Rotor Position Sensor Detection Device with Windable Wire Coils
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Solution Overview
Problem
Conventional position sensors, particularly those used in rotor position sensing for electrical machines, are expensive due to the high cost of printed circuit boards, which require a large installation space and are susceptible to interference from high magnetic fields and temperatures, leading to poor spatial resolution.
Innovation Solution
Replace expensive printed circuit boards with windable conductor wires that form primary and secondary windings, mounted on a device body or partially integrated into circuit boards, reducing manufacturing costs and minimizing interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printed circuit boards are used for sensor arrays, then manufacturing precision can be maintained, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the coil structures from the printed circuit board substrate and implements them as discrete windable conductor wires mounted on the device body. This separation eliminates the need for complex multi-layer PCB routing while maintaining the electrical connections needed for sensor operation, thereby reducing device complexity while preserving manufacturing precision.
Solution Approach 2:
The patent replaces expensive printed circuit boards with simpler, more cost-effective windable conductor wires that can be mounted directly on the device body. This substitution reduces material costs and manufacturing complexity while maintaining the functional requirements for sensor array operation.
2Reliability
If large-area primary coils are used, then sensor coverage is improved, but installation space requirements increase
Solution Approach 1:
The patent implements secondary coils that are arranged within the area of the primary coil, creating a nested configuration. This allows the sensor to maintain comprehensive coverage with multiple sensing elements while containing the overall device footprint, as the secondary coils utilize the space already defined by the primary coil rather than requiring additional external space.
3Ease of operation
If coil-based sensor arrangements are used, then contactless detection is achieved, but susceptibility to electromagnetic interference increases
Solution Approach 1:
The patent introduces a magnetic core element as an intermediary between the coil structures and the measurement target. This magnetic core serves multiple functions: it concentrates and guides the magnetic field for contactless detection, while also providing shielding that reduces the coils' susceptibility to external electromagnetic interference, thereby mitigating the harmful effects while preserving the contactless operation 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 use of windable conductor wires allows for a compact, cost-effective detection device with improved immunity to electromagnetic interference, enabling precise position determination at lower manufacturing costs.
Implementation Method 1
a primary winding (4a) and at least one secondary winding (4b), wherein at least one of the primary winding (4a) and the at least one secondary winding (4b) is at least partially formed by a conductor wire
Implementation Method 2
the position-dependent generation of eddy currents is used to determine the position of a component
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
In illustrative embodiments, the invention provides a detection device for a position sensor, preferably a rotor position sensor, comprising a circuit board. This detection device comprises a primary winding and at least one secondary winding, wherein at least one of the primary winding and the at least one secondary winding is at least partially formed by a windable conductor wire. Furthermore, the detection device comprises a device body, wherein the conductor wire of the primary winding and/or the at least one secondary winding is completely mounted on a surface portion of a surface of the device body.