Integrated Proximity Sensor Control for PLC-Free Load Actuation
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Solution Overview
Problem
Existing proximity sensors require external devices like PLCs and timing modules for processing and control functions, adding significant cost to the system.
Innovation Solution
A proximity sensor with integrated control features, including a sensing circuit, interface circuit, output electronics, and a microcontroller unit, capable of detecting targets, processing input signals, and generating actuation signals for external actuators without the need for external devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If external devices such as PLCs or timing modules are used in combination with the proximity sensor, then processing and control functions can be provided, but system cost increases significantly
Solution Approach 1:
The patent combines the proximity sensing function with integrated timing and control logic features into a single device. The microcontroller unit incorporates both the sensing circuitry and the control logic that previously required separate external devices, thereby reducing system complexity and cost while maintaining full processing and control capabilities.
Solution Approach 2:
The proximity sensor is designed to perform multiple functions: detecting target presence, processing input signals, generating timing signals, and controlling output devices. This multi-functional integration eliminates the need for separate dedicated devices for each function, reducing overall system cost and complexity.
2Adaptability or versatility
If multiple external devices are used for processing and control, then desired application support is achieved, but the number of components and system complexity increases
Solution Approach 1:
The patent merges the functionality of multiple external devices (proximity sensor, PLC, timing module) into a single integrated device. The microcontroller unit consolidates these separate components, reducing the number of parts in the system while maintaining the ability to support various applications through programmable control logic.
3Adaptability or versatility
If external devices are used for signal processing and control, then processing functions are provided, but installation and system setup become more complex
Solution Approach 1:
By integrating all processing and control functions into a single proximity sensor device, the system requires fewer connections and integrations during installation. The unified device eliminates the need to coordinate multiple external components, simplifying both installation and maintenance procedures.
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 integrated proximity sensor reduces system costs by incorporating all necessary electronics for detection, processing, and actuation, while minimizing erroneous responses due to noise events.
Implementation Method 1
use may be made of electromagnetic sensors in the form of inductive or capacitive proximity sensors that respond to metal members near the detection element of the sensor
Data Source
AI summary
A proximity sensor with integrated control features includes a sensing circuit that detects a target feature in proximity thereto and generates a sensor signal responsive to detection of the target feature, an interface circuit that receives inputs from an external device and conditions the inputs to provide digital logic outputs, output electronics that selectively provide actuation signals for driving a load operatively connected to the proximity sensor, and a microcontroller unit in communication with the sensing circuit, the interface circuit, and the output electronics. The microcontroller unit receives sensor signals and digital logic outputs from the sensing circuit and the interface circuit, samples the sensor signals and digital logic outputs, and selectively provides activation signals to the output electronics based on the state of the digital logic outputs and/or the sensor signals, wherein the activation signals cause the output electronics to output the actuation signals to drive the load.