Wireless Magnetic Cylinder Sensor with Kinetic Energy Harvesting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic cylinder sensors for detecting piston positions in industrial robots face challenges such as complex and time-consuming cable installations, high failure rates due to line breaks, and inefficiencies in wireless solutions like inductive coupling, which are costly and space-intensive.
Innovation Solution
A compact, wireless magnetic cylinder sensor with a self-sufficient energy supply using a kinetic energy generator that converts relative movement between a permanent magnet and an energy generator into electrical energy, eliminating the need for cables and enabling wireless signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wireless sensors are operated using inductive coupling via huge conductor loops, then wireless operation is achieved, but the system requires a lot of space, has high installation and costs, and induces eddy currents in metal parts
Solution Approach 1:
The sensor generates its own operating energy through the kinetic energy of the moving piston, eliminating the need for external power supply infrastructure like conductor loops. The energy generator converts mechanical movement directly into electrical energy, making the sensor self-sufficient and avoiding the space-consuming wireless infrastructure.
2Ease of operation
If electrical storage capacitors are used for wireless transmission, then wireless signal transmission is achieved, but the system requires complex charging infrastructure and has low switching frequency
Solution Approach 1:
The sensor continuously generates its own operating energy through the kinetic energy of the moving piston via the energy generator, eliminating the need for external charging infrastructure and enabling high switching frequencies limited only by the mechanical response of the piston-cylinder system.
3Reliability
If connection lines are used to supply power and transmit signals, then the sensor can be powered and communicate, but the installation is very material and time-consuming and line breaks cause frequent failures
Solution Approach 1:
The sensor generates its own operating energy through the kinetic energy of the moving piston, eliminating the need for connection lines for power supply. The wireless transmission of position signals removes the need for signal cables, thereby eliminating installation complexity and the risk of line breaks.
4Ease of manufacture
If a compact sensor design is used, then assembly and installation work is reduced, but the sensor requires a self-sufficient energy supply to eliminate cables
Solution Approach 1:
The energy generator converts the kinetic energy of the moving piston directly into electrical energy, providing a self-sufficient power supply within the compact sensor housing. This eliminates the need for external power connections while maintaining a compact design suitable for integration into the piston or cylinder.
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
This solution reduces assembly and installation work, increases system availability, and allows for more flexible sensor placement, with improved reliability and reduced downtimes, while enabling complete encapsulation for harsh environments and higher switching frequencies.
Implementation Method 1
means for converting the kinetic energy that results from a relative movement between the permanent magnet and the energy generator when the piston moves, into electrical energy
Implementation Method 2
the signal is sent wirelessly from the sensor to a higher-level controller
Data Source
Figure 1~2
Figure 3~4
AI summary
The sensor (20) has an electronic evaluation unit (26) for magnetically detecting a piston position and delivering a signal, which represents the piston position. An energy generator (28) supplies energy to the evaluation unit. The generator has a converting unit for converting kinetic energy into electrical energy, where the kinetic energy is produced during movement of the piston by a relative movement between a permanent magnet (22.1) and the generator. A transmission unit (30) wirelessly transmits the signal from the sensor to a higher-level controller or other sensors.