Inductive proximity sensor for detecting ferromagnetic, non-permeable or magnet targets

Abstract

A core of a proximity sensor is made of a highly permeable metal and is shaped and sized to operate as a saturable core proximity sensor, a variable reluctance proximity sensor, and an eddy current proximity sensor. The core has a cross-sectional shape including a head portion, two legs extending from the head portion, and two foot portions (feet) extending from the two legs. The head portion forms a substantially planar section along the upper surface and is perpendicular to the sectional direction created by the two legs. The sectional direction of the two legs are perpendicular to the sectional direction of the two feet. The two feet are in a common plane along the bottom surface. Both foot portions are also parallel to the head portion. The cross-sectional shape of the core may further comprises two tail portions (tails), wherein each tail extends from one of the two foot portions in a direction toward the upper surface.

Description

FIELD OF THE INVENTION

[0002] The present invention relates to a non-contact proximity sensor and, more particularly, a proximity sensor having an increased sensing range and capable of sensing magnetic, ferromagnetic, and conductive targets.

BACKGROUND OF THE INVENTION

[0003] A proximity sensor is a device used to detect the presence of an object. The design of a proximity sensor can be based on a number of principles of operation, some examples include: variable reluctance, eddy current loss, saturated core, and Hall effect. Depending on the principle of operation, each type of sensor will have different performance levels for sensing different types of objects. In particular, saturated core and Hall effect sensors are primarily used to detect the presence of magnetic objects, while variable reluctance and eddy current loss sensors are primarily used to detect the presence of metal objects.

[0004] Saturated core sensors are known in the prior art. Such proximity sensors typically include a core made from a material that will magnetically saturate when exposed to a magnetic field of a certain flux density. As a magnetic object is moved toward the core assembly, a distance is reached where the magnetic field of the object finds the core to be the smallest reluctance path. As a result, the flux of the field enters the core and, as the distance is decreased the flux density increases and eventually saturates the core. The saturation of the core causes the impedance of the coil to decrease. By measuring changes in the impedance of the coil, the presence of the magnetic object may be detected.

[0005] One example of a saturated core sensor can be found in U.S. Pat. No. 4,719,362 to Nest et al. (“the Nest Patent”). The Nest patent discloses an inductive proximity sensor having a core, a conductive coil, and an oscillator circuit. The core is made from a metal that magnetically saturates when exposed to the magnetic field of a target.

[0006] Variable reluctance sensors are also known in the prior art. Such proximity sensors typically include a U-type core and coils wound around the core legs. Other typical shapes of variable reluctance proximity sensors cores include: Pot cores, pins, T-cores, E-cores and plates. These devices also typically include an electronic drive device for producing an oscillating electromagnetic field around the coil. Square waves, sine waves, trapezoidal waves, and other unique wave shapes have been used to interface to these sensors. As a permeable object is moved toward the variable reluctance proximity sensor, the permeable object reduces the reluctance of the electromagnetic system, and this variation in the reluctance is measured as a change in the inductance and AC resistance of the coil. When the permeable object moves toward a variable reluctance sensor, the inductance and AC losses of the coil increase.

[0007] In some designs, two coils are used, one to produce the electromagnetic field and another to measure the variations in the reluctance. In conventional variable reluctance proximity sensors, it has been common practice to use a ferrite core. The sensing coils are placed on the core to optimize the magnetic field extending to the target material. The core is shaped to contain and extend the electromagnetic field surrounding the coil in a sensing direction or to concentrate or channel the field in other directions, such as behind and to the sides of the coil. One example of a variable reluctance sensor is shown in U.S. Pat. No. 4,387,339 to Akerblom (“the Akerblom patent”). The Akerblom patent discloses an apparatus for measuring the distance between two moving objects.

[0008] Eddy current sensors are also known in the prior art. Such proximity sensors have a similar design to variable reluctance sensors in that they typically include Pot cores or U-type core, a coil wound around the center post of the core or the core legs, and an oscillator for producing an oscillating electromagnetic field around the coil. As with the variable reluctance proximity sensor, the eddy current sensor detects the presence of a conducting object by measuring the real and imaginary AC losses of the coil; however, in this design, if the target material is only conductive, the inductance of the coil decreases as the object is moved toward the target.

SUMMARY OF THE INVENTION

[0009] The present invention provides a proximity sensor that operates as a saturable core proximity sensor, a variable reluctance proximity sensor, and an eddy current proximity sensor. In the preferred embodiment, the core is made of a highly permeable metal. The preferred embodiment provides a durable, low cost, lightweight proximity sensor with increased sensitivity and additional manufacturing benefits.

[0010] The precision shaped metal core and the supporting assembly are designed to optimize the sensitivity of the device in three modes of operation. In one mode of operation, the proximity sensor is used to detect the presence of a magnet. When the magnet approaches the sensor, the unique shape and dimensions of the core allow for easy saturation of the core in the magnetic field. When the magnet is close to the sensing device, the core saturates and significantly changes the impedance of a coil configured around the core. A first sensing circuit connected to the coil is used to detect variations in the impedance and configured to provide a signal to indicate the presence of a magnetic object when the coil impedance fluctuates.

[0011] In a second mode of operation, the proximity sensor is used to detect the presence of ferromagnetic metals objects, also referred to as permeable metals. In this mode, the coils around the core provide a source field and also provide a means for measuring variations in source field. When a permeable object moves into the source field, the inductance of the coil increases. A second sensing circuit connected to the coil is used to detect variations in the inductance of the coil and configured to provide a signal to indicate the presence of a ferromagnetic target when the coil inductance fluctuates. The highly permeable steel sensor core provides a design with increased sensitivity for detecting ferromagnetic objects at increased ranges.

[0012] In a third mode of operation, the proximity sensor is used to detect the presence of conductive objects, such as copper or aluminum. In this mode, the inductance of the coil decreases when a conductive object moves into the source field. The second sensing circuit connected to detect variations in the inductance of the coil. Similar to the variable reluctance mode, when a permeable object moves into the source field, the inductance of the coil increases. A second sensing circuit connected to the coil is used to detect variations in the inductance of the coil and configured to provide a signal to indicate the presence of a ferromagnetic target when the coil inductance fluctuates. The highly permeable steel sensor core also provides a design with increased sensitivity for detecting conductive objects at increased ranges.

[0013] A specific core design that can be used in the present invention is a thin, highly permeable metal that is preferably formed from a single piece of sheet metal. The core comprises a substantially flat, rectangular member bent in four locations to form a shape that resembles a rectangular Greek omega character having a head, two legs, and two feet. The bends are right angles with 60 degree bend radii so that the head is perpendicular to the two legs, and the two legs are perpendicular to the two feet. The two feet are parallel to each other, occupy a common plain and also parallel to the head.

[0014] The core is positioned in a housing with two inductive coils, each coil being positioned around one of the feet of the core. Another embodiment of the present invention also provides a core and coil assembly with a calibration bolt that is placed through the center of the core to adjust the inductance range of the proximity sensor.

[0015] The thin metal structure of the core also provides many other benefits in the manufacturing process of the proximity sensor. Specifically, the thin metal core allows for a more efficient manufacturing process that does not require a considerable amount of machine work, as compared to the prior art U-type metal cores. The core design also provides a rugged, lightweight structure that is not susceptible to great temperature fluctuations. Another advantage of the present invention is that it can be used as a permeable metal target sensor, an eddy-current-loss sensor, or a magnetic field sensor without the need of special preparations to switch the detectors for different types of applications. The proximity sensors of the present invention also provide a core design with increased sensitivity while having a design that is produced in a sufficiently small size.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

[0017] FIG. 1 is a top front perspective of one embodiment of a proximity sensor utilizing an omega core in accordance with the present invention;

[0018] FIG. 2 is a section along line 2-2 of FIG. 1;

[0019] FIG. 3 is a top rear perspective of the proximity sensor of FIG. 1, with parts shown in exploded relationship;

[0020] FIG. 4A is an enlarged perspective of the core used in the proximity sensor of FIGS. 1-3; FIG. 4B is a side elevation of FIG. 4A; FIG. 4C is an end elevation thereof; FIGUTRE 4D is a bottom plan thereof;

[0021] FIG. 4E is a longitudinal vertical section thereof;

[0022] FIG. 5 is a section corresponding to FIG. 2, but showing another embodiment of a proximity sensor in accordance with the present invention;

[0023] FIG. 6A is an enlarged perspective of the core used in the proximity sensor of FIG. 5; FIG. 6B is a side elevation of FIG. 6A; FIG. 6C is an end elevation thereof; FIG. 6D is a bottom plan thereof;

[0024] FIG. 7 is a somewhat diagrammatic top plan of a proximity sensor in accordance with the present invention adjacent to a magnetic target;

[0025] FIG. 8 is a graph of the impedance of the sensor coils as a function of the distance between the magnetic target and the proximity sensor of FIG. 6;

[0026] FIG. 9 is a somewhat diagrammatic top plan of a proximity sensor in accordance with the present invention adjacent to a permeable target;

[0027] FIG. 10 is a graph showing the sensitivity of the sensor coils versus the distance between the permeable target as the proximity sensor is used in the variable reluctance mode;

[0028] FIG. 11 is a graph showing the sensitivity of the sensor coils versus the distance between the permeable target as the proximity sensor is used in the eddy current loss mode;

[0029] FIG. 12 is a side view of another embodiment of a proximity sensor utilizing a cup core in accordance with the present invention;

[0030] FIG. 13A is a section along line 13A-13A of FIG. 12, FIG. 13B is a top rear perspective of the proximity sensor of FIG. 12 with parts shown in exploded relationship;

[0031] FIG. 14A is a side elevation of the core used in the proximity sensor of FIG. 12; FIG. 14B is a section along line 14B-14B of FIG. 14A;

[0032] FIG. 15A is an axial section of yet another embodiment of a proximity sensor utilizing a cup core in accordance with the present invention; and FIG. 15B is a top front perspective of the embodiment of a proximity sensor of FIG. 15A with parts shown in exploded relationship;

[0033] FIG. 16 is a diagrammatic side elevation of a proximity sensor in accordance with the present invention adjacent to a magnetic target with parts broken away;

[0034] FIG. 17 is a graph of the impedance of the sensor coils as a function of the distance between the magnetic target and the proximity sensor of FIG. 16;

[0035] FIG. 18 is a diagrammatic side elevation of a proximity sensor in accordance with the present invention adjacent to a permeable target with parts broken away; and

[0036] FIG. 19 is a graph showing the sensitivity of the sensor coils of a proximity sensor versus the distance between the permeable target as the proximity sensor is used in the variable reluctance mode.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0037] While advances have been made in the design of proximity sensors to improve their range and sensitivity, improvements of the various proximity sensors have not focused on providing a proximity sensing device that operates efficiently under different principles of operation. More specifically, prior art proximity sensors that have been developed to operate as a variable reluctance sensor do not operate efficiently as a saturated core sensor. Accordingly, prior art proximity sensors that have been designed to operate as a saturated core sensor do not operate well as a variable reluctance sensor. The present invention provides a core design that is able to operate under both principles of operation and provide a core design that also operates as an eddy current loss sensor. The present invention provides a highly sensitive, low cost, rugged core design that can operate under different principles of operation and that can detect multiple classes of target materials. In particular, the present invention provides a proximity sensor that is of a relatively straightforward structure that makes use of elements common to existing sensors, and adapted to accommodate magnetic and non-magnetic metal objects.

[0038] In addition, the present invention provides a core design with an extended sensing field without the need of a ferrite material or machined metal core. Proximity sensors that use ferrite cores have a degradation in their performance due to fluctuations in operating temperatures, age and particular material properties, such as brittleness and variance in initial material conditions. Other proximity sensors using a machined metal or metal laminated cores have been used in the art; however, these core designs are typically more difficult and more expensive to manufacture. The core design of the present invention using a thin permeable material provides increased performance as well as providing other manufacturing benefits.

[0039] The present invention provides a proximity sensor that operates as a saturable core proximity sensor, a variable reluctance sensor, and an eddy current loss sensor. In one mode of operation, the proximity sensor is used to detect the presence of a magnet. In another mode of operation, the proximity sensor is used to detect ferromagnetic objects or permeable targets. In yet another mode of operation, the proximity sensor is used to detect conductive targets such as copper or aluminum, along with any combination thereof. Target material recognition, and combining materials in a target are common methods of improving discriminating functions. The structure and methods of different embodiments of the present invention will become more readily apparent from the following detailed description, when taken in conjunction with the accompanying drawings.

[0040] With reference to FIGS. 1 and 2, a first embodiment of a proximity sensor 100 in accordance with the present invention includes a housing 102 having a target-facing front surface 104 and four sidewalls 106 extending at right angles from surface 104. The sidewalls 106 and front surface 104 form a hollow interior region in the housing 102. As shown diagrammatically in broken lines in FIG. 1, a sensing region 200 extends out from the target-facing front surface 104 in a generally hemispherical shape. For example, in a representative embodiment, the proximity sensor 100 can have an effective sensing range of approximately 0.8 inches in the Y direction (around to the front 104) and an effective range diameter of approximately 1.5 inches in the X-Z plane (parallel to the surface 104). The proximity sensor 100 in FIG. 1 is effective for detecting magnetic, permeable, and non-permeable conductive metallic targets in the sensing region 200.

[0041] The housing 102 includes two flanges 108 extending outward from the opposite sidewalls 106. The flanges 108 have apertures 110 to permit the proximity sensor 100 to be mounted on a support member by the use of bolts or screws, such as on a frame or sash for a closure member. The housing 102 is preferably made from a durable, non-magnetic material having a fairly low electrical conductivity, i.e., a conductivity level approximate to titanium. It is preferred that a physically strong, low conductivity, non-corrosive and non-magnetic material, like titanium or stainless steel be used in the construction of housing 102. However, to maximize the performance of the proximity sensor, other nonconducting materials such as formable plastics can be used to construct the housing 102. The performance of the sensor increases as the conductivity of the housing 102 decreases. The use of a highly conductive material should be avoided because eddy currents may form on the housing surface and reduce the effective range 200 of the proximity sensor 100. In addition, the use of ferromagnetic materials should be avoided because the housing 102 may contain the sensing field produced by the proximity sensor 100.

[0042] The housing 102 also includes a rear opening to the hollow interior for the insertion of the internal components. Referring now to FIG. 3, the proximity sensor 100 is assembled by sliding the two insulators 116 into the opening of the housing 102. The two insulators 116 are preferably constructed from a nonconductive material such as plastic or Mylar with a thickness approximate to three Mils. The two insulators 116 may be molded in a cup shaped form to provide an insulating shield between two coil assemblies 118 and the housing 102.

[0043] The two coil assemblies 118 are then inserted into the two insulators 116. The two coil assemblies 118 comprise a plurality of turns of a relatively fine copper wire with a preferred gauge of thirty-seven. Although a gauge of thirty-seven is preferred, the two coil assemblies 118 may be constructed from any insulated wire material with a gauge range from twenty-six to fifty. From a view looking into the opening of the housing 102, the coil assemblies are formed by turning the wire of one coil in a clockwise direction and by turning the wire of the second coil in a counterclockwise direction. Either coil may have the wire turn in the clockwise direction so long as the wire in the other coil is turned in the opposite direction. One wire from one coil should be connected to one wire from the other coil to create a closed loop circuit between the two coils. The other two open ends of each coil are connected to electrical contacts in an external connector 140.

[0044] The closed loop circuit formed by the coil wires is connected to a circuit 101 external to the housing 102. Two different circuits can be connected to the two coil assemblies 118 through the external connector 140 to accommodate three modes of operation. For the saturated core mode of operation, the closed circuit created between the two coil assemblies is connected to a circuit that has the capability of measuring the impedance of the two coils. This arrangement allows the proximity sensor 100 to detect the presence of magnetic targets. The impedance measuring circuit used in this configuration can be similar to a circuit that is commonly used in the art to measure impedance, such as an impedance meter.

[0045] In the other two modes of operation, the closed loop circuit created between the two coil assemblies is connected to a circuit having the capability to detect inductance of the two coils and to provide an alternating current to the two coils. This arrangement allows the proximity sensor 100 to detect the presence of permeable and conductive objects by sensing variations in the inductance of the two coils. The inductance measuring circuits used in these configurations are similar to those circuits that are commonly used in the art to operate common variable reluctance and eddy current loss proximity sensors, or again, an impedance meter.

[0046] The two coil assemblies 118 are also suitably formed in a rectangular configuration to accommodate the insertion of the core's foot portions. As described below, one embodiment of the core 120 has foot portions having a width of 0.292 inches and a length of 0.275 inches, thus the core should have a center opening of approximately 0.302 by 0.285 inches. The height of the coil in this embodiment should be approximately 0.250 inches.

[0047] After the two coil assemblies 118 are inserted, the core 120 is placed into the housing 102, such that the legs of the core 120 fit tightly into the openings of the two coil assemblies 118. FIGS. 4A-4E illustrate various views of the core 120 to show the unique aspects of its design. The core 120 comprises a substantially flat, rectangular member bent in four locations to form a shape that resembles a rectangular Greek omega character having a head portion 220, two legs 222, and two foot portions (feet) 224. The bends are at right angles so that the head portion 220 is perpendicular to the two legs 222, and the two legs are perpendicular to the two feet 224. The two feet 224 are parallel to each other and coplanar, extend oppositely from the respective legs. Both feet portions 224 are also parallel to the head portion 220.

[0048] The head portion of the core 220 has a preferred width of 0.370 inches and a preferred length of 0.39 inches. The two legs 222 that extend at right angles from the head portion 220 have a preferred width of 0.292 inches and a preferred length of 0.300 inches. The two feet 224 extend away from each other and have a preferred length of 0.275 inches and preferred width of 0.292 inches. As illustrated in FIG. 4B, if the omega shaped core is positioned to stand on the two feet 224, the core would have a height of 0.320 inches and a total length of 0.94 inches.

[0049] FIGS. 4A-4E also show that the top section of each of the two legs has a width equal to the width of the head portion 220, and the bottom section of each leg has a width that is more narrow than the width of the top section. The wider top section should extend down each leg approximately 0.050 inches. Accordingly, the narrow bottom section of the each leg should extend down the remaining portion of each leg having a length of approximately 0.250 inches.

[0050] FIG. 4E is a side section of the core 120 illustrating the orientation of the above-described core 220 components. More specifically, FIG. 4E illustrates that a section of the core comprises a head portion 220, two legs 222, and two foot portions (feet) 224. As shown in FIG. 4E, the section of the core illustrates that the two legs 222 extend in a plane that is at a right angle from the plane created by the head portion 220. In addition, the two feet 224 extend away from each other and each foot creates a plane that is preferably parallel to one another and parallel to the plane created by the head portion 220.

[0051] The core 120 is preferably constructed from a highly permeable material such as soft iron, cast iron, transformer steel, or any other like material. The relative permeability should be at least 10,000. Although a relative permeability is suggested to be at least 10,000, higher values are desired to increase the sensor's performance. One material that is preferred is referred to in the art as HyMu “80”®, available from Carpenter Steel Company of New Jersey. It is also preferred to form the core from one piece of metal with a thickness of approximately 0.020 inches. Although this embodiment shows a core with a thickness of 0.020 inches, the core thickness can range from 0.0005 to 0.050 inches.

[0052] With reference to FIGS. 4A-4E, each of the four bends in the metal sheet that make up the core 120 should have a radius of 0.060 inches in the preferred embodiment. More specifically, the arc of each bend should form a quarter circle having a radius of 0.060 inches. These precise bends apply to the bends between all surfaces of the core 120. In addition, it is also important to note that the corners 226 of the core also require a radial measurement. Each corner 226 should have a curvature that creates an arc with a maximum radius of 0.020 inches. Accordingly, all comers or edges that form a sharp edge should be ground down or properly finished as sharp comers on the core will reduce the sensing performance. The tolerances for these radius bends and the core measurements listed above are ±0.005 inches for linear measurements and +5 degrees for the right angle bends.

[0053] Since cold bends in the metal change the magnetic properties of the core, an annealing process should be applied to the core to properly complete its construction. Thus, after the bends are made, the core should be cleaned such that all contaminants such as oil, grease, lacquer, and water, are removed from the core surface. In addition, the core should not be exposed to carbon, sulfur, or nitrogen during the annealing process. Once properly cleaned, the core is preferably annealed in an oxygen free, dry hydrogen atmosphere with a dew point below −40 degrees Celsius during the entire hydrogen annealing stage. If multiple cores are annealed at this part of the process, an insulating powder should be used to keep the cores from touching other cores or other objects. Preferred insulating powders include: magnesium, aluminum oxide, clean ceramic paper or an equivalent clean ceramic material.

[0054] The core should be annealed for seven to eight hours at temperature range between 1121 to 1177 degrees Celsius. After the seven to eight hour period, the core should be furnace cooled to a temperature approximate to 593 degrees Celsius. Once the core is cooled to 593 degrees Celsius, the core should be cooled at a rate between 260 and 316 degrees Celsius per hour to 371 degrees Celsius and then furnace cooled until a room temperature is reached.

[0055] Returning to FIG. 3, after the core 120 is placed into the housing 102, a spyder 122 is inserted on top of the core 120 to affix the core 120 and the two coil assemblies 118. The spyder 122 is preferably made from a nonconductive material such as a glass filled polymer. An adhesive can be used to secure the spyder 122 to the coils 118. A spring 124 and washer 126 are then placed on the spyder 122 and a snap ring 128 is used to secure the spring 124 and washer 126 to the spyder 122. Machined groves lined in the inside wall of the housing 102 receive the snap ring 128 to hold the snap ring 128 down onto the washer 126 and spring 124.

[0056] The cover 130 can be affixed to the housing 102 by a metal welding with a minimum weld penetration of 0.010 inches. Similar to the housing 102, the cover 130 is preferably made from a non-magnetic material with low conductivity such as titanium or stainless steel.

[0057] A proper seal between the metal cover 130 and the metal housing 102 prevent adverse effects caused by lightning strikes or other external sources of electrical current. This allows the proximity sensor 100 to provide consistent, repeatable proximity detection information even in the presence of relatively strong electromagnetic fields generated by current from a source external to the sensor assembly. For instance, when proximity sensor 100 is installed in an aircraft, the latter may be subjected to lightning strikes having a peak current of 200 KA or more. This current, which sheets along the outer skin of the aircraft, generates electromagnetic fields having an intensity of 10,000 amps/M or more, which fields may intercept the proximity sensor 100 when positioned adjacent to the outer skin of the aircraft. Such fields could temporarily adversely affect the operation of proximity sensor 100 by saturating core, thereby causing the inductance of coil to decrease to a level indicative of a magnetic target.

[0058] The embodiment of proximity sensor 100 in accordance with the present invention shown in FIG. 5 is constructed in a manner similar to the proximity sensor shown in FIGS. 2 and 3. The main difference in the embodiment of FIG. 5 is that a calibration bolt 132 is inserted through the center of the core 120′. The calibration bolt 132 is used to change the level of inductance that is measured from the coils to accommodate the external circuitry.

[0059] Much like the material of the core 120′, the calibration bolt 132 is preferably constructed from a highly permeable material such as soft iron, cast iron, transformer steel, or any other like material. The calibration bolt 132 should have a relative permeability of approximately 90 or higher. As with the material of the core 120′, the performance of the device is increased as the relative permeability of the calibration bolt 132 is increased.

[0060] As shown in FIG. 5, the calibration bolt 132 should be positioned to extend through the center of the core 120′ and into a hole 121 in the center of the spyder 122. The calibration bolt 132 should be positioned such that it is substantially perpendicular to the head surface of the core 120′. The calibration bolt 132 can be formed into a threaded screw to facilitate the calibration process.

[0061] The core utilized in the embodiment employing the calibration bolt 132, shown in FIGS. 6A-6D, is similar to the core of FIG. 4A-4D. The core 120′ of FIGS. 6A-6D comprises a substantially flat, rectangular member bent in four locations to form a shape that resembles a rectangular Greek omega character having a head portion 220′, two legs 222′, and two foot portions (feet) 224′. The core of FIGS. 6A-6D also comprises an aperture in the center of the head portion 220′ sized to receive the calibration bolt 132. In addition, the center of the head portion 220′ has an extended width to provide additional strength to the core's structure and to improve the sensitivity of the proximity sensor.

[0062] The core 120′ of FIGS. 6A-6D is also shaped with bends at right angles so that the head portion 220′ is perpendicular to the two legs 222′, and the two legs are perpendicular to the two feet 224′. The two feet 224′ are parallel to each other and coplanar, extend oppositely from the respective legs. Both feet portions 224′ are also parallel to the head portion 220′.

[0063] The top section of each of the two legs has a width equal to the width of the head portion 220′, and the bottom section of each leg 222′ has a width that is more narrow than the width of the top section. The wider top section should extend down each leg approximately 0.050 inches. Accordingly, the more narrow bottom section of the each leg should extend down the remaining portion of each leg having a length of approximately 0.250 inches.

[0064] Similar to the core 120 of FIGS. 3A-3D, each of the four bends in the metal sheet that make up the core 120′ should have a precise radius bend of 0.060 inches. More specifically, the arc of each bend should form a quarter circle having a radius of 0.060 inches. These precise bends apply to the bends between all surfaces of the core 120′. In addition, it is also important to note that the comers 226′ of the core also require a radial measurement. Each corner 226′ should have a curvature that creates an arc with a maximum radius bend of 0.020 inches. Accordingly, all corners or edges that form a sharp edge should be ground down or properly finished, as sharp comers on the core will reduce the sensing performance. The tolerances for these radius bends and the core measurements listed above are ±0.005 inches for linear measurements and ±5 degrees for the right angle bends.

[0065] As described above, the proximity sensor 100 is used to detect three different types of objects. In one mode of operation, the proximity sensor 100 is used to detect the presence of objects that emit a magnetic field such as a magnetically charged iron. When used in this mode of operation, the proximity sensor 100 operates as a saturated core sensor. In another mode of operation, the proximity sensor 100 is used to detect the presence of permeable objects, also known as ferromagnetic metals. When used in this second mode of operation, the proximity sensor 100 operates as a variable reluctance sensor. In yet another mode of operation, the proximity sensor 100 is used to detect the presence of conductive metals or nonferrous objects such as aluminum, copper, brass or other like metals. When used in this third mode of operation, the proximity sensor 100 operates as an eddy current loss sensor.

[0066] FIG. 7 illustrates the proximity sensor 100 used as a saturated core sensor to detect a magnetic object 301. The target facing surface 104 of the proximity sensor 100 is directed toward a magnetic object 301 producing a magnetic field 302. As the magnetic object 301 moves toward the proximity sensor 100, a point is reached where flux lines 302 begin to enter the core 120 and follow the core as the least reluctant path. As the proximity sensor 100 is moved deeper into the magnetic field, the core 120 begins to react to the magnetic field, thus changing the impedance value of the coils surrounding the core 120. Eventually, the core reaches a level of saturation where the impedance value of the coil significantly reacts to the changed state of the core 120. This reaction in the impedance value in relation to the saturation level is shown in FIG. 8.

[0067] FIG. 8 is a graph of the coil impedance versus the distance between the magnetic object and the proximity sensor 100. As illustrated by the line 310, when the magnetic object 301 reaches a distance of approximately 0.8 inches (indicated by point A), the core begins to saturate. From this distance of 0.8 inches, as the magnetic object 301 moves toward the proximity sensor 100, the impedance significantly decreases as the core begins to saturate. When the core saturates, the impedance of coil drops rapidly from a relatively high value representing virtually no saturation of the core to a relatively low value representing virtually complete saturation of the core. The “no saturation” inductance level is represented by the upper horizontal portion of inductance curve 310 in FIG. 8, and the “complete saturation” inductance level is represented by the lower horizontal portions of curve 310.

[0068] Thus, by measuring the impedance levels in the coils, the presence of a magnetic object can be detected. The physical dimensions of the core determine when the core reaches magnetic saturation. The unique design of the present invention provides optimal performance of a saturated core proximity sensor as characterized in the graph of FIG. 8. As a result of the unique shape and dimensions of the core, the core will saturate at a greater distance away from the magnetic field source than a conventional U-type core of an equivalent size.

[0069] When the proximity sensor 100 is used as a variable reluctance sensor, the configuration of the proximity sensor 100 is somewhat different than the configuration shown in FIG. 7. FIG. 9 shows an apparatus 303 with the proximity sensor 100 adjacent to a permeable target 306. When the proximity sensor 100 is used as a variable reluctance sensor, the proximity sensor 100 generates an alternating magnetic field as illustrated by the flux lines 304.

[0070] To detect the presence of permeable materials, an external alternating current source is used to drive the coils of the proximity sensor 100. When the permeable target 306 is moved into the magnetic field of the proximity sensor 100, the reluctance between the permeable target 306 and proximity sensor 100 changes. This change in reluctance increases the inductance of the sensing coils. Thus, an inductance measuring circuit can be used to detect the presence of the permeable target 306.

[0071] FIG. 10 is a graph of the coil sensitivity as a function of the distance between a permeable target 306 and the proximity sensor 100. The sensitivity of the proximity sensor 100 is measured in units of microhenrys per Mil. For example, if the conductive target 306 moves one Mil, with a distance of 0.14 inches between the proximity sensor and the conductive target, the coils' inductance changes by five microhenrys (as indicated by point B). If the permeable target 306 is 0.02 inches away from the proximity sensor 100 and moves one Mil, the coils' inductance changes by 42 microhenrys (as indicated by point C). The sensitivity of the proximity sensor 100 increases at an exponential rate as the permeable target 306 moves toward the proximity sensor 100. In this configuration, the coil inductance increases as the permeable target 306 moves toward the proximity sensor 100.

[0072] When the proximity sensor 100 is used as an eddy current loss sensor to detect conductive targets, the configuration of the proximity sensor 100 is similar to the configuration of the variable reluctance sensor as shown in FIG. 9. However, the inductance of the coils has a different reaction to the conductive targets compared to the permeable targets.

[0073] The proximity sensor shown in FIG. 9 is also used to describe the eddy current configuration, only the target 306 now consists of a conductive, non-permeable target such as aluminum or copper. When the conductive target 306 is moved into the magnetic field 304 of the proximity sensor 100, the conductive target 306 will intercept a portion of the magnetic field 304 produced by the alternating current fed into the coil. This interception of the magnetic field 304 induces eddy currents in the conductive target 306 that are temporally (ninety degrees) out of phase with the source current. In turn, these eddy currents do two things; they dissipate energy as heat within the conductor and generate another magnetic field. The magnetic field generated by the eddy currents within the conductive target 306 opposes the magnetic source field 304 eventually causing additional currents back in the sensor coils. Thus, when the conductive target 306 enters the magnetic source field 304, the current in the coils increases. This reaction in the current level is detected by electronic circuitry that measures the inductance over the coil. When the conductive target 306 moves toward the proximity sensor 100, the inductance of the coils decreases, thereby indicating the presence of the conductive target 306. FIG. 11 is a graph of the coil sensitivity as a function of the distance between a conductive target and the proximity sensor. Similar to the graph of FIG. 10, the sensitivity of the proximity sensor 100 is measured in units of microhenrys per Mil. For example, if the conductive target moves one Mil, with a distance of 0.03 inches between the proximity sensor and the conductive target, the coils' inductance changes by eight microhenrys (as indicated by point D). In this configuration, the inductance of the coils decreases as the conductive target is moved toward the proximity sensor. Thus, the present invention provides a highly sensitive proximity sensor that operates in the eddy current loss mode to detect the presence of a conductive, non-permeable target by simply measuring the inductance in the coils.

[0074] The graph of FIG. 11 also displays the performance levels of the proximity sensor 100 at different operating frequencies. The first line 312 reveals the sensitivity of the proximity sensor when the source current is at 2 KHz. As shown by the other lines 314-320 corresponding with other operating frequencies of 5, 6, 7 and 8 KHz, the performance of the proximity sensor peaks at 8 KHz and decreases as the frequency increases.

[0075] As with the embodiment utilizing the proximity sensor as a saturated core sensor, the physical dimensions of the core, together with the dimensions and configuration of the coil, determine the sensor's ability to detect targets at an optimal distance. The unique design of the core and the placement of the coils provide a variable reluctance and eddy current loss proximity sensor having the performance characterized in the graphs of FIGS. 10 and 11. As a result of the unique shape and dimensions of the core, the proximity sensor 100 is able to detect variations in the source magnetic field (304 of FIG. 9) at a greater distance away from the proximity sensor 100 than a conventional U-type core of an equivalent size.

[0076] FIGS. 12, 13A and 13B show another embodiment of a proximity sensor 1200 having a cup core 1220 in accordance with the present invention. This embodiment includes a housing 1201 having a target-facing front surface 1251 and a cylindrical sidewall 1252 extending from the front surface 1251. The sidewall 1252 and the front surface 1251 form a hollow interior region in the housing 1201. As shown diagrammatically in broken lines in FIG. 12, a sensing region 1250 extends out from the target-facing front surface 1251 in a generally hemispherical shape. For example, in an exemplary embodiment, the proximity sensor 1200 can have an effective sensing region of approximately 0.3 inches in a direction perpendicular to the surface 1251. Similar to the operation of the cores shown in FIGS. 4A-4E and 6A-6D, the proximity sensor 1200 of FIG. 12 is effective for detecting magnetic, permeable, and non-permeable conductive metallic targets in the sensing region 1250.

[0077] The housing 1201 is preferably made of a durable, nonmagnetic material having a fairly low electrical conductivity, i.e., a conductivity level approximate to the conductivity level of titanium. It is preferred that a physically strong, low conductivity, noncorrosive and nonmagnetic material, like titanium or stainless steel, be used in the construction of the housing 1201. However, to maximize the performance of the proximity sensor, other nonconductive materials such as formable plastics can be used to construct the housing 1201. The performance of the sensor increases as the conductivity of the housing 1201 decreases. The use of highly conductive materials should be avoided because eddy currents may form on the housing surface and reduce the effective range 1250 of the proximity sensor 1200. In addition, the use of ferromagnetic materials should be avoided because the housing 1201 may contain the sensing field produced by the proximity sensor 1200.

[0078] The housing 1201 includes an opening to the hollow interior that is preferably positioned opposite the front surface 1251. The opening in the housing 1201 allows for the insertion of the internal components of the proximity sensor 1200. As known to one of ordinary skill in the art, a hollowed cylinder housing, such as the housing 1201, can be formed from a machining process. Referring now to FIGS. 13A and 13B, in one embodiment the proximity sensor 1200 is assembled by sliding an insulator 1202 into the opening of the housing 1201. The insulator 1202 is preferably constructed from a non-conductive material such as plastic or Mylar with a thickness approximate to 3 Mils. The insulator 1202 may be molded into a cup-shaped form to provide an insulating shield between a coil assembly 1203 and the housing 1201.

[0079] As shown in FIG. 13A, the coil assembly 1203 is affixed to a flex circuit 1204 and, in one embodiment, the flex circuit 1204 is affixed to the coil assembly 1203 by a solder joint or another like bonding material. The coil assembly 1203 is constructed of a disc shaped bracket and sized to be inserted into the insulator 1202. More specifically, the coil assembly 1203 is formed into a disk having an aperture through the center of the disk. The coil assembly 1203 also comprises a bobbin having a hollowed interior formed to receive a wire coil. The wire coil housed inside the coil assembly 1203 is configured to allow a plurality of wire windings to surround the aperture of the coil assembly 1203. The flex circuit 1204 is preferably constructed from a thin flexible polyimide tape with embedded copper traces (not shown). The copper traces extend from the coil assembly 1203 to a pair of conductors 1211 and provide electronic communication between the coil assembly 1203 and conductors 1211.

[0080] Also shown in FIGS. 13A and 13B, a cup core 1220 having an aperture therethrough is positioned such that the flex circuit 1204 passes through the aperture of the coil core 1220. Details of the construction of the cup core 1220 are described in further detail below with reference to FIGS. 14A and 14B. Generally described, the cup core 1220 is sized to be received in the opening of the housing 1201. In addition, the cup core 1220 comprises an annular groove sized to receive the coil assembly 1203. As shown in FIGS. 13A and 13B, once the coil assembly 1203 is inserted into the annular groove of the cup core 1220, the wire coils housed in the coil assembly 1203 are then positioned to wind around the annular grove of the cup core 1220. In addition, the conductive ends of the wire coil housed in the coil assembly 1203 are positioned to pass through the aperture of the cup core 1220 and follow the flex circuit 1204 such that they are led to and electronically conducted to the pair of conductors 1211. In one embodiment, the wire in the coil assembly 1203 comprises approximately 474 turns of 42-gauge wire. Once the coil assembly 1203, flex circuit 1204, and cup core 1220 are combined, the components are then slidably inserted into the insulator 1202 positioned in the housing 1201.

[0081] Details of the cup core 1220 are best seen in FIGS. 14A and 14B. In one embodiment, the cup core 1220 comprises a generally cylindrical shaped cup having an annular groove in an upper surface 1221 of the cup core 1220. The upper surface 1221 of the cup core 1220 is substantially planar and when installed into the housing 1201, the upper surface 1221 is substantially parallel to the sensing surface 1251 of the housing 1201. The cup core 1220 further comprises a bottom surface 1223 having a circular cavity extending from the bottom surface 1223 toward the upper surface 1221. The circular cavity is positioned in the center of the cup core 1220 and configured to extend at a right angle from the bottom surface 1223. The cup core 1220 further comprises an aperture 1222 extending inwardly from a bottom surface 1223 of the cup core 1220 to facilitate the passage of the flex circuit 1204 and/or wire (not shown).

[0082] As seen in FIG. 14B, a diametric section of the cup core 1220 comprises a head portion 1231, two legs 1232, and two foot portions (feet) 1233. The head portion 1231 forms a substantially planar section along the upper surface 1221 and is perpendicular to the sectional direction created by the two legs 1232. The sectional direction of the two legs 1232 is perpendicular to the sectional direction of the two feet 1233. The two feet 1233 are in a common plane along the bottom surface 1223. Both feet 1233 are parallel to the head portion 1231. In addition, the section of the cup core 1220 comprises two tail portions (tails) 1234. Each tail 1234 extends from the outer edges of the two feet 1233. The sectional direction of the tails 1234 are perpendicular to the sectional direction of the two feet 1233.

[0083] In one exemplary embodiment, as shown in the section of FIG. 14B, the head portion 1231 of the cup core 1220 has a width of 0.200 inches, which is equal to the outer diameter of the center post 1235 shown in FIG. 14A. The two legs 1232 extending at right angles from the head portion 1231 have a preferred height of 0.144 inches measuring from the top surface to the bottom surface. The two legs 1232 create one side of the annular ring, and the annular ring has a depth of 0.124 inches. The two feet 1233 extend away from each other from the two legs. Each foot portion 1233 has a preferred length of 0.16675 inches that measures from the outer perimeter of the core to the inside of the two legs 1232. In this embodiment, each tail 1234 has a preferred length of 0.144 inches, and each tail 1234 is generally parallel to the legs 1232. The surfaces of the head 1231, leg 1232, feet 1233 and tail 1234 portions have a thickness of 0.02 inches.

[0084] The annular groove is created by the surfaces of the leg 1232, feet 1233 and tail 1234 portions. In one embodiment, the depth of the annular groove is 0.124 inches. Each of the four corner edges or fillets 1240 in the bottom of the annular groove should have a radius of 0.015 inches, where each bend or fillet 1240 should form a quarter circle having that radius. The tail portions 1234 have a preferred height of 0.144 inches.

[0085] In another embodiment, the two legs of the cup core extend at right angles from the head portion and have a preferred height of 0.174 inches measuring from the top surface to the bottom surface. The two legs create one side of the annular ring and, in this embodiment, the annular ring has a depth of 0.154 inches. Each tail has a preferred length of 0.174 inches, and each tail is generally parallel to the legs. In this embodiment, the surfaces of the head, leg, feet and tail portions have a thickness of 0.02 inches.

[0086] The cup core 1220 is preferably constructed from a high permeable material such as soft iron, cast iron, transformer steel, or any of the like material. The relative permeability should be at least 10,000. Although a relative permeability is suggested to be at least 10,000, higher values are desired to increase the sensor's performance. One material that is preferred is referred to in the art as HyMu “80”®, available from Carpenter Steel Company of New Jersey.

[0087] In one embodiment, the cup core 1220 is formed by a machining process of one solid piece of metal. Since the machining process creates changes in the magnetic properties of the core metal, an annealing process should be applied to the core to properly complete its construction. Thus, after the machining process is complete to form the cup core 1220 into the above-described specifications, the cup core 1220 should be cleaned so that all contaminants such as oil, grease, lacquer and water are removed from the core surface. In addition, the core should not be exposed to carbon, sulfur, or nitrogen during the annealing process. Once properly cleaned, the core is preferably annealed in an oxygen free, dry hydrogen atmosphere with a dew point below −40° C. during the entire hydrogen annealing stage. If multiple cores are annealed at this part of the process, an insulating powder should be used to keep the cores from touching one another or other objects. Preferred insulating powders include: magnesium, aluminum oxide, clean ceramic paper, or an equivalent cleaning ceramic material.

[0088] The core should be annealed for 7-8 hours at a temperature of 1,121°-1,177° C. After the 7-8 hour period, the core should be furnace cooled to a temperature of approximately 593° C. Once the core is cooled to 593° C., the core should be cooled at a rate between 260° and 316° C. per hour to 371° C., and then furnace cooled until room temperature is reached.

[0089] Returning again to FIGS. 13A and 13B, the construction of the proximity sensor 1200 is continued where a spring 1206, washer 1207, and a carrier assembly 1208 are respectively inserted into the housing 1201 to hold the cup core 1220, coil assembly 1203 and flex circuit 1204 in place. In this step, the spring may be fixed to the cylindrical bracket 1205 by the application of an RTV adhesive. The carrier assembly 1208 comprises a hollow cylindrical housing having two sections, wherein a leading section has a diameter sized to be inserted into the bore of the spring 1206 and the cylindrical bracket 1205. The trailing section of the carrier assembly 1208 has a larger diameter sized to be slidably inserted into the housing 1201 and yet large enough to produce a shoulder to engage upon the adjacent end of the spring 1206. Once the spring 1206, washer 1207, and carrier assembly 1208 are inserted into the housing 1201, a connector assembly 1209 is used to seal the opening of the housing 1201 and hold the assembly together with the spring 1206 partially compressed.

[0090] As shown in FIG. 13A and 13B, the connector assembly 1209 comprises a generally cylindrical body sized to be inserted into the opening of the housing 1201 and to create an air tight seal around the opening of the housing 1201. The connector assembly 1209 has at least two internal electronic connectors 1211 and at least two external electric conductors 1210 for producing an electronic communication channel between the outer portion of the housing 1201 and the conductors internal to the housing 1201. The connector assembly 1209 may create a seal with the opening of the housing 1201 by the use of threaded or mechanical locking devices. Although threaded and mechanical locking devices are used in this embodiment, any mechanical device or adhesive may be used to create a seal between the connector assembly 1209 and the housing 1201.

[0091] As described above, the various embodiments of the proximity sensor are used to detect three different types of objects. In one mode of operation, the proximity sensor is used to detect the presence of objects that emit a magnetic field, such as magnetically charged iron. When used in this mode of operation, the proximity sensor operates as a saturated core sensor. In another mode of operation, the proximity sensor is used to detect the presence of permeable objects, known as ferromagnetic metals. When used in this second mode of operation, the proximity sensor operates as a variable reluctance sensor. In yet another mode of operation, the proximity sensor is used to detect the presence of conductive metals or non-ferrous objects, such as aluminum, copper, brass, or other like materials. When used in this third mode of operation, the proximity sensor operates as an eddy current loss sensor.

[0092] Referring again to FIG. 13A, various circuit configurations (box 1225) that create a closed circuit loop in the wire of the proximity sensor 1200 can be used to produce each mode of operation described above. Each circuit described above with reference to FIG. 3, can be used to produce the various operating modes of the proximity sensor. For instance, any circuit configured to measure impedance can be used with the proximity sensor. In this embodiment, a circuit can be used to measure the impedance over the conductor housed in the core to ultimately detect the presence of an object.

[0093] In yet another embodiment, an Eddy Current Kill Oscillator (ECKO) circuit can be configured in box 1225 of FIG. 13A to allow the proximity sensor 1200 to operate as an eddy current loss sensor. As known to one having ordinary skill in the art, an ECKO circuit is generally described as an oscillator circuit that oscillates at a frequency defined by a tank circuit. One example of an ECKO circuit is commercially available from the MICRO SWITCH division of the Honeywell Corporation.

[0094] The tank circuit is composed of a sensor (inductance and resistance) in parallel with a capacitor. To calibrate the ECKO circuit to a certain actuation point, a calibration resistor is adjusted to match the resident impedance of the tank circuit, e.g., Z at 0° phase. As long as the resident impedance of the tank is above the impedance of the calibration resistor, the circuit will oscillate. As will be described in more detail below with reference to FIG. 16, when a target moves toward the proximity sensor closer than the actuation point, the real losses increase and the oscillator eventually ceases operation.

[0095] In yet another embodiment, the ECKO circuit and proximity sensor 1200 can be configured with specific components to operate in a saturated core mode (SCORE), this embodiment can be referred to an Eddy Current Loss All Metal Sensor (ECAMS)Tm. In this embodiment, the capacitor in the ECKO circuit comprises a 1,800 picofarad capacitor in the tank circuit. This configuration causes the tank to oscillate at 28 kHz and reduces the amount of variance over temperature providing the best sensitivity to the proximity sensor. In this embodiment, the coil can comprise of 900 turns of 42-gauge wire. As described above, the target utilized with the SCORE sensor is a magnet target.

[0096] Another embodiment of a proximity sensor 1500 having a cup core 1220 is shown in FIG. 15A and 15B. The embodiment of FIG. 15A and 15B generally comprises the components of the embodiment depicted in FIGS. 13A and 13B. More specifically, the embodiment of FIG. 15A and 15B comprises a housing 1501 with a sensing surface 1550 and cylindrical wall 1540 that is substantially perpendicular to the sensing surface 1550. The housing 1501 comprises a hollow center inside of the cylindrical wall 1540 and an opening to allow the insertion of the various components described below. As shown in FIG. 15B, an insulator cup 1502 is slidably inserted into the opening of the housing 1501. The construction of the insulator cup 1502 is constructed similar to that of the embodiment depicted in FIGS. 13A and 13B, except the insulator cup 1502 is sized to produce an electronically insulating shield between the housing 1501 and a coil assembly 1503. The proximity sensor 1500 also comprises a spring cushion 1504, which secures the carrier assembly 1508 into position.

[0097] Similar to the embodiment of FIGS. 13A and 13B, the coil assembly 1503 comprises a plastic bobbin which houses a plurality of wire windings wherein the coil assembly 1503 and the wire windings are sized to be inserted into the hollow portion of the cup core 1220. The spring cushion 1504 is constructed of a silicon rubber and shaped in a disk configuration and sized to be slidably inserted into the hollow portion of the cup core 1220. The spring cushion 1504 functions as a brace for the coil assembly 1503 such that coil assembly 1503 can be affixed into a locked position inside the hollow portion of the cup core 1220. The coil assembly 1503, spring cushion 1504 and the cup core 1220 are slidably inserted into the insulator cup 1502 positioned in the housing 1501. The spring 1506 has been placed on top of the cup core 1220 and, may be affixed to the cup core 1220 by the use of a RTV adhesive.

[0098] Similar to the embodiment of FIGS. 13A and 13B, the coil assembly 1503, spring cushion 1504 and cup core 1220 are configured to accommodate a wire winding 1509 that creates a wire coil inside the coil assembly 1503 having approximately 900 rotations, wherein the conductive ends of the wires are routed through the spring cushion 1504, the cup core 1220, and eventually routed into a carrier 1508 and ultimately connected to a substrate assembly 1510. The carrier assembly 1508 is of similar construction to the carrier assembly of FIGS. 13A and 13B, however, the carrier assembly 1508 comprises a hollowed inner portion sized to receive a substrate assembly 1510.

[0099] The substrate assembly 1510 may comprise a circuit board for carrying any type of circuitry that may be used with the proximity sensor 1500. The above-described electronic circuitry can be constructed on the substrate assembly 1510, and the circuitry electronically is connected to the wire 1509 and the external conductors 1515 via a set of conductors 1511. The substrate assembly 1510 is inserted into the carrier assembly 1508 and secured into place by an adhesive. The connector assembly 1512 is then secured to the opening of the housing 1501, thereby creating a seal between the connector assembly 1512 and the housing 1501.

[0100] As will be explained below, detection of a target object will cause a change in the state of the circuit coupled to the coil which, in turn, can be used to energize a device, turn on a switch, transmit a signal, etc. For example, FIG. 16 shows one embodiment of a proximity sensor 1200 having a housing 1201 and illustrates a radial section of the cup core 1220, which is used as a saturated core (SCORE) sensor to detect a magnetic object 1251. The target facing surface 1251 of the proximity sensor is directed toward a magnetic object 901 producing a magnetic field 902. As the magnetic object 901 moves toward the proximity sensor 1200, a point is reached where flux lines 902 begin to enter the core 1220 and follow the core as the path of least reluctance. As the proximity sensor 1200 is moved deeper into the magnetic field, the core 1220 begins to react to the magnetic field, thus changing the impedance value of the wire coils 1275 that are placed in the annular grove of the cup core 1220. Eventually, the cup core 1220 reaches a level of saturation where the impedance value of the coil significantly reacts to the changed state of the cup core 1220. This reaction in the inductance value in relation to the saturation level is shown in FIG. 17.

[0101] FIG. 17 is a graph of the coil inductance versus the distance between the magnetic object 901 and the proximity sensor 1200. As illustrated by the line 910, when the magnetic object 901 reaches a distance of approximately 0.3 inches (indicated by point A), the core begins to saturate. From this distance of 0.3 inches, as the magnetic object 901 moves toward the proximity sensor 1200, the impedance significantly decreases as the cup core begins to saturate. When the cup core saturates, the impedance of coil drops rapidly from a relatively high value representing virtually no saturation of the core to a relatively low value representing virtually complete saturation of the cup core. The “no saturation” inductance level is represented by the upper horizontal portion of inductance curve 910 in FIG. 17, and the “complete saturation” inductance level is represented by the lower horizontal portion of curve 910.

[0102] Thus, by measuring the impedance levels in the coils, the presence of a magnetic object can be detected. The physical dimensions of the core determine when the core reaches magnetic saturation. The unique design of the present invention provides optimal performance of a saturated core proximity sensor as characterized in the graph of FIG. 17. As a result of the unique shape and dimensions of the cup core, the cup core will saturate at a greater distance away from the magnetic field source than a conventional prior art core of an equal size.

[0103] When the proximity sensor 1200 is used as a variable reluctant sensor, the configuration of the proximity sensor 1200 is somewhat different than the configuration shown in FIG. 16. In one example, a proximity sensor may be configured as a variable reluctance sensor to sense a permeable target. FIG. 18 shows an apparatus 1800 with a proximity sensor 1200 adjacent to a permeable target 908. When the proximity sensor 1200 is used as a variable reluctance sensor, the proximity sensor 1200 generates an alternating magnetic field as illustrated by the flux lines 903.

[0104] To detect the presence of permeable materials, an external alternating current source is used to drive the coils 1276 of the proximity sensor 1200. When the permeable target 908 is moved into the magnetic field of the proximity sensor 1200, the reluctance between the permeable target 908 and the proximity sensor 1200 changes. This change in reluctance increases the inductance of the sensing coils 1276. Thus, an inductance measuring circuit can be used, such as one of the circuits described above, to detect the presence of the permeable target 908.

[0105] FIG. 19 is a graph of the coil sensitivity as a function of the distance between the permeable target 908 and the proximity sensor 1200. The sensitivity of the proximity sensor 1200 is measured in units of microhenrys per Mil. For example, if the conductive target 908 moves one Mil, the distance of 0.060 inches between the proximity sensor 1200 and the target 908, the coils' inductance changes by approximately 19 microhenrys (as indicated by point B). If the permeable target 908 is 0.04 inches away from the proximity sensor 1200 and moves one Mil, the coils' inductance changes by approximately 28.6 microhenrys (as indicated by point C). The sensitivity of the proximity sensor 1200 increases at an expediential rate as the permeable target 908 moves toward the proximity sensor 1200. In this configuration, the coil inductance increases as the permeable target 908 moves toward the proximity sensor 1200.

[0106] When the proximity sensor is used as an eddy current loss sensor to detect conductive targets, the configuration of the proximity sensor 1200 is similar to the configuration of the variable reluctance sensor as shown and described above. However, the inductance of the coils has a different reaction to the conductive targets compared to the permeable targets.

[0107] The proximity sensor 1200 shown in FIG. 18 is also used to describe the eddy current configuration, only the target 908 now consists of a conductive, non-permeable target such as aluminum or copper. When the conductive target 908 is moved into the magnetic field 903 of the proximity sensor 1200, the conductive target 908 will intercept a portion of the magnetic field 903 produced by the alternating current fed into the coil 1276. This interception of the magnetic field 903 induces eddy currents in the conductive target 908 that are temporally (90 degrees) out-of-phase with the current source. In turn, these eddy currents do two things: they dissipate energy as heat within the conductor; and they generate another magnetic field. The magnetic field generated by the eddy currents within the conductive target 908 opposes the magnetic source field 903 eventually causing additional currents back in the sensor coils. Thus, when the conductive target 908 enters the magnetic source field 903, the current in the coils increases. This reaction in the current level is detected by electronic circuitry that measures the inductance over the coil. When the conductive target 908 moves toward the proximity sensor 1200, the inductance of the coils decreases, thereby indicating the presence of the conductive target 908.

[0108] As with the embodiment utilizing the proximity sensor as a saturated core sensor, the physical dimensions of the core, together with the dimensions and the configuration of the coil, determine the sensor's ability to detect targets at an optimal distance. The unique design of each core disclosed and described above, and the placement of the coils provide a variable reluctance and eddy current loss proximity sensor having the performance characterized in the graphs described above. As the result of the unique shape and dimensions of the above-described cores, a proximity sensor is able to detect variations in the source magnetic field at a greater distance away from the proximity sensor than a conventional core having an equivalent size.

[0109] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.

Claims

1. A proximity sensor, comprising: a core with a cross-sectional shape including a head portion, two foot portions on opposite sides of the head portion and two leg portions each extending between one of the foot portions and the head portion; and a sensing coil positioned around the leg portions for allowing magnetic flux communication between the sensing coil and the core.

2. The proximity sensor of claim 1, wherein the cross-sectional shape of the core further comprises two tail portions, wherein each tail portion extend from an outer edge of one of the two foot portions, and wherein the tail portions are perpendicular to two foot portions.

3. The proximity sensor of claim 1, wherein the legs are elongated and extend transversely of the central part and the foot portions.

4. The proximity sensor of claim 1, wherein the head portion forms an substantially planar upper surface of the core and is perpendicular to the direction created by each of the two leg portions, the direction of the two leg portions being perpendicular to the direction of the two foot portions, the two foot portions lying in a common bottom surface plane, and wherein the two leg portions form an annular grove in the core that opens along side the upper surface of the core.

5. The proximity sensor of claim 1, further comprising a housing supporting the sensing coil and the core.

6. A proximity sensor, comprising: a member having a top surface, a bottom surface, and a side surface having a width between the top and the bottom surfaces of the member, wherein the top surface is generally planar, and wherein the member defines a cavity that extends into the member from the top surface, wherein the top and the bottom surfaces have a thickness less than or equal to 0.06 inches; and a sensing coil positioned in the cavity for allowing magnetic flux communication between the sensing coil and the core.

7. The proximity sensor of claim 6, wherein the top and the bottom surfaces of the member have a thickness less than 0.06 inches and greater than or equal to 0.005 inches.

8. The proximity sensor of claim 6, wherein the member is constructed from a permeable material.

9. The proximity sensor of claim 6, wherein the member is generally cylindrical in shape.

10. The proximity sensor of claim 6, wherein the width of the member is in the range of 0.2 to 5 inches.

11. The proximity sensor of claim 6, wherein the top surface is spaced radially outwardly of the outer perimeter of the member.

12. A proximity sensor, comprising: a core formed of a permeable material, the core having a generally planar top surface, a bottom, a side surface having a depth between the top and the bottom surface of the core, and an outer perimeter bounding the side surface of the core, the core defining a groove which extends into the core from the top surface of the core; a sensing coil positioned in the groove of the core; and an oscillator circuit coupled to the sensing coil for energizing the sensing coil to define a sensing region in relation to the sensing coil, the oscillator circuitry sensing an object in the sensing region based on the output signal of the sensing coil, the core and sensing coil being constructed so as to be operational to detect ferromagnetic, non-permeable or magnetic targets.

13. The proximity sensor of claim 12, wherein the oscillator circuit also energizes the sensing coil to create the sensing region of the core.

14. The proximity sensor of claim 12, wherein the oscillator circuit is formed of an eddy current kill oscillator circuit.

15. The proximity sensor of claim 12, wherein the oscillator circuit is formed of an eddy current loss all metal sensor circuit.

16. A method for detecting the presence of a magnetic object which comprises: providing a core formed of a permeable material, the core having a generally planar top surface, a bottom, a side surface having a depth between the top and the bottom surface of the core, and an outer perimeter bounding the side surface of the core, the core defining a groove which extends into the core from the top surface of the core; providing at least one sensing coil positioned around the groove of the core; and measuring the impedance over the sensing coil, and if the impedance varies greater than a predetermined value, generating a signal to indicate the presence of the magnetic object.

17. The method of claim 16, wherein the top and the bottom surfaces of the core have a thickness less than 0.05 inches and greater than or equal to 0.02 inches.

18. The method of claim 16, wherein the core is generally cylindrical in shape.

19. A method for detecting the presence of a ferromagnetic object which comprises: providing a core formed of a permeable material, the core having a generally planar top surface, a bottom, a side surface having a depth between the top and the bottom surface of the core, and an outer perimeter bounding the side surface of the core, the core defining a groove which extends into the core from the top surface of the core; providing at least one sensing coil positioned around the groove of the core; supplying an electronic signal to the sensing coil; and measuring the inductance over the sensing coil, and if the inductance varies greater than a predetermined value, generating a signal to indicate the presence of the ferromagnetic object.

20. The method of claim 19, wherein the top and the bottom surfaces of the core have a thickness less than 0.05 inches and greater than or equal to 0.02 inches.

21. The method of claim 19, wherein the core is generally cylindrical in shape.

22. A method for detecting the presence of a conductive object which comprises: providing a core formed of a permeable material, the core having a generally planar top surface, a bottom, a side surface having a width between the top and the bottom surface of the core, and an outer perimeter bounding the side surface of the core, the core defining a groove which extends into the core from the top surface of the core; providing at least one sensing coil positioned around the groove of the core; supplying an electronic signal to the sensing coil; and measuring the inductance over the sensing coil, and if the inductance varies greater than a predetermined value, generating a signal to indicate the presence of the conductive object.

23. The method of claim 22, wherein the top and the bottom surfaces of the core have a thickness less than 0.05 inches and greater than or equal to 0.02 inches.

24. The method of claim 22, wherein the core is generally cylindrical in shape.