overview
Problem
Existing spindle monitoring systems face challenges in achieving sufficient measuring accuracy and ease of integration across different spindle diameters while being protected from environmental influences.
Innovation Solution
A measuring system comprising a cylindrical housing with a carrier ring that encases sensors for radial and axial displacement measurements, protected from environmental influences, and an electronics module for data exchange, which can be adapted to various spindle diameters by using interchangeable housings and carrier rings, ensuring optimal sensor positioning and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sensors are mounted on the support ring without encapsulation, then the device complexity is reduced, but the sensors are exposed to environmental influences such as moisture, temperature differences, and mechanical/chemical factors
Solution Approach 1:
The sensors are encapsulated in a potting compound that forms a protective shell around them. This shell protects the sensors from moisture, temperature extremes, and mechanical/chemical influences while allowing the sensors to maintain their measurement functions. The potting compound acts as a flexible protective barrier that conforms to the sensor geometry.
2Ease of manufacture
If sensors are positioned with loose tolerances for ease of assembly, then the ease of manufacture is improved, but the measuring accuracy deteriorates
Solution Approach 1:
The sensors are pre-positioned and fixed in their precise measurement positions during the encapsulation process. The potting compound is applied in a state that allows precise positioning, and once cured, it permanently locks the sensors in their optimal positions. This preliminary precise positioning before final assembly ensures both manufacturing feasibility and measurement accuracy.
Solution Approach 2:
The potting compound creates a rigid encapsulation that precisely holds the sensors in their predetermined positions. This encapsulation structure provides mechanical stability and maintains the sensors' positional accuracy during operation, ensuring measurement precision while allowing for practical assembly.
3Manufacturing precision
If the measuring system is designed for a specific spindle diameter, then the manufacturing precision is improved, but the adaptability to different spindle diameters deteriorates
Solution Approach 1:
The measuring system is designed with a universal support ring structure that can accommodate different spindle diameters. The support ring with its standardized sensor mounting pattern can be adapted to various spindle sizes while maintaining the same precise measurement capabilities. This universal design allows the system to function accurately across multiple applications.
Solution Approach 2:
The measuring system is divided into modular components including the support ring, sensor array, and encapsulation unit. This segmentation allows the core measurement technology to remain standardized while adapting to different spindle diameters through configuration changes. The modular design enables precision manufacturing of individual components that can be assembled for different applications.
4Measurement precision
If multiple sensors are arranged distributed around the support ring for accurate multi-directional measurement, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
Multiple sensors measuring different parameters (radial displacement in x and y directions, axial displacement) are merged into a single integrated support ring structure. This unified mounting platform simplifies the overall device complexity by consolidating what would otherwise be separate mounting structures, while maintaining the distributed sensor arrangement needed for comprehensive measurement accuracy.
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 system provides reliable and accurate monitoring of spindle displacements with enhanced protection against environmental factors, achieving measuring accuracy of 1 μm and ease of integration across different spindle diameters.
Implementation Method 1
The sensors are preferably designed as eddy current sensors
Implementation Method 2
The sensors are preferably designed as eddy current sensors
Data Source
AI summary
The invention relates to a measuring system (01) for monitoring a spindle. The measuring system (01) comprises a cylindrical housing (02), which can be arranged in a spindle housing and can be mechanically firmly connected to the latter. A carrier ring (05) is arranged inside the housing (02). Housing (02) and carrier ring (05) are mechanically firmly connected. Three first sensors (07) for measuring a radial displacement of the spindle and three further sensors (08) for measuring an axial displacement of the spindle are arranged to be distributed over the circumference of the carrier ring (05) and mechanically firmly connected to the carrier ring (05). The sensors (07) are cast with the carrier ring (05).