Sensor Coupler for Piston-Cylinder Position Detection
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Solution Overview
Problem
Existing position sensing technologies for piston-cylinder assemblies face challenges due to high hydraulic fluid pressure, which can damage sensors and make it difficult to accurately determine the piston's position, especially when the sensor is housed within the assembly.
Innovation Solution
A sensor coupler with a first and second end member, connected by cables, is used to transmit position signals from the piston-cylinder assembly to a sensor positioned outside the cylinder, utilizing a biasing member to maintain contact and absorb vibrations, and a telescopic enclosure to protect cables from fluid leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is housed within the piston-cylinder assembly, then the sensor can directly detect piston position, but the sensor is exposed to high hydraulic fluid pressure which can damage it
Solution Approach 1:
A sensor coupler assembly acts as an intermediary between the sensor and the high-pressure hydraulic environment. The coupler includes a first end member with a port that communicates with the cylinder chamber, and a second end member that interfaces with the sensor, allowing position detection while isolating the sensor from damaging pressures
Solution Approach 2:
The sensor is extracted from the high-pressure zone inside the piston-cylinder assembly and positioned outside through the port. The sensor coupler enables the sensor to read indicia on the piston rod while being housed in a low-pressure environment, separating the sensing function from the high-pressure actuation environment
2Object-affected harmful factors
If the sensor is positioned outside the piston-cylinder assembly, then the sensor is isolated from high pressure, but the sensor must be connected through a port which complicates the structure
Solution Approach 1:
The sensor coupler is divided into distinct segments: a first end member that interfaces with the cylinder port, a second end member that interfaces with the sensor, and a biasing member that connects them. This segmentation allows each component to perform its specific function while maintaining overall simplicity
Solution Approach 2:
The biasing member provides a dynamic connection between the first and second end members, allowing the coupler to accommodate movements and maintain contact force without rigid constraints. This dynamic element simplifies the connection while ensuring reliable signal transmission
3Adaptability or versatility
If the sensor coupler uses cables to transmit signals, then the sensor can be positioned remotely, but the cables are vulnerable to transverse movements and fluid leakage
Solution Approach 1:
The biasing member provides pre-compression force to the cable assembly, cushioning it against transverse movements and preventing excessive bending or pulling. This prior cushioning protects the cable from damage due to vibrations and movements before they can cause failure
Solution Approach 2:
The sensor coupler assembly acts as a protective intermediary for the cable, providing mechanical support and isolation from the harsh hydraulic environment. The coupler structure shields the cable from direct exposure to high-pressure fluid and physical damage
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 effectively isolates the sensor from high pressure, allows for accurate piston position detection, and enables the use of various sensor types, while being retro-fittable and adaptable to different piston-cylinder assembly configurations.
Implementation Method 1
The sensor coupler further includes a biasing member to connect the first end member and the second end member
Implementation Method 2
The one or more cables are configured to transmit signals indicative of a position of a piston in the piston-cylinder assembly to the sensor
Data Source
AI summary
A sensor coupler adapted to operatively connect a sensor to a piston-cylinder assembly. The sensor coupler includes a first end member and a second end member. The first end member is disposed on a port of the piston-cylinder assembly, in communication with the sensor, and the second end member is disposed in a cylinder chamber of the piston-cylinder assembly. Further, one or more cables are extending between the first end member and the second end member. The one or more cables are configured to transmit signals indicative of a position of a piston in the piston-cylinder assembly to the sensor. The sensor coupler further includes a biasing member to connect the first end member and the second end member.