Digital Linear Position Sensor Hall Switch Array
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Solution Overview
Problem
Existing linear position sensors for hydraulic cylinders, such as those using Hall switches, face challenges in cost efficiency, calibration complexity, and sensor replacement difficulties, which hinder effective stroke detection in hydraulic cylinders used in underground mining applications.
Innovation Solution
A digital linear position sensor design featuring a mounting device with multiple rows of Hall switches offset from each other on a printed circuit board (PCB), which adjusts total resistance between voltage nodes upon magnetic field actuation, enhancing resolution and reliability while allowing for adaptable lengths and redundant measuring signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple Hall sensors are used to detect piston stroke, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The measuring rod is segmented into multiple sections, each containing a Hall sensor at a specific position. This segmentation allows the system to detect piston stroke at multiple discrete points along the rod, improving measurement precision while keeping each individual sensor simple and manageable
Solution Approach 2:
Multiple Hall sensors are integrated onto a single measuring rod structure, combining their functions into one unified component. This merging approach improves stroke detection precision by providing multiple measurement points while reducing overall system complexity compared to using separate sensor assemblies
2Measurement precision
If multiple Hall sensors are used to detect piston stroke, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The measuring rod serves multiple functions: it acts as both the structural support element and the carrier for multiple Hall sensors. This multi-functionality allows the same component to provide both mechanical support and measurement capabilities, improving stroke detection precision without proportionally increasing manufacturing cost
Solution Approach 2:
The system uses discrete positional parameters along the measuring rod, with Hall sensors positioned at specific intervals. By changing the spatial parameters (positions) rather than using continuous measurement, the system achieves improved stroke detection precision using cost-effective discrete sensors rather than expensive continuous measurement systems
3Measurement precision
If Hall sensors are mounted on the measuring rod, then measurement precision is improved, but ease of repair decreases
Solution Approach 1:
The measuring rod is divided into modular sections with Hall sensors positioned at discrete intervals. This segmentation allows individual sensor sections to be accessed and replaced independently, improving ease of repair while maintaining measurement precision through the distributed sensor array
Solution Approach 2:
The Hall sensors are extracted as replaceable components from the measuring rod structure. This extraction allows sensors to be removed and replaced without replacing the entire measuring rod assembly, improving ease of repair while maintaining the precision benefits of multiple measurement points
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 configuration reduces material and manufacturing costs, increases resolution and reliability, and allows for easier adaptation to different lengths by using cost-efficient PCB components and redundant signals, improving the accuracy and durability of stroke detection in hydraulic cylinders.
Implementation Method 1
Each Hall switch is configured to adjust a total resistance of the plurality of resistors between the first voltage node and the second voltage node upon actuation by an applied magnetic field
Data Source
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AI summary
A sensing device (36) for a digital linear position sensor is disclosed. The sensing device (36) includes a mounting device (28) including a mounting surface (27), and a plurality ofresistors (38) mounted on the mounting surface. The plurality of resistors (38) is electrically connected in series between a first voltage node and a second voltage node. A plurality of Hall switches (34) is mounted on the mounting surface (27) at predetermined intervals in a longitudinal direction. A magnet device may move in the longitudinal direction with respect to the Hall switches (34), thereby selectively opening and closing one or more Hall switches. This may result in a change in the resistance of the plurality of resistors (38) and produce an output signal from which a position of the magnet device with respect to the sensing device (36) can be determined.