Magnetic Angle Sensor with Segmented Elements for Shaft Position
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Solution Overview
Problem
Existing angle sensors for detecting the rotational position of a shaft, particularly in engine applications, face challenges in achieving high accuracy due to limited accessibility and space constraints, leading to inaccurate determination of the rotational position when the magnetic field arrangement is larger than the sensor module.
Innovation Solution
A magnetic angle sensor system comprising a first and second sensor element mechanically coupled to a support structure, which is connected to the hull enclosing the shaft, allowing for accurate detection of the rotational position by positioning the sensor elements along an arc to capture varying magnetic field patterns, utilizing trigonometric identities and algorithms like CORDIC to determine the rotation angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the magnetic field arrangement is made larger to improve detection accuracy, then the measurement precision is improved, but the device complexity and space requirements increase
Solution Approach 1:
The sensor module is segmented into multiple independent sensor elements (first sensor element, second sensor element) that are distributed at different positions around the shaft. Each sensor element detects magnetic field components at its specific location, and the combined measurements from multiple segments achieve high rotational position accuracy without requiring a single large magnetic field arrangement
Solution Approach 2:
The solution transitions from a single-point measurement to a multi-dimensional measurement approach by placing sensor elements at different spatial positions and orientations. The sensor elements detect magnetic field components in different directions (radial and axial components), creating a multi-dimensional measurement system that achieves high accuracy with compact individual sensor elements
2Measurement precision
If the sensor elements are positioned closer to the shaft to improve measurement accuracy, then the measurement precision is improved, but the ease of operation and accessibility for replacement deteriorate
Solution Approach 1:
The sensor elements are nested within a support structure that is integrated into the engine hull. The support structure provides a framework that holds the sensor elements in their optimal measurement positions while allowing the entire sensor module to be installed and removed as a compact unit through the engine access points
Solution Approach 2:
The support structure acts as an intermediary between the sensor elements and the engine hull. It provides mechanical coupling and positioning for the sensor elements while maintaining accessibility for the entire sensor module. The support structure translates the measurement requirements into a mechanically accessible configuration
3Reliability
If the sensor elements are mechanically coupled to the hull to improve stability, then the reliability is improved, but the ease of repair and replacement deteriorate
Solution Approach 1:
The sensor elements and support structure are merged into a single sensor module assembly that is mechanically coupled to the engine hull. This merging provides stable mechanical positioning through the support structure while maintaining the sensor module as a replaceable unit. The mechanical coupling ensures reliable positioning during operation but allows complete module replacement when needed
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 achieves high accuracy in determining the rotational position of the shaft with improved robustness against external magnetic disturbances and assembly tolerances, while being cost-efficient and allowing for easy replacement without disassembling the engine.
Implementation Method 1
a magnetic field arrangement, which generates a magnetic field that varies with a rotation angle of the shaft
Data Source
AI summary
An embodiment relates to an angle sensor for detecting a rotational position of a shaft to which a magnetic field arrangement is attached, comprising: a first sensor element, a second sensor element, a support structure, wherein the first sensor element and the second sensor element are mechanically coupled to the support structure, wherein the support structure is arranged to be mechanically connected to a hull, wherein the hull at least partially encloses the shaft.