Inductively Coupled Coil Sensor for Gap-Tolerant Position Detection
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Solution Overview
Problem
Contactless position sensors face challenges in maintaining sensing range and accuracy due to physical gaps and environmental factors like dirt or grease, and require precise alignment, which can be difficult to maintain, especially when the target structure is at varying distances from the sensor.
Innovation Solution
A contactless position sensor system utilizing a set of inductively coupled coils to generate and detect changes in the electromagnetic near-field, allowing for the detection of a target structure's presence and relative position, even at greater distances, by measuring voltage changes across the coils, which are indicative of the target's position within the near-field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a physical gap is maintained between the sensor and target structure for contactless operation, then electrical noise and contact wear are reduced, but sensing range and accuracy deteriorate
Solution Approach 1:
Multiple coils are combined to form a coil assembly where the magnetic fields of individual coils merge and reinforce each other, creating a stronger and more extended electromagnetic near-field that maintains sensing accuracy over greater distances while preserving contactless operation
Solution Approach 2:
The patent transitions from single-point sensing to distributed multi-coil sensing across a spatial array, using the relative position information from multiple coils to determine target position through signal comparison, thereby extending sensing range without sacrificing precision
2Length of stationary object
If the distance between the sensor and target structure is increased, then sensing range is improved, but signal strength and detection sensitivity deteriorate
Solution Approach 1:
Multiple coils are merged into a coordinated assembly that generates combined magnetic flux, creating a stronger electromagnetic near-field that extends the sensing range to greater distances while maintaining adequate signal strength for reliable detection
Solution Approach 2:
The coil assembly is pre-configured with specific geometric arrangements and coupling relationships that optimize magnetic field distribution before target detection, enabling the system to maintain signal strength at extended distances through预先 designed field reinforcement
3Reliability
If magnetic sensors are used to detect target position, then contactless sensing is achieved, but precision housing and mechanical assembly are required to avoid alignment errors
Solution Approach 1:
The sensing function is segmented across multiple coils rather than relying on a single sensitive element, allowing each coil to contribute to the overall detection capability and reducing the impact of individual coil misalignment on total system accuracy
Solution Approach 2:
The system uses feedback from multiple coil measurements to determine target position, where the relative position information from each coil is processed to compensate for alignment variations and achieve accurate position sensing without requiring extreme precision in mechanical assembly
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 increases the sensing range and reduces sensitivity to distance variations, providing accurate detection of the target structure's position with improved signal strength and reduced noise, making it suitable for applications where precise alignment is challenging.
Implementation Method 1
the first coil upon receiving energy, generates an electromagnetic near-field, such that the electromagnetic near-field provides at least a portion of the energy to the second coil through inductive coupling, inducing a current to pass through the set of coils
Implementation Method 2
the magnetic flux of an electromagnetic near field generated during inductive coupling is sensitive to any variations in the electromagnetic near-field. The variations in the electromagnetic near-field caused by the changes of the magnetic flux can be detected by, e.g., by measuring the voltage of across the coil caused by the current induced by the magnetic flux via inductive coupling
Data Source
AI summary
A sensor including a set of coils. The set of coils include a first coil and a second coil, wherein the first coil upon receiving energy, generates an electromagnetic near-field, such that the electromagnetic near-field provides at least a portion of the energy to the second coil through inductive coupling, inducing a current to pass through the set of coils. Further, a detector for measuring a voltage across at least one of the first coil or the second coil, wherein the detector includes a voltmeter. Finally, a processor for detecting a presence of a target structure in proximity to the set of coils upon detecting a change in a value of the voltage, wherein the target structure is an electromagnetic structure moving at a distance from the set of coils.