Sensor Assembly With Movable Target for Contactless Teach-In
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor arrangements face challenges in calibration due to the need for complex and costly power line routing through the housing for teach-in processes, especially in harsh environments, and require external tools like screwdrivers for actuation, which can be unreliable and increase production costs.
Innovation Solution
A sensor arrangement with a movable target outside the housing that acts as a mechanical actuator for a contactless teach-in element within the housing, eliminating the need for external tools and power line routing, and ensuring the sensor is calibrated without exposing the internal components to the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power lines are routed from outside the housing to the teach-in element inside the housing, then the teach-in element can be actuated from outside, but the housing requires complex sealing and opening routes resulting in high production costs
Solution Approach 1:
The patent replaces the mechanical electrical connection system (power lines and cable seals) with a contactless electromagnetic field-based teach-in element. The teach-in element is designed as a capacitive or inductive sensor that can be actuated by external objects through the housing wall without physical contact or electrical connections, thereby eliminating the need for complex power line routing and sealing.
2Ease of operation
If the housing is provided with openings for power line passage, then the teach-in element can be actuated externally, but the openings must be sealed off resulting in complicated and expensive production
Solution Approach 1:
The patent extracts the teach-in element as a separate functional component within the housing that operates independently of external electrical connections. By designing the teach-in element to respond to external objects through electromagnetic or capacitive coupling through the housing wall, the need for openings and associated sealing structures is completely eliminated, simplifying the housing to a simple enclosed structure.
3Ease of repair
If a separate handling tool like a screwdriver is used to actuate the teach-in element, then calibration can be performed, but the user must have special tools available and a defined approach is required which cannot always be guaranteed
Solution Approach 1:
The patent enables the teach-in element to be actuated by common objects that users already have available, such as keys, coins, or other metallic objects, eliminating the need for special handling tools like screwdrivers. The capacitive or inductive teach-in element responds to the presence of these everyday objects, allowing calibration to be performed during normal installation without requiring users to obtain or learn to use specialized tools.
4Ease of manufacture
If the teach-in element requires contactless actuation through the housing, then production costs are reduced, but the actuation must be reliable without external tools
Solution Approach 1:
The patent optimizes the parameters of the teach-in element (such as capacitance value, inductance, or sensitivity thresholds) to ensure reliable detection of common objects like keys or coins at appropriate distances. By carefully tuning these parameters, the system achieves robust and consistent actuation response to everyday objects while maintaining the contactless, tool-free operation that eliminates complex housing modifications.
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
Simplifies the calibration process, reduces production costs by eliminating the need for fluid-tight power cable routing, and enhances reliability by using a defined mechanical actuator that can be easily integrated into the housing, providing effective protection against environmental conditions.
Implementation Method 1
The additional sensor is arranged inside the housing and designed as a teach-in element for contactless calibration of the sensor. The target is designed to be movable outside the housing and is connected to the housing, so that the additional sensor can be actuated with the target as a teach-in element by moving the target.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The sensor arrangement (1) has a housing (4), a sensor (2), and an auxiliary sensor (3) and a target (6), where the sensor or a section of the sensor is arranged within the housing. The auxiliary sensor is arranged within the housing and is formed as a teach-in element for contact-less calibration of the sensor. The target is movably carried out outside the housing and is connected with the housing, so that the auxiliary sensor is actuated as teach-in element by a movement of the target. The housing is formed of plastic, stainless steel, aluminum or brass.