Planar Proximity Sensor Assembly for Narrow-Clearance Detection
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Solution Overview
Problem
Conventional proximity sensors with a tubular/cylindrical shape are limited by their size and directional signal emission, making them unsuitable for areas with narrow clearances or where installation is not feasible, such as in slots, slits, or without drilling a hole.
Innovation Solution
A proximity sensor assembly with a substrate having planar surfaces and an antenna, where the cable is fed parallel to these surfaces and attached to the side surface, allowing the sensor to be inserted in narrow spaces, with the cable oriented perpendicular to the electromagnetic field, enabling right-angle proximity measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional tubular/cylindrical proximity sensor is used, then the sensor can provide reliable proximity detection, but the sensor requires sufficient clearance and cannot be installed in narrow spaces
Solution Approach 1:
The patent transitions from a three-dimensional tubular sensor geometry to a two-dimensional planar sensor geometry. The sensing element is formed on a planar substrate with the cable fed parallel to the planar surfaces, creating a low-profile sensor that can be installed in narrow clearances where cylindrical sensors cannot fit.
Solution Approach 2:
The patent inverts the conventional cable orientation relative to the sensing element. Instead of the cable being perpendicular to the sensing face (as in cylindrical sensors), the cable is fed parallel to the planar surfaces and attached to the side surface, with the cable oriented substantially perpendicular to the electromagnetic field direction, enabling right-angle proximity measurements.
2Power
If a conventional tubular/cylindrical proximity sensor is used, then the sensor can emit proximity detection signals, but the sensor length and signal direction require sufficient clearance
Solution Approach 1:
The patent reduces the sensor from a three-dimensional tubular structure to a two-dimensional planar structure. The sensing element is formed on planar surfaces of a substrate, creating a short, low-profile sensor that minimizes the length dimension and clearance requirements while maintaining electromagnetic field emission capability.
3Reliability
If a conventional proximity sensor requires hole drilling or bracket installation, then the sensor can be securely mounted, but the installation process becomes complex and time-consuming
Solution Approach 1:
The planar sensor design can be mounted in multiple configurations and locations without requiring specialized mounting hardware. The sensor can be attached to flat surfaces, edges, or corners using simple adhesive bonding, eliminating the need for hole drilling or brackets, and enabling installation in locations where conventional sensors cannot be mounted.
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
This configuration allows for a short, low-profile sensor that can be inserted into tight spaces, providing effective proximity measurements in areas previously inaccessible to cylindrical sensors.
Implementation Method 1
a signal generation and processing component for generating an electrical driving signal that causes generation of an electromagnetic field from the proximity sensor that is directed toward the object
Implementation Method 2
the cable is oriented substantially perpendicular to the direction of the electromagnetic field emitted from the sensing element
Data Source
AI summary
A proximity sensor assembly with a sensing element having a substrate and an antenna pattern disposed on one or more planar surfaces of the substrate is disclosed. The cable is fed substantially parallel to the planar surfaces of the substrate and is attached to the side surface of the substrate, such that the cable is oriented substantially perpendicular to the direction of the electromagnetic field emitted from the sensing element.