Noncontact position sensor

1. Technical Field

The present invention relates to a non-contact position sensor that detects a position of an object with magnetic field.

2. Background Art

FIG. 7 is a perspective view of conventional non-contact position sensor 501 described in Patent Document 1. Magnet 1 is magnetized in its thickness direction. Magnetic body 2 is made of permalloy and has an isosceles triangle shape having different widths at positions along a longitudinal direction. Magnetic body 2 is provided on an upper surface of magnet 1. Magnet 1 is provided on an upper surface of shaft 3. Shaft 3 has a side surface having groove 4 provided therein. Projection 6 is provided on an inner side surface of slider 5. While projection 6 is engaged with groove 4 of shaft 3, slider 5 slides in longitudinal direction 501A of shaft 3. Magnetoelectric converter 7 is provided on an upper surface of slider 5 and detects a magnetic field changing depending on the width of magnetic body 2. Magnetoelectric converter 7 is connected to lead wire 8. Lead wire 8 is connected to an external device, such as a computer.

An operation of conventional non-contact position sensor 501 will be described below.

Upon shaft 3 being displaced in longitudinal direction 501A with respect to magnetoelectric converter 7, magnetic body 2 having the isosceles triangle shape is displaced and the width of magnetic body 2 facing magnetoelectric converter 7 changes, accordingly changing a magnetic field crossing magnetoelectric converter 7. The change of the magnetic field is converted by magnetoelectric converter 7 to a change of a voltage. This change of the voltage is output via lead wire 8 to the external device, thus allowing the external device to detect the displacement of shaft 3.

Conventional position sensor 501 includes magnetic body 2 having an intricate shape, such as the isosceles triangle shape, and made of permalloy, thus being prevented from being manufactured easily.

Patent Document 1: JP5-264326A

A non-contact position sensor includes a magnet, first to third magnetoresistive elements arranged on a line extending in a predetermined direction on a pole surface of the magnet with predetermined intervals, and an object made of magnetic material displaceable in the predetermined direction. The first to third magnetoresistive elements are connected serially between a power supply and a ground. The first magnetoresistive element is connected to the second magnetoresistive element at a first node. The second magnetoresistive element is connected to the third magnetoresistive element at a second node. The object includes a projection and a shaft connected to the projection. The projection can face the first to third magnetoresistive elements. The shaft is located away from the pole surface by a distance longer than a distance between the projection and the pole surface of the magnet.

This non-contact position sensor does not include a component having a complicated shape and can be manufactured easily.

FIG. 1 is an exploded perspective view of a non-contact position sensor according to an exemplary embodiment of the present invention.

FIG. 2 is a cross-sectional view of the non-contact position sensor according to the embodiment.

FIG. 3 is a circuit diagram of the non-contact position sensor according to the embodiment.

FIG. 4 is a schematic view of the non-contact position sensor according to the embodiment.

FIG. 5A is a schematic view of the non-contact position sensor according to the embodiment for illustrating an operation.

FIG. 5B is a schematic view of the non-contact position sensor according to the embodiment for illustrating the operation.

FIG. 5C is a schematic view of the non-contact position sensor according to the embodiment for illustrating the operation.

FIG. 5D is a schematic view of the non-contact position sensor according to the embodiment for illustrating the operation.

FIG. 6 illustrates the operation of the non-contact position sensor according to the embodiment.

FIG. 7 is a schematic view of a conventional non-contact position sensor.

21 Magnet

21 A Pole Surface

22 Magnetoresistive Element (First Magnetoresistive Element)

23 Magnetoresistive Element (Third Magnetoresistive Element)

24 Magnetoresistive Element (Second Magnetoresistive Element)

25 A Node (First Node)

25 B Node (Second Node)

26 Power supply

27 Ground

28 Voltage Divider Circuit (First Voltage Divider Circuit)

28 A Node (Third Node)

29 A Fixed Resistor (First Fixed Resistor)

29 B Fixed Resistor (First Fixed Resistor)

30 Voltage Divider Circuit (Second Voltage Divider Circuit)

30 A Node (Fourth Node)

31 a Fixed Resistor (Second Fixed Resistor)

31 B Fixed Resistor (Second Fixed Resistor)

34 Comparator (First Comparator)

37 Comparator (Second Comparator)

41 Digital/Analog Converter

47 Object

48 Shaft

49 Projection

FIG. 1 is an exploded perspective view of non-contact position sensor 1001 according to an exemplary embodiment of the present invention. FIG. 2 is a cross-sectional view of non-contact position sensor 1001 . FIG. 3 is a circuit diagram of non-contact position sensor 1001 .

Magnet 21 has pole surface 21 A generating a magnetic field. Magnetoresistive elements 22 , 23 , and 24 are provided on pole surface 21 A and are arranged in this order on a line extending in predetermined direction 1001 A with predetermined intervals P 1 . Magnetoresistive elements 22 to 24 are connected serially between power supply 26 and ground 27 to constitute magnetoresistive series assembly 25 . Power supply 26 is connected to magnetoresistive element 22 . Magnetoresistive elements 22 and 24 are connected at node 25 A. Magnetoresistive element 23 and 24 are connected at node 25 B. Ground 27 is connected to magnetoresistive element 23 . Voltage divider circuit 28 includes fixed resistors 29 A and 29 B serially connected to each other at node 28 A. Voltage divider circuit 30 includes fixed resistors 31 A and 31 B serially connected to each other at node 30 A. Fixed resistors 31 A and 31 B are connected to power supply 32 and ground 33 , respectively. The ratio of the resistance of fixed resistor 31 A to the resistance of fixed resistor 31 B is determined to be 2 to 1 so as to the potential at node 30 A is set to ⅓ of the voltage of power supply 32 .

Comparator 34 outputs a high level signal (high potential) from output port 34 A when the potential of inverting input port 35 is lower than that of non-inverting input port 36 , and outputs a low level signal (low potential) from output port 34 A when the potential of inverting input port 35 is higher than that of non-inverting input port 36 . Inverting input port 35 is connected to node 25 A of magnetoresistive series assembly 25 . Non-inverting input port 36 is connected to node 28 A of voltage divider circuit 28 . Comparator 37 outputs a high level signal (high potential) from output port 37 A when the potential of inverting input port 38 is lower than that of non-inverting input port 39 , and outputs a low level signal (low potential) from output port 34 A when the potential of inverting input port 38 is higher than that of non-inverting input port 39 . Inverting input port 38 is connected to node 25 B of magnetoresistive series assembly 25 via amplifier 40 . Non-inverting input port 39 is connected to node 30 A of voltage divider circuit 30 . According to the embodiment, amplifier 40 functions as a voltage follower. Inverting input port 38 of comparator 37 receives a potential at node 25 B of magnetoresistive series assembly 25 . Fixed resistor 29 A of voltage divider circuit 28 is connected to power supply 26 . Fixed resistor 29 B is connected to inverting input port 38 of comparator 37 . Digital/analog (D/A) converter 41 has most significant bit (MSB) input port 41 A connected to output port 34 A of first comparator 34 , least significant bit (LSB) input port 41 B connected to output port 37 A of comparator 37 , and output port 41 C for outputting an analog signal (potential) depending on the level of a signal (potential) input to input ports 41 A and 41 B. Magnet 21 and magnetoresistive elements 22 , 23 , and 24 are fixed to end 42 A of base 42 made of resin. Voltage divider circuits 28 and 30 , comparators 34 and 37 , amplifier 40 , and D/A converter 41 are mounted onto side surface 42 B of base 42 , Connector terminal 43 is provided at end 42 C opposite to end 42 A across side surface 42 B of base 42 . Case 44 made of resin accommodates base 42 therein, and has connector terminal 45 projecting from case 44 to an outside of the case. Connector terminal 45 is connected to connector terminal 43 of base 42 . Cover 46 seals an opening of case 44 . Object 47 made of magnetic material includes shaft 48 , and projection 49 which is connected to shaft 48 and has a columnar shape.

FIG. 4 is a schematic view of non-contact position sensor 1001 . Magnetoresistive elements 22 , 23 , and 24 are arranged in direction 1001 A with predetermined intervals P 1 between them. Object 47 is displaceable in direction 1001 A. Projection 49 has width W 1 in direction 1001 A that is equal to or smaller than the twice of interval P 1 . Shaft 48 and projection 49 are arranged in direction 1001 A. Distance D 1 between pole surface 21 A and projection 49 is shorter than distance D 2 between pole surface 21 A and shaft 48 . As described above, a surface of object 47 facing pole surface 21 A, i.e., magnetoresistive elements 22 , 23 , and 24 , and has a irregular shape. Thus, non-contact position sensor 1001 does not necessarily include a magnetic body having an intricate shape, hence being manufactured easily and efficiently.

Next, a method of manufacturing non-contact position sensor 1001 will be described. First, magnetoresistive elements 22 , 23 , and 24 are formed by vapor deposition on pole surface 21 A of magnet 21 via a silicon substrate. Next, connector terminal 43 is placed in a die to form base 42 having end 42 C into which connector terminal 43 is embedded. Next, magnet 21 is fixed to end 42 A opposite to end 42 C of base 42 . Next, voltage divider circuits 28 and 30 , comparators 34 and 37 , amplifier 40 , and D/A converter 41 are mounted onto side surface 42 B of base 42 . Case 44 having connector terminal 45 integrated therewith is prepared. Base 44 is accommodated in case 44 . Then, connector terminal 43 of base 42 is soldered to connector terminal 45 of case 44 . The opening of case 44 is sealed with cover 46 . Then, object 47 is attached to a position facing a lower surface of case 44 so that projection 49 faces magnetoresistive elements 22 , 23 , and 24 .

An operation of non-contact position sensor 1001 will be described below. FIG. 5A to FIG. 5D are schematic views of non-contact position sensor 1001 for illustrating the operation. In FIG. 5A to FIG. 5D , intervals P 1 between magnetoresistive elements 22 , 23 , and 24 arranged in direction 1001 A are 1.75 mm. Projection 49 of object 47 facing magnetoresistive elements 22 , 23 , and 24 has width W 1 in direction 1001 A that is twice longer than interval P 1 . FIG. 5A illustrates an initial position corresponding to a moving stroke of zero of object 47 . An entire moving stroke of object 47 in direction 1001 A is 7 mm. FIG. 6 illustrates voltage Vout output from output port 41 C of D/A converter 41 . In FIG. 6 , the horizontal axis represents moving stroke L 1 of object 47 in direction 1001 A and the vertical axis represents voltage Vout. Magnetoresistive elements 22 , 23 , and 24 have characteristics identical to each other. Magnetoresistive elements 22 , 23 , and 24 have resistances changing according to the strength of a magnetic field crossing the elements. According to the embodiment, the larger the strength of magnetic field is, the higher the resistances are.

As shown in FIG. 5A , when moving stroke L 1 ranges from 0 mm to 1.75 mm, projection 49 faces magnetoresistive element 22 and does not face magnetoresistive element 23 or 24 . The magnetic field generated from pole surface 21 A of magnet 21 concentrates locally to projection 49 of object 47 made of magnetic material. Magnetoresistive element 22 through which the concentrating magnetic field crosses has a resistance increase, and magnetoresistive elements 23 and 24 have resistances decrease. The potential at node 25 A of magnetoresistive series assembly 25 is accordingly reduced. The ratio of a voltage between both ends of fixed resistor 29 A of voltage divider circuit 28 to a voltage between ends of fixed resistor 29 B is fixed. Thus, the ratio of the voltage between power supply 26 and node 28 A to the voltage between power supply 26 and node 25 B is fixed. Thus, the potential of node 25 A becomes lower than potential V 1 of node 28 A, hence allowing comparator 34 to output the high level signal. The potential of node 25 B of magnetoresistive series assembly 25 is reduced. Since potential V 2 of node 30 A of voltage divider circuit 30 is fixed, comparator 37 outputs the high level signal. Thus, the high level signals are input to input ports 41 A and 41 B, hence allowing D/A converter 41 to output voltage Vout of about 4.7V.

As shown in FIG. 5B , when moving stroke L 1 of object 47 ranges from 1.75 mm to 3.5 mm, projection 49 faces both of magnetoresistive elements 22 and 23 , and does not face magnetoresistive element 24 . As a result, magnetoresistive elements 22 and 23 have resistances increase, and magnetoresistive element 24 has a resistance decrease. This raises the potential of node 25 A of magnetoresistive series assembly 25 . The ratio of a voltage between power supply 26 and node 28 A to the sum of voltages between respective both ends of magnetoresistive elements 22 and 24 , i.e., a voltage between power supply 26 and node 25 B, is fixed. Thus, the potential of node 25 A becomes lower than potential V 1 of node 28 A, hence allowing comparator 34 to output the high level signal. At this moment, while the potential of node 25 B of magnetoresistive series assembly 25 rises, potential V 2 of node 30 A of voltage divider circuit 30 is fixed, hence allowing comparator 37 to output a low level signal. Thus, the high level signal is input to input port 41 A of most significant bit, and the low level signal is input to input port 41 B of least significant bit, hence allowing D/A converter 41 to output voltage Vout of about 3.3V.

As shown in FIG. 5C , when moving stroke L 1 of object 47 ranges from 3.5 mm to 5.25 mm, projection 49 faces both of magnetoresistive elements 23 and 24 , and does not face magnetoresistive element 22 . Thus, magnetoresistive elements 23 and 24 have the resistances increase, and magnetoresistive element 22 has the resistance decrease. As a result, the potential at node 25 A of magnetoresistive series assembly 25 is educed. The ratio of the voltage between power supply 26 and node 28 A to the sum of voltages between respective both ends of magnetoresistive elements 22 and 24 , i.e., a voltage between power supply 26 and node 25 B, is fixed. Thus, the potential of node 25 A becomes higher than potential V 1 of node 28 A, hence allowing comparator 34 to output a low level signal. At this moment, while the potential of node 25 B of magnetoresistive series assembly 25 rises, potential V 2 at node 30 A of voltage divider circuit 30 is fixed, hence allowing comparator 37 to output a low level signal. Thus, the low level signals are input to input ports 41 A and 41 B, D/A converter 41 outputs voltage Vout of about 0.3V.

As shown in FIG. 5D , when moving stroke L 1 of object 47 ranges from 5.25 mm to 7 mm, projection 49 faces magnetoresistive element 24 and does not face magnetoresistive element 22 or 23 . Thus, magnetoresistive element 24 has a resistance increase, and magnetoresistive elements 22 and 23 have resistances decrease. As a result, the potential of node 25 A of magnetoresistive series assembly 25 increases. The ratio of the voltage between power supply 26 and node 28 A to the sum of voltages between respective both ends of magnetoresistive elements 22 and 24 , i.e., the voltage between power supply 26 and node 25 B is fixed. Thus, the potential of node 25 A becomes higher than potential V 1 of node 28 A, hence allowing comparator 34 to output a low level signal. At this moment, the potential of node 25 B of magnetoresistive series assembly 25 rises, and potential V 2 of node 30 A of voltage divider circuit 30 is fixed, hence allowing comparator 37 to output a high level signal. Therefore, a low level signal is input to input port 41 A of most significant bit, and a high level signal s input to input port 41 B of least significant bit, hence allowing D/A converter 41 outputs voltage Vout of about 1.8V.

Comparator 34 compares the potential of node 25 A with fixed potential V 1 , and outputs a high level signal and a low level signal based on the result of comparison. Comparator 37 compares the potential of node 25 B with fixed potential V 2 and outputs a high level signal and a low level signal based on the result of comparison. D/A converter 41 converts a digital signal including the signals output from comparators 34 and comparator 37 into an analog signal (voltage Vout). Projection 49 of object 47 can face magnetoresistive elements 22 , 23 , and 24 . Shaft 48 of object 47 that is displaceable in predetermined direction 1001 A is located away from pole surface 21 A by distance D 2 longer than distance D 1 between projection 49 and pole surface 21 A of magnet 21 .

The detailed shape of object 47 , an order of the arrangement of magnetoresistive elements 22 , 23 , and 24 , and the circuit are not limited to the above-described ones.

A non-contact position sensor according to the present invention does not include a component having an intricate shape and can be manufactured easily. The non-contact position sensor is useful for detecting a position of an object based on a change of magnetic field.