Spindle Monitoring Sensor Ring for Accurate Displacement Measurement
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Solution Overview
Problem
Existing spindle monitoring systems face challenges in achieving sufficient measuring accuracy across varying spindle diameters while being cost-effective and environmentally resilient.
Innovation Solution
A measuring system comprising a cylindrical housing with a carrier ring and encapsulated sensors, including eddy-current sensors, that can be securely positioned on spindle housings of different diameters, ensuring optimal protection and accuracy, with electronic modules for data and energy exchange connected via flexible printed circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are positioned on the carrier ring without encapsulation, then the measuring accuracy can be maintained, but the sensors are vulnerable to environmental influences such as moisture, extreme temperature differences, and mechanical and chemical influences
Solution Approach 1:
The sensors are encapsulated in a flexible protective shell that forms a sealed barrier against environmental influences. This encapsulation protects the sensors from moisture, temperature extremes, and chemical exposure while maintaining their measuring functionality and positioning accuracy on the carrier ring.
2Adaptability or versatility
If housings and carrier rings of differing diameters are used to adapt to different spindle diameters, then the system becomes versatile, but the complexity of the measuring system increases
Solution Approach 1:
The measuring system is designed with universal components that can be adapted to different spindle diameters. The carrier ring with encapsulated sensors serves as a universal measuring unit that can be installed in various housing diameters, eliminating the need for completely different sensor assemblies for each spindle size and reducing overall system complexity.
Solution Approach 2:
The system is segmented into modular components: the housing, the carrier ring with sensors, and the electronic module. This segmentation allows the sensor assembly to be standardized and reused across different applications, while only the housing dimensions need to vary to accommodate different spindle diameters.
3Reliability
If electronic modules are distributed over the circumference of the carrier ring, then the system becomes more robust, but the device complexity increases
Solution Approach 1:
Electronic modules are distributed at specific locations around the circumference of the carrier ring, positioned according to their specific functional requirements. This localized distribution optimizes signal quality and functional performance for each sensor type while maintaining a manageable system architecture through systematic arrangement.
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 system provides reliable, high-accuracy monitoring of spindle displacements and tilts across different spindle diameters, protected from environmental influences, ensuring precise measurements with small positioning tolerances and adaptability.
Implementation Method 1
The inner ring consists of a target ring, having axial and radial measuring surfaces, which is mounted on a steel carrier ring. There are three radial and three axial eddy-current sensors
Data Source
AI summary
A measuring system monitors a spindle. The measuring system includes a cylindrical housing which can be arranged in and mechanically firmly connected to a spindle housing. A carrier ring is arranged inside the cylindrical housing. Three sensors for measuring a radial displacement and three sensors for measuring an axial displacement of the spindle are distributed over a circumference of the carrier ring. The sensors are cast with the carrier ring.