Wireless Clamp Position Sensing With Energy-Harvesting Microswitches
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional position detection devices for clamps are hindered by the short lifespan due to cutting lubricants and require extensive wiring and space, which can lead to unreliable operation and safety issues when clamp positioning is not precise.
Innovation Solution
A wireless position detection device utilizing battery-less energy harvesting microswitches with RF capabilities, eliminating the need for wires and allowing for compact, reliable, and sealed operation, with three equally offset microswitches and antennas to detect piston rod positions effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional limit switches are used for position detection, then position detection function is achieved, but the lifespan is shortened due to cutting lubricants and installation area is increased
Solution Approach 1:
The patent replaces conventional mechanical limit switches with magnetic sensors that detect the position of a detecting rod through magnetic field interaction. This substitution eliminates mechanical contact points that are vulnerable to cutting lubricants, thereby extending the device lifespan while maintaining compact dimensions suitable for constrained installation areas.
Solution Approach 2:
The patent employs a sealed housing structure with thin wall formations that protect the magnetic sensor components from external contaminants including cutting lubricants. The sealed design allows the sensor to operate reliably in harsh machining environments without requiring large protective enclosures, thus extending lifespan while minimizing installation area.
2Reliability
If conventional limit switches with wiring are used, then position detection is achieved, but device complexity and installation space are increased
Solution Approach 1:
The patent replaces wired mechanical limit switches with wireless magnetic sensors that communicate position data electronically. This eliminates the need for complex wiring harnesses and routing to controller enclosures, reducing device complexity while maintaining operational reliability through contactless magnetic field detection.
Solution Approach 2:
The magnetic sensor system integrates multiple functions including position detection, signal processing, and wireless communication within a single compact unit. This multi-functionality eliminates the need for separate wiring connections and external controller interfaces, thereby reducing overall system complexity while ensuring reliable operation.
3Reliability
If sealed clamp design is used to prevent liquid ingress, then reliability is improved, but positioning precision may be compromised
Solution Approach 1:
The patent employs a sealed housing with precision-engineered wall formations that create protected chambers for the magnetic sensor components. These seals prevent liquid and debris ingress while maintaining the magnetic field transmission necessary for accurate detecting rod position measurement, thus preserving positioning precision within the sealed environment.
Solution Approach 2:
By using magnetic field-based detection instead of mechanical contact sensors, the system can achieve precise positioning measurements through the sealed housing walls without requiring physical access points that would compromise the seal. The magnetic fields penetrate the non-magnetic sealed structure, enabling accurate position detection while maintaining protection against contaminants.
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 solution provides a reliable, cost-effective, and compact position detection system that maintains device integrity and prevents liquid and debris ingress, ensuring precise clamp positioning without the need for batteries or extensive wiring.
Implementation Method 1
The microswitches generate their own energy by the physical movement of the switch lever, and for transmission of certain RF signals
Implementation Method 2
energy harvesting radio frequency (RF) switches. Each of the switches is connected to an independent antenna wherein each antenna fits within an antenna tube
Data Source
AI summary
A position detecting device having a clamp body with a movable piston rod. A plurality of energy harvesting microswitches is mounted along a bottom of the piston rod using pin actuators to operate each microswitch depending on the piston rod position. The piston rod has a plurality of cutouts constructed and arranged to engage said pin actuators upon actuation of each microswitch, indicating a position which is transmitted wirelessly through the antenna. The antenna used to transmit a signal upon activation of a microswitch.