Hydraulic Piston Limit Sensing Without Wear-Prone Cables
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Solution Overview
Problem
Existing liquid delivery systems face challenges with wear and tear on cables used for charging sensors and communication in hydraulic applicators, which can lead to sensor malfunction and require real-time detection of piston position and speed throughout the stroke, especially in plural component systems where precise ratios are critical.
Innovation Solution
A wireless charging and communication system for sensors, utilizing hall effect sensors and a controller with integrated software to monitor piston position, speed, and direction, and enable wireless communication for remote reporting of anomalies, with a solenoid valve and hydraulic fluid flow management to control piston movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are used for charging sensors and communication in hydraulic applicators, then power supply and data transmission are achieved, but wear and tear occurs leading to sensor malfunction
Solution Approach 1:
The patent removes cables from the system by implementing wireless charging and communication. The sensor is powered and communicates with the controller wirelessly, eliminating the physical cable connection that causes wear and tear. This extraction of the harmful element (cable) directly resolves the contradiction between sensor reliability and cable service life.
Solution Approach 2:
The patent replaces the mechanical cable connection with electromagnetic fields for both power transmission and data communication. The controller transmits power and signals wirelessly to the sensor using electromagnetic induction or radiation, substituting the mechanical contact-based cable system with a field-based wireless system, thereby eliminating wear and tear.
2Manufacturing precision
If real-time piston position detection is implemented throughout the stroke, then precise ratio control is achieved in plural component systems, but system complexity increases
Solution Approach 1:
The sensor performs self-powered operation by harvesting energy from the controller's wireless transmissions. The same electromagnetic field used for communication also charges the sensor's internal power source, eliminating the need for separate power cables and reducing system complexity while enabling continuous monitoring for precise ratio control.
Solution Approach 2:
The wireless communication signal serves dual purposes: it transmits control commands and simultaneously charges the sensor's power source. This multi-functionality reduces the number of separate systems needed, lowering overall system complexity while maintaining precise piston position detection capability.
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 system effectively reduces wear and tear risks, provides real-time piston position monitoring, and enables early detection of potential failures, ensuring consistent performance and product quality by eliminating cable damage and allowing remote diagnosis of issues.
Implementation Method 1
sensor device located outside the hydraulic cylinder and configured to sense a position of the rod and to generate a signal indicating the sensed position
Data Source
AI summary
A liquid delivery system includes a source of hydraulic fluid and a hydraulic cylinder fluidically coupled to the source of hydraulic fluid and having a hydraulic piston movable between first and second limit positions. The liquid delivery system includes a rod connected to the piston and extending out of the hydraulic cylinder and a sensor device located outside the hydraulic cylinder and configured to sense a position of the rod and to generate a signal indicating the sensed position. The liquid delivery system includes a liquid cylinder comprising a liquid piston, operably driven by the rod, to pump a liquid along a flow path to a fluid applicator.