Piston Assembly With Integrated Waveguide Position Sensing
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Solution Overview
Problem
Existing piston assemblies, such as gas springs and dampers, lack the capability for accurate, non-contact position sensing during extension and compression strokes, limiting their ability to provide real-time feedback on the position and velocity of moving parts.
Innovation Solution
Integration of a linear position sensing system within the piston assembly, utilizing a waveguide sensor and a magnet to detect the position of the piston rod without affecting the normal functioning of the gas spring or damper, and maintaining functionality during power disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a linear position sensing system is integrated into the piston assembly, then position sensing capability is improved, but device complexity increases
Solution Approach 1:
The waveguide sensor is integrated within the existing piston assembly structure, nesting the sensing system inside the gas spring or damper housing. This allows position sensing functionality to be added without significantly increasing external dimensions or overall device complexity, as the sensor is contained within the existing structural envelope.
Solution Approach 2:
The piston assembly is designed to perform multiple functions: it provides mechanical force output (gas spring/damper function) while simultaneously providing position sensing capability through the integrated waveguide sensor. This multi-functionality reduces the need for separate sensing devices, thereby limiting the increase in overall device complexity.
2Measurement precision
If a waveguide sensor and magnet are integrated into the piston assembly, then non-contact position sensing is improved, but manufacturing complexity increases
Solution Approach 1:
The waveguide sensor and magnet are designed as separate, modular components that can be independently manufactured and then assembled into the piston assembly. This extraction of the sensing function into discrete components allows for specialized manufacturing of each component using appropriate processes, rather than requiring complex integrated manufacturing of the entire assembly.
Solution Approach 2:
The sensing system is segmented into distinct components (waveguide sensor, magnet, housing elements) that can be manufactured separately and assembled. This segmentation allows each component to be optimized for its specific manufacturing requirements and simplifies the overall manufacturing process by breaking down the complex integrated system into manageable parts.
3Measurement precision
If position sensing components are added to the gas spring or damper, then position detection capability is improved, but corrosion protection may be compromised
Solution Approach 1:
The waveguide sensor and magnet are nested within the existing sealed housing of the gas spring or damper, utilizing the existing corrosion protection infrastructure. This nesting approach allows the sensing components to be protected by the same sealing and protective measures already in place for the main assembly, rather than requiring separate corrosion protection systems.
Solution Approach 2:
The existing housing and sealing structures act as an intermediary barrier between the corrosive external environment and the position sensing components. This intermediary protection layer allows the sensing components to function without direct exposure to corrosive elements, maintaining both position detection capability and corrosion protection.
4Loss of information
If a linear position sensing system is integrated, then real-time feedback capability is improved, but ease of repair decreases
Solution Approach 1:
The sensing system is designed as a modular, segmented component that can be independently accessed and replaced. The waveguide sensor and magnet are positioned and mounted in a way that allows them to be serviced separately from the main gas spring or damper components, facilitating easier repair and maintenance while maintaining real-time feedback capability.
Solution Approach 2:
The position sensing components are extracted as separate, removable units from the main piston assembly. This extraction allows the sensing system to be independently tested, calibrated, or replaced without having to service the entire gas spring or damper, thereby improving ease of repair while maintaining real-time feedback functionality.
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
Enables accurate, non-contact position sensing and velocity calculation of moving parts, maintaining output forces and motion control while providing electrical output signals, ensuring continuous operation and independent replaceability of components.
Implementation Method 1
a waveguide sensor and a magnet to detect the position of the piston rod
Data Source
AI summary
A piston assembly for use in a gas spring or damper can include a piston rod partially positioned within a pressure tube, and a linear position sensing apparatus capable of tracking and determining the velocity of the piston rod. The linear position sensing apparatus can include a sensor, such as a waveguide sensor, connected to the piston rod such that the sensor moves with the piston rod. A beacon, such as a magnet, can be contained within the pressure tube and the sensor can detect the position of the beacon relative to the sensor.