Modular Inductive Sensor Circuit Boards for Motor Configurations
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Solution Overview
Problem
Inductive sensors face challenges in accommodating different electric motor or generator configurations without requiring modifications to the interconnect assembly, as existing designs lack flexibility in coil configurations and processing circuitry arrangements.
Innovation Solution
The inductive sensor features modular circuit boards with interconnect points that remain fixed in location across different coil and processing configurations, allowing for interchangeable circuit boards to accommodate various motor or generator configurations without modifying the interconnect assembly, and includes a housing with a target that shields the circuit boards from external electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the sensor uses fixed coil configurations and processing circuitry arrangements, then the manufacturing and assembly process is simplified, but the sensor cannot accommodate different electric motor or generator configurations
Solution Approach 1:
The sensor is divided into separate modular circuit boards, each with specific coil configurations and processing circuitry. This segmentation allows individual boards to be manufactured with fixed configurations for simplicity, while the system as a whole achieves versatility through modular assembly and interchangeability of these standardized modules.
Solution Approach 2:
The circuit boards are designed with standardized interconnect points and mounting features that allow the same basic module structure to serve multiple functions across different motor and generator configurations. The universal interface enables a single module design to accommodate various applications by changing only the specific coil configuration on the board.
2Adaptability or versatility
If the sensor requires modifications to the interconnect assembly for different configurations, then precise positioning is maintained, but the complexity and cost of customization increases
Solution Approach 1:
The circuit boards are pre-configured with interconnect points at predetermined locations during manufacturing. This preliminary action ensures that when the boards are assembled into the sensor, the interconnect assembly requires no modifications - the positioning is already optimized for the specific configuration. Different configurations are achieved by selecting pre-made boards with appropriate coil layouts, not by modifying the interconnect assembly.
3Adaptability or versatility
If the circuit boards are designed with interchangeable configurations, then adaptability to different motors is improved, but the risk of electromagnetic coupling with external metal components increases
Solution Approach 1:
The patent acknowledges that inductive sensors are inherently sensitive to electromagnetic coupling, but converts this sensitivity into a benefit by using it for shielding. The circuit board design incorporates metal components and structures that, while potentially sources of interference, are strategically positioned and configured to create electromagnetic shielding that protects the sensor from external interference. The same inductive coupling principle that causes vulnerability is used to create protection.
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 enables seamless interchangeability of circuit boards for different electric motor or generator configurations, preventing electromagnetic coupling with external metal components and ensuring accurate position and speed determination of the target relative to the sensor element.
Implementation Method 1
The transmit coil is configured to induce an electrical current in the plurality of receive coils via a target
Data Source
AI summary
An inductive sensor includes a first circuit board having a sensor element configurable in a plurality of different coil configurations. The sensor element includes a transmit coil and a plurality of receive coils. The first circuit board includes interconnect points positioned at a same location on the first circuit board for each of the plurality of different coil configurations. The inductive sensor includes a second circuit board spaced apart from the first circuit board along the axial direction. The second circuit board includes processing circuitry associated with the sensor element and configurable in a plurality of different configurations. The second circuit board includes interconnect points positioned at a same location on the second circuit board for each of the configurations of the processing circuitry. Furthermore, each interconnect point on the second circuit board is aligned with a corresponding interconnect point on the first circuit board along circumferential and radial directions.