Solenoid Plunger Position Detection via Frame Sensor
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Solution Overview
Problem
Conventional solenoid assemblies face challenges in determining and indicating if the plunger has reached the fully extended position, leading to potential misalignment and failure in locking objects, as the plunger end may not align with the locking recess, causing improper operation.
Innovation Solution
A solenoid assembly with a sensor system that detects the position of the plunger end through a frame with specific openings, using a sensor to generate electrical outputs based on the plunger's position, allowing a control system to determine and indicate whether the plunger is properly extended, including a visual indicator for misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional solenoid assembly is used without a sensor system, then the structure remains simple, but the ability to determine plunger position is lost leading to potential misalignment
Solution Approach 1:
A sensor is introduced as an intermediary component between the plunger and the control system. The sensor detects the position of the plunger end relative to the frame opening and converts this physical position information into an electrical signal, enabling precise position measurement without requiring direct mechanical connection or complex mechanical feedback mechanisms.
Solution Approach 2:
The patent replaces potential mechanical position indication systems with an electrical sensing system. Instead of using mechanical linkages, gears, or direct mechanical feedback to indicate plunger position, an optical or electrical sensor is used to detect the presence or position of the plunger end, converting mechanical position into an electrical signal for the control system.
2Reliability
If the plunger end is designed to engage objects without position detection, then the assembly is simpler to manufacture, but misalignment with locking recesses occurs causing improper operation
Solution Approach 1:
The patent implements a feedback mechanism where the sensor continuously monitors the plunger position and provides this information to the control system. The control system can then determine whether the plunger is properly aligned with the locking recess and can take appropriate action, such as indicating misalignment or preventing operation, thereby ensuring reliable locking operation.
Solution Approach 2:
The sensor detects the plunger position in advance before the locking operation is attempted. This preliminary detection allows the control system to verify proper alignment before engagement, preventing misalignment issues and ensuring that the plunger is correctly positioned to engage with the locking recess.
3Loss of information
If no position indication system is implemented, then the device is easier to operate, but there is no way to determine if the plunger is properly extended leading to potential failure
Solution Approach 1:
The sensor provides real-time feedback information about the plunger position to the control system. This feedback loop ensures that the control system has accurate information about whether the plunger is properly extended and aligned, eliminating information loss while maintaining ease of operation through automatic detection and indication.
Solution Approach 2:
The sensor system enables the solenoid assembly to self-monitor its own operational state. The plunger's position automatically triggers the sensor, which then provides position information to the control system without requiring manual checking or external observation, allowing the system to inform itself of its state.
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
Ensures proper operation by accurately determining the plunger's position, preventing misalignment and allowing for proper engagement with objects, thus enhancing the reliability of solenoid assemblies.
Implementation Method 1
A plunger positioned in the passageway moves between different positions as electrical power is applied to the coil. For instance, when electrical power is applied the coil, the plunger moves from a retracted position to an extended position.
Implementation Method 2
A sensor is positioned on the solenoid frame to detect the state of the first plunger end. When the sensor detects the first plunger end extending through the first opening, the sensor generates a first electrical output. If the sensor does not detect the first plunger end, the sensor generates a second electrical output.
Data Source
AI summary
A solenoid assembly includes a solenoid having a coil that defines a passageway and a plunger movable within the passageway from a retracted position to an extended position. The plunger extends along an axis between a first plunger end and an opposite second plunger end. A frame holds the solenoid and has a first opening through which the first plunger end extends when the plunger is in the retracted position and a second opening through second end of the plunger extends when the plunger is in the extended position. When the plunger is in the extended position the first plunger end retracts into the frame via the first opening.