Connection Element Magnetic Core Enhances Inductive Sensor Coupling
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Solution Overview
Problem
Existing inductive interfaces in sensor connections for process automation suffer from inefficiencies in signal and energy transfer due to suboptimal magnetic coupling, leading to increased losses and reduced power availability at the sensor side.
Innovation Solution
A connection element with a cylindrical core and magnetic bodies of varying diameters enhances magnetic coupling and inductance, reducing losses and increasing efficiency by using fewer windings in the primary coil and a magnetic body surrounding the secondary coil, which is designed to improve the transformer's efficiency and power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the primary coil has more windings to increase inductance, then the inductance increases, but the losses (copper resistance, eddy current losses) increase and efficiency decreases
Solution Approach 1:
The patent changes the magnetic permeability parameter by introducing a magnetic core with high relative permeability (μr > 1). This allows the inductance to be increased without proportionally increasing the number of windings, thereby reducing copper resistance losses while maintaining the required inductance value.
Solution Approach 2:
The patent uses a composite structure combining a non-magnetic cylindrical core with magnetic bodies made of materials having high relative permeability. This composite approach optimizes the magnetic coupling and inductance while minimizing energy losses in the primary coil.
2Reliability
If the air gap between secondary coil and primary coil is reduced to improve coupling, then the coupling increases, but the mechanical design becomes more difficult and manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a magnetic core as an intermediary element between the primary and secondary coils. This core extends into both coils, providing a continuous magnetic path that enhances coupling while allowing for larger air gaps and more relaxed manufacturing tolerances.
Solution Approach 2:
The magnetic core extends axially into both the primary and secondary coils, utilizing the axial dimension to improve magnetic coupling. This dimensional approach allows the core to bridge the gap between coils effectively, reducing the impact of radial air gaps.
3Loss of energy
If the number of windings is reduced to decrease losses, then the efficiency increases, but the inductance and power transfer capability decrease
Solution Approach 1:
The patent changes the magnetic permeability parameter by introducing a magnetic core, which allows for a significant reduction in the number of windings while maintaining the required inductance. This reduction in windings decreases alternating current losses and improves efficiency while the core ensures adequate power transfer capability.
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 improved magnetic coupling and reduced losses result in increased efficiency and power availability at the sensor side, while also providing design flexibility and enhanced corrosion protection and mechanical durability.
Implementation Method 1
The inductive interfaces in question are usually implemented as a system having two coils that are plugged into each other, e.g., via the plug connection in question. These are referred to as the primary coil on the side of the connection element and secondary coil on the side of the sensor. They form a transformer.
Implementation Method 2
The magnetic coupling of the two coils determines the efficiency of the transformer, and therefore the quality of the signal transfer and energy transfer.
Implementation Method 3
the core at one end comprises a first magnetic body that is greater in diameter than the core and extends into the first segment
Data Source
AI summary
The present disclosure discloses a connection element comprising an essentially cylindrical core, a primary coil for transmission and reception of data and/or for transmission of energy from or to a secondary coil, wherein the primary coil surrounds the core, and a first coupling body with a first segment and a second segment, wherein the second segment comprises the primary coil. In the connection element, the core at one end comprises a first magnetic body that is greater in diameter than the core and extends into the first segment. The present disclosure likewise discloses a sensor, as well as a sensor connection element including such a sensor and such a connection element.