PCB Rotary Position Sensor Without Laminations or Wound Coils

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Solution Overview

Problem

Existing rotary position sensors face challenges such as high manufacturing costs due to complex designs, require skilled labor, and have limited applicability due to magnetic interference and temperature constraints, with resolvers and RVDTs needing complex processes and laminations.

Innovation Solution

A configurable rotary position sensor with a printed circuit board (PCB) assembly that eliminates the need for laminations and physical poles, featuring primary and secondary coil elements printed on the PCB, which reduces manufacturing complexity and cost, and allows for quadrature sinusoidal or quadrant linear outputs based on coil element numbers and geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional resolver or RVDT designs are used, then reliable rotary position sensing is achieved, but manufacturing complexity and cost increase due to laminations and complex assembly processes

Engineering Contradiction:

Improverotary position sensing reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical lamination structures with a printed circuit board (PCB) assembly. The PCB serves as the stator assembly, eliminating the need for complex lamination processes while maintaining the electromagnetic functionality required for reliable rotary position sensing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses printed coil patterns on the PCB to replicate the functionality of traditional wound coils. This copying approach simplifies manufacturing by using standard PCB fabrication processes instead of complex wire winding and lamination techniques.

Inventive Principle:

Principle #26Copying

2Reliability

If traditional sensor designs with wound coils are used, then electromagnetic functionality is achieved, but skilled labor is required for assembly

Engineering Contradiction:

Improveelectromagnetic functionalityVSAvoidassembly labor skill requirement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent substitutes manual wire winding and coil assembly operations with automated PCB fabrication processes. The coil patterns are printed directly on the PCB using standard manufacturing techniques, eliminating the need for skilled labor in coil assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The PCB structure integrates both the stator assembly and base assembly functions into a single component that manufactures itself through standard PCB processes, eliminating the need for separate assembly operations requiring skilled labor.

Inventive Principle:

Principle #25Self-service

3Reliability

If resolvers and RVDTs are manufactured using conventional processes, then functional sensors are produced, but manufacturing cost increases due to complex processes and laminations

Engineering Contradiction:

Improvesensor functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replicates the electromagnetic functionality of traditional resolvers and RVDTs using printed patterns on a standard PCB. This copying approach allows the use of inexpensive, high-volume PCB manufacturing processes instead of costly custom winding and lamination operations.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent employs a standard PCB as the sensor core, which can be manufactured at low cost using high-volume production techniques. The PCB serves as a disposable or replaceable component that simplifies the overall manufacturing cost structure.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 provides a cost-effective, simplified manufacturing process for rotary position sensors that can operate across various environments, reducing production costs and improving applicability by eliminating the need for skilled labor and complex assembly processes.

Implementation Method 1

a rotary position sensor is provided. In some embodiments, the rotary position sensor comprises a rotor assembly comprising a rotor assembly opening for securing the rotor assembly to a shaft structure; a stator assembly comprising a stator assembly opening for receiving the shaft structure; and a base assembly secured to the stator assembly

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP4467931A1Rotary position sensor

Publication Date: 2024.11.27 HONEYWELL INTERNATIONAL INC

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AI summary

Apparatuses, systems, and methods for sensing rotary positions are provided. For example, an example rotary position sensor includes a rotor assembly having a rotor assembly opening for securing the rotor assembly to a shaft structure, a stator assembly having a stator assembly opening for receiving the shaft structure, and a base assembly secured to the stator assembly. In some examples, the base assembly (such as, but not limited to, a PCB assembly) comprises a plurality of primary coil elements printed on a first side of the base assembly and a plurality of secondary coil elements printed on a second side of the base assembly.