Flat Proximity Sensor Coil Layout for Long-Range Detection
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Solution Overview
Problem
Flat-type proximity sensors face challenges in achieving both downsizing and maintaining a long detection distance, with the risk of collision with detection objects and complex processing requirements for pulse-shaped excitation currents.
Innovation Solution
The design incorporates a head body with a case member, coil, and head board, featuring two independent coils for transmission and reception, along with an amplifier outside the head body, and includes an electric shield and magnetic shield to reduce noise and interference, allowing for downsizing while maintaining a long detection range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the flat-type proximity sensor is downsized to reduce collision risk, then the detection distance becomes short
Solution Approach 1:
The system is divided into two separate coils: a transmission coil for generating the magnetic field and a reception coil for detecting changes. This segmentation allows each coil to be optimized independently, enabling the overall sensor to achieve long detection distance while maintaining a compact form factor that reduces collision risk.
Solution Approach 2:
The transmission coil acts as an intermediary that generates a magnetic field extending beyond the physical sensor boundaries. This intermediary magnetic field enables detection at distances greater than the sensor's physical dimensions would suggest, resolving the contradiction between small size and long detection range.
2Length of stationary object
If pulse-shaped excitation current is used to increase detection distance, then processing complexity increases
Solution Approach 1:
The transmission coil is excited with periodic pulse-shaped currents to generate alternating magnetic fields that extend the detection range. The reception coil detects periodic changes in magnetic flux, and the system processes these periodic signals to determine detection object presence, achieving long detection distance while managing processing complexity through the regular periodic nature of the signals.
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 enables both downsizing and a longer detection distance by processing independent detection currents and reducing external noise and interference, enhancing assemblability and detection accuracy.
Implementation Method 1
The coil generates a magnetic field by applying a pulse-shaped excitation current
Implementation Method 2
A detection current that changes due to a change in a magnetic field flows through the head circuit
Data Source
AI summary
The flat-type proximity sensor detects a detection object in proximity to a plate-shaped member, and includes a head body, a cable, and an amplifier. The head body includes a case member, a coil, and a head board. The case member has a first surface and a second surface. The coil and the head board are accommodated in the case member, the first surface includes a detection surface, and the second surface is installed on the installation surface. The coil generates a magnetic field by applying a pulse-shaped excitation current. The head board includes a head circuit through which a detection current flows due to a change in a magnetic field. The cable guides the detection current from the head circuit to the amplifier. The amplifier includes a processing circuit that performs processing related to detection of the detection object based on the change in the detection current.