Magnetic Scale Sensor Layout for High-Resolution Relative Motion
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Solution Overview
Problem
Existing sensor systems for detecting relative movement in controllable dampers lack high resolution and rapid operation, especially under difficult usage conditions, and are not cost-effective or simple in design.
Innovation Solution
A sensor unit with a scale unit featuring axially or radially magnetized magnetic bodies arranged in a defined periodic manner, combined with a pre-tensioning unit to prevent unwanted movement, allowing for precise and rapid detection of relative movement with minimal installation space and high magnetic field strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor system with high resolution and rapid operation is used, then measurement precision and speed are improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical sensor systems with a magnetic field-based detection system. Magnetic bodies are arranged in a periodic pattern along the scale unit, creating a magnetic field distribution that varies with position. A magnetic sensor detects these field variations to determine relative movement, achieving high resolution without complex mechanical components. This substitution of magnetic field interaction for mechanical sensing resolves the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent utilizes changes in magnetic field parameters (strength and distribution) as a function of position to encode movement information. By arranging magnetic bodies with specific magnetization directions (axial or radial) in periodic patterns, the system creates distinct magnetic field signatures at different positions. The magnetic sensor detects these parameter changes to achieve high-resolution measurement, transforming a complex mechanical measurement problem into a simpler magnetic field parameter detection task.
2Measurement precision
If magnetic bodies are arranged in a periodic manner to enhance detection accuracy, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The scale unit is segmented into multiple discrete magnetic bodies arranged in periodic patterns along the measuring section. Each magnetic body can be independently manufactured and then assembled in the periodic arrangement. This segmentation allows for standardized production of individual magnetic elements followed by modular assembly, reducing overall manufacturing complexity while maintaining the periodic structure necessary for high-precision detection.
Solution Approach 2:
The patent specifies that magnetic bodies can be magnetized in different directions (axially or radially) to create the desired magnetic field distribution. This parameter change in magnetization direction provides flexibility in manufacturing - different magnetization approaches can be selected based on production capabilities and performance requirements, easing the manufacturing process while maintaining detection accuracy through controlled magnetic field patterns.
3Reliability
If a pre-tensioning unit is added to prevent unwanted movement of magnetic bodies, then reliability is improved, but device complexity increases
Solution Approach 1:
The pre-tensioning unit applies a preliminary counteracting force to prevent unwanted movement or displacement of the magnetic bodies from their intended periodic positions. By establishing this pre-tensioning force, the system proactively compensates for potential disturbances, thermal expansion, or mechanical stresses that could degrade measurement reliability. This preliminary anti-action ensures the magnetic bodies maintain their precise periodic arrangement without requiring complex active control mechanisms.
4Measurement precision
If magnetic bodies are arranged to repel or attract each other, then measurement precision is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes changes in magnetization parameters (direction and strength) of the magnetic bodies to create repulsive or attractive interactions. By carefully controlling these magnetic parameters during manufacturing, the system can achieve the desired interaction forces that enhance measurement precision. The specification of different magnetization directions (axial vs. radial) provides multiple parameter adjustment options to optimize both the interaction effects and manufacturing feasibility, balancing measurement accuracy with manufacturing precision requirements.
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 high-resolution, cost-effective, and reliable detection of relative movement, enabling precise control of damping forces even under challenging conditions, with the magnetic bodies arranged to repel or attract each other for enhanced measurement accuracy.
Implementation Method 1
The scale unit has at least one structure having magnetic bodies repeating in a defined (and in particular periodical) manner at least along the measuring section. The magnetic bodies are axially magnetized and are arrayed having identical magnetic poles along the measuring section, so that adjacent magnetic bodies repel one another (repelling arrangement) and/or the magnetic bodies are radially magnetized
Data Source
AI summary
A device has a sensor unit for detecting measurement data about a relative movement of two components that are moved relative to one another. The sensor unit includes a scale unit connected to one of the components and extending in a movement direction of the relative movement over a measuring section. The scale unit includes a structure having magnetic bodies repeating in a defined manner along the measuring section. The magnetic bodies are axially magnetized and are arrayed having identical magnetic poles along the measuring section and/or the magnetic bodies are radially magnetized and are arrayed in alternation with respect to their magnetic poles along the measuring section. The sensor unit includes a pre-tensioning unit which fixes the arrayed magnetic bodies using a pre-tensioning force.