Tension Element Position Sensor Modular Housing Design
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Solution Overview
Problem
Existing tension element position sensors face challenges in using tension bands, requiring complex assembly, large housing spaces, and varying pullout lengths, with existing solutions being cumbersome and risky to assemble, especially when using multi-turn scanning mechanisms.
Innovation Solution
A modular housing design with three axial components, including a center housing with a pass-through for the winding drum, a lateral housing for the spiral spring, and another for the rotation angle sensor, allowing preassembly and easy integration of a spring motor and magnetic field-sensitive sensors, enabling flexible production of sensors with different pullout lengths and redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the spiral spring is arranged directly in the interior of the winding drum, then the housing becomes axially short, but assembly becomes more difficult and requires sufficiently large free space
Solution Approach 1:
The housing is divided into three separate axial components: a first housing component containing the rotation angle sensor, a second housing component containing the winding drum, and a third housing component containing the spiral spring. This segmentation allows each component to be assembled independently and then joined together, avoiding the assembly difficulties that would arise from trying to assemble all components within a single compact housing.
2Ease of manufacture
If the cable is wound in one layer on the winding drum, then processing is simplified, but the housing requires sufficiently large free space
Solution Approach 1:
The patent transitions from a single-layer cable winding arrangement to a multi-layer band winding arrangement in the radial plane. This dimensional change allows the tension element to be wound in multiple layers, reducing the axial space required while maintaining the simplified processing benefits of a structured winding pattern.
3Adaptability or versatility
If magnetic field direction sensitive angle sensors are used, then multi-turn scanning capability is achieved, but additional measures and complexity are required
Solution Approach 1:
The patent replaces complex mechanical multi-turn scanning mechanisms with a magnetic field direction sensitive angle sensor that detects the rotation of a magnet coupled to the winding drum. This substitution eliminates the need for additional mechanical components and measures while achieving the same multi-turn scanning capability through magnetic field detection.
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
Facilitates quick, risk-free assembly and production of position sensors with various tension elements and pullout lengths using pre-fabricated sub-assemblies, ensuring reliable operation even during power outages, and allows for different sensor configurations with minimal components.
Implementation Method 1
magnetic field direction sensitive angle sensors have been added in which a magnet with its pole axis transversal to the rotation axis of the winding drum is coupled with the winding drum and the rotation of the magnetic field is detected
Data Source
AI summary
The tension element position sensor includes three housing elements, wherein the two outer housing elements are configured pot shaped with a base towards a center housing component, wherein one element is the spring motor and the other is the rotation angle sensor. Thus the rotation angle sensor includes two Hall sensors, wherein an encoder magnet rotates as a function of the rotation of the winding drum opposite to the faces of the Hall sensors on the face side of one respective gear of two gears meshing with one another. Herein the arrangement of the gears and circuit boards in the receiver of this lateral housing component is of particular importance. Also the spring motor can be completely preassembled and stored in a closed manner.