Contactless Inductive Torque Sensing via Magnetic Encoding
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Solution Overview
Problem
Conventional contactless torque sensors have lower sensitivity and require complex calibration, resulting in limited accuracy for measuring torque in rotary drive mechanisms, particularly in applications like automobile engines and industrial motors.
Innovation Solution
A contactless inductive force sensing system utilizing magnetically encoded regions on a shaft, where the magnetic permeability changes with applied torque, allowing for enhanced sensitivity and accuracy by detecting alterations in the magnetic field through inductive sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional contactless torque sensors are used, then non-contact measurement is achieved, but sensitivity and measurement accuracy deteriorate
Solution Approach 1:
The shaft is segmented into multiple magnetically encoded regions with alternating polarities (first, second, third, and fourth magnetically encoded regions) separated by torque-sensitive regions. This segmentation allows the sensor to detect differential magnetic field changes, enhancing measurement sensitivity while maintaining a relatively simple contactless sensor structure.
Solution Approach 2:
The invention utilizes changes in magnetic permeability of the torque-sensitive regions in response to applied torque. By encoding magnetic regions with alternating polarities and measuring the differential change in magnetic field parameters, the system achieves high measurement accuracy without requiring complex sensor arrangements or calibration procedures.
2Measurement precision
If direct magnetostrictive effect is used for measuring torque, then contactless measurement is achieved, but sensitivity decreases and calibration becomes difficult
Solution Approach 1:
The shaft is pre-encoded with magnetic regions of alternating polarities during manufacturing or installation. This preliminary magnetic encoding creates a known reference pattern that simplifies subsequent torque measurements, eliminating the need for complex calibration procedures while maintaining high measurement accuracy.
Solution Approach 2:
The invention creates a magnetic field pattern copy of the torque state by measuring the differential magnetic field changes in the torque-sensitive regions. This magnetic copying approach provides a direct representation of torque magnitude without requiring complex calibration, as the alternating polarity pattern inherently provides the reference needed for accurate measurement.
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 system provides improved sensitivity and accuracy in measuring torque by minimizing the impact of intrinsic material properties, enabling precise control and diagnosis of rotary drive systems, and optimizing energy efficiency.
Implementation Method 1
conventional contactless sensors have lower sensitivity and the sensitivity is substantially dependent on the material properties of the shaft. In other words, use of direct magnetostrictive effect for measuring torque of large shafts requires complex sensor arrangements
Implementation Method 2
A contactless inductive force sensing system utilizing magnetically encoded regions on a shaft, where the magnetic permeability changes with applied torque, allowing for enhanced sensitivity and accuracy by detecting alterations in the magnetic field through inductive sensors
Data Source
AI summary
A system includes a device and a contactless inductive force sensing system. The device includes a first band having a first magnetically encoded region with a first magnetic polarity spaced apart from a second magnetically encoded region having a second magnetic polarity. The device further includes a second band having a third magnetically encoded region with the second magnetic polarity spaced apart from a fourth magnetically encoded region having the first magnetic polarity. The contactless inductive force sensing system is used for measuring one or more mechanical force components of the device and generating a mechanical force component signal.