Electromagnetic Connector Magnetic Circuit Signal Induction
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Solution Overview
Problem
Multi-pin connectors in industrial control systems are high maintenance and costly due to precision requirements, susceptibility to corrosion, and the need for galvanic isolation, which increases complexity and cost.
Innovation Solution
Electromagnetic connectors forming magnetic circuits with core members and coils that couple to create a magnetic circuit for signal induction, eliminating the need for precise alignment and reducing the requirement for multiple PWMs, power transformers, and multi-pin connectors by using a magnetic circuit as a passive hub for power and communication transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-pin connectors are used to complete electrical circuits in industrial control systems, then good electrical connections can be achieved, but the connectors become high maintenance and costly due to precision requirements, susceptibility to corrosion, and need for galvanic isolation
Solution Approach 1:
The patent replaces mechanical electrical contacts (multi-pin connectors requiring precise alignment and physical contact) with an electromagnetic coupling system. The primary coil generates a magnetic field that induces signals in secondary coils, eliminating the need for direct mechanical contact between mating connectors. This substitution resolves the contradiction by maintaining reliable signal transmission through electromagnetic induction while eliminating the precision alignment and corrosion issues inherent in mechanical pin connectors.
Solution Approach 2:
The patent introduces magnetic field coupling as an intermediary between electrical circuits. Instead of direct electrical contact through pins, the system uses magnetic fields generated by coils as a mediator to transfer energy and signals. This intermediary approach enables galvanic isolation (preventing corrosion and ground loops) while maintaining reliable communication, thus resolving the contradiction between connection reliability and device complexity.
2Reliability
If multiple PWMs, power transformers, and multi-pin connectors are used for power and communication transmission, then complete electrical circuits can be achieved, but costs and complexity increase
Solution Approach 1:
The patent combines power transmission and communication functions into a single electromagnetic coupling system. The primary coil on one side couples with secondary coils on the other side through magnetic field interaction, simultaneously enabling both power delivery and bidirectional communication. This merging eliminates the need for separate PWM circuits, power transformers, and multi-pin connectors, thereby reducing component count and complexity while maintaining reliable power and communication transmission.
Solution Approach 2:
The electromagnetic connector system performs multiple functions through a single mechanism: it provides galvanic isolation, transmits power, enables bidirectional communication, and ensures precise energy transfer all through the magnetic coupling between primary and secondary coils. This multi-functionality resolves the contradiction by consolidating what would traditionally require multiple separate components (PWMs, transformers, connectors) into a unified system that achieves all necessary functions with reduced 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 solution reduces costs and complexity, enhances galvanic isolation, and provides environmentally robust signal transmission, minimizing field failures from corrosion and misalignment.
Implementation Method 1
the magnetic circuit is configured to induce a signal in a first coil of the multiple coils and the coil of the second electromagnetic connector when a second coil of the multiple coils is energized
Data Source
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AI summary
An electromagnetic connector is disclosed that is configured to form a first magnetic circuit portion comprising multiple coils disposed about a first core member. The electromagnetic connector is configured to mate with a second electromagnetic connector that is configured to form a second magnetic circuit portion comprising a coil disposed about a second core member. When the electromagnetic connector is mated with the second electromagnetic connector, the first core member and the second core member are configured to couple the multiple coils of the electromagnetic connector to the coil of the second electromagnetic connector with a magnetic circuit formed from the first magnetic circuit portion and the second magnetic circuit portion. The magnetic circuit is configured to induce a signal in a first coil of the multiple coils and the coil of the second electromagnetic connector when a second coil of the multiple coils is energized.