PCB Inductive Angular Sensing for Harsh Industrial Environments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical and capacitive sensors in industrial automation are susceptible to environmental factors like dust, moisture, and lubricants, leading to inoperability and inaccurate results.
Innovation Solution
An inductive sensor system using a transmitter coil and receiver coils on a printed circuit board assembly to measure angular motion, inducing eddy currents in an electrically conductive target, which alter output signals based on angular displacement, providing robust and accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical control sensors are used for measuring angular motion, then measurement precision can be achieved, but the sensors become susceptible to environmental factors such as dust, moisture, and lubricants causing inoperability and inaccurate results
Solution Approach 1:
The patent replaces optical sensors with an inductive sensing system that uses magnetic fields instead of light. The transmitter coil generates a magnetic field that induces eddy currents in the conductive target, and receiver coils detect changes in this field based on angular position. This substitution eliminates the use of delicate optical components while maintaining measurement precision and improving reliability in harsh industrial environments with dust, moisture, and lubricants.
Solution Approach 2:
The patent changes the physical parameter used for sensing from optical (light) to electromagnetic (magnetic field). By using a transmitter coil to generate a magnetic field and receiver coils to detect changes in the magnetic field caused by eddy currents in the target, the system achieves contactless angular position measurement that is immune to environmental contaminants while maintaining high measurement precision.
2Measurement precision
If capacitive sensors are used for measuring angular motion, then measurement capability is provided, but the outputs remain sensitive to foreign matters such as moisture, water, and lubricant
Solution Approach 1:
The patent replaces capacitive sensors with an inductive sensing system that uses magnetic fields and eddy currents. The transmitter coil generates a magnetic field that induces eddy currents in the conductive target, and receiver coils detect changes in the magnetic field. This substitution eliminates the sensitivity to foreign matters that plagues capacitive sensors while maintaining angular motion measurement capability.
Solution Approach 2:
The patent introduces a conductive target as an intermediary element that interacts with the magnetic field. The target, which can be a separate component or integrated into the moving part, carries the angular position information through changes in the magnetic field it experiences and generates. This intermediary approach allows the sensing system to remain isolated from environmental contaminants while accurately measuring angular motion.
3Measurement precision
If contact-based sensors are used for angular motion sensing, then direct measurement is achieved, but the sensors are exposed to harsh environmental conditions leading to inoperability
Solution Approach 1:
The patent introduces a conductive target as an intermediary that carries the measurement information without the sensor itself being exposed to harsh conditions. The transmitter and receiver coils remain stationary on the PCBA, while the conductive target moves with the component being monitored. This intermediary approach enables direct angular motion measurement while protecting the sensitive sensor components from environmental damage.
Solution Approach 2:
The patent replaces contact-based mechanical sensors with a contactless inductive sensing system. By using magnetic fields to transmit measurement information across a gap between the stationary coils and the moving conductive target, the system achieves direct angular motion measurement without mechanical contact, thereby eliminating wear and exposure to harsh conditions.
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 inductive sensor system offers robust, real-time, and accurate angular motion sensing in harsh industrial environments, enabling health monitoring of electrical protective devices and predicting component health.
Implementation Method 1
a transmitter coil on a sensor portion of the PCBA. The transmitter coil is configured for producing a magnetic field when energized
Implementation Method 2
The magnetic field induces eddy currents in the electrically conductive target
Implementation Method 3
The eddy currents produce a counter magnetic field configured to alter the one or more output signals of the receiver coils responsive to an angular displacement of the electrically conductive target
Data Source
AI summary
An inductive sensor is integrated on a printed circuit board assembly (PCBA) of an electrical protective device, such that the inductive sensor is configured to contactlessly measure angular motion of an electrically conductive target mounted on the PCBA corresponding to a component of the electrical protective device. The inductive sensor comprises an integrated circuit, a transmitter coil, and receiver coils spaced apart vertically from the electrically conductive target. The integrated circuit is electrically coupled to the transmitter coil such that the integrated circuit is configured to transmit a high frequency time varying signal into the transmitter coil. The high frequency time varying signal energizes the transmitter coil thereby inducing a magnetic field. The magnetic field induces one or more output signals on the receiver coils and eddy currents in the electrically conductive target. The eddy currents produce a counter magnetic field that alters the output signals responsive to an angular displacement of the electrically conductive target.