# US 11,305,368 B2 · Inductive position sensor with switch function > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,305,368 B2 - Document ID: US11305368B2 - Status: Granted - Kind: B2 - Application number: 16/777,185 - Filed: 2020-01-30 - Published: 2021-08-05 - Granted: 2022-04-19 - Earliest claimed: 2020-01-30 - Assignees: Illinois Tool Works Inc. - Applicants: Illinois Tool Works Inc. - Inventors: Michael V. Hoeger - Web page: https://patentgrep.com/patent/US11305368B2 ## CPC - B23K 9/0956: {using sensing means, e.g. optical} - G01D 5/202: {by movable a non-ferromagnetic conductive element (G01D5/2033 takes precedence)} - B23K 9/164: {making use of a moving fluid} - B23K 37/04: for holding or positioning work - H03K 17/965: Switches controlled by moving an element forming part of the switch - H05K 1/147: {at least one of the printed circuits being bent or folded, e.g. by using a flexible printed circuit (H05K1/148 takes precedence)} - H05K 1/165: {incorporating printed inductors} - H03K 17/97: using a magnetic movable element - H05K 2201/10151: Sensor - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - G01D: MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR - H03K: PULSE TECHNIQUE (measuring pulse characteristics G01R; modulating sinusoidal oscillations with pulses H03C; transmission of digital information H04L; discriminator circuits detecting phase difference between two signals by counting or integrating cycles of oscillation H03D3/04; automatic control, starting, synchronisation or stabilisation of generators of electronic oscillations or pulses where the type of generator is irrelevant or unspecified H03L; coding, decoding or code conversion, in general H03M) - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS ## Abstract A sensor which includes inductive coils and an inductance to digital converter. The output of the sensor may be used to replace the functions of a switch and a potentiometer to initiate and control various outputs in welding-type systems and applications. ## Claims ### Claim 1 A sensor, comprising: a first coil having a first region and a second region, the first region having a spacing between successive corresponding portions of turns of the first coil less than a first threshold distance, and the second region having a spacing between successive corresponding portions of turns of the first coil greater than the first threshold; a second coil having a third region and a fourth region, the third region having a spacing between successive corresponding portions of turns of the second coil less than a second threshold distance, and the fourth region having a spacing between successive corresponding portions of turns of the second coil greater than the second threshold; a conductive target configured to travel within a travel zone extending from a first location to a second location, wherein both the first location and the second location are adjacent to both the second region and the fourth region; and measurement circuitry configured to: measure a first response of the first coil and a second response of the second coil to detect when a combination of the first response and the second response satisfies a threshold value; while the conductive target is within the travel zone, determine a position of the conductive target within the travel zone; output a first signal indicating whether the combination satisfies the threshold value; and output a second signal based on the magnitude of the combination if the combination satisfies the threshold value. ### Claim 2 (depends on 1) The sensor of claim 1, wherein the combination is a function of the first response and the second response. ### Claim 3 (depends on 1) The sensor of claim 1, wherein the measurement circuitry is configured to determine the position of the conductive target relative to the first coil and the second coil based on the combination of the first response and the second response after determining that the combination satisfied the third threshold. ### Claim 4 (depends on 1) The sensor of claim 1, wherein the first response corresponds to a first inductance and the second response corresponds to a second inductance. ### Claim 5 (depends on 1) The sensor of claim 1, wherein the first coil is connected to a first resonant circuit and the second coil is connected to a second resonant circuit, and wherein the first response comprises a first resonant frequency of the first resonant circuit and the second response comprises a second resonant frequency of the second resonant circuit. ### Claim 6 (depends on 1) The sensor of claim 1, wherein the first coil and the second coil are formed on a first circuit board, and wherein the conductive target comprises a conductive strip or a second circuit board. ### Claim 7 (depends on 6) The sensor of claim 6, wherein the first circuit board is a rigid printed circuit board and the second circuit board is a flexible circuit board. ### Claim 8 (depends on 7) The sensor of claim 7, wherein the second circuit board is biased to reduce a variation in distance between the first circuit board and the second circuit board as the target travels within the travel zone. ### Claim 9 (depends on 1) The sensor of claim 1, wherein the first coil and the second coil are located in a first plane, wherein the conductive target is configured to travel in a second plane, and wherein the second plane is parallel to the first plane. ### Claim 10 (depends on 1) The sensor of claim 1, wherein the first coil and the second coil are arranged such that the first response increases in magnitude and the second response decreases in magnitude as the target moves from the first location to the second location. ### Claim 11 (depends on 1) The sensor of claim 1, wherein the first coil and the second coil are arranged such that the first response decreases in magnitude and the second response decreases in magnitude as the target moves from the first location to the second location. ### Claim 12 (depends on 1) The sensor of claim 1, wherein the first coil and the second coil are arranged such that the first response increases in magnitude and the second response increases in magnitude as the target moves from the first location to the second location. ### Claim 13 A mechanically actuated controller comprising: a first coil having a first region and a second region, the first region having a spacing between successive corresponding portions of turns of the first coil less than a first threshold distance, and the second region having a spacing between successive corresponding portions of turns of the first coil greater than the first threshold; a second coil having a third region and a fourth region, the third region having a spacing between successive corresponding portions of turns of the second coil less than a second threshold distance, and the fourth region having a spacing between successive corresponding portions of turns of the second coil greater than the second threshold; a mechanical travel device configured to actuate a conductive target, wherein the conductive target is configured to travel within a travel zone extending from a first location to a second location, wherein both the first location and the second location are adjacent to both the second region and the fourth region; and measurement circuitry configured to: measure a first response of the first coil and a second response of the second coil to detect when a combination of the first response and the second response satisfies a threshold value; while the conductive target is within the travel zone, determine a position of the conductive target within the travel zone; output a first signal indicating whether the combination satisfies the threshold value; and output a second signal based on the magnitude of the combination if the combination satisfies the threshold value. ### Claim 14 (depends on 13) The controller of claim 13, wherein the mechanical travel device is a foot pedal. ### Claim 15 A welding control device comprising: a first coil having a first region and a second region, the first region having a spacing between successive corresponding portions of turns of the first coil less than a first threshold distance, and the second region having a spacing between successive corresponding portions of turns of the first coil greater than the first threshold; a second coil having a third region and a fourth region, the third region having a spacing between successive corresponding portions of turns of the second coil less than a second threshold distance, and the fourth region having a spacing between successive corresponding portions of turns of the second coil greater than the second threshold; a conductive target configured to travel within a travel zone extending from a first location to a second location, wherein both the first location and the second location are adjacent to both the second region and the fourth region; measurement circuitry configured to measure a first response of the first coil and a second response of the second coil to a position of the conductive target within the travel zone; and communications circuitry configured to: communicate, to a welding device, an enable signal indicating whether to enable or disable a welding process based on whether a combination of the first response and the second response satisfies a third threshold; and communicate, to the welding device, a control signal to control the welding process based in part on the combination if the combination satisfies the third threshold. ### Claim 16 (depends on 15) The welding control device of claim 15, comprising a mechanical travel device configured to actuate the conductive target.