Position Sensor Circuit Board Coil Integration
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Solution Overview
Problem
The complexity of mechanical construction in inductive and eddy current position sensors, which requires both mechanical support for ferromagnetic cores and space for coils, limits their design and efficiency in contactless position measurement applications, particularly in industrial environments like linear electric machines.
Innovation Solution
The use of circuit boards with electric conductors and connectors to form coils around ferromagnetic cores, eliminating the need for separate coil windings and allowing for shared circuit boards among multiple position sensors, thereby simplifying the mechanical structure and enhancing measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate coil windings and mechanical support structures are used for ferromagnetic cores, then the position sensor can perform contactless position measurement, but the mechanical construction becomes complex and requires more space
Solution Approach 1:
The patent merges the coil winding function with the circuit board structure. The circuit board itself serves as the mechanical support for the ferromagnetic core, while conductive traces on the circuit board form the coil windings. This integration eliminates the need for separate coil winding processes and reduces the number of mechanical components required.
Solution Approach 2:
The circuit board performs multiple functions simultaneously: it provides mechanical support for the ferromagnetic core, serves as the structural framework for the sensor, and contains the conductive traces that form the coil windings. This multi-functionality reduces device complexity while maintaining the contactless measurement capability.
2Reliability
If separate coil windings are used around the ferromagnetic core, then the position sensor achieves proper magnetic flux conduction, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The coil windings are merged with the circuit board manufacturing process. Conductive traces are created using standard PCB fabrication techniques during board production, eliminating the need for separate coil winding operations. This integration significantly improves manufacturing efficiency while ensuring proper magnetic flux conduction paths.
Solution Approach 2:
The coil structure is pre-formed as part of the circuit board manufacturing process before the position sensor assembly is completed. The conductive traces are created during PCB fabrication, which occurs early in the manufacturing sequence, allowing subsequent assembly steps to focus only on integrating the ferromagnetic core and other components.
3Strength
If traditional mechanical support structures are used for ferromagnetic cores, then the position sensor maintains structural integrity, but the overall device size increases and compact configurations become difficult
Solution Approach 1:
The circuit board serves as both the structural support framework and the electrical connection medium. This eliminates the need for additional mechanical support structures, allowing the position sensor to maintain structural integrity while achieving a more compact configuration that fits within tighter spatial constraints.
Solution Approach 2:
The mechanical support function is merged with the circuit board structure. The rigid PCB provides the necessary structural framework to hold the ferromagnetic core in place, eliminating the need for separate mechanical support components and reducing the overall device volume.
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 approach reduces the complexity of the sensor design, allows for more compact configurations, and improves measurement accuracy by enabling the use of multiple position sensors with shared circuit boards, enhancing the performance in contactless position measurement applications.
Implementation Method 1
a ferromagnetic core for conducting a magnetic flux
Implementation Method 2
at least one coil each surrounding a part of the ferromagnetic core
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
A position sensor (120) comprises a ferromagnetic core (101) for conducting a magnetic flux and at least one coil (102) surrounding a part of the ferromagnetic core. The position sensor comprises circuit boards (104, 105) so that the part of the ferromagnetic core is between the circuit boards and between electric connectors (110, 111) that connect the circuit boards electrically to each other. The coil comprises electric conductors (106-109) of the circuit boards and the electric connectors that connect the electric conductors of one of the circuit boards to the electric conductors of another one of the circuit boards. Thus, there is no need for a separate coil winding because the coil is implemented when the circuit boards are connected to each other with the aid of the electric connectors.