Non-Contact Hall Sensor for Articulated Mast Angle Measurement
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Solution Overview
Problem
Existing methods for measuring the articulation angle of large manipulators, such as those used in truck-mounted concrete pumps, are often imprecise, expensive, or prone to mechanical wear, and face challenges when dealing with thick matter conveying pipes and complex conversion inaccuracies.
Innovation Solution
A non-contact rotation angle sensor system utilizing Hall sensors and movable magnets, which allows for precise and long-lasting angle measurement without mechanical wear, and can tolerate component tolerances and harsh environments, is integrated into the manipulator's articulated joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical angle-of-rotation measuring systems (rotary protractors) are used, then articulation angle can be detected, but measurement precision is insufficient and device complexity increases due to additional mechanical deflection mechanisms
Solution Approach 1:
The patent replaces mechanical angle measurement systems with a magnetic field-based measurement system. A magnet is attached to one component of the articulated joint, and a Hall effect sensor is attached to the other component. The sensor detects changes in magnetic field position as the joint moves, providing precise angle measurement without any mechanical measurement components, thereby eliminating the need for complex mechanical deflection mechanisms.
2Measurement precision
If rotary potentiometers are used for articulation angle detection, then absolute angle value is immediately available, but mechanical wear occurs causing resistance changes and measurement falsification over time
Solution Approach 1:
The patent eliminates mechanical contact in the measurement system by using a magnetic field-based Hall effect sensor to detect articulation angle. The magnet moves with one joint component while the sensor remains stationary on the other component, detecting angular position through magnetic field changes without any physical contact, thus preventing wear and maintaining measurement accuracy indefinitely.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the moving and stationary components of the articulated joint. The magnet generates the magnetic field that serves as the mediator for transmitting positional information from one component to the sensor on the other component, enabling contactless measurement and eliminating direct mechanical contact that would cause wear.
3Reliability
If inclination sensors are used for angle measurement, then measurement robustness is improved, but cost increases and calibration is required at the beginning of each measurement
Solution Approach 1:
The patent replaces expensive inclination sensors with a simpler magnetic field-based measurement system using a magnet and Hall effect sensor. This substitution maintains measurement robustness while significantly reducing cost and eliminating the need for calibration at the beginning of each measurement, as the system provides absolute position information without requiring reference calibration.
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
This solution provides accurate, cost-effective, and durable angle measurement, enabling safe and precise operation of large manipulators by directly detecting the articulation angle between mast segments without conversion errors, even in harsh conditions.
Implementation Method 1
A non-contact rotation angle sensor system utilizing Hall sensors and movable magnets
Data Source
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AI summary
The invention relates to a large manipulator having an articulated mast which can be folded out and which has a fifth wheel (12) that is rotatable about a vertical axis and a plurality of mast segments (14, 16, 18), wherein the mast segments (14, 16, 18) can each be pivoted to a limited extent by a drive unit (26) with respect to an adjacent mast segment (14, 16, 18) or the fifth wheel (12) about respectively horizontal axes of articulation. According to the invention the large manipulator (10) has at least one rotational angle sensor (38, 38') operating without contact for measuring the angle of articulation between two adjacent mast segments (14, 16, 18). The rotational angle sensor operating without contact is preferably a Hall sensor arrangement (38, 38'), which has a Hall sensor (40, 40') and at least one movable magnet (42, 42') corresponding to the Hall sensor (40, 40'). The invention further relates to an automatic concrete pump .