Track Rail End-Surface Sensor Mounting for Full Stroke Travel

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Solution Overview

Problem

The existing sensor mounting structures for rolling guide devices limit the stroke range of the moving member and complicate the mounting and removal of sensors, making maintenance difficult, especially when retrofitting existing systems.

Innovation Solution

A sensor mounting structure that fixes a sensor holder to the end surface of the track rail, using a base plate and an elastically deformable holding plate to securely attach and easily remove a sensor casing, allowing interference-free movement of the moving member and facilitating maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the sensor is fixed to the side surface or upper surface of the track rail, then the sensor can detect operational changes, but the sensor and moving member interfere with each other, limiting the stroke range

Engineering Contradiction:

Improvesensor detection capabilityVSAvoidstroke range of moving member

Core Design Contradiction:

Measurement precisionVSLength of moving object

Solution Approach 1:

The sensor is relocated from the side/upper surface to the end surface of the track rail, changing the mounting dimension. This spatial repositioning allows the sensor to detect vibrations along the longitudinal axis without interfering with the moving member's stroke range, as the end surface is positioned outside the moving member's operational path.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If the sensor is fixed to the side surface or upper surface of the track rail, then the sensor can be mounted, but the sensor must be specially removed for maintenance of the moving member

Engineering Contradiction:

Improvesensor mountingVSAvoidmoving member maintenance

Core Design Contradiction:

Ease of manufactureVSEase of repair

Solution Approach 1:

The sensor mounting structure is segmented into a sensor holder (fixed to the track rail) and a sensor unit (removable from the holder). This segmentation allows the sensor to be easily removed from the holder without affecting the track rail or moving member, facilitating maintenance while keeping the mounting structure simple.

Inventive Principle:

Principle #1Segmentation

3Length of moving object

If the sensor is fixed to the end surface of the track rail, then the moving member can move freely, but the sensor cannot be easily removed for maintenance

Engineering Contradiction:

Improvestroke range of moving memberVSAvoidsensor removal and maintenance

Core Design Contradiction:

Length of moving objectVSEase of repair

Solution Approach 1:

The sensor mounting structure is divided into a fixed sensor holder attached to the track rail end surface and a removable sensor unit. This segmentation enables the sensor to be easily detached from the holder for maintenance while the holder remains fixed, ensuring both free movement of the moving member and ease of sensor maintenance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The sensor holder has a localized pressing structure that applies elastic force only to the sensor unit, allowing the sensor to be securely held during operation but easily removed when needed. This localized quality ensures the sensor is firmly positioned for accurate detection while enabling simple maintenance access.

Inventive Principle:

Principle #3Local quality

4Reliability

If a rigid mounting structure is used to fix the sensor, then the sensor is securely attached, but the mounting structure is complex and difficult to assemble

Engineering Contradiction:

Improvesensor attachment securityVSAvoidmounting structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mounting structure uses elastic deformation of the pressing portion instead of rigid fastening mechanisms. By changing the parameter from rigid to elastic, the structure achieves secure sensor attachment through simple elastic force, reducing complexity while maintaining reliability. The pressing portion's elasticity provides sufficient holding force without requiring complex locking mechanisms.

Inventive Principle:

Principle #35Parameter changes

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

Enables the sensor to be mounted and removed without limiting the stroke range of the moving member, ensuring easy maintenance and effective detection of operational changes in the rolling guide device.

Implementation Method 1

another end formed as a free end elastically deformable with respect to the base plate, the holding plate being configured to press the sensor casing toward the end surface of the track rail by the free end

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS11319996B2Sensor attachment structure for roller guiding device

Publication Date: 2022.05.03 THK CO LTD

AI summary

Provided is a sensor mounting structure for a rolling guide device, which enables easy mounting and removal of a sensor of a type among various types with respect to the track rail, the sensor mounting structure including: a sensor holder to be fixed to an end surface of the track rail in a longitudinal direction of the track rail; and a sensor casing to be held on the track rail by the sensor holder, the sensor holder including: a base plate to be fixed to the end surface of the track rail, and a holding plate having one end continuous with the base plate as a fixed end, and another end formed as a free end elastically deformable with respect to the base plate, the holding plate being configured to urge the sensor casing toward the end surface of the track rail by the free end.