Magnetic Linear Sensor Compact Coil Arrangement
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Solution Overview
Problem
Conventional magnetic linear sensors face challenges in improving detection accuracy and miniaturization due to the limitations of increasing the number of concentric circles in conductive patterns and stacking pair sheets, which affect the size and sensitivity of the sensor.
Innovation Solution
A magnetic linear sensor configuration featuring a linear scale with alternating magnetic response sections and a sensor head with a multilayer structure of conductive patterns and through holes, allowing for a compact arrangement of coil elements and improved detection accuracy by reducing the detection pitch and increasing the number of coil elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of concentric circles in conductive patterns is increased to obtain a larger detection signal, then the detection signal is improved, but the size of the first conductive pattern in the radial direction increases
Solution Approach 1:
The patent transitions from a planar concentric circle arrangement to a three-dimensional stacked arrangement of conductive patterns. Multiple pairs of first and second conductive patterns are stacked in the thickness direction, allowing the number of coil elements to be increased without increasing the radial footprint. This dimensional transition resolves the contradiction by achieving higher detection signal through vertical stacking rather than radial expansion.
Solution Approach 2:
The patent divides the detection section into multiple stacked pairs of conductive patterns, where each pair forms a separate coil element. This segmentation allows the total number of coil elements to be increased by adding more stacked pairs, thereby improving detection signal without requiring each individual pattern to be larger. The detection section is segmented into multiple functional units arranged in the thickness direction.
2Measurement precision
If the number of stacked pair sheets is increased to improve detection accuracy, then the detection accuracy is improved, but the size in the axial direction increases
Solution Approach 1:
The patent merges multiple detection sections into a single integrated sensor head structure. The stacked pairs of conductive patterns are combined within one sensor head, and multiple sensor heads are arranged in the displacement detection direction. This merging approach improves detection accuracy through multiple detection sections while controlling the overall size by efficiently packaging the stacked structures within compact sensor head units.
Solution Approach 2:
The patent arranges multiple sensor heads in the displacement detection direction (one dimension) while stacking conductive patterns in the thickness direction (another dimension). This multi-dimensional arrangement allows high detection accuracy through multiple sections without proportionally increasing the axial size, as the stacking provides vertical integration that reduces the footprint in other dimensions.
3Measurement precision
If the detection pitch is reduced to improve detection accuracy, then the detection accuracy is improved, but the number of coil elements must be increased which complicates the structure
Solution Approach 1:
The patent segments the detection section into multiple stacked pairs of conductive patterns, where each pair forms a coil element. This segmentation provides a modular structure that simplifies the overall design while enabling high coil element counts. Each stacked pair is a repeatable unit that can be independently fabricated, reducing the complexity of manufacturing and assembly even as the number of elements increases to support finer detection pitch.
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 a smaller, more accurate magnetic linear sensor with enhanced detection sensitivity and a compact configuration, allowing for precise detection of displacement and improved signal retrieval.
Implementation Method 1
displacement sensors that measure the displacement of a measurement target using electromagnetic induction phenomena
Implementation Method 2
The first magnetic response section is configured such that changes in magnetic influence on the sensor head appear alternately and repeatedly at every first pitch
Data Source
AI summary
A magnetic response section provided by a scale of a magnetic linear sensor is configured so that changes in magnetic influence on a magnetic detection head appear alternately and repeatedly every first pitch in a displacement detection direction. The magnetic detection head is provided on one side of the scale in the first direction, which is a direction perpendicular to the displacement detection direction, and provided with a base substrate section and a plurality of signal output sections. The signal output sections are arranged on an insulating plate and in the displacement detection direction at a second pitch based on a first pitch. The first conductive pattern and the second conductive pattern included by each of the signal output sections are formed to arrange coil elements side by side in an elongated area in a second direction orthogonal to both the displacement detection direction and the first direction.