Date post: | 11-May-2015 |
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S i & F db k T h l i Sensing & Feedback Technologies
The Latest Sensor Trends
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PRESENTATION : New Tech
AgendaAgenda
• Miniature sensors open up new applications
• Alternatives to Fiber optics• Pneumatic cylinder sensing: y g
Dual systems, analog and lifetime warranties are just a start
• Direct load monitoring: a better way to close the loopa better way to close the loop
• Sensors survivability: it’s not by chance
• SmartLevel:• SmartLevel: a fusion for capacitive and conductance technologies
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PRESENTATION : New Tech
Miniature Sensors
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SuperShorty™ Miniature Inductive SensorsSuperShorty Miniature Inductive SensorsImagine the Possibilities...
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SuperShorty™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 requiredy g y p q– Easy to install – (2) different threaded mounting brackets
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SuperShorty™SuperShortyApplication: Pneumatic-motor
Ø6.5 X 6mm
Even in the very space-critical pneumatic-motor, there is enough room for (3)motor, there is enough room for (3) SuperShorty sensors. In this application the sensors have to verify the “step” position
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verify the step position.
PRESENTATION : New Tech
SuperShorty™
Ø6.5 x 6mm
p yApplication: Pick-and-place
Ideal for highly-dynamic applicationsapplicationsApplications with extremely high accelerations, e. g. pick-and-place,
d ibl d t it li htare made possible due to its light weight (just 0.7 grams).
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SuperShorty™SuperShortyApplication: Vertical Linear Slide
Ø6.5 X 6mm
Easy to integrate…e g in linear slides for end-of-… e. g. in linear slides for end-of-travel monitoring. Electronics are fully integrated in the 6 mm housing. No machine space is
f f
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needed for an external amplifier.
PRESENTATION : New Tech
Fiber Optic AlternativesFiber Optic Alternatives
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PRESENTATION : New Tech
Ultraframe ApplicationsUltraframe Applications Fiber Optic Upgrade
Absolute #1 solution for feed systemsy
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PRESENTATION : New Tech
Ultraframe ApplicationsU t a a e pp cat o s
Precision Laser “L” Shape– About 10x the resolution and repeatability of standard visible red
L Shape– Ideal for 2 axis movements– Extremely rugged– Powerful light source
– Beam visible in all conditions
g
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PRESENTATION : New Tech
Distributor Program RemindergULTRAFRAME™
Family of self-contained thru-beam sensors
BGL BOW
Thru-beam reliability in a single-piece package• Four different shapes to choose from
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BGL BOW
• Up to four application-specific light sources available• IP67 rated housings• Greatly reduces installation time
BWL
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BWL
PRESENTATION : New Tech
Error Proofing Sensors in ToolingError Proofing Sensors in Tooling
Kohler Case Assembly Press: 30 inspections with Ultraframe
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PRESENTATION : New Tech
New Transparent Detection
Ideal for detecting:- Glass bottles- PET bottles- Transparent films- Glass sheets- Vials
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PRESENTATION : New Tech
P ti C li dPneumatic Cylinder Position SensorsPosition SensorsSuperior Magnetoresistive technologyUniversal and application specific housingsUniversal and application specific housings Lifetime warrantyAnalog versions for cylinders and grippers
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PRESENTATION : New Tech
The Solid Solid-StateThe Solid Solid StatePneumatic Cylinder Sensor Lifetime Warranty
Magnetically Actuated Sensors
Proven Magnetoresistivetechnology offers unmatched reliability
CompatibleCylinder Profiles
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Technology ComparisonTechnology Comparison
The Upgrade forThe Upgrade for pneumatic cylinders
WWW.BALLUFF.COM Giant MagnetoResistive (GMR) Chip manufacturer ad
PRESENTATION : New Tech
New Product: V-Twin SeriesNew Product: V-Twin Series • Two sensors one connector• Reduce connection cost and installation time• Detect multiple positions on grippers and 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
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PRESENTATION : New Tech
Pneumatic Cylinder with FeedbackPneumatic 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
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PRESENTATION : New Tech
DC Motor with FeedbackDC 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
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PRESENTATION : New Tech
Direct load monitoringA b tt t l th lA better way to close the loop
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PRESENTATION : New Tech
Multiple Feedback Motion ControlMultiple Feedback Motion Control
• More AC servo drives are appearing with multiple feedback inputs• Rather than closing just one variable these newer drive controllers• 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
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Multiple Feedback Motion ControlMultiple Feedback Motion Control
• Linear encoders augment, rather than l h f dreplace, 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 loadsAll hi h d f h l d– Allows higher speeds for heavy loads
– Prevents surging, hunting, and position overshoot
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Rotary Encoders
Indirect Position Monitoring
– 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: 10.0000”
Rotary EncoderLoad Carriage
Reported Position: 10.0000Actual Position: 10.0721”
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Rotating Ball ScrewBall Screw Follower Motor
PRESENTATION : New Tech
Indirect Load Monitoring
R t d it lf i tRotary encoder itself is accurateRotary encoder correctly reports shaft positionBUT h ft iti i l ti t f t lBUT…shaft position is only an estimate of actual load position due to mechanical factors such as backlashAccuracy decreases as drive wears and backlash increasesA li it d b i i f d iAccuracy limited by precision of driveUsing a precision drive to improve rotary encoder accuracy adds to machine cost
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accuracy adds to machine cost
PRESENTATION : New Tech
Di t P iti M it iLinear Encoder Systems
Direct Position Monitoringy
– Sensor head moves with load– Sensor head reads actual position of load
Reported Position: 10.0000”Actual Position: 10 0000”
Load Carriage
Actual Position: 10.0000
Linear Encoder ScaleSensor head
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Linear Encoder ScaleSensor headMotor
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Direct Position Monitoring
Load position is directly reportedLoad position is directly reported
Backlash of actuator drive mechanism is eliminated as a source of inaccuracyas 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
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Sensors survivability
It’s not by chance
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PRESENTATION : New Tech
Welding FunctionWelding Function
Common Process Issues that Stop Production
Sensor Impact
Improvement
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PRESENTATION : New Tech
Welding FunctionWelding FunctionCommon Process Issues that Stop Production
Slag Buildup
Improvement
TM
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PRESENTATION : New Tech
Welding FunctionWelding Function
Common Process Issues that Stop Production
Cable Damage
Improvement
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PRESENTATION : New Tech
Welding FunctionWelding FunctionCommon Process Issues that Stop Production
Improper Mounting
Improvement
Bunker BlockTM
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Bunker Block
PRESENTATION : New Tech
Welding FunctionWelding Function
Common Process Issues that Stop Production
Heat Damage
Improvement
Bunker BlockTM
++ High Temp Sensors
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PRESENTATION : New Tech
SMARTLevel TechnologySMARTLevel Technology
Proximity Sensors that detect more than just metal
Now with technology to auto-tune difficult fill
li tiWWW.BALLUFF.COM
applications
PRESENTATION : New Tech
The Solution: SMARTLevel TechnologyThe Solution: SMARTLevel TechnologySMARTLevel 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
SMARTL l d t i t
reliable
filming and other influences to the sensing field.
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.
SMARTLevel sensors are also available in complete
Less assembly and maintenance time
SMARTLevel sensors are also available in complete PTFE (Teflon®) housings to withstand harsh chemical environments.
R b stness
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Rubustness
PRESENTATION : New Tech
Trouble with Standard Capacitive SensorsTrouble with Standard Capacitive Sensors
Wall
C-Wall + C-Ground
Foam / Material
ConductiveTarget
Build-up
SENSORTarget
(e.g. water) Standard Capacitive Sensors cannotdistinguish between the true level andmaterial build-up, foaming or filming.
Ground
Result: - Inconsistent and false triggering - Frequent readjustments- Replacements - Maintenance cleaning procedures
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Product Family - smartLEVELProduct Family smartLEVEL
New technology for liquid level detection.SMARTLevel
-Compensates for humidity, foam and adhering-Senses through glass or plastic up to 10mm thicknessDetects aqueous and highly conductive liquids reliable
Solve more applications, because of smartLEVEL technology
-Detects aqueous and highly-conductive liquids reliable
Reduce cost-Free of routine maintenance-Self-adjusting for most applications-Reduced material and engineering efforts
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Standard vs SMARTLevelStandard vs. SMARTLevelAmplifier with Oscillator
Standard Sensor Operation Principle
No Oscillation without presence of an object
OscillationFunction of
Oscillation
distance +coverage +
dielectric factor
Cylindrical Sensor
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Cylindrical Sensor from top view
PRESENTATION : New Tech
Standard vs SMARTLevelStandard vs. SMARTLevelWall
SMARTLevel
Amplifier
oscillator amplitude
Oscillator
C-FIX
C-FIXC-COMP
The additionally introduced wall material causes an increase in C-COMPhi h l d t hi h ill t lit d Th d t ti– which leads to a higher oscillator amplitude. The sensor does not active
the output at increasing oscillator amplitudes – unlike the standardcapacitive sensors. The result is the ability to compensate and self-adjust.
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Standard vs SMARTLevelStandard vs. SMARTLevelWallConductive
Liquid SMARTLevel
oscillator amplitude
Oscillator Amplifier
C-FIX C-FIX
C-COMPC-GND
The increase of C-GND reduces the outputvoltage and pulls the oscillator to 0V – the trigger condition is reached and the sensor
t t ill b ti t d
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output will be activated.
PRESENTATION : New Tech
Standard vs SMARTLevelStandard vs. SMARTLevelWhat happens now with material build-up?
Resistor
- A thin film has a low electrical conductivity. - Extremely high AC frequency (~6.5MHz) causesadditional resistance versus ground.
GND
Sensor doesn’t recognize material build-up anymore asvalid target without this ground reference.
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AgendaAgenda
• Miniature sensors open up new applications
• Alternatives to Fiber optics• Pneumatic cylinder sensing: y g
Dual systems, analog and lifetime warranties are just a start
• Direct load monitoring: a better way to close the loopa better way to close the loop
• Sensors survivability: it’s not by chance
• SmartLevel:• SmartLevel: a fusion for capacitive and conductance technologies
WWW.BALLUFF.COM