Patent Application
20100301846
1. Field of the Invention
This invention is directed to devices for measuring the speed of a rotating shaft using a magnetic speed sensor.
2. Description of the Related Art
Speed sensors for rotating shafts are well known in the art. Historically, such devices required some sort of well-defined geometrical structure around a portion of the shaft, such as teeth or grooves, to produce detectable signals representing a change in a magnetic flux. For example, in U.S. Pat. No. 3,769,533, which discloses an adaptive braking wheel speed sensor mounted near a vehicle differential, the disclosed device uses a toothed ring attached to the rear wheel axle. The teeth are circumferentially spaced on the outside of the ring. An electro-magnetic pick-up device having a U-shaped core member made of magnetic iron extends close to the teeth so the ends of the core member sense when one of the teeth is near the ends (or when one of the intermediate spaces between the teeth is near). As the rear wheel axle turns, so does the ring and its teeth, which generates a pulsed electrical output in the core member, the frequency of which is proportional to the speed of the rotation of the axle.
In U.S. Pat. No. 5,223,760, which also discloses a wheel speed sensor for a drive axle, the disclosed device involves a rotor and circular stator element, each having teeth defining slots formed on the inner face of a the stator element. An axially-poled annular magnet provides a magnetic flux that is sensed with a magnetic flux sensor. The magnetic flux sensor may be a simple multi-turn winding having an axis coincident with the axis of the sensor. The rotor is driven by a shaft and positioned co-axially and nested with the stator elements. The teeth and slots of the elements cooperatively create a time- and position-varying magnetic flux that increases and decreases in the magnetic circuit, indicating the angular velocity of the axle.
These spaced gear teeth in the above patents are magnetized from an external magnetic field source such as those provided by permanent magnets or electromagnets. When magnetized, the gear teeth rotate with the shaft to which they are attached, and produce a sinusoidal-shaped electrical output (voltage) signal which can be processed. A Hall sensor, fluxgate sensor, or the like, is mounted proximate to the gear teeth to receive the fluctuating magnetic field. Though useful, such devices are known to be difficult and expensive to manufacture, as discussed in, for example U.S. Pat. No. 6,203,464.
It is therefore desirable to have a speed sensor for a rotating shaft that does not require any projections, indentations, teeth, grooves or other physical manifestations or alterations and thus can be fabricated relatively fast and in a cost-effective manner.
It is a principle object of the present invention to provide a speed sensing devices for measuring the speed of a rotating shaft using a high resolution, cost effective and fast fabrication magnetic speed sensor.
It is another object of the present invention to provide a shaft that does not require a separate element which is affixed to the shaft, projects away from the surface of the shaft, or is in relief or sunken-relief relative to the surface of the shaft, for generating a dynamic magnetic flux.
It is still another object of the present invention to provide a fabrication method for a rotating shaft speed sensor by simply rotating a shaft and using strong magnetic signals from paired magnets which inject strong, local, gradient magnetic fields onto the shaft.
It is yet another object of the present invention to provide a fabrication method that is less expensive and requires less time to manufacture compared to prior art geared or teeth devices.
Still another object of the invention is to provide a method for making a speed sensor made from a shaft of generally homogeneous chemical composition throughout, having separate active and passive regions having magnetic properties appropriate for its respective function by endowing each such region with magnetic properties appropriate for its respective function.
Briefly described, the above and other objects and advantages of the present invention are accomplished, as embodied and fully described herein, by a method for forming a magnetic speed sensor for a rotatable shaft including the steps of forming a plurality of magnetic portions on the shaft, the magnetic portions capable of outputting a magnetic field detectable by at least one magnetic field sensor as the shaft rotates; and positioning the at least one magnetic field sensor near the shaft for outputting a signal corresponding to the angular speed of the shaft as the shaft rotates, wherein the magnetic portions are integrally formed in the shaft by magnetically polarizing the shaft material itself.
The method includes the step of providing the shaft, a portion of which is first endowed with a magnetic polarization directed substantially in a circumferential direction. The plurality of magnetic portions are approximately equally spaced apart magnetic portions that produce substantially the same or different external magnetic fields. The spaced apart magnetic portions are approximately equally spaced apart at pre-determined angles around the shaft, which may be 5, 10, 15, 30, 45, 60, 90 and 120 degrees apart. Each of the plurality of magnetic portions are formed using a magnetic pair that is positioned close to the shaft at each of the locations of the magnetic portions for a pre-determined time period.
The above and other objects and advantages of the present invention are also accomplished, as embodied and fully described herein, by a method for operating an angular speed sensor.
The objects and advantages of the present invention are further accomplished, as embodied and fully described herein, by an apparatus for determining the speed of a rotating shaft, the apparatus including plurality of magnetic portions on a shaft that output a magnetic field from each of the plurality of magnetic portions, wherein the plurality of magnetic portions are integrally formed in the shaft by magnetically polarizing the shaft material itself The apparatus also includes at least one magnetic field sensor positioned proximate to the shaft for detecting the magnetic field from each of the plurality of magnetic portions and for outputting a signal corresponding to the angular speed of the shaft as the shaft rotates. The apparatus further includes a computation means for calculating the angular speed value of the shaft, and a display device for displaying the calculated speed value. The shaft may be part of a vehicle or other useful device.
Several preferred embodiments of the present invention are described for illustrative purposes, it being understood that the invention may be embodied in other forms not specifically shown in the drawings. The figures will be described with respect to the structure and functions that achieve one or more of the objects of the invention and/or receive the benefits derived from the advantages of the invention as understood by persons skilled in the art or explicitly set forth herein.
Turning first to
As indicated by the double arrow, the paired magnets 110a, 110b and single magnet 110c may be moved toward and away from the shaft 105. In a first, or initial, position, the magnets are positioned about 5 inches from the surface of the shaft 105 such that the magnetic fields from the magnets would not reach to the shaft 105. In the figures, the magnets 110a, 110b, 110c are shown in a second position. In the second position, the magnets have been advanced toward the surface of the shaft 105 and are held in place there. In that position, the magnets may be as close as 0.5 mm relative to the surface of the shaft 105, or they may actually touch the shaft 105. When moved toward the surface of the shaft 105, the magnets 110a, 110b, 110c move at a rate of about 1 to 3 inches per second. When moved away from the surface of the shaft 105, the magnets move at the same or a different rate.
The magnets 110a, 110b, 110c (collectively “110”) may be NdBFe magnets that preferably have a magnetic strength of about 42 MOe or higher.
The poles of the magnets 110 are such that the magnetic flux emanating from the north pole of the magnet 110a closest to the shaft 105 enters the south pole of the magnet 110b closest to the shaft 105. Likewise, to close the magnetic circuit, the flux emanating from the other end of the magnet 110b enters the other end of the magnet 110a. The same thing occurs in the case of a single magnet 110c, but the magnetic flux emanating from the north pole closest to the shaft 105 enters the south pole of the magnet 110c at the other end.
In this way, at least a portion of the shaft 105 is locally magnetically polarized due to it being in the path of the magnetic flux from the magnets 110. Any number of these magnetic spots 115 may be generated on and into the shaft 105 by the rotation of the shaft 105 relative to the magnets 110 (in their second position closest to the shaft) or by the repositioning of the magnets 110 relative to the surface of the shaft 105.
The general approach to magnetizing a shaft is taught in, for example, U.S. Pat. No. 5,351,555 and U.S. Pat. No. 5,520,059, which describe how the crystalline and magnetic nature of ferromagnetic materials are susceptible to being magnetized by a permanent magnet or an electro-magnet, thereby endowing the ferromagnetic material with a remanent magnetization. As noted in those disclosures, the shaft 105 does not have to be purely iron, as other materials may be included in the shaft 105, including alloy substances and substances that increase or decrease the ability of the material to hold a remanent magnetization.
Turning to
To further illustrate, in
The shaft 105 is initially prepared by remanently magnetizing it in a circumferential direction, as taught in, for example, U.S. Pat. No. 5,351,555 and U.S. Pat. No. 5,520,059. The material that is not circumferentially magnetized may become reactively magnetized from other magnetic sources, including the magnetic portions 115, and thus become a source of parasitic fields. The entire cross-section of the shaft 105 does not need to be circumferentially magnetized. This is because the torsional shear stress applied at the outer surface of the shaft 105 is reduced as the distance from the surface to the axis of the shaft 105 increases, and thus the relative potential contribution to the magnetic flux signal from the more central regions of the shaft 105 are minimal. Thus, it is only necessary to circumferentially magnetize the shaft 105 to a depth, in a small diameter shaft, of about 50-percent of the radius of the shaft 105.
Even if deeper regions of the shaft 105 were to develop field intensities at their location, the contribution from those deep location fields to the field intensity observed at the location where the external field sensor 130 is positioned, which is some distance radially outward from the surface of the shaft 105, would be substantially reduced and minimal. Thus, even in very large shafts, the circumferential magnetization deeper than 10-20 mm would provide little benefit. In many hollow shafts, penetrations to such depths would reach to the inside surface. This would be a desirable condition for hollow shafts, especially for thin wall hollow shafts, since they are made hollow in order to more efficiently use the available material strength and to reduce weight. If all of the shaft cross section is transmitting useful torque, it would make sense to have all of the cross section contribute to generating a detectable signal field rather than have some of it detract from the signal field and then contribute to the parasitic fields. As a practical matter, however, it is extremely difficult to magnetize to a depth greater than about 1-2 mm, even on large diameter shafts, because it is difficult to generate a strong enough magnetic field so far from the magnetic field source.
The same factors discussed above also reduce the capability of deeply interior, non-circumferentially magnetized regions to produce significantly troublesome parasitic fields at “distant” field sensors. Thus, while it is desirable to circumferentially magnetize the shaft 105 to a desirable depth, the fact that the rest of the shaft contains random local magnetizations, some of which may not be oriented circumferentially, is of no importance to the operation of the present invention for speed sensing purposes.
As shown in
Magnetization in this way can place more localized magnetic spots 115 on the shaft 105 than using the single magnet 110c as shown in
Another method of magnetization is placing the paired magnets as shown in
This external flux may be detectable using, as noted above, a fluxgate sensor 130. The amount of the external field produced by each of the individual magnetic spots 115 should be approximately equal, but this is not required. The actual field strength is less important, because it is the time between peak signals that is important in terms of monitoring the speed of the shaft 105.
The dimensions of the magnetic spots 115 are defined first in the radial direction z, from the outer surface 135 of the shaft 105 to an annular depth dl, which depth is dependant on the strength of the magnets 110, as noted above. In the axial direction, the magnetic spot 115 is defined by the approximate width d2, which may be approximately the width of the permanent magnet pair 110, but could be wider or narrower. As noted above, this dimension could be about 5 mm, if two 2-mm wide magnets are used and spaced about 1 mm apart. Those of ordinary skill in the art will appreciate that the physical dimensions of the magnetic spot 115 could vary from one magnetic spot 115 to another on the same shaft 105, and they do not have to have the same curved polyhedron shape as depicted in the figure (which is for illustration purposes only). Indeed, the solid lines depicting the extent of the magnetic spots 115 in the shaft 105 in
Also, the shaft 105 does not have to have a uniform diameter along its axial direction, but could have a varying diameter along the length of the shaft 105. For example, the magnetized spots 115 could taper to a diameter that is less than the diameter of the rest of the shaft 105. The shaft 105 could also have a step increase or decrease in its diameter at an axially-extending portion relative to the rest of the shaft 105. As noted above, the shaft 105 may also be thin-walled (hollow).
Because the shaft 105 may undergo an applied torque in its rotating state (i.e., the drive axle of a vehicle during operation), the magnetized spots 115 must possess some source of anisotropy to return the magnetization to the established (during the polarization process) direction when the torque is reduced to zero, otherwise, the polarization may be degraded over time after repeated applications of torque. The degradation may be measured by the degree of the external magnetic field sensed by the field sensor 130. The anisotropy may be inherent in the nature of the crystalline material making up the shaft 105 (i.e., crystalline anisotropy), or may be imparted in the shaft 105 by any one of several physical treatment processes known in the art.
To ensure a symmetrical “spring back” response to both clockwise and counter-clockwise torques, or from other forces applied to an end of the shaft 105, the distribution of the local magnetizations should predominantly lie in the desired direction, though not all of the local magnetizations must be flipped in that direction during the aforementioned magnetization process. All that is required is that a sufficient number of the local magnetizations be in the desired direction in order for the leaking flux from those portions to sufficiently exceed (1) any parasitic fields arising from portions of the shaft 105 that are not magnetized in the manner described above, (2) any external fields from nearby field-generating sources (near sources); and (3) any background fields from distant sources. In order to cancel out such noise effects in (1), (2), and (3) above, an oppositely oriented fluxgate sensor coil S2 is placed just close (˜5 mm) to the fluxgate sensor coil S1 which measures speed signal as shown in
Turning now to
Turning now to
Thus, if the shaft 105 in the example above had a circumference, C, of 1 unit and the magnetic field sensor 130 detected six peaks corresponding to the six magnetic spots 115 during a time period, T, equal to 1 second, the average angular speed of the shaft at the end of the time period T would be C/T or 1 unit/sec. If twelve peaks were detected at the end of the second period, 2T, or 1.5 seconds (i.e., 1 second for the first rotation and 0.5 second for the second rotation), the average angular speed of the shaft at the end of the second time period would be calculated from 2C/2T or (2 units)/(1.5 sec)=1.33 units/sec. Of course, instantaneous or near real-time calculations could be made after each peak is detected (the calculations would not be quasi real-time because of the slight delay in detecting the peak signal and processing the signal in the system control circuit (not shown). The above calculations may be done by a computational subsystem, which includes a printed circuit board having at least specific logic circuits, software, a memory device, and a power source. The calculated angular speed values may be stored in memory for later downloading to another device.
The specific calculations performed by the subsystem are described generally above. Expressed as an algorithm, they would include the steps of receiving from a user or embedded in a memory a value representing the circumference of the shaft and/or the angle between the magnetic spots; receiving the signal from the magnetic field sensor in the form of, for example, a voltage; processing the signal using conditioning circuits as needed; determining the time at which a peak signal was detected at the magnetic field sensor; determining the time at which a second peak signal was detected at the magnetic field sensor; adjusting the time values to account for environmental conditions, device-specific factors, lag time, or any other factor that would affect the calculations; calculating the interval of time between the peaks; retrieving the circumference and/or angle value between the plurality of magnetic spots for the shaft; calculating the angular speed; storing and/or outputting the calculated value; and repeating all or some of the above steps. The stored values may be overwritten by more recent calculated values such that only the most recent value is stored in the memory.
The graph in
The output signal from the magnetic field sensors S1, S2, 130, 150, and 155 according to the present invention could be in the form of an amount of voltage relative to ground. The signal may be processed using known signal conditioning circuits (not shown) to produce a signal useful, for example, displaying a real-time speed value on a display device indicating the actual or average angular speed of the shaft 105, or the speed of another object attached to the shaft 105 (e.g., a vehicle wheel, gear, steering column, drive shaft, auger shaft, propeller, etc.). The signal may also be used as an input to a speed regulating device (e.g., a braking system), or as input to a system monitoring device (e.g., as part of a computerized system for determining a maintenance schedule).
Although certain presently preferred embodiments of the disclosed invention have been specifically described herein, it will be apparent to those skilled in the art to which the invention pertains that variations and modifications of the various embodiments shown and described herein may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention be limited only to the extent required by the appended claims and the applicable rules of law.
This application is related to and claims priority to U.S. Provisional Appl. 61/182,783, filed Jun. 1, 2009, the content of which is incorporated herein.
| Number | Date | Country | |
|---|---|---|---|
| 61182783 | Jun 2009 | US |
