Gravity-Swing Distance Sensor Module for Accurate Tilted Installation
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Solution Overview
Problem
Existing distance sensor modules, especially non-contact types, face challenges in maintaining accurate measurements when improperly oriented, such as when installed on a tilted manhole cover, leading to inaccurate water surface detection and increased maintenance needs.
Innovation Solution
A non-contact distance sensor module design featuring a housing with a sensor container section and an attachment section that ensures the transmission and reception section remains oriented vertically downward due to gravity, even if the attachment target changes orientation, using a swing axis mechanism and cushion for stability and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a non-contact distance sensor module is installed on a tilted or improperly oriented attachment target, then the sensor can be easily installed without precise orientation requirements, but the measurement accuracy deteriorates because the detection signal is not emitted vertically downward
Solution Approach 1:
The sensor body is made swingable relative to the housing, allowing it to dynamically adjust its orientation based on gravity rather than being fixed in a static position. This enables the sensor to automatically orient itself vertically downward regardless of the housing's orientation on the attachment target.
Solution Approach 2:
A weight is attached to the sensor body to create a gravity-based orientation mechanism. The weight acts as a counterbalancing element that ensures the sensor body swings to a position where the detection signal is emitted vertically downward, counteracting the effect of improper housing orientation.
2Adaptability or versatility
If a non-contact distance sensor module is configured to emit detection signal at an angle other than 90 degrees to the water surface, then the sensor can be installed in various orientations, but distance calculation complexity increases due to the need for angle-based calculations
Solution Approach 1:
The sensor body is made swingable relative to the housing, allowing it to dynamically adjust its orientation based on gravity rather than being fixed in a static position. This enables the sensor to automatically orient itself vertically downward regardless of the housing's orientation on the attachment target.
Solution Approach 2:
The sensor system uses gravity and the attached weight to automatically orient itself without requiring external adjustment or complex calculation mechanisms. The system self-adjusts to the correct orientation, eliminating the need for angle-based distance calculations.
3Ease of manufacture
If a contact type distance sensor module is used, then the device cost is reduced, but the sensor may be deformed or damaged through contact with objects in water and requires frequent maintenance
Solution Approach 1:
The invention extracts the sensor body from direct contact with the water environment by using a non-contact distance measurement method. The sensor is mounted on the housing that remains outside the water, while only the detection signal (ultrasonic wave or light beam) interacts with the water surface, eliminating mechanical contact and associated damage risks.
4Reliability
If a non-contact distance sensor module is used, then the sensor is not deformed or damaged and maintenance is easier, but the sensor needs to be precisely oriented to maintain measurement accuracy
Solution Approach 1:
The sensor body is made swingable relative to the housing, allowing it to dynamically adjust its orientation based on gravity rather than being fixed in a static position. This enables the sensor to automatically orient itself vertically downward regardless of the housing's orientation on the attachment target.
Solution Approach 2:
The sensor system uses gravity and the attached weight to automatically orient itself without requiring external adjustment or complex calculation mechanisms. The system self-adjusts to the correct orientation, eliminating the need for angle-based distance calculations.
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 accurate distance measurement between the sensor and the target surface regardless of the orientation of the attachment target, reducing maintenance efforts and preventing damage from impact or vibration.
Implementation Method 1
receive the detection signal as reflected by the measurement target
Implementation Method 2
measure a distance between the distance sensor and the measurement target as a result of the transmission and reception section receiving the detection signal
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A distance sensor module (A) includes a distance sensor (S) and a housing (H). The distance sensor (S) includes a sensor body (10) and a transmission and reception section (12) connected to the sensor body (10) and configured to emit a detection signal toward a measurement target and receive the detection signal as reflected by the measurement target. The distance sensor (S) is configured such that the sensor body (10) is configured to measure the distance between the distance sensor (S) and the measurement target as a result of the transmission and reception section (12) receiving the detection signal. The housing (H) includes a sensor container section (Hs) containing the distance sensor (S), and an attachment section (22) configured to attach the sensor container section (Hs) to an external attachment target. The sensor container section (Hs) is configured to keep the transmission and reception section (12) so oriented due to gravity as to have a vertically downward detection direction with the attachment section (22) attached to the attachment target.