Assembling Electromagnetically Coupled Coils for Precision Current Measurement
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Solution Overview
Problem
Electromagnetically coupled components in electrical devices, such as fault status indicators and wireless chargers, face challenges with electromagnetic interference and measurement accuracy due to air gaps in flux concentrators, which affect the reliability and precision of current measurements across a wide dynamic range.
Innovation Solution
A device assembling system and method that determine optimal physical alignment of electromagnetically coupled coils, including distance and orientation, to manage electromagnetic coupling, minimize interference, and enhance measurement accuracy while maintaining size and weight constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the airgap between core sections is reduced to minimize leakage flux and improve measurement accuracy, then measurement precision improves, but core saturation increases which degrades reliability
Solution Approach 1:
The patent applies parameter changes by precisely controlling the airgap dimension between core sections. The airgap is maintained within a specific range (0.01mm to 0.05mm) to optimize the balance between reducing leakage flux for accurate measurement and preventing core saturation for reliable operation. This dimensional parameter optimization resolves the contradiction between measurement precision and reliability.
2Use of energy by moving object
If the distance between electromagnetically coupled coils is reduced to improve coupling efficiency, then energy transfer improves, but electromagnetic interference increases which degrades measurement accuracy
Solution Approach 1:
The patent applies local quality by creating spatial differentiation between the energy harvesting coil and measurement coil. The energy harvesting coil is positioned closer to the core for efficient coupling, while the measurement coil is positioned at an optimized distance to minimize electromagnetic interference. This localized positioning strategy resolves the contradiction between energy transfer efficiency and measurement precision.
Solution Approach 2:
The patent uses magnetic shielding materials as intermediaries between the electromagnetically coupled coils. These shielding elements redirect leakage flux away from the measurement coil, allowing the coils to be positioned closer for efficient energy transfer while preventing electromagnetic interference from degrading measurement accuracy.
3Reliability
If the airgap between core sections is increased to reduce core saturation, then reliability improves, but leakage flux increases which degrades measurement accuracy
Solution Approach 1:
The patent employs flux concentrators with specific geometric configurations that create controlled magnetic flux paths. The concentrator geometry is designed to guide and concentrate the magnetic flux, effectively copying the desired flux distribution pattern that minimizes leakage while maintaining appropriate airgap distances for reliability. This geometric copying approach resolves the contradiction between reliability and measurement precision.
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 system effectively reduces electromagnetic interference and increases measurement accuracy by optimizing the alignment of coils, ensuring reliable operation and precise current measurement across a wide dynamic range without compromising the physical dimensions of the devices.
Implementation Method 1
The energy harvester coil harvests power from the current flowing through the power line
Implementation Method 2
a leakage flux caused in the flux concentrator links with the measurement coil and affects accuracy of the current being measured
Implementation Method 3
a flux concentrator having, for example, a ferromagnetic core
Data Source
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AI summary
A device assembling system (100) for assembling an electrical device (400, 700), comprising a data reception module (101) and a position determination module is disclosed. The data reception module (101) obtains device data associated and design constraint data associated with the electrical device (400, 700). The position determination module (102) determines a physical alignment between at least two coils (402B, 403, and 701B, 702) electromagnetically coupled with one another, of the electrical device, based on the device data and the design constraint data such that an electromagnetic coupling between the components is managed. Also, provided is a method for managing an electromagnetic coupling between one or more components of the electrical device (400, 7000). Also, provided is an electrical device (400) assembled by employing the device assembling system (100) with minimized coupling and an electrical device (700) assembled by employing the device assembling system (100) with maximized coupling.