Wireless Magnetic Sensor for Remote Jig Control

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Solution Overview

Problem

Conventional jig control systems in automobile production require workers to be physically close to the jigs, posing safety risks and involving inconvenient wired magnetic sensors that require frequent replacements due to wire disconnections.

Innovation Solution

A remote jig control system utilizing wireless magnetic sensors that transmit state information via zigbee communication, allowing user terminals to connect via Wi-Fi and BLE for secure and efficient control of air pressure actuators, eliminating the need for physical proximity and reducing wiring issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wired magnetic sensors are used for jig control, then the sensor can detect the position of air pressure actuator, but the wiring job is inconvenient and wire disconnections occur frequently requiring sensor replacement

Engineering Contradiction:

Improvesensor reliabilityVSAvoidinstallation convenience

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts the wiring connection from the magnetic sensor system by implementing a wireless magnetic sensor that transmits detection signals without physical wire connections. This eliminates the wiring job and wire disconnection issues while maintaining the position detection function of the magnetic sensor.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical wiring connection system with a wireless communication system. The magnetic sensor communicates with the control panel through wireless signals (such as radio frequency communication) instead of electrical wires, eliminating the need for physical connections and associated maintenance issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If workers are positioned close to the jig to control clamps, then they can monitor the air pressure actuator position, but they are exposed to safety risks and hassles

Engineering Contradiction:

Improvecontrol accessibilityVSAvoidworker safety risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a wireless communication system as an intermediary between the magnetic sensor on the jig and the control panel. This allows workers to control the jig from a safe distance while maintaining full monitoring and control capabilities through wireless data transmission, eliminating the need for physical proximity to hazardous areas.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical approach of physical monitoring and manual control with an automated wireless monitoring and control system. The system automatically transmits position data wirelessly and enables remote control operations, allowing workers to operate from safe distances without direct exposure to moving parts and high-pressure actuators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If wired magnetic sensors are installed in the jig, then the sensor can detect actuator position, but frequent wire disconnections require frequent sensor replacement increasing maintenance costs

Engineering Contradiction:

Improveposition detection accuracyVSAvoidsensor maintenance frequency

Core Design Contradiction:

Measurement precisionVSEase of repair

Solution Approach 1:

The patent extracts the physical wire connection from the sensor system, implementing a wireless magnetic sensor that maintains position detection accuracy without requiring wire connections. This eliminates wire disconnections and the associated frequent sensor replacements, significantly reducing maintenance frequency while preserving measurement precision.

Inventive Principle:

Principle #2Taking out (Extraction)

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 safe and efficient remote monitoring and control of jigs, reducing the need for frequent sensor replacements and minimizing wiring complications, thereby enhancing operational safety and reducing maintenance costs.

Implementation Method 1

a magnetic detector configured to detect a current position of the air pressure actuator

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Data Source

PatentUS10493599B2System and method for remotely controlling jig using wireless magnetic sensor

Publication Date: 2019.12.03 SUN HST CO LTD

AI summary

A remote jig control system may comprise a jig configured to place a car body to a particular position, a wireless magnetic sensor installed in the jig, a control panel wirelessly connected with the wireless magnetic sensor via first wireless communication to receive state information about the jig from the wireless magnetic sensor, a gateway connected with the control panel via the first wireless communication to receive the state information, a user terminal connected with the gateway via second wireless communication to receive the state information; and monitoring server configured to receive the state information from the gateway and store the state information, wherein the control panel is configured to be controlled through the user terminal to generate a jig control signal corresponding to the state information.