Proximity Sensor Housing Layout for Long-Range Pulse Detection
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Solution Overview
Problem
Existing proximity sensors face challenges in achieving a long detection distance while maintaining a compact size, particularly when using pulse-type excitation currents, which require complex calculations and larger control circuit boards, leading to increased head shaft body dimensions.
Innovation Solution
The proximity sensor design includes a detection coil housed in a head housing, with a separate amplifier board in an amplifier housing, allowing for a downsized head shaft body by separating the control circuit from the head housing, and utilizing a pulse-shaped excitation current to improve detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the head shaft body is made shorter for easy disposal in obstacle environments, then ease of installation is improved, but the detection distance becomes long which weakens the magnetic field change
Solution Approach 1:
The invention divides the sensor system into two separate housings: a head housing containing the detection coil and a separate amplifier housing containing the control circuit. This segmentation allows the head housing to be compact for easy installation while the amplifier housing can be positioned elsewhere to maintain detection accuracy through pulse-type excitation current.
2Measurement precision
If pulse type excitation current is used to capture weak magnetic field changes, then detection accuracy is improved, but the control circuit board size increases leading to larger head shaft body
Solution Approach 1:
The invention extracts the control circuit from the head housing and places it in a separate amplifier housing. This allows the head housing to remain compact while the amplifier housing contains the larger control circuit board needed for pulse-type excitation current processing, thus maintaining detection accuracy without increasing head shaft body size.
3Volume of moving object
If the head housing is downsized for compact installation, then ease of installation is improved, but the control circuit requires more space for complex calculations
Solution Approach 1:
The invention introduces a power supply cable as an intermediary element that connects the head housing to the amplifier housing. This cable serves as a mediator that allows the control circuit in the amplifier housing to process complex pulse-type excitation current calculations while the head housing remains compact, effectively decoupling the spatial requirements of the detection element from the processing element.
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 enables a long detection distance with improved detection accuracy and reduced risk of collision, while allowing for easier installation in spaces with obstacles, by downsizing the head housing and maintaining the control circuit's complexity outside the head housing.
Implementation Method 1
a detection coil 1 that generates a magnetic field for detection
Data Source
AI summary
The proximity sensor includes a detection coil, a metal head housing, and a power supply cable. The detection coil generates a detection current. The metal head housing houses the detection coil. The power supply cable has an electrical connection with the detection coil and is connected to the metal head housing. At least a part of an internal space of the metal head housing is filled with a filler so as to bury the detection coil. As the filler, an adhesive and an additive having a relative permittivity lower than that of the adhesive are mixed.