Sensing & Feedback Technologies

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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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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.


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

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needed for an external amplifier.


Fiber Optic AlternativesFiber Optic Alternatives

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Ultraframe ApplicationsUltraframe Applications Fiber Optic Upgrade

Absolute #1 solution for feed systemsy

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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

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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


Error Proofing Sensors in ToolingError Proofing Sensors in Tooling

Kohler Case Assembly Press: 30 inspections with Ultraframe

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New Transparent Detection

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

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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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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


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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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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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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Direct load monitoringA b tt t l th lA better way to close the loop

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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


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


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


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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Welding FunctionWelding Function

Common Process Issues that Stop Production

Sensor Impact

Improvement

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Welding FunctionWelding FunctionCommon Process Issues that Stop Production

Slag Buildup

Improvement

TM

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Cable Damage

Improvement

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Welding FunctionWelding FunctionCommon Process Issues that Stop Production

Improper Mounting

Improvement

Bunker BlockTM

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Bunker Block




Heat Damage

Improvement

Bunker BlockTM

++ High Temp Sensors

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SMARTLevel TechnologySMARTLevel Technology

Proximity Sensors that detect more than just metal

Now with technology to auto-tune difficult fill

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applications


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


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


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.


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