Perforated Contact Carrier for Low-Force Position Sensor Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing position sensors require high magnetic forces for actuation, leading to wear when mechanical contact is used, and high magnetic forces are necessary for non-contact actuation.
Innovation Solution
The contact carrier is perforated to reduce its rigidity and stability, allowing for local elastic deformation with lower actuation forces, and a web is used to concentrate magnetic forces for non-contact actuation, reducing the required magnetic forces and minimizing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the contact carrier is made rigid to ensure stability, then structural stability is improved, but actuation force requirement increases
Solution Approach 1:
The contact carrier is divided into multiple segments through perforations (slots or holes) that run through its structure. This segmentation allows the carrier to be flexible in the actuation direction while maintaining overall structural stability, enabling actuation with lower forces.
Solution Approach 2:
The contact carrier has different structural properties in different regions: the perforated areas provide flexibility for actuation, while the solid regions maintain structural integrity. This local differentiation allows the carrier to be easily deformed where needed while remaining stable overall.
2Ease of operation
If mechanical contact actuation is used to actuate the position sensor, then actuation is simple, but wear occurs
Solution Approach 1:
The patent replaces mechanical contact actuation with magnetic field actuation. A magnet is positioned near the contact carrier, and magnetic forces are used to deform the carrier and establish contact between the sliding contact and the resistive track, eliminating mechanical wear.
3Reliability
If non-contact magnetic actuation is used, then wear is eliminated, but magnetic force requirement increases
Solution Approach 1:
The perforated structure of the contact carrier reduces the magnetic force required for actuation by providing structural flexibility. The slots or holes allow the carrier to deform more easily under magnetic attraction, eliminating the need for high magnetic forces while maintaining wear-free operation.
4Force
If the contact carrier is made flexible to reduce actuation force, then actuation force requirement decreases, but structural stability worsens
Solution Approach 1:
The contact carrier exhibits different mechanical properties in different locations: perforated regions provide flexibility for low-force actuation, while solid regions maintain structural stability. This localized differentiation resolves the contradiction between flexibility and stability.
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 enables position sensors to be actuated with significantly lower forces, reducing wear and simplifying non-contact magnetic actuation, while maintaining accuracy.
Implementation Method 1
an actuating device 22 that can be attracted by means of magnetic forces
Implementation Method 2
The contact carrier 3 can be elastically deformed locally by locally acting actuating forces 6
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
The sensor (1) has a base support (2) for supporting a component (4) of a position detection circuit (5) e.g. potential meter circuit. A flexible contact support (3) is arranged at a distance to the component of the position detection circuit. The contact support is locally or elastically deformed by magnetic actuating forces (6). The component and another component (8) of the detection circuit are electrically contacted in a local manner. The contact support is provided with a locally, elastically deformable perforation part.