Ferrite Core Coil Sensor for Turbocharger Speed Measurement
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Solution Overview
Problem
Turbocharger speed sensors face challenges in accurately measuring the rotational speed of thin compressor wheels due to weak signal amplitudes and the occurrence of 'double peaks' in detection signals, which can lead to erroneous rpm values, especially in high-temperature environments and with the use of large flat coils that cause aerodynamic disturbances and are difficult to integrate into small turbochargers.
Innovation Solution
A ferrite core coil device with a coil divided into two sectors, one bent around the ferrite core's bending edge and the other on the core's bed, forming an L-shape, which enhances signal amplitude and avoids double peaks by using a flexible polymer substrate and an integrated SOI circuit for robust temperature resistance and precise signal processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large flat coil is used as sensing element, then signal amplitude is improved, but device size increases and aerodynamic disturbances occur
Solution Approach 1:
The patent applies curvature by bending the coil around a ferrite core instead of using a flat planar coil. The coil is formed into a curved or L-shape configuration that follows the contour of the ferrite core, allowing the sensing element to achieve compact three-dimensional arrangement. This curved configuration maintains effective sensing area and signal amplitude while reducing the overall sensor device size and eliminating aerodynamic disturbances associated with large flat coils in turbocharger environments.
Solution Approach 2:
The patent implements nesting by integrating the coil around a ferrite core, where the coil is wrapped or bent around the core structure. This nested arrangement allows the sensing element to achieve a compact form factor by placing the coil in three-dimensional space around the magnetic core, rather than spreading it out in a large flat configuration. The nested structure maximizes the use of available space while maintaining effective sensing area.
2Measurement precision
If a large flat coil is used as sensing element, then signal amplitude is improved, but aerodynamic disturbances increase
Solution Approach 1:
The patent applies curvature by bending the coil around a ferrite core instead of using a flat planar coil. The coil is formed into a curved or L-shape configuration that follows the contour of the ferrite core, allowing the sensing element to achieve compact three-dimensional arrangement. This curved configuration maintains effective sensing area and signal amplitude while reducing the overall sensor device size and eliminating aerodynamic disturbances associated with large flat coils in turbocharger environments.
3Ease of manufacture
If standard flat coil is used, then manufacturing is simple, but double peaks occur in detection signal
Solution Approach 1:
The patent applies curvature by bending the coil around a ferrite core instead of using a flat planar coil. The coil is formed into a curved or L-shape configuration that follows the contour of the ferrite core, allowing the sensing element to achieve compact three-dimensional arrangement. This curved configuration maintains effective sensing area and signal amplitude while reducing the overall sensor device size and eliminating aerodynamic disturbances associated with large flat coils in turbocharger environments.
Solution Approach 2:
The patent transitions from a two-dimensional flat coil configuration to a three-dimensional curved coil arrangement around the ferrite core. By adding the dimensional aspect of curving the coil around the core, the patent eliminates double peak artifacts while maintaining manufacturing feasibility through standard winding or bending processes applied to the coil around the core structure.
4Measurement precision
If sensor tip is made large to accommodate large coil, then signal amplitude is improved, but integration into small turbochargers becomes difficult
Solution Approach 1:
The patent implements nesting by integrating the coil around a ferrite core, where the coil is wrapped or bent around the core structure. This nested arrangement allows the sensing element to achieve a compact form factor by placing the coil in three-dimensional space around the magnetic core, rather than spreading it out in a large flat configuration. The nested structure maximizes the use of available space while maintaining effective sensing area.
Solution Approach 2:
The patent applies curvature by bending the coil around a ferrite core instead of using a flat planar coil. The coil is formed into a curved or L-shape configuration that follows the contour of the ferrite core, allowing the sensing element to achieve compact three-dimensional arrangement. This curved configuration maintains effective sensing area and signal amplitude while reducing the overall sensor device size and eliminating aerodynamic disturbances associated with large flat coils in turbocharger environments.
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 ferrite core coil device increases signal amplitude and sensitivity, allowing for accurate detection of single peaks and reducing the risk of double peak errors, while its compact design fits within small turbochargers and withstands high temperatures, ensuring reliable rotational speed measurement.
Implementation Method 1
a magnetic field is generated by an oscillating system and a sensing coil is used to detect compressor blades when they pass through the magnetic field in front of the sensor tip
Implementation Method 2
A ferrite core coil device as a sensing element for a sensor device determining a rotational speed of a metallic rotatable object includes a coil having a first sector and a second sector and a ferrite core holding the coil
Data Source
AI summary
A ferrite core coil device as a sensing element for a sensor device determining a rotational speed of a metallic rotatable object includes a coil having a first sector and a second sector and a ferrite core holding the coil. The ferrite core has a shape of a disk lacking a disk sector and defined by a contour of the disk and a chord of the disk. The chord forms a bending edge of the ferrite core. The first sector of the coil is not arranged on a bed of the ferrite core and the second sector of the coil is arranged on the bed. The first sector is bent around the bending edge at a bending angle with respect to the second sector.