Manual Positioning Stage With Hall Sensor Readout
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Solution Overview
Problem
Compact manual lead screw-driven positioning stages require external measurement devices for accurate slider translation, which are inaccurate and consume space, compromising the compact size and precision of the stages.
Innovation Solution
Integration of a sensor that measures the rotation of the lead screw using a magnetic Hall Effect sensor, connected via a flexible circuit to a display enclosure for real-time position measurement, either wired or wirelessly, allowing for accurate and compact position tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external measurement devices (micrometers) are used to measure slider translation, then measurement capability is provided, but the device size increases and measurement accuracy is insufficient for submicron positioning
Solution Approach 1:
The patent integrates the measurement function directly into the slider by incorporating a magnetic sensor within the slider body. This merging of the measurement device with the moving component eliminates the need for separate external micrometers, achieving submicron measurement accuracy while maintaining the compact stage design. The sensor measures lead screw rotation directly at the slider location, providing precise position feedback without adding external measurement equipment.
2Loss of information
If external measurement devices are attached to the stage, then position measurement is enabled, but the compact size of the stage is compromised
Solution Approach 1:
The patent embeds the magnetic sensor within the internal structure of the slider, nesting the measurement function inside the existing stage components. The sensor is positioned within the slider body to measure lead screw rotation, effectively hiding the measurement capability within the compact stage assembly rather than attaching external devices that would increase the stage footprint.
3Measurement precision
If a sensor is integrated into the slider to measure lead screw rotation, then measurement accuracy and compactness are improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical measurement systems (micrometers with mechanical scales and pointers) with a magnetic sensing system. The magnetic sensor detects the rotation of a magnet attached to the lead screw, converting mechanical rotation into electrical signals for digital processing. This substitution provides higher measurement accuracy and enables digital readout while maintaining compact dimensions, despite the increased complexity of integrating electronic sensors.
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 submicron resolution and repeatable positioning within a compact form factor, enhancing the precision and usability of manual micro-positioning stages without the need for external measurement devices.
Implementation Method 1
The sensor comprises a device that measures the motion of a rotating inhomogeneous magnetic field associated with a magnet mounted on the end of the lead screw
Data Source
AI summary
The disclosed device comprises a manually-actuated micro positioning stage that incorporates a mechanism for measurement and electronic output of the stage slider position. A Hall Effect sensor device is used to sense rotary position of the lead screw. based on the lead screw pitch. Processor means converts the Hall Effect sensor measurement of the lead screw rotational displacement into linear displacement of the stage slider for presentation on an electronic display. A magnetically-permeable cap contains a small disc magnet that is poled diametrically and is affixed to the end of the lead screw that is in contact with the stage slider by means of a sensor housing. The Hall Effect sensor contained in a surface mount electronic package is enclosed in a sensor housing that is part of the stage slider that is in contact with the lead screw and is positioned coaxially with the lead screw.