Rotating Magnetic Sensor for Multi-Parameter Machine Tool Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotating sensing modules for machine tools require multiple sensors to measure rotation speed, load, and deflection, leading to increased costs, space requirements, and reduced reliability due to the need for complex integration and labor-intensive repairs.
Innovation Solution
A rotating sensing device with a base, rotating element, magnetic element sets, and magnetic sensing element sets that include axial and radial components, allowing simultaneous measurement of rotation speed, load, and deflection using magnetic variations sensed by Hall sensors or magneto-resistive sensors, enabling efficient data acquisition and fault tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensing elements (rotating encoder, infrared tachometer, pressure sensing device, eddy current sensing device) are integrated into a single sensing module to sense rotation speed, load, and deflection, then the sensing ability is improved, but the arrangement space increases, costs increase, and device complexity increases
Solution Approach 1:
The patent merges multiple sensing functions (rotation speed sensing, load sensing, and deflection sensing) into a single magnetic sensing device. By integrating a rotating encoder for rotation speed, a pressure sensing device for load, and an eddy current sensing device for deflection into one unified sensing module, the patent achieves comprehensive measurement capabilities while reducing the overall number of separate devices needed, thereby managing device complexity despite the multifunctional requirement
Solution Approach 2:
The sensing module is designed as a universal device that can simultaneously perform multiple sensing functions. The single sensing module incorporates multiple sensing elements that can measure rotation speed, load, and deflection concurrently, making it a multi-functional device that replaces what would traditionally require multiple separate sensing devices, thus improving sensing ability while controlling the increase in device complexity
2Measurement precision
If multiple sensing elements are integrated into a single sensing module, then the sensing ability is improved, but the arrangement space increases
Solution Approach 1:
The patent employs a nested structure where multiple sensing elements are arranged concentrically around the rotating element. The rotating encoder, pressure sensing device, and eddy current sensing device are positioned at different radial distances from the rotation axis, allowing them to be packed into a compact cylindrical arrangement. This nesting approach enables comprehensive sensing capabilities while minimizing the overall arrangement space required for the multi-functional sensing module
3Measurement precision
If multiple sensing elements are integrated into a single sensing module, then the sensing ability is improved, but the reliability decreases because the module must be replaced or repaired if one sensor fails
Solution Approach 1:
The patent divides the sensing module into independent, modular sensing elements that can be individually replaced. Each sensing element (rotating encoder, pressure sensing device, eddy current sensing device) is designed as a separate functional unit within the module, allowing selective replacement of only the failed component rather than the entire sensing module. This segmentation maintains high reliability by enabling quick repair while preserving the comprehensive sensing capabilities of the multi-functional design
4Area of stationary object
If the sensing module is arranged in embedding manner, then the arrangement space is reduced, but the repair time and labor costs increase because the rotating element has to be dismantled for replacement and repair
Solution Approach 1:
The patent designs the sensing module with pre-configured access points and removable components that allow repair personnel to reach and replace sensing elements without complete disassembly of the rotating element. The modular structure includes quick-release mechanisms and accessible mounting positions that were prepared in advance, enabling rapid replacement of failed sensors while maintaining the compact embedded arrangement. This preliminary design consideration reduces repair time and labor costs despite the space-saving embedded configuration
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 solution reduces arrangement and repair costs, minimizes space requirements, enhances reliability by allowing single-unit replacement, and accurately measures displacements along both axial and radial directions, improving overall sensing ability and reducing labor costs.
Implementation Method 1
a magnetic variation relative to the axial magnetic element and a magnetic variation relative to the radial magnetic element are respectively sensed by the axial magnetic sensing element and the radial magnetic sensing element, so as to generate a sensing signal
Data Source
AI summary
A rotating sensing device includes a base, a rotating element, at least one magnetic element set, at least one magnetic sensing element set, and a processing unit. The magnetic element set is arranged on the rotating element and includes an axial magnetic element and a radial magnetic element. The magnetic sensing element set is arranged on the base and includes an axial magnetic sensing element and a radial magnetic sensing element. When the rotating element is rotated relatively to the base, a magnetic variation relative to the axial magnetic element and a magnetic variation relative to the radial magnetic element are respectively sensed by the axial magnetic sensing element and the radial magnetic sensing element, so as to generate a sensing signal. The processing unit is adapted to obtain a rotation speed, a loading value, and a deflection value. In addition, a rotating sensing method is also provided.