Apparatus for the automated manufacture of a probe tip

1. A proximity probe apparatus offset to an axis defining an extension cable comprising:

a sensing element;

a cylindrical part molded with a moldable material;

a recess configured in one of two opposing ends defining said cylindrical part to receive said sensing element;

a first and a second ferrule each extending from opposing surfaces defining an exterior of said cylindrical part, a first axis defining said first and second ferrules being offset from a second axis defining said cylindrical part; and

an extension cable operably attached to said sensing element via said first and second ferrules, said sensing element being disposed offset relative to said extension cable.

2. The apparatus of claim 1 wherein said first and second ferrules are linearly spaced apart along said first axis.

3. The apparatus of claim 2 wherein said first and second ferrules are placed on a pin support within a mold, said moldable material is one of injection molded and transfer molded around said first and second ferrules thereby forming a component alignment perform.

4. The apparatus of claim 3 wherein said component alignment perform is molded as a cylinder, said cylinder being machined to include an annular recess and opposing cavities substantially perpendicular to said recess for respective said first and second ferrules.

5. The apparatus of claim 3 wherein said component alignment perform is formed in a first injection molding process where said moldable material includes one of PolyPhenylene Sulfide (PPS) and PolyEthylEther Keytone (PEEK).

6. The apparatus of claim 4 wherein said moldable material includes a material capable of rigorous chemical and temperature extremes.

7. The apparatus of claim 1 wherein said offset includes a 90° angle.

8. The apparatus of claim 1 wherein said cylindrical molded part is molded having a diameter of about 0.231 inch.

9. The apparatus of 1 wherein said sensing element is disposed within said recess, a first lead of said sensing element is resistance welded to said first ferrule, a second lead of said sensing element is resistance welded to said second ferrule, a center conductor of the extension cable is inserted into said first ferrule from said second ferrule, a coaxial conductor of the extension cable is inserted into said second ferrule, and the extension cable is electrically and mechanically connected with respective ferrules using an automated solder application and melting process.

10. The apparatus of claim 9 wherein an inductive heating is used to cause at least one of a solder pellet, solder paste, and a solder ring to melt and flow over exposed conductors of the extension cable, and said exposed conductors are allowed to cool to electrically and mechanically secure bores defining each of said first and second ferrules with a respective said exposed conductors.

11. The apparatus of claim 9 wherein respective bores are configured transverse to first and second cylinders defining corresponding apertures for each of said first and second ferrules, said bores generally extending tangential to an exterior circumferential surface defining said cylindrical part to allow access to each respective said first and second ferrules for said resistance welding the first and second leads with a corresponding ferrule of said first and second ferrules.

12. The apparatus of claim 1 wherein said first and second ferrules are formed from brass.

13. The apparatus of claim 1 wherein said moldable material includes an electrical insulating material which has a characteristic of bonding to itself.