Tubular Magnetic Core Radial Protrusion Indent Locking
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Solution Overview
Problem
Existing electromagnetic devices, such as Linear Variable Differential Transducers (LVDTs), face challenges in preventing relative movement between the magnetic core and the core support, which affects the device's operation and requires complex adjustments to compensate for manufacturing tolerances.
Innovation Solution
The use of a tubular magnetic core with radial protrusions and complementary indents on the core support prevents longitudinal and other directional movements, ensuring stable operation by forming the core from rolled or folded sheet metal, where the protrusions penetrate to create indents that match their shape, thereby securing the core in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional magnetic core assembly methods are used, then manufacturing is simpler, but relative longitudinal movement between core support and magnetic core occurs affecting device operation
Solution Approach 1:
The magnetic core is segmented into multiple sections along its length, with each section having indents formed at specific positions. These indents engage with protrusions on the core support, creating discrete positioning points that prevent longitudinal movement while maintaining overall core integrity and functionality.
Solution Approach 2:
The solution transitions from preventing movement in one dimension to using features in another dimension. By forming indents in the radial direction that engage with protrusions, the patent prevents longitudinal movement through a dimensional approach rather than direct longitudinal constraint mechanisms.
2Manufacturing precision
If manufacturing tolerances are not compensated, then manufacturing is easier, but device accuracy deteriorates requiring complex adjustments
Solution Approach 1:
The indents are pre-formed in the magnetic core sections during the manufacturing process, before final assembly. This preliminary action ensures that when the core is assembled to the core support, the protrusions automatically engage with the pre-formed indents, providing precise positioning that compensates for manufacturing tolerances without requiring complex post-assembly adjustments.
Solution Approach 2:
The engageable features (indents and protrusions) are designed to automatically self-align and self-position the magnetic core relative to the core support. This self-service mechanism eliminates the need for complex external adjustment mechanisms, allowing the assembly to compensate for manufacturing variations through its own geometric features.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~4
AI summary
An electromagnetic device is disclosed, the electromagnetic device comprising a core support (14) having an exterior surface comprising at least one radial protrusion (30), a tubular magnetic core (12) positioned around a portion of the length of the core support (14), the tubular magnetic core (12) having an interior surface, at least one indent (34) located in the interior surface of the tubular magnetic core (12), wherein the at least one protrusion (30) is located within the at least one indent (34) to prevent relative longitudinal movement between the core support (14) and tubular magnetic core (12), and a primary coil (16) and at least one secondary coil (18,20), each coil positioned around a portion of a length of the tubular magnetic core (12).