Piston Rod Sensor Coupling for Liquid-Filled Linear Drives
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Solution Overview
Problem
Existing linear drive systems lack effective monitoring of piston rod conditions, particularly in liquid-filled environments, leading to unexpected outages and reduced operational lifecycle due to uncontrolled fatigue loads, as traditional monitoring methods using electromagnetic waves are not suitable for such environments.
Innovation Solution
A sensor system utilizing inductive coupling between a first coil winding on the housing and a second coil winding on the piston rod, allowing for the measurement and transmission of piston rod characteristics like strain and stress through a range of linear movement, enabling accurate monitoring and control even in liquid-filled environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If radio frequency antennas are used to transmit data from the piston, then data transmission is enabled, but the system becomes unsuitable for liquid-filled environments and requires antennas to be within a given range
Solution Approach 1:
The patent introduces an inductive coupling mechanism as an intermediary between the piston and housing for data transmission. Instead of using radio frequency antennas that fail in liquid environments, the system uses magnetic field coupling through coil windings - a first coil on the housing and a second coil on the piston rod. This intermediary magnetic coupling method enables reliable data transmission through the liquid-filled environment without the limitations of electromagnetic wave transmission.
2Device complexity
If no monitoring system is implemented, then the system structure remains simple, but unexpected outages occur and operational lifecycle is reduced due to uncontrolled fatigue loads
Solution Approach 1:
The patent implements a feedback mechanism where sensors on the piston rod continuously monitor conditions such as position, load, and fatigue. This data is transmitted via inductive coupling to a controller on the housing, which processes the information and provides feedback control. The feedback system enables real-time monitoring and control of fatigue loads, allowing the system to adjust operating conditions to prevent outages and extend operational lifecycle.
3Ease of operation
If no direct measurement system is implemented, then the system is easier to operate, but the ability to control and reduce fatigue loads is limited
Solution Approach 1:
The patent enables the piston rod monitoring system to be self-sufficient by using the piston rod itself as part of the measurement and transmission mechanism. Sensors are mounted directly on the piston rod, and the rod's movement and operational conditions are measured directly without requiring external measurement systems. The inductive coupling allows the piston rod to transmit its own operational data autonomously, eliminating the need for complex external measurement infrastructure while maintaining ease of operation.
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
Enhances monitoring and control of piston rod conditions, reducing unplanned outages and extending the operational lifecycle of linear drive systems by providing real-time data transmission and load management within liquid-filled environments.
Implementation Method 1
a second coil winding coupled to the piston rod and inductively coupled to the first coil winding and configured to communicate with the first coil winding through a range of linear movement of the piston rod relative to the housing
Data Source
AI summary
A sensor system for monitoring a condition of a piston rod includes an interrogator system having a first coil winding coupled to a housing and radially spaced from the piston rod such that a gap is defined between the first coil winding and the piston rod. A second coil winding is coupled to the piston rod and is inductively coupled to the first coil winding. The second coil winding is configured to communicate with the first coil winding through a range of linear movement of the piston rod relative to the housing. A sensor is coupled to the second coil winding. The sensor is configured to measure a characteristic associated with the piston rod and generate a current in the second coil winding to transmit, via the inductive coupling with the first coil winding, an electrical output signal associated with the characteristic to the interrogator system.