Shielded Coil Displacement Sensor for Stable Impedance Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional non-contact displacement sensors face challenges in achieving uniform coil impedance, secure physical connections, and easy position adjustment, particularly when placed near rotational shafts in chiller systems, due to space limitations and variability in coil winding intervals.
Innovation Solution
A displacement sensor design featuring a wound coil structure with a shield member and housing that includes a depressed region on the outer surface, allowing for precise positioning adjustments using a fastening instrument, and a rigid connection to a control circuit through connectors, ensuring constant impedance and improved physical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If coils are formed on the upper and lower surfaces of the sensing module, then the sensor can detect displacement, but the coil impedance varies due to non-uniform winding intervals
Solution Approach 1:
The patent changes the physical configuration of the coil structure by winding it around a cylindrical core rather than forming flat coils on surfaces. This parameter change in structural geometry ensures uniform winding intervals and constant impedance, resolving the manufacturing precision issue while maintaining displacement detection capability
Solution Approach 2:
The patent employs a cylindrical (curved) coil structure instead of flat planar coils. The curved geometry around a cylindrical core provides uniform radial winding intervals, ensuring constant coil impedance across all positions, thereby resolving the impedance consistency problem
2Volume of moving object
If the terminal size is limited, then the sensor fits in compact spaces, but the physical connection between terminal and PCB breaks easily
Solution Approach 1:
The patent merges the terminal connection function directly into the PCB structure by having the coil structure electrically connected to the PCB without separate terminals. This integration eliminates weak terminal-PCB connections while maintaining compact sensor dimensions, resolving both the size and reliability concerns
3Reliability
If the gap sensor is physically coupled to the PCB, then electrical connection is achieved, but space for sensor placement is limited
Solution Approach 1:
The patent merges the coil structure directly with the PCB by having the coil wound around a cylindrical core that is electrically connected to the PCB. This integration eliminates the need for separate terminal connections and reduces the overall space required for sensor placement while maintaining stable electrical connection
4Ease of manufacture
If the gap sensor placement space is fixed in the product, then assembly is simplified, but fine adjustment of sensor position becomes difficult
Solution Approach 1:
The patent introduces a movable mounting structure with adjustment mechanisms that allow the sensor position to be dynamically adjusted after assembly. The sensor can be positioned at different locations along the cylindrical core and fixed at the desired position, providing both assembly simplicity and fine adjustment 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 design enables fine adjustment of the sensor position, reduces sensed value dispersion, and enhances the accuracy of control, while maintaining constant coil impedance and secure connections, addressing the limitations of existing sensors.
Implementation Method 1
A general gap sensor may generate a magnetic field around a coil through a high-frequency current flowing through a coil of a probe and detect a distance between the coil and the object based on an eddy current generated by an object located in the magnetic field.
Implementation Method 2
a shield member formed to surround an outer periphery of the coil structure
Data Source
AI summary
The present disclosure relates to a displacement sensor. A displacement sensor according to the embodiment of the present disclosure includes a coil structure consisting of wound coil, a shield member formed to surround an outer periphery of the coil structure and a housing, wherein the housing comprises an upper side wall part surrounding an outer periphery of the shield member and a lower side wall part formed to extend from the upper side wall part, wherein an inner circumferential surface of the lower side wall part is protruded toward the inside of the housing more than an inner circumferential surface of the upper side wall part, wherein an outer circumferential surface of the lower side wall part may include a depressed region formed to be depressed into the inside of the housing by a predetermined depth.