Sensor Module Toroidal Coil Segmented Housing
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Solution Overview
Problem
Modular plug connectors often face space constraints when routing multiple data signals and currents, limiting the integration of effective sensor modules for monitoring machines or systems.
Innovation Solution
A sensor module comprising a dumbbell-shaped core segment and four outer segments forming a toroidal cavity, with conductor tracks and contact points to create a toroidal coil, allowing for efficient space utilization and electrical connectivity, utilizing MID technology for easy manufacturing and coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensor modules are integrated into modular plug connectors, then monitoring capability is improved, but space consumption increases
Solution Approach 1:
The sensor module is divided into multiple segments (first segment, second segment, third segment, fourth segment) that are arranged around a central axis and can be assembled together. Each segment contains portions of the conductor tracks, which when connected form the complete toroidal coil. This segmentation allows the sensor module to be compact and adaptable to the limited space in modular plug connectors while maintaining full monitoring functionality.
2Measurement precision
If effective sensor modules are integrated into modular plug connectors, then monitoring precision is improved, but device complexity increases
Solution Approach 1:
The sensor module combines multiple functional elements into a single integrated structure: the toroidal coil for current sensing, the housing for structural support and insulation, and the contact points for electrical connections. The conductor tracks are applied directly to the housing segments, eliminating the need for separate circuit boards or additional mounting structures. This merging reduces device complexity while maintaining monitoring precision.
Solution Approach 2:
The sensor module employs a toroidal (doughnut-shaped) coil configuration where the conductor tracks form a curved path around a central cavity. This toroidal geometry is inherently compact and efficient for magnetic field sensing, providing good measurement precision while occupying minimal space. The curved arrangement of conductor tracks on the segmented housing naturally forms this efficient geometric configuration.
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
Enables effective monitoring of current flows by forming a toroidal coil that can be easily integrated into a Rogowski sensor circuit, providing efficient data evaluation within the limited space of modular connectors.
Implementation Method 1
The conductor tracks (4) together form, when connected, the shape of a toroidal coil (7), which can measure the current flow of a contact element (10) in a sensor circuit, which is also integrated in the sensor module (1), according to the Rogowski principle
Data Source
Figure 1~2b
Figure 3~4
Figure 5
AI summary
The invention relates to a sensor module for a modular plug connector, wherein the sensor module (1) comprises a core segment (2) and at least two outer segments (3, 3', 3", 3"') arranged around the latter, wherein the segments (2, 3, 3', 3", 3"') enclose a cavity with one another when assembled. In the cavity, conductor tracks (4) are fitted with the aid of MID technology, wherein all the conductor tracks (4) in the connected state together form the shape of an annular coil (7). In a sensor circuit, the annular coil can measure the current flow of a contact element in accordance with the Rogowski principle, which contact element is likewise integrated in the sensor module.