Wiegand Wire Position Sensor with Hall Interpolation
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Solution Overview
Problem
Existing position measurement devices for linear and rotary applications are limited by the need for expensive low-power components and complex systems to minimize battery usage, which restricts fine position resolution and flexibility.
Innovation Solution
A position sensor system using a long track of spaced magnets with a detector that counts incremental distances and interpolates magnetic flux between magnets, employing digital and analog sensors, and a processor to provide both coarse and fine position resolution, allowing for 'infinite length' measurement with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If expensive low-power components (non-volatile memory, very low power gate arrays) are used to minimize battery usage, then power consumption is reduced, but device cost increases and complexity increases
Solution Approach 1:
The position sensing system is divided into two independent subsystems: a fine position sensing system using Hall sensors for high-resolution measurement, and a coarse position sensing system using Wiegand wires for integer position tracking. This segmentation allows each subsystem to be optimized independently, eliminating the need for expensive low-power integration while maintaining overall system efficiency
Solution Approach 2:
The coarse position sensing system using Wiegand wires serves dual functions: it provides integer position counting and simultaneously powers the electronic management unit through generated electrical pulses. This multi-functionality eliminates the need for separate power management components, reducing both cost and complexity
2Reliability
If a self-powered position determining system is implemented using coarse position sensing to power fine position sensing, then external power supply is eliminated, but fine position resolution is limited
Solution Approach 1:
The system separates fine position sensing (Hall sensors) from coarse position sensing (Wiegand wires), allowing the fine position subsystem to achieve high resolution without being constrained by power limitations of self-powered architectures
Solution Approach 2:
The system changes the operational parameters by using a battery-powered architecture, which removes the power consumption constraints that limit fine position resolution in self-powered systems. This allows the use of higher-resolution Hall sensors and more sophisticated processing algorithms
3Duration of action of moving object
If non-volatile memory and low-power components are used to minimize battery usage, then battery life is extended, but component cost increases
Solution Approach 1:
The coarse position sensing system using Wiegand wires generates electrical pulses that power the electronic management unit, creating a self-service power architecture. This eliminates the need for expensive low-power components and non-volatile memory, reducing component cost while maintaining operational efficiency
Solution Approach 2:
The Wiegand wire system performs dual functions of position counting and power generation, eliminating the need for separate power management components and reducing overall system cost
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 accurate fine position determination up to 0.003 inch with a 64-bit number, capable of measuring distances of 1.455 EE 14 miles, using less expensive components and optimizing battery life by minimizing power consumption.
Implementation Method 1
a fine position signal detector that measures signal strength between at least one adjacent pair of positional signal emitters
Data Source
AI summary
An absolute position sensor having a detector with a plurality of Wiegand wire sensors that each have a pair of Hall sensors bracketing or straddling the Wiegand wire used by a processor in interpolating relative ratios of signals from the bracketing Hall sensors in not only providing increased fine position determination between magnets but also providing coarse position count increment or decrement verification. Such an absolute position sensor provides increased fine position determination accuracy while also enhancing increment and/or decrement error prevention and/or correction during position sensor operation.