Gauge Sensor Attachment Layout for Stable Magnetic Sensing
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Solution Overview
Problem
Attaching a sensor to a gauge using double-side tape can decrease the accuracy of the sensor due to variations in the distance between the sensor and the gauge, as described in Patent Literature 1.
Innovation Solution
A sensor device configuration that attaches to a gauge without coinciding with the sensor section along the axis, using a separate attacher fixed to the transparent plate, eliminating the need for double-side tape, and ensuring consistent distance for high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If double-side tape is used to attach the sensor to the gauge, then the sensor can be easily attached, but the sensing accuracy decreases due to variations in distance between the sensor and gauge
Solution Approach 1:
The attachment function is separated from the sensor section by introducing a dedicated attacher component. The attacher is positioned at a location that does not coincide with the sensor section along the axis, allowing the sensor to maintain its optimal position for accurate measurement while the attacher provides the attachment function through welding to the transparent plate.
Solution Approach 2:
The attacher serves as an intermediary component between the sensor device body and the gauge. By positioning the attacher separately from the sensor section and welding it to the transparent plate, the sensor can be held at a consistent distance from the gauge without direct contact or interference from attachment materials like double-side tape.
2Device complexity
If the attacher coincides with the sensor section along the axis, then the attachment structure is simplified, but the distance variation between sensor and magnet increases reducing accuracy
Solution Approach 1:
The device is segmented into distinct functional zones: the attacher positioned for attachment purposes and the sensor section positioned for measurement purposes. This spatial segmentation ensures that the attacher does not coincide with the sensor section along the axis, preventing distance variations that would affect sensing accuracy while maintaining clear functional separation.
3Device complexity
If welding is used to fix the attacher to the transparent plate, then additional attachment materials are eliminated, but the manufacturing process becomes more complex
Solution Approach 1:
The mechanical attachment system (double-side tape or adhesive) is replaced with a welding process to fix the attacher to the transparent plate. This substitution eliminates the need for separate attachment materials and reduces the number of components, even though it introduces a thermal processing step to the manufacturing process.
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 configuration maintains high sensing accuracy by minimizing variations in the sensor-gauge distance and prevents the need for additional attachment methods, ensuring reliable measurements.
Implementation Method 1
a sensor section that coincides with the axis as viewed along the axis and that is configured to obtain information on a position of the magnet
Implementation Method 2
a protrusion protruding from the facing section along the axis away from the sensor device body and welded to the transparent plate to be fixed to the transparent plate
Data Source
Figure 1
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AI summary
A sensor device (100) obtains a measurement from a gauge (G1) including: a dial plate (G16) having a scale face (G16a) with a scale mark; a shaft (G17) having an axis (AX) and orthogonal to the scale face (G16a); a needle (G14); a magnet (G18) rotatable about the axis (AX) together with the needle (G14); and a transparent plate (G15) covering the dial plate (G16), the needle (G14), and the magnet (G18). The sensor device (100) includes: a sensor device body (D1) including a sensor section (21) that coincides with the axis (AX) as viewed along the axis (AX) and that is configured to obtain information on a position of the magnet (G18), the sensor device body (D1) being configured to obtain the measurement based on the information; and an attacher (A1) configured to attach the sensor device body (D1) to the gauge (G1) and be fixed to the transparent plate (G15) in such a manner as to not coincide with the sensor section (21) as viewed along the axis (AX).