Magnetic Core Flux Sensor for Weight Reduction
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Solution Overview
Problem
Existing electromagnetic devices, such as transformers and inductors, often require overdesigning due to the lack of direct methods for measuring magnetic flux within their cores, leading to excess weight and volume, which is particularly problematic in applications like aircraft and aerospace where weight and size are critical considerations.
Innovation Solution
A magnetic core flux sensor assembly is introduced, featuring a flux sensor core portion with elongated openings and sensor holes that allow for the measurement of magnetic flux without disrupting the flux flow, using sensor conductor windings to generate electrical signals corresponding to the magnetic flux at different distances from the edges of the openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic flux is measured using finite element analysis or similar techniques, then magnetic flux can be estimated, but the measurement is not direct and leads to overdesigning with excess weight and volume
Solution Approach 1:
A magnetic core flux sensor assembly is introduced as an intermediary device to directly measure magnetic flux within the core. The sensor includes a flux sensor core portion with sensor holes and sensor conductor windings that couple to the magnetic flux, converting it into measurable electrical signals without disrupting the overall flux flow in the main core
Solution Approach 2:
The magnetic core is segmented to include a flux sensor core portion with sensor holes and openings, separating the measurement function from the main magnetic flux path. This allows direct measurement while maintaining the integrity of the overall magnetic circuit
2Reliability
If magnetic core size is increased to prevent saturation, then reliability improves, but weight and volume increase significantly
Solution Approach 1:
The magnetic core flux sensor provides real-time feedback on the magnetic flux levels and saturation patterns within the core. This information allows for optimized core design that prevents saturation through proper sizing and configuration, rather than overdesigning with excessive margins
3Measurement precision
If sensor holes are added to measure magnetic flux, then measurement capability improves, but magnetic flux flow disruption occurs
Solution Approach 1:
Sensor holes and openings are strategically positioned in specific locations within the flux sensor core portion where they minimize disruption to the overall magnetic flux flow. The sensor conductor windings are configured to couple with the flux at these specific locations without significantly affecting the global flux distribution
Solution Approach 2:
The flux sensor core portion acts as an intermediary structure that contains the sensor holes and openings, isolating their potential disruptive effects from the main magnetic core. This mediator structure allows measurement while protecting the primary magnetic flux path
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 enables direct measurement of magnetic flux within the core, allowing for more efficient design and reducing the weight and volume of electromagnetic devices by up to 50% compared to existing configurations, while maintaining high efficiency and low emissions.
Implementation Method 1
The magnetic flux flow generates an electrical signal in each sensor conductor winding
Data Source
AI summary
A magnetic core flux sensor assembly may include a flux sensor core portion and at least one elongated opening for receiving a conductor winding through the flux sensor core portion. An electrical current flowing through the conductor winding generates a magnetic field about the conductor winding and a magnetic flux flow about the elongated opening. A plurality of pairs of sensor holes are positioned relative to the elongated opening for preventing significant disruption of the magnetic flux flow and for sensing the magnetic flux flow at different distances from an edge of the elongated opening. A sensor conductor winding passes through each pair of sensor holes. The magnetic flux flow generates an electrical signal in each sensor conductor winding. The electrical signal in a particular sensor conductor winding corresponds to the magnetic flux flow at a location of the particular sensor conductor winding.