Sealed Wire Position Sensor for Harsh-Environment Linear Measurement
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Solution Overview
Problem
Existing sensors for measuring the position of telescopic arms on construction vehicles are prone to signal degradation due to environmental factors and assembly issues, leading to inaccurate readings and potential contamination of electrical components.
Innovation Solution
A linear distance measuring system is developed with an air-tight compartment housing first, second, and third coils, along with an intermediate cover and cover, which includes a cylindrical protrusion to receive a spool, converting linear motion into a signal while minimizing exposure to environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If potentiometers and gears are used to convert linear motion to signal, then the sensor can measure linear distance, but the gears may move during assembly causing offset and environmental elements can access electric components causing degradation
Solution Approach 1:
The patent replaces the mechanical potentiometer-gear system with an inductive sensor system using coils and a spool. The inductive coils detect the position of the spool through magnetic field changes, eliminating mechanical contact and gear mechanisms that cause offset during assembly and are vulnerable to environmental contamination. This substitution maintains linear distance measurement capability while improving reliability.
Solution Approach 2:
The patent employs an air-tight compartment that encloses the inductive coils and spool assembly. This sealed compartment acts as a protective barrier that prevents environmental elements such as water, sand, and ice from reaching the electric components, thereby preventing signal degradation and maintaining measurement accuracy in harsh environments.
2Ease of manufacture
If the sensor is exposed to the environment for ease of assembly, then assembly is simpler, but environmental factors cause signal degradation and component contamination
Solution Approach 1:
The patent uses an air-tight compartment that seals the inductive sensor components from environmental contamination. The compartment is designed to be sealed around the spool and coils, preventing water, sand, and ice from reaching electrical components while still allowing the sensor to be assembled as a complete unit. This sealing approach protects against harmful environmental factors without complicating the assembly process.
3Ease of manufacture
If the spool is exposed during assembly, then assembly is easier, but the spool position cannot be detected after power removal
Solution Approach 1:
The patent replaces mechanical position indication with an inductive detection system. The coils continuously detect the spool's position through magnetic field changes, and this position information is stored in memory even after power removal. When power is reapplied, the system recalls the stored position data, eliminating the need for the spool to be in a specific position during assembly while maintaining position detection capability.
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 system reduces signal degradation from environmental factors and assembly offsets, providing a reliable, contact-less sensor assembly that maintains accurate measurements.
Implementation Method 1
a first coil, a second coil, a third coil... converting linear motion into a signal
Data Source
AI summary
Methods and systems for generating a signal that is indicative of linear motion in harsh operating environments are described. In one example, signal generating electronics of a sensor are housed in an air-tight compartment to reduce a possibility of signal generation capacity degradation while mechanical components of the sensor are partially shielded from environmental conditions.