Magnetic Sensor Recess Conductor Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high production cost of winding coils in existing magnetic field-sensitive sensors poses a significant challenge, necessitating a more cost-effective manufacturing approach.
Innovation Solution
A magnetic field-sensitive sensor design featuring a body made of magnetic material with a continuous recess and a wall, where an electrical conductor extends between two ends and is guided through the recess without wrapping around the wall, allowing for simplified assembly and reduced manufacturing complexity, akin to a coil with one turn, using highly permeable materials like nanocrystalline iron or ferrite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a coil is wound around the wall of the magnetic body, then the sensor provides sufficient signal strength and inductance, but the production cost and manufacturing complexity increase significantly
Solution Approach 1:
The patent replaces the traditional multi-turn wound coil with a single straight conductor that copies the essential function of the coil through the magnetic core's high permeability material. The magnetic core amplifies the effect of the single conductor turn, reproducing the inductance and signal characteristics of a multi-turn coil without the manufacturing complexity of winding
Solution Approach 2:
The patent changes the key parameter from number of turns (in traditional coils) to magnetic permeability (in the core material). By using materials with very high permeability (nanocrystalline iron or ferrite), a single conductor turn achieves the same inductance and signal strength that would traditionally require many turns, thereby simplifying manufacturing while maintaining measurement precision
2Reliability
If a coil is wound around the wall of the magnetic body, then the sensor achieves adequate inductance, but the device complexity and assembly steps increase
Solution Approach 1:
The essential function of the wound coil (creating inductance through magnetic field circulation) is copied by passing a straight conductor through the magnetic core. The high permeability material guides and concentrates the magnetic flux, achieving the same inductance effect with a much simpler conductor configuration that requires no winding or securing to the core surface
Solution Approach 2:
Instead of wrapping the conductor around the external surface of the magnetic core (traditional approach), the conductor is passed through the internal bore of the core. This inversion of the conductor's spatial relationship to the core simplifies the assembly process while maintaining the magnetic coupling necessary for inductance
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 design significantly reduces production costs, enhances manufacturing efficiency, and maintains high signal accuracy with redundancy options, enabling fail-safe and diagnostic capabilities while minimizing space requirements.
Implementation Method 1
from whose magnetic field the permeability of the body can be varied depending on the distance between the body and the magnet
Implementation Method 2
at least one electrical conductor extending between two ends and which is guided through the recess
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a measuring arrangement comprising a sensor (2) which is sensitive to magnetic fields and has a body (10) which is provided with a continuous recess (12) and a wall (26) defining said recess and consists of a magnetic material, and at least one electrical conductor (5) extending between two ends and guided through the recess (12); a magnet (22) that can be moved in relation to the body (10) and has a magnetic field which enables the permeability of the body (10) to vary according to the distance between the body (10) and the magnet (22); and an evaluation device (4) that can be connected or is connected to the conductor (5) and by which means the variation in the permeability of the body (10) can be detected. The conductor (5) does not surround the wall (26).