Integrated Piston Controller for Linear Actuator Cabling
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Solution Overview
Problem
The complexity and cost of cabling between controllers and linear actuators lead to reliability issues and increased latency due to the need for multiple cables and connections, especially with long-stroke actuators requiring multiple coils and separate power and signal lines.
Innovation Solution
Integrating a controller directly onto the piston assembly with an encoder sensor and direct current coils, allowing for a single power input and reduced cabling, which improves reliability and response time by eliminating the need for separate power and signal wire connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a remotely mounted controller with separate power and signal cables is used, then the linear actuator can be controlled, but the cabling complexity increases and reliability decreases
Solution Approach 1:
The controller is integrated directly onto the piston assembly, merging the controller, encoder sensor assembly, and DC coil into a single unified unit. This eliminates the need for separate power and signal cables between the controller and linear actuator, reducing cabling complexity from multiple shielded bundles to a single integrated component.
2Reliability
If multiple cables and connections are used between controller and linear actuator, then power and signal transmission is achieved, but the risk of failures increases
Solution Approach 1:
By integrating the controller onto the piston assembly with the encoder and coil, the patent reduces the number of cable connections from multiple separate power and signal lines to a single integrated unit, thereby reducing potential failure points and improving reliability.
Solution Approach 2:
The integrated controller serves as an intermediary that directly processes encoder feedback and controls coil activation without requiring external cable connections, eliminating the need for intermediate cable connections that could fail.
3Reliability
If the controller is remotely mounted, then installation flexibility is provided, but latency between sensor feedback and actuation increases
Solution Approach 1:
The controller is physically merged with the piston assembly, placing the control electronics at the same location as the actuator components. This eliminates distance-related latency between encoder feedback and coil actuation, as all components are co-located on the same moving assembly.
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 integration reduces the risk of failures and enhances the responsiveness of the linear actuator by simplifying the cabling and protecting the wiring from interference, thereby improving the overall reliability and efficiency of the system.
Implementation Method 1
The controller outputs direct current to a direct current coil to generate a magnetic field
Data Source
AI summary
Disclosed herein are apparatus and methods for linear actuators that can deliver strokes and forces at different values. The linear actuators include both multi-coil and single-coil actuator designs. The linear actuators include a controller that is removably or permanently coupled to a piston assembly having any number of coils. An encoder may also be removably or permanently coupled to the piston assembly. The piston assembly, controller and encoder move as one unit during actuation of the linear actuator.