Coil-on-chip Inductive Sensor for Actuation Limit Detection
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Solution Overview
Problem
Existing limit position sensors in actuation units for mechanical processing, such as those used in motor vehicle manufacturing, face variability in inductance due to coil winding and material tolerances, leading to reduced accuracy and reliability, especially under temperature and electromagnetic field exposure.
Innovation Solution
The use of coil-on-chips integrated in a printed circuit for inductive sensing elements, combined with a second reference coil-on-chip for differential measurements to isolate inductive effects from environmental noise, results in stable and accurate detection of actuating member positions with reduced size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional wire-wound coils are used in inductive sensing elements, then the sensing elements can be manufactured using conventional techniques, but the inductance values exhibit high variability due to winding tolerances and ferrite material broad tolerances
Solution Approach 1:
The patent replaces the mechanical wire-winding process with a printed circuit board (PCB) fabrication process. The inductive sensing elements are created as conductive traces on PCBs, eliminating manual or automated wire winding operations. This substitution provides consistent inductance values through standardized PCB manufacturing processes while maintaining ease of manufacture through conventional PCB fabrication techniques.
Solution Approach 2:
The patent changes the physical form and manufacturing parameters of the inductive sensing elements from wire-wound coils to printed circuit traces. This parameter change includes transitioning from ferrite core materials to PCB substrate materials, and from winding geometry to trace geometry. These parameter changes enable precise control of inductance values through PCB design parameters (trace width, length, spacing) while maintaining compatibility with standard manufacturing processes.
2Adaptability or versatility
If inductive sensing elements are exposed to temperature variations and electromagnetic fields, then the sensing elements can operate in industrial environments, but the inductance values become unstable and inaccurate
Solution Approach 1:
The replacement of wire-wound coils with PCB-based inductive sensing elements provides inherent stability against temperature and electromagnetic field variations. The PCB substrate and trace geometry maintain consistent electrical characteristics across environmental conditions, eliminating the inductance drift observed in traditional wire-wound ferrite-based sensors when exposed to industrial environmental variations.
3Measurement precision
If limit position sensors are positioned inside the actuation unit body, then the detection accuracy is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the inductive sensing elements directly into the PCB structure that also houses the electronic processing circuitry. This integration combines the sensing function with the processing function on a single board, eliminating separate sensor components and reducing overall device complexity while maintaining high measurement precision through the integrated design.
Solution Approach 2:
The PCB serves multiple functions: it provides structural support, houses the electronic processing circuitry, and contains the inductive sensing elements. This multi-functionality reduces the number of separate components needed in the actuation unit, simplifying the overall device while enabling accurate position detection through the integrated sensing elements positioned within the actuation unit body.
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 repeatability and stability of inductance values, improving measurement accuracy and resistance to electromagnetic fields, while allowing for compact and cost-effective production of reliable limit position detection devices.
Implementation Method 1
at least one sensing element of the inductive type... wherein the at least one sensing element comprises at least a first measuring coil-on-chip
Data Source
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AI summary
The present invention relates to a device and a method for detecting the reaching of a limit position and an actuation unit using such device and relative method for detecting the reaching of a limit position. In particular, the limit position detection device (10) for use in actuation units (50) of the type equipped with an actuating member (52) movable between a first operative limit position (55) and a second non-operative limit position comprises a hollow body (13) inside of which electronic processing means are housed for processing signals detected by at least one sensing element (11, 12), and at least one sensing element (11, 12) of the inductive type electrically connected to the electronic processing means, wherein the at least one sensing element (11, 12) defines a sensing area within which the sensing element (11, 12) is able to detect at least the partial presence of a triggering component (57a, 58a, 57b, 58b) moved due to a translational motion of the actuating member (52), and is characterized in that the at least one sensing element (11, 12) comprises at least a first measuring coil-on-chip (16) positioned in such a manner as to detect the presence of a triggering component (57a, 58a, 57b, 58b) within the sensing area, and in that it comprises at least a second reference coil-on-chip (19) positioned in such a manner as to detect the presence of a triggering component (57a, 58a, 57b, 58b) within the sensing area.