Abstract:
A bobbin and coil architecture is provided for use in an inductive sensor. The architecture eliminates the need for coil shielding and reduces the sensor&#39;s sensitivity to temperature and proximate mounting hardware. In one or more embodiments, all or portions of separate coils are located in a common slot on the bobbin, rather than being segregated into separate slots. In an example configuration, two receiver coils may be located in respective two slots on the bobbin, and a transmitter coil may divided into two substantially equal subsets of windings, with each subset wound together with one of the receiver coils in a common slot. This yields a symmetrical and balanced winding architecture that requires fewer slots relative to designs that segregate all coils into separate slots.

Description:
BACKGROUND 
       [0001]    The subject matter disclosed herein relates generally to inductive sensors, and, more particularly, to an inductive sensor coil architecture that reduces sensitivity to environmental variables and reduces the size of sensor components. 
       BRIEF DESCRIPTION 
       [0002]    The following presents a simplified summary in order to provide a basic understanding of some aspects described herein. This summary is not an extensive overview nor is intended to identify key/critical elements or to delineate the scope of the various aspects described herein. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later. 
         [0003]    In one or more embodiments, an assembly for supporting coils of an inductive sensor is provided, comprising a transmitter coil and at least one receiver coil, wherein at least a portion of the transmitter coil is co-located with at least a portion of a receiver coil of the at least one receiver coil. 
         [0004]    A method for arranging inductive coils of an inductive sensor is also described, the method comprising locating at least a first portion of a transmitter coil of the inductive sensor on a section of a winding structure, and locating at least a second portion of a receiver coil of the inductive sensor on the section of the winding structure together with at least the first portion of the transmitter coil. 
         [0005]    Also, an inductive sensor is provided, comprising a transmitter coil comprising a first number of turns, and a receiver coil comprising a second number of turns, wherein at least a subset of the first number of turns of the transmitter coil are wound together with at least a subset of the second number of turns of the receiver coil. 
         [0006]    To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the annexed drawings. These aspects are indicative of various ways which can be practiced, all of which are intended to be covered herein. Other advantages and novel features may become apparent from the following detailed description when considered in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a generalized diagram of an example multi-coil inductive sensor. 
           [0008]      FIG. 2   a  is a side view of an example three-slot bobbin. 
           [0009]      FIG. 2   b  a three-dimensional view of the example three-slot bobbin. 
           [0010]      FIG. 3   a  is a side view of an example two-slot bobbin. 
           [0011]      FIG. 3   b  is a three-dimensional view of the example two-slot bobbin 
           [0012]      FIG. 4  is a multi-view drawing of an example two-slot bobbin. 
           [0013]      FIG. 5  is a flowchart of an example methodology for winding coils of an inductive sensor. 
           [0014]      FIG. 6  is a flowchart of an example methodology for winding coils of an inductive sensor comprising two receiver coils and one transmitter coil. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    The subject disclosure is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the subject disclosure can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. 
         [0016]    As used in this application, the terms “component,” “system,” “platform,” “layer,” “controller,” “terminal,” “station,” “node,” “interface” are intended to refer to a computer-related entity or an entity related to, or that is part of, an operational apparatus with one or more specific functionalities, wherein such entities can be either hardware, a combination of hardware and software, software, or software in execution. For example, a component can be, but is not limited to being, a process running on a processor, a processor, a hard disk drive, multiple storage drives (of optical or magnetic storage medium) including affixed (e.g., screwed or bolted) or removable affixed solid-state storage drives; an object; an executable; a thread of execution; a computer-executable program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components can reside within a process and/or thread of execution, and a component can be localized on one computer and/or distributed between two or more computers. Also, components as described herein can execute from various computer readable storage media having various data structures stored thereon. The components may communicate via local and/or remote processes such as in accordance with a signal having one or more data packets (e.g., data from one component interacting with another component in a local system, distributed system, and/or across a network such as the Internet with other systems via the signal). As another example, a component can be an apparatus with specific functionality provided by mechanical parts operated by electric or electronic circuitry which is operated by a software or a firmware application executed by a processor, wherein the processor can be internal or external to the apparatus and executes at least a part of the software or firmware application. As yet another example, a component can be an apparatus that provides specific functionality through electronic components without mechanical parts, the electronic components can include a processor therein to execute software or firmware that provides at least in part the functionality of the electronic components. As further yet another example, interface(s) can include input/output (I/O) components as well as associated processor, application, or Application Programming Interface (API) components. While the foregoing examples are directed to aspects of a component, the exemplified aspects or features also apply to a system, platform, interface, layer, controller, terminal, and the like. 
         [0017]    As used herein, the terms “to infer” and “inference” refer generally to the process of reasoning about or inferring states of the system, environment, and/or user from a set of observations as captured via events and/or data. Inference can be employed to identify a specific context or action, or can generate a probability distribution over states, for example. The inference can be probabilistic—that is, the computation of a probability distribution over states of interest based on a consideration of data and events. Inference can also refer to techniques employed for composing higher-level events from a set of events and/or data. Such inference results in the construction of new events or actions from a set of observed events and/or stored event data, whether or not the events are correlated in close temporal proximity, and whether the events and data come from one or several event and data sources. 
         [0018]    In addition, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form. 
         [0019]    Furthermore, the term “set” as employed herein excludes the empty set; e.g., the set with no elements therein. Thus, a “set” in the subject disclosure includes one or more elements or entities. As an illustration, a set of controllers includes one or more controllers; a set of data resources includes one or more data resources; etc. Likewise, the term “group” as utilized herein refers to a collection of one or more entities; e.g., a group of nodes refers to one or more nodes. 
         [0020]    Various aspects or features will be presented in terms of systems that may include a number of devices, components, modules, and the like. It is to be understood and appreciated that the various systems may include additional devices, components, modules, etc. and/or may not include all of the devices, components, modules etc. discussed in connection with the figures. A combination of these approaches also can be used. 
         [0021]    Many industrial applications utilize inductive sensors for detecting presence of metal objects near the sensors. For example, proximity switches are often mounted at key locations on a conveyor system to detect when a part is present at that location. In another example, proximity switches may be mounted at the extreme ends of travel of an actuating component (e.g., a pneumatic cylinders, a clamp, etc.) to confirm when the actuating component has moved to a desired position (e.g., fully retracted, fully extended, clamped, unclamped, etc.). 
         [0022]      FIG. 1  is a generalized diagram of an example multi-coil inductive sensor. Inductive sensor  102  comprises a transmitter coil  106  and receiver coil  108 . Although example inductive sensor  102  depicts only a single transmitter coil and receiver coil, some inductive sensors may include multiple transmitter coils and/or receiver coils. An alternating current (AC) voltage or current source  104  (e.g., a sinusoidal or periodic voltage or current) is connected to transmitter coil  106 , causing the transmitter coil  106  to generate an oscillating magnetic field that induces a current on receiver coil  108 . Detection circuitry  112  monitors the induced current on receiver coil  108 . 
         [0023]    The transmitter coil  106  is generally located within the inductive sensor  102  such that the oscillating magnetic field is created in proximity of a sensing surface of the sensor, where the strength of the magnetic field is strongest in the axis of the sensor perpendicular to the sensing face. When an electrically conductive metal object  110  is located near the sensing surface in the axis of the sensor coils or the magnetic field, the presence of the object modifies the reparation of energy in the magnetic field, which in turn modifies the amplitude of the receive signal induced on receiver coil  108 . Depending on the type of metal comprising object  110 , presence of the object  110  may cause the current or voltage of the receive signal to either increase or decrease. Detection circuitry  112  is configured to generate an output in response to detecting that the induced current on receiver coil  108  has been modified in a manner indicative of the presence of object  110  (e.g., by determining that the induced current has fallen below or increased above a threshold indicative of the presence of a metal object in proximity to the sensing surface). For some types of sensors, such as proximity switches, the sensor may generate a discrete output indicating the presence of object  110 . Other types of sensors may be configured to measure a distance of the object from the sensing surface. Such sensors may be configured to generate an analog value that is a function of the distance of the object  110  from the sensing surface. The output may be delivered to an industrial controller and used as an input for a control program. Some sensors may also include an LED  114  mounted on the sensor body that illuminates when the object  110  is detected. 
         [0024]    In some sensor designs, the transmitter coils and receiver coils are wound around a multi-coil bobbin or other structure within the sensor. These bobbins are designed such that the transmitter and receiver coils are wound independently into separate slots of the bobbins. However, this coil configuration can be sensitive to environmental variables such as temperature and pressure. This configuration may also be sensitive to the presence of metal mounting components (e.g., brackets, nuts, or other mounting hardware). Additionally, this configuration requires a bobbin large enough to accommodate each coil within an individual slot 
         [0025]    To address these and other problems, one or more embodiments of this disclosure provide a winding architecture wherein multiple coils are wound together on a common portion of a winding structure (e.g., one coil on top of another coil or wound together with the other coil within a common slot of a bobbin or other winding structure). The receiver and transmitter coil can be wound on this bobbin according to a particular winding configuration. For example, for a sensor comprising two receiver coils and one transmitter coil, the two receiver coils may occupy respective two slots, and the transmitter coil may be divided into two halves, with each half wound together with one of the receiver coils. In another example winding, each transmitter coil may share a slot with a receiver coil. Other winding combinations are also considered. 
         [0026]    Since multiple coils or coil portions are wound together, this winding architecture consumes less winding surface area. Thus, a smaller bobbin or other winding structure can be used, reducing the overall size of the sensor. Moreover, winding the coils in common slots can reduce sensitivity of the sensor to temperature and surrounding metals. Also, stacking the windings within common slots can cause the coils to behave as shielded coils without the need for a shield, thereby saving on manufacturing costs. In this regard, it is noted that conventional coil shields increase the temperature sensitivity of the overall sensing system due to the high temperature coefficient of the metal conductivity. Moreover, expansion and compression of the metal may cause stress on the shield and other components. The winding architecture described herein can mitigate these effects by eliminating the need for a shield. 
         [0027]      FIG. 2   a  is a side view of an example three-slot bobbin according to one or more embodiments of this disclosure.  FIG. 2   b  is a three-dimensional view of the example bobbin. Although example winding configurations are described herein as being supported by a bobbin, it is to be appreciated that the winding architectures described herein are not dependent on the particular structure on which the windings reside, and can be implemented on any suitable winding structure. Additionally, in some embodiments, the winding architectures described herein may be implemented without the use of a winding structure. 
         [0028]    The bobbin depicted in  FIGS. 2   a  and  2   b  is designed for use in a sensor comprising one transmitter coil and two receiver coils. As shown in  FIG. 2   a , the two outer slots  202   a  and  202   b  may be dedicated to the two receiver (Rx) coils, respectively, and the middle slot  204  may be dedicated to the transmitter (Tx) coil. In an example, non-limiting configuration, the two receiver coils may comprise 120 turns each, wherein all 120 turns of the first receiver coil are located in slot  202   a  and all 120 turns of the second receiver coil are located in slot  202   b.  The transmitter coil may comprise 100 turns, all of which reside in slot  204 . 
         [0029]    If the two receiver coils comprise a greater number of turns then the transmitter coil, the middle slot  204  can be designed to be narrower than slots  202   a  and  202   b.  Alternatively, all three slots  202   a,    202   b,  and  204  may be designed to have equal widths. In an example, non-limiting design, middle slot  204  may have a width D of approximately 0.8 mm, while slots  202   a  and  202   b  may have a width C of approximately 1.0 mm each. The dividing sections  210   a  and  210   b  between the transmitter coil slot  204  and receiver coil slots  202   a  and  202   b  may have widths A of approximately 1.0 mm, while the flanges  208   a  and  208   b  may have widths B of approximately 0.5 mm. The width E of spindle  212  relative to the width F of flanges  208   a  and  208   b  determines the depth of each slot. These measurements are only intended to be exemplary, and it is to be appreciated that any suitable dimensions may be used for the various elements. As shown in  FIG. 2   b , pins  206  protrude from one surface of the bobbin, and serve as electrical terminals for the coil ends. Other sensor components, such as AC voltage source  104 , detection circuitry  112 , or other components, can be electrically connected to the coil endpoints via pins  206 . 
         [0030]      FIG. 3   a  is a side view of an example two-slot bobbin according to one or more embodiments, and  FIG. 3   b  is a three-dimensional view of this example bobbin. This example bobbin comprises two slots  302   a  and  302   b.  In an example winding, each slot  302   a  and  302   b  can contain both receiver coil and transmitter coil windings. For example, for a sensor comprising two receiver coils and one transmitter coil, each of the two slots  302   a  and  302   b  can contain one of the two receiver coils, such that the two receiver coils are separated by divider  304 . The transmitter coil can then be divided such that half of the transmitter coil windings reside in slot  302   a  (sharing the slot with the first receiver coil) and the other half of the transmitter coil windings reside in slot  302   b  (sharing the slot with the second receiver coil). By this winding configuration, each receiver coil shares a slot with half of the transmitter coil windings. For example, if the receiver coils comprise 130 turns each and the transmitter coil comprises 100 turns, slot  302   a  can contain all 130 turns of the first receiver coil and 50 of the transmitter coil turns. Similarly, slot  302   b  can contain all 130 turns of the second receiver coil and the remaining 50 turns of the transmitter coil. Accordingly, slots  302   a  and  302   b  are each sized to accommodate a total of 180 turns. Thus, although the bobbin of  FIGS. 3   a  and  3   b  holds three coils (one transmitter coil and one receiver coil), this bobbin requires one less slot than the design depicted in  FIGS. 2   a  and  2   b , reducing the size of the bobbin. 
         [0031]    In an example, non-limiting design, slots  302   a  and  302  may each have a width C of approximately 1.8 mm, divider  304  may have a width A of approximately 1.0 mm, and flanges  306   a  and  306   b  may have a width B of approximately 0.5 mm. These coil sizes and dimensions are only intended to be exemplary, and it is to be appreciated that any suitable dimensions can be used in the design of the example bobbin illustrated in  FIGS. 3   a  and  3   b , for accommodation of any number of transmitter and receiver coils of any number of windings. The width E of spindle  310  and the width F of flanges  306   a  and  306   b  can be sized as needed to accommodate the expected number of windings to be placed within each slot. 
         [0032]    As in the example bobbin depicted in  FIGS. 2   a  and  2   b , the two-slot bobbin of  FIGS. 3   a  and  3   b  can include pins  308  that protrude from one of the flanges, which serve as terminals for the coil ends. 
         [0033]    It is to be appreciated that the winding architecture described above—whereby different coils or portions of coils are wound in a same location or slot on a bobbin—is not limited to use with the two-slot bobbin illustrated in  FIGS. 3   a  and  3   b . In this regard, a bobbin having any number of slots, on which different coils or portions of coils are located in a common slot, is within the scope of one or more embodiments of this disclosure. For example, the above-described winding architecture may be adopted for the three-slot bobbin illustrated in  FIGS. 2   a  and  2   b . In an example, non-limiting winding architecture for the three-slot bobbin, three receiver coils may be located in the three slots, respectively, and a transmitter coil may be divided into three portions that each reside within one of the three slots. 
         [0034]      FIG. 4  is a multi-view drawing of an example two-slot bobbin  402  according to one or more embodiments. As in previous examples, the bobbin  402  includes a spindle  410  and flanges  406  connected to each end of the spindle  410 . Two slots  412  are defined by the spindle  410 , flanges  406 , and a dividing section  414 . The slots  412  are configured to hold multiple windings of a transmitter coil and/or a receiver coil. In some example windings, each slot can contain both receiver coil windings and transmitter coil windings. For example, two receiver coils may be placed respectively in the two slots  412 , and the windings of a transmitter coil may be divided into two halves, with each half placed in one of the two slots  412  with one of the receiver coils. This configuration is only intended to be exemplary, and it is to be appreciated that any winding configuration in which windings of separate coils share a common slot on a bobbin is within the scope of one or more embodiments of this disclosure. By allowing windings of separate coils to share slots on the bobbin  402 , the size of bobbin  402  can be kept small relative to bobbin designs in which each coil must reside in a separate slot. Moreover, co-locating all or portions of separate coils within common slots can reduce the resulting sensor&#39;s sensitivity to temperature and surrounding metals. 
         [0035]    Pins  404  protrude from one of the flanges  406 , and server as terminals for the coil ends. Bobbin  402  includes six pins, providing terminals for three coils (e.g., one transmitter coil and two receiver coils). The pins  404  can be manufactured from any suitable conductive material. In some embodiments, pins  404  may be coated with a phosphorous bronze solder coating. 
         [0036]    Bobbin  402  may also include notches  408  in the flanges  406  and dividing section  414 , yielding open channels on opposite sides of the bobbin that run through both flanges and the dividing section. A hole  416  runs through the flanges  406  and spindle  410  to facilitate location and mounting of the bobbin  402  within the sensor. 
         [0037]      FIGS. 5-6  illustrate various methodologies in accordance with one or more embodiments of the subject application. While, for purposes of simplicity of explanation, the one or more methodologies shown herein are shown and described as a series of acts, it is to be understood and appreciated that the subject innovation is not limited by the order of acts, as some acts may, in accordance therewith, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all illustrated acts may be required to implement a methodology in accordance with the innovation. Furthermore, interaction diagram(s) may represent methodologies, or methods, in accordance with the subject disclosure when disparate entities enact disparate portions of the methodologies. Further yet, two or more of the disclosed example methods can be implemented in combination with each other, to accomplish one or more features or advantages described herein. 
         [0038]      FIG. 5  illustrates an example methodology  500  for winding coils of an inductive sensor. Initially, at  502 , at least a first portion of a first coil of an inductive sensor is wound within a slot of a bobbin. The first coil may be a receiver coil or a transmitter coil of the sensor. At  504 , at least a second portion of a second coil of the inductive sensor is wound within the slot, thereby causing the two coils (or coil portions) to reside in the same slot. 
         [0039]      FIG. 6  illustrates an example methodology  600  for winding coils of an inductive sensor comprising two receiver coils and one transmitter coil. Initially, at  602 , a first receiver coil of an inductive sensor is wound within a first slot of a bobbin. At  604 , a second receiver coil of the inductive sensor is wound within a second slot of the bobbin. At  606 , a first portion of a transmitter coil of the inductive sensor is wound within the first slot. In some scenarios, the first portion may be half or approximately half of the total number of transmitter coil windings. However, the first portion may be some other subset of the total number of transmitter coil windings. As a result of winding the first portion of the transmitter coil within the first slot, both the first receiver coil and the first portion of the transmitter coils are located within the first slot of the bobbin. At  608 , a second portion of the transmitter coil (e.g., the remaining windings of the transmitter coil after the first portion has been wound into the first slot) is wound into the second slot, thereby placing the second portion of the transmitter coil within the same slot as the second receiver coil. 
         [0040]    What has been described above includes examples of the subject innovation. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the disclosed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the subject innovation are possible. Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. 
         [0041]    In particular and in regard to the various functions performed by the above described components, devices, circuits, systems and the like, the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., a functional equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the herein illustrated exemplary aspects of the disclosed subject matter. In this regard, it will also be recognized that the disclosed subject matter includes a system as well as a computer-readable medium having computer-executable instructions for performing the acts and/or events of the various methods of the disclosed subject matter. 
         [0042]    In addition, while a particular feature of the disclosed subject matter may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “includes,” and “including” and variants thereof are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising.” 
         [0043]    In this application, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion. 
         [0044]    Various aspects or features described herein may be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques. The term “article of manufacture” as used herein is intended to encompass a computer program accessible from any computer-readable device, carrier, or media. For example, computer readable media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips . . . ), optical disks [e.g., compact disk (CD), digital versatile disk (DVD) . . . ], smart cards, and flash memory devices (e.g., card, stick, key drive . . . ).