Proximity Sensor Gap Estimation Using Nonlinear Inductance Modeling
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Solution Overview
Problem
Existing proximity sensing systems introduce substantial errors in gap estimation when linear relationships are assumed, which holds only for a small range of sensor-target gaps, and fail to account for the non-negligible relationship between sensor resistance and gap, leading to inaccurate measurements and potential false alarms.
Innovation Solution
A system and method that utilize a nonlinear model to estimate the gap between a sensor and a target based on inductance values, accounting for the relationship between inductance, resistance, and temperature, thereby increasing the range of accurate gap estimation and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a linear relationship between cable length and measured sensor inductance is used, then the system is simple to operate, but substantial error is introduced into the gap estimate outside of a small range of sensor-target gap
Solution Approach 1:
The patent transforms the linear relationship assumption into a nonlinear relationship model between cable length and measured sensor inductance. This parameter change allows the system to maintain accuracy across a wide range of sensor-target gaps while preserving ease of operation through automated nonlinear compensation algorithms.
Solution Approach 2:
The system dynamically adjusts the gap estimation by selecting appropriate models or compensation methods based on the operating range. The nonlinear compensation is applied adaptively to maintain measurement precision across varying gap conditions without requiring manual intervention.
2Device complexity
If sensor resistance is considered constant as a function of gap, then the calculation is simplified, but additional error is introduced into the gap estimate
Solution Approach 1:
The patent changes the assumption about sensor resistance from constant to variable with respect to gap. By incorporating resistance as a function of gap into the estimation model, the system achieves higher measurement precision while managing complexity through integrated compensation algorithms.
Solution Approach 2:
The system uses measured resistance values as feedback to continuously update and refine the gap estimation. This feedback mechanism allows the system to account for resistance variations without requiring complex manual calculations, maintaining both precision and operational simplicity.
3Measurement precision
If a nonlinear model is applied to account for the relationship between inductance, resistance, and temperature, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The processing equipment is designed to perform multiple functions: measuring inductance, measuring resistance, estimating temperature, and applying nonlinear compensation models. By integrating these functions into a single multi-functional system, the patent reduces overall complexity compared to having separate systems for each measurement and compensation task.
Solution Approach 2:
The system performs self-compensation by automatically applying nonlinear models to correct for temperature effects and resistance variations. This self-service capability eliminates the need for external calibration or manual intervention, improving measurement precision without proportionally increasing operational complexity.
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 nonlinear model enhances the accuracy of gap estimation over a larger range, reduces noise robustness, and avoids false alarms by compensating for the non-negligible relationship between sensor resistance and gap, improving confidence in notifications and alerts.
Implementation Method 1
a sensor configured to generate a magnetic field and sense inductance, wherein the inductance is affected by the target when the target is proximate the sensor
Implementation Method 2
a sensor cable coupled to the sensor, the sensor cable being configured to provide the sensed inductance from the sensor to processing equipment
Data Source
AI summary
A method is provided for sensing proximity of a target. The method includes sensing inductance associated with a magnetic field, wherein the inductance is affected by the target when the target is proximate the magnetic field. The method further includes providing the sensed inductance for processing. The processing includes determining an inductance value from at least the sensed inductance and estimating a parameter of a gap between a location of sensing the inductance and the target as a function of the inductance value and application of a nonlinear model of a relationship between the gap and inductance.