Modular Position Sensor Device for Linear Drive Range Adaptation
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Solution Overview
Problem
Existing position sensor devices require multiple sensors of different lengths for monitoring varying distances, leading to increased production and warehousing costs, and extending the measuring range by stacking sensors results in complex signal processing and larger electronic control devices.
Innovation Solution
A modular position sensor device with interchangeable sensor modules that output relative position signals, allowing for flexible assembly of any desired length and a unified position signal, reducing the number of inputs needed for the electronic control device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple sensors of different lengths are used to monitor varying distances, then the measuring range is adapted, but production and warehousing costs increase
Solution Approach 1:
The position sensor device is divided into multiple identical sensor modules that can be connected in series to form a module string. Each module has the same structure and can be independently manufactured, then assembled into different-length sensors by connecting varying numbers of modules together, eliminating the need to manufacture and store multiple different sensor types.
Solution Approach 2:
Each sensor module is designed with universal electrical interface means that enable identical modules to be connected in series to form module strings of any desired length. This universal design allows a single module type to serve multiple functions and configurations, reducing manufacturing complexity and inventory requirements.
2Length of stationary object
If sensors are stacked to extend measuring range, then the detection capability is improved, but signal processing complexity and electronic control device size increase
Solution Approach 1:
Multiple sensor modules are electrically connected in series through their interface means to form a unified module string that outputs a single position signal. This merging approach consolidates the output signals from multiple modules into one unified signal, simplifying the electronic control device's input requirements and signal processing complexity while maintaining extended measuring range capability.
3Length of stationary object
If multiple sensor modules are connected in series, then the measuring range is extended, but the number of electronic control device inputs increases
Solution Approach 1:
The electrical interface means are designed to merge the output signals from multiple sensor modules into a single unified position signal. When modules are connected in series, their individual position signals are combined through the interface means, allowing the electronic control device to receive only one consolidated input signal regardless of how many modules are connected, thus maintaining simple device architecture while extending measuring range.
Data Source
Figure 1~5
Figure 2
Figure 3
AI summary
The device (3) has sensor units comprising a detection unit e.g. hall-sensor, for detecting movement components (5a) i.e. output units, and a communication interface (25) for outputting position signals based on measuring signals of the sensor units. The sensor units are designed as sensor modules (18) provided with electrical interface units that are variably strung together under electrical bonding to form a module strand (16). An electrical evaluation device is installed upstream of the communication interface for receiving the measuring signals of the sensor units. An independent claim is also included for a linear drive device comprising a position sensor device.