Sensor Pressure Plate Prevents Galling in Clamping Grooves
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Solution Overview
Problem
Existing position sensors face challenges in secure and permanent fixation within anchoring grooves, leading to potential overloading and galling issues due to high compressive forces and rotational movements during clamping, especially when used in fluid-actuated drives.
Innovation Solution
Incorporation of a pressure plate between the clamping unit and the sensor housing, which distributes compressive forces and serves as a pivot bearing, preventing material deformation and galling by reducing surface pressure and transmitting forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the clamping unit directly presses on the sensor housing, then the clamping force is transmitted effectively, but the sensor housing is subjected to local overloading and galling due to high compressive forces and rotational movement
Solution Approach 1:
A pressure plate is introduced as an intermediary component between the clamping unit and the sensor housing. This pressure plate distributes the compressive forces over a larger area and serves as a pivot bearing during rotational movement, preventing direct contact between the clamping unit and sensor housing, thereby avoiding local overloading and galling while maintaining effective force transmission.
Solution Approach 2:
The pressure plate creates a localized zone of force distribution at the contact point between the clamping unit and sensor housing. By concentrating the force distribution function in this specific local area, the sensor housing material is protected from high-stress concentrations that would otherwise occur at the direct contact interface.
2Ease of operation
If the actuating part rotates directly against the sensor housing, then the clamping unit can be activated, but galling occurs between the actuator and sensor housing due to high friction and rotational movement
Solution Approach 1:
The pressure plate serves as a pivot bearing that mediates the rotational movement between the actuating part and the sensor housing. During activation, the actuating part rotates against the pressure plate rather than directly against the sensor housing, reducing friction and preventing galling while still enabling effective activation of the clamping unit.
Solution Approach 2:
The introduction of the pressure plate changes the friction characteristics and contact parameters at the rotation interface. By providing a dedicated bearing surface with appropriate material properties, the friction coefficient and wear rate are reduced, enabling smooth rotational activation without galling.
3Ease of manufacture
If the sensor housing material is soft to allow easy clamping, then installation is easier, but the material deforms under high compressive forces reducing clamping effectiveness
Solution Approach 1:
The pressure plate acts as a mediator that protects the sensor housing material from direct high-compression contact. This allows the use of softer, more easily installed materials in the sensor housing while the pressure plate (made from more compression-resistant material) bears the brunt of the compressive forces, preventing material deformation and maintaining clamping effectiveness.
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 pressure plate ensures secure and permanent fixation of the sensor, prevents material deformation, and maintains clamping force integrity by distributing compressive forces and reducing surface pressure, thereby enhancing the durability and reliability of the sensor housing.
Implementation Method 1
the pressure plate, which in turn rests on the floor that delimits the recess and is part of the main part of the housing, so that the sensor housing with its lower part Support surface is pressed against the groove base of the anchoring groove
Implementation Method 2
the pressure plate can also serve in a double function as a pivot bearing for the actuating part, which is designed as a screw, for example. During a clamping movement, the actuating part is rotated around the vertical axis
Implementation Method 3
the clamping unit, which serves to clamp the sensor in an anchoring groove and is supported on the bottom of the recess, is arranged
Data Source
Figure 1~1a
Figure 2~2a
Figure 3~4
AI summary
The sensor (2) has an actuating part downward supported at bottom of a recess (44) without a threaded engagement. A clamping part and the actuating part are rotated at a rotational axis (58) relative to a sensor housing and relative to each other. The actuating part is downwardly supported at the bottom of the recess without the threaded engagement. The clamping part is moved in a clamping position by rotational actuation of the actuating part. A pressure plate (90) is arranged between the clamping unit and the sensor housing and made of metallic or ceramic material. The pressure plate is formed as a plane-parallel plate. An INDEPENDENT CLAIM is also included for a working device comprising a working unit and a sensor.