Monolithic Ultrasonic Sensor with Integrated Reference Path
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Solution Overview
Problem
Existing ultrasonic sensors for guiding agricultural and construction machinery are large, high-maintenance, and costly due to complex designs with individual recessed transducers and protruding arms, which lead to dirt accumulation and reduced precision in position detection, especially in varying environmental conditions.
Innovation Solution
A sensor with a flat, elongated monolithic ultrasonic transducer array and integrated reference measurement path, featuring inclined reflector surfaces and a continuous acoustic matching layer, allows for precise horizontal and vertical measurements while simplifying maintenance and reducing manufacturing costs by eliminating the need for additional mechanical arms and providing effective temperature and environmental compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual ultrasonic transducers are arranged in recesses with protruding arms for reference measurement, then temperature and environmental compensation is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the reference measurement function into the same housing as the measurement transducers, eliminating the need for separate protruding arms. The reference transducer is positioned in a recess within the housing, integrating both measurement and reference functions into a single compact unit, thereby reducing device complexity while maintaining temperature compensation capability.
Solution Approach 2:
The housing serves multiple functions: it protects the measurement transducers, contains the reference transducer, provides structural support, and houses the evaluation electronics. This multi-functional design reduces the need for separate components and simplifies the overall sensor structure.
2Measurement precision
If individual ultrasonic transducers are built into recesses, then measurement capability is provided, but ease of maintenance deteriorates due to dirt accumulation
Solution Approach 1:
The sensor housing is designed with accessible recesses that allow individual transducers to be cleaned or replaced without disassembling the entire sensor unit. The recessed structure provides easy access to the transducer surfaces, enabling maintenance operations while preserving the integrated measurement and reference functions.
3Measurement precision
If multiple ultrasonic transducers are arranged in a tightly spaced row, then measurement coverage is improved, but device complexity increases
Solution Approach 1:
Multiple ultrasonic transducers are integrated into a single monolithic array structure with a common matching layer and housing recess, reducing the complexity of individual component assembly. The transducers are arranged in a compact configuration that maximizes measurement coverage while minimizing the number of separate parts that need to be manufactured and assembled.
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 solution provides high-precision position detection with reduced maintenance and manufacturing costs, as the monolithic design is easy to clean and integrates environmental compensation, enhancing the sensor's reliability and efficiency in dynamic conditions.
Implementation Method 1
a flat, elongated ultrasonic transducer array that has multiple measurement ultrasonic transducers
Implementation Method 2
the electronic analysis device that provides measured values for the position of the guide surface as a function of measurement signals of the measurement ultrasonic transducers
Implementation Method 3
The matching layer has the task of matching the characteristic acoustic impedance of the piezo material to the characteristic impedance of the air
Implementation Method 4
The back of the piezo plate is glued to the matching layer. Fine stranded wires, which are soldered to the piezo plate, produce the electrical connection
Implementation Method 5
one reflector surface apiece is attached at a distance from the bottom side and in alignment with the reference ultrasonic transducers
Data Source
AI summary
A sensor and a method for detecting a position of the sensor relative to a guide surface, comprising a housing and an electronic analysis device which outputs measurement values for the position of the guide surface on the basis of the measurement signals. The sensor contains an ultrasonic transducer array, each of the two outer ends of which is additionally equipped with a respective reference ultrasonic transducer and a respective reflector surface flush with the reference piezo disc at a distance from the base side, said ultrasonic transducers and reflector surfaces being inclined by 45° relative to the base side and pointing towards one another, thus forming a reference measurement path with a known length between the two reference ultrasonic transducers. In the method for detecting the relative position, the measurement values are corrected with respect to environmental influences by measurements in a reference path.