Position Sensor Assembly Combining Swing and Inclination Measurement
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Solution Overview
Problem
Existing position sensors for heavy machines require separate sensors for measuring different angular movements, leading to complex data analysis and increased error-prone communication, which complicates the determination of angular movements and alignment of rotatable components.
Innovation Solution
A sensor assembly with a data sensor and a communication sensor integrated on a single printed circuit board, capable of detecting swing and inclination angles, and converting data into a unified communication packet for transmission to an Engine Control Unit (ECU) using a CAN transceiver, reducing wiring and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate position sensors are used for measuring different angular movements, then measurement coverage is improved, but device complexity and data processing complexity increase
Solution Approach 1:
The patent combines multiple sensor functions (swing angle sensing and inclination sensing) into a single integrated position sensor assembly. The sensor assembly includes a data sensor with a first printed circuit board having sensor elements for detecting swing angle, and a communication sensor with a second printed circuit board for data transmission, both integrated within one housing structure. This merging reduces the number of separate sensors needed while maintaining comprehensive measurement coverage.
Solution Approach 2:
The integrated position sensor assembly performs multiple functions simultaneously: it measures both swing angle and inclination angle, processes data locally, and communicates with the Engine Control Unit through a unified system. The single sensor assembly replaces what would traditionally require multiple separate sensors, making the system more versatile while reducing overall complexity.
2Measurement precision
If separate position sensors are used for different angular movements, then measurement precision is maintained, but reliability of data transmission and processing decreases
Solution Approach 1:
By merging the data sensor and communication sensor into a single integrated assembly with unified data processing, the system eliminates the complexity of coordinating multiple separate sensor systems. The integrated design ensures consistent data formatting and transmission protocols, reducing errors in data communication between sensors and the Engine Control Unit while maintaining measurement precision.
3Quantity of substance
If multiple data packets are sent through different buses, then comprehensive data collection is improved, but ease of operation and data analysis complexity worsen
Solution Approach 1:
The integrated position sensor combines swing angle data and inclination data into a single unified data packet for transmission to the Engine Control Unit. This eliminates the need for multiple separate data packets traveling through different communication buses, simplifying the data analysis process while maintaining complete data collection for both angular movements.
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 integrated sensor assembly simplifies data processing by combining swing and inclination angle measurements into a single communication packet, enhancing accuracy and reducing errors in position determination for heavy machine components.
Implementation Method 1
the inclination sensing unit is electrically connected with at least one of a gyroscope and an accelerometer
Implementation Method 2
the inclination sensing unit is electrically connected with at least one of a gyroscope and an accelerometer
Implementation Method 3
the inclination sensing unit is electrically connected with at least one of a gyroscope and an accelerometer
Data Source
AI summary
A sensor assembly for a position sensor is provided. The sensor assembly comprises a data sensor and a communication sensor. The data sensor has a first printed circuit board and the first printed circuit board has a plurality of sensor elements disposed on a first side of the first printed circuit board. The first printed circuit board has a swing angle sensing unit and an inclination sensing unit. The communication sensor is electrically connected to the data sensor. The communication sensor has a second printed circuit board. The second printed circuit board is aligned such that the second printed circuit board faces a second side of the first printed circuit board.