Sensor for detecting piston axial position

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Discussion Overview

The discussion revolves around detecting the position of a steel piston located beneath a thick steel wall without drilling into the wall. Participants explore various sensor technologies and experimental methods to achieve this, considering factors such as temperature, speed, and external vibrations.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Experimental/applied

Main Points Raised

  • One participant suggests using an inductive sensor but expresses concern that it may always detect the wall instead of the piston.
  • Another participant inquires about the temperature, speed, and oscillation frequency of the piston to better understand the situation.
  • A participant proposes attaching a strong permanent magnet to the piston and using a Hall effect sensor or magnetic compass to detect its position through the wall.
  • There is a question about calculating how much a steel wall dampens the magnetic field of a magnet, with a suggestion that experimentation might be more practical.
  • A participant describes an experimental approach involving a microphone to log output during piston strokes and suggests using filters to identify when the piston passes.
  • Another participant emphasizes the need to characterize the noise produced by the piston passing to develop a specification for detection.
  • One participant mentions considering an Arduino with a Hall sensor and magnet as a potential solution.
  • A participant notes that using an Arduino and Hall sensor is a conventional approach, contrasting it with more unconventional methods.
  • One participant observes that the piston behaves differently during outward and inward travel, noting changes in damping time and asking how to convert this information into a voltage signal.
  • A suggestion is made to use a comparator to detect transients for determining when the piston passes, followed by digitizing the pulse shape for further analysis.

Areas of Agreement / Disagreement

Participants express a range of ideas and suggestions, with no clear consensus on the best approach to detect the piston position. Multiple competing views and methods are presented, and the discussion remains unresolved.

Contextual Notes

Participants mention various factors that could influence detection methods, such as temperature variations, external vibrations, and the differing behavior of the piston during its travel. These factors may complicate the selection of an appropriate sensing technology.

Andrea Vironda
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Hi,
I have a steel piston running below a 3-4 mm thick steel wall.
I'd need to know the piston position below the wall without drilling the wall. I'm thinking to an inductive sensor but I think it will not work because it will detect all the time something in front of him (the fixed wall) despite the fast the piston is moving.
Which other technology could I use to fix this problem? Piston diameter is about 40 mm.
 
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What is the temperature of the piston ?
How fast and far does the piston move ?
Or does the piston oscillate at some frequency ?
 
Hi, the temperature stands between 20-120 °C, the stroke is about 30-40 mm and the speed is not so high (i think around 1" to perform the complete stroke).
There are no oscillations, the stroke is performed around 10 times a hour, but the system is placed receive vibrations from machining. (let's say 30-40 Hz, but few amplitude)
 
Maybe you could fit a strong permanent magnet to the piston.
The position can then be sensed through the wall of the tube with a Hall effect sensor, or a magnetic compass.
 
Is it possible to calculate how much a wall of steel dampers the magnetic field of a magnet?
 
Andrea Vironda said:
Is it possible to calculate how much a wall of steel dampers the magnetic field of a magnet?
Yes, but it might be easier to do an experiment with a magnet and a compass.
 
Here is a description of a research experiment: Fix a microphone of some sort to the wall (close to the piston). Log the output of the microphone over several piston strokes. Experiment with filters until you have something that indicates "Piston is passing".
 
Svein said:
Experiment with filters
Thanks for suggestion. Can you be more clear here?
 
Andrea Vironda said:
Thanks for suggestion. Can you be more clear here?
The whole point of the suggestion is to make you think "outside the box". When you have recorded the noise look if you can see something that tells you "yes, this is where the piston passed". Then try to characterize that noise - is it amplitude, frequency or something else? Then write a specification detailing what to discover. Then ask around how to solve it.
 
  • #10
Interesting, I was thinking to use an Arduino and a Hall sensor plus a magnet I can buy easily online
 
  • #11
Andrea Vironda said:
Interesting, I was thinking to use an Arduino and a Hall sensor plus a magnet I can buy easily online
Yes - that is what is "inside the box".
 
  • #12
I'm not native english, what do you mean for "inside the box"? Thinking like a robot?
 
  • #13
Andrea Vironda said:
I'm not native english, what do you mean for "inside the box"? Thinking like a robot?
Neither am I. "Thinking outside the box" means an unconventional approach. So "thinking inside the box" has to mean using a conventional (or obvious) approach.
 
  • #14
Hi,
I made the proof and I notice the piston behaviour is not the same on the outward and inward travel.
For example the damping time changes.
How can I convert this information in a tension [V] on a machine?
 

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  • #15
Better than I expected! The obvious approach would be to set up a comparator to detect the transients - this will tell you when the piston passes. Then, if you want more information, use an A/D converter to digitize the pulse shape and do some conclusions from that.
 

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