Coil Former Magnetic Core Assembly for Sensor
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Solution Overview
Problem
The existing methods for producing inductive measuring pickups are complex, particularly due to the need for adhesive bonding of magnetic cores, which can lead to thermal stresses, mechanical stresses, and corrosion risks, and do not efficiently manage temperature changes or mechanical loads.
Innovation Solution
A method involving the use of a thermosetting plastic coil former with a form-fitting connection to hold the magnetic core, eliminating the need for adhesive bonding, and incorporating a transfer molding process to reduce thermal and mechanical stresses, along with a housing body for protection and improved electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to attach the magnetic core to the coil former, then the magnetic core can be securely held, but thermal stresses and mechanical stresses increase, and corrosion risks arise
Solution Approach 1:
The invention extracts and eliminates the adhesive bonding step from the production process. By using a form-fitting connection where the coil former is inserted into a receptacle of the magnetic core, the harmful adhesive bonding operation is completely removed, thereby eliminating the source of thermal stresses, mechanical stresses, and corrosion risks while still achieving secure holding of the magnetic core
Solution Approach 2:
The invention introduces a coil former as an intermediary component that mediates between the magnetic core and the external environment. The coil former with its form-fitting connection serves as a mechanical interface that secures the magnetic core without requiring adhesive bonding, thereby resolving the contradiction between secure holding and harmful stress/corrosion factors
2Ease of manufacture
If conventional production methods are used, then manufacturing can proceed with standard processes, but the production procedure becomes very involved and complex
Solution Approach 1:
The invention merges the coil former and magnetic core assembly into a single integrated unit through form-fitting connection. This combination eliminates the need for separate adhesive bonding steps and simplifies the production procedure, reducing overall manufacturing complexity while maintaining standard production processes
Solution Approach 2:
The invention employs preliminary action by pre-forming the coil former with the appropriate receptacle geometry before assembly. This preliminary preparation of the form-fitting connection enables simple insertion of the magnetic core without requiring complex bonding operations during final assembly, thereby reducing production procedure complexity
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 cycling stability of the measuring pickup by minimizing thermal and mechanical stresses, reducing the risk of corrosion and wire breakage, while maintaining dimensional stability and electromagnetic compatibility.
Implementation Method 1
the coil former is formed by means of a transfer molding process
Implementation Method 2
A thermosetting plastic material has a particularly low coefficient of thermal expansion and barely shrinks after the transfer molding process
Implementation Method 3
the thermosetting plastic material adheres optimally to the electrical connections and thus results in a particularly tight connection between the electrical connections and the coil former
Implementation Method 4
the magnetic core is held in the coil core by a form-fitting connection
Data Source
AI summary
A method for producing a coil as a measurement transmitter for a sensor, including: providing electrical connections and a magnetic core for the coil, forming a coil former around the magnetic core in such a way that the magnetic core is at least partially enclosed by the coil former and the electrical connections are held by the coil former, winding at least one coil wire onto the formed coil former, and connecting the wound coil wire to the electrical connections.