Integrated Inductive Position Sensing in Compact Electromagnetic Clutches
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Solution Overview
Problem
Conventional position sensors for new energy vehicles are bulky, require specific environmental conditions, and need reserved space, which limits their integration in compact power systems.
Innovation Solution
A high-precision, compact inductive position sensor with a magnetic circuit formed by a movable magnetic conductor and an induction coil assembly, allowing for accurate position detection based on the relationship between input and feedback currents, and eliminating the need for specific connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional position sensors are used, then position detection function is achieved, but volume is large and spatial structure is affected
Solution Approach 1:
The patent combines the position sensor with the electromagnetic clutch assembly, integrating the sensor into the existing structure. The sensor housing is formed as part of the clutch assembly housing, eliminating the need for separate sensor housing and reducing overall volume while maintaining detection precision through the magnetic circuit design.
Solution Approach 2:
The induction coil assembly is nested within the electromagnetic clutch structure, with the coil positioned inside the clutch housing. The movable magnetic conductor is integrated with the clutch moving components, allowing the sensor to occupy minimal space within the existing clutch volume while achieving accurate position detection.
2Adaptability or versatility
If conventional position sensors are used, then position detection is achieved, but specific connectors and layout space must be reserved
Solution Approach 1:
The sensor input and output ends are directly integrated with the electromagnetic clutch electrical interfaces. The induction coil assembly terminals are connected to the clutch control circuitry without requiring separate connectors, and the sensor housing is formed as part of the clutch assembly housing, eliminating the need for reserved layout space and specific connector installations.
Solution Approach 2:
The electromagnetic clutch assembly serves dual functions: as the actuator itself and as the housing/structure for the position sensor. The clutch housing provides the sensor mounting structure, the clutch moving parts serve as the magnetic circuit components, and the clutch electrical connections provide the sensor signal interfaces, eliminating the need for separate sensor connectors and mounting structures.
3Reliability
If conventional position sensors are used, then position detection is achieved, but anti-magnetic interference ability is insufficient
Solution Approach 1:
The sensor magnetic circuit is merged with the electromagnetic clutch magnetic circuit. The same iron core and magnetic conductors used in the clutch actuation serve as the magnetic circuit elements for position detection. This integration provides inherent shielding against external magnetic interference since the clutch structure itself forms a closed magnetic path, while maintaining manufacturing simplicity by using the existing clutch components.
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 position sensor provides flexible and compact design, enhanced anti-magnetic interference, and optimized space usage, making it suitable for a wide range of environments and applications in new energy vehicles.
Implementation Method 1
an induction coil assembly adjacent to the movable part, wherein the induction coil assembly and the movable part form a magnetic circuit
Implementation Method 2
the induction coil assembly and the movable part form a magnetic circuit
Data Source
AI summary
An inductive position sensor, may include a movable part which is a magnetic conductor, and an induction coil assembly adjacent to the movable part. The induction coil assembly and the movable part form a magnetic circuit, the induction coil assembly has an input end for inputting a current and an output end for outputting a feedback current, and the inductive position sensor is used to detect a position of the movable part based on a relationship between the feedback current and the input current. The inductive position sensor has a flexible and compact structural design, and can be adjusted and arranged according to different applications and structural spaces, so it is applicable to a wide range of environments. An electromagnetic clutch is also disclosed.