Inductive Position Sensor Coil Carrier Groove Design
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Solution Overview
Problem
Existing linear inductive position sensors face challenges in efficiently using space due to the need for delimiting elements that restrict the winding area and are mechanically sensitive, particularly when manufactured via injection molding.
Innovation Solution
The approach involves winding the second and third coils onto the coil carrier first, allowing the first coil to be wound over them, using grooves as delimiting elements for mechanical support without restricting the winding space, and optimizing the coil carrier design for strength and material efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If webs are used as delimiting elements to hold the second and third coils, then material usage is efficient, but the webs are mechanically sensitive and restrict the winding space for the first coil
Solution Approach 1:
The patent extracts the delimiting function from thin webs and relocates it to grooves formed in the coil carrier base body. The grooves provide mechanical support and delimitation without requiring separate web elements, thereby eliminating the mechanical sensitivity issue while maintaining material efficiency.
Solution Approach 2:
The patent merges the delimiting function with the coil carrier base body structure itself. The grooves are integrated into the base body, combining the support structure and delimiting elements into a single component, which eliminates the need for separate web elements and improves mechanical robustness.
2Ease of manufacture
If the first coil is wound directly on the coil carrier, then the winding process is simple, but the delimiting elements restrict the available winding space
Solution Approach 1:
The patent performs preliminary action by first forming the grooves in the coil carrier base body before winding any coils. This preliminary structuring of the winding space ensures that the delimiting elements are in place to guide subsequent coil winding, preventing space restriction issues during the manufacturing process.
Solution Approach 2:
The patent implements nesting by placing the second and third coils within the grooves of the base body, and then winding the first coil over these nested coils. This nested arrangement allows efficient use of space while maintaining clear delimitation between different coil windings.
3Loss of substance
If the delimiting elements are made thinner for efficient material use, then material consumption is reduced, but they become mechanically too sensitive and can be damaged
Solution Approach 1:
The patent extracts the delimiting function from thin, weak web elements and transfers it to the grooves formed in the base body. The grooves provide structural support through the base body material itself, eliminating the need for thin, mechanically sensitive separate delimiting elements.
Solution Approach 2:
The patent utilizes the composite structure of the base body material (plastic) to provide both the structural support and the delimiting function. The grooves are formed as integral parts of the base body, combining multiple functions into a single material structure that provides both strength and delimitation.
4Productivity
If the coil carrier is manufactured by injection molding, then mass production is efficient, but the delimiting elements must have sufficient strength to withstand manufacturing loads
Solution Approach 1:
The patent merges the delimiting elements with the coil carrier base body structure, creating an integrated component that is manufactured as a single piece through injection molding. This eliminates the need for separate delimiting elements that would need to be attached afterward, simplifying the manufacturing process while ensuring sufficient strength.
Solution Approach 2:
The base body structure serves multiple functions: it provides mechanical support, forms the delimiting grooves, and withstands manufacturing loads during injection molding. This multi-functional design eliminates the need for separate reinforcement elements, streamlining the manufacturing process.
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 configuration enhances the sensor's mechanical robustness and efficient use of space, reducing material costs and mechanical sensitivity while maintaining effective position detection capabilities.
Implementation Method 1
a first coil extending in the moving direction and wound on the bobbin, and second and third coils aligned with the first bobbin and wound on the bobbin so that the second and third coils with form a first and second transmitter corresponding to the first coil, the transmission ratio of which depends on the position of the transmitter magnet
Data Source
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AI summary
A sensor for detecting a position of a transducer magnet in a movement direction, including: —a coil carrier extending in the movement direction, —a first coil extending in the movement direction that is wound onto the coil carrier and—a second and a third coil oriented according to the first coil, which are wound onto the coil carrier such that the second and third coils accordingly form a first and second transformer with the first coil, the transformation ratio of which is dependent on the position of the transducer magnet, —wherein at least the second coil or the third coil is arranged between the coil carrier and the first coil.