Pneumatic Actuator Sensor Assembly Using Plastic Deformation
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Solution Overview
Problem
Existing methods for making detection devices for pneumatic actuators require high precision and are costly due to the need for precise welding or gluing to ensure fluid-tight sealing and correct positioning of components, which can lead to imperfections and damage to the detection sensor.
Innovation Solution
A method involving the use of projecting elements and corresponding holes for irremovable connection between parts, followed by plastic deformation and polymeric sealing to ensure fluid-tight protection of the detection sensor, simplifying the manufacturing process and enhancing sensor protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise welding or gluing is used to connect parts of the detection device, then fluid-tight sealing and correct positioning are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical welding or gluing process with a magnetic field-based detection and positioning system. The detection device uses magnetic fields to detect the position of the movable rod and determine whether correct positioning has been achieved, eliminating the need for complex precision welding or gluing operations while maintaining reliable fluid-tight sealing.
Solution Approach 2:
The detection device enables self-positioning and self-verification of the connection between parts. By using magnetic field detection to identify the correct position of the movable rod, the system allows the assembly process to self-correct and self-verify, reducing the need for complex external positioning and sealing operations.
2Manufacturing precision
If precise welding or gluing is used to connect parts of the detection device, then correct positioning is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive precision welding or gluing operations with a magnetic field-based detection system. The detection device uses magnetic fields to detect the position of the movable rod and provide feedback on positioning accuracy, eliminating the need for costly precision manufacturing processes while maintaining high positioning precision.
Solution Approach 2:
The detection device provides real-time feedback on the position of the movable rod during the assembly process. By detecting the magnetic field changes as the movable rod moves, the system can determine when correct positioning has been achieved, allowing for cost-effective manufacturing with built-in quality control.
3Reliability
If precise welding or gluing is used to connect parts of the detection device, then fluid-tight sealing is achieved, but risk of imperfections and sensor damage increases
Solution Approach 1:
The patent replaces the mechanical welding or gluing process with a magnetic field-based detection system that does not involve physical contact or high heat. This eliminates the risk of imperfections in the sealing process and prevents damage to the detection sensor that could occur during welding or gluing operations, while still achieving reliable fluid-tight sealing.
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 method allows for easier and cost-effective production of detection devices with improved protection of the detection sensor, reducing the risk of imperfections and maintaining mechanical stability.
Implementation Method 1
detection of a magnetic field... a magnet fixed to the movable rod and of a device for detecting the magnetic field comprising for example a Hall effect sensor... Movement of the magnet relative to the detection sensor varies the intensity of the magnetic field present at the sensor
Implementation Method 2
sealing step, in which the housing is sealed by at least partly filling the housing with a polymeric material in a liquid state or in the form of a gel, the polymeric material then being made to solidify
Data Source
AI summary
A method for making a detection device (2) for detecting a position of a movable rod (4) of a pneumatic actuator (1) comprises a step of taking a first body (17) comprising a connecting portion (19), a supporting portion (20), an electrical connector (21), a detection sensor (15) for detecting a magnetic field and electrical connecting means (22). The method then comprises a step of taking a second body (18) comprising a housing (14) in which the supporting portion (20) can be inserted, a step of inserting the supporting portion (20) and the detection sensor (15) positioned on it in the housing (14) and a step of irremovably constraining the first body (17) to the second body (18). The first body (17) and the second body (18) comprise, one at least one projecting element (25) and the other at least one corresponding hole (26); during the insertion step the projecting element (25) is inserted in the hole (26). During the constraining step the first body (17) is irremovably constrained to the second body (18) by plastically deforming the projecting element (25) to prevent it from being extracted from the hole (26) in which it is inserted.