Cross-Wound Coil Former with Ferromagnetic Ball
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Solution Overview
Problem
Eddy current sensors face challenges in sensitivity when testing highly curved contours, such as those found in wave claws, due to their size and shape, leading to inadequate signal production and uneven testing power from cross-wound coils.
Innovation Solution
A coil body with crossing circumferential grooves is designed to allow for a coil wire to be wound in a cross-pattern around a winding core, incorporating a ferromagnetic ball to distort the magnetic field and ensure uniform winding distance, with a winding device to automate the process and minimize space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If cross-wound coils are used in eddy current sensors, then the magnetic field coverage is improved, but the uniformity of winding distance deteriorates leading to uneven testing power
Solution Approach 1:
The patent introduces a ferromagnetic ball as an intermediary element positioned at the center of the coil former. This ball serves as a precise positioning reference that ensures uniform winding distance for the coil wire, thereby maintaining consistent magnetic field distribution while achieving the required magnetic field coverage for effective testing of shaft claws
Solution Approach 2:
The coil former is pre-configured with circumferential grooves and a centrally positioned ferromagnetic ball before the winding process. This preliminary arrangement of the winding structure and positioning elements ensures that when the coil wire is wound, it automatically maintains uniform distance from the center, eliminating the need for complex real-time adjustments during winding
2Object-affected harmful factors
If eddy current sensors are used for testing shaft claws, then the need for chemical testing agents is eliminated, but the sensitivity for highly curved contours deteriorates due to sensor size and shape
Solution Approach 1:
The patent employs a ferromagnetic ball with a spherical geometry that naturally conforms to and follows the curved contours of shaft claws during inspection. This spherical shape allows the sensor to maintain consistent contact and magnetic field coupling with highly curved surfaces, thereby preserving measurement sensitivity while eliminating the need for chemical testing agents
3Ease of operation
If the coil wire is wound manually, then flexibility is maintained, but the productivity and consistency of sensor manufacturing deteriorates
Solution Approach 1:
The coil former with its circumferential grooves and central ferromagnetic ball is designed to guide the coil wire automatically during the winding process. The grooves constrain the wire path and the ferromagnetic ball maintains consistent spacing, allowing the winding operation to proceed with minimal manual intervention while ensuring high consistency and productivity across multiple sensor productions
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
This approach enhances the sensitivity and uniformity of eddy current sensors, allowing for effective testing of complex contours by ensuring consistent winding and improved magnetic field distribution.
Implementation Method 1
incorporating a ferromagnetic ball to distort the magnetic field and ensure uniform winding distance
Implementation Method 2
eddy current sensors face challenges in sensitivity when testing highly curved contours
Implementation Method 3
coil wire to be wound around the winding core in the manner of a cross winding
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a coil former for producing an eddy current sensor having a winding head (2) defining a longitudinal axis (X), in the outer surface of which winding head two circumferential grooves (3, 4) are formed and each extend along the entire circumference of the winding head (2) around a winding core (5), wherein the circumferential grooves (3, 4) cross at the top side and the bottom side of the winding head (2) at the longitudinal axis position and serve to hold a coil wire (6) that is to be wound around the winding core (5) in the manner of a cross-wound winding, and wherein the circumferential grooves (3, 4) are limited by holding webs (8, 9, 10, 11), as seen in the circumferential direction, which holding webs extend in the longitudinal axis direction and project beyond the winding core (5) in the direction of the two axial end regions of the coil former (1) and in the radial direction.