Abstract: Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the high temperature electromagnetic coil assembly includes a coiled anodized aluminum wire and an electrically-insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded. The electrically-insulative, high thermal expansion ceramic body has a coefficient of thermal expansion greater than 10 parts per million per degree Celsius and less than the coefficient of thermal expansion of the coiled anodized aluminum wire.

Abstract: Methods and devices are provided for supporting a wire having a minimum tolerable bend radius. The device comprises a core portion with a longitudinal axis supporting at least a first portion of the wire and a flange portion attached to the core portion supporting at least a second portion of the wire. The device has at least one hole with a first opening in the first surface defined by a first rim and a second opening in the second surface defined by a second rim. The hole allows the wire to pass through and also supports the wire. The hole is oriented in three dimensions to forestall a bend that may occur in the wire having a bend radius that is less than the minimum tolerable bend radius of the wire.

Abstract: Methods and devices are provided for supporting a wire having a minimum tolerable bend radius. The device comprises a core portion with a longitudinal axis supporting at least a first portion of the wire and a flange portion attached to the core portion supporting at least a second portion of the wire. The device has at least one hole with a first opening in the first surface defined by a first rim and a second opening in the second surface defined by a second rim. The hole allows the wire to pass through and also supports the wire. The hole is oriented in three dimensions to forestall a bend that may occur in the wire having a bend radius that is less than the minimum tolerable bend radius of the wire.

Abstract: Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the high temperature electromagnetic coil assembly includes a coiled anodized aluminum wire and an electrically-insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded. The electrically-insulative, high thermal expansion ceramic body has a coefficient of thermal expansion greater than 10 parts per million per degree Celsius and less than the coefficient of thermal expansion of the coiled anodized aluminum wire.

Abstract: Embodiments of a method are provided for joining a secondary wire to a magnet wire, such as a fine gauge aluminum or silver wire. Further provided are embodiments of a disparate wire splice connector and embodiments of an electromagnetic coil assembly including such a splice connector. In one embodiment, the electromagnetic coil assembly includes disparate wire splice connector having a first blind bore and a second blind bore. A coiled magnet wire having a segment inserted into the first blind bore is soldered to the disparate wire splice connector. A secondary wire having a segment inserted into the second blind bore is also soldered to the disparate wire splice connector such that the secondary wire is electrically coupled to the coiled magnet wire through the disparate wire splice connector.

Abstract: Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the method includes the steps of applying a high thermal expansion ceramic coating over an anodized aluminum wire, coiling the coated anodized aluminum wire around a support structure, and curing the high thermal expansion ceramic coating after coiling to produce an electrically insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded.

Abstract: A three-wire transformer position sensor is provided that includes an excitation coil and an output coil. The excitation coil is adapted to be electrically excited with an excitation signal, and has a first end and a second end. The output coil includes a first coil and a second coil and is inductively coupled to the excitation coil upon electrical excitation thereof the excitation coil. The first end of the first coil is electrically connected to the second end of the second coil and to the second end of the excitation coil, and the second end of the first coil is electrically connected to the first end of the second coil. The output coil is configured, when it is balanced and the excitation coil is being electrically excited, to supply a null output signal.

Abstract: Embodiments of a method are provided for joining a secondary wire to a magnet wire, such as a fine gauge aluminum or silver wire. Further provided are embodiments of a disparate wire splice connector and embodiments of an electromagnetic coil assembly including such a splice connector. In one embodiment, the electromagnetic coil assembly includes disparate wire splice connector having a first blind bore and a second blind bore. A coiled magnet wire having a segment inserted into the first blind bore is soldered to the disparate wire splice connector. A secondary wire having a segment inserted into the second blind bore is also soldered to the disparate wire splice connector such that the secondary wire is electrically coupled to the coiled magnet wire through the disparate wire splice connector.

Abstract: Linear variable differential transformers include a core comprising a non-ferromagnetic material and a ferromagnetic material, and a coil assembly including an axial bore within which the core is disposed and through which the core axially translates.

Abstract: Embodiments of a high temperature electromagnetic coil assembly are provided, as are embodiments of a method for fabricating such a high temperature electromagnetic coil assembly. In one embodiment, the method includes the steps of applying a high thermal expansion ceramic coating over an anodized aluminum wire, coiling the coated anodized aluminum wire around a support structure, and curing the high thermal expansion ceramic coating after coiling to produce an electrically insulative, high thermal expansion ceramic body in which the coiled anodized aluminum wire is embedded.

Abstract: A three-wire transformer position sensor is provided that includes an excitation coil and an output coil. The excitation coil is adapted to be electrically excited with an excitation signal, and has a first end and a second end. The output coil includes a first coil and a second coil and is inductively coupled to the excitation coil upon electrical excitation thereof the excitation coil. The first end of the first coil is electrically connected to the second end of the second coil and to the second end of the excitation coil, and the second end of the first coil is electrically connected to the first end of the second coil. The output coil is configured, when it is balanced and the excitation coil is being electrically excited, to supply a null output signal.

Abstract: Embodiments of a method are provided for joining an aluminum wire to a secondary wire, as are embodiments of an aluminum wire splice connector and embodiments of an electromagnetic coil assembly including an aluminum wire splice connector. In one embodiment, the method includes the steps providing a splice connector having a first blind bore and a second blind bore, inserting a segment of a coiled aluminum magnet wire into the first blind bore, and inserting a segment of the secondary wire into the second blind bore. The splice connector is soldered to the segments of the aluminum wire and the secondary wire inserted into the first and second blind bores, respectively, to electrically couple the coiled aluminum magnet wire and the secondary wire through the splice connector.

Abstract: Linear variable differential transformers include a core comprising a non-ferromagnetic material and a ferromagnetic material, and a coil assembly including an axial bore within which the core is disposed and through which the core axially translates.

Abstract: Methods and devices are provided for supporting a wire having a minimum tolerable bend radius. The device comprises a core portion with a longitudinal axis supporting at least a first portion of the wire and a flange portion attached to the core portion supporting at least a second portion of the wire. The device has at least one hole with a first opening in the first surface defined by a first rim and a second opening in the second surface defined by a second rim. The hole allows the wire to pass through and also supports the wire. The hole is oriented in three dimensions to forestall a bend that may occur in the wire having a bend radius that is less than the minimum tolerable bend radius of the wire.