Inductive Plug Transformer Asymmetric Coil Design
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Solution Overview
Problem
Existing inductive plug-in connection transformers are highly sensitive to deviations in the relative positions of their components, leading to significant changes in the inductive coupling factor, which makes them prone to manufacturing accuracy issues and operational disruptions due to dirt and deposits in industrial environments.
Innovation Solution
The transformer design features staggered axial lengths of the ferrite core and coils (d1 > d3 > d2) with an axially asymmetric positioning of the primary coil, allowing it to protrude over the secondary coil, reducing the impact of positional deviations on the coupling factor by compensating for changes through increased coupling when the primary winding moves into the secondary winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ferrite core and coils are positioned symmetrically (d1=d3>d2) to maximize inductive coupling, then the coupling factor is optimized, but the system becomes highly sensitive to positional deviations
Solution Approach 1:
The patent applies asymmetry by positioning the primary coil asymmetrically on the ferrite core such that d1 > d3 > d2, with the primary coil shifted toward one end of the ferrite core. This asymmetric configuration creates a more gradual coupling gradient, reducing sensitivity to positional deviations and allowing less precise manufacturing while maintaining reliable coupling.
2Reliability
If the primary coil is positioned symmetrically within the secondary coil, then maximum inductive coupling is achieved, but slight displacements cause large changes in coupling factor
Solution Approach 1:
The asymmetric positioning (d1 > d3 > d2) with the primary coil shifted toward one end creates a more tolerant coupling configuration. The staggered arrangement ensures that even when dirt or deposits prevent exact positioning, the coupling factor remains stable because the asymmetric geometry provides a broader optimal positioning range compared to symmetric alignment.
3Reliability
If the ferrite core length is made equal to or greater than the secondary coil length (d1≥d3), then coupling is maximized, but the system becomes more sensitive to relative position deviations
Solution Approach 1:
The patent resolves this contradiction by introducing asymmetry in the form of staggered lengths (d1 > d3 > d2) combined with asymmetric coil positioning. The primary coil is shifted toward one end of the ferrite core, creating a configuration where the coupling factor varies more gradually with position, thus providing both good coupling and tolerance to position variation.
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 design significantly reduces the relative change in the inductive coupling factor when the transformer is shifted, enhancing its robustness against positional deviations and maintaining a satisfactory coupling factor even in less-than-ideal conditions.
Implementation Method 1
inductive plug-in connection transmitter with a ferrite core 3, a primary coil 1 which is seated on the ferrite core 3 and with a secondary coil 11 for inductive contactless transmission
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An inductive plug-type connection transformer comprises - a ferrite core (3) with an axial length d1, - a primary coil (1) resting on the ferrite core (3) with an axial winding length d2, - a secondary coil (11) with an axial winding length d3, into which the ferrite core primary coil unit (1, 3) can be pushed radially symmetrically and axially into a transmission desired position (P1), in which the ferrite core (3) protrudes axially with its free end (4) plugged through the secondary coil (11) beyond said secondary coil (11), - a position of the ferrite core which is axially symmetrical with respect to the secondary winding, - staggered axial lengths of ferrite core (3), primary coil (1) and secondary coil (11) in accordance with the relationship d1 > d3 > d2, - positioning of the primary coil (1) on the ferrite core (3) which is shifted asymmetrically axially in the direction of the free end (4) of said ferrite core (3), and - positioning of the primary coil (1) in the transmission desired position (P1) within the secondary coil (11) in such a way that the primary coil (1) protrudes axially beyond the secondary coil (11) by an excess distance of d4 < d2 over part of its length.