Inductive Sensor Module With Central Signal Processor
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Solution Overview
Problem
Existing inductive rotational sensors with transmitter and receiving coils on a printed circuit board face challenges in packaging due to the placement of the signal processor radially outward from the coils, making them difficult to use for certain applications.
Innovation Solution
A compact inductive sensor module with the signal processor located centrally within the transmitter and receiving coils, allowing the entire module to be positioned inside a cavity matching the diameter of the rotational element being sensed, and featuring a coupler on the target's end, ensuring a non-contacting, movable-part-free design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the signal processor is mounted radially outward from the coils on the PCB, then the processor can be provided in an ASIC, but the sensor module becomes difficult to package and use for certain applications
Solution Approach 1:
The patent inverts the conventional radial arrangement by placing the signal processor at the center of the coils rather than radially outward. This central positioning allows the entire sensor module to be compact and concentric with the shaft, enabling it to fit within tight packaging constraints while maintaining functionality.
Solution Approach 2:
The signal processor is nested within the inner diameter of the transmitter coil, creating a compact concentric arrangement. This nesting allows the processor, coils, and shaft to be arranged in a space-efficient manner, with each component fitting within the diameter constraints of the previous component.
2Adaptability or versatility
If the sensor module is positioned inside a cavity matching the diameter of the rotational element, then packaging flexibility is improved, but the signal processor placement becomes more constrained
Solution Approach 1:
The signal processor is nested within the inner diameter of the transmitter coil, which itself is positioned within the cavity. This nested arrangement allows all components to fit within the cavity diameter while maintaining proper spacing and functionality, resolving the constraint between compact packaging and processor placement.
Solution Approach 2:
Instead of placing the processor outside the coil diameter, the patent inverts the arrangement by positioning the processor inside the coil's inner diameter, enabling the entire assembly to fit within the cavity while maintaining manufacturing feasibility.
3Reliability
If a coupler is mounted on the target end, then non-contacting sensing is achieved, but the target structure becomes more complex
Solution Approach 1:
The patent extracts the sensing function from requiring complex target structures by using a simple coupler mounted on the target end. This coupler works with the inductive fields to enable non-contacting sensing, separating the sensing complexity from the target structure and simplifying the overall system.
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 arrangement enables a more compact and efficient inductive rotational position sensor that can be concentric with the shaft and bore, allowing for precise rotational position sensing without the need for external targets or moving parts, enhancing packaging flexibility and accuracy.
Implementation Method 1
The coupler permits eddy currents to be generated in receiving coils
Implementation Method 2
A processor determines a voltage proportional to the eddy currents
Data Source
AI summary
Embodiments of the present invention are directed to a novel inductive rotational position sensor that includes a sensor module having transmitting and receiving coils formed on a printed circuit board with a signal processor located in a center area enclosed by the transmitting and receiving coils. This arrangement permits a more compact sensor module. The entire sensor module can be positioned inside a cavity, which has a diameter generally the same as the diameter of the rotational element whose position is being sensed. The arrangement also permits a coupler to be formed on the end of the target. The sensor is concentric with the transfer case shaft and an annulus bore of a transfer case. The sensor is non-contacting and has no movable parts.