Rotary Element Angular Position Determination Using Redundant Sensor Groups

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Solution Overview

Problem

Existing methods for determining the angular position of a rotary element, such as a ball bearing, are prone to significant accuracy decreases if one of the sensors fails, as they rely on a single sensor set for computation.

Innovation Solution

A method and system where sensors are arranged in multiple groups, allowing for the verification of combined electric signals to ensure consistency and accuracy, enabling the use of alternative sensor groups if one group is defective, thereby maintaining angular position determination accuracy even if one or more sensors fail.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a single sensor set is used to determine angular position, then the device complexity is reduced, but the measurement precision decreases significantly when a sensor fails

Engineering Contradiction:

Improveangular position determination accuracyVSAvoidsensor group configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor system is divided into multiple independent groups (at least two groups), where each group can independently determine the angular position. This segmentation allows the system to maintain functionality and accuracy even when one group fails, as other groups can continue to provide reliable measurements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system verifies the consistency of signals by checking parameters (sine and cosine values) against mathematical relationships (sin² + cos² = 1). When parameter verification fails, the system switches to using data from other sensor groups, thereby maintaining measurement precision through parameter-based fault detection and recovery.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If multiple sensor groups are used to ensure fault tolerance, then the reliability improves, but the device complexity increases

Engineering Contradiction:

Improvesystem operational continuityVSAvoidsignal verification and selection mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements feedback by verifying signal consistency through mathematical relationships (checking if sin² + cos² = 1 within acceptable tolerance). This feedback mechanism allows the system to detect faulty sensor groups and switch to reliable ones, ensuring continuous operation without manual intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent prepares for potential sensor failures by pre-configuring multiple sensor groups and establishing verification rules beforehand. When a fault occurs, the system can immediately switch to pre-validated alternative groups, cushioning against the impact of sensor failures on system reliability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Measurement precision

If sensor signals are verified against consistency rules, then the measurement precision is maintained, but the processing time increases

Engineering Contradiction:

Improveangular position accuracyVSAvoidsignal verification time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The verification process checks only essential mathematical relationships (sin² + cos² = 1) rather than comprehensive signal analysis. This partial verification approach maintains measurement precision by checking critical consistency conditions while minimizing processing time through focused validation.

Inventive Principle:

Principle #16Partial or excessive action

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

Ensures that the angular position of a rotary element can be determined with minimal accuracy loss if one sensor group is faulty, as the system can rely on redundant sensor groups to compute the position, ensuring continuous operation.

Implementation Method 1

Hall effect sensors regularly distributed around a magnetic ring to supply sinusoidal type electric signals

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS9188423B2Method and a system for determining the angular position of a rotary element using multiple groups of sensors, and a bearing including such a system

Publication Date: 2015.11.17 AB SKF SKF PATENT DEPARTMENT

AI summary

This method determines an angular position of a rotary element in a system where a magnetic ring rotatably fastened to the rotary element in communication with multiple sensors each suitable for issuing a unitary electric signal representative of a magnetic field generated by the magnetic ring. At least two groups of sensors adapted to generate, based on the unitary sensor signals, at least one combined electric signal representative of the angular position of the magnetic ring. This method comprises; a) verifying the consistency the combined electric signal with at least one given rule b) assessing whether or not each group of sensors is correctly working based on the verification of step a); and if, a first group of sensors is not correctly working, disregarding its combined electric signal and relying on the combined electric signal of at least a second group of sensors for determining an angular position value.