Magnetostrictive Sensor Alignment Mounting Assembly
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Solution Overview
Problem
Accurate stress measurement with magnetostrictive sensors is challenging due to small changes in magnetic permeability caused by applied stress, leading to measurement inaccuracies from varying air gaps between sensor poles.
Innovation Solution
A sensor system with a mounting assembly that allows adjustable positioning of the sensor assembly relative to the target object along multiple axes, including pitch, yaw, and roll, and includes a control module to process signals and correct for gap size variations, ensuring consistent stress signal measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment is used to position the sensor, then the sensor can be installed on the target object, but different air gaps are defined between each detector pole resulting in measurement inaccuracies
Solution Approach 1:
The mounting assembly incorporates adjustable components that allow dynamic positioning of the sensor assembly relative to the target object. The mounting assembly can be adjusted along multiple axes (X, Y, and Z) to optimize the gap distance between the sensor and target surface, ensuring consistent air gaps across all detector poles while maintaining ease of installation.
Solution Approach 2:
The system enables changing the gap parameter between the sensor and target object to achieve optimal measurement conditions. By allowing adjustment of the mounting assembly position, the air gap can be standardized across all detector poles, transforming a source of measurement error into a controlled variable that can be maintained at a consistent value.
2Ease of manufacture
If the sensor assembly is fixed in position, then the installation is simple, but the gap size variations cause measurement errors
Solution Approach 1:
The mounting assembly transitions from a fixed configuration to a dynamically adjustable one, allowing the sensor assembly to be positioned at different locations and orientations. This dynamic capability enables optimization of the gap distance between the sensor and target surface while maintaining ease of installation through the adjustable mounting mechanism.
Solution Approach 2:
The mounting assembly allows preliminary adjustment and optimization of the sensor position before final installation. The adjustable components enable the user to pre-position the sensor assembly to achieve consistent air gaps across all detector poles, ensuring manufacturing precision is achieved during the installation process itself.
3Measurement precision
If multiple adjustment axes are provided, then the sensor can be precisely aligned, but the device complexity increases
Solution Approach 1:
The mounting assembly is segmented into multiple independent adjustable components, each responsible for adjustment along a specific axis (X, Y, and Z). This segmentation allows the complex alignment task to be broken down into simpler, independent adjustment steps, achieving precise sensor alignment while keeping each individual component relatively simple in structure.
Solution Approach 2:
The mounting assembly provides adjustment capability across multiple dimensions (three spatial axes), transforming a single-point fixed installation into a multi-dimensional adjustable system. This dimensional expansion enables precise alignment of the sensor assembly relative to the target object by allowing adjustment in each spatial direction independently.
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 solution enables precise and accurate stress measurements by maintaining consistent gap sizes between the sensor and target, reducing measurement errors and improving the reliability of stress readings.
Implementation Method 1
The control and processing module can provide an alternating current input drive signal to the drive element to cause a magnetic flux to be generated in a central arm of the sensor assembly
Implementation Method 2
The at least one detection element can generate the raw stress signals after the magnetic flux has passed through a gap formed between the at least one detection element and the target
Implementation Method 3
Ferromagnetic materials can have magnetostrictive properties that can cause the materials to change shape in the presence of an applied magnetic field. The inverse can also be true. When a stress is applied to a conductive material, magnetic properties of the material, such as magnetic permeability, can change
Data Source
AI summary
A sensor system for positioning, orienting, and/or aligning a sensor assembly to a target object are provided. In some embodiments, the sensor system can include a sensor assembly and a control and processing module coupled to the sensor assembly. The control and processing module can be configured to process signals generate by the sensor assembly. The sensor system can include a mounting assembly configured to receive the sensor assembly and to position the sensor assembly relative to a surface of a target object. The mounting assembly can include a retaining element configured to translate along a first axis.