Clamp Sensor Core Overlap Structure for Strong Magnetic Coupling
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Solution Overview
Problem
Existing clamp sensors face challenges in maintaining sufficient magnetic coupling force and preventing gaps in the closed magnetic circuit due to size reduction and potential distortion or foreign matter interference, which affects detection accuracy.
Innovation Solution
The clamp sensor design includes protruding portions on both core members that overlap in the closed state, increasing contact area and magnetic coupling force, while also preventing foreign matter interference and noise ingress, allowing smooth clamping and detection in narrow spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cross-sectional area of the magnetic core is reduced to decrease the size of the clamp sensor, then the clamp sensor can be easily used in narrow spaces, but the magnetic coupling force between the first core and the second core becomes insufficient
Solution Approach 1:
The invention transitions from surface contact to volume contact by providing through-holes that extend in the circumferential direction. The second core fits through these holes, creating a three-dimensional overlapping region between the first and second cores. This dimensional change from 2D surface contact to 3D volume contact significantly increases the magnetic coupling force while maintaining a compact cross-sectional area, enabling the clamp sensor to operate in narrow spaces without sacrificing coupling strength.
2Ease of operation
If the clamp sensor is designed with a slide structure to reduce opening space requirements, then the clamp sensor can be operated in narrow spaces, but the first core and second core may become inclined due to case distortion, making it difficult to maintain surface contact
Solution Approach 1:
The invention segments the contact interface into multiple discrete through-holes distributed around the circumferential direction. This segmentation allows the magnetic cores to maintain contact at multiple separate points rather than relying on a single continuous surface contact. Even if the case distorts and causes inclination, the distributed through-holes ensure that at least some contact points remain aligned, maintaining reliable magnetic coupling under varying operational conditions.
3Device complexity
If the clamp sensor uses surface contact between the first core and second core, then the structure is simple, but foreign matter can be caught between the contact surfaces, generating gaps in the magnetic circuit
Solution Approach 1:
The invention extracts the potential problem of foreign matter entrapment by replacing the continuous surface contact interface with discrete through-holes. By removing the continuous surface where foreign matter could be caught, the design eliminates the gap-forming mechanism while maintaining the essential magnetic coupling function. The through-holes provide defined contact points that are less susceptible to foreign matter interference, thereby preserving detection accuracy.
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 design enhances magnetic coupling force and detection accuracy by increasing contact area between core members, preventing gaps, and ensuring smooth clamping and detection, even in narrow spaces.
Implementation Method 1
a magnetic core arranged annularly in a closed state... an annular closed magnetic circuit is formed around the detection target
Implementation Method 2
the first core unit and the second core unit are coupled to each other with a sufficient magnetic coupling force
Data Source
AI summary
Device designed to cause both core members to adopt a state of being coupled together with a sufficient magnetic coupling force, while achieving a reduction in size. This clamp sensor includes a first core member constituting a part, in a circumferential direction, of a magnetic core that is arranged annularly, and a second core member constituting another part thereof. The clamp sensor is configured such that: first protruding portions that protrude along the circumferential direction are provided at tip ends and in the circumferential direction of the member, and second protruding portions that protrude along the circumferential direction are provided at tip ends and in the circumferential direction of the member; and in a closed state, the first protruding portions on the tip end side and the second protruding portions on the tip end side overlap in an insertion direction.