Off-Axis Magnetic Sensor Layout for Wider Airgap Accuracy
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Solution Overview
Problem
Existing resolver designs with vertically and horizontally mounted magnetic field sensors result in bulky, heavy sensor packages and limited airgap, constraining accuracy and applicability.
Innovation Solution
A horizontally oriented printed circuit board assembly (PCBA) housing a pair of magnetic field sensors, configured parallel to a magnet's planar surface, generates phase-shifted electrical signals via rotational displacement, allowing for a larger airgap and improved accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vertically mounted magnetic field sensors are used, then measurement precision is improved, but device complexity and weight increase
Solution Approach 1:
The patent combines multiple magnetic field sensors (first and second sensors) onto a single PCBA that is horizontally mounted, eliminating the need for separate vertical and horizontal PCBAs. This merging approach maintains measurement precision while reducing device complexity and weight by integrating sensors that were previously required to be mounted in different orientations on separate boards.
Solution Approach 2:
The patent transitions from vertical mounting to horizontal mounting of the PCBA, changing the dimensional orientation of the sensor assembly. This dimensional change allows the sensors to be positioned parallel to the magnet's planar surface, enabling a larger airgap while maintaining measurement accuracy and simplifying the overall device structure.
2Measurement precision
If vertically mounted magnetic field sensors are used, then measurement precision is improved, but weight increases
Solution Approach 1:
The patent combines multiple magnetic field sensors (first and second sensors) onto a single PCBA that is horizontally mounted, eliminating the need for separate vertical and horizontal PCBAs. This merging approach maintains measurement precision while reducing device complexity and weight by integrating sensors that were previously required to be mounted in different orientations on separate boards.
3Measurement precision
If vertically mounted magnetic field sensors are used, then measurement precision is improved, but airgap is limited
Solution Approach 1:
The patent transitions from vertical mounting to horizontal mounting of the PCBA, changing the dimensional orientation of the sensor assembly. This dimensional change allows the sensors to be positioned parallel to the magnet's planar surface, enabling a larger airgap while maintaining measurement accuracy and simplifying the overall device structure.
Solution Approach 2:
The patent changes the mounting orientation parameter from vertical to horizontal, which directly enables a larger airgap between the magnet and sensors. This parameter change allows the airgap to exceed the 1-2 mm limitation imposed by vertical mounting, while the horizontal configuration maintains the necessary measurement precision through proper sensor positioning and signal processing.
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 reduces package size and weight, enables a wider airgap, and enhances accuracy and applicability to various applications by generating reliable, redundant electrical signals.
Implementation Method 1
the plurality of radial spiral shapes provides variance in one or more magnetic fields that are induced by the plurality of magnetic poles on the pair of magnetic field sensors upon causing a rotational displacement between the plurality of magnetic poles and the pair of magnetic field sensors
Implementation Method 2
the pair of magnetic field sensors are configured to generate the respective pair of electrical signals based on a variance in one or more magnetic fields that are induced on the pair of magnetic field sensors
Data Source
AI summary
A sensor assembly comprising a printed circuit board assembly (PCBA) housing that is configured horizontally or in parallel with a planar surface of a magnet. The PCBA housing comprises a PCBA that is deposed within a cavity of the PCBA housing. The PCBA comprises a pair of magnetic field sensors that (i) are oriented horizontally with respect to the planar surface of the magnet and (ii) comprises a first magnetic field sensor of the pair of magnetic field sensors that is configured a predetermined distance from a second magnetic field sensor of the pair of magnetic field sensors, wherein the pair of magnetic field sensors are configured to generate a respective pair of electrical signals that comprise a phase-shift between the respective pair of electrical signals proportional to the predetermined distance.