Helical Magnetic Actuator Position Sensor
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Solution Overview
Problem
Existing position sensors for mechanical systems, particularly in pneumatic automation, face challenges such as high energy consumption, the need for absolute positioning due to frequent calibration, and non-linearity in measurement, especially when managing long strokes and high mechanical dynamics.
Innovation Solution
A device comprising a magnetic contactless sensor system with a helical magnetic component and multiple Hall effect sensors, integrated into a single electronic board, which generates a precise magnetic field and uses a decoding algorithm to process field strength values across multiple directions, enabling accurate measurement of both linear and angular displacements without measurable stroke limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a contactless magnetic sensor is used, then component wear is eliminated and useful life is extended, but the sensor requires a magnetic field generating component which increases device complexity
Solution Approach 1:
The patent replaces contact-based mechanical sensors with a contactless magnetic sensing system. The magnetic sensor detects position through a magnetic field generated by a magnetic component attached to the moving element, eliminating mechanical contact and wear while extending the sensor's useful life.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the sensor and the moving mechanical element. The magnetic component attached to the moving element generates a magnetic field that the contactless sensor detects, enabling position measurement without direct mechanical contact.
2Loss of time
If an absolute position sensor is used to avoid frequent calibration, then calibration time is reduced, but the sensor requires higher energy consumption
Solution Approach 1:
The patent employs a magnetic sensing system that provides absolute position information without requiring frequent calibration. The magnetic field generated by the moving magnetic component provides continuous reference information to the sensor, eliminating the need for recalibration while maintaining low energy consumption through efficient magnetic field detection.
3Ease of operation
If a magnetic sensor measures field intensity to determine position, then contactless measurement is achieved, but non-linearity in measurement increases
Solution Approach 1:
The patent transitions from measuring only magnetic field intensity (one dimension) to measuring magnetic field direction and orientation (adding spatial dimensions). By detecting the direction of the magnetic field vector rather than just its magnitude, the system achieves linear position measurement across the full stroke range while maintaining contactless operation.
Solution Approach 2:
The patent changes the measurement parameter from magnetic field intensity magnitude to magnetic field vector direction. This parameter transformation converts the non-linear intensity variation into a linear directional relationship, enabling accurate position measurement throughout the actuator's stroke.
4Measurement precision
If a sensor operates continuously to provide position feedback, then positioning accuracy is maintained, but energy consumption increases
Solution Approach 1:
The magnetic sensing system provides continuous position feedback with inherently low energy consumption. The passive magnetic component requires no power, and the active sensor consumes minimal energy to continuously detect the magnetic field and provide positioning accuracy throughout the actuator's 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
The solution provides low energy consumption, eliminates the need for frequent calibration, and reduces non-linearity, allowing for efficient control of mechanical systems with long strokes and high dynamic performance, effectively managing both translational and rotational motions.
Implementation Method 1
A magnetic field B, in general, can be schematized as a vector field
Implementation Method 2
The sensor, which is not in itself part of the present invention but is in combination with the magnetic component, is based on a technology that integrates the action of several distinct Hall effect sensors
Data Source
AI summary
A device for checking the position of a mechanical element in translational or rotational motion which performs a predetermined stroke, the device being provided with a magnetic component integral with the mechanical element whose position is to be determined and a stationary magnetic sensor, the magnetic component has at least one magnetic element arranged according to a helical pattern.