Linear Position Sensor with Segmented Housing
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Solution Overview
Problem
Existing position sensors, particularly non-contacting magnetic sensors, face challenges with precision and durability due to magnetic irregularities, mechanical vibrations, and temperature changes, which can lead to inaccurate position measurements.
Innovation Solution
A linear position sensor design featuring a housing with separate cavities for a magnet carrier and a magnetic sensor, where the magnet carrier is biased by a spring and moves relative to the sensor, allowing for precise measurement of the magnetic field changes indicative of the object's position, thus isolating electronic components from environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-contacting magnetic sensor is used, then durability is improved by eliminating physical wear, but measurement precision deteriorates due to magnetic irregularities and vibrations
Solution Approach 1:
A ferromagnetic shield is introduced as an intermediary component between the magnet and the Hall effect sensor. This shield mediates the magnetic field interaction, creating a more stable and predictable magnetic field pattern that reduces the impact of magnetic irregularities and external interference, thereby improving measurement precision while maintaining the non-contacting durability advantage
Solution Approach 2:
The patent modifies the magnetic field parameters by introducing a ferromagnetic shield that alters the field distribution and strength. This parameter change creates a more stable magnetic field environment for the sensor, reducing sensitivity to vibrations and external magnetic interference, thus improving measurement accuracy without sacrificing the wear-free operation
2Object-affected harmful factors
If the sensor components are isolated in separate cavities, then protection from environmental factors is improved, but device complexity increases
Solution Approach 1:
The housing is segmented into separate cavities: one cavity houses the magnet and carrier assembly, while another cavity houses the Hall effect sensor. This segmentation physically isolates sensitive electronic components from environmental factors such as moisture, dust, and extreme temperatures, while the modular design allows for manageable assembly and maintenance despite the increased structural complexity
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 design enhances the accuracy and durability of position sensing by reducing the impact of vibrations and environmental factors, providing reliable positional data across varying conditions.
Implementation Method 1
A Hall Effect device is used to produce an electrical signal that is dependent upon the magnitude and polarity of the magnetic flux incident upon the device
Implementation Method 2
A magnet carrier is positioned in one of the cavities and a magnet is coupled to the magnet carrier. The magnet carrier is coupled to the moveable object
Data Source
AI summary
A sensor used to sense the position of an attached movable object. The sensor can be mounted to a pneumatic actuator. The sensor includes a housing that has a pair of cavities or pockets separated by a wall. A magnet carrier is positioned within one of the cavities and a magnet is coupled to the magnet carrier. The magnet carrier is coupled to the moveable object. A magnetic sensor is positioned in the other of the cavities. The magnetic sensor generates an electrical signal that is indicative of a position of the movable object.