PCB Waveguide Structure for Velocity-Compensated Position Sensing
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Solution Overview
Problem
Current production methods for pulsed waveguides require complex processes, high capital investment, and tight manufacturing control, often compromising quality consistency.
Innovation Solution
A PCB-based pulsed waveguide position sensing system that incorporates a compensator to measure both reflected and end-of-line pulses, compensating for variations in propagation velocity due to temperature, magnetic fields, and manufacturing tolerances, allowing for accurate position determination irrespective of waveguide characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional production methods for pulsed waveguides are used, then manufacturing capability is maintained, but quality consistency deteriorates due to complex processes and tight manufacturing control requirements
Solution Approach 1:
The patent changes the physical parameters of the waveguide by introducing a magnetic layer with specific permeability characteristics and controlling its thickness relative to the skin depth. This parameter optimization allows the waveguide to achieve desired electromagnetic properties while simplifying the manufacturing process and improving quality consistency through more controllable fabrication parameters.
Solution Approach 2:
The patent employs a composite structure combining conductive layers, magnetic layers, and dielectric layers. This composite material approach enables the waveguide to achieve superior electromagnetic performance while allowing each layer to be manufactured using standard, well-controlled processes, thereby improving overall quality consistency without requiring complex integrated manufacturing.
2Measurement precision
If conventional waveguide structures are used, then structural simplicity is maintained, but position measurement accuracy deteriorates due to propagation velocity variations from temperature and manufacturing tolerances
Solution Approach 1:
The patent optimizes the magnetic layer thickness to be between 0.5 to 2 times the skin depth, and controls the permeability ratio between magnetic and non-magnetic regions. These parameter changes make the propagation velocity less sensitive to temperature variations and manufacturing tolerances, improving position measurement accuracy without requiring complex compensation mechanisms.
Solution Approach 2:
The patent converts the potentially harmful effect of manufacturing tolerances and environmental variations into a benefit by designing the magnetic layer parameters such that these variations produce minimal impact on propagation velocity. The specific thickness and permeability ratios are chosen to minimize sensitivity to tolerances, turning what would be sources of error into robust design features.
3Reliability
If complex production processes are used for pulsed waveguides, then manufacturing capability is maintained, but capital investment and direct labour involvement increase
Solution Approach 1:
The patent divides the waveguide into distinct functional layers (conductive layers, magnetic layers, dielectric layers) that can be manufactured separately using standard PCB fabrication processes. This segmentation allows each layer to be produced using conventional, cost-effective methods rather than requiring complex integrated manufacturing processes, thereby reducing capital investment and labor costs while maintaining manufacturing capability.
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 system achieves consistent and accurate position sensing across various applications, including fluid level systems and robotic systems, by dynamically adjusting pulse timing to account for environmental and manufacturing-induced changes, thereby enhancing quality and reducing production costs.
Implementation Method 1
The magnet 14 creates an impedance discontinuity 11 in a region of the waveguide 12 proximate to the magnet 14
Implementation Method 2
A reflection of the pulse 21 is reflected from the point of impedance discontinuity 11, resulting in reflected pulse 23
Implementation Method 3
a compensator configured to compensate for a change in propagation velocity of the waveguide in determining a position of the magnet relative to the waveguide
Data Source
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AI summary
Provided are waveguide sensors and position sensing systems. In some embodiments, a position sensing system may include a waveguide configured to receive and transmit a pulse, and a magnet moveable relative to the waveguide. The waveguide may include a first core layer and a second core layer, a magnetic layer between the first and second core layers, and a conductive winding around the first core layer, the second core layer, and the magnetic layer. The position sensing system may further include a first substrate layer above the conductive winding and a second substrate layer below the conductive winding.