Rotational Angle Sensor Dynamic Range Calibration
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Solution Overview
Problem
Existing rotation angle sensor systems face limitations in resolution and usability due to limited measurement angle intervals, which can lead to incorrect signal interpretation and reduced flexibility in installation positions, especially when dealing with vehicle deflections caused by wear or stone chips.
Innovation Solution
A rotation angle sensor system that maintains internal resolution by using a one-to-one mapping of the digital output signal over a maximum angle interval of 0° to 360°, ensuring uncomplicated signal processing and flexibility in installation positions, with a measurement angle interval that can cover up to 360° without ambiguity and includes a discontinuity only at its edges for clear signal interpretation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the measurement angle interval is limited to a small range (e.g., -45° to +45°), then the resolution of the output signal can be maintained at 2^12 bits, but the system cannot handle excessive vehicle deflections and requires frequent recalibration
Solution Approach 1:
The patent implements a dynamic measurement angle interval that automatically adapts to the actual vehicle deflection range. The system determines the minimum and maximum angles from calibration data and sets the measurement interval dynamically, allowing the sensor to handle both small and large deflections without requiring fixed limited ranges or recalibration
Solution Approach 2:
The system changes the parameter of measurement angle interval based on calibration results. By storing minimum and maximum angles and using them to define the valid output signal range, the system adapts its measurement parameters to match actual vehicle conditions, resolving the contradiction between fixed resolution and variable measurement needs
2Adaptability or versatility
If the measurement angle interval is extended to cover large deflections, then the system can handle excessive vehicle deflections, but the output signal may exceed valid ranges leading to incorrect interpretation
Solution Approach 1:
The system uses calibration feedback to establish the valid output signal range. By determining minimum and maximum angles during calibration and using these values to define the valid signal interval, the system ensures that output signals remain within interpretable ranges while accommodating large deflections, preventing incorrect signal interpretation
Solution Approach 2:
The patent performs preliminary calibration to determine the minimum and maximum angles before normal operation. This preliminary action establishes the valid output signal range in advance, ensuring that during actual operation, even with large deflections, the output signals remain within the pre-determined valid range for accurate interpretation
3Device complexity
If the zero position is fixed during installation, then the output signal can be simplified, but the system lacks flexibility in installation positions and requires precise alignment
Solution Approach 1:
The patent implements a dynamic zero position that is determined during calibration rather than being fixed during installation. The system automatically adapts to the actual installation position by determining the zero angle from calibration data, eliminating the need for precise alignment while maintaining simplified output signal processing through automatic range adjustment
4Measurement precision
If the internal resolution is maintained at high levels, then measurement precision is improved, but data degradation occurs with conventional interfaces due to electromagnetic interference and long cable runs
Solution Approach 1:
The patent extracts only the necessary portion of the high-resolution internal data for output. By determining the valid output signal range based on actual measurement needs and transmitting only this reduced data set, the system maintains high internal resolution for accurate measurement while reducing transmitted data to levels that are immune to electromagnetic interference and cable run degradation
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 allows for full utilization of internal resolution without restricting the measurement angle interval, preventing incorrect signal interpretation and enabling flexible installation and operation, even with excessive vehicle deflections, by ensuring each output signal value corresponds to a specific angle, thus enhancing the system's usability and accuracy.
Implementation Method 1
a magnetic encoder rotates with the motion sensor, and its angular position is detected by a Hall effect sensor or another type of sensor
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a rotational angle sensor system comprising: a rotatably mounted movement sensor; a sensor that is designed to detect a rotation of the movement sensor, wherein the rotation occurs at a measurement angle interval (∆α); an evaluation electronics system designed to receive an analogue signal from the sensor and to digitalise same using an internal resolution, and to emit a digital output signal (D(α)) reporting the rotation detected by the sensor, characterised in that the resolution of the digital output signal (D(α)) for a measurement angle interval (∆α) of less than or equal to 360° is the same size as the internal resolution.