Modular Magnetic Switch Array for Long-Range Position Sensing
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Solution Overview
Problem
Existing position-sensing systems for movable objects are difficult to assemble correctly in the field, lack durability, and provide inadequate resolution at long operating lengths, particularly in applications like fume hoods and elevators.
Innovation Solution
A modular sensing system comprising switch units with keyed connectors and magnet units with indexed mechanical connectors, ensuring proper assembly and maintaining consistent magnetic fields for accurate position sensing, utilizing an array of switch units and magnet units to detect relative position changes with minimal and maximum resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a modular sensing system with multiple switch units and magnet units is used to achieve high resolution position sensing at long operating lengths, then measurement precision is improved, but device complexity increases due to the need for multiple components and their assembly
Solution Approach 1:
The sensing system is divided into multiple identical switch units and magnet units that can be assembled in series to achieve the desired operating length and resolution. Each unit contains a switch, resistor, and connector assembly that can be independently manufactured and then combined into a complete sensor array, allowing high resolution sensing without requiring a single complex device
Solution Approach 2:
The connector design incorporates asymmetric keyed features with specific orientations (first and second keyed features with different orientations) that prevent incorrect assembly. This asymmetry ensures that switch units and magnet units can only be connected in the correct orientation, eliminating assembly errors while maintaining modular scalability for high-resolution sensing
2Reliability
If keyed connectors with specific orientations are used to prevent incorrect assembly, then reliability is improved, but ease of manufacture decreases due to more complex connector design
Solution Approach 1:
The connector incorporates keyed features with specific asymmetric orientations that mechanically prevent incorrect assembly. The first and second keyed features have different orientations that must match between mating connectors, ensuring reliable connection while using simple geometric shapes that are straightforward to manufacture with standard molding or machining processes
3Measurement precision
If magnet units with indexed mechanical connectors are used to maintain consistent magnetic fields, then measurement precision is improved, but device complexity increases due to indexed connector requirements
Solution Approach 1:
The indexed mechanical connector uses asymmetric keyed features that enforce a specific orientation when assembling magnet units. This ensures that magnets are consistently positioned relative to the switch units, maintaining uniform magnetic field strength and direction across the entire sensor array, which is critical for accurate position sensing
Solution Approach 2:
The magnetic field consistency is achieved through segmented magnet units that can be independently assembled in series. Each magnet unit contains a magnet and indexed connector that maintains proper orientation, allowing the system to achieve consistent magnetic fields over long operating lengths through modular assembly rather than requiring a single complex magnet assembly
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 system allows for quick, reliable assembly from inexpensive components, ensuring accurate position sensing with high resolution even at extended lengths, preventing incorrect assembly and maintaining consistent magnetic fields.
Implementation Method 1
Each magnet unit having an interior space between the top side and the bottom side containing a magnet therein
Implementation Method 2
The switch is normally open but closed when proximate a sufficiently strong magnetic field
Data Source
AI summary
A modular sensing system for determining the relative lineal position between a first object and a second object includes an array of switch units fixed with the first object and an array of magnet units fixed with the second object. Each switch unit contains an electric circuit that includes a switch, a resistor, and conductors arranged to convey electricity from one of a pair of front connectors to one of a pair of rear connectors, and from the other front connector to the other rear connector through either the resistor or the switch when the switch is closed. The switch is normally open but closed when proximate one of the magnet units, each of which houses a magnet. Resistance between a pair of wires of a first switch unit in the array is related to the relative linear position between the arrays of switch units and magnet units.