Slide Operating Device Dead Zone Sensor Protection
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Solution Overview
Problem
Conventional fader devices with linear scales experience malfunctions due to excessive travel of the operating knob or unexpected sensor position, leading to incorrect signal output and high costs associated with reference position detection.
Innovation Solution
Incorporation of dead zones on the linear scale outside the stopper points, making the sensor insensitive to positions beyond the stopper limits, preventing unexpected signal output and ensuring accurate control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor portion is made massive to improve detection stability, then the detection stability is improved, but the sensor portion can travel to unexpected positions due to momentum when the stopper is extruded
Solution Approach 1:
The patent extracts the harmful effect by introducing dead zones that exclude the unexpected position travel region from the detection range. The dead zone removes the magnetic markings in the region where the sensor might travel due to momentum, thereby extracting the harmful signal generation from the system.
Solution Approach 2:
The patent converts the harmful momentum-driven travel into a beneficial feature by designing dead zones that intentionally create insensitive regions. The sensor's massive nature and potential for momentum-driven travel are converted into a design feature where the dead zones ensure that any such travel results in no signal output, transforming a potential fault into a protective mechanism.
2Reliability
If conventional reference position detection sensors are added to prevent malfunction, then the malfunction prevention is improved, but the device cost increases
Solution Approach 1:
The patent makes the existing sensor portion multi-functional by designing it to serve both normal detection operations and malfunction prevention through the dead zone mechanism. The same sensor that detects position during normal operation also benefits from the dead zone protection during abnormal conditions, eliminating the need for separate reference position detection sensors.
Solution Approach 2:
The patent implements self-service by allowing the existing sensor portion and dead zone structure to work together to prevent malfunctions without requiring additional dedicated sensors or complex reference position detection systems. The system uses its own components in a novel configuration to achieve protection against the problems they were originally designed to detect.
3Ease of operation
If the operating knob is allowed to travel freely to improve ease of operation, then the ease of operation is improved, but the stopper can be extruded causing excessive count
Solution Approach 1:
The patent applies beforehand cushioning by pre-establishing dead zones in the regions beyond the stopper positions. These dead zones act as a protective cushion that absorbs any potential harmful effects from stopper extrusion or excessive travel, ensuring that even if the stopper is breached, the sensor will not generate incorrect signals due to the insensitive regions.
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
Prevents malfunction by ensuring the sensor does not output incorrect signals even if the stopper is extruded or the sensor travels unexpectedly, maintaining accurate control and reducing costs by eliminating the need for high-cost reference position detection.
Implementation Method 1
a magnetic sensor composed of an MR element is mounted to a moving block, while a magnetic pattern in which a north pole and a south pole are alternately arranged is applied as markings to one of paired parallel guides
Data Source
AI summary
A slide operating device (e.g., fader device of a mixer) has a moving block 5 which is slidable along a moving guide 3 and a secondary moving guide 4. The moving guide 3 is composed of a non-magnetic stainless shank 31 and a scale portion 32 formed by magnetizing a permanent magnetic member to have magnetic poles (markings). The moving block 5 is provided with a magnetic sensor 7 opposed to the scale portion 32. The magnetic sensor 7 senses magnetic poles provided on the scale portion 32. Mounting hardware 11A, 11B are provided as stoppers which stop a lever 6a of an operating knob 6. Areas outside a range sandwiched between the stoppers where the magnetic sensor 7 is allowed to travel are dead zones 3A, 3B which do not have magnetic poles. Even if the magnetic sensor 7 travels beyond the points where the operating knob 6 is expected to stop due to an excessive force exerted on the operating knob, the slide operating device can prevent from keeping abnormal count which could be caused by sensing of magnetic poles by the magnetic sensor 7.