Redundant PCB Inductive Resolvers for EMI-Resilient Steering
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Solution Overview
Problem
Existing vehicle steering systems lack redundancy in sensor operation, making them susceptible to failure due to electromagnetic interference and single-point failures, which can compromise vehicle control.
Innovation Solution
Implementing redundant inductive resolver sensors on a single printed circuit board (PCB) with multiple coils and processors, allowing for backup operation if one sensor fails, and using inductive coils in a coaxial and annular arrangement to minimize interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single sensor is used in the steering system, then the device complexity is reduced, but the reliability deteriorates due to susceptibility to electromagnetic interference and single-point failures
Solution Approach 1:
The sensor system is segmented into multiple independent inductive resolver sensors (first sensor with first receiver coil, second sensor with second receiver coil) that can operate independently. Each sensor has its own receiver coil and processing circuitry, allowing one sensor to fail while the other continues to provide steering control signals.
Solution Approach 2:
The system incorporates redundant sensors before failures occur, creating a cushion against potential single-point failures. The redundant sensors are pre-configured on the same PCB with independent power management circuits, ready to take over immediately if the primary sensor fails due to electromagnetic interference or component failure.
2Reliability
If redundant sensors are implemented, then the reliability improves, but the device complexity increases
Solution Approach 1:
Multiple redundant inductive resolver sensors are merged onto a single PCB substrate. The first receiver coil and second receiver coil are positioned on the same PCB with shared power management circuits and processing capabilities, reducing the overall system complexity compared to separate sensor assemblies while maintaining redundancy.
Solution Approach 2:
The PCB is designed with universal functionality to support multiple sensors and their processing circuits. The same PCB housing, power management infrastructure, and signal processing architecture serve all redundant sensors, eliminating the need for separate dedicated circuits for each sensor and thereby limiting the increase in device complexity.
3Object-affected harmful factors
If inductive coils are arranged in coaxial and annular configuration, then the electromagnetic interference is minimized, but the manufacturing precision requirements increase
Solution Approach 1:
The receiver coils are arranged in asymmetric coaxial and annular configurations rather than symmetric arrangements. This asymmetric positioning optimizes the electromagnetic field distribution to minimize mutual interference between coils while maintaining adequate spacing and alignment, reducing the stringency of manufacturing precision requirements.
Solution Approach 2:
The PCB substrate serves as an intermediary platform that provides precise mechanical support and positioning for the inductive coils. The PCB's rigid structure and integrated design enable accurate placement of coils in coaxial and annular arrangements, facilitating precise alignment during manufacturing while maintaining the electromagnetic benefits of the complex coil configuration.
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
Ensures continuous vehicle control by switching to a functional redundant sensor in case of failure, reducing susceptibility to electromagnetic interference and maintaining steering functionality.
Implementation Method 1
inductive resolver sensors... using inductive coils in a coaxial and annular arrangement
Data Source
AI summary
Disclosed examples include a printed circuit board (PCB) having a first power management circuit coupled to a first transmission coil; a second power management circuit; a first receiver coil including a first coil portion on a first layer of the PCB and a second coil portion on a second layer of the PCB; a second receiver coil including a third coil portion on the first layer of the PCB and a fourth coil portion on the second layer of the PCB, the second receiver coil in coaxial alignment with the first transmission coil and the first receiver coil.