PCB Inductive Coupling for Rotary Torque Monitoring
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Solution Overview
Problem
Conventional inductive power transfer systems for rotary torque sensors require custom-designed ferrite cores and copper wire windings, leading to high costs and manufacturing delays.
Innovation Solution
The use of coaxial and parallel printed circuit boards (PCBs) with conductive spirals replaces traditional wound copper wire coils and ferrite cores, with the shaft acting as a magnetic core, and the PCBs connected through electronics for power and data transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If custom-designed ferrite cores and copper wire windings are used for inductive power transfer, then power transfer efficiency is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent extracts the ferrite core material from the inductive coupling system and replaces it with a non-magnetic material housing. The shaft itself serves as the magnetic path, eliminating the need for custom-designed ferrite cores and copper wire windings, thereby reducing manufacturing complexity while maintaining functional performance
Solution Approach 2:
The patent merges the housing structure with the magnetic circuit function. The non-magnetic housing encloses the air gap between primary and secondary windings, while the shaft serves as the magnetic path, combining structural and functional elements to eliminate separate ferrite core components
2Reliability
If traditional wound copper wire coils are used, then inductive coupling performance is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent replaces the mechanical winding process with PCB-based conductive traces. Instead of manually or mechanically winding copper wire into coils, conductive patterns are created on PCB substrates, eliminating complex winding machinery and manual labor while achieving the required inductance values
Solution Approach 2:
The patent changes the geometric parameters of the conductive traces on PCBs to achieve the required inductance values. By adjusting trace width, trace length, trace spacing, and number of traces, the desired electrical properties are obtained without complex winding structures
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 solution reduces manufacturing costs and time by eliminating the need for custom components, achieving efficient power transfer and data communication with improved availability and efficiency.
Implementation Method 1
The two PCB inductors are linked together inductively to supply power to the system electronics
Implementation Method 2
the shaft itself can function in part as the magnetic core. The shaft may, for example, be made of stainless steel
Data Source
AI summary
An inductive power transfer system for the shaft mounted electronics of a rotary torque signal generating system includes a pair of planar PCB inductors formed by spiral copper traces on the planar surfaces of one or more layers of PCB substrate material. A primary inductor comprising a copper trace on a planar PCB substrate surrounds but is not connected to a steel torque transmission shaft. A secondary PCB trace inductor on another planar substrate is mounted for rotation with the shaft and in coaxial relation with both the shaft and primary inductor substrate so as to be inductively linked therewith.