Sensor Assembly Position Error Detection via Clearing Size Control
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Solution Overview
Problem
Existing sensor arrangements for position measurement lack high error reliability, particularly in systems where multiple sensors are used to determine absolute positions, leading to potential errors and inaccuracies in position detection.
Innovation Solution
A sensor arrangement with two independently operating sensor systems, each with a position sensor and a cooperative target, calculates position measurements to a common clearing size, allowing for continuous control and error detection through setpoint comparison, enhancing functional reliability by accounting for inevitable measured value fluctuations within a tolerance band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple position sensors are used to determine absolute positions, then measurement coverage and redundancy are improved, but error reliability and accuracy deteriorate due to potential errors and inaccuracies in position detection
Solution Approach 1:
The control unit continuously monitors the clearing size calculated from multiple position sensors and compares it against a predetermined setpoint value. This feedback mechanism enables real-time detection of measurement errors and deviations, allowing the system to identify when sensor readings become inaccurate while maintaining the benefits of multiple sensors for redundancy and coverage.
Solution Approach 2:
The invention transforms the verification approach by changing the parameter being monitored from individual sensor readings to the derived clearing size. By calculating the clearing size from multiple sensor measurements and comparing this composite parameter against a setpoint, the system achieves error detection without sacrificing the redundancy benefits of multiple sensors.
2Reliability
If continuous control and error detection are implemented through setpoint comparison, then functional reliability is improved, but system complexity increases
Solution Approach 1:
The control unit performs multiple functions: it processes position data from multiple sensors, calculates the clearing size, compares the result against a setpoint, and detects errors. This multi-functionality approach consolidates error detection capabilities within the existing control unit rather than adding separate dedicated verification systems, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The system uses its own existing infrastructure (control unit, communication interfaces, and processing capabilities) to perform error detection and verification. The control unit leverages its normal operational data flow to simultaneously conduct safety monitoring, making the system self-verify without requiring external or additional dedicated verification hardware.
3Reliability
If two independently operating sensor systems are used, then error detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The system divides the monitoring function into two independent sensor systems that each contribute to the clearing size calculation. This segmentation allows error detection through comparison of the combined result against the setpoint, while maintaining independence of the sensor systems for enhanced reliability without requiring a fully redundant dual-system architecture.
Solution Approach 2:
The invention merges the outputs of two independent sensor systems into a single clearing size parameter that can be verified against a setpoint. This combining approach allows the benefits of multiple independent sensors (error detection capability) to be achieved while consolidating the verification logic into a single comparison operation, reducing overall system 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 sensor arrangement achieves high functional reliability by ensuring error-free operation through continuous control of the clearing size, reducing the risk of errors and maintaining accurate position detection even with fluctuations, thereby improving overall system safety.
Implementation Method 1
an optical sensor with a light-emitting transmitter and a light-receiving receiver
Implementation Method 2
whereby the distance measurement can be performed according to the phase measurement principle or with a pulse-time-of-flight method
Implementation Method 3
with a pulse-time-of-flight method
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a sensor arrangement (1) comprising a first position sensor (4a) and an associated first cooperative target, which define a detection range. First position measurements are obtained by the first position sensor (4a) relative to the first cooperative target. Furthermore, a second position sensor (4b) and an associated second cooperative target are provided, which define the detection range. Second position measurements are obtained by the second position sensor (4b) relative to the second cooperative target. The function of the position sensors (4a) is controlled by a control unit (7), in which the first and second position measurements of the two position sensors (4a, 4b) are processed into a single value.