Variable Flux Collector Position Sensor Gap Insensitivity
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Solution Overview
Problem
Current magnetic sensors are unable to make repeatable measurements over a long range using a small magnet, as they are limited by the magnet's size and sensitive to variations in the gap between the magnet and the measurement system.
Innovation Solution
A position measurement system using a small magnet and multiple collector plates to concentrate and collect magnetic flux, with a ratio of magnetic sensor signals or a magnetic angle sensor to determine the magnet's position, allowing for measurements across a large range while being insensitive to small variations in the gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a small magnet is used for position measurement, then the device size is reduced, but the measurement range is limited
Solution Approach 1:
The patent divides the magnetic field collection into multiple discrete collector elements arranged in an array. Each collector captures flux from a specific spatial region, and the combined signals from multiple collectors enable determination of magnet position over a range much larger than the magnet dimensions. This segmentation allows the system to achieve long measurement range while using a small magnet.
2Device complexity
If conventional magnetic sensors are used, then the system is simple, but the measurements are sensitive to gap variations
Solution Approach 1:
The patent introduces magnetic collector elements as intermediary components between the magnet and the sensor. These collectors serve as flux conduits that guide and concentrate magnetic flux onto the sensor, creating a more stable flux path that is less sensitive to variations in the gap between the magnet and sensor assembly. This intermediary structure improves reliability while maintaining relative system simplicity.
3Volume of moving object
If a small magnet is used, then the device is compact, but repeatable measurements over long range are not achievable
Solution Approach 1:
The patent transitions from a single-point magnetic field measurement to a distributed array of collectors that sample the magnetic field across multiple spatial dimensions. By processing signals from multiple collectors in an array configuration, the system can determine magnet position with high repeatability over a measurement range that is orders of magnitude larger than the magnet size, effectively adding spatial dimensionality to the measurement capability.
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 repeatable position measurements over a large range using a small magnet, maintaining sensitivity and compatibility with off-the-shelf sensing devices, and reducing the impact of gap variations.
Implementation Method 1
a magnet and several 'collector' plates or collectors. The collectors collect and concentrate the flux on one, or more, magnetic sensors
Implementation Method 2
The first and second variable collectors are positioned to transmit some of the magnetic flux generated by the magnet as the magnet moves along the path
Data Source
AI summary
A magnetically-based position sensor. The sensor includes a magnet assembly that moves along a path, a common collector, one or more magnetic sensing elements, a first variable collector, and a second variable collector. The one or more magnetic sensing elements are coupled to the common collector. The first and second variable collectors are coupled to one of the one or more magnetic sensors and are configured to collect a magnetic field. The first and second variable collectors are positioned to transmit some of the magnetic flux generated by the magnet assembly as the magnet assembly moves along the path. The first variable collector and the second variable collector have a geometry and orientation such that the flux collected by the first and second variable collectors varies as the magnet moves along the path.