Sensor unit and sensor device

Abstract

To provide a sensor unit capable of surely insulating a sensor part from a metal container and housing the sensor part in a correct position with respect to the metal container.SOLUTION: In a sensor unit 100 having a sensor part 110, an insulating container 120, and a metal container 130, the insulating container 120 houses the sensor part 110 so that a positioning protrusion 123 and a positioning recess 113 overlap each other, and the metal container 130 houses the insulating container 120 so that an insulating container reference position display part 122 and a metal container reference position display part 132 coincide with each other in a circumferential direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a sensor unit and a sensor device, and more particularly to a sensor unit and a sensor device that house a sensor portion in a correct position relative to a metal container while insulating the sensor portion from the metal container. [Background technology]

[0002] In a sensor unit in which a sensor part is housed in a metal container, the sensor part needs to be electrically insulated from the metal container. Conventionally, there are two methods: a first method in which an insulating resin tape is manually wrapped around the sensor part before housing it in the metal container, and a second method in which the sensor part is housed in the metal container and then filled with insulating resin. The second method is described in Patent Document 1. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. Hei 2-201183 Summary of the Invention [Problem to be solved by the invention]

[0004] In the first method described above, there were differences in the way the insulating resin tape was wrapped by different workers, resulting in exposed areas and causing insulation defects. Furthermore, workers could scratch the thin insulating resin tape while working, or the insulating resin tape could be damaged by vibrations during use, causing insulation defects. In the second method described above, the exposed metal part of the sensor unit and the metal container could already be in contact before the insulating resin was filled, and filling the insulating resin could not resolve the insulation defects. If an insulation failure occurs, the sensor will not be able to output correct measurement values, which will result in the problem of not being able to properly control the equipment being controlled.

[0005] Furthermore, when the insulating tape is wrapped around the sensor unit by the first method, it is difficult to accommodate the sensor unit wrapped with the insulating tape in the correct orientation and position relative to the metal container. When filling insulating resin into a metal case using the second method described above, it is difficult to hold or fix the sensor part in the correct position or orientation before filling the insulating resin, and it is also difficult to store the sensor part in the correct orientation and position relative to the metal container after the filled insulating resin has hardened. This has resulted in a problem in that the azimuth is shifted when the position or orientation of the sensor part within the metal container is shifted, resulting in errors in the detection results.

[0006] The present invention has been made to solve the above-mentioned problems, and aims to provide a sensor unit and a sensor device in which a sensor part is housed in a metal container, in which the sensor part is reliably insulated from the metal container and the sensor part can be housed in the correct position relative to the metal container. [Means for solving the problem]

[0007] The sensor unit of this invention is a sensor unit having a sensor portion, an insulating container, and a metallic container, wherein the sensor portion comprises a sensor element having a positioning recess and an electrode portion, and a substrate to which the electrode portion is attached, the insulating container comprises a cylindrical insulating portion that covers the periphery of the sensor portion, a positioning protrusion corresponding to the positioning recess, and an insulating container reference position indicator portion that indicates a circumferential reference position of the cylindrical insulating portion, the metallic container comprises a tubular portion configured to be able to accommodate the insulating container, and a metallic container reference position indicator portion that indicates a circumferential reference position of the tubular portion, the insulating container accommodates the sensor portion so that the positioning protrusion and the positioning recess overlap, and the metallic container accommodates the insulating container so that the insulating container reference position indicator portion and the metallic container reference position indicator portion coincide circumferentially.

[0008] In the insulating container and metallic container of the sensor unit of this invention, if the end closest to the detection portion of the sensor element is defined as a first end and the end opposite the first end is defined as a second end, the insulating container has an insulating container reference position indicator at the second end of the cylindrical insulating portion, and the metallic container has a metallic container reference position indicator at the second end of the cylindrical portion.

[0009] In the metal container of the sensor unit of this invention, when the end closest to the detection portion of the sensor element is defined as a first end and the end opposite the first end is defined as a second end, the metal container further includes a detection reference position indicator at the first end of the tubular portion, which indicates the reference position for detection in the sensor unit.

[0010] The sensor device of this invention comprises the above-mentioned sensor unit and a sensor case that houses the sensor unit, and when the end of the sensor case that houses the sensor unit is closest to the detection unit is defined as a first end and the end opposite the first end is defined as a second end, the sensor case is provided at the first end with a sensor case reference position indicator that indicates the reference position for detection in the sensor case. [Effects of the Invention]

[0011] In the sensor unit and sensor device of this invention, the insulating container houses the sensor part so that the positioning convex portion and the positioning concave portion overlap, and the metal container houses the insulating container so that the insulating container reference position indicator portion and the metal container reference position indicator portion are aligned circumferentially. This makes it possible to reliably insulate the sensor section from the metal container in a sensor unit and sensor device in which the sensor section is housed in a metal container, and to house the sensor section in the correct position relative to the metal container. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 2 is an exploded perspective view showing the structure of the sensor unit according to the first embodiment in an exploded state. [Figure 2] 1 is a front view showing the structure of a sensor unit according to embodiment 1 in an exploded state. [Figure 3]3 is an explanatory diagram showing how each part of the sensor unit according to the first embodiment is housed. FIG. [Figure 4] 2 is an explanatory diagram showing a sensor device according to the first embodiment and a state of alignment in the sensor device. FIG. [Figure 5] 4 is an explanatory diagram showing an alignment state between the sensor device and the jig according to the first embodiment. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A sensor unit and a sensor device according to an embodiment of the present invention will now be described with reference to the accompanying drawings. In the drawings, the same parts are designated by the same reference numerals.

[0014] Embodiment 1 First, the structure of the sensor unit 100 according to the first embodiment will be described with reference to FIGS. Fig. 1 is an exploded perspective view showing the structure of sensor unit 100 according to embodiment 1. Fig. 2 is a front view showing the structure of sensor unit 100 according to embodiment 1 in an exploded state.

[0015] [Structure of sensor unit 100] The sensor unit 100 mainly comprises a sensor section 110, an insulating container 120, and a metal container 130. The sensor unit 100 detects changes in a magnetic field or the presence or absence of a magnetic body as changes in voltage using the magnetoresistance effect, and is primarily used for detecting the speed of trains. Here, (a) of Figure 1 and (a) of Figure 2 show the sensor unit 110. (b) of Figure 1 and (b) of Figure 2 show the insulating container 120. (c) of Figure 1 and (c) of Figure 2 show the metal container 130. In the following description, when the insulating container 120 houses the sensor part 110 and the metal container 130 further houses the insulating container 120, the end of the sensor part 110 closest to the detection part 112 is referred to as the first end A, and the end opposite the first end A is referred to as the second end B.

[0016] The sensor unit 110 mainly includes a sensor element 111 and a substrate 115. The sensor element 111 is provided with a detection unit 112, a positioning recess 113, and an electrode unit 114. The positioning recess 113 is provided to correspond to the positioning protrusion 123 of the insulating container 120 so that the sensor unit 110 can be housed in an appropriate orientation and position relative to the insulating container 120. The electrode unit 114 is an electrode pin provided for supplying power to the sensor element 111 and for externally outputting a detection signal from the detection unit 112. Electrode portions 114 from the sensor element 111 and lead wires 116 from the outside are connected to the substrate 115. Various circuit elements may be mounted on the substrate 115 as needed. The lead wires 116 are provided for supplying power to the sensor element 111 and for externally outputting a detection signal from the sensor element 111.

[0017] The insulating container 120 mainly includes a cylindrical insulating portion 121, an insulating container reference position display portion 122, and a positioning protrusion 123. The insulating container 120 accommodates the sensor portion 110 in the cylindrical insulating portion 121 such that the positioning protrusion 123 and the positioning recess 113 of the sensor portion 110 overlap with each other. The cylindrical insulating part 121 is configured to cover and insulate the periphery of the sensor part 110. The insulating container reference position indicator 122 is provided at the second end B of the cylindrical insulating part 121 so as to indicate a reference position of the cylindrical insulating part 121 in the circumferential direction. Here, the circumferential direction is defined as the direction along the annular shape that constitutes the cylinder of the cylindrical insulating part 121. The insulating container reference position indicator 122 may be a notch in the cylindrical insulating part 121 or a visual indicator. The positioning protrusion 123 is provided at the first end A of the cylindrical insulating part 121 so as to correspond to the positioning recess 113 of the sensor part 110. That is, the positioning protrusion 123 is provided to correspond to the positioning recess 113 of the sensor part 110 so that the sensor part 110 can be accommodated in the insulating container 120 in an appropriate orientation and position.

[0018] The metallic container 130 mainly includes a cylindrical portion 131, a metallic container reference position display portion 132, and a detection reference position display portion 133. The metallic container 130 accommodates the insulating container 120 in the cylindrical portion 131 so that the metallic container reference position display portion 132 and the insulating container reference position display portion 122 of the insulating container 120 are aligned in the circumferential direction. The cylindrical portion 131 is configured to magnetically shield the sensor portion 110 and to be able to house the insulating container 120. The metal container reference position indicator 132 is provided at the second end B of the cylindrical portion 131 so as to indicate a reference position of the cylindrical portion 131 in the circumferential direction. Here, the direction along the annular shape of the tube that constitutes the cylindrical portion 131 is defined as the circumferential direction. The metal container reference position indicator 132 may be a notch in the cylindrical portion 131 or a visual indicator. The detection reference position display section 133 is provided at the first end A of the tubular section 131 so as to indicate the detection reference position of the sensor unit 100. The detection reference position display section 133 may be a notch in the tubular section 131 or a visual display. The detection reference position display section 133 is used for alignment with the sensor case reference position display section 203 in the sensor case 201 when the sensor unit 100 is housed in the sensor case 201 described below.

[0019] [Procedure for producing the sensor unit 100] The procedure for producing sensor unit 100 according to the first embodiment will be described with reference to Fig. 3. Fig. 3 is an explanatory diagram showing how each part of sensor unit 100 according to the first embodiment is housed.

[0020] Fabrication of the sensor unit 110: The electrode portion 114 of the sensor element 111 and an external lead wire 116 are connected to a substrate 115 by soldering or the like, thereby producing the sensor portion 110.

[0021] Housing of the sensor unit 110 in the insulating container 120: The sensor section 110 is housed in the insulating container 120 so that the positioning recess 113 of the sensor section 110 and the positioning protrusion 123 of the insulating container 120 overlap each other.

[0022] Enclosing the insulating container 120 in the metal container 130: The insulating container 120 containing the sensor unit 110 is housed in the metallic container 130 so that the insulating container reference position display portion 122 of the insulating container 120 and the metallic container reference position display portion 132 of the metallic container 130 are aligned in the circumferential direction.

[0023] The positioning recess 113, positioning protrusion 123, insulating container reference position display portion 122, and metallic container reference position display portion 132 are determined in advance so that the sensor portion 110 is oriented and positioned correctly after alignment. By the above manufacturing procedure, the sensor unit 100 is completed, in which the sensor part 110 is reliably insulated from the metal container 130 via the insulating container 120, and the sensor part 110 is housed in the correct orientation and position relative to the metal container 130 via the insulating container 120, regardless of the level of skill of the worker. Furthermore, after the sensor unit 100 is completed, it is possible to check whether the sensor part 110 via the insulating container 120 has been placed in the correct orientation and position relative to the metallic container 130 by checking the degree of alignment between the insulating container reference position display part 122 and the metallic container reference position display part 132.

[0024] [Structure of sensor device 200] The sensor device 200 will be described below with reference to Fig. 4. Fig. 4 is an explanatory diagram showing the sensor device 200 according to the first embodiment and the state of alignment in the sensor device 200. Note that Fig. 4 shows a state in which mounting members for the sensor unit 100 in the sensor case 201 are omitted. The sensor device 200 mainly has the sensor unit 100 and the sensor case 201. The sensor case 201 corresponds to a housing for the sensor unit 100 in an actual usage environment. In the following description, the end closest to the detection section 112 of the sensor unit 100 is referred to as the first end A, the end closest to the first end A of the sensor case 201 is referred to as the sensor case first end A2, and the end opposite the sensor case first end A2 is referred to as the sensor case second end B2. A sensor case reference position display unit 203 is provided at the sensor case first end A2 to indicate the reference position of the sensor case 201. The sensor case reference position display unit 203 is used for alignment with the detection reference position display unit 133 of the sensor unit 100. The detection reference position display unit 133 and the sensor case reference position display unit 203 are determined in advance so that the sensor unit 110 is oriented and positioned correctly after alignment.

[0025] [Fabrication of sensor device 200 (1)] The fabrication and adjustment of the sensor device 200 according to the first embodiment will be described.

[0026] The sensor unit 100 is attached to the sensor case 201 so that the detection reference position display section 133 of the sensor unit 100 manufactured according to the manufacturing procedure described above is aligned with the sensor case reference position display section 203 of the sensor case 201. Furthermore, when adjusting the position of the sensor unit 100 within the sensor case 201 while the sensor unit 100 is attached within the sensor case 201, the detection reference position display section 133 of the sensor unit 100 is aligned with the sensor case reference position display section 203 in the sensor case 201. In this specific example, first end A of sensor unit 100 is configured to protrude from sensor case first end A2 of sensor case 201. Therefore, when viewed from the front side in the direction perpendicular to the plane of FIG. 4, detection reference position display section 133 of sensor unit 100 and sensor case reference position display section 203 of sensor case 201 can be aligned. If the first end A of the sensor unit 100 does not protrude from the sensor case first end A2 of the sensor case 201, it is possible to check from the bottom of the paper in Figure 4 and align the detection reference position display unit 133 of the sensor unit 100 with the sensor case reference position display unit 203 on the sensor case 201.

[0027] By the above manufacturing procedure, the sensor device 200 is completed, in which the sensor unit 100 is housed in the correct orientation and position while insulating the sensor part 110 from the metal container 130, and is attached to the sensor case 201 in the correct orientation and position, regardless of the level of skill of the worker. Furthermore, after the sensor device 200 is completed, it is possible to check whether the sensor unit 100 has been attached to the sensor case 201 in the correct orientation and position by checking the degree of alignment between the detection reference position display unit 133 and the sensor case reference position display unit 203.

[0028] [Procedure for manufacturing the sensor device 200 (2)] Another example of the fabrication and adjustment of the sensor device 200 according to the first embodiment will be described with reference to Fig. 5. Fig. 5 is an explanatory diagram showing the alignment state of the sensor device 200 according to the first embodiment and the jig 300. Note that Fig. 5 shows a state in which mounting members for the sensor unit 100 in the sensor case 201 and the like are omitted.

[0029] Jig 300 is an auxiliary tool used to fix sensor device 200, which is the object to be produced, in a predetermined position and to position sensor unit 100. Jig 300 is provided with board 301, holders 302a and 302b, and adjustment reference position display unit 303. Board 301 is a flat table on which sensor device 200, which is the object to be produced, is placed. Holders 302a and 302b are holding means that clamp sensor device 200, which is the object to be produced, so that it is in a predetermined position on board 301. The adjustment reference position display section 303 is provided as a reference position for adjusting the position of the detection reference position display section 133 of the sensor unit 100 in the sensor case 201 in the sensor device 200 placed on the board section 301.

[0030] First, sensor device 200 housing sensor unit 100 is placed on board 301. Then, holders 302a and 302b on board 301 are adjusted to clamp sensor device 200 at a predetermined position. Thereafter, the position of sensor unit 100 in sensor case 201 is finely adjusted so that detection reference position display section 133 and adjustment reference position display section 303 are aligned. After adjusting the position of the sensor unit 100 in the sensor case 201 so that the detection reference position indicator 133 and the adjustment reference position indicator 303 are aligned, the holders 302 a and 302 b are loosened and the sensor device 200 is removed from the jig 300 .

[0031] By the above-described procedure for manufacturing the sensor device 200 using the jig 300, the sensor device 200 is completed, regardless of the level of skill of the worker, and the sensor unit 100 is housed in the correct orientation and position while insulating the sensor part 110 from the metal container 130, and is attached to the sensor case 201 in the correct orientation and position.

[0032] [Effects obtained by the first embodiment] The sensor unit 100 and the sensor device 200 according to the first embodiment can provide the following effects.

[0033] (1) The sensor unit 100 according to the first embodiment includes a sensor section 110, an insulating container 120, and a metal container 130. The sensor section 110 includes a sensor element 111 having a positioning recess 113 and an electrode section 114, and a substrate 115 to which the electrode section 114 is attached. The insulating container 120 includes a cylindrical insulating section 121 that covers the periphery of the sensor section 110, a positioning protrusion 123 that corresponds to the positioning recess 113, and an insulating container reference position indicator 122 that indicates a reference position of the cylindrical insulating section 121 in the circumferential direction. The metal container 130 includes a tube section 131 configured to accommodate the insulating container 120, and a metal container reference position indicator 132 that indicates a reference position of the tube section 131 in the circumferential direction. Here, the insulating container 120 accommodates the sensor part 110 so that the positioning convex part 123 and the positioning concave part 113 overlap, and the metal container 130 accommodates the insulating container 120 so that the insulating container reference position display part 122 and the metal container reference position display part 132 are aligned in the circumferential direction. This makes it possible for the sensor unit 100, which houses the sensor part 110 in the metal container 130, to reliably insulate the sensor part 110 from the metal container 130 and house the sensor part 110 in the correct position relative to the metal container 130, regardless of the level of skill of the operator.

[0034] (2) In the sensor unit 100 of (1) above, with respect to the insulating container 120 and the metal container 130, if the end closest to the detection section 112 of the sensor element 111 is defined as the first end A and the end opposite the first end A is defined as the second end B, the insulating container 120 has an insulating container reference position indicator 122 at the second end B of the cylindrical insulating section 121, and the metal container 130 has a metal container reference position indicator 132 at the second end B of the cylindrical section 131. As a result, the metallic container 130 can accommodate the insulating container 120 in the cylindrical portion 131 such that the metallic container reference position indicator 132 and the insulating container reference position indicator 122 are aligned in the circumferential direction at the second end B. This allows the sensor portion 110 via the insulating container 120 to be accommodated in the correct orientation and position relative to the metallic container 130. Furthermore, after the sensor unit 100 is completed, it can be confirmed whether the sensor portion 110 via the insulating container 120 is accommodated in the correct orientation and position relative to the metallic container 130 based on the degree of alignment between the insulating container reference position indicator 122 and the metallic container reference position indicator 132.

[0035] (3) In the sensor unit 100 described in (1) to (2) above, when the end of the metal container 130 closest to the detection section 112 of the sensor element 111 is defined as a first end A and the end opposite the first end A is defined as a second end B, the metal container 130 further includes a detection reference position display section 133 at the first end A of the tubular section 131, which indicates the reference position for detection in the sensor unit 100. When installing the sensor unit 100 in the sensor case 201 or adjusting the position of the sensor unit 100 in the sensor case 201, the detection reference position display section 133 of the sensor unit 100 is aligned with the sensor case reference position display section 203 in the sensor case 201. This allows the sensor unit 100 to be attached to the sensor case 201 in the correct orientation and position. Furthermore, depending on the degree of agreement between the detection reference position display section 133 and the sensor case reference position display section 203, it can be confirmed whether the sensor unit 100 has been attached to the sensor case 201 in the correct orientation and position.

[0036] (4) The sensor device 200 includes the sensor unit 100 described above in (3) and a sensor case 201 that houses the sensor unit 100. In the sensor case 201 that houses the sensor unit 100, if the end closest to the detection unit 112 is defined as a first end A and the end opposite to the first end A is defined as a second end B, the sensor case 201 includes a sensor case reference position indicator 203 at the first end A that indicates the reference position for detection in the sensor case 201. When installing the sensor unit 100 in the sensor case 201 or adjusting the position of the sensor unit 100 in the sensor case 201, the detection reference position display section 133 of the sensor unit 100 is aligned with the sensor case reference position display section 203 in the sensor case 201. This makes it possible to manufacture the sensor device 200 in which the sensor unit 100 is attached to the sensor case 201 in the correct orientation and position, regardless of the level of skill of the worker. Furthermore, after the sensor device 200 is completed, it is possible to check whether the sensor unit 100 is attached to the sensor case 201 in the correct orientation and position based on the degree of agreement between the detection reference position display unit 133 and the sensor case reference position display unit 203.

[0037] (5) In the sensor unit 100 and the sensor device 200 described above in (1) to (4), when the sensor unit 100 is attached to the sensor case 201 using the jig 300, or when the position of the sensor unit 100 is adjusted within the sensor case 201, the sensor device 200 is placed in a predetermined position on the jig 300, and the detection reference position display unit 133 of the sensor unit 100 is aligned with the adjustment reference position display unit 303 of the jig 300. This makes it possible to manufacture the sensor device 200 in which the sensor unit 100 is attached to the sensor case 201 in the correct orientation and position, regardless of the level of skill of the worker. [Explanation of symbols]

[0038] 100 sensor unit, 110 sensor part, 111 sensor element, 112 detection part, 113 positioning recess, 114 electrode part, 115 substrate, 116 lead wire, 120 insulating container, 121 cylindrical insulating part, 122 insulating container reference position display part, 123 positioning protrusion, 130 metal container, 131 cylindrical part, 132 metal container reference position display part, 133 detection reference position display part, A first end, B second end, 200 sensor device, 201 sensor case, 203 sensor case reference position display part, 300 jig, 301 board part, 302a, 302b holder, 303 adjustment reference position display part.

Claims

1. A sensor unit (100) having a sensor section (110), an insulating container (120), and a metal container (130), The sensor unit (110) includes a sensor element (111) having a positioning recess (113) and an electrode unit (114), and a substrate (115) on which the electrode unit (114) is attached. the insulating container (120) includes a cylindrical insulating portion (121) that surrounds the sensor portion (110), a positioning protrusion (123) that corresponds to the positioning recess (113), and an insulating container reference position indicator (122) that indicates a reference position of the cylindrical insulating portion (121) in the circumferential direction; The metal container (130) includes a cylindrical portion (131) configured to accommodate the insulating container (120) and a metal container reference position indicator (132) that indicates a reference position in the circumferential direction of the cylindrical portion (131), the insulating container (120) accommodates the sensor section (110) such that the positioning protrusion (123) and the positioning recess (113) overlap each other; The metal container (130) accommodates the insulating container (120) so that the insulating container reference position indicator (122) and the metal container reference position indicator (132) are aligned in the circumferential direction. Sensor unit.

2. In the insulating container (120) and the metal container (130), when an end portion of the sensor element (111) close to the detection portion (112) is defined as a first end portion (A) and an end portion opposite to the first end portion (A) is defined as a second end portion (B), the insulating container (120) is provided with an insulating container reference position indicator (122) at the second end (B) of the cylindrical insulating part (121); The metal container (130) includes a metal container reference position indicator (132) at the second end (B) of the cylindrical portion (131). The sensor unit according to claim 1 .

3. In the metal container (130), when an end portion of the sensor element (111) close to the detection portion (112) is defined as a first end portion (A) and an end portion opposite to the first end portion (A) is defined as a second end portion (B), The metal container (130) further includes a detection reference position indicator (133) at the first end (A) of the cylindrical portion (131) to indicate a detection reference position of the sensor unit (100). The sensor unit according to claim 1 or 2.

4. A sensor unit (100) according to claim 3; a sensor case (201) that houses the sensor unit (100); In the sensor case (201) accommodating the sensor unit (100), when an end portion close to the detection portion (112) is defined as a first end portion (A) and an end portion opposite to the first end portion (A) is defined as a second end portion (B), The sensor case (201) is provided at the first end (A) with a sensor case reference position indicator (203) that indicates a reference position for detection in the sensor case (201). A sensor device having:

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