Position Sensor Ferrite Core PCB Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional eddy current sensors are costly, difficult to integrate, and prone to electromagnetic disturbances due to separate coils and cables, requiring individual calibration and being sensitive to environmental factors like dust and fluids.
Innovation Solution
A position sensor arrangement featuring multiple sensors with ferrite cores and sensor coils printed on a common circuit board, allowing for accurate position sensing of a shaft in multiple dimensions without runout-induced disturbances, using ferrite cores and printed circuit board tracks to enhance sensitivity and reduce calibration needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate coils and cables are used in eddy current sensors, then position sensing capability is achieved, but electromagnetic interference sensitivity increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple sensor coils into a single integrated printed circuit board structure, eliminating separate cables and reducing electromagnetic interference. The sensor array integrates multiple sensing elements that share common circuitry and housing, reducing the overall complexity while maintaining sensing capabilities.
Solution Approach 2:
The patent replaces traditional mechanical coil-winding and cable-connection systems with printed circuit board technology. The sensor coils are fabricated as traces on the PCB, eliminating the need for separate cables and manual connections, thereby reducing electromagnetic susceptibility and simplifying assembly.
2Measurement precision
If individual calibration is performed for each traditional sensor, then measurement accuracy is achieved, but calibration time and complexity increase
Solution Approach 1:
The patent creates a universal sensor array where multiple sensing elements share common calibration characteristics. The integrated PCB design ensures that all sensors in the array have identical electrical characteristics, allowing a single calibration procedure to apply to the entire array rather than requiring individual calibration for each sensor.
Solution Approach 2:
The patent performs calibration at the manufacturing stage for the entire sensor array as a unified component. The PCB fabrication process ensures consistent electrical properties across all sensors, and the array is pre-calibrated before deployment, eliminating the need for time-consuming field calibration of individual sensors.
3Adaptability or versatility
If multiple separate sensors are positioned around the shaft, then multi-dimensional position sensing is achieved, but sensor integration difficulty increases
Solution Approach 1:
The patent merges multiple separate position sensors into a single integrated sensor array mounted on one PCB. The array includes multiple sensing elements positioned at different locations and orientations around the shaft, all integrated into a single housing and assembly process, eliminating the need to manually position and integrate multiple independent sensors.
4Reliability
If traditional sensors are used in challenging environments, then position feedback is provided, but sensitivity to dust and fluids increases
Solution Approach 1:
The patent uses a sealed housing structure that encloses the entire sensor array and PCB, creating a protective barrier against dust and fluids. The integrated design allows for a single sealed enclosure rather than multiple separate sensor housings, improving environmental protection while maintaining sensing capabilities through the sealed interface.
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 compact, cost-effective, and robust position sensor capable of accurate motion feedback in challenging environments, reducing manufacturing costs and sensitivity to electromagnetic interference.
Implementation Method 1
each of the position sensors comprises a ferrite core and a sensor coil configured to provide a sensor signal
Implementation Method 2
Eddy current or inductive sensors are suitable for non-contact measurement of position, proximity, motion, displacement and/or distance
Implementation Method 3
each of the position sensors comprises a ferrite core and a sensor coil configured to provide a sensor signal
Data Source
AI summary
A position sensor for sensing position or motion, includes: a ferrite core, and a sensor coil configured to provide a sensor signal. The sensor coil is implemented on a printed circuit board, and the ferrite core is configured to be fitted into the printed circuit board.