Inductive Rotor Coil Layout for Shaft Misalignment Sensing
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Solution Overview
Problem
Existing methods for detecting shaft misalignments in machines and motors are limited in sensitivity, flexibility, and capability, often requiring indirect measurements and failing to accurately detect finer misalignments, which can lead to vibrations and safety risks.
Innovation Solution
The development of inductive sensors with a rotor and stator configuration, including excitation and receiver coils, that can detect slip, tilt, and eccentricity misalignments by measuring changes in induced voltages, with a dual rotor configuration enhancing sensitivity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If indirect measurement methods are used for shaft misalignment detection, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent replaces indirect mechanical measurement methods with direct inductive sensing. The inductive sensor uses electromagnetic fields to directly detect shaft misalignment, eliminating the need for complex mechanical coupling devices or indirect vibration analysis systems while achieving high measurement precision through direct coupling between the rotor coil and stator coil.
2Ease of operation
If conventional sensor placement is used, then ease of installation is improved, but measurement precision deteriorates
Solution Approach 1:
The inductive sensor is nested within the motor structure, with the rotor coil integrated into the rotor assembly and the stator coil positioned in the stator assembly. This nested configuration allows the sensor to be installed within existing motor components without requiring external mounting, maintaining ease of installation while achieving high measurement precision through close proximity coupling.
3Device complexity
If single rotor configuration is used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The sensor system is segmented into multiple independent coils: a first rotor coil, a second rotor coil, a first stator coil, and a second stator coil. Each coil can be independently positioned and optimized for specific measurement functions. This segmentation allows the system to achieve high measurement precision for detecting misalignments in multiple directions while maintaining manageable device complexity through modular coil design.
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 inductive sensors effectively detect misalignments with high sensitivity, enabling precise monitoring and preventing equipment damage by accurately measuring changes in air gaps and induced voltages, thus improving operational safety and efficiency.
Implementation Method 1
an excitation coil, and an eccentricity receiver coil where the excitation coil and the eccentricity receiver coil are physically coupled to the stator layer
Data Source
AI summary
In at least one general aspect, an inductive sensor can include a shaft having an axis of rotation, and a rotor physically coupled to the shaft and including a rotor coil. The rotor and the rotor coil can be aligned along a plane orthogonal to the axis of rotation. The inductive sensor can include a stator including a stator layer, an excitation coil, and an eccentricity receiver coil where the excitation coil and the eccentricity receiver coil are physically coupled to the stator layer.