Non-circular Coupler Sensor Signal Correction
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Solution Overview
Problem
Current rotary sensor systems with non-circular couplers generate non-sinusoidal input signals due to eddy currents and airgaps, leading to harmonic errors that deviate from a perfect sinusoid wave, which existing solutions attempt to correct using complex coil and coupler shapes, reducing signal strength.
Innovation Solution
A system comprising a coupler, sensor, memory module, and processor module, where the sensor includes a transmitter coil and two receiving coils generating sine-like and cosine-like functions, with the processor module computing arctangents, applying scaling factors, and calculating offsets to correct geometric errors and compensate for non-sinusoidal output signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complicated coil shapes and coupler shapes are used to generate sine signals, then measurement precision is improved, but device complexity increases and received signal strength is reduced
Solution Approach 1:
The patent replaces complex mechanical shaping of coils and couplers with an electronic signal processing system. The processor module applies correction algorithms to the raw signals from simple circular coils, substituting mechanical complexity with computational complexity to achieve the same sine wave generation goal.
Solution Approach 2:
The patent changes the approach from modifying physical geometry parameters (coil shapes, coupler shapes) to modifying signal parameters through digital processing. By applying correction factors and algorithms to the electrical signals, the system achieves accurate sine waves without complex physical structures.
2Measurement precision
If complicated coil shapes and coupler shapes are used to generate sine signals, then measurement precision is improved, but received signal strength is reduced
Solution Approach 1:
The patent replaces energy-intensive complex coil geometries with simple circular coils and compensates through low-power digital signal processing. This substitution maintains measurement precision while significantly reducing energy loss and improving received signal strength.
3Adaptability or versatility
If non-circular couplers are used, then rotational position sensing is enabled, but non-sinusoidal signals are generated causing harmonic errors
Solution Approach 1:
The patent uses simple circular couplers instead of complex non-circular shapes, and substitutes the mechanical signal conditioning function with electronic correction algorithms in the processor module, achieving both rotational sensing capability and sinusoidal signal accuracy.
4Loss of energy
If the coupler is placed close to the receiving coils, then signal strength is maximized, but airgap variations cause non-sinusoidal signals
Solution Approach 1:
The processor module acts as an intermediary that receives raw signals from the coil assembly and applies correction algorithms to eliminate airgap-induced distortions. This allows the physical system to operate at optimal coupling distance while the digital intermediary corrects the resulting non-sinusoidal components.
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 approach fundamentally eliminates errors associated with non-sinusoidal input signals, maximizing signal strength without reducing the coil area, and dynamically adjusts for varying airgaps, ensuring accurate rotational position measurement.
Implementation Method 1
a sensor spaced apart from a coupler to form a gap. The sensor includes a transmitter coil adapted to be energized by a high frequency current source
Implementation Method 2
couplers are made of metal and will have eddy currents flowing in the presence of a high frequency magnetic field. The eddy currents will produce a magnetic field that opposes the magnetic field that produced it.
Data Source
AI summary
A system including a non-circular coupler, a sensor, a memory module, and a processor module is provided. The sensor includes a transmitter coil adapted to be energized by a high frequency current source and at least two receiving coils. One of the receiver coils generate a sine-like function output signal and the other generates a cosine-like function output signal upon rotation of the coupler. The memory module is operable to compensate for non-sinusoidal output signals caused by a plurality of geometric errors and a gap between the coupler and the at least two receiving coils. The processor module configured to process the non-sinusoidal output signals from both the first and second receiver coils, determine an error in the non-sinusoidal output signals from both the first and second receiver coils, mathematically compensate the assembly to eliminate the error and generates an output signal representative of the rotational position of the coupler.