Motor Control Piston Position Tracking via Magnetic Sensor
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Solution Overview
Problem
Existing motor control systems for piston-actuated motors lack precision and reliability in tracking the position of the piston, particularly in applications requiring continuous and accurate control.
Innovation Solution
A motor control system with a magnetically coupled sensor generating continuous output signals, processed by a controller to monitor and control the piston's position, velocity, and actuation within the piston chamber, enabling precise upstroke and downstroke movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If discrete position sensors (photoelectronic or magnetic hall sensor) are used to detect piston position, then the device complexity is reduced, but the measurement precision and tracking continuity of the piston position deteriorates
Solution Approach 1:
The patent replaces discrete mechanical/optical sensing systems with a magnetic field-based sensing system. A magnet is coupled to the piston assembly and a magnetic sensor (such as a Hall effect sensor or magnetoresistive sensor) continuously detects the magnetic field strength, which varies with piston position. This substitution enables continuous analog position tracking without the mechanical complexity of photoelectronic sensors or discrete switching hall sensors, thereby improving measurement precision while maintaining relatively simple device complexity.
2Device complexity
If discrete position signals are used to control piston actuation, then the control system simplicity is improved, but the reliability and precision of piston actuation control deteriorates
Solution Approach 1:
The patent implements continuous feedback control by using the magnetic sensor to continuously monitor piston position and feeding this information back to the controller. The controller processes the continuous position signal and adjusts actuation commands in real-time to achieve precise control of the piston's upstroke and downstroke. This continuous feedback mechanism significantly improves the reliability and precision of piston actuation control compared to discrete position signaling, while the control system complexity remains manageable through efficient signal processing algorithms.
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 achieves continuous and accurate tracking of the piston's position, enhancing precision and reliability in controlling the actuation, facilitating applications like adhesive dispensing with precise metering and dispensing.
Implementation Method 1
A magnet is coupled to the piston assembly to move therewith and a sensor is axially mounted with respect to the piston assembly to generate a continuous output signal corresponding to a position of the magnet relative to the sensor
Implementation Method 2
In another example, a magnetic hall sensor is disposed on a circumferential wall that defines the piston chamber and a magnet is coupled to the piston
Data Source
AI summary
A motor control system includes a piston chamber and a piston assembly disposed within the piston chamber to move therein between first and second positions. A magnet is coupled to the piston assembly to move therewith and a sensor is axially mounted with respect to the piston assembly to generate a continuous output signal corresponding to a position of the magnet relative to the sensor. The motor control system also includes a controller for processing the output signal from the sensor to monitor continuously the position of the piston assembly within the piston chamber and for actuating the piston assembly to move in an upstroke toward the first position and in a downstroke toward the second position.