JP2007242633A - Proximity sensor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To enable to achieve simple design/production of products to various product specifications without several characteristic adjustments even if outer shell cases of different materials are combined. <P>SOLUTION: A proximity sensor 717 comprises a combination of an arbitrarily selected one each of a plurality of types of detection end modules 707, a plurality of types of output circuit modules 709 and a plurality of types of outer shell cases 711. The detection end module 707 includes an integrated arrangement having detection coil assemblies (705, 701, 702) with the detection characteristics self-completed by a mask conductor 700 for reducing conductor detection sensitivity in a specific peripheral area where the outer shell case is assumed to exist, and a detection circuit assembly (703) with coils of the detection coil assemblies as a resonance circuit element. The characteristics of the proximity sensor are completely adjusted before shipment. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an inductive proximity sensor that detects the approach of a metal body or the like in a non-contact manner through a magnetic field, and in particular, a proximity sensor and a proximity sensor that can realize an abundant product lineup while suppressing manufacturing costs. The module used for

  The basic components of the proximity sensor include a detection coil assembly including a coil and a core, an oscillation circuit unit, an output circuit unit, and an outer shell case for housing them. In order to respond flexibly to a wide range of product specifications required by users, manufacturers must consolidate the components of these basic components as much as possible to reduce costs.

  Regarding the proximity sensor, there are various problems peculiar to the proximity sensor from both the magnetic circuit viewpoint and the electric circuit viewpoint in promoting cost reduction by consolidating components.

  From the viewpoint of magnetic circuit, the following problems have been pointed out regarding the cost reduction due to the integration of components due to the characteristics and structure of the detection coil assembly.

  An inductive proximity sensor has a sensing coil assembly for sensing the proximity of metal. The sensing coil assembly includes a coil and a ferrite core. The proximity detection of the metal is performed by utilizing the characteristic change of the detection coil assembly. For the proximity sensor body case (outer shell case), material variations such as brass, stainless steel, resin, etc. are available due to the variety of usage environments. The detection performance of the proximity sensor also varies depending on the outer diameter of the detection coil assembly. Therefore, there are various variations in the outer diameter of the detection coil assembly, as represented by the cylindrical types M8 (outer diameter of about 8 mm), M12 (outer diameter of about 12 mm), and M30 (outer diameter of about 30 mm). It is prepared.

The detection characteristics of the detection coil assembly in an inductive proximity sensor are affected by the material and shape of the main body case (outer shell case), the plating thickness variation of the main body case, and the assembly position variation between the detection coil assembly and the main body case. Receive greatly. As a result, the following various problems occur.
(1) In order to provide products with different body case materials, shapes, and dimensions, it is necessary to design the detection coil assembly and oscillation circuit individually and each time, increasing design man-hours and costs, and consolidating parts. This leads to an increase in component costs due to difficulties. Production lines are also individually designed, requiring multiple lines and processes.
(2) In order to stabilize the variation in the detection distance, the assembly position of the detection coil assembly and the main body case is improved, the quality of the main body case is improved, the detection distance is adjusted, etc. This is necessary and leads to an increase in parts costs, production man-hours and costs.

  The above problem in the inductive proximity sensor will be examined in more detail with some specific examples of the detection coil assembly.

[Conventional example 1 of detection coil assembly]
FIG. 23 shows the structure of a detection coil assembly of a shield type (which can be embedded in a mounting metal) using a metal body case.

  In the figure, 101 is a cylindrical main body case (outer shell case) using a metal such as brass or stainless steel, 101a is a male screw portion formed on the outer peripheral surface of the main body case, 102 is a ferrite core, and 103 is a detection coil. A coil 104 is a bottomed cylindrical insulating inner case for housing the core 102 and the coil 103.

  In the detection coil assembly having such a structure, the detection characteristics of the detection coil assembly vary greatly depending on the material of the main body case 101 located on the outer periphery of the coil 103 and the core 102. It is presumed that the main body case 101 itself is also placed in the magnetic field formed by the coil 103.

  A graph showing the detection characteristics of Conventional Example 1 of the detection coil assembly is shown in FIG. This graph is drawn based on measurement data of an M8 shield type sensing coil assembly. The horizontal axis represents the detection distance (mm), and the vertical axis represents the detection coil conductance g (μS). The conductance of the detection coil increases due to the approach of the metal body. The operation principle of the proximity sensor is to generate a detection signal using a change in conductance g of the detection coil. As is apparent from the graph, when the material of the main body case 101 is different from resin (nonmetal), brass, and stainless steel, it can be seen that the conductance characteristics (in other words, the detection characteristics) greatly vary accordingly. For this reason as well, it is necessary to change the circuit constants of the detection circuit according to the material of the main body case 101 (oscillator circuit constants, threshold values for the oscillation amplitude, etc.), and it is difficult to consolidate parts. It will be understood that.

[Conventional example 2 of detection coil assembly]
FIG. 25 shows the structure of a detection coil assembly of a non-shield type (which is not suitable for being embedded in a mounting metal and has a longer detection distance than the shield type) using a metal body case.

  In the figure, 107 is a cylindrical main body case (outer shell case) made of metal such as brass or stainless steel, 107a is a male screw portion formed on the outer peripheral surface of the main body case, 102 is a ferrite core, and 103 is a detection coil. A coil 108 is a bottomed cylindrical coil case made of resin that accommodates the coil 103 and the core 102. As is apparent from the figure, the resin coil case 108 protrudes forward from the metal main body case 107.

  In the detection coil assembly having such a structure, the detection characteristics of the detection coil assembly are greatly different because the materials of the main body case 107 located in the back direction of the coil 103 and the core 102 are different.

  A graph showing the detection characteristics of Conventional Example 2 of the detection coil assembly is shown in FIG. This graph is drawn based on the measurement data of the M8 unshielded type detection coil assembly. The horizontal axis represents the detection distance (mm), and the vertical axis represents the detection coil conductance g (μS). The conductance g of the detection coil increases due to the approach of the metal body. The operation principle of the proximity sensor is to generate a detection signal using a change in conductance g of the detection coil. As can be seen from the graph, when the material of the main body case 107 is different from resin (non-metal), brass, and stainless steel, the conductance characteristic (in other words, the detection characteristic) varies greatly. For this reason as well, it is necessary to change the circuit constants of the detection circuit according to the material of the main body case 107 (oscillator circuit constants, threshold values for the oscillation amplitude, etc.), and it is difficult to consolidate parts. It will be understood that.

  Next, from an electrical circuit perspective, the cost reduction due to the consolidation of components is due not only to the characteristics and structure of the detection coil assembly, but also to the oscillation circuit, output circuit configuration, etc. The following problems have been pointed out.

  As described above, in an inductive proximity sensor, an oscillation circuit including a coil changes its oscillation state due to the approach of a metal body. Therefore, by detecting the change in the oscillation state, the metal body Is detected. Inductive proximity sensors vary in outer diameter because the detection performance varies depending on the outer diameter of the coil of the detection coil assembly. Therefore, the oscillation circuit constant is determined for each coil outer diameter to be used or for each detection distance to be adjusted.

  On the other hand, assuming a sensor application example at a production site that detects the presence or absence of a metal workpiece and controls various actuators with the detection signal, the configuration of the power supply line and the signal line connected to the proximity sensor is due to various circumstances. DC 3-wire system, DC 2-wire system, AC 2-wire system, etc. are used properly. Also, the output form is properly used, such as NPN type / PNP type, voltage output type / current output type, detection time drive type / non-detection time drive type. Therefore, when commercializing proximity sensors, circuit variations are prepared according to each power supply form and output form. In recent years, in order to reduce the size of proximity sensors, the above-described oscillation circuit, power supply / output circuit, and the like have been integrated into a one-chip IC.

Because of this background, when designing a proximity sensor, if one of the functional parts is to be renewed (for example, longer sensing distance, lower current consumption of the circuit, lower voltage drive of the power supply) Etc.), it is necessary to recreate all the circuits constituting the proximity sensor into a one-chip IC. In addition, in order to cope with various product variations, it is necessary to review the design of component constants and coil constants around the IC. As a result, the following various problems have been pointed out.
(1) The development cost of new products becomes enormous.
(2) Products that meet the usage conditions of the proximity sensor user cannot be provided immediately.
(3) Product variations become enormous, and production costs increase due to production costs, management costs, parts costs, etc. due to various small-volume production.
(4) Substitute design / procurement work when parts are discontinued is enormous.
(5) When a common quality problem occurs, it is not possible to quickly respond to all products.

  The above-mentioned problem in the inductive proximity sensor will be described in more detail with some specific examples of oscillation or output circuits.

[Conventional example 1 of proximity sensor circuit]
FIG. 27 shows a circuit configuration of a DC three-wire proximity sensor. In the figure, 200 is a metal body (for example, a metal workpiece), 201 is a custom IC, 202 is an oscillation circuit, 203 is an integration circuit, 204 is a discrimination circuit, 205 is a logic circuit, 206 is an output control circuit, and 207 is a constant. Voltage circuit, 208 is a power reset circuit, 209 is a short circuit protection circuit, 210 is a display circuit, 211 is a detection coil, 212 is a capacitor forming a resonance circuit, 213 is an adjustment circuit, 214 is a capacitor forming an integration circuit, 215 is An output transistor, 216 is a light emitting element, 217 is a first power supply terminal, 218 is a second power supply terminal, and 219 is a signal output terminal.

[Conventional sensor circuit 2]
FIG. 28 shows a circuit configuration of a DC 2-wire proximity sensor. In this figure, 220 is a metal body (for example, metal workpiece), 221 is a custom IC, 222 is an oscillation circuit, 223 is an integration circuit, 224 is a discrimination circuit, 225 is a logic circuit, 226 is an output control circuit, and 227 is a constant voltage. 228 is a power reset circuit, 229 is a short circuit protection circuit, 230 is a display circuit, 231 is a detection coil, 232 is a capacitor forming a resonance circuit, 233 is an adjustment circuit, 234 is a capacitor forming an integration circuit, 235 is an output Transistors 236 and 237 are light emitting elements, 238 is a first power supply terminal, and 239 is a second power supply terminal.

  In the above-described conventional examples 1 and 2, most of the circuit elements are common except for the difference in the power supply system. Therefore, the configuration and operation of the circuit elements of the conventional example 2 shown in FIG. Explained.

  The detection coil 231 is obtained by winding a single copper wire or a litz wire twisted together by the appropriate number of turns. The resonance capacitor 232 is connected in parallel with the detection coil 231 to form an LC parallel resonance circuit, and is connected to the oscillation circuit 222. The custom IC 221 is an IC (integrated circuit) in which the main circuit of the proximity sensor is built in one chip. The custom IC 221 includes an oscillation circuit 222, an integration circuit 223, a discrimination circuit 224, a logic circuit 225, an output control circuit 226, a constant voltage circuit 227, a power reset circuit 228, a short circuit protection circuit 229, and a display circuit 230. Yes. The adjustment circuit 233 is a circuit in which a plurality of resistors are combined, and the detection sensitivity of the proximity sensor is adjusted by changing the gain of the oscillation circuit 222 by changing a part of the resistance value or changing it by laser trimming or the like. It is possible. The integrating capacitor 234 is combined with the integrating circuit 223 to constitute a CR integrating circuit. The output transistor 235 drives a large current based on a control signal (CONT) output from the custom IC 221. An operation indicator 236 displays the output operation state of the proximity sensor. Reference numeral 237 denotes a setting indicator which indicates that the setting position can be reliably detected even if the detection distance varies depending on the use environment. Reference numerals 238 and 239 denote power supply terminals which are led out of the proximity sensor via a cord, a connector, and the like. In this example, since it is a two-wire proximity sensor, the first power supply terminal 238 also serves as an output terminal.

  FIG. 29 shows an example of a specific circuit configuration of the oscillation, integration, and discrimination circuit of Conventional Example 2 shown in FIG. FIG. 30 shows an operation time chart of the circuit shown in FIG.

  As shown in these drawings, the oscillation voltage of the oscillation circuit 222 (see FIG. 30B) is smoothed by the integration circuit 223. The smoothed output thus obtained ((c) in FIG. 30) is compared with the reference voltages C and D of the discrimination circuit 224 and binarized, thereby generating detection signals E and F which are binarized signals. (See (d) and (e) of FIG. 30).

  The detection signals E and F are sent to the output control circuit 226 via the logic circuit 225, control the output transistor 235, turn on / off the output 238 of the proximity sensor (see (f) of FIG. 30), and display the operation. The lamp 236 and the setting indicator lamp 237 are also turned on / off (see (g) and (h) of FIG. 30).

  The oscillation circuit 222 has a characteristic that the oscillation amplitude changes substantially linearly according to the approach distance of the metal object. When the metal object 230 is not approaching, the oscillation amplitude A (see FIG. 30B) is sufficiently large, and the binarized detection signals E and F are off (FIGS. 30D and 30D). e)). As the metal object 230 approaches, the oscillation amplitude A and the integrated output B gradually decrease according to the approach distance. When the integral output B becomes equal to or lower than the reference voltage C, the detection signal E is turned on. When the integration output B becomes equal to or lower than the reference voltage D, the detection signal F is turned on. These detection signals E and F are logically operated by the logic circuit 225 shown in FIG. 28 and sent to the output control circuit 226. Thereafter, the output transistor 235 is driven by the action of the output control circuit 226.

  The constant voltage circuit 227 is supplied with power from the power supply terminals 238 and 239, generates a constant voltage output, drives each internal circuit, and a minimum necessary voltage for driving the circuit when the output is turned on. Is left on the power terminal. The power reset circuit 228 prohibits output until the constant voltage output becomes stable after power is supplied from the outside. The short-circuit protection circuit 229 detects that the output terminal 238 is directly connected to the power supply and an overcurrent flows through the output transistor 235, activates the power reset circuit 228, and inhibits output.

  Given the circuit configuration described above, the problem of cost reduction will be more easily understood. As described above, since the detection distance of the proximity sensor greatly depends on the outer diameter of the coil 231, it is necessary to prepare many proximity sensor types having different outer diameters. In addition, the specifications of the power supply and output are DC / AC, 3-wire (Fig. 27) / 2-wire (Fig. 28), NPN / PNP, normally open / normally closed according to the convenience of the proximity sensor user. It is necessary to prepare a large number of products such as code output / connector output. Furthermore, it is necessary to prepare a large number of products such as metal case / resin case, brass / stainless steel, short body / long body, etc. according to the environment where the proximity sensor is used.

  Until now, products that combine many of these specifications have been designed and produced on a case-by-case basis, so it is customary for manufacturers to supply a huge variety of products. Under such circumstances, even if there are further requests from many users, such as increasing the detection distance for each product, reducing the cost of the product, or improving the quality, it is no longer the manufacturer. On the side, it is becoming increasingly difficult to respond to all of them.

  For example, in response to a request for increasing the detection distance, an oscillation circuit design for that is required for each of the custom ICs 201 and 221 having different power supply specifications. In addition, the capacitance value of the resonance capacitor 232 that determines the oscillation circuit constant, the resistance value of the adjustment circuit 233, the capacitance value of the integration capacitor 234 that determines the integration time constant, and the like are designed for each coil having different outer diameter specifications. It is also necessary. As a result, several types of custom ICs are newly added, and dozens of IC external parts are also increased. In addition, the detection characteristics of the proximity sensor are greatly affected by the material of the main body case. For example, even if the outer diameter is M18 shield type and the same specification with a rated detection distance of 7 mm, there is a difference in detection characteristics between the metal case and the resin case. The constants must be different. From this, it will be understood that it is difficult to reduce manufacturing costs by consolidating parts while maintaining diversification of product specifications.

  The above-described problems of the conventional configuration in terms of magnetic circuit or electric circuit have caused various inconveniences in the manufacturing process of the proximity sensor.

  FIG. 31 is a process diagram showing a conventional manufacturing process for a proximity sensor of a shield type (which can be embedded in a mounting metal) using a metal body case.

  In the figure, in the first step (A), the detection end assembly 304 is manufactured by assembling a coil 301, a ferrite core 302, and a component mounting board 303 integrally. In the next step (B), the coil 301 and the component mounting board 303 are soldered in the detection end assembly 304. In the next step (C), an operation confirmation test (distance inspection or the like) and an appearance inspection are performed on the detection end assembly 304 that has been soldered. In the next step (D), the coil case 305 is filled with an epoxy resin. In the next step (E), the detection end assembly 304 completed earlier is housed and positioned in the coil case 305 filled with epoxy resin. In the next step (F), for example, the resin is cured by leaving it at room temperature for about one hour, and the detection end assembly 307 with a coil case is completed. In the next step (G), the distance is adjusted by an operation test of the detection end assembly 307 with a coil case completed in the previous step. This distance adjustment is performed by performing an operation test in a state where the detection end assembly 307 with a coil case is installed in the dummy case 307a, and adjustment based on the test result is performed by changing the chip resistance or the like. In the next step (H), the cord 308 is soldered to the detection end assembly 307 with coil case to complete the detection end assembly 309 with cord. In the next step (I), the proximity sensor semi-finished product 312 is obtained by assembling the detection end assembly with cord 309, the cylindrical metal main body case 310, and the cord clamp 311 together. In the next step (J), the proximity sensor finished product 313 is obtained by injecting resin into the proximity sensor semifinished product 312 and curing it. In the next step (K), a withstand voltage test and a characteristic test are performed to obtain a tested final product 314.

  In the above manufacturing process, when adjusting the detection distance in the step (G), the detection distance is adjusted while being inserted into a dummy case 307a having the same material and shape as the metal main body case to be actually mounted. Therefore, due to variations in both materials, variations in plating thickness, as well as variations in the case and coil position relative to the metal case, measurement was performed with the detection distance adjusted during detection distance adjustment and the actual metal case attached. Due to the difference in the detection distance, it becomes a defective product, and the yield may be deteriorated or reworking may be required. In addition, regarding the difference in material of the metal case, it was necessary to prepare a separate dummy case, and the number of dummy cases increased and a lot of setup changes occurred, which was wasteful.

  In addition, since the IC was configured to include an oscillation circuit and an output circuit, even if the oscillation circuit itself was the same, a changeover (due to different power supplies) occurred due to the difference in the output circuit, and the efficiency was poor. .

  Further, in the detection distance adjustment step, with the dummy case 307a mounted, the adjustment resistance value is read by applying a terminal having a variable resistance to the wiring of the adjustment resistance portion of the substrate on which the circuit including the oscillation circuit is mounted. However, because the difference in equipment and the resistance value between the connection between the terminal and the equipment are different, there is a difference between the read resistance value and the resistance value that must actually be attached. Although the correction value is determined, the correction value varies depending on the component variation, IC variation, assembly variation (coil and core position variation, core and case position variation, etc.) Each product lot had to be changed every time, which was inefficient. Further, in addition to the above changes, a difference in output form is also added, resulting in frequent changeovers and reduced production efficiency.

  Also, in the detection circuit adjustment process, adjustment resistance value reading equipment has been introduced, but there is also variation between equipment, and there was a problem that adjustment could not be done if a model different from the original model was assembled. .

  Furthermore, in the detection distance adjustment process, the adjustment resistance value reading equipment is affected by noise from other equipment, and the correction value is determined in a form that includes that noise, so when moving equipment or replacing equipment parts Sometimes, the correction value must be changed each time, so that the efficiency is poor.

  The present invention has been made paying attention to the above problems in the conventional proximity sensor, and the object of the present invention is to design and design products easily for various product specifications in this type of proximity sensor. It is to enable production.

  The detection end module used in the proximity sensor of the present invention includes a detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil of the detection coil assembly as a resonance circuit element, and a set thereof. A module component for manufacturing a proximity sensor product having an outer shell case in which a three-dimensional object is stored, and includes a detection coil assembly, a detection circuit assembly, an output circuit assembly, and an outer shell case. Thus, the detection coil assembly and the detection circuit assembly are integrally coupled to form a module component. The detection coil assembly incorporates a mask conductor for reducing conductor detection sensitivity in a specific peripheral region where the presence of the outer shell case is assumed, and the detection circuit assembly is in an oscillation state of the oscillation circuit. It is designed to output a signal in a certain form according to the object detection signal of the proximity sensor to the outside, thereby appropriately using the object detection signal output from the detection circuit assembly to provide an output stage circuit. By configuring, a proximity sensor product can be arbitrarily prepared.

  Here, the “proximity sensor” is a sensor that determines the approach of the detection object and outputs the determination result as a binary signal (proximity switch), and a sensor that outputs the approach of the detection object by other methods. For example, there is one that outputs the distance to the detection target as an analog signal or an encoded signal.

  According to such a configuration, the relationship between the distance and the detection output hardly changes regardless of the presence / absence of the outer shell case, the difference in shape, the difference in material, etc. , It is no longer necessary to perform mechanical or electrical design individually, and by using common parts for proximity sensors of various specifications, the integration of parts is promoted and a wide assortment is maintained. Therefore, it is possible to reduce the manufacturing cost.

  In a preferred embodiment of the detection end module according to the present invention, the detection end module further includes a coil case for housing the coil and the core, and the mask conductor is in the coil case, and the conductive cylindrical body or the coil surrounding the coil and the core. It is considered as an annular body.

  In another preferred embodiment of the detection end module of the present invention, the conductive block further includes a coil case for housing the coil and the core, and the mask conductor is in the coil case, and partitions the back surface of the coil and the core. It is made a board.

  As described above, when the mask conductor is provided in the coil case, the wall of the coil case prevents or suppresses water from entering the inside, and as a result, an effect that the mask conductor is excellent in rust prevention can be obtained. Therefore, for example, it can be said that it is particularly suitable for use in an environment where water is always applied, such as the food industry.

  In still another preferred embodiment of the detection end module of the present invention, the detection end module further includes a coil case for accommodating the coil and the core, and the mask conductor is outside the coil case, and the conductive material surrounding the coil and the core is provided. A cylindrical body or an annular body.

  The term “outside the coil case” here means that the mask conductor is not exposed to the inside (inner wall surface) of the coil case, and therefore, the mask conductor is embedded in the wall of the coil case. Such cases are also included in “outside the coil case”.

  When the mask conductor is provided in the coil case, for example, when an external impact is applied, the coil case 403 is partially cracked and the mask conductor is exposed. There is a concern that the problem may extend to the sensor internal circuit. However, according to such an embodiment, even if a partial crack is generated in the coil case, an insulator is provided in most parts between the mask conductor and the sensor internal circuit. A certain coil case remains. For this reason, discharge between the sensor internal circuit and the mask conductor can be prevented. Therefore, for example, it can be said that the present invention is particularly suitable for use in an environment where there is a high risk that some mechanical stress is applied to the coil case, such as a metal processing industry and a transportation industry.

  In a preferred embodiment of the detection end module of the present invention, the detection circuit assembly incorporates an adjustment circuit that is integrated as a detection end module and can adjust the oscillation state of the oscillation circuit.

  In a preferred embodiment of the detection end module of the present invention, the detection circuit assembly includes a discrimination circuit that switches when the oscillation state reaches a specified value, and an output of the discrimination circuit is externally output as an object detection signal.

  In a preferred embodiment of the detection end module of the present invention, a circuit for outputting an analog signal corresponding to the oscillation state is incorporated in the detection circuit assembly, and the output of this circuit is output externally as an object detection signal.

  In a preferred embodiment of the detection end module of the present invention, the detection circuit assembly incorporates a constant voltage circuit that stabilizes a power supply voltage supplied from the outside.

  In a preferred embodiment of the detection end module of the present invention, a coil, a core, and a detection circuit assembly are housed in a bottomed cylindrical container made of an insulating material and integrated with resin.

  The detection end module of the present invention viewed from another aspect includes a detection coil assembly including a coil and a core and having a detection characteristic self-completed by a mask conductor, and detection using the coil of the detection coil assembly as a resonant circuit element. The circuit assembly is integrally coupled to form module parts, and the characteristic adjustment is completed prior to shipment.

  According to such an aspect, it is possible to develop a product with good detection accuracy even by selling the detection end module whose characteristics are guaranteed in advance. In other words, once the characteristics are adjusted, the characteristics no longer change depending on the shape and material of the main body case and mounting member. Therefore, even if the purchaser does not need to adjust the characteristics again, the proximity sensor is matched to the company's specifications. Can be manufactured.

  Next, the proximity sensor product of the present invention has an output in which a detection end module configured as described above and an output stage circuit that drives an output element based on an object detection signal output from the detection end module are incorporated. An output circuit module formed by modularizing the circuit assembly is electrically connected.

  In a preferred embodiment of the proximity sensor product of the present invention, an output circuit module support member for supporting the output circuit module, a detection end module attached to one end side thereof, and an output circuit module support member attached to the other end side thereof. A cylindrical outer shell case that holds the detection end module and the output circuit module with a space therebetween, and a connection member that is interposed between the detection end module and the output circuit module and electrically connects the two modules. Further provided.

  In the proximity sensor product of the present invention, the detection end module and the output circuit module are separate members. Therefore, when these two modules are integrated via the outer shell case, You must consider how to support the output circuit module. Therefore, in the preferred embodiment, the output circuit module is supported on the outer shell case via the output circuit module support member. The output circuit module may have a configuration in which a member for attachment to the output circuit module support member is attached to the circuit board in advance.

According to such an aspect, the following effects can be obtained.
(1) By changing or adjusting the connection member, the same type of detection end module, output circuit module, and output circuit module support member can be used regardless of the length of the outer shell case.
(2) When using flexible connection members of appropriate length (connection members such as harnesses that give freedom to the distance between the detection end module and the output circuit module), regardless of the length of the outer shell case The same type of connecting member can be used.
(3) In general, the output circuit is easily affected by electrical noise that enters from the outside through the cord, and easily generates heat due to opening and closing of the output. According to such a configuration, the output circuit is included in the detection end module. Since the detection circuit assembly to be detected is separated from the output circuit included in the output circuit module, the influence of electrical noise and heat on the detection circuit assembly can be suppressed.
(4) Since the output circuit module is arranged on one end side of the outer shell case, when the indicator lamp (LED or the like) for displaying the operation state of the proximity sensor is provided on the output circuit module, the indicator lamp is attached to the outer shell. It is also easy to make the configuration visible from one end of the case.

Next, the production method of the proximity sensor product of the present invention is:
A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil as a resonance circuit element and outputting an object detection signal according to an oscillation state of the oscillation circuit, and an outer shell case A first step of selecting one type of detection end module from among a plurality of types of detection end modules integrated with a mask conductor for reducing the influence of detection characteristics due to detection, and output based on the object detection signal A second step of selecting one type of output circuit module from among a plurality of types of output circuit modules in which an output circuit for driving the element is incorporated; a detection end module selected in the first step; And a third step of connecting the output circuit module selected in the step.

  According to such a proximity sensor production method, various types of proximity sensor products can be prepared based on the combination of the detection end module and the output circuit module. Cost reduction and faster product preparation are achieved.

  According to another aspect of the present invention, a method for producing a proximity sensor product includes a detection coil assembly including a coil and a core, and an oscillation circuit having the coil as a resonance circuit element, and according to an oscillation state of the oscillation circuit. A detection circuit assembly that outputs an object detection signal to the outside and a mask conductor for reducing the influence of detection characteristics by the outer shell case are integrated into one type from among a plurality of types of detection end modules. A first step of selecting a detection end module; a second step of selecting one type of outer case from a plurality of types of outer case that can be combined with the detection end module; and a first step And a third step of attaching the detection end module selected in (2) to the outer shell case selected in the second step.

  According to such a proximity sensor product production method, various types of proximity sensor products can be prepared based on the combination of the detection end module and the outer shell case, while satisfying an abundant product lineup, Reduction of manufacturing cost and speed of product preparation are achieved. In addition, since the detection end module is almost unaffected by the detection characteristics of the selected outer shell case, there is no need to adjust the sensitivity to match the outer shell case, which also reduces manufacturing costs. In addition, speeding up of product preparation can be achieved.

  According to still another aspect of the present invention, a method for producing a proximity sensor product includes a detection coil assembly including a coil and a core, and an oscillation circuit having the coil as a resonance circuit element, according to the oscillation state of the oscillation circuit. A detection circuit assembly for outputting a detected object detection signal to the outside and a mask conductor for reducing the influence of detection characteristics by the outer shell case, one type from among a plurality of types of detection end modules A first step of selecting a detection end module, and a first step of selecting one type of output circuit module from among a plurality of types of output circuit modules incorporating an output circuit for driving an output element based on an object detection signal. A second step, a third step of selecting one type of outer case from a plurality of types of outer cases that can be combined with the detection end module, and a first step. The detection end module selected in the second step and the output circuit module selected in the second step are electrically connected, and the outer shell case selected in the third step is attached to the detection end module. And a step.

  According to such a production method of proximity sensor products, various types of proximity sensor products can be prepared based on the combination of the detection end module, the output circuit module, and the outer shell case, thus satisfying an abundant product lineup. In addition, the manufacturing cost can be reduced and the product preparation can be speeded up. In addition, since the detection end module is almost unaffected by the detection characteristics of the selected outer shell case, there is no need to adjust the sensitivity to match the outer shell case, which also reduces manufacturing costs. In addition, speeding up of product preparation can be achieved.

  According to another aspect of the present invention, a method for producing a proximity sensor product includes a detection coil assembly including a coil and a core, and an oscillation circuit having the coil as a resonance circuit element, and according to an oscillation state of the oscillation circuit. A first step of preparing a detection end module that integrates a detection circuit assembly that outputs a detected object detection signal to the outside and a mask conductor for reducing the influence of detection characteristics by the outer shell case; A second step of preparing a plurality of types of shell cases that can be combined with the detection end module, and selecting one type of shell case from the plurality of types of shell cases prepared in the second step And a fourth step of attaching the outer shell case selected in the third step to the detection end module prepared in the first step, thereby providing a third step. The sensitivity of the detection end module for adaptation to the outer shell case that is selected in step is obtained by a product can be shipped in a non adjustment.

  Here, as described in “Preparation of detection end module”, in the production method of the proximity sensor product, the manufacturing process of the detection end module is not questioned. That is, it can be said that this aspect is a production method suitable for the case where the detection end module and the outer shell case are attached in-house using, for example, a detection end module as a finished product purchased from another company. This method also eliminates the need to adjust the sensitivity of the detection end module to be adapted to the selected outer shell case, so that it is possible to reduce manufacturing costs and speed up product shipment.

  A preferred embodiment of the method for producing a proximity sensor product of the present invention includes a detection coil assembly including a coil and a core, and an oscillation circuit having the coil as a resonance circuit element, and detecting an object according to an oscillation state of the oscillation circuit. Detection end module that integrates a detection circuit assembly that outputs a signal to the outside and a mask conductor that reduces the influence of the detection characteristics of the outer shell case, and drives the output element based on the object detection signal An output circuit module in which an output circuit is incorporated, an output circuit module support member that has a through hole for receiving the output circuit module and supports the output circuit module, and a detection end module attached to the front end side of the output circuit module support member The output circuit module support member is attached to the detection end module, thereby holding the detection end module and the output circuit module apart from each other. A first step of preparing a cylindrical outer shell case and a flexible connecting member interposed between the detection end module and the output circuit module to electrically connect the two modules; A second step of electrically connecting the detection end module prepared in the step and the output circuit module via a connecting member; and a detection end module in which the output circuit module is electrically connected in the second step. A third step of projecting a part or all of the output circuit module from the rear end side of the outer shell case by attaching to the outer shell case at the front end side of the outer shell case prepared in the first step; In the fourth step, the output circuit module, part or all of which protrudes from the rear end side of the outer shell case in step 3, is inserted into the through hole of the output circuit module support member. And a fifth step of attaching the output circuit module support member, through which the output circuit module is penetrated in the fourth step, to the outer shell case on the rear end side of the outer shell case, and the outer shell through the fifth step. And a sixth step of attaching to the output circuit module support member an output circuit module that protrudes through the output circuit module support member on the rear end side of the case.

  In a conventional general proximity sensor product, the detection circuit assembly and the output circuit assembly are configured on one board, and this board is fixed to a coil case or the like. It can be said that the handling of the substrate was easy. On the other hand, when the output circuit module of the proximity sensor according to the present invention is connected to the detection end module via a flexible connection member (connection member such as a harness having a variable connection interval), the connection member or It is also assumed that a force that causes damage to the connection part between the connection member and the output circuit module is applied. In such a case, it is necessary to carefully consider the procedure for assembling the proximity sensor product. There is. The embodiment shown here was created from such a viewpoint, and according to this, the proximity sensor that connects the detection end module and the output circuit module with a flexible connecting member without applying excessive force. The product can be assembled properly.

  In addition, in order to deepen an understanding, about the production method of the proximity sensor product according to this embodiment, the third step and after will be described more specifically at the example level. At the stage where the third step is completed, the output circuit module is connected to other members only through a flexible connecting member, and thus is in an unstable support state. In the fourth step, since the output circuit module support member is not yet attached to the outer shell case, the output circuit module can be easily inserted into the through hole.

  In the fifth step, since the output circuit module support member is attached to the outer shell case while the output circuit module is passed through the through hole, there is no possibility that an excessive force is applied to the connection member. When attaching the output circuit module support member to the outer shell case before attaching the detection end module to which the output circuit module is connected via the connecting member, the output circuit module is attached to the front end of the outer shell case. It may be possible to adopt a slightly unreasonable method, such as inserting from the side and inserting it through the through hole of the output circuit module support member on the opposite side (rear end side). May occur. Note that the sixth step may be performed simultaneously with the fifth step or before the fifth step.

  In a more preferred embodiment, after the detection end module is attached to the outer shell case, the output circuit module support member is attached to the outer shell case, and the output circuit module is attached to the output circuit module support member, And a seventh step of injecting the filling resin into the portion and an eighth step of soldering the electric cord to the portion of the output circuit module protruding outside after the filling resin is cured.

  According to such an aspect, since the filling resin is fixed so that the output circuit module and the connection member do not move in the outer shell case, the electric cord is soldered to the output circuit module. There is no possibility that the flexible connecting member or the connecting portion between the connecting member and the substrate will be damaged due to the force exerted by the connection.

  Next, a proximity sensor commercialization system according to the present invention includes a detection coil assembly that includes a coil and a core and has a detection characteristic self-completed by a mask conductor, and a detection circuit that uses the coil of the detection coil assembly as a resonant circuit element. A detection coil assembly comprising: a circuit assembly; an output circuit assembly having a power element for driving a load; and a control circuit assembly for controlling an operation of the output stage circuit in accordance with an oscillation state of the oscillation circuit. And the detection circuit assembly are integrated to form a detection end module, and the output circuit assembly forms an output circuit module for each product specification such as output format and power supply voltage. The solid is incorporated into the detection end module side or the output stage module side at once, or divided into the detection end module side and the output stage module side as appropriate. Ri, and a detection end module, combined with a group of first output circuit module selected from the output circuit module corresponding to the detection end module, is obtained by adapted to prepare order product.

  According to such a proximity sensor commercialization system, it is possible to achieve manufacturing cost and quick product preparation while satisfying an abundant product lineup.

  When the present invention is considered at the level of a more specific embodiment, detection of a detection coil assembly including a coil, a ferrite core in which the coil is housed, and a cylindrical mask conductor made of brass, copper, aluminum, or the like. The characteristics are not easily affected by the material and shape of the main body case, the plating thickness variation of the main body case, or the assembly position variation of the sensor unit and the main body case (the influence is reduced). Therefore, even if the main body case (material / shape) is different, a proximity sensor with the same performance can be realized with the same detection end module. As a result, (1) design man-hours and costs are reduced, (2) high-performance detection performance can be obtained with any body case material, (3) parts can be consolidated, and parts costs can be reduced. (4) It is possible to produce in the same line and process, (5) The variation in detection distance can be reduced, (6) The assembly position of the sensor unit and the body case can be simplified, Various effects such as simplification of the detection distance adjustment method can be obtained.

  Further, by providing the cylindrical mask conductor, a performance improvement effect as a proximity sensor can also be obtained. For example, the influence of surrounding metal (detection characteristic change due to the influence of the metal of the mounting portion) can be reduced compared to the conventional structure. In addition, it is possible to reduce the distance of mutual interference (proximity sensors interfere with each other and cause malfunctions).

  In addition, when the cylindrical mask conductor is grounded to a stable potential, a shielding effect against disturbance noise can be obtained, eliminating the need for conventional noise countermeasures (shield plates and vapor deposition films on ferrite cores). Cost and production man-hours can be reduced.

  Next, a model selection support method as a business method related to the sales of the proximity sensor described above will be described. The proximity sensor model selection support method of the present invention includes a detection coil assembly including a coil and a core, and an oscillation circuit having the coil as a resonance circuit element, and outputs an object detection signal according to the oscillation state of the oscillation circuit to the outside. And a detection end module that integrates a mask conductor to reduce the influence of the detection characteristics of the outer shell case, and an output circuit that drives the output element based on the object detection signal. A proximity sensor model selection support method comprising: an output circuit module; a detection end module; and an outer shell case for housing the output circuit module, wherein one detection end module selected from a plurality of types of detection end modules; One output circuit module selected from multiple types of output circuit modules and one selected from multiple types of outer shell cases A step of preparing a database in which information for identifying a model of a proximity sensor that can be configured by a combination of outer shell cases and specifications of the model is registered in a server storage device, and a customer via a terminal device that communicates with the server To input a part or all of the specification conditions necessary for specifying the proximity sensor model, and through the terminal device, information identifying the proximity sensor model satisfying the specification condition input by the customer is presented to the customer And a step.

  In a conventional proximity sensor, a detection circuit and an output circuit are configured on one circuit board, and a detection coil is integrated with the circuit board to form one composite part. For this reason, even if only one of the specifications of the detection coil, the detection circuit, and the output circuit is different, the composite component as a whole becomes a different specification. Therefore, the composite component must be designed separately. This is also a factor that cannot increase the number of proximity sensors that can be ordered.

  In contrast, in the proximity sensor model selection support method of the present invention, a proximity sensor can be prepared by variously combining separately prepared detection end modules, output circuit modules, and outer shell cases. The number of types of proximity sensors that can be ordered can be obtained much more than the number of types of detection end modules, the number of types of output circuit modules, and the number of types of outer shell cases.

  Furthermore, even if the model ordered is a model with little demand or a model that has not received an order in the past, that is, the combination of the detection end module, output circuit module, and outer shell case used for that model is rare, Modules and cases can be used when configuring other models, so keeping these modules and cases in stock has no particular impact on maintenance costs, production costs, production lead times, etc. Even rare models can be provided without difficulty. Further, even when the number of proximity sensors ordered is very small (for example, one), it can be handled (provided) without any problem.

  In addition, the detection end module used in the implementation of the model selection support method of the present invention is configured to be hardly affected by the detection characteristics of the outer shell case, so that it is detected according to the material of the outer shell case to be combined. There is no need to individually adjust the end modules. Therefore, it is possible to quickly assemble a proximity sensor having a specification according to an order from a customer that can stock the detection end module as a completed intermediate product.

  In the model selection support method of the present invention, the specifications registered in the database are all or some of the technically possible combinations of the detection end module, the output circuit module, and the outer shell case. That is, combinations that are technically impossible, or combinations that are technically possible but unnecessary due to the convenience of the proximity sensor provider, etc. may not be registered.

  As input modes for the specification conditions necessary for specifying the proximity sensor model, you can enter specific specifications for each of the multiple specification items prepared in advance (selection from options, input of arbitrary phrases, etc.) And the like in which indirect information (information such as the use of the proximity sensor) for narrowing down is roughly input.

  The “specification conditions” may include specification conditions related to the connection method. Specifically, it is based on the specification conditions based on whether it is a cord drawer (pre-wire) type or a connector type, in the case of the cord drawer type, further on the specification conditions based on the material and length of the cord, and in the case of the connector type, further based on the connector type An example is specification conditions.

  In the model selection support method of the present invention, a step for guiding a method for purchasing a proximity sensor may be further provided after any step or before any step or before inputting the specification conditions. Good.

  In this case, in the step of guiding the purchase method, it is possible to provide information about a store where the proximity sensor can be purchased. In addition, after presenting information for identifying a model that satisfies the specifications desired by the customer via the terminal device on the customer side, a purchase application for the presented model may be accepted. Further, the purchase application method may be guided by e-mail, telephone, facsimile, or mail.

  In a preferred embodiment of the model selection support method of the present invention, when there are a plurality of proximity sensor models that satisfy the specifications input by the customer in the step of presenting information for identifying the model, these are selected via the customer side terminal device. The method further includes a step of presenting a list of models and causing the customer to select one or more models from the model list via the terminal device.

  According to such an aspect, the customer can specify the model by the procedure of inputting only the specification conditions that are considered important for his / her application and then selecting the desired one from the list of models presented. Compared to the case where all the specification conditions necessary for specifying the model have to be input, the time and effort required for the input operation is reduced, and the model selection can be easily performed.

  More preferably, if there is a model for which inventory by prospective production is prepared among the models presented in the list, the list should be created so that the customer can identify such models in the list. Make it present.

  “For customers to identify”, for example, this may be the case where specific characters, figures, symbols, colors, etc. are displayed in the list to indicate that the model is in stock. This is the case. According to such an aspect, the customer can select whether the model shown in the list is a model that is in stock (the model that can be obtained the earliest) or a model that is produced after receiving an order (a model that is delayed by several days). And can select the model based on that.

  Preferably, in the step of inputting the specification conditions, only a part of the specification conditions necessary for specifying the model can be input, and the list includes the specification conditions input by the customer. In addition to the information for identifying the models of the plurality of proximity sensors that are satisfied, the contents of the specification conditions that are not applicable to the part of the specification conditions that can be input for each model are included.

  Here, as “specification conditions not applicable to some specification conditions that can be input”, it is preferable to assign specification conditions that are not usually emphasized from the viewpoint of model selection. For example, assuming that both normally open and normally closed operation modes are available in most cases regardless of other specifications, it may be sufficient to decide which one to select at the end. Therefore, in this case, in the step of inputting the specification condition, it may be desirable to prevent the input of normally open or normally closed. Thereby, the customer can concentrate attention on inputting only the specifications closely related to the application in the step of inputting the specification conditions.

  Preferably, in the model selection support method of the present invention, a step of receiving an information presentation request from a customer via the terminal device for a model of a proximity sensor presented as satisfying the specification condition input by the customer; And a step of presenting the customer with information indicating characteristics of the proximity sensor model and / or information including a drawing showing the outer shape via the terminal device in response to the request.

  According to such an aspect, the customer can immediately confirm the detailed information about the models presented in the list, so that the model selection can be performed more accurately and smoothly.

  The above-described model database is preferably created by the model database creation method of the present invention. The model database creation method of the present invention includes a detection coil assembly including a coil and a core, an oscillation circuit having the coil as a resonance circuit element, and outputs an object detection signal according to the oscillation state of the oscillation circuit to the outside. An output circuit incorporating a detection circuit assembly, a detection end module in which a mask conductor for reducing the influence of detection characteristics due to an outer shell case is integrated, and an output circuit for driving an output element based on an object detection signal A method of creating a proximity sensor model database in which specifications of each model are registered for a plurality of proximity sensor models including a module and an outer shell case that houses a detection end module and an output circuit module. Specification data for each detection end module for end module, specifications for each outer case for multiple types of outer case For specifying the output data module specification data in the computer storage device and the combination of the detection end module and the outer shell case as inappropriate. The step of preparing the combination prohibition information in the computer storage device and the specification data of each detection end module, the specification data of each outer case, and the specification of each output circuit module, except for the combination specified by the prohibition information Are combined by a computer and selected from one detection end module selected from a plurality of types of detection end modules, one outer case selected from a plurality of types of outer shell cases, and a plurality of types of output circuit modules. Proximity that can be configured by combining one output circuit module And creating a model database in which specifications are registered for each type of capacitors, characterized in that it comprises a.

  According to the method for creating a proximity sensor model database of the present invention, a database of a huge number of proximity sensor models can be created quickly and accurately. With conventional proximity sensors, if there are differences in any of the basic specifications such as outer diameter, detection distance, output form, etc., there was always a part that was individually designed. It was not possible to automatically create a model database based on this. However, according to this proximity sensor model database creation method for the proximity sensor according to the present invention including the detection end module, the output circuit module, and the outer shell case having a high degree of freedom of combination, the proximity sensor model database is stored as a computer program. It becomes possible to create by executing.

  In this proximity sensor model database creation method, specification data relating to the connection method may be further prepared, and a model database including the specification data may be created by executing a computer program.

  Further, here, the detection end module used as one module part of the proximity sensor product includes a detection coil assembly including a coil and a core and having a detection characteristic self-completed by a mask conductor, and a coil of the detection coil assembly. The detection circuit assembly as a resonance circuit element is integrally coupled to form a module component, and the characteristic adjustment is completed prior to shipment.

  As described above, the present invention is useful as an inductive proximity sensor that detects the approach of a metal body or the like in a non-contact manner through a magnetic field, and in particular, can flexibly meet user needs while suppressing manufacturing costs. It is suitable for realizing a rich product lineup that can be handled.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

  The main feature of the proximity sensor of the present invention is that it is manufactured using a detection end module having a novel configuration. This detection end module is formed by integrating a detection coil assembly including a coil and a core, and a detection circuit assembly including an oscillation circuit having the coil of the detection coil assembly as a resonance circuit element.

  This detection coil assembly incorporates a mask conductor for reducing the conductor detection sensitivity in a specific peripheral region where the presence of a metal outer shell case (main body case) is assumed. In addition, the detection circuit assembly is configured to output a signal in a certain form according to the oscillation state of the oscillation circuit to the outside as an object detection signal of the proximity sensor.

  For this reason, by configuring the output stage circuit appropriately using the object detection signal output from the detection circuit assembly, a signal in a desired format can be output from the proximity sensor.

  As will be described in detail later, a good conductor such as brass, copper, or aluminum is used as the material of the mask conductor. Further, the shape thereof may be a cylindrical body or an annular body surrounding the detection coil assembly.

  FIG. 1 shows an embodiment (first embodiment) of a detection coil assembly 404 that is a constituent part of the detection end module of the present invention, together with a main body case (outer shell case) 405. This detection coil assembly 404 is intended to be a shield type, and includes a coil 401 and a ferrite core 402 housed in a bottomed cylindrical coil case 403. In this example, the coil case 403 is an insulator using a resin as a material. A cylindrical body case 405 is press-fitted and fitted around the outer periphery of the detection coil assembly 404. As a material of the main body case 405, a metal such as brass or stainless steel, a resin, or the like can be used. As a material of the coil case 403, an insulator such as a resin is used.

  A mask conductor 406 is disposed on the inner peripheral surface of the coil case 403 surrounding the coil 401 and the ferrite core 402 to reduce the conductor detection sensitivity in a specific peripheral region where the metal main body case 405 is assumed to exist. The mask conductor 406 shown in the first embodiment has a cylindrical shape, and a good conductor such as brass, copper, or aluminum is used as the material thereof. The cylindrical mask conductor 406 has substantially the same overall length as the ferrite core 402 and is arranged in a state where it is pushed to the end of the coil case 403 on the tip side (left side in the figure). Further, the end face on the front end side (left side in the figure) of the main body case 405 is a position slightly retracted from the end face on the front end side of the cylindrical mask conductor 406.

  In this example, the cylindrical mask conductor 406 has a structure in which a step is provided on the inner peripheral surface of the coil case 403, but this step may be omitted. The arrangement method of the cylindrical mask conductor 406 may be a method of inserting the cylindrical mask conductor 406 into the coil case 403 or a method of insert molding the cylindrical mask conductor 406 into the coil case 403. Alternatively, instead of the coil case 403, a method of forming with an insulator so that the coil 401, the ferrite core 402, the cylindrical mask conductor 406, and the substrate mounted on the detection end module described later may be integrated. If the cylindrical mask conductor 406 is grounded to a stable potential (ground), a shielding effect against disturbance noise can be obtained.

  A graph showing the detection characteristics of the detection coil assembly of the first embodiment is shown in FIG. This graph is drawn based on measurement data of an M8 shield type sensing coil assembly. The horizontal axis represents the detection distance (mm), and the vertical axis represents the conductance g (μS) of the detection coil. Details of the graph (contents, meanings of terms, etc.) will be explained at the end of the [Embodiments of the Invention] section, so please refer to them.

  As shown in the figure, when the material of the main body case 405 is different from resin (non-metal), brass (brass), and stainless steel, the conductance characteristic (in other words, detection characteristic) of the detection coil assembly 404 is accordingly accompanied. Also fluctuate. However, as apparent from the comparison with the detection characteristic of the conventional example 1 shown in FIG. 24, the variation width of the detection characteristic of the detection coil assembly of the present embodiment is the detection coil of the conventional example 1 that does not have the mask conductor 406. It will be understood that it is much smaller than the fluctuation range of the assembly (see FIG. 23). This is presumably due to the fact that the provision of the cylindrical mask conductor 406 reduces the conductor detection sensitivity in a limited region where the case body 405 exists.

  Therefore, the influence of the material / shape and size of the main body case 405, the plating thickness variation, or the variation in the assembly position of the detection coil assembly 404 and the main body case 405 on the detection characteristics of the detection coil assembly 404 is reduced. Even if the materials, shapes, etc. are different, a proximity sensor with a small difference in detection characteristics can be realized with the same detection end module (details will be described later).

  As a result, (1) design man-hours and costs can be reduced, (2) parts can be consolidated and parts costs can be reduced, and (3) different models of proximity sensors can be produced in the same line and process. , (4) The variation in the detection distance can be reduced, (5) The assembly position alignment between the sensor unit and the main body case can be simplified, and (6) The detection distance adjustment method can be simplified. Various effects can be obtained.

  In addition, by providing the cylindrical mask conductor 406, the performance improvement effect as a proximity sensor can be obtained. For example, the influence of surrounding metal (detection characteristic change due to the influence of the metal of the mounting portion) can be reduced compared to the conventional structure. There is also an effect that the distance at which mutual interference (proximity sensors interfere with each other and cause malfunctions) can be reduced.

  Further, when the cylindrical mask conductor 406 is grounded to a stable potential, a shielding effect against disturbance noise can be obtained, so that noise countermeasures (shield plate and vapor deposition film on the ferrite core) that have been conventionally performed are unnecessary, Parts costs and production man-hours can be reduced.

  FIG. 32 shows a modification of the first embodiment of the detection coil assembly described above. In the first embodiment, the cylindrical mask conductor 406 is arranged on the inner side (inner peripheral surface) of the coil case 403. However, the mask body is a coil as the cylindrical mask conductor 4060 as shown in FIG. It can also be provided outside the case 403.

  A cylindrical mask conductor 4060 shown in this modification has an inner diameter that is slightly larger than that of the previous cylindrical mask conductor 406, and is fitted into a stepped portion 403 a formed on the outer peripheral surface of the coil case 403. The total length and the position of the tip portion (slightly forward) with respect to the end surface of the main body case 403 are substantially the same as those of the mask conductor 406 described above.

  On the other hand, the main body case 405 is press-fitted and fitted to the outer periphery of the detection coil assembly 404 so as to cover most of the outer peripheral surface of the cylindrical mask conductor 4060 and to slightly expose the distal end portion of the outer peripheral surface. Note that the detection characteristics of the detection coil assembly 404 in this aspect are substantially the same as those shown in FIG.

  When the mask conductor is provided on the inner periphery of the coil case 403, for example, when a partial crack is generated in the coil case 403 due to an external impact or the like, and the mask conductor is exposed, There is a concern that some kind of electrostatic discharge may reach the sensor internal circuit via the mask conductor. However, if the mask conductor 4060 is arranged outside the coil case in this way, even if a partial crack occurs in the coil case 403, the gap between the mask conductor and the detection circuit assembly is not ensured. Since the coil case 403 that is an insulator remains in most of the portions, discharge between the sensor internal circuit and the mask conductor can be prevented.

  The cylindrical mask conductor 4060 may be provided so as to be embedded in the coil case 403 so that the outer peripheral surface thereof is completely covered. In this case, in addition to the above-described discharge prevention, the mask conductor 4060 can be imparted with a high rust prevention property.

  In this example, the cylindrical mask conductor 4060 has a structure in which the stepped portion 403a is provided on the outer periphery of the coil case 403, but this step may be omitted. The cylindrical mask conductor 4060 may be bonded and fixed to the coil case 403 or may be integrally formed with the coil case 403. Further, instead of the coil case 403, the coil 401, the ferrite core 402, the cylindrical mask conductor 4060, and a substrate to be mounted on the detection end module to be described later are molded with an insulator (for example, a resin mold). May be.

  Further, if the cylindrical mask conductor 4060 is grounded to a stable potential (ground), a shielding effect against disturbance noise can be obtained.

  FIG. 3 shows another embodiment (second embodiment) of the detection coil assembly 404 together with the main body case 405. Here, parts that are substantially the same as those of the first embodiment shown in FIG. The shape of the coil case 403 is slightly different based on the difference in configuration of the mask conductors (406, 407) of the first embodiment and the second embodiment, but those points will be understood by those skilled in the art. If so, no special explanation will be required.

  The second embodiment is different from the first embodiment in the configuration of the mask conductor 407. The mask conductor 407 is configured as a flanged cylindrical shape having an annular flange portion 407b on the outer periphery of the tip end portion of the cylindrical main body portion 407a. The material is the same as that of the previous mask conductor 406.

  The flanged mask conductor 407 may be composed of two different independent members (a flange-shaped portion and a cylindrical portion). The flanged mask conductor 407 has a structure in which a step is provided on the inner peripheral surface of the coil case 403, but the step may be omitted. In that case, it is only necessary to fit the annular flange 407a to the step. Further, the flanged mask conductor 407 can be insert-molded or integrally molded in the same manner as the mask conductor 406 shown in the first embodiment. Further, the shield function can be applied in the same manner (grounded).

  A graph showing the detection characteristics of the detection coil assembly of the second embodiment is shown in FIG. As shown in the figure, also in the second embodiment, when the material of the main body case 405 is different from resin (nonmetal), brass (brass), and stainless steel, the conductance characteristic (detection characteristic) varies accordingly. However, it is understood that the fluctuation range of the detection characteristic is much smaller than the fluctuation range of the detection coil assembly of the conventional example 1 (see FIGS. 23 and 24) that does not have the mask conductor. However, in the second embodiment, the detection coil assembly 404 of the first embodiment shown in FIG. 2 is detected by forming the flange portion 407b in an annular shape on the outer periphery of the distal end portion of the flanged mask conductor 407. It will be understood that a further reduction in variation than the characteristic is achieved.

  FIG. 33 shows a modification of the second embodiment of the detection coil assembly described above. As shown in the figure, also in the second embodiment, the flanged mask conductor can be provided outside the coil case 403.

  The flanged mask conductor 4070 shown in this modified example is fitted into a stepped portion 403 a formed on the outer peripheral surface of the coil case 403. Note that the overall length of the flanged mask conductor 4070 and the position of the tip (slightly forward) with respect to the end surface of the main body case 403 are substantially the same as those of the above-described flanged mask conductor 407.

  On the other hand, the body case 405 is press-fitted and fitted to the outer periphery of the detection coil assembly 404 so as to cover the outer peripheral surface of the flanged mask conductor 4070 and to expose the outer peripheral surface of the flange portion 407b.

  The detection characteristics of the detection coil assembly 404 in this modification are almost the same as those shown in FIG. 4, and the effects obtained by providing the mask conductor on the outer periphery of the coil case or its application examples Since this can be considered in the same manner as that described in the description of the modification of the first embodiment, redundant description here will be avoided.

  FIG. 5 shows another embodiment (third embodiment) of the detection coil assembly 404 together with the main body case 405. Similarly, the same portions as those in the first embodiment or the second embodiment described above are denoted by the same reference numerals, and the description thereof is omitted.

  The third embodiment is different from the first embodiment or the second embodiment in the configuration of the mask conductor 408. The mask conductor 408 shown in the third embodiment is configured as an annular mask conductor 408.

  The annular mask conductor 408 has a structure in which a step is provided at the tip of the inner peripheral surface of the coil case 403, but this step may be omitted as in the first and second embodiments. In addition, the annular mask conductor 408 can be formed by insert molding or integral molding in the same manner as the mask conductors 406 and 407 shown in the first and second embodiments. Further, the shield function can be applied in the same manner (grounded).

  Although the illustration of the characteristic graph is omitted, even in the third embodiment, the fluctuation range of the detection characteristic due to the different material of the main body case 405 is the fluctuation of the detection coil assembly of the conventional example 1 having no mask conductor. It becomes much smaller than the width. This is also presumed to be due to the decrease in conductor detection sensitivity in the region where the case main body 405 exists due to the provision of the annular mask conductor 408.

  FIG. 34 shows a modification of the third embodiment of the detection coil assembly described above. As shown in the figure, an annular mask conductor can be provided outside the coil case 403 also in the third embodiment.

  An annular mask conductor 4080 shown in this modification is fitted into a stepped portion (fitting portion 403a) formed at the distal end portion of the outer peripheral surface of the coil case 403. On the other hand, the main body case 405 is press-fitted and fitted around the outer periphery of the detection coil assembly 404 without covering the outer peripheral surface of the annular mask conductor 4080.

  Note that the detection characteristics of the detection coil assembly 404 in this aspect are substantially the same as those of the third embodiment, and the effects obtained by providing the mask conductor on the outer periphery of the coil case or its application examples are as follows. It can be considered in the same manner as that described in the description of the modification of the first embodiment.

  FIG. 6 shows another embodiment (fourth embodiment) of the detection coil assembly 404 together with the main body case 405. This detection coil assembly 404 is intended to be a non-shield type, and as is apparent from comparison with the first to third embodiments described above, the outer case 405 has a large portion of the outer peripheral surface of the coil case 403. Is press-fitted and fitted at the rear end of the coil case 403. In addition, the ferrite core 402 used in this example has a T-shaped cross section, and since the ferrite core 402 does not exist outside the coil 403, although the shielding effect is inferior, the detection distance (detection performance) is first to first. This is an improvement over that of the third embodiment. The materials of the coil 401, the ferrite core 402, the coil case 403, and the main body case 405 are the same as those in the first to third embodiments.

  In the fourth embodiment, a cylindrical mask conductor 409 is used. The mask conductor 409 is disposed on the inner peripheral surface of the coil case 403 such that the mask conductor 409 is located behind the coil 401 and the ferrite core 402 and the tip side thereof is located forward of the tip side of the coil case 405. The material of the mask conductor 409 is the same as that of the first to third embodiments.

  The cylindrical mask conductor 409 has a structure in which a step is provided on the inner peripheral surface of the coil case 403, but this step may be omitted. In addition, the cylindrical mask conductor 409 can be insert-molded or integrally molded in the same manner as the mask conductors (406, 407, 408) shown in the first to third embodiments. Further, the shield function can be applied in the same manner (grounded).

  A graph showing the detection characteristics of the detection coil assembly of the fourth embodiment is shown in FIG. As shown in the figure, also in the fourth embodiment, when the material of the main body case 405 is different from resin (nonmetal), brass (brass), and stainless steel, the conductance characteristic (detection characteristic) fluctuates accordingly. However, as apparent from the comparison with the detection characteristic of the conventional example 2 shown in FIG. 26, the detection characteristic is much larger than the fluctuation range of the detection coil assembly of the conventional example 2 (see FIG. 25). It is getting smaller.

  FIG. 35 shows a modification of the fourth embodiment of the detection coil assembly described above. As shown in the figure, the cylindrical mask conductor 4090 can be provided outside the coil case 403 also in the fourth embodiment.

  A cylindrical mask conductor 4090 shown in this modification is fitted into a stepped portion 403 a formed on the outer peripheral surface of the coil case 403. The position of the cylindrical mask conductor 4090 with respect to the coil and the core is substantially the same as that of the cylindrical mask conductor 409 described above. On the other hand, the main body case 405 is press-fitted and fitted to the outer periphery of the detection coil assembly 404 so as to cover more than half of the outer peripheral surface of the cylindrical mask conductor 4090 and to expose the tip of the outer peripheral surface.

  Note that the detection characteristics of the detection coil assembly 404 in this aspect are substantially the same as those shown in FIG. 7, and for the effect obtained by providing the mask conductor on the outer periphery of the coil case or its application example, It can be considered in the same manner as that described in the description of the modification of the first embodiment.

  FIG. 8 shows another embodiment (fifth embodiment) of the detection coil assembly 404 together with the main body case 405. Similarly to the fourth embodiment shown in FIG. 6, this detection coil assembly is also intended to be a non-shield type, and the same reference numerals are assigned to the same parts as those in the fourth embodiment, and the description thereof will be given. Omitted.

  The fifth embodiment differs from the fourth embodiment in the configuration of the mask conductor 410. The mask conductor 410 shown in the fifth embodiment is configured as a flanged cylindrical shape having an annular flange portion 410b on the outer periphery of the tip end portion of the cylindrical main body portion 410a.

  The flanged mask conductor 410 may be composed of two different independent members (a flanged portion and a cylindrical portion). The flanged mask conductor 410 has a structure in which a step is provided on the inner peripheral surface of the coil case 403, but the step may be omitted. Further, like the mask conductor 409 shown in the fourth embodiment, insert molding or integral molding can be performed. Further, the shield function can be applied in the same manner (grounded).

  A graph showing the detection characteristics of the detection coil assembly of the fifth embodiment is shown in FIG. As shown in the figure, also in the fifth embodiment, when the material of the main body case 405 is different from resin (nonmetal), brass (brass), and stainless steel, the conductance characteristic (detection characteristic) varies accordingly. However, the fluctuation range of the detection characteristic is much smaller than that of the detection coil assembly of the conventional example 2 (see FIGS. 25 and 26) that does not have the mask conductor. However, in the fifth embodiment, since the flange portion 410b is formed in an annular shape on the outer periphery of the distal end portion of the flanged mask conductor 410, the variation further exceeds the detection characteristics of the fourth embodiment shown in FIG. It will be appreciated that width reduction has been achieved.

  FIG. 36 shows a modification of the fifth embodiment of the detection coil assembly described above. As shown in the figure, also in the fifth embodiment, the flanged mask conductor can be provided outside the coil case 403.

  The flanged mask conductor 4100 shown in this modification is fitted into a stepped portion 403 a formed on the outer peripheral surface of the coil case 403. Note that the position of the flanged mask conductor 4070 with respect to the coil and the core is substantially the same as that of the flanged mask conductor 410 described above. On the other hand, the main body case 405 is press-fitted and fitted around the outer periphery of the detection coil assembly 404 so as to cover the outer peripheral surface of the flanged mask conductor 4100 and to expose the outer peripheral surface of the flange portion 407b.

  The detection characteristics of the detection coil assembly 404 in this aspect are substantially the same as those shown in FIG. 9, and the effects obtained by providing the mask conductor on the outer periphery of the coil case or its application examples are as follows. It can be considered in the same manner as that described in the description of the modification of the first embodiment.

  FIG. 10 shows another embodiment (sixth embodiment) of the detection coil assembly 404 together with the main body case 405. Similarly, parts that are substantially the same as those in the fourth embodiment or the fifth embodiment described above are denoted by the same reference numerals, and description thereof is omitted.

  The sixth embodiment is different from the fourth embodiment or the fifth embodiment in the configuration of the mask conductor 411. That is, the mask conductor 411 shown in the sixth embodiment is configured as an annular mask conductor 411.

  The annular mask conductor 411 has a structure in which a step is provided on the inner peripheral surface of the coil case 403, but this step may be omitted. In addition, the annular mask conductor 411 can be insert-molded or integrally molded in the same manner as the mask conductor shown in the fourth and fifth embodiments. Further, the shield function can be applied in the same manner (grounded).

  Although the illustration of the characteristic graph is omitted, even in the sixth embodiment, the fluctuation range of the detection characteristic due to the different material of the main body case 405 is that of the detection coil assembly of the conventional example 2 that does not have the mask conductor. Compared to the fluctuation range, it becomes much smaller. This is also presumed to be due to the decrease in the conductor detection sensitivity in the region where the case main body 405 exists due to the provision of the annular mask conductor 411.

  FIG. 37 shows a modification of the sixth embodiment of the detection coil assembly described above. As shown in the figure, the annular mask conductor 4110 can be provided outside the coil case 403 also in the sixth embodiment.

  An annular mask conductor 4110 shown in this modification is fitted into a stepped portion (fitting portion 403 a) formed on the outer peripheral surface of the coil case 403. On the other hand, the body case 405 is press-fitted and fitted to the outer periphery of the detection coil assembly 404 without covering the outer peripheral surface of the annular mask conductor 4110.

  The detection characteristics of the detection coil assembly in this aspect are substantially the same as those in the sixth embodiment, and the effects obtained by providing the mask conductor on the outer periphery of the coil case or the application examples thereof are described above. It can be considered in the same manner as that described in the description of the modification of the first embodiment.

  FIG. 11 shows still another embodiment (seventh embodiment) of the detection coil assembly 404 together with the main body case 405. This detection coil assembly is intended to be a non-shield type as in the fourth to sixth embodiments, but the mask conductor 412 is different from the fourth to sixth embodiments. The mask conductor 412 shown in this embodiment has a disk shape, and is arranged so as to close the rear opening of the coil case 403 and to be in close contact with the back surface of the ferrite core 402.

  The material of the disk-shaped mask conductor 412 is the same as that of the mask conductors 406 to 411 shown above. If the disk-shaped mask conductor 412 is grounded to a stable potential (ground), a shielding effect against disturbance noise can be obtained. can get.

  Although the characteristic graph is omitted, even in the seventh embodiment, the fluctuation width of the detection characteristic due to the different material of the main body case 405 is the fluctuation width of the detection coil assembly of the conventional example 2 that does not have the mask conductor. It has been confirmed that it is much smaller than that.

  Next, the detection circuit assembly 500, which is another component of the detection end module of the present invention, and the entire proximity sensor circuit configured using the detection circuit assembly 500 and the output circuit assembly are described in detail. This will be explained with examples.

  FIG. 12 shows a circuit configuration of an embodiment (first embodiment) of a detection circuit assembly constituting the detection end module according to the present invention. In FIG. 27, 501 is an oscillation circuit, 502 is an integration circuit, 503 is a discrimination circuit, 504 is a detection coil, 505 is a resonance capacitor, 506 is an adjustment circuit, 507 is an integration capacitor, and 509 is an output terminal. The same operation as that of the corresponding circuit element in the conventional example is performed. These circuit elements are appropriately integrated and mounted on a circuit board (not shown) to constitute a detection circuit assembly 500 as will be described later.

  Reference numerals 508 and 510 denote power supply terminals for receiving a constant voltage for driving the detection circuit assembly 500 from the outside (output circuit module). Reference numeral 509 denotes a detection signal output terminal of the detection circuit assembly 500. Reference numeral 511 denotes a custom IC (integrated circuit) in which main circuit elements of the detection circuit assembly 500 are built in one chip.

  The oscillation voltage of the oscillation circuit 501 is smoothed by the integration circuit 502, and then compared with the reference voltage by the discrimination circuit 503, whereby a binarized detection signal appears at the detection signal output terminal 509.

  The adjustment circuit 506 supplies a predetermined constant voltage (a constant voltage value supplied by an output circuit module described later) to the power supply terminals 508 and 510 to keep the detection circuit assembly 500 in an operable state, and performs a predetermined detection. It is used to adjust the gain of the oscillation circuit 501 by changing some of the plurality of resistors so as to achieve sensitivity or by laser trimming.

  Note that the oscillation circuit 501 may be a circuit in which oscillation stops / starts in response to the approach of a metal object, or a circuit in which the oscillation frequency does not change and the oscillation frequency changes. The circuit block built in the custom IC 511 is not limited to the illustrated example, and a part of the circuit block may be taken out of the IC if necessary. The adjustment circuit 506 does not have to be incorporated unless the detection sensitivity varies greatly. A temperature correction circuit using a thermistor or the like may be incorporated in the adjustment circuit at the same time.

  As the detection coil assembly constituting the detection circuit assembly 500, any of the first to seventh embodiments (including modifications) of the detection coil assembly 404 described above with reference to FIGS. Is used. Such a detection coil assembly 404 includes a coil 401 and a core 402, and this coil 401 corresponds to the detection coil 504 of FIG. For the oscillation circuit 501 included in the detection circuit assembly 500, the coil 504 included in the detection coil assembly 404 serves as a resonance circuit element.

  As described with reference to FIGS. 1 to 11, the detection coil assembly 404 incorporates a mask conductor for reducing conductor detection sensitivity in a specific peripheral region where the main body case 405 is assumed to exist. .

From the output terminal 509 of the detection circuit assembly 500, a signal in a certain form corresponding to the oscillation state of the oscillation circuit 501 is output to the outside as an object detection signal of the proximity sensor.
This detection signal is a binarized signal.

  By configuring the output stage circuit appropriately using the object detection signal output from the output terminal 509 of the detection circuit assembly 500, a signal in a desired format can be output from the proximity sensor. This will be described in detail later.

  According to the detection circuit assembly shown in FIG. 12 described above, (1) since the detection function part of the proximity sensor is separated from the output circuit part, the same detection circuit assembly 500 is provided with different power supply specifications / Can be shared with output form. In addition, by using oscillation / adjustment circuit constants according to the specifications of the coil to be connected and adjusting the detection distance according to each distance, a highly common detection end module can be realized.

  Furthermore, as compared with the conventional integration of the entire proximity sensor circuit, it is only necessary to integrate a much smaller circuit, and the number of different ICs required for different detection specifications can be reduced (1). The usage quantity of the type is greatly increased). This greatly reduces IC procurement costs. In addition, even if IC design changes, quality improvements, etc. occur, one type of IC can be shared by many proximity sensor models, so there is no need to deal with each of various products individually. There are many cases that can be dealt with by making changes.

  FIG. 13 shows a circuit configuration of another embodiment (second embodiment) of the detection circuit assembly constituting the detection end module according to the present invention. In the figure, 501 is an oscillation circuit, 502 is an integration circuit, 513 is a discrimination circuit that outputs two systems of binary signals with different reference thresholds, 504 is a detection coil, 505 is a resonance capacitor, 506 is an adjustment circuit, and 507 is Integration capacitors 514 and 515 are output terminals, and 516 is a constant voltage circuit, each performing the same operation as the corresponding circuit element in the conventional example of FIG. These circuit elements are appropriately integrated and mounted on a circuit board (not shown) to constitute a detection circuit assembly 500 as will be described later.

  In the second embodiment, since the constant voltage circuit 516 is provided in the detection circuit assembly (first embodiment) 500, the detection circuit assembly (first embodiment) is more stable against slight fluctuations in the external constant voltage supplied from the outside. Therefore, the detection sensitivity can be made more accurate.

  In addition, since two systems of binarized signals with different reference threshold values are obtained from the discrimination circuit 513, the oscillation state of the oscillation circuit can be recognized more accurately, and the presence of an object to be detected (if only the presence or absence of an object is detected). It is possible to detect more accurately whether it is near or far.

  The custom IC 517 includes an oscillation circuit 501, an integration circuit 502, a discrimination circuit 513, and a constant voltage circuit 516. Since other configurations are the same as those of the first embodiment shown in FIG. 12, the description thereof is omitted by giving the same reference numerals.

  The detection sensitivity of the oscillation circuit is extremely sensitive to fluctuations in the driving voltage, but according to the detection circuit assembly of the second embodiment, the constant voltage circuit 516 is provided in the detection circuit assembly 500. Even if the constant voltage supplied to the assembly 500 fluctuates, the detection sensitivity can be stabilized with high accuracy (in other words, the constant voltage of the output circuit module may be configured with rough accuracy).

  As a result, in the detection end module production line, the drive power supply accuracy at the time of detection sensitivity adjustment can be made rough (inexpensive), and the adjusted detection sensitivity is shifted due to variations in the constant voltage output of the output circuit module to be connected later. This can be prevented.

  FIG. 14 shows a circuit configuration of another embodiment (third embodiment) of the detection circuit assembly constituting the detection end module according to the present invention. In the figure, 501 is an oscillation circuit, 502 is an integration circuit, 504 is a detection coil, 505 is a resonance capacitor, 506 is an adjustment circuit, 507 is an integration capacitor, and 518 outputs an analog signal corresponding to the oscillation state of the oscillation circuit 501. Each of these output terminals performs the same operation as the corresponding circuit element in the conventional example of FIG. These circuit elements are appropriately integrated and mounted on a circuit board (not shown) to constitute a detection circuit assembly 500 as will be described later.

  In the third embodiment, the output of the integrating circuit 502 is output from the output terminal 518 as it is without being binarized. As the oscillation circuit 501, a circuit having a characteristic in which the oscillation amplitude changes approximately linearly according to the approach distance of the metal object is adopted. Therefore, the detection signal obtained at the output terminal 518 is also approximately the distance from the metal object. Linear output voltage characteristics are shown. Further, when the output of the integration circuit 502 is output to the outside as it is, discrimination processing can be performed on the basis of an arbitrary threshold value outside the detection circuit assembly 500, and the detection distance or the like is accordingly increased. The degree of freedom in design will increase.

  The custom IC 519 includes an oscillation circuit 501 and an integration circuit 502. Since other configurations are the same as those of the first embodiment shown in FIG. 12, the description thereof is omitted by giving the same reference numerals.

  According to the detection circuit assembly (third embodiment) 500 shown in FIG. 14 described above, since the detection signal output of the detection end module is an analog output (generally linear), the detection sensitivity is arbitrarily detected on the output circuit module side. Can be adjusted (set). Therefore, since it is not necessary to change the oscillation circuit constant, it is possible to easily provide various products for various user needs. Also, the output from the proximity sensor can be an analog output.

  FIG. 15 shows a circuit configuration of another embodiment (fourth embodiment) of the detection circuit assembly constituting the detection end module according to the present invention. In the figure, 501 is an oscillation circuit, 502 is an integration circuit, 503 is a discrimination circuit, 504 is a detection coil, 509 is an output terminal from which the binarized output of the discrimination circuit 503 is output as a detection signal, 505 is a resonance capacitor, 506 Is an adjustment circuit, 507 is an integrating capacitor, 508 and 510 are power supply terminals, 520 is a discrimination level variable circuit for adjusting the discrimination level of the discrimination circuit 503, 521 is a connection terminal of an external resistor for adjustment, and 522 is for adjustment Variable resistance. Of these, those already described perform the same operations as the corresponding circuit elements in the conventional example of FIG. These circuit elements are appropriately integrated and mounted on a circuit board (not shown) to constitute a detection circuit assembly 500 as will be described later.

  In the fourth embodiment, a variable resistor 522 having a variable range corresponding to a detection sensitivity / resistance value characteristic designed in advance is connected between the external terminals 521 and 510 of the detection circuit module 500 once adjusted. Thus, the detection sensitivity can be finely adjusted.

  Note that the method of inputting data from the external terminal 521 is not limited to the connection of a variable resistor. For example, a method of inputting a predetermined data by incorporating a microcomputer in the discrimination level variable circuit 520 may be used.

  According to the detection circuit assembly (fourth embodiment) 500 shown in FIG. 15 described above, the detection sensitivity is adjusted by the detection end module. However, when it is desired to finely correct the detection sensitivity according to user needs, etc. Therefore, it is possible to easily provide products (design and production) without adjusting the detection sensitivity by configuring a discrimination circuit on the output circuit module side.

  16 is configured using the detection circuit assembly (first embodiment) 500 shown in FIG. 12 and an output circuit module (also referred to as an output circuit assembly) (first embodiment) separately manufactured. The entire electrical circuit of the proximity sensor is shown.

  Note that the detection circuit assembly (first embodiment) 500 has already been described in detail with reference to FIG.

  The first embodiment of the output circuit assembly 600 corresponds to a three-wire output system. That is, in the figure, 601 is a logic circuit, 602 is an output control circuit, 603 is an output transistor, 604 and 605 are power supply terminals to the output circuit assembly 600, 606 is an output terminal of a proximity sensor, 607 is a constant voltage circuit, 608 is a short circuit protection circuit, 609 is a power reset circuit, 610 is a display circuit, 611 is an operation indicator lamp, 612 and 614 are constant voltage terminals for supplying driving power to the detection circuit assembly 600, and 613 is detection of the detection circuit assembly. This is a detection signal input terminal for receiving a signal from the signal output terminal 509. Reference numeral 621 denotes a custom IC (integrated circuit) in which the main circuit of the output circuit assembly 600 is built in one chip.

  In the figure, the detection signal taken into the output circuit assembly 600 via the detection signal input terminal 613 is processed by a logic circuit 601 (inverted or non-corresponding to whether the operation mode is normally open or normally closed). After being inverted, the output is supplied to the output control circuit 602. Then, the output transistor 603 operates by the action of the output control circuit 602, and the load connected to the output terminal 606 is driven. At the same time, the display circuit 610 operates and the operation indicator lamp 611 is driven.

  When an overcurrent flows through the output transistor 603, the short circuit protection circuit 608 operates, the power reset circuit 609 is activated, and the output transistor 603 is cut off via the output control circuit 602.

  The constant voltage circuit 607 supplies a constant voltage power source to each circuit of the output circuit assembly 600 and the detection circuit assembly 500.

  In the figure, the output format of the output stage switching element is an NPN open collector type output, but it may be a PNP open collector type or a voltage output type.

  FIG. 17 shows an entire electric circuit of a proximity sensor configured using the detection circuit assembly (first embodiment) 500 shown in FIG. 12 and an output circuit assembly (second embodiment) separately manufactured. Has been.

  Note that the detection circuit assembly (first embodiment) 500 has already been described in detail with reference to FIG.

  The second embodiment of the output circuit assembly 600 corresponds to a direct current two-wire output system. That is, in the figure, 601 is a logic circuit, 602 is an output control circuit, 603 is an output transistor, 608 is a short circuit protection circuit, 609 is a power reset circuit, 610 is a display circuit, 611 is an operation indicator lamp, and 615 and 616 are output circuits. A power supply terminal and an output terminal for the assembly 600, 612 and 614 are constant voltage terminals for supplying driving power for the detection circuit assembly 500, and 613 is a detection signal for receiving a signal from the detection circuit assembly 500 detection signal output terminal 509. An input terminal 617 is a constant voltage circuit. Reference numeral 618 denotes a custom IC (integrated circuit) in which the main circuit of the output circuit assembly 600 is built in one chip.

  In the figure, a detection signal taken into the output circuit assembly 600 via the detection signal input terminal 613 is logically processed by the logic circuit 601 and then supplied to the output control circuit 602. Then, the output transistor 603 operates by the action of the output control circuit 602, and the load connected to the output terminal 615 is driven. At the same time, the display circuit 610 operates and the operation indicator lamp 611 is driven.

  The constant voltage circuit 617 supplies constant voltage power to each circuit of the output circuit assembly 600 and the detection circuit assembly 500. In the figure, the output form of the output stage switching element is a DC 2-wire output, but it may be an AC 2-wire type.

  FIG. 18 shows an entire electric circuit of a proximity sensor configured using the detection circuit assembly (second embodiment) 500 shown in FIG. 13 and an output circuit assembly (third embodiment) separately manufactured. Has been.

  Note that the detection circuit assembly (second embodiment) 500 has already been described in detail with reference to FIG.

  The third embodiment of the output circuit assembly 600 corresponds to a direct current two-wire output system. That is, in the figure, 602 is an output control circuit, 603 is an output transistor, 608 is a short circuit protection circuit, 609 is a power reset circuit, 610 is a display circuit, 612 and 614 are constant voltage terminals for supplying driving power for the detection circuit assembly 500. 615, 616 are power supply terminals and output terminals for the output circuit assembly 600, 617 is a constant voltage circuit, and 619 is a logic circuit. Reference numerals 618 a and 618 b denote detection signal input terminals for receiving detection signals from the detection signal output terminals 514 and 515 of the detection circuit assembly 500. Reference numeral 611a denotes an output operation indicator which displays the output operation state of the proximity sensor. Reference numeral 611b denotes a setting indicator which indicates that the setting position can be reliably detected even if the detection distance varies depending on the use environment. Reference numeral 620 denotes a custom IC (integrated circuit) in which the main circuit of the output circuit assembly 600 is built in one chip.

  In the figure, the detection signal taken into the output circuit assembly 600 via the detection signal input terminals 618a and 618b is logically processed by the logic circuit 619 and then supplied to the output control circuit 602. Then, the output transistor 603 operates by the action of the output control circuit 602, and the load connected to the output terminal 615 is driven. At the same time, the output operation indicator lamp 611a is driven. The setting indicator lamp 611b is also driven by the action of the output control circuit 602. The output, the output operation indicator lamp 611a, and the setting indicator lamp 611b change with the approach of the detection target object are the same as in FIG. The constant voltage circuit 617 supplies constant voltage power to each circuit of the output circuit assembly 600 and the detection circuit assembly 500.

  FIG. 19 shows the entire electric circuit of the proximity sensor configured using the detection circuit assembly (third embodiment) 500 shown in FIG. 14 and an output circuit assembly (fourth embodiment) separately manufactured. Has been.

  Note that the detection circuit assembly (third embodiment) 500 has already been described in detail with reference to FIG.

  The fourth embodiment of the output circuit assembly 600 corresponds to a direct current two-wire output system. That is, in the figure, 602 is an output control circuit, 603 is an output transistor, 608 is a short circuit protection circuit, 609 is a power reset circuit, 610 is a display circuit, 612 and 614 are constant voltage terminals for supplying driving power for the detection circuit assembly 500. 615, 616 are power supply terminals and output terminals for the output circuit assembly 600, 617 is a constant voltage circuit, and 619 is a logic circuit. Reference numeral 622 denotes a detection signal input terminal for receiving an analog detection signal from the detection signal output terminal 518 of the detection circuit assembly 500. Reference numeral 611a denotes an output operation indicator which displays the output operation state of the proximity sensor. Reference numeral 611b denotes a setting indicator which indicates that the setting position can be reliably detected even if the detection distance varies depending on the use environment. Reference numeral 620 denotes a custom IC (integrated circuit) in which the main circuit of the output circuit assembly 600 is built in one chip.

  In the figure, an analog detection signal taken into the output circuit assembly 600 via the detection signal input terminal 622 is binarized by a discrimination circuit 621 with a predetermined threshold as a reference, and further processed by a logic circuit 619. Then, it is supplied to the output control circuit 602. Then, the output transistor 603 operates by the action of the output control circuit 602, and the load connected to the output terminal 615 is driven. At the same time, the output operation indicator lamp 611a is driven. The setting indicator lamp 611b is also driven by the action of the output control circuit 602. The constant voltage circuit 617 supplies constant voltage power to each circuit of the output circuit assembly 600 and the detection circuit assembly 500.

  FIG. 20 shows the entire electric circuit of the proximity sensor configured using the detection circuit assembly (fourth embodiment) 500 shown in FIG. 15 and an output circuit assembly (second embodiment) manufactured separately. Has been.

  Since the detection circuit assembly (fourth embodiment) 500 has already been described in detail with reference to FIG. 15, duplication of the configuration description and the operation description is avoided.

  The second embodiment of the output circuit assembly 600 corresponds to a direct current two-wire output system. That is, in the figure, 601 is a logic circuit, 602 is an output control circuit, 603 is an output transistor, 608 is a short circuit protection circuit, 609 is a power reset circuit, 610 is a display circuit, 611 is an operation indicator lamp, and 615 and 616 are output circuits. A power supply terminal and an output terminal for the assembly 600, 612 and 614 are constant voltage terminals for supplying driving power to the detection circuit assembly 500, and 613 is a detection for receiving a signal from the detection signal output terminal 509 of the detection circuit assembly 500. A signal input terminal 617 is a constant voltage circuit. Reference numeral 618 denotes a custom IC (integrated circuit) in which the main circuit of the output circuit assembly 600 is built in one chip.

  In the figure, a detection signal taken into the output circuit assembly 600 via the detection signal input terminal 613 is logically processed by the logic circuit 601 and then supplied to the output control circuit 602. At this time, the discrimination level of the discrimination circuit 503 can be finely adjusted by operating the variable resistor 522. Therefore, by using this adjustment function, even if the detection circuit assembly 500 has already been adjusted, an optimum detection distance can be set by further fine adjustment. When the detection signal obtained through such fine adjustment is input to the terminal 613, the output transistor 603 operates by the action of the output control circuit 602, and the load connected to the output terminal 615 is driven. At the same time, the display circuit 610 operates and the operation indicator lamp 611 is driven. The constant voltage circuit 617 supplies constant voltage power to each circuit of the output circuit assembly 600 and the detection circuit assembly 500.

  As is apparent from FIGS. 16 to 20 described above, according to the present invention, the same detection circuit assembly 500 can be used for products having different power supply specifications and output forms.・ Easy production. As a result, the development cost is reduced, the development period is shortened, the number of parts is reduced, the delivery time management cost / part cost is reduced by procurement of small and large parts, and the number of detection end modules is much smaller than the number of proximity sensor models. In addition, various effects such as unification of production facilities by using output circuit modules and reduction of production lead time and production cost by reduction of setup change can be obtained.

  In FIG. 21, two detection circuit assemblies (first embodiment) 500 shown in FIG. 12 are prepared, and one output circuit assembly (third embodiment) 600 manufactured separately is prepared. The entire electrical circuit of the proximity sensor is shown.

  Note that the detection circuit assembly (first embodiment) 500 has already been described in detail with reference to FIG.

  In the figure, 630 is a custom IC, 631 and 634 are terminals for supplying stabilized power to the detection circuit assembly 500, 632 and 633 are detection signal input terminals for receiving detection signals from the detection circuit assembly 500, and 635 and 636 are respectively DC power supply terminal and output terminal for the output circuit assembly 600, 637 is a logic circuit that performs logical operation of two systems of detection signals, 638 is an output control circuit, 639 is an output transistor, 640 is the output circuit assembly 600 and detection A constant voltage circuit for supplying a stabilized DC power to both circuit assemblies 500, 641 is a short circuit protection circuit, 642 is a power reset circuit, 643 is a display circuit, and 644 is an operation indicator lamp.

  As shown in the figure, in this proximity sensor circuit, two detection circuit assemblies (first embodiment) 500 are connected in parallel, and each constant voltage power supply terminal 508, 510 is connected to an output circuit group. The detection signal output terminal 509 is connected to the detection signal input terminals 632 and 633 of the output circuit assembly 600. Then, the detection signals given to the input terminals 632 and 633 are logically processed by the logic circuit 637 (for example, a process of outputting a signal when any of the detection circuit assemblies detects an object), and an output control circuit A detection signal is sent to 638. Subsequent operations are as described above with reference to FIG.

  According to the circuit configuration shown in FIG. 21 described above, two proximity sensors have been used so far for the user needs of multipoint detection, but the detection function is separated from the output circuit function. Since a plurality of detection circuit assemblies 500 are combined and connected to one output circuit assembly 600, circuits corresponding to one output block can be reduced, so that the production cost can be reduced. Further, since only the detection circuit assembly whose detection sensitivity is adjusted is combined, the complicated adjustment of adjusting the detection sensitivities in a state where the multipoint head is incorporated is not necessary.

  Next, the feature points of the proximity sensor according to the present invention will be described more specifically from the viewpoint of commercialization. In the above description, the proximity sensor of the present invention resonates the detection coil assembly 404 having the characteristics including the coil 401, the core 402, and the mask conductors 406 to 412, and the coil 401 of the detection coil assembly 404. It will be understood that the sensing circuit assembly 500 includes an oscillation circuit as a circuit element, and the output circuit assembly 600 includes a power element for driving a load.

  Here, the meaning of the term “assembly” corresponds to an assembly in English and indicates a state in which magnetic parts, circuit parts, structural parts, and the like are assembled together. In a commercialization system to which the present invention is applied, those assemblies are preferably modularized into several units so as to be easier to handle.

  Specifically, the detection coil assembly 404 and the detection circuit assembly (circuit board on which the detection circuit is mounted) 500 are physically integrated using a resin molding technique or the like, thereby providing a detection end module. The

  On the other hand, the output circuit assembly 600 itself can be called an output circuit module. When a member for fixing the output circuit assembly in the case is attached to the output circuit assembly, the member including the member can also be called an output circuit module.

  In consideration of flexibly responding to various product variations, the mounting circuit of the detection end module will include at least an oscillation circuit component. In addition, the power circuit will be included in the mounting circuit of the output circuit module.

  However, it is not always possible to discuss unconditionally which module includes other circuit elements (in particular, an integration circuit, a discrimination circuit, a constant voltage circuit, and a logic circuit). This can be easily understood by referring to the circuit variations shown in FIGS. It may be considered that the circuit function is divided into an output circuit module and a control circuit module, and each of them is a separate module.

  That is, according to the present invention, the following proximity sensor commercialization system can be realized. In this commercialized system, a detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil of the detection coil assembly as a resonance circuit element, and an output having a power element for driving a load A circuit module and a control circuit assembly for controlling the operation of the output stage circuit according to the oscillation state of the oscillation circuit are prepared.

  The detection coil assembly and the detection circuit assembly are integrated to form a detection end module. At this time, it is preferable that a mask conductor is incorporated in the detection coil assembly of the detection end module so that the detection output does not vary greatly no matter what case body is attached.

  Output circuit modules are prepared according to specifications such as output format and power supply voltage.

  The control circuit assembly is integrated into the detection end module side or the output circuit module side in a lump, or is divided into the detection end module side and the output stage module side as appropriate, and further is itself a control circuit. Configure the module.

  Thus, a product is prepared by combining one detection end module and one output circuit module selected from a group of output circuit modules corresponding to the detection end module.

  A production process corresponding to a specific example of the proximity sensor commercialization system according to the present invention is shown in FIG. In the figure, in the first step (A), a coil 701, a ferrite core 702, and a detection circuit mounting substrate 703 in which circuit components such as an oscillation circuit are mounted on a small rectangular substrate are prepared, and these are integrated. The assembled product 704 is obtained by assembling.

  In the next step (B), laser beam irradiation is performed on a part to be electrically connected to the product 704 that is in the middle of assembly, thereby soldering the corresponding part of the product 704 that is being assembled.

  In the next step (C), an operation confirmation test and an appearance inspection are performed on the intermediate product 704 that has been soldered.

  In the next step (D), a coil case 705 in which an assembling product 704 is to be accommodated is prepared and filled with, for example, polyurethane resin to prepare for mold integration. In this example, a mask conductor made of brass, copper, aluminum, or the like (for example, the cylindrical mask conductor 407 with a flange shown in FIG. 3) is attached in advance to the outside of the coil case 705 along the outer periphery thereof. ing.

  In the next step (E), an assembling product 704 is placed in a coil case 705 filled with resin.

  In the next step (F), for example, the resin is cured by leaving it at room temperature for about 1 hour to obtain the detection end module 706.

  In the next step (G), laser trimming technology is used to adjust the distance so that the operation is reliably performed at a specified distance. At this time, the adjustment can be performed without attaching the main body case, and there is no need to consider various problems due to the mounting of the dummy case as in the prior art. This is because the detection characteristics hardly change regardless of the presence or absence of the main body case because the mask conductor is incorporated in the detection end module 706.

  In this way, the detection end module 706 is completed in which the presence or absence of the main body case does not significantly affect the detection characteristics, in other words, the characteristics are complete.

  In the next step (H), a characteristic inspection is further performed to ensure reliability, and an inspected detection end module 707 is obtained.

  The detection end module 707 is also suitable for shipping as a completed part for use in proximity sensors. Further, the detection end module 707 manufactured by another supplier may be obtained and the manufacture of the proximity sensor may be started from the next step (I).

  In step (I), the inspected detection end module 707 obtained above, a connection member 708 between the detection circuit and the output circuit, and a separately manufactured output circuit mounting board (output circuit module) 709 are prepared, Using solder or a conductive adhesive, they are thermocompression-bonded and integrated to obtain an intermediate product 710 with an entire circuit.

  In the next step (J), an assembly-finished product with an entire circuit 710, a cylindrical main body case (metal or resin) 711, and an output circuit mounting board 709 (output circuit module) are held and the light of the indicator lamp (LED) is emitted. An output circuit module support member (cord clamp) 712 to be led out to the outside is prepared, and these are press-fitted and integrated to obtain an intermediate product 713 with case.

  In the next step (K), the case and the parts are integrated by injecting and curing the resin with the case-assembled product 713 obtained above.

  In the next step (L), the cord 714 is soldered to the case-under-assembly product 713 integrated by resin injection to complete the cord-in-assembly product 715.

  In the next step (M), the cord 714 is securely protected by covering the lead end of the cord 714 with a cord holding portion (protector) 716 to perform a protector molding process.

  In the last step (N), withstand voltage and characteristic inspection are performed, and the proximity sensor product 717 is completed.

  A specific example of the proximity sensor manufactured through the steps (A) to (N) will be described with reference to FIGS. 38 to 44.

  FIG. 38 is an exploded perspective view showing a shield-type proximity sensor created through the steps (A) to (N). In addition, the code | symbol shown in the figure respond | corresponds to what was shown in FIG.

  The proximity sensor includes a coil (spool) 701, a ferrite core 702, and a detection circuit assembly 703 that constitute the intermediate product 704 in the steps (A) to (C), and the steps (D) to (H). A coil case 705 on which a mask conductor 700 is mounted that is mounted on an intermediate product 704 and forms a detection end module 707 (706), and an output circuit module that is electrically connected to the detection circuit assembly 703 in step (I). 709, a connecting member 708 that bridges and electrically connects the detection circuit assembly 703 and the output circuit module 709, and a cylindrical main body case 711 integrated with the coil case 705 in steps (J) to (K). And a cord clamp that holds the output circuit module 709 and is integrated with the main body case 711 (supporting the output circuit module) With product) 712, a code 714 that is soldered to the cord clamp 712 in step (L), and a cord holding portion 716 attached as a protector for the code 714 in the step (M).

  FIG. 39 shows a detailed configuration of the detection end module 707 shown in FIG. In the figure, (a) is a perspective view of the detection end module 707, (b) is a central sectional view of the detection end module 707, and (c) is an enlarged view of a portion “A” shown in (b) in the figure. Figures are shown respectively.

  In addition, illustration of a coil winding is abbreviate | omitted in (b) in the figure. For the detection circuit assembly 703, only the cross section of the board is shown by hatching, and only the cross section of the components on the board is schematically shown. The same applies to FIGS. 40 to 44 described later.

  As shown in FIG. 39, in this example, a mask conductor 700 is provided at the tip of the outer peripheral surface of a bottomed cylindrical coil case 705. The mask conductor 700 is of the type (cylindrical cylindrical shape) previously shown in FIG. 33 (modified example of the second embodiment). As shown in (b) in the figure, in this example, the ridge end 700a of the mask conductor 700 protrudes outward. By disposing the mask conductor on the outer peripheral surface of the coil case 705 in this way, discharge between the mask conductor and the sensor internal circuit is avoided.

  Further, as shown in (a) in the figure, in this example, it is confirmed that the cross-shaped detection circuit assembly 703 is arranged in an upright state inside the center of the coil case 705.

  Cross-sectional views of the proximity sensor 717 shown in FIG. 38 are shown in FIGS.

  In the figure, for the output circuit module 709, only the cross section of the substrate is shown by hatching, and only the cross sectional shape of components (including the LED 709a) on the substrate is schematically shown. Further, the shape of the cord clamp (output circuit module support member) 712 is schematically shown as a partially broken body. The same applies to FIGS. 43 and 44 described later.

  In this example, two types of main body cases 711 are prepared: a short type 711A (see FIG. 40) with a short overall length and a long type 711B (see FIG. 41) with a long overall length. FIG. 40 shows a proximity sensor 717A using a short type 711A, and FIG. 41 shows a proximity sensor 717B using a long type 711B.

  As is clear from the comparison between FIG. 40 and FIG. 41, in this example, by using a common flexible connection member (connection member such as a harness having a variable connection length) 708, other component configurations are changed. It is possible to install either the long or short body case. Note that which type of main body case is to be mounted is appropriately determined in consideration of the environment in which the proximity sensor is used.

  More specifically, the connection member 708 is a connection in which polyimide is used as a base material and the number of parallel wires necessary for electrically connecting the detection end module 707 and the output circuit board module 709 is formed thereon. It is a harness (flexible substrate) whose length is variable. As the connection member 708, a simple lead wire, a rigid glass epoxy substrate, or the like can be used.

  In this example, the center of the connection member 708 is formed in a mountain shape. When the short-type main body case 711A is mounted, as shown in FIG. 40, the assembled connection member 708 maintains the shape as it is formed. On the other hand, when the long-type main body case 711B is mounted, the formed portion of the connection member 708 is gently extended. In this example, when applied to the short-type main body case 711A, consideration is given so that the connecting member 709 does not contact the inner surface of the main body case 711A.

  Thus, the total length and the forming shape of the connecting member 708 are defined in advance so as to be applicable to both the short type main body case 711A and the long type main body case 711B. Therefore, since one type of connection member can be used regardless of the length of the main body case 711, inventory management of the connection member and cost reduction are facilitated. Also,

  In addition, you may make it prepare a connection member for the long type 711A and the short type 711B separately for the optimal length. For example, it is assumed that a connecting member having a length suitable for a main body case used for sensor assembly is cut out from a long flexible substrate roll and used each time.

  The cord clamp 712 will be described. The cord clamp 712 is formed of a transparent resin. In this example, the light emitted from the LED 709a provided on the circuit board of the output circuit module 709 is led out to the outside. It is configured as follows. That is, the cord clamp 712 is provided with a rectangular hole (through hole), from which a part of the circuit board (a portion where the electric cord 714 is soldered) is exposed. The circuit board is fixed to the cord clamp 712 with heat caulking.

  Next, non-shielded proximity sensors produced through steps (A) to (N) shown in FIG. 22 are shown in FIGS.

  FIG. 42 is a diagram illustrating details of the detection end module 707 related to the non-shielded proximity sensor. The assembly parts (700 to 716) have the same configuration as that of the shield type shown in FIG.

  42A is a perspective view of the non-shield type detection end module 707, FIG. 42B is a central sectional view of the detection end module 707, and FIG. 42C is a portion shown in FIG. 42B. Each enlarged view of “B” is shown.

  The ferrite core 702 used in this example has a T-shaped cross section, and since the ferrite core 702 does not exist outside the coil spool 701, the shield effect is inferior, but the detection distance (detection performance) is of the shield type. Has been improved. Further, in this example, the type (cylindrical cylindrical shape) mask conductor 700 previously shown in FIG. 36 (modified example of the fifth embodiment) is provided at the rear end portion of the outer peripheral surface of the coil case 705.

  43 and 44 show assembly sectional views of this non-shielded proximity sensor. 43 shows a case where the short type 711A is used as the main body case, and FIG. 44 shows a case where the long type 711B is used as the main body case. As is clear from these drawings, in this non-shielded proximity sensor, the tip surface of the coil case 705 protrudes more forward than the main body case 711 as compared to the shield type. Is understood.

  Even in a non-shielded proximity sensor, by using a common flexible connecting member 708, it is possible to mount either a long type or a short type main body case without changing other component configurations. Note that the connection member 708 is the same as that used in the shield type, and the details are omitted.

  Next, the model selection support method according to the present invention as a business method related to the sale of the proximity sensor described above will be described.

  FIG. 45 is a diagram showing an overall configuration of a model selection support system as an embodiment for realizing the model selection support method. To briefly explain the above, this model selection support system selects one from each of a plurality of types of detection end modules, output circuit modules, and main body cases prepared in advance, and a combination of them selects the customer's request. In order to provide a proximity sensor model that satisfies the specifications, it is intended to assist customers in selecting sensor models via the Internet.

  As shown in the figure, this model selection support system includes a customer-side computer terminal 1602, a support server 1601 that provides the customer-side computer terminal 1602 with various Web pages to be described later for model selection support, It comprises a communication network (Internet) 1600 connecting the customer side computer 1602 and the support server 1601.

  The support server 1601 has a model specification database 1601a. The database 1601a stores various specification data necessary for configuring the contents of various Web pages related to model selection support.

  The customer-side computer terminal 1602 is a commercially available personal computer, and displays a Web page provided from a server by executing a browser by a customer operation.

  FIG. 46 is a diagram showing a list of specifications of the detection end modules prepared in the model selection support system of the present embodiment in a table format. In this example, detection end modules (a total of 42 types) having specifications corresponding to ◯ marks are prepared.

  In the figure, “M8”, “M12”, “M18”, “M30” are the outer diameter types, “distance range × 1”, “distance range × 1.5”, and “distance range × 2” are detection distances. Each type is shown. Each detection distance type is further classified into four types based on the types of shield / non-shield, standard frequency / different frequency.

  For example, a circle in the upper left corner means a detection end module having a specification that the outer diameter of the coil is M8, the distance range is 1 time, the shield is provided, and the standard frequency.

  “M8” means that the size is suitable for the main body case of the M8 specification. The same applies to M12, M18, and M30.

  “Shield” means that it can be combined with a shield case (with shield). “Non-shielded” means that it can be combined with a non-shielded (unshielded) body case.

  “Standard frequency” and “different frequency” relate to the oscillation frequency of the detection circuit. Normally, a proximity sensor with an oscillation frequency specification corresponding to the standard frequency is used, but when it is desired to avoid mutual interference with other proximity sensors, a proximity sensor with an oscillation frequency specification corresponding to a different frequency is used.

  FIG. 47 is a diagram showing the correspondence relationship between the distance range magnification (× 1, × 1.5, × 2) and the detection distance (in mm) in a table format.

  “Distance range magnification” is a simple expression of the detection distance. As shown in FIG. 47, for each combination of outer diameter and shield / non-shield, three types of detection distances expressed as a distance range of 1, 1.5, and 2 are defined. .

  FIG. 48 is a diagram showing a list of specifications of the main body case prepared in the model selection support system of the present embodiment in a table format. In this example, main body cases (22 types in total) having specifications corresponding to ◯ marks are prepared.

  In the figure, “M8”, “M12”, “M18”, and “M30” indicate the outer diameter types, and “Short body” and “Long body” indicate the specification types for the length of the main body case, respectively. Each specification type is further classified into four types based on the types of stainless steel / brass and shield / non-shield.

  “M8” means that an M8 metric screw is formed on the outer surface of the main body case. The same applies to M12, M18, and M30.

  “Stainless steel” and “brass (brass)” indicate the material type of the main body case.

  “Shield” means a shield main body case that covers the side surface of the coil case. “Non-shielded” means a non-shielded main body case having a shape exposing the side surface portion of the detection coil.

  FIG. 49 is a table showing a list of specifications of the output circuit module prepared in the model selection support system of this embodiment. In the figure, an output circuit module having a specification corresponding to a circle is prepared. However, the vertical circles indicate the same type of output circuit modules. That is, the same output circuit module is used for any outer diameter (M8 to M30). Therefore, the number of types of output circuit modules is represented by the number of columns in the table, and a total of 15 types are prepared as shown in FIG.

  In the figure, “PNP open collector output”, “NPN open collector output”, “DC 2-wire”, “NPN voltage output”, and “PNP voltage output” indicate the specification types of output forms. The specifications other than the DC 2-wire are the output forms of the DC 3-wire.

  Furthermore, the specification types based on the above output forms are classified into four types based on the types of NO (normally open), NC (normally closed), DC10-30V, DC10-55V, or no self-diagnosis / with self-diagnosis, respectively. ing.

  Here, “NO (normally open)” and “NC (normally closed)” indicate the specifications of the operation mode, and “DC10-30V” and “DC10-55V” indicate the specifications of the operating voltage range, respectively. . “With self-diagnosis” and “Without self-diagnosis” indicate the presence / absence of a function for diagnosing whether or not a predetermined type of failure has occurred in itself (proximity sensor) and notifying the result to the outside. ing.

  In the present embodiment, a proximity sensor can be configured by selecting one connection method from a plurality of connection methods prepared. FIG. 50 shows a list of specifications of connection methods prepared in the model selection support system of the present embodiment in a table format.

  In the figure, connection methods (22 types in total) having specifications corresponding to the circles are prepared. For the connection method, any of the pre-wire 2m, pre-wire 5m, special cable 2m, connector relay M12, M12 connector 4pin, connector relay M8, M8 connector 4pin can be specified for each outer diameter (M8 to M30). it can.

  Here, “pre-wire 2 m” and “pre-wire 5 m” mean a cord drawing system having cords of 2 m and 5 m in length, respectively. “Special cable 2 m” means a cord drawing system having a special cable having a length of 2 m. “Connector relay M12”, “M12 connector 4pin”, “connector relay M8”, and “M8 connector 4pin” mean a connector connection method, and indicate the type of connector used.

  The contents of the data for each sensor model stored in the model specification database 1601a are shown in a table format in FIG.

  In the figure, “Sensor 1”, “Sensor 2”, and “Sensor 3” represent the serial numbers of sensor models of proximity sensors that can be provided by the combination of the specifications of each component described above. Although only “Sensor 3” is shown in the figure, there are actually 10,000 or more sensor models. In this database, the specification contents (detection method, shape, etc. shown in the “item” column in the figure) are registered for every sensor model. In addition to the specifications, the “Item” column also shows the format (model name, “catalog format” in FIG. 51), standard price, standard stock model or order-made model. It is registered.

  The contents of the detection end module specification data, main body case specification data, and output circuit module specification data for creating the database (model specification database) shown in FIG. 51 are shown in a table form in FIG.

  As shown in FIG. 5A, in this example, specification data for each type of detection end module is prepared. The same applies to the main body case and the output circuit module (see (b) and (c) in the figure). Although illustration is omitted, specification data is also prepared for the connection method. Hereinafter, these specification data are collectively referred to as module specification data. The module specification data is stored in a storage device of an arbitrary computer (not limited to the server in FIG. 1) on the proximity sensor provider side.

  The model specification database shown in FIG. 51 is created by combining module specification data using a computer corresponding to possible combinations of detection end module, main body case, output circuit module, and connection method. A method for creating a model specification database according to the present invention will be described below.

  The method of combining module specification data differs depending on the “item” in the model specification database. For many items in the model specification database, the contents of the specification data items of the detection end module, main body case, output circuit module, and connection method are copied as they are.

  For some items in the model specification database, the values of the specifications of the proximity sensor may be obtained by calculating numerical values of a plurality of specification data. For example, the current consumption of the proximity sensor is obtained by adding the current consumption of the detection end module and the current consumption of the output circuit module. In such a case, a rule is previously determined as to which item in the model specification database is copied from which module specification data item, and which item in the model specification database is obtained by what operation.

  Some of the items in the model specification database are not based on the specification data but the contents thereof are input separately. The above-mentioned distinction between standard price and standard stock model or made-to-order model is an example. The format is automatically created from the specification data by defining a naming rule based on the specification of the proximity sensor.

  Whether or not a specific combination of the detection end module, the main body case, the output circuit module, and the connection method is possible is determined with reference to the prohibition information stored in the storage device of the computer on the provider side.

One of the prohibition information relates to the combination of the detection end module and the main body case. The prohibition information in this case is, for example, the following condition, and a combination corresponding to any of them is “prohibited”.
・ "Outside diameter (size) is different"
・ "Shield type or non-shield type is different"

  Prohibition information is also provided for the combination of the detection end module and the output circuit module, the combination of the main body case and the connection method, the combination of the output circuit module and the connection method, and the combination of the main body case and the output circuit module as necessary.

  A computer program for executing the model specification database creation method described above is prepared in the storage device on the proximity sensor provider side, and the model specification database 1601a is created by executing this program.

  The outline of the operation contents of the server 1601 related to the model selection support is shown in the flowchart of FIG. When requested by the customer's computer, the server 1601 first transmits a model selection Web screen to the customer's computer (step 5301).

  An example of a model selection screen displayed on the customer computer 1602 is shown in FIG. A plurality of specification items (outer diameter, case material, shield, detection distance, etc.) are displayed on the model selection screen. The customer selects desired specification contents from a pull-down menu prepared for each specification item. As an example of the pull-down menu display on the right side of the figure, the display modes for the specification items “outer diameter” and “output form” are shown side by side. In addition, a list of specification contents prepared for each specification item is shown in a table form in FIG.

  In FIG. 55, “detection distance” which is one of the specification items is designated by a distance range. In this case, the proximity sensor within the range in which the detection distance specification is designated is searched.

  In this example, “not specified” is initially displayed for all specification items. Customers can enter only the specification items that they consider important for their application. When the input is completed, the customer clicks the “Search” button on the model selection screen shown in FIG. 54 to instruct execution of the search (Step 5302 in the flowchart of FIG. 53). As a result, the server 1601 searches the model specification database 1601a for a sensor model corresponding to the input specification condition, and transmits a search result screen to the corresponding customer computer 1602 (step 5304).

  An example of the search result screen displayed on the customer side computer 1602 is shown in FIG. This example shows a case where there are four sensor models corresponding to the input specification conditions. On the left side of the screen, a model name (E2E-X7D1, etc.) is displayed as sensor model identification information.

  In the model selection screen shown in FIG. 54, the operation mode (NO, NC) cannot be input (not applicable to some specification conditions that can be input), but as shown in FIG. 56, the specification condition search is performed. The operation screen (NO, NC) is shown on the result screen. If the sensor model is a standard stock, a mark (in this example, ◎) is displayed in the item “standard stock” column, and is displayed preferentially in the upper part of the list. A model without the standard stock model mark is a build-to-order model, and is displayed at the lower level than the standard stock model. In this example, the delivery date of each model is also displayed.

  In this example, the order method (purchase method) is guided through the search result screen, such as “Please order products from XX Co., Ltd.”. At this time, “XX Co., Ltd.” is set as a link to the Web page of the company.

  On the search result screen, when the display portion of the format name such as “E2E-X7D1” is clicked by the customer, the server 1601 transmits the individual information of the model specified by the selected format name (FIG. 53). In the flowchart of step 5307). Thereby, the model individual information screen is displayed on the customer side computer. On the other hand, when the “return” button is clicked by the customer on the search result screen, the previous model selection screen (FIG. 54) is displayed again on the customer-side computer terminal 1602.

  An example of the model individual information screen is shown in FIG. On this screen, the specification table indicated by symbol A in the figure, the detection characteristic graph indicated by symbol B (the material of the target object is a parameter, the horizontal axis is the length of one side of the detection distance, and the vertical axis is the distance graph. ), A time chart indicated by symbol C (a graph showing the ON / OFF of the setting indicator lamp and the operation indicator lamp and the ON / OFF state of the control output with the distance to the detection distance as the horizontal axis), the output indicated by symbol D A circuit diagram showing a circuit system and an external dimension diagram indicated by symbol E are displayed. When the “return” button is selected (clicked) on this screen, the search result screen shown in FIG. 54 is displayed again.

  The customer can easily select the desired proximity sensor model through the model selection support system. In addition, since the model selection support system shown in the present embodiment uses the Internet, any number of people can easily use it without worrying about time. Of course, it is also possible to define a usage system such that only a previously contracted one can be used using a password or the like.

  Note that various types of product purchase application modes after model selection are applicable. For example, the purchase selection method may be guided by e-mail, telephone, facsimile, or mail through this model selection support system. As another example, after a model satisfying the specification condition is presented via the customer-side computer 1602, a purchase application for the presented model may be accepted on the Internet. In addition to this, a person skilled in the art will envisage various things.

  Finally, details (contents) of the detection characteristic graph of the proximity sensor (detection coil assembly) shown in FIG. 2, FIG. 4, FIG. 7, and FIG. 9 will be described. Here, in order to further clarify the present invention, although partially overlapping with the description so far, actual measurement of each of the conventional proximity sensor (see FIG. 58 (a)) and the proximity sensor according to the present invention. A detection characteristic graph based on the result is shown, and the practicality of the present invention is verified at the implementation level through comparison between the two.

  59 shows a detection characteristic graph obtained using the conventional proximity sensor, and FIG. 60 shows a detection characteristic graph obtained using the proximity sensor according to the present invention. Note that the conventional proximity sensor is applied with a detection coil assembly 1000 whose outline is shown in FIG. Further, the detection coil assembly 404 previously shown in FIG. 36 is applied to the proximity sensor according to the present invention. Both detection coil assemblies are of the unshielded type, and the only difference between them is the presence or absence of the mask conductor 4100.

The terms used in the detection characteristic graph are defined as follows.
“In”: Distance from the detection surface of the proximity sensor to an arbitrary detection target object (reference numeral M1 in FIG. 58) (graph horizontal axis (mm))
“Ion”: Distance (rated detection distance) to the detection target object (symbol M2 in the figure) when the output is reversed in the presence / absence detection (binarization) type proximity sensor
“G”: Conductance values at both ends of the LC resonance circuit (vertical axis of graph) constituted by connecting the coil 1001 (401) of the detection coil assembly to the resonance capacitor 1006 (505) as shown in FIG. (G))
“Gon”: Conductance value (threshold value) when the output is inverted in the proximity sensor of presence / absence detection

  In the detection characteristic graphs (FIGS. 59 and 60), the curve indicated by “characteristic a” represents the change in conductance value (g) when measured using a resin case as the main body case, as “characteristic b”. The curve shown is a change in conductance value (g) when measured with a main body case made of brass C3604, and the curve shown by "characteristic c" is a conductance value (g) when measured with a main body case made of stainless steel SUS303. Each change is shown.

  Further, a point A on the characteristic a curve, a point B on the characteristic b curve, and a point C on the characteristic c curve indicate the intersections of the straight line In = 4 (mm) and each characteristic curve. A point D on the characteristic b curve and a point E on the characteristic c curve indicate the intersections of the straight line g = gon and each characteristic curve.

  Here, a case where the threshold value gon is set so that the rated detection distance Ion when the resin main body case is used is 4 mm is taken as an example.

  As shown in FIG. 59, when a brass main body case is used in a conventional proximity sensor, the detection distance is 4.8 mm indicated by a point D on the characteristic b curve when the threshold value gon is the same. That is, the detection distance becomes longer by 0.8 mm (ΔI1) than when a resin main body case is used. Further, when a stainless steel body case is used in the conventional proximity sensor, the characteristic c curve does not intersect the straight line ‘(g) = gon’ in the case of the same threshold value gon. That is, it can be said that the detection distance becomes longer by ∞ mm (ΔI2) than when the resin main body case is used.

  Thus, in the conventional proximity sensor, the detection distance variation ΔI due to the difference in the main body case was as large as ± 20% (0.8 mm to ∞ / 4.0 mm) or more, so the main body case made of brass was attached. In this case, the threshold value gon is increased by Δg1 (difference in conductance between point A and point B), and when a stainless steel body case is attached, the threshold value gon is increased by Δg2 (point C and point A). It was necessary to adjust the rated detection distance Ion (4 mm) by increasing the difference in conductance value).

  On the other hand, as shown in FIG. 60, in the proximity sensor of the present invention, when the threshold value gon is constant, the detection distance is 3.8 mm (point D) in the brass body case, and the stainless steel body case Then, the detection distance is 4.2 mm (point E in FIG. 60), and the difference is as small as ± 0.2 mm (ΔI1, ΔI2) compared to 4 mm when the resin main body case is used. That is, the detection distance fluctuation ΔI due to the main body case material is ± 5% (1/4 of the conventional one). This proves that the detection characteristics of the proximity sensor according to the present invention are hardly influenced by the material of the main body case in comparison with the proximity sensor having no conventional mask conductor.

  For this reason, in the present invention, after the main body case is attached, the troublesome work of changing the threshold value gon and readjusting the rated detection distance Ion is unnecessary, and as a result, (1) design man-hours and costs as described above are reduced. It can be reduced, (2) it is possible to consolidate parts, and the cost of parts can be reduced, (3) it is possible to produce different types of proximity sensors in the same line and process, and (4) the variation in detection distance can be reduced. (5) It is possible to obtain various effects such as (5) simplification of the assembly position alignment of the sensor unit and the main body case, and (6) simplification of the adjustment method of the detection distance.

  As described above, the present invention is useful as an inductive proximity sensor that detects the approach of a metal body or the like in a non-contact manner through a magnetic field, and in particular, can flexibly meet user needs while suppressing manufacturing costs. It is suitable for realizing a rich product lineup that can be handled.

It is structure explanatory drawing of 1st Embodiment of a detection coil assembly. It is a graph which shows the detection characteristic of 1st Embodiment (shield type / cylindrical mask conductor) of a detection coil assembly. It is structure explanatory drawing of 2nd Embodiment of a detection coil assembly. It is a graph which shows the detection characteristic of 2nd Embodiment (shield type / shape mask conductor with a flange) of a detection coil assembly. It is structure explanatory drawing of 3rd Embodiment of a detection coil assembly. It is structure explanatory drawing of 4th Embodiment of a detection coil assembly. It is a graph which shows the detection characteristic of 4th Embodiment (non-shielding type / cylindrical mask conductor) of a detection coil assembly. It is structure explanatory drawing of 5th Embodiment of a detection coil assembly. It is a graph which shows the detection characteristic of 5th Embodiment (non-shielding type / flange shape mask conductor) of a detection coil assembly. It is structure explanatory drawing of 6th Embodiment of a detection coil assembly. It is structure explanatory drawing of 7th Embodiment of a detection coil assembly. It is a circuit diagram showing a first embodiment of a detection circuit assembly. It is a circuit diagram which shows 2nd Embodiment of a detection circuit assembly. It is a circuit diagram which shows 3rd Embodiment of a detection circuit assembly. It is a circuit diagram which shows 4th Embodiment of a detection circuit assembly. It is a circuit diagram (the 1) which shows the whole structure of the proximity sensor circuit comprised combining the detection circuit assembly (1st Embodiment) and the output circuit assembly (1st Embodiment). It is a circuit diagram (the 2) which shows the whole structure of the proximity sensor circuit comprised combining the detection circuit assembly (1st Embodiment) and the output circuit assembly (2nd Embodiment). It is a circuit diagram (the 3) which shows the whole structure of the proximity sensor circuit comprised combining the detection circuit assembly (2nd Embodiment) and the output circuit assembly (3rd Embodiment). It is a circuit diagram (the 4) which shows the whole structure of the proximity sensor circuit comprised combining the detection circuit assembly (3rd Embodiment) and the output circuit assembly (4th Embodiment). It is a circuit diagram (the 5) which shows the whole structure of the proximity sensor circuit comprised combining the detection circuit assembly (4th Embodiment) and the output circuit assembly (2nd Embodiment). It is a circuit diagram (the 6) which shows the whole structure of the proximity sensor circuit comprised combining the 2 detection circuit assembly (1st Embodiment) and the output circuit assembly (3rd Embodiment). It is process drawing which shows the manufacturing process of the proximity sensor using the detection end module which concerns on this invention. It is structure explanatory drawing of the prior art example 1 of a detection coil assembly. It is a graph which shows the detection characteristic in the case of the prior art example 1 (shield type / no cylindrical member) of a detection coil assembly. It is structure explanatory drawing of the prior art example 2 of a detection coil assembly. It is a graph which shows the detection characteristic in the case of the prior art example 2 (non-shielding type / no cylindrical member) of a detection coil assembly. It is a block diagram which shows the circuit structure of the direct current | flow 3-wire type proximity sensor equivalent to the prior art example 1. FIG. It is a block diagram which shows the circuit structure of the direct current | flow 2-wire type proximity sensor equivalent to the prior art example 2. FIG. It is a circuit diagram which shows the specific structure of the oscillation, integration, and discrimination circuit in the prior art example 2. 10 is an operation time chart in Conventional Example 2. It is process drawing which shows the conventional manufacturing process. It is a figure which shows the modification of 1st Embodiment of a detection coil assembly. It is a figure which shows the modification of 2nd Embodiment of a detection coil assembly. It is a figure which shows the modification of 3rd Embodiment of a detection coil assembly. It is a figure which shows the modification of 4th Embodiment of a detection coil assembly. It is a figure which shows the modification of 5th Embodiment of a detection coil assembly. It is a figure which shows the modification of 6th Embodiment of a detection coil assembly. It is a disassembled perspective view which shows the shield type proximity sensor manufactured by the manufacturing method of the proximity sensor of this invention. It is a figure which shows the detailed structure of the shield type detection end module manufactured by the manufacturing method of the proximity sensor of this invention. It is sectional drawing of the shield type proximity sensor with which the short type main body case was attached. It is sectional drawing of the shield type proximity sensor with which the long type main body case was attached. It is a figure which shows the detailed structure of the non-shielding type detection end module manufactured by the manufacturing method of the proximity sensor of this invention. It is sectional drawing of the non-shield type proximity sensor with which the short type main body case was attached. It is sectional drawing of the non-shield type proximity sensor with which the long type main body case was attached. It is a figure which shows the whole structure of the model selection assistance system for implement | achieving the model selection assistance method of this invention. It is a figure which shows the specification list of the detection end module prepared by the model selection assistance system in a table format. It is a figure which shows the correspondence of distance range magnification and detection distance in a table format. It is a figure which shows the specification list of the main body case prepared by the model selection support system in a table format. It is a figure which shows the specification list of the output circuit module prepared with the model selection assistance system in a table form. It is a figure which shows the specification list of the connection system prepared by the model selection assistance system in a table format. It is a figure which shows the content of the data for every sensor model stored in a model specification database in a table format. It is a figure which shows the content of the detection end module specification data, main body case specification data, and output circuit module specification data for creating a model specification database in a table format. It is a figure which shows the outline of the operation | movement content of the server which comprises a model selection assistance system with a flowchart. It is a figure which shows an example of the model selection screen displayed on a customer side computer. It is a figure which shows the list of the specification content prepared for each specification item displayed on a model selection screen in a table format. It is a figure which shows an example of the search result screen displayed on a customer side computer. It is a figure which shows an example of the model separate information screen displayed on a customer side computer. It is a figure for demonstrating the terminology used by the structure and graph of the detection circuit assembly of the conventional proximity sensor. It is a detection characteristic graph obtained using the conventional proximity sensor. It is a detection characteristic graph obtained using the proximity sensor which concerns on this invention.

Explanation of symbols

401 Coil 402 Ferrite core 403 Coil case 403a Stepped portion 404 Coil assembly 405 Main body case (outer shell case)
406 Mask conductor 407 Masked mask conductor 407a Cylindrical main body portion 407b Toroidal collar portion 408 Toroidal mask conductor 409 Cylindrical mask conductor 410 Braided mask conductor 410a Cylindrical body portion 410b Mask mask 500 Detection circuit assembly 501 Oscillation circuit 502 Integration circuit 503 Discrimination circuit 504 Detection coil 505 Resonance capacitor 506 Adjustment circuit 507 Integration capacitor 508 Power supply terminal 509 Output terminal 510 Power supply terminal 511 Custom IC (integrated circuit)
513 Discrimination circuit 514, 515 Output terminal 516 Constant voltage circuit 517 Custom IC
518 Output terminal 519 Custom IC
520 Discrimination level variable circuit 521 External terminal 522 Adjustment variable resistor 600 Output circuit assembly 601 Logic circuit 602 Output control circuit 603 Output transistor 604, 605 Power supply terminal 606 Output terminal 607 Constant voltage circuit 608 Short circuit protection circuit 609 Power supply reset circuit 610 Display circuit 611 Operation indicator lamp 611a Output operation indicator lamp 611b Setting indicator lamp 612, 614 Constant voltage terminal 613 Detection signal input terminal 615, 616 Power supply terminal / output terminal 617 Constant voltage circuit 618 Custom IC (integrated circuit)
618a, 618b Detection signal input terminal 619 Logic circuit 620 Custom IC (integrated circuit)
621 Custom IC (Integrated Circuit)
630 Custom IC (Integrated Circuit)
631,634 Power supply terminal 632,633 Detection signal input terminal 635,636 Power supply terminal / output terminal 637 Logic circuit 638 Output control circuit 639 Output transistor 640 Constant voltage circuit 641 Short circuit protection circuit 642 Power supply reset circuit 643 Display circuit 644 Operation display Light 700 Mask conductor 700a Cone tip 701 Coil 702 Ferrite core 703 Detection circuit mounting board 704 In-assembly product 705 Coil case 706 Detection end module 707 Tested detection end module 708 Connection member 709 Output circuit mounting board (output circuit module)
709a LED
710 In-process product with entire circuit 711 Cylindrical body case 712 Output circuit module support member (code clamp)
713 Mid-assembly product with case 714 Code 715 Mid-assembly product with cord 716 Cord holder (Protector)
1001 Coil of detection coil assembly 1006 Resonant capacitor 1602 Computer terminal on customer side 1601 Support server 1600 Communication network (Internet)
1601a Model specification database 1000 Detector coil assembly 4060 Cylindrical mask conductor 4070 Braided mask conductor 4080 Circular mask conductor 4090 Cylindrical mask conductor 4100 Braided mask conductor 4110 Circular mask conductor

Claims (13)

A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil of the detection coil assembly as a resonance circuit element, and an output element based on an object detection signal output from the detection circuit assembly 1 module component for manufacturing a proximity sensor product having an output circuit assembly in which an output stage circuit to be driven is incorporated, and an outer shell case in which the assembly is housed,
Of the detection coil assembly, the detection circuit assembly, the output circuit assembly, and the outer shell case, the detection coil assembly and the detection circuit assembly are integrally coupled. Made into modular parts,
The detection coil assembly incorporates a mask conductor for reducing conductor detection sensitivity in a specific peripheral region where the outer shell case is assumed to exist, and the detection circuit assembly is an oscillation circuit of an oscillation circuit. It is structured to output a signal in a certain form according to the state to the outside of the module part as an object detection signal of the proximity sensor,
As a result, the proximity sensor product can be arbitrarily prepared by separately configuring the output circuit assembly outside the module component by appropriately using the object detection signal output from the detection circuit assembly. End module. A coil case for accommodating the coil and the core;
2. The detection end module according to claim 1, wherein the mask conductor is a conductive cylindrical body or annular body in the coil case and surrounding the coil and the core. A coil case for accommodating the coil and the core;
2. The detection end module according to claim 1, wherein the mask conductor is a conductive blocking plate in the coil case that partitions the coil and the back surface of the core. A coil case for accommodating the coil and the core;
The detection end module according to claim 1, wherein the mask conductor is a conductive cylindrical body or annular body that is outside the coil case and surrounds the coil and the core.   5. An output circuit assembly including a detection end module according to any one of claims 1 to 4 and an output stage circuit for driving an output element based on an object detection signal output from the detection end module. Proximity sensor product characterized by being electrically connected to an output circuit module. An output circuit module support member for supporting the output circuit module;
The detection end module is attached to one end side thereof, and the output circuit module support member is attached to the other end side thereof, whereby a cylindrical outer shell that holds the detection end module and the output circuit module with a space therebetween. Case and
A connection member interposed between the detection end module and the output circuit module and electrically connecting the two modules;
The proximity sensor product according to claim 5, further comprising: A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil as a resonance circuit element and outputting an object detection signal according to an oscillation state of the oscillation circuit, and an outer shell A first step of selecting one type of detection end module from a plurality of types of detection end modules integrated with a mask conductor for reducing the influence of detection characteristics due to the case;
A second step of selecting one type of output circuit module from a plurality of types of output circuit modules in which an output circuit for driving the output element based on the object detection signal is incorporated;
A third step of connecting the detection end module selected in the first step and the output circuit module selected in the second step;
A method for producing a proximity sensor product, comprising: A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil as a resonance circuit element and outputting an object detection signal according to an oscillation state of the oscillation circuit, and an outer shell A first step of selecting one type of detection end module from a plurality of types of detection end modules integrated with a mask conductor for reducing the influence of detection characteristics due to the case;
A second step of selecting one type of outer case from a plurality of types of outer cases that can be combined with the detection end module;
A third step of attaching the detection end module selected in the first step to the outer shell case selected in the second step;
A method for producing a proximity sensor product, comprising: A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil as a resonance circuit element and outputting an object detection signal according to an oscillation state of the oscillation circuit, and an outer shell A first step of selecting one type of detection end module from a plurality of types of detection end modules integrated with a mask conductor for reducing the influence of detection characteristics due to the case;
A second step of selecting one type of output circuit module from a plurality of types of output circuit modules in which an output circuit for driving the output element based on the object detection signal is incorporated;
A third step of selecting one type of outer shell case from a plurality of types of outer shell cases that can be combined with the detection end module;
The detection end module selected in the first step and the output circuit module selected in the second step are electrically connected, and the outer shell case selected in the third step is connected to the detection end A fourth step of attaching to the module;
A method for producing a proximity sensor product, comprising: A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil as a resonance circuit element and outputting an object detection signal according to an oscillation state of the oscillation circuit, and an outer shell A first step of preparing a detection end module integrated with a mask conductor for reducing the influence of detection characteristics due to the case;
A second step of preparing a plurality of types of outer shell cases that can be combined with the detection end module;
A third step of selecting one type of outer shell case from a plurality of types of outer shell cases prepared in the second step;
A fourth step of attaching the outer shell case selected in the third step to the detection end module prepared in the first step;
A proximity sensor product production method that enables the product to be shipped without adjusting the sensitivity of the detection end module for adapting to the outer shell case selected in the third step. A detection coil assembly including a coil and a core, a detection circuit assembly including an oscillation circuit having the coil as a resonance circuit element and outputting an object detection signal according to an oscillation state of the oscillation circuit, and an outer shell A detection end module integrated with a mask conductor for reducing the influence of detection characteristics due to the case, an output circuit module incorporating an output stage circuit for driving an output element based on an object detection signal, and an output circuit An output circuit module support member having a through hole for receiving the module and supporting the output circuit module, and a detection end module attached to the front end side and an output circuit module support member attached to the rear end side, thereby detecting the end module A cylindrical outer shell case that holds the output circuit module and the output circuit module apart from each other, a detection end module, and the output circuit module. A first step of providing a flexible connecting member for electrically connecting the two modules is interposed between the Le,
A second step of electrically connecting the detection end module prepared in the first step and the output circuit module via a connecting member;
The detection end module, to which the output circuit module is electrically connected in the second step, is attached to the outer shell case on the front end side of the outer shell case prepared in the first step. A third step of projecting a part or all of the output circuit module from the rear end side;
A fourth step of inserting the output circuit module partially or entirely protruding from the rear end side of the outer shell case in the third step into the through hole of the output circuit module support member;
A fifth step of attaching the output circuit module support member, through which the output circuit module is penetrated in the fourth step, to the outer shell case on the rear end side of the outer shell case;
A sixth step of attaching to the output circuit module support member an output circuit module which is on the rear end side of the outer shell case through the fifth step and protrudes through the output circuit module support member;
A method for producing a proximity sensor product. After the detection end module is attached to the outer shell case, the output circuit module support member is attached to the outer shell case, and the output circuit module is attached to the output circuit module support member, the resin inside the outer shell case is filled. A seventh step of injecting
An eighth step of soldering the electric cord to the portion of the output circuit module protruding outside after the filling resin is cured;
The method for producing a proximity sensor product according to claim 11, further comprising: A module component by integrally coupling a detection coil assembly including a coil and a core and having a detection characteristic self-completed by a mask conductor and a detection circuit assembly having the coil of the detection coil assembly as a resonant circuit element A detection end module used as one module part of a proximity sensor product, characterized in that the characteristic adjustment is completed prior to shipment.

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