Flexible Measuring Element With Metallic Carrier Layer
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Solution Overview
Problem
Existing length measuring systems face limitations due to adhesive attachment issues, reduced accuracy from minimum distance scanning, and susceptibility to dirt and wear, particularly with plastic-based tapes.
Innovation Solution
A flexible measuring element comprising a non-magnetic metallic first layer and a magnetizable second layer, where the metallic first layer serves as a carrier and protective layer, allowing for precise scanning and improved wear resistance, and enabling mechanical contact during scanning without damaging the magnetizable layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a plastic-based measuring element with magnetizable particles is used, then the measuring element can be scanned contactlessly, but the accuracy is limited due to the minimum distance requirement between the reading head and the measuring element
Solution Approach 1:
A non-magnetic carrier layer is introduced as an intermediary between the magnetizable measuring layer and the reading head. This carrier layer allows the reading head to scan through it without direct contact with the magnetizable particles, enabling accurate measurement while maintaining the contactless scanning advantage. The carrier layer acts as a mediator that transmits magnetic field signals while protecting the measuring layer from mechanical contact.
Solution Approach 2:
The measuring element is constructed as a composite structure combining a non-magnetic carrier layer material and a magnetizable measuring layer material. This composite design allows the carrier layer to provide mechanical support and protection while the magnetizable layer contains the measurement information, achieving both accuracy and durability.
2Ease of manufacture
If the measuring element is attached using adhesive connection, then the attachment process is simple, but a permanent secure fit cannot be guaranteed
Solution Approach 1:
The adhesive connection is replaced with a mechanical integration system where the measuring element is formed as an integrated component with the support structure. The measuring element is inserted into a recess or channel of the support structure, creating a mechanical fit that guarantees permanent secure attachment without relying on adhesive bonds that may degrade over time.
3Ease of manufacture
If plastic measuring elements are used, then the elements are easy to manufacture, but they are susceptible to wear and dirt accumulation
Solution Approach 1:
The measuring element uses a composite structure where the carrier layer is made from wear-resistant metallic material while the measuring layer contains magnetizable particles. This composite design combines the manufacturing ease of thin metallic foils with the wear resistance of metallic materials, protecting the measuring layer from dirt and wear while maintaining ease of production.
Solution Approach 2:
The carrier layer is designed as a thin metallic foil that provides flexible protection to the magnetizable measuring layer. This thin film structure protects the measuring layer from mechanical damage and dirt accumulation while maintaining the flexibility needed for the measuring element to function properly.
4Measurement precision
If the thickness of the first layer is reduced to separate the graduation, then the measurement signals are enhanced, but the mechanical strength is reduced
Solution Approach 1:
The carrier layer is made from metallic material that provides high mechanical strength even at thin thicknesses. This metallic carrier layer can be made sufficiently thin to allow clear separation and scanning of the magnetizable graduation while maintaining the structural integrity and mechanical strength needed for durable operation.
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
Enhances measurement accuracy and durability by maintaining a consistent distance between the scanning device and the magnetizable layer, reducing wear and ensuring reliable scanning while avoiding mechanical contact with the magnetizable layer.
Implementation Method 1
the second layer comprises a plurality of magnetized areas which form the material measure
Implementation Method 2
Metallic materials have a relatively high mechanical strength and a relatively high resistance to wear (for example to wear due to abrasion)
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a measurement element (1, 11, 17, 26) for a length measuring system (40) in the form of a flexible strip comprising a measurement body (4) that can be scanned using a measuring unit (41) of the respective length measuring system (40). The flexible strip consists of a non-magnetic first layer (2, 13, 19, 28) and a magnetisable second layer (3, 14, 20, 29). The first layer (2, 13, 19, 28) is designed as a strip consisting of a metal material, coated at least in part on one side with the second layer (3, 14, 20, 29), said first layer acting as a support layer for the second layer. The second layer (3, 14, 20, 29) comprises several magnetisable regions that form the measurement body (4).