Magnetostrictive Torque Sensor Compact Flexible Substrate Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetostrictive torque sensors face challenges in securing installation space due to their size, necessitating a reduction in sensor dimensions.
Innovation Solution
A magnetostrictive torque sensor design featuring a holder with a cylinder portion and protrusion, combined with a flexible substrate having detection coils and signal lines, where the signal line portion is fixed to the protrusion and led out of the holder, allowing for a compact configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a resin housing with internal cable connections is used, then the sensor structure is enclosed and protected, but the sensor size increases making installation difficult
Solution Approach 1:
The patent extracts the cable connection function from the internal housing structure and moves it to an external configuration. The flexible substrate with signal lines extends outward from the holder, allowing cable connections to be made outside the main sensor body. This extraction eliminates the need for a large enclosed housing while maintaining the sensor's protective and functional properties.
Solution Approach 2:
The patent transitions from a three-dimensional enclosed housing structure to a more planar, extended configuration. The flexible substrate with signal lines creates a two-dimensional expansion path that allows cable connections without increasing the core sensor volume, effectively using dimensional change to resolve the space constraint.
2Volume of moving object
If the sensor is reduced in size, then installation space is saved, but the structural complexity of accommodating cables and connections increases
Solution Approach 1:
The patent merges the signal transmission function and the cable connection function into a single integrated flexible substrate structure. The signal lines are directly formed on the flexible substrate, which also serves as the connection interface for cables. This merging eliminates the need for separate cable management components, reducing overall structural complexity despite the compact size.
Solution Approach 2:
The flexible substrate serves multiple functions simultaneously: it provides structural support, carries signal lines for electrical connections, and acts as the interface for cable attachment. This multi-functionality reduces the number of separate components needed, thereby reducing structural complexity while maintaining compact dimensions.
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 design achieves a reduction in sensor size, facilitating easier installation in limited spaces while maintaining detection accuracy and sensitivity.
Implementation Method 1
magnetostrictive torque sensor configured to be attached around a rotating shaft exhibiting a magnetostrictive effect and detects torque transmitted by the rotating shaft
Data Source
AI summary
A magnetostrictive torque sensor is configured to be attached around a rotating shaft exhibiting a magnetostrictive effect and detects torque transmitted by the rotating shaft, and includes a holder having a cylinder portion with a hollow cavity in a center through which the rotating shaft is inserted and a protrusion provided to protrude radially outward from the cylinder portion, and a flexible substrate that includes a detection portion on which a coil group including a combination of a plurality of detection coils aligned in a predetermined direction is formed by a wiring pattern, and a signal line portion on which a plurality of signal lines electrically connecting the coil group to an external device are formed by a wiring pattern, wherein the detection portion is wrapped around an outer circumference of the cylinder portion of the holder, and wherein a part in a longitudinal direction of the signal line portion is fixed to the protrusion of the holder by a fixing member, and a tip end-side portion of the signal line portion than the fixed portion is led out of the holder.