Wireless Piston Position Sensor with Self-Powered Coil
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Solution Overview
Problem
Existing magnetic or inductive sensors for detecting piston positions in working cylinders are cumbersome, require extensive cabling, and are prone to failures due to line breaks, while wireless solutions are costly and inefficient in terms of space and energy usage.
Innovation Solution
A wireless magnetic sensor with a self-sufficient energy supply unit using a permanent magnet and energy converter magnet, which induces voltage in a coil as the piston moves, eliminating the need for cables and enabling compact, cost-effective operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired sensors are used for detecting piston position, then power supply and signal transmission are reliable, but assembly and installation work is extensive and system availability decreases due to line breaks
Solution Approach 1:
The patent extracts the energy supply and signal transmission functions from external cables and integrates them into the sensor housing itself. The coil winding is arranged in the sensor housing to serve dual purposes: as part of the sensing mechanism and as an energy storage unit, eliminating the need for external connection lines and their associated vulnerabilities.
Solution Approach 2:
The coil winding performs multiple functions simultaneously: it acts as both the sensing element for detecting piston position and as an energy storage unit for powering the sensor. This multi-functionality eliminates the need for separate power supply cables and signal transmission lines, reducing device complexity while maintaining reliability.
2Device complexity
If wireless sensors with external energy supply are used, then cabling is eliminated, but space requirements and installation costs increase significantly
Solution Approach 1:
The energy storage coil is nested within the sensor housing structure itself, utilizing the existing spatial arrangement of the sensor components. The coil winding is integrated into the housing in such a way that it occupies minimal additional space while providing sufficient energy storage capacity, avoiding the need for large external conductor loops.
3Reliability
If conventional wired sensors are used, then power and signals can be transmitted reliably, but connection lines represent weak points for failures and tightness issues
Solution Approach 1:
The patent removes the vulnerable connection lines entirely from the system by integrating the energy supply and signal transmission functions directly into the sensor housing. The coil winding serves as both the sensing element and energy storage unit, eliminating external cables that are prone to line breaks and connection failures.
Solution Approach 2:
The sensor becomes self-sufficient by using its own coil winding as the energy storage unit. The system serves itself by generating and storing energy internally through the coil, eliminating dependence on external power supply connections and their associated failure points.
4Device complexity
If wireless sensors with large conductor loops are used for energy supply, then cables are eliminated, but radiated energy is very high and installation costs increase
Solution Approach 1:
The energy storage coil is nested within the compact sensor housing, utilizing the existing magnetic field from the piston magnet efficiently. This nested arrangement creates a tight magnetic coupling that maximizes energy transfer efficiency while minimizing radiated energy, avoiding the high radiation associated with large external conductor loops.
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 reduces assembly and installation work, minimizes downtimes, and allows for complete encapsulation, enhancing system availability and enabling new applications with freely movable sensors, particularly in harsh environments.
Implementation Method 1
When the piston moves, a force is exerted on the energy converter magnet via the piston magnet and the magnetic coupling
Implementation Method 2
When the energy converter magnet, which is designed as a permanent magnet, is displaced within the coil, a voltage U is induced in the coil due to the associated change in magnetic flux dφ/dt
Data Source
Figure 1~3
Figure 4~6b
AI summary
The invention relates to a magnetic or inductive sensor comprising an electronic evaluation unit, wherein a piston of the working cylinder carries a piston magnet designed as a permanent magnet, the position of which can be detected by the evaluation unit, and wherein the evaluation unit can output a signal representing the piston position. To provide an improved sensor that can operate wirelessly, it is proposed that a power supply unit be provided for the evaluation unit, comprising at least one coil and at least one energy converter magnet designed as a permanent magnet, which is displaceable within the coil, and wherein the signal can be transmitted wirelessly from the sensor to a higher-level control system.