Electromagnetic Connector Magnetic Circuit Coupling
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Solution Overview
Problem
Industrial control systems face challenges with multi-pin connectors due to high maintenance costs, susceptibility to corrosion, and complexity, especially in environments requiring precise signal transmission and isolation, where traditional connectors can lead to intermittent failures and increased costs.
Innovation Solution
Electromagnetic connectors forming magnetic circuits with core members and coils are used to transmit power and signals, eliminating the need for precise contact and alignment, and replacing multiple PWMs and transformers with a single magnetic circuit configuration, providing galvanic isolation and reducing environmental vulnerabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-pin connectors are used to complete electrical circuits in industrial control systems, then electrical connections can be established, but the connectors are susceptible to corrosion, misalignment, and intermittent failures leading to high maintenance costs
Solution Approach 1:
The patent replaces traditional mechanical multi-pin connectors with electromagnetic connectors that use magnetic fields for contactless coupling. The first electromagnetic connector includes a first coil and first core member, while the second electromagnetic connector includes a second coil and second core member. When mated, these form a magnetic circuit that couples the coils magnetically, eliminating mechanical contact and its associated problems of corrosion, misalignment, and wear.
Solution Approach 2:
The invention changes the fundamental operating parameter from mechanical electrical contact to magnetic field coupling. By transforming the connection mechanism from direct metal-to-metal contact to electromagnetic induction through a magnetic circuit, the system achieves reliable signal and power transmission without the physical degradation issues of traditional connectors.
2Manufacturing precision
If traditional electromagnetic connectors are used, then signal transmission can be achieved, but precise contact and alignment are required increasing manufacturing and assembly complexity
Solution Approach 1:
The magnetic circuit coupling eliminates the need for precise mechanical alignment between mating connectors. The magnetic field naturally couples the coils when the connectors are brought into proximity, providing self-alignment and tolerance compensation that greatly simplifies manufacturing and assembly compared to traditional mechanical connectors requiring precise pin-to-socket alignment.
3Reliability
If multiple PWMs and transformers are used for power and signal transmission, then isolation and transmission can be achieved, but system complexity and component count increase
Solution Approach 1:
The patent combines the functions of multiple PWMs and transformers into a single integrated electromagnetic connector system. The magnetic circuit formed by the first and second core members couples the coils to provide both power transmission and galvanic isolation simultaneously, eliminating the need for separate components and reducing overall system complexity.
Solution Approach 2:
The electromagnetic connector performs multiple functions within a single component: it provides galvanic isolation, transmits power, and transmits signals simultaneously through the magnetic circuit coupling. This multi-functionality replaces what would traditionally require multiple separate components including PWMs and transformers.
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 maintenance costs, enhances reliability by minimizing corrosion and misalignment issues, and simplifies the system architecture while maintaining high-frequency AC power transmission and communication efficiency.
Implementation Method 1
The magnetic circuit is configured to induce a signal in the first coil when the second coil is energized
Implementation Method 2
a magnetic circuit formed from the first magnetic circuit portion and the second magnetic circuit portion
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A communications control system/switch fabric is disclosed that includes a serial communications interface and a parallel communications interface (e.g., for coupling input/output modules with a control module). The serial communications interface is configured for connecting input/output modules/slave devices to a control module/master device in parallel, and the parallel communications interface is configured for separately connecting the input/output modules/slave devices to the control module/master device.