Electric Winch Control Module Magnetic Flux Shield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for monitoring electric winch motor parameters, particularly current, are slow, difficult to interface, and prone to interference from external electromagnetic fields due to reliance on potentiometers and toroid devices.
Innovation Solution
An electric winch control module with a magnetic flux shield made of ferromagnetic material is used to shield the power lead from external interference while allowing the magnetic flux sensor to detect changes in the current, enhancing signal integrity and reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic flux sensor is placed in close proximity to a current-carrying wire to detect current changes, then measurement sensitivity is improved, but the sensor becomes vulnerable to external electromagnetic interference
Solution Approach 1:
A ferromagnetic shield is introduced as an intermediary element between the external environment and the magnetic flux sensor. The shield selectively guides external magnetic field lines away from the sensor while allowing the sensor to detect the magnetic field generated by the current-carrying wire, thus mediating between interference protection and measurement sensitivity
Solution Approach 2:
The space around the current-carrying wire is segmented into different zones using the ferromagnetic shield. The shield creates a designated measurement zone where the sensor can operate without interference, while external field lines are redirected into separate zones that do not affect the sensor
2Reliability
If a ferromagnetic shield surrounds the current-carrying wire to block external interference, then signal integrity is improved, but the magnetic flux sensor may not detect the current-induced magnetic field
Solution Approach 1:
The ferromagnetic shield is designed with non-uniform local properties: it provides strong shielding in directions where external interference comes from, while maintaining magnetic field permeability in the direction of the sensor to allow detection of the current-induced magnetic field. The shield's geometry and material distribution are optimized to differentiate between harmful external fields and useful signal fields
3Object-affected harmful factors
If the magnetic flux shield completely encloses the power lead, then external interference is maximally blocked, but the lead cannot be properly positioned and the sensor cannot detect the field
Solution Approach 1:
Instead of completely enclosing the wire (which would block detection), the shield is designed with an inverted approach: it provides shielding for most directions while intentionally leaving openings or gaps in the direction of the sensor. This allows the wire to be positioned freely while the sensor maintains detection capability through the designated openings
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 effectively amplifies the magnetic flux field strength, reducing external interference and improving the accuracy of current monitoring, enabling faster response and robust signal output for overload and thermal load management.
Implementation Method 1
a magnetic flux shield made of ferromagnetic material is used to shield the power lead from external interference
Implementation Method 2
The magnetic flux shield is made of a ferromagnetic material
Implementation Method 3
a magnetic flux sensor, the magnetic flux sensor located toward the vertical centerline of the channel, above and adjacent to the top wall of the channel and arranged coaxial to the channel
Data Source
AI summary
An electric winch control module of this disclosure provides improved means for detecting changes in a current carried by an electric winch motor power lead. The module's housing includes a magnetic flux shield contained within an exposed channel of the housing and located at or toward a vertical centerline of the channel and opposite a magnetic flux sensor of the control module. The magnetic flux shield is made of a ferromagnetic material and includes a bottom wall spanning the width of the open bottom of the channel, an open top arranged opposite the top wall of the channel, and opposing sidewalls opposite a respective sidewall of the channel. The shield surrounds the side and lower portions of the lead below the sensor when in the channel, shielding the wire and sensor from outside interference while at the same time exposing an upper portion of the lead to the sensor.