Linear Position Sensing Component with Feedback Control for Harsh Environments
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Solution Overview
Problem
Existing position sensing components, such as LVDTs and Hall-effect sensors, are not suitable for harsh environments due to complex circuitry and non-linear outputs, and struggle to provide reliable data in dirty or high-vibrational conditions, especially in applications like braking systems where they can be affected by wear and ferrous material accumulation.
Innovation Solution
A position sensing component comprising a sensing coil, a moveable core, an oscillator circuit, and a feedback control circuit that maintains a fixed amplitude voltage and generates an oscillator output signal linearly proportional to the position of the moveable core, along with a health monitoring circuit and linearization circuit for robust and efficient operation in harsh environments, using a variable reluctance coil and DC input/DC output configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnet-based position sensing components (LVDTs, Hall-effect sensors) are used, then position detection capability is achieved, but reliability deteriorates in harsh environments due to complex circuitry and susceptibility to wear and ferrous material accumulation
Solution Approach 1:
The patent extracts and eliminates the permanent magnet component from traditional LVDT structures, replacing it with a DC-excited coil system. This removal of the magnet simplifies the overall device structure, eliminates susceptibility to ferrous material accumulation, and reduces complexity while maintaining position sensing capability through a different physical mechanism (electromagnetic induction rather than magnetic field interaction).
Solution Approach 2:
The patent replaces the magnetic field-based sensing mechanism with an electromagnetic induction-based system using DC-excited coils. This substitution eliminates the need for permanent magnets and complex magnetic circuitry, thereby improving reliability in harsh environments while reducing device complexity through a more robust electromagnetic approach that is less susceptible to wear and contamination.
2Ease of manufacture
If magnet-based position sensing components are used, then position detection is achieved, but manufacturing cost increases due to complex circuitry and non-linear output requirements
Solution Approach 1:
By removing the permanent magnet and associated complex magnetic circuitry, the patent simplifies the manufacturing process and reduces component costs. The DC-excited coil system requires fewer precision components and simpler assembly procedures, directly lowering manufacturing costs while the inherent linearity of the electromagnetic induction mechanism provides improved measurement precision.
Solution Approach 2:
The patent changes the operating parameters from AC-excited magnetic field interaction to DC-excited electromagnetic induction. This parameter change enables a more linear relationship between core position and output voltage, eliminating the need for complex linearization circuits and thereby reducing both manufacturing cost and improving measurement precision simultaneously.
3Productivity
If non-linear output components are used, then position sensing is achieved, but data transmission efficiency decreases due to requirement for additional linearization processing
Solution Approach 1:
The substitution of DC-excited electromagnetic induction for AC-excited magnetic field sensing inherently produces a linear output signal. This eliminates the need for additional linearization processing circuits or algorithms, thereby improving data transmission efficiency by providing ready-to-use linear position data while maintaining high measurement precision through the direct proportional relationship between core displacement and induced voltage.
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 a robust, linear output suitable for harsh environments, with integral health monitoring and cost-effective manufacturing, enabling efficient data transmission and integration with Analog-to-Digital converters for digital outputs, overcoming the limitations of magnet-based technologies.
Implementation Method 1
a sensing coil; a moveable core disposed within the sensing coil... providing, by an oscillator circuit in conjunction with a feedback control circuit, a variable current signal
Implementation Method 2
a feedback control circuit coupled to the oscillator circuit, wherein the position sensing component is configured to: maintain a fixed amplitude voltage in response to a variable current signal provided by the oscillator circuit in conjunction with the feedback control circuit
Data Source
AI summary
Methods, apparatuses and systems for providing a position sensing component are disclosed herein. An example position sensing component may comprise: a sensing coil; a moveable core disposed within the sensing coil; an oscillator circuit; and a feedback control circuit coupled to the oscillator circuit, wherein the position sensing component is configured to: maintain a fixed amplitude voltage in response to a variable current signal provided by the oscillator circuit in conjunction with the feedback control circuit, and generate an oscillator circuit output signal that is linearly proportional to a position of the moveable core with respect to the sensing coil.