Biaxial Magnetic Sensor Axle Alignment Measurement
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Solution Overview
Problem
Current methods for measuring axle collinearity during operation are inadequate due to changes caused by loading and temperature fluctuations, requiring an on-line measurement system that can handle harsh industrial environments with temperature variations and dirtiness.
Innovation Solution
A biaxial orthogonal magnetic sensor system comprising a sensor and a magnet, capable of independently measuring angle and offset errors, and a reference sensor to determine error orientation, allowing for precise alignment of axles in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser-based systems are used for measuring axle alignment when axles are stationary, then measurement precision is improved, but the system cannot provide on-line measurement during operation
Solution Approach 1:
The patent replaces laser-based optical measurement systems with a magnetic field-based measurement system. The magnetic sensor detects the magnetic field generated by the magnet on the coupling, enabling measurement during operation without requiring the axles to be stationary, thus achieving on-line measurement capability while maintaining measurement precision
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the magnet on one coupling and the magnetic sensor on the other coupling. This magnetic field mediator enables transmission of alignment information through the environment without requiring direct line-of-sight or stationary conditions, allowing on-line measurement during operation
2Adaptability or versatility
If magnetic sensors are used in harsh industrial environments with temperatures up to 150°C and dirty conditions, then on-line measurement capability is improved, but sensor reliability deteriorates
Solution Approach 1:
The patent employs simple magnetic sensors that are robust, inexpensive, and can withstand harsh industrial environments including high temperatures up to 150°C and dirty conditions. These sensors are designed to be replaceable if needed, providing reliable on-line measurement capability in environments where complex or sensitive sensors would fail
Solution Approach 2:
The patent selects magnetic sensors and magnets with material properties suitable for high-temperature environments. The magnetic materials are chosen to maintain their magnetic characteristics at temperatures up to 150°C, ensuring reliable operation in harsh industrial conditions without degradation of measurement accuracy
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 on-line measurement of axle alignment, minimizing energy losses and wear by providing robust and reliable orientation under varying operational conditions, independent of angle and offset errors.
Implementation Method 1
A magnetic sensor system with one sensor and one magnet, where the sensor is placed on one coupling and the magnet on the other coupling
Data Source
AI summary
The invention concerns a system for measuring the alignment error of two axles provided with a first and a second coupling part by means of a biaxial orthogonal magnetic sensor system comprising a sensor and a magnet, wherein said sensor is designed to be placed on the first coupling part with its one direction of sensing oriented in one direction of magnetization of said magnet, which magnet is designed to be placed on the other coupling part and means for reading off an angle error and offset error independently of each other during the rotation of the axles on-line. The system moreover includes a reference sensor for determining said angle error and offset error orientation relative to a known direction.