Differential Transformer Magnetic Sensor Coil Segmentation
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Solution Overview
Problem
Differential transformer type magnetic sensors used in image forming apparatuses face challenges in maintaining measurement accuracy due to displacement of coil positions, leading to variations in magnetic flux and output dispersion.
Innovation Solution
The design includes a first coil layer with a detection coil and a first drive coil, and a second coil layer with a reference coil and a second drive coil, both layers being electrically connected to ensure the direction of drive and induced currents are consistent, with an insulating layer in between, allowing for precise detection of toner residual amounts without positional displacement affecting magnetic flux differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If planar coils are used to reduce sensor size, then the sensor dimensions are reduced, but measurement precision deteriorates due to coil position displacement affecting magnetic flux
Solution Approach 1:
The sensor is divided into multiple independent coil layers (first coil layer with detection coil and first drive coil, second coil layer with reference coil and second drive coil), where each layer operates independently. This segmentation allows the sensor to maintain compact planar structure while reducing the impact of position displacement on measurement precision through layered isolation.
Solution Approach 2:
An insulating layer is introduced as an intermediary between the first coil layer and the second coil layer. This insulating layer prevents magnetic coupling between layers, ensuring that position displacement in one layer does not affect the magnetic flux measurement of another layer, thereby maintaining measurement precision in the compact sensor structure.
2Adaptability or versatility
If coils are arranged on the same core to form differential transformer, then sensor functionality is achieved, but output dispersion increases due to position variations
Solution Approach 1:
The differential transformer is segmented into multiple independent coil layers with dedicated drive and detection coils in each layer. This segmentation ensures that position variations in different layers do not propagate to each other, maintaining output consistency while preserving differential transformer functionality for toner detection.
Solution Approach 2:
The insulating layer acts as a mediator that isolates the magnetic fields of different coil layers. This prevents position variations in one layer from affecting the magnetic flux in another layer, thereby reducing output dispersion and improving reliability while maintaining the differential transformer's ability to detect toner residual amounts.
3Measurement precision
If drive coils and detection coils are electrically connected to ensure consistent current direction, then measurement accuracy is maintained, but device complexity increases
Solution Approach 1:
The coil system is segmented into distinct first and second coil layers, each with its own drive coil and detection coil. This segmentation allows for simplified electrical connections within each layer while maintaining overall system accuracy, reducing the complexity of inter-layer connections compared to a single-layer differential transformer.
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 configuration ensures consistent magnetic flux measurements across the sensor, reducing output dispersion and maintaining accuracy even with coil position displacements, thereby enhancing the reliability of toner detection in image forming apparatuses.
Implementation Method 1
a detection coil (4) formed of a planar spiral first wire (4a) located on a plane and a first drive coil (5) formed of a planar spiral second wire (5a) running in parallel to the first wire (4a) on the same plane as the first wire (4a)
Implementation Method 2
The first drive coil (5) and the second drive coil (7) are electrically connected together so that a direction of drive current flowing in the first drive coil (5) is the same as a direction of drive current flowing in the second drive coil (7)
Data Source
AI summary
A differential transformer type magnetic sensor includes a first coil layer, a second coil layer, and an insulating layer formed between the first coil layer and the second coil layer. The first coil layer includes a detection coil and a first drive coil. The second coil layer includes a reference coil and a second drive coil. The first drive coil and the second drive coil are electrically connected together so that a direction of drive current flowing in the first drive coil is the same as a direction of drive current flowing in the second drive coil. The detection coil and the reference coil are electrically connected together so that a direction of induced current flowing in the detection coil is reverse to a direction of induced current flowing in the reference coil.