Inductive Distance Sensor Flange Geometry for Core Positioning
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Solution Overview
Problem
Inductive distance sensors require time-consuming and error-prone adjustments due to variations in axial core positions within the winding carrier, affecting measuring accuracy and production efficiency.
Innovation Solution
The design features two ring disk-shaped flanges with different outside diameters, allowing the coil to be precisely positioned within a ferromagnetic pot, eliminating the need for axial screwing and enabling easy mounting of the core by slipping the pot over the coil, with axially parallel spacer pillars maintaining the pot's distance from the rear flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the core is adjusted axially in the winding carrier to achieve precise positioning, then measuring accuracy is improved, but assembly complexity and production time increase
Solution Approach 1:
The flanges are pre-formed with different outer diameters during manufacturing, creating the positioning function in advance. This eliminates the need for subsequent axial adjustment of the core, as the flange geometry itself ensures proper positioning when the pot is assembled over the coil assembly.
Solution Approach 2:
The asymmetric flange design enables self-positioning of the core and pot assembly. When the pot is slipped over the coil, the different flange diameters automatically establish the correct axial position without requiring external adjustment mechanisms or manual intervention.
2Measurement precision
If fine adjustment of the core position is performed for each coil, then measurement precision is improved, but production efficiency deteriorates
Solution Approach 1:
The positioning function is built into the flange geometry during initial manufacturing, eliminating the need for individual adjustment operations during assembly. This preliminary incorporation of the positioning function maintains high production rates while ensuring consistent measurement precision across all units.
Solution Approach 2:
Each coil-pot assembly automatically achieves correct positioning through the asymmetric flange design during standard assembly operations. No additional adjustment steps are required, allowing all units to be produced at maximum speed with consistent precision.
3Stability of the object's composition
If the core is firmly fixed in the winding carrier, then positioning stability is improved, but assembly ease deteriorates
Solution Approach 1:
The core achieves stable positioning automatically through the asymmetric flange geometry when the pot is assembled. The design eliminates the need for separate fixing operations while ensuring the core remains firmly positioned during operation, combining ease of assembly with positioning stability.
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 solution simplifies the assembly process, reduces adjustment effort, and ensures consistent core positioning, thereby enhancing measuring accuracy and production rates by eliminating the need for inductive adjustments.
Implementation Method 1
The oscillating circuit 14 feeds a coil 16, which is mounted axially in front of it on a coil body 15 made of plastic, with medium frequency (in the one to two-digit kilohertz range)
Implementation Method 2
This causes eddy current losses in a ferromagnetic environment. This leads to the amplitude and phase influence of the supply frequency when the ferromagnetic mass changes as a result of the approach or removal of a ferromagnetic object
Data Source
AI summary
An inductive alignment of the coil (16), equipped with core, of an eddy current distance sensor (11) can be avoided if the coil (16) fills an annular space, which is predefined by the design, between the winding carrier (17) of the plastic coil body (15) and the flanges (18-19) thereof and the wall (21) of a crucible (20) made of ferromagnetic material, which is placed over the rear smaller flange (18) and at the end face (21) is seated against an annular area of the front larger flange (19) having the diameter of the crucible (20). The ferromagnetic coil core (31) coaxially engaging with the winding carrier (17) can therefore be arranged at the bottom (24) of the crucible (20) and can thus be mounted simultaneously with the crucible (20).