A segmented ladder transformer type linear displacement sensor

Abstract

The present invention discloses a segmented step transformer linear displacement sensor, comprising a housing guide tube assembly, a coil assembly and a butterfly spring housed within the housing guide tube assembly, a rear cover fixedly connected to the rear end of the housing guide tube assembly, a filler injected into the interior of the housing guide tube assembly to secure the coil assembly, and a circular electrical connector fixedly connected to the rear end of the housing guide tube assembly. The coil assembly comprises a coil frame, on which a plurality of spacer rings are spaced to separate the coil frame into a plurality of partitions. The sensor has the advantages of high control accuracy, high reliability, miniaturization, low power consumption, strong anti-interference capability, no human reading error, easy installation, and reliable use. It solves the problems of large winding space requirements, step-like sensor output voltage, asymmetric coil resistance, poor insulation, high-temperature welding burns to the wires, and high output accuracy commonly encountered in domestic large-stroke linear displacement sensors.

Description

Technical Field

[0001] The present invention relates to a segmented ladder transformer type linear displacement sensor, belonging to the technical field of linear displacement sensors. Background Art

[0002] With the widespread use of full-authority digital control (FADEC) systems in engine control systems, their performance in all aspects has significantly surpassed that of traditional mechanical and hydraulic control systems. Linear displacement sensors are a core component of FADEC systems. As one of the primary signal conversion elements, their role and status in control systems are becoming increasingly important. They offer advantages such as high control accuracy, high reliability, miniaturization, low power consumption, strong anti-interference capabilities, no human reading errors, easy installation, and reliable use. They are currently widely used in aviation, shipbuilding, and some specialized electronic control fields. However, common domestic large-stroke linear displacement sensors currently suffer from issues such as large winding space requirements, step-like sensor output voltage, asymmetric coil resistance, and high output accuracy. Summary of the Invention

[0003] The present invention aims to provide a segmented step transformer linear displacement sensor. This sensor offers the advantages of high control accuracy, high reliability, miniaturization, low power consumption, strong anti-interference capability, no human-induced reading errors, easy installation, and reliable operation. It addresses common problems in domestic large-stroke linear displacement sensors, such as large winding space requirements, step-like sensor output voltage, asymmetric coil resistance, poor insulation, high-temperature welding burns to the wires, and high output accuracy.

[0004] The technical solution of the present invention is: a segmented step transformer type linear displacement sensor, including a shell guide tube assembly, a coil assembly and a butterfly spring are installed in the shell guide tube assembly, the tail of the shell guide tube assembly is fixedly connected to a rear cover, the inside of the shell guide tube assembly is poured with filler to fix the coil assembly, and the rear end of the shell guide tube assembly is also fixedly connected to a circular electrical connector, the coil assembly includes a coil frame, and a plurality of spacer rings are arranged at intervals on the coil frame to separate it into multiple partitions.

[0005] In the aforementioned segmented step transformer type linear displacement sensor, the coil assembly also includes an enameled round copper wire, which is wound on the coil frame by a segmented step winding method. Each partition corresponds to a coil, forming an interlaced primary coil and secondary coil structure. During winding, the primary coil and the secondary coil are wound separately in segments.

[0006] In the aforementioned segmented step transformer linear displacement sensor, the secondary coil includes a secondary coil I and a secondary coil II superimposed on each other. When the total number of winding layers of the secondary coil I and the secondary coil II is n, the number of winding layers of the secondary coil I from left to right or from right to left gradually decreases from n-1 to one layer, and the number of winding layers of the secondary coil II is just opposite to that of the secondary coil I. During the step winding process of the secondary coils I and II, with the middle primary coil as the symmetry point, the secondary coil II on one side is wound first, and then the secondary coil I is wound from the other end. After the secondary coil I is wound, the secondary coil II on the other side is wound.

[0007] In the aforementioned segmented step transformer type linear displacement sensor, the coil frame is made of special engineering plastic PEEK.

[0008] In the aforementioned segmented step transformer type linear displacement sensor, the shell guide tube assembly includes a front cover plate, a shell outlet tube assembly and a guide tube assembly installed therein, the shell outlet tube assembly includes a shell and an outlet tube, the guide tube assembly includes a guide tube, a guide tube plug is fixed in the guide tube, the coil frame is sleeved on the outside of the guide tube assembly, and the coil assembly also includes a connecting rod assembly, which is inserted into the guide tube. During assembly, the guide tube assembly is first assembled into the shell guide tube assembly and fixed, and then the coil assembly is installed on the guide tube in the shell guide tube assembly.

[0009] In the aforementioned segmented step transformer linear displacement sensor, each layer of enameled round copper wire is isolated with a polyimide film silicone pressure-sensitive tape, and then each layer of enameled round copper wire is fixed with silicone insulating varnish. Then, a polytetrafluoroethylene insulated light cable is welded to the enameled round copper wire with solder and then led out. The led-out part of the polytetrafluoroethylene insulated light cable is protected with a Teflon heat shrink tube, the welded part is insulated with a polytetrafluoroethylene tube, and the welded part of the enameled round copper wire is fastened with an alkali-free glass fiber rope and then fixed with high-temperature resistant epoxy glue; then the magnetic tube is inserted into the outside of the coil frame, and magnetic rings are connected to both ends of the coil frame.

[0010] Beneficial effects of the present invention: Compared with the prior art, the present invention has the following advantages:

[0011] 1. As attached Figure 6 As shown in the figure, the sensor coil frame is changed from an integrated structure to a segmented structure (corresponding spacer rings are added in the middle part of the coil frame). Under the same winding method, the segmented coil frame structure isolates each section of the coil, avoiding the problems of winding edge collapse and axial movement, greatly improving the winding accuracy of the coil assembly, and thus improving the output accuracy of the sensor.

[0012] 2. As attached Figure 7As shown, compared with the traditional integrated coil frame structure, the coil frame and the guide cylinder are separated. During assembly, the guide cylinder assembly is first assembled into the shell guide cylinder group and welded and fixed, and then the coil assembly is installed on the guide cylinder in the shell guide cylinder assembly. This avoids the damage to the winding insulation layer of the coil assembly caused by the high temperature of welding during the assembly of the integrated coil frame structure, which leads to product failure. While ensuring the insulation of the coil assembly, it improves the output accuracy of the sensor and reduces the product scrap rate.

[0013] 3. As attached Figure 7 As shown, the coil frame is made of special engineering plastic PEEK. Compared with traditional metal coil frames, it reduces the need for insulation treatment on the coil frame surface during winding. While ensuring structural strength and temperature resistance, it also avoids scratches on the enameled round copper wire by the metal coil frame during winding, ensuring the insulation of the coil assembly.

[0014] 4. As attached Figure 8 As shown in the figure, the winding method of the coil assembly adopts a new segmented stepped combined winding structure. Compared with the traditional primary and secondary stacked coil structure, the primary coil and the secondary coil are wound separately in segments, and the secondary coil 1 and the secondary coil 2 are wound in steps. This solves the problems of spatial voltage step in the sensor, uneven magnetic field distribution, and large winding space, and improves the output accuracy of the sensor while ensuring the refined structure of the sensor.

[0015] 5. As attached Figure 8 As shown, when winding the coil assembly, the front half of the secondary coil 2 is wound first, and then the second half of the secondary coil 2 is wound after the secondary coil 1 is wound. This winding method ensures that the secondary coil 1 and the secondary coil 2 are completely symmetrical, thereby ensuring the symmetry of the resistance of the secondary coil 1 and the secondary coil 2.

[0016] In summary, the sensor has the advantages of high control accuracy, high reliability, miniaturization, low power consumption, strong anti-interference ability, no human reading error, easy installation and reliable use. It solves the problems of large winding space requirements, step jumps in sensor output voltage, asymmetric coil resistance, poor insulation, high welding temperature burning wires, and large output accuracy in common domestic large-stroke linear displacement sensors. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a structural schematic diagram of the present invention;

[0018] Figure 2 It is a structural diagram of the shell guide cylinder assembly;

[0019] Figure 3 It is a structural diagram of the shell outlet barrel;

[0020] Figure 4 It is a structural diagram of the guide cylinder assembly;

[0021] Figure 5 It is a structural diagram of the coil assembly;

[0022] Figure 6 It is a structural diagram of the segmented coil former;

[0023] Figure 7 It is a structural diagram of the cooperation between the guide cylinder and the coil frame;

[0024] Figure 8 It is a schematic diagram of the segmented stepped winding structure;

[0025] Figure 9 This is a schematic diagram of the specific winding structure of the secondary coil.

[0026] Figure numerals: 1. Shell guide tube assembly; 2. Coil assembly; 3. Back cover; 4. Butterfly spring; 5. Circular electrical connector; 6. Cylindrical head screw with safety hole on the head; 7. Filler; 8. Front cover; 9. Shell outlet barrel assembly; 10. Guide barrel assembly; 11. Shell; 12. Outlet barrel; 13. Guide barrel; 14. Guide barrel plug; 15. Magnetic ring; 16. Coil frame; 17. Magnetic barrel; 18. Connecting rod assembly; 19. Enameled round copper wire; 20. High-temperature resistant epoxy adhesive; 21. Polytetrafluoroethylene insulated light cable; 22. Polyimide film silicone pressure-sensitive tape; 23. Solder; 24. Polytetrafluoroethylene tube; 25. Alkali-free glass fiber rope; 26. Teflon heat shrink tubing; 27-spacer ring, 28-primary coil, 29-secondary coil, 30-secondary coil I, 31-secondary coil II. DETAILED DESCRIPTION

[0027] The present invention will be further described below with reference to the accompanying drawings and examples, but they are not intended to limit the present invention.

[0028] Embodiment: A segmented ladder transformer type linear displacement sensor is mainly composed of a shell guide cylinder assembly 1, a coil assembly 2, a shell outlet cylinder assembly 9, a guide cylinder assembly 10, a connecting rod assembly 18, etc.

[0029] As attached Figure 1 As shown, during assembly, the coil assembly 2 is installed into the housing guide cylinder assembly 1, the butterfly spring 4 is installed into the housing guide cylinder assembly 1, and the back cover 3 is installed into the housing guide cylinder assembly 1 and welded to fix; filler 7 is poured into the housing guide cylinder assembly 1 to fix the coil assembly 2; the circular electrical connector 5 is press-fitted into the hole of the housing guide cylinder assembly 1; and the circular electrical connector 5 is tightened with a cylindrical head screw 6 with a safety hole on the head.

[0030] As attached Figure 2 As shown, the housing guide barrel assembly is mainly composed of a front cover plate 8, a housing outlet barrel assembly 9, and a guide barrel assembly 10.

[0031] During assembly, first press the front cover plate 8 into the housing outlet barrel assembly 9 and then weld and fix it; then press the guide barrel assembly 10 into the hole of the front cover plate 8 and weld and fix it.

[0032] As attached Figure 3 As shown, the housing outlet barrel assembly mainly consists of a housing 11 and a wire outlet barrel 12.

[0033] During assembly, the wire barrel 12 is mounted on the housing 11 and then fixed by welding.

[0034] As attached Figure 4 As shown, the guide tube assembly is mainly composed of a guide tube 13 and a guide tube plug 14.

[0035] During assembly, the guide tube plug 14 is pressed into the guide tube 13 and then fixed by welding.

[0036] As attached Figure 5 As shown, the coil assembly mainly consists of a magnetic ring 15, a coil frame 16, a magnetic cylinder 17, a connecting rod assembly 18, an enameled round copper wire 19, a high-temperature resistant epoxy adhesive 20, a polytetrafluoroethylene insulated light cable 21, a polyimide film silicone pressure-sensitive tape 22, solder 23, a polytetrafluoroethylene tube 24, an alkali-free glass fiber rope 25, and a Teflon heat shrink tube 26.

[0037] During assembly, the enameled round copper wire 19 is wound on the coil frame 16 by a segmented step winding method, and each layer of enameled round copper wire 19 is isolated by a polyimide film silicone pressure-sensitive tape 22, and then each layer of enameled round copper wire 19 is fixed with silicone insulating varnish, and then the polytetrafluoroethylene insulated light cable 21 is welded to the enameled round copper wire 19 by solder 23 and then led out. The lead-out part of the polytetrafluoroethylene insulated light cable 21 is protected by a Teflon heat shrink tube 26, and the welded part is insulated and protected by a polytetrafluoroethylene tube 24, and the welded part of the enameled round copper wire 19 is fastened with an alkali-free glass fiber rope 25, and then fixed with a high-temperature resistant epoxy glue 20; then the magnetic cylinder 17 is installed on the coil frame 16, and the magnetic ring 15 is transferred to both ends of the coil frame 16. During the test, the coil frame 16, the magnetic ring 15 and the connecting rod assembly 18 are installed on the guide cylinder assembly for performance testing.

[0038] As attached Figure 6 As shown, the coil frame 16 is changed from an integrated structure to a segmented structure, and a corresponding spacer ring 27 is added in the middle part of the coil frame 16 to divide the coil frame 16 into multiple partitions. Under the same winding method, the segmented coil frame structure isolates each section of the coil, avoiding the problems of winding edge collapse and axial movement, greatly improving the winding accuracy of the coil assembly 2, and thus improving the output accuracy of the sensor.

[0039] As attached Figure 7As shown, compared with the traditional integrated coil frame structure, the coil frame 16 is separated from the guide tube 13. During assembly, the guide tube assembly 10 is first assembled into the shell guide tube assembly 1 and welded and fixed, and then the coil assembly 2 is installed on the guide tube 13 in the shell guide tube assembly 1. This avoids the damage to the winding insulation layer of the coil assembly 2 caused by the high temperature of welding during the assembly of the integrated coil frame structure, resulting in product failure. While ensuring the insulation of the coil assembly 2, it improves the output accuracy of the sensor and reduces the product scrap rate.

[0040] As attached Figure 7 As shown, the coil frame 16 is made of special engineering plastic PEEK. Compared with traditional metal coil frames, the surface insulation treatment of the coil frame 16 is reduced during winding. While ensuring structural strength and temperature resistance, it also avoids scratching of the enameled round copper wire by the metal coil frame during winding, thereby ensuring the insulation of the coil assembly 2.

[0041] As attached Figure 8 As shown, the coil assembly 2 utilizes a novel segmented and stepped combined winding structure. Enameled round copper wire 19 is wound around the coil former 16 using a segmented and stepped winding method. Each segment corresponds to a coil, forming a staggered arrangement of primary coils 28 and secondary coils 29. During winding, the primary coils 28 and secondary coils 29 are wound separately and segmented.

[0042] As attached Figure 9 As shown, the secondary coil 29 includes a secondary coil I30 and a secondary coil II31 that are superimposed on each other. When the total number of winding layers of the secondary coil I30 and the secondary coil II31 is n, the number of winding layers of the secondary coil I30 from left to right or from right to left gradually decreases from n-1 to one layer, and the number of winding layers of the secondary coil II31 is just opposite to that of the secondary coil I30. During the step-winding process of the secondary coils I30 and II31, the middle primary coil 28 is used as the symmetry point, and the secondary coil II31 on one side is wound first, and then the secondary coil I30 is wound from the other end. After the secondary coil I30 is wound, the secondary coil II31 on the other side is wound.

[0043] Attach Figure 9For example, when the total number of winding layers of secondary coil I30 and secondary coil II31 is 5, the number of winding layers of secondary coil I30 from left to right is 4 layers, 3 layers, 2 layers, and 1 layer, while the number of winding layers of secondary coil II31 from left to right is 1 layer, 2 layers, 3 layers, and 4 layers, ensuring the total number of winding layers is 5. During the step winding process of secondary coils I30 and II31, with the middle primary coil 28 as the symmetry point, the 4th layer and then the 3rd layer of secondary coil II31 on the left are wound first. Then, starting from the right end, the 4th layer and the 3rd layer of secondary coil I30 are wound. 2 layers of secondary coil I30 and 1 layer of secondary coil I30 are wound on the 4th layer and the 3rd layer of secondary coil II31 respectively. Finally, the secondary coil II31 is wound on the wound secondary coil I30 on the right, ensuring the total number of layers of the secondary coils is consistent.

[0044] Compared with the traditional primary and secondary stacked coil structure, the present invention winds the primary coil 28 and the secondary coil 29 separately in sections, and the secondary coil I30 and the secondary coil II31 in steps, which solves the problems of spatial voltage step, uneven magnetic field distribution, and large winding space in the sensor, and improves the output accuracy of the sensor while ensuring the refined structure of the sensor.

[0045] When winding the coil assembly 2, the front half of the secondary coil II31 is wound first, and then the secondary coil I30 is wound. After the secondary coil I30 is wound, the second half of the secondary coil II31 is wound. This winding method ensures that the secondary coil I30 and the secondary coil II31 are completely symmetrical, thereby ensuring the symmetry of the resistance of the secondary coil I30 and the secondary coil II31.

Claims

1. A segmented ladder transformer type linear displacement sensor, characterized in that: The invention comprises a shell guide tube assembly (1), wherein a coil assembly (2) and a butterfly spring (4) are installed in the shell guide tube assembly (1), a rear cover (3) is fixedly connected to the tail of the shell guide tube assembly (1), a filler (7) is poured into the interior of the shell guide tube assembly (1) to fix the coil assembly (2), and a circular electrical connector (5) is also fixedly connected to the rear end of the shell guide tube assembly (1), and the coil assembly (2) comprises a coil frame (16), and a plurality of spacer rings (27) are arranged on the coil frame (16) to separate it into a plurality of partitions; The coil assembly further includes an enameled round copper wire (19), which is wound on the coil frame (16) by a segmented step winding method, with each segment corresponding to a coil, forming a structure of staggered primary coils (28) and secondary coils (29), and the primary coils (28) and the secondary coils (29) are wound separately in segments during winding. The secondary coil (29) includes a secondary coil I (30) and a secondary coil II (31) that are stacked together. When the total number of winding layers of the secondary coil I (30) and the secondary coil II (31) is n, the number of winding layers of the secondary coil I (30) from left to right or from right to left gradually decreases from n-1 to one layer, and the number of winding layers of the secondary coil II (31) is just opposite to that of the secondary coil I (30). During the step winding process of the secondary coils I (30) and the secondary coil II (31), the middle primary coil (28) is used as a symmetrical point, and the secondary coil II (31) on one side is wound first, and then the secondary coil I (30) is wound from the other end. After the secondary coil I (30) is wound, the secondary coil II (31) on the other side is wound.

2. The segmented ladder transformer type linear displacement sensor according to claim 1, characterized in that: The coil frame (16) is made of special engineering plastic PEEK.

3. The segmented ladder transformer type linear displacement sensor according to claim 1, characterized in that: The shell guide barrel assembly (1) includes a front cover (8), a shell outlet barrel assembly (9), and a guide barrel assembly (10) installed therein. The shell outlet barrel assembly (9) includes a shell (11) and an outlet barrel (12). The guide barrel assembly (10) includes a guide barrel (13). A guide barrel plug (14) is fixedly inserted into the guide barrel (13). The coil frame (16) is sleeved on the outside of the guide barrel assembly (10). The coil assembly (2) also includes a connecting rod assembly (18). The connecting rod assembly (18) is inserted into the guide barrel (13). During assembly, the guide barrel assembly (10) is first assembled into the shell guide barrel assembly (1) and fixed, and then the coil assembly (2) is assembled onto the guide barrel (13) in the shell guide barrel assembly (1).

4. The segmented ladder transformer type linear displacement sensor according to claim 1, characterized in that: Each layer of enameled round copper wire (19) is isolated by a polyimide film silicone pressure-sensitive tape (22), and then each layer of enameled round copper wire (19) is fixed with silicone insulating paint, and then a polytetrafluoroethylene insulated light cable (21) is welded to the enameled round copper wire (19) through solder (23) and then led out, and the lead-out part of the polytetrafluoroethylene insulated light cable (21) is protected by a Teflon heat shrink tube (26), and the welded part is insulated and protected by a polytetrafluoroethylene tube (24), and the welded part of the enameled round copper wire (19) is fastened with an alkali-free glass fiber rope (25), and then fixed with a high-temperature resistant epoxy glue (20); then the magnetic tube (17) is inserted into the outside of the coil frame (16), and magnetic rings (15) are connected to both ends of the coil frame (16).

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