Magnetic Position Detector with Integrated Tilt Sensor
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Solution Overview
Problem
Conventional magnetic position detectors require accurate machining and assembly of guide surfaces for fixation, leading to increased costs and the need for multiple fixing jigs for different sizes, with detection accuracy deteriorating if the sensor and scale surfaces are not parallel.
Innovation Solution
Incorporating a tilt sensor in the sensor section to detect and adjust for tilt between the scale and sensor surfaces, eliminating the need for guide surfaces and dedicated fixing jigs, allowing for accurate and cost-effective fixation and improved detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If guide surfaces are accurately machined for fixation, then detection accuracy is improved, but manufacturing cost and machining difficulty increase
Solution Approach 1:
The patent replaces the mechanical guide surface system with a magnetic field-based detection system. The scale section uses magnetic patterns (circles, arcs, or gear-shaped patterns) that generate magnetic field variations, allowing the sensor to detect position and alignment without requiring mechanically precision-machined guide surfaces. This substitution eliminates the need for accurate machining while maintaining detection accuracy.
Solution Approach 2:
The patent changes the detection parameter from mechanical contact/alignment to magnetic field interaction. By using magnetic materials and patterns on the scale section, the system detects position through magnetic field variations rather than mechanical guide surfaces, thereby reducing machining requirements while preserving measurement precision.
2Measurement precision
If guide surfaces are accurately machined for fixation, then detection accuracy is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent eliminates mechanical guide surfaces and replaces them with a magnetic field-based alignment and detection system. The scale section with magnetic patterns and the sensor section work together through magnetic field interaction, simplifying the assembly process by removing the need for complex mechanical guiding structures and reducing assembly difficulty.
3Measurement precision
If fixing jigs are used for different scale sizes, then detection accuracy is maintained, but device complexity and cost increase
Solution Approach 1:
The patent creates a universal magnetic field-based detection system that works across different scale section sizes without requiring size-specific fixing jigs. The magnetic patterns and sensor configuration can detect position and alignment regardless of the specific scale size, making the system multi-functional and eliminating the need for multiple dedicated fixing tools.
Solution Approach 2:
By replacing mechanical fixing jigs with a magnetic field-based detection and alignment system, the patent eliminates the need for multiple size-specific mechanical fixtures. The magnetic interaction provides a universal solution that adapts to different scale sizes through field-based rather than mechanically constrained alignment.
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
Enables accurate and cost-effective fixation of the sensor section to the detection target with improved detection accuracy, reducing the need for complex machining and multiple fixing jigs, while allowing for real-time monitoring and adjustment of the sensor's installation state.
Implementation Method 1
the sensor section has a magnetic position sensor on its surface close to a circumference surface of the scale section. When the rotation shaft 1 rotates, the magnetic position sensor 5 detects a magnetic change caused by the concavities and convexities on the circumference surface of the scale section 2.
Implementation Method 2
In the position detector, a tilt sensor is incorporated into the sensor section 24.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A scale section is made of a magnetic material. A repeated pattern is recorded at a uniform pitch on the surface of the scale section. A sensor section is provided independently from the scale section. The sensor section is provided with a magnetic position sensor that reads the pattern, on a surface close to the surface of the scale section. Further, the sensor section is provided with a magnetic tilt sensor that detects a tilt between the surface of the scale section and the surface of the sensor section on which the position sensor is located. The magnetic position detector in which the scale section and the sensor section are separated from each other can be efficiently fixed to a detection target using the tilt sensor.