The Latest Sensor Trends

Transcription

1 Sensing & Feedback Technologies The Latest Sensor Trends

2 Agenda Miniature sensors open up new applications Alternatives to Fiber optics Pneumatic cylinder sensing: Dual systems, analog and lifetime warranties are just a start Direct load monitoring: a better way to close the loop Sensors survivability: it s not by chance SmartLevel: a fusion for capacitive and conductance technologies

3 Miniature Sensors

4 SuperShorty Miniature Inductive Sensors Imagine the Possibilities...

5 SuperShorty Imagine the Possibilities... Main Features: The shortest self contained inductive sensors in the world! Cable out models only 6mm & 10mm long M8 connectorized models only 18mm long Incredibly light weight 6mm long version (0.7g) makes them ideal for high speed and highly-dynamic applications Easy to Integrate - No bulky external amplifier required Easy to install (2) different threaded mounting brackets

6 SuperShorty Application: Pneumatic-motor Ø6.5 X 6mm Even in the very space-critical pneumatic- motor, there is enough room for (3) SuperShorty sensors. In this application the sensors have to verify the step position.

7 SuperShorty Application: Pick-and-place Ø6.5 x 6mm Ideal for highly-dynamic applications Applications with extremely high accelerations, e. g. pick-and-place, are made possible due to its light weight (just 0.7 grams).

8 SuperShorty Application: Vertical Linear Slide Ø6.5 X 6mm Easy to integrate e. g. in linear slides for end-oftravel monitoring. Electronics are fully integrated in the 6 mm housing. No machine space is needed for an external amplifier.

9 Fiber Optic Alternatives

10 Ultraframe Applications Fiber Optic Upgrade Absolute #1 solution for feed systems

11 Ultraframe a Applications Precision Laser About 10x the resolution and repeatability of standard visible red Beam visible in all conditions L Shape Ideal for 2 axis movements Extremely rugged Powerful light source

12 Distributor Program Reminder ULTRAFRAME Family of self-contained thru-beam sensors BGL BOW Thru-beam reliability in a single-piece package Four different shapes to choose from Up to four application-specific light sources available IP67 rated housings Greatly reduces installation time BWL BWL

13 Error Proofing Sensors in Tooling Kohler Case Assembly Press: 30 inspections with Ultraframe

14 New Transparent Detection Ideal for detecting: - Glass bottles - PET bottles - Transparent films - Glass sheets - Vials

15 Pneumatic Cylinder Position Sensors Superior Magnetoresistive technology Universal and application specific housings Lifetime warranty Analog versions for cylinders and grippers

16 The Solid Solid-State State Pneumatic Cylinder Sensor Lifetime Warranty Magnetically Actuated Sensors Proven Magnetoresistive technology offers unmatched reliability Compatible Cylinder Profiles

17 Technology Comparison The Upgrade for pneumatic cylinders Giant MagnetoResistive (GMR) Chip manufacturer ad

18 New Product: V-Twin Series Two sensors one connector Reduce connection cost and installation time Detect multiple positions on grippers and cylinders M8 and M12 versions Uses Magneto-resistive technology Lifetime warranty Multiple versions available for C-Slot, T-Slot, tie rod, round and dovetail Replaces reed and Hall-Effect switches

19 Pneumatic Cylinder with Feedback Linear Feedback for Automated Changeover Allows use of low-cost pneumatic cylinders Rod locks hold position Rod follower or internal magnet tracking Absolute position feedback

20 DC Motor with Feedback Linear Feedback for Automated Changeover Allows use of low-cost DC Motor Use standard Acme screw Recipe driven automatic changeover Absolute position feedback

21 Direct load monitoring A better way to close the loop

22 Multiple Feedback Motion Control More AC servo drives are appearing with multiple feedback inputs Rather than closing just one variable, these newer drive controllers can close multiple loops These new drives are opening up more applications for linear encoders

23 Multiple Feedback Motion Control Linear encoders augment, rather than replace, rotary shaft encoders Torque loop closed by motor current sensor Velocity loop closed by motor shaft encoder Position loop not closed by shaft encoder Position loop closed by linear encoder Allows more precise control high-inertia loads Allows higher h speeds for heavy loads Prevents surging, hunting, and position overshoot

24 Indirect Position Monitoring Rotary Encoders Report motor shaft position, not actual load position Report load position through mechanical drive system: Ball screws, rack & pinion, synchronous belt drives Mechanical drive tolerances limit practical accuracy Reported Position: Actual Position: Load Carriage Rotary Encoder Ball Screw Follower Rotating Ball Screw Motor

25 Indirect Load Monitoring Rotary encoder itself is accurate Rotary encoder correctly reports shaft position BUT shaft position is only an estimate t of actual load position due to mechanical factors such as backlash Accuracy decreases as drive wears and backlash increases Accuracy limited it by precision i of drive Using a precision drive to improve rotary encoder accuracy adds to machine cost

26 Direct Position Monitoring i Linear Encoder Systems Sensor head moves with load Sensor head reads actual position of load Reported Position: Actual Position: Load Carriage Sensor head Linear Encoder Scale Motor

27 Direct Position Monitoring Load position is directly reported Backlash of actuator drive mechanism is eliminated as a source of inaccuracy Constant position accuracy over time regardless of drive wear and backlash Accurately reports position regardless of actuator drive precision or backlash Allows use of less precise, less expensive actuator with no sacrifice of position accuracy

28 Sensors survivability It s not by chance

29 Welding Function Common Process Issues that Stop Production Sensor Impact Improvement

30 Welding Function Common Process Issues that Stop Production Slag Buildup Improvement TM

31 Welding Function Common Process Issues that Stop Production Cable Damage Improvement

32 Welding Function Common Process Issues that Stop Production Improper Mounting Improvement Bunker Block TM

33 Welding Function Common Process Issues that Stop Production Heat Damage Improvement Bunker Block TM + High Temp Sensors

34 SMARTLevel Technology Proximity Sensors that detect more than just metal Now with technology to auto-tune difficult fill applications

35 The Solution: SMARTLevel Technology SMARTLevel capacitive sensors incorporate a new patented evaluation circuit to compensate and adjust automatically for material-build, foaming, filming and other influences to the sensing field. reliable SMARTLevel sensors do not require any setup procedure or cleaning maintenance since the technology allows the sensor to tune out glass or plastic walls automatically. Less assembly and maintenance time SMARTLevel sensors are also available in complete PTFE (Teflon ) housings to withstand harsh chemical environments. Rubustness

36 Trouble with Standard Capacitive Sensors C-Wall + C-Ground Foam / Material Build-up Wall Conductive Target (e.g. water) SENSOR Standard Capacitive Sensors cannot distinguish between the true level and material build-up, foaming or filming. Ground Result: - Inconsistent and false triggering - Frequent readjustments - Replacements - Maintenance cleaning procedures

37 Product Family - smartlevel SMARTLevel New technology for liquid level detection. Solve more applications, because of smartlevel technology -Compensates for humidity, foam and adhering -Senses through glass or plastic up to 10mm thickness -Detects aqueous and highly-conductive liquids reliable Reduce cost -Free of routine maintenance -Self-adjusting for most applications -Reduced material and engineering efforts

38 Standard vs. SMARTLevel Amplifier with Oscillator Standard Sensor Operation Principle No Oscillation without presence of an object Oscillation Oscillation Function of distance + coverage + dielectric factor Cylindrical Sensor from top view

39 Standard vs. SMARTLevel Wall SMARTLevel oscillator amplitude Amplifier Oscillator C-FIX C-FIX C-COMP The additionally introduced wall material causes an increase in C-COMP which h leads to a higher h oscillator amplitude. The sensor does not active the output at increasing oscillator amplitudes unlike the standard capacitive sensors. The result is the ability to compensate and self-adjust.

40 Standard vs. SMARTLevel Conductive Liquid Wall SMARTLevel oscillator amplitude Oscillator Amplifier C-FIX C-FIX The increase of C-GND reduces the output voltage and pulls the oscillator to 0V the trigger condition is reached and the sensor output t will be activated. t C-COMP C-GND

41 Standard vs. SMARTLevel What happens now with material build-up? Resistor - A thin film has a low electrical conductivity. - Extremely high AC frequency (~6.5MHz) causes additional resistance versus ground. GND Sensor doesn t recognize material build-up anymore as valid target without this ground reference.

42 Agenda Miniature sensors open up new applications Alternatives to Fiber optics Pneumatic cylinder sensing: Dual systems, analog and lifetime warranties are just a start Direct load monitoring: a better way to close the loop Sensors survivability: it s not by chance SmartLevel: a fusion for capacitive and conductance technologies