Magnetic Bearing Sensor Holder for Precise Rotor Position Detection
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Solution Overview
Problem
Existing magnetic bearing devices struggle to accurately determine the position of a rotor with high precision due to inaccuracies in sensor placement, such as soldering or gluing, which affects the accuracy of rotor position determination.
Innovation Solution
A magnetic bearing device with a stator design featuring coil cores and a cup-shaped recess, incorporating magnetic field sensors housed in an annular holder with defined cavities, ensuring precise sensor positioning and accurate rotor position determination through the use of a soft potting compound and separate guide elements for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic field sensors are mounted using soldering or gluing methods, then the device complexity is reduced and ease of manufacture is improved, but the manufacturing precision of sensor placement deteriorates, affecting rotor position determination accuracy
Solution Approach 1:
The patent introduces an intermediate component (sensor holder with cavity) between the circuit board and the magnetic field sensor. This holder provides a precisely engineered cavity that receives and positions the sensor with high accuracy, eliminating the need for direct soldering or gluing of the sensor to the board. The intermediary structure decouples the mounting process from the positioning precision requirement.
Solution Approach 2:
The sensor holder is pre-formed with a cavity of precise dimensions before the sensor is installed. This preliminary preparation of the mounting structure ensures that when the sensor is placed in the cavity, its position is automatically determined with high precision by the cavity geometry, rather than relying on the precision of the attachment process itself.
2Device complexity
If magnetic field sensors are arranged around the cup-shaped recess without precise positioning structures, then the device complexity is reduced, but the measurement precision of rotor position deteriorates
Solution Approach 1:
The sensor holder acts as an intermediary structure that provides precise positioning for multiple sensors around the cup-shaped recess. Each sensor is received in a separately defined cavity, ensuring accurate radial and axial positioning without requiring complex overall sensor array structures.
Solution Approach 2:
The sensor holder is designed with multiple separate cavities, each independently formed to receive a specific magnetic field sensor. This segmentation allows each sensor to be positioned with high precision in its own cavity while maintaining a relatively simple overall holder structure, avoiding the need for complex integrated positioning features.
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 solution enables very high accuracy in determining the rotor's position, reducing inaccuracies from sensor placement methods and enhancing the precision of rotor control.
Implementation Method 1
The rotor is supported and stabilized by magnetic forces generated by a stator within the magnetic bearing device
Implementation Method 2
a plurality of magnetic field sensors for determining the position of the rotor are arranged around the cup-shaped recess
Data Source
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AI summary
A magnetic bearing device is proposed for the contactless magnetic bearing of a rotor (3) comprising a disk-shaped or annular magnetically active core (31), wherein the magnetic bearing device has a stator (2) comprising a plurality of coil cores (25), each of which comprises a longitudinal leg (26) extending from a first end (261) in an axial direction (A) to a second end (262), and a transverse leg (27) arranged at the second end (262) of the longitudinal leg and extending in a radial direction perpendicular to the axial direction (A), wherein at least one concentrated winding (61) is provided on each longitudinal leg (26), which surrounds the respective longitudinal leg (26), wherein the stator (2) further has a cup-shaped recess (211) into which the rotor (3) can be inserted,wherein the cup-shaped recess (211) is arranged at an axial end of the stator (2), wherein the transverse legs (27) are arranged around the cup-shaped recess (211), and wherein a plurality of magnetic field sensors (8) for determining the position of the rotor (3) are arranged around the cup-shaped recess (211). An annular holding device (9) is provided for the magnetic field sensors (8), which has a cavity (95) for each magnetic field sensor (8), which is delimited with respect to the radial direction by an inner wall (951) and by an outer wall (952), wherein the magnetic field sensor (8) can be inserted into the cavity (95), and wherein the cavity (95) is dimensioned such that the inner wall (951) and the outer wall (952) lie flat against the magnetic field sensor (8). Furthermore, a centrifugal pump with such a magnetic bearing device is proposed.