Active magnetic sensor
By designing an active magnetic sensor containing a sensitive wire and induction coil, the problem of uncontrollable pulse signals in the prior art is solved, miniaturization and cost reduction of sensors are achieved, and suitable for encoders and smart instruments.
Patent Information
- Application Number
- CN202422082889.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-27
- Publication Date
- 2025-08-19
- Estimated Expiration
- 2034-08-27
AI Technical Summary
The existing Wiegand sensors cannot achieve controllable number of pulse signals, and the induction voltage of multiple sensitive wires is uncertain, which affects its accuracy and reliability in encoders and other applications.
An active magnetic sensor is designed, including a sensitive wire, an induction coil, two magnetic beads and two electrodes. The sensitive wire is built into the induction coil. The magnetic beads are installed at both ends of the coil, the electrodes are connected to the wire head, and are encapsulated in the cavity of the shell to achieve controllable number of pulse signals.
It realizes the miniaturization and integration of active magnetic sensors, reduces production costs, and ensures the controllability of the number of pulse signals, and is suitable for scenarios such as encoders and smart instruments.
Smart Images
Figure CN223244798U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of sensor technology, and in particular to an active magnetic sensor. Background Art
[0002] As an active magnetic sensor, the Wiegand sensor primarily consists of a sensitive wire, a bobbin, and external pins. A high-precision, high-reliability magnetic sensor, the Wiegand sensor plays a vital role in industrial automation, new energy, electronic instrumentation, and other fields. Its operating principle is that when relative motion occurs between the magnet and the sensor, the magnetization direction of the treated sensitive wire changes. This magnetization change can be replicated by applying an external magnetic field with varying polarity, causing the detection coil to output an induced voltage pulse, reflecting the detected magnetic motion.
[0003] Typically, Wiegand sensors function as energy-sourcing devices in battery-free solutions, so multiple sensitive wires need to be placed in the detection coil to output sufficient energy. However, the different sensitive magnetic fields of the multiple sensitive wires may generate induced voltages at different times, resulting in an uncertain number of pulse signals being detected. This situation is unfavorable for the application of Wiegand sensors in encoders, and existing Wiegand sensors cannot control the number of pulse signals. Utility Model Content
[0004] The present application provides an active magnetic sensor, the purpose of which is to achieve controllable number of pulse signals.
[0005] In order to achieve the above objectives, this application provides the following technical solutions:
[0006] An active magnetic sensor, comprising:
[0007] Sensitive wire (100), induction coil (200), magnetic beads (300), electrodes (400) and housing (500);
[0008] The number of the sensitive wire (100) is one, and the sensitive wire (100) is built into the induction coil (200);
[0009] The induction coil (200) comprises a coil body (201) and two wire ends (202), and the coil body (201) is in the shape of a hollow cylinder;
[0010] There are two magnetic beads (300), and the two magnetic beads (300) are respectively mounted at two ends of the coil body (201);
[0011] There are two electrodes (400), and the two electrodes (400) are connected to the two wire ends (202) respectively;
[0012] The housing (500) includes a cavity (501), and the cavity (501) is used to encapsulate the induction coil (200), the magnetic bead (300) and the electrode (400); wherein the electrode (400) includes a welding portion (401) and an exposed portion (402); the welding portion (401) is placed in the cavity (501) and is used to be welded to the wire head (202); the exposed portion (402) is exposed outside the housing (500) and is used to serve as a pin of the active magnetic sensor.
[0013] Optionally, the active magnetic sensor further includes:
[0014] The insulating hose (600) is used to wrap the sensitive wire (100) so as to insulate and isolate the sensitive wire (100) from the induction coil (200).
[0015] Optionally, the length of the insulating hose (600) is the same as the length of the coil body (201), and the insulating hose (600) is embedded in the inner hollow of the coil body (201) to fix the sensitive wire (100) in the inner hollow of the coil body (201).
[0016] Optionally, the outer diameter of the coil body (201) is in the range of 4-7 mm, the inner diameter is in the range of 0.3-0.7 mm, and the length is in the range of 10-15 mm.
[0017] Optionally, the wire material used by the induction coil (200) is an enameled wire, and the wire diameter of the enameled wire is in the range of 0.03-0.1 mm.
[0018] Optionally, the wire end (202) includes a bare wire segment obtained after de-enamelling a portion of the enameled wire, and the bare wire segment is folded multiple times to form a corresponding reinforced wire end, and the reinforced wire end is used for welding with the electrode (400).
[0019] Optionally, the shell (500) is a shell having a uniform thickness throughout, and the thickness of the shell (500) is in the range of 1-2 mm.
[0020] Optionally, the two magnetic beads (300) are in the shape of cylinders, and the diameter of the cylinders is determined based on the outer diameter of the coil body (201).
[0021] Optionally, the cross-sectional shape of the cavity (501) is a combination of a rectangle and a semicircle, the length of the cavity (501) is the sum of the length of the coil body (201) and the length of the two magnetic beads (300), and the inner curved surface diameter of the cavity (501) is consistent with the outer diameter of the coil body (201).
[0022] Optionally, the cavity (501) includes a potting compound, and the potting compound is used to fix the induction coil (200), the magnetic bead (300) and the electrode (400).
[0023] The technical solution provided by the present application is that the active magnetic sensor includes a sensitive wire, an induction coil, a magnetic bead, an electrode and a shell. The number of sensitive wires is one, and the sensitive wire is built into the induction coil. The induction coil includes a coil body and two wire ends. The coil body is in the shape of a hollow cylinder. The number of magnetic beads is two, and the two magnetic beads are respectively installed at the two ends of the coil body. The number of electrodes is two, and the two electrodes are respectively connected to the two wire ends. The shell includes a cavity, which is used to encapsulate the induction coil, the magnetic bead and the electrode. The active magnetic sensor shown in the present application only includes one sensitive wire, which can realize the controllable number of pulse signals, and the sensitive wire is built into the induction coil. Magnetic beads are respectively installed at both ends of the induction coil. When the induction coil, the magnetic beads and the electrodes are deployed in the cavity of the shell, the volume of the active magnetic sensor can be controlled, which not only realizes the miniaturization and integration of the active magnetic sensor, but also reduces the automated production cost of the active magnetic sensor. BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.
[0025] Figure 1 A schematic structural diagram of an active magnetic sensor provided in an embodiment of the present application;
[0026] Figure 2 A schematic diagram of an assembly of an induction coil, an insulating hose, and a sensitive wire provided in an embodiment of the present application;
[0027] Figure 3 A schematic structural diagram of an induction coil provided in an embodiment of the present application;
[0028] Figure 4 A schematic diagram of a coil body provided in an embodiment of the present application;
[0029] Figure 5 A schematic diagram of the structure of an electrode provided in an embodiment of the present application;
[0030] Figure 6 A schematic structural diagram of a housing provided in an embodiment of the present application;
[0031] Figure 7A schematic diagram of a cavity packaging provided in an embodiment of the present application;
[0032] Figure 8 A schematic structural diagram of a thread end provided in an embodiment of the present application. DETAILED DESCRIPTION
[0033] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.
[0034] In this application, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. The terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article or apparatus. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of other identical elements in the process, method, article or apparatus comprising the element.
[0035] like Figure 1 , which is a schematic structural diagram of an active magnetic sensor provided in an embodiment of the present application, including the following components.
[0036] Sensitive wire 100 , induction coil 200 , magnetic beads 300 , electrodes 400 and housing 500 .
[0037] There is one sensitive wire 100 , and the sensitive wire 100 is built into the induction coil 200 .
[0038] It's important to note that because the active magnetic sensor only contains one sensitive wire 100, each time the active magnetic sensor detects a signal, the induction coil 200 only emits one pulse signal. This allows for controllable pulse quantity, enabling the active magnetic sensor to be used in encoders. Furthermore, the pulses generated by a single sensitive wire 100 also possess sufficient energy to satisfy the application of active magnetic sensors in other scenarios, such as smart meters.
[0039] In some examples, the sensitive wire 100 can be considered as a Wiegand wire.
[0040] Optional, see Figure 2 As shown, the active magnetic sensor further includes an insulating hose 600 .
[0041] The insulating hose 600 is used to wrap the sensitive wire 100 so as to insulate and isolate the sensitive wire 100 from the induction coil 200 .
[0042] It is understandable that the insulating hose 600 is used to achieve insulation isolation between the sensitive wire 100 and the induction coil 200, which can prevent the sensitive wire 100 from contacting the induction coil 200 and avoid signal interference.
[0043] Optionally, the length of the insulating hose 600 is the same as that of the coil body 201 , and the insulating hose 600 is embedded in the inner hollow of the coil body 201 to fix the sensitive wire 100 in the inner hollow of the coil body 201 .
[0044] In some examples, insulating hose 600 may be a non-metallic hose.
[0045] In some examples, the insulating hose 600 remains parallel to the axis of the coil body 201 , and accordingly, the sensitive wire 100 also remains parallel to the axis of the coil body 201 .
[0046] See also Figure 3 As shown, the induction coil 200 includes a coil body 201 and two wire ends 202 , and the coil body 201 is in the shape of a hollow cylinder.
[0047] Optionally, the outer diameter of the coil body 201 is in the range of 4-7 mm, the inner diameter is in the range of 0.3-0.7 mm, and the length is in the range of 10-15 mm.
[0048] See also Figure 4 As shown, the outer diameter of the coil body 201 can be regarded as the coil outer diameter a of the induction coil 200 , the inner diameter of the coil body 201 can be regarded as the coil inner diameter c of the induction coil 200 , and the length of the coil body 201 can be regarded as the coil length b of the induction coil 200 .
[0049] Optionally, the wire material used by the induction coil 200 is an enameled wire, and the diameter of the enameled wire ranges from 0.03 to 0.1 mm.
[0050] In some examples, the number of turns of the induction coil 200 may be 6000, and the coil resistance may be 480Ω.
[0051] Optionally, the wire end 202 includes a bare wire segment obtained after partially removing the enameled wire from the enameled wire, and the bare wire segment is folded multiple times to form a corresponding reinforced wire end, which is used for welding with the electrode 400 .
[0052] In some examples, the length of the exposed wire segment can be 3-6 times that of the reinforcing wire end, and the exposed wire segment is folded 3-6 times and then twisted, and the twisted portion of the exposed wire segment is tinned to obtain a reinforcing wire end with higher toughness. In a possible embodiment, the twisted portion of the exposed wire segment is tinned to obtain a reinforcing wire end with higher toughness, which can be seen in Figure 8 shown.
[0053] In some examples, the reinforced wire end obtained by tinning can be more easily welded to the electrode 400 .
[0054] In a possible embodiment, the wire end 202 may be sintered to remove the surface paint of the portion of the enameled wire to which the wire end 202 originally belonged, or a paint remover may be used to remove the surface paint of the portion of the enameled wire to which the wire end 202 originally belonged, to obtain a bare wire segment.
[0055] It is understandable that the wire end 202 is to be welded and connected to the electrode 400. Therefore, after the wire end 202 is connected to the electrode 400, it will be subjected to corresponding tension. If the wire end 202 is only a thin and long enameled wire, it will have low toughness and will be more easily torn off by the tension. For this reason, the wire end 202 needs to be processed into a reinforced wire end to increase its toughness to avoid being torn off by the tension, which can also facilitate the stability of the assembly of the active magnetic sensor.
[0056] In some examples, the reinforcing thread head may also be fixed on the coil body 201 . In a possible implementation, the reinforcing thread head may be solidified on the coil body 201 using colloid or glue.
[0057] There are two magnetic beads 300 , which are respectively mounted at two ends of the coil body 201 .
[0058] In some examples, the two magnetic beads 300 can be mounted on both ends of the coil body 201 by gluing.
[0059] In some examples, the two magnetic beads 300 can be respectively mounted on both ends of the coil body 201 by physical extrusion.
[0060] In some examples, the two magnetic beads 300 are made of the same material, which can be a soft magnetic material with high magnetic permeability, such as a ferrite material.
[0061] Optionally, the two magnetic beads 300 are in the shape of cylinders, and the diameter of the cylinders is determined based on the outer diameter of the coil body 201 .
[0062] In some examples, the diameter of the cylinder may be equal to the outer diameter of coil body 201 .
[0063] It should be noted that the use of a cylindrical magnetic bead 300, in which the diameter of the cylinder shown by the magnetic bead 300 is equal to the outer diameter of the coil body 201, can not only reduce the difficulty of assembling the active magnetic sensor and facilitate the automation of the subsequent packaging process, but also, under the condition of the same length of sensitive wire 100, the signal intensity generated by the cylindrical magnetic bead 300 is greater than that generated by the ring-shaped magnetic bead 300.
[0064] That is to say, the cylindrical magnetic bead 300 can facilitate packaging and prevent the sensitive wire 100 from moving axially. Compared with the ring-shaped magnetic bead 300, the residual pulse signal energy of the cylindrical magnetic bead 300 is stronger.
[0065] In some examples, the length of the cylinder shown by the magnetic bead 300 can be designed according to actual conditions. By shortening the length of the magnetic bead 300 , the volume of the active magnetic sensor can be shortened.
[0066] There are two electrodes 400 , and the two electrodes 400 are connected to the two wire ends 202 respectively.
[0067] See also Figure 5 As shown, the electrode 400 includes a welding portion 401 and an exposed portion 402, wherein the welding portion 401 is placed in the cavity 501 for welding with the wire head 202. The exposed portion 402 is exposed outside the housing 500 and is used as a pin of the active magnetic sensor.
[0068] It should be emphasized that the exposed portion 402 of the electrode 400 is exposed outside the housing 500 and is used to serve as a pin of the active magnetic sensor. The type of the pin can be regarded as a patch, that is, the active magnetic sensor can be installed on a designated circuit board in the form of a patch.
[0069] Generally speaking, the welding portion 401 of the electrode 400 is more stably connected to the reinforcing wire head, and the exposed portion 402 is used as the pin of the active magnetic sensor, which can reduce the volume of the active magnetic sensor.
[0070] The housing 500 includes a cavity 501 , which is used to encapsulate the induction coil 200 , the magnetic beads 300 and the electrodes 400 .
[0071] Optional, see Figure 6 As shown, the cross-sectional shape of the cavity 501 is a combination of a rectangle and a semicircle, and the shell 500 is a shell with a uniform thickness. The thickness of the shell 500 ranges from 1 to 2 mm. The length of the cavity 501 is the sum of the length of the coil body 201 and the length of the two magnetic beads 300. The internal curved surface diameter of the cavity 501 is consistent with the outer diameter of the coil body 201.
[0072] In some examples, the length of the coil body 201 is 20 mm, the length of the magnetic bead 300 is 2 mm, and the length of the cavity 501 can be set to 24 mm.
[0073] Optionally, the cavity 501 further includes a potting compound, and the potting compound is used to fix the induction coil 200 , the magnetic beads 300 and the electrodes 400 .
[0074] In some examples, after the induction coil 200, the magnetic beads 300 and the electrodes 400 are fixed by potting glue, the layout of the induction coil 200, the magnetic beads 300 and the electrodes 400 in the cavity 501 can be seen in FIG. Figure 7 shown.
[0075] It is understandable that the potting compound can also be used to protect the induction coil 200 , magnetic beads 300 and electrodes 400 installed in the cavity 501 .
[0076] The active magnetic sensor shown above includes only one sensitive wire, which can realize the controllable number of pulse signals. The sensitive wire is built into the induction coil, and magnetic beads are installed at both ends of the induction coil. When the induction coil, magnetic beads and electrodes are deployed in the cavity of the shell, the volume of the active magnetic sensor can be controlled, which not only realizes the miniaturization and integration of the active magnetic sensor, but also reduces the automated production cost of the active magnetic sensor.
[0077] Although the subject matter has been described in language specific to structural features and / or methodological logical acts, it should be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are merely example forms of implementing the claims.
[0078] Although several specific implementation details are included in the above discussion, these should not be construed as limiting the scope of this application. Certain features described in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented in multiple embodiments individually or in any suitable sub-combination.
[0079] The above description is merely a preferred embodiment of the present application and an illustration of the technical principles employed. Those skilled in the art should understand that the scope of disclosure in this application is not limited to the technical solutions formed by a specific combination of the above-mentioned technical features, but also encompasses other technical solutions formed by any combination of the above-mentioned technical features or their equivalents without departing from the above-mentioned disclosed concepts. For example, a technical solution formed by replacing the above-mentioned features with (but not limited to) technical features with similar functions disclosed in this application.
Claims
1. An active magnetic sensor, characterized in that: include: Sensitive wire (100), induction coil (200), magnetic beads (300), electrodes (400) and housing (500); The number of the sensitive wire (100) is one, and the sensitive wire (100) is built into the induction coil (200); The induction coil (200) comprises a coil body (201) and two wire ends (202), and the coil body (201) is in the shape of a hollow cylinder; There are two magnetic beads (300), and the two magnetic beads (300) are respectively mounted at two ends of the coil body (201); There are two electrodes (400), and the two electrodes (400) are connected to the two wire ends (202) respectively; The housing (500) includes a cavity (501), and the cavity (501) is used to encapsulate the induction coil (200), the magnetic bead (300) and the electrode (400); wherein the electrode (400) includes a welding portion (401) and an exposed portion (402); the welding portion (401) is placed in the cavity (501) and is used to be welded to the wire head (202); the exposed portion (402) is exposed outside the housing (500) and is used to serve as a pin of the active magnetic sensor.
2. The active magnetic sensor according to claim 1, wherein: The active magnetic sensor further comprises: The insulating hose (600) is used to wrap the sensitive wire (100) so as to insulate and isolate the sensitive wire (100) from the induction coil (200).
3. The active magnetic sensor according to claim 2, wherein: The length of the insulating hose (600) is the same as that of the coil body (201), and the insulating hose (600) is embedded in the inner hollow of the coil body (201) to fix the sensitive wire (100) in the inner hollow of the coil body (201).
4. The active magnetic sensor according to claim 1, wherein: The outer diameter of the coil body (201) is in the range of 4-7 mm, the inner diameter is in the range of 0.3-0.7 mm, and the length is in the range of 10-15 mm.
5. The active magnetic sensor according to claim 1, wherein: The wire material used in the induction coil (200) is an enameled wire, and the wire diameter of the enameled wire is in the range of 0.03-0.1 mm.
6. The active magnetic sensor according to claim 5, characterized in that The wire end (202) comprises a bare wire segment obtained after partially removing the enameled wire from the enameled wire, and the bare wire segment is folded multiple times to form a corresponding reinforced wire end, and the reinforced wire end is used for welding with the electrode (400).
7. The active magnetic sensor according to claim 1, wherein: The outer shell (500) is a shell having a uniform thickness throughout, and the thickness of the outer shell (500) is in the range of 1-2 mm.
8. The active magnetic sensor according to claim 1, wherein: The two magnetic beads (300) are in the shape of cylinders, and the diameter of the cylinders is determined based on the outer diameter of the coil body (201).
9. The active magnetic sensor according to claim 1, wherein: The cross-sectional shape of the cavity (501) is a combination of a rectangle and a semicircle, the length of the cavity (501) is the sum of the length of the coil body (201) and the length of the two magnetic beads (300), and the inner curved surface diameter of the cavity (501) is consistent with the outer diameter of the coil body (201).
10. The active magnetic sensor according to claim 1, wherein: The cavity (501) includes a potting compound, and the potting compound is used to fix the induction coil (200), the magnetic bead (300) and the electrode (400).