Sensing & Feedback Technologies

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The lastest sensor trends (Balluff) Drive for Technology 2010 presentation

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Sensing & Feedback Technologies

  1. 1. WWW.BALLUFF.COM Sensing & Feedback Technologies S i F db k T h l i The Latest Sensor Trends WWW.BALLUFF.COM
  2. 2. PRESENTATION : New Tech Agenda • 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 loop • Sensors survivability: it’s not by chance • SmartLevel: a fusion for capacitive and conductance technologies WWW.BALLUFF.COM
  3. 3. PRESENTATION : New Tech Miniature Sensors WWW.BALLUFF.COM
  4. 4. WWW.BALLUFF.COM SuperShorty SuperShorty™ Miniature Inductive Sensors Imagine the Possibilities... WWW.BALLUFF.COM
  5. 5. PRESENTATION : New Tech 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 y g y p q – Easy to install – (2) different threaded mounting brackets WWW.BALLUFF.COM
  6. 6. PRESENTATION : New Tech SuperShorty 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 step position. WWW.BALLUFF.COM
  7. 7. PRESENTATION : New Tech SuperShorty™ p y 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 d ibl d t it li ht weight (just 0.7 grams). WWW.BALLUFF.COM
  8. 8. PRESENTATION : New Tech SuperShorty SuperShorty™ Application: Vertical Linear Slide Ø6.5 X 6mm Easy to integrate… … e g in linear slides for end-of- e. g. travel monitoring. Electronics are fully integrated in the 6 mm housing. No machine space is needed f an external amplifier. for f WWW.BALLUFF.COM
  9. 9. PRESENTATION : New Tech Fiber Optic Alternatives WWW.BALLUFF.COM
  10. 10. PRESENTATION : New Tech Ultraframe Applications Fiber Optic Upgrade Absolute #1 solution for feed systems y WWW.BALLUFF.COM
  11. 11. PRESENTATION : New Tech U t a a e pp cat o s Ultraframe Applications Precision Laser “L” Shape L – About 10x the resolution and – Ideal for 2 axis movements repeatability of – Extremely rugged standard visible red – Powerful light source g – Beam visible in all conditions WWW.BALLUFF.COM
  12. 12. PRESENTATION : New Tech Distributor Program Reminder g 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 f four application-specific light sources available f • IP67 rated housings • Greatly reduces installation time BWL BWL WWW.BALLUFF.COM
  13. 13. PRESENTATION : New Tech Error Proofing Sensors in Tooling Kohler Case Assembly Press: 30 inspections with Ultraframe WWW.BALLUFF.COM
  14. 14. PRESENTATION : New Tech New Transparent Detection Ideal for detecting: - Glass bottles - PET bottles - Transparent films - Glass sheets - Vials WWW.BALLUFF.COM
  15. 15. PRESENTATION : New Tech Pneumatic Cylinder P ti C li d Position Sensors  Superior Magnetoresistive technology  Universal and application specific housings  Lifetime warranty  Analog versions for cylinders and grippers WWW.BALLUFF.COM
  16. 16. PRESENTATION : New Tech The Solid Solid-State Solid State Pneumatic Cylinder Sensor Lifetime Warranty Magnetically Actuated Sensors Proven Magnetoresistive technology offers unmatched reliability Compatible Cylinder Profiles WWW.BALLUFF.COM
  17. 17. PRESENTATION : New Tech Technology Comparison The Upgrade for pneumatic cylinders WWW.BALLUFF.COM Giant MagnetoResistive (GMR) Chip manufacturer ad
  18. 18. PRESENTATION : New Tech 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 WWW.BALLUFF.COM
  19. 19. PRESENTATION : New Tech 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 WWW.BALLUFF.COM
  20. 20. PRESENTATION : New Tech 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 WWW.BALLUFF.COM
  21. 21. PRESENTATION : New Tech Direct load monitoring A b tt way t close the loop better to l th l WWW.BALLUFF.COM
  22. 22. PRESENTATION : New Tech Multiple Feedback Motion Control • More AC servo drives are appearing with multiple feedback inputs • Rather than closing just one variable, these newer drive controllers variable can close multiple loops • These new drives are opening up more applications for linear encoders WWW.BALLUFF.COM
  23. 23. PRESENTATION : New Tech Multiple Feedback Motion Control • Linear encoders augment, rather than replace, rotary shaft encoders l h f d • 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 – All Allows hi h speeds f h higher d for heavy l d loads – Prevents surging, hunting, and position overshoot WWW.BALLUFF.COM
  24. 24. PRESENTATION : New Tech 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: 10.0000 10.0000” Actual Position: 10.0721” Load Carriage Rotary Encoder Ball Screw Follower Rotating Ball Screw Motor WWW.BALLUFF.COM
  25. 25. PRESENTATION : New Tech Indirect Load Monitoring Rotary encoder itself is accurate R t d it lf i t Rotary encoder correctly reports shaft position BUT…shaft position is only an estimate of actual BUT h ft iti i l ti t f t l load position due to mechanical factors such as backlash Accuracy decreases as drive wears and backlash increases Accuracy li it d by precision of drive A limited b i i fd i Using a precision drive to improve rotary encoder accuracy adds to machine cost WWW.BALLUFF.COM
  26. 26. PRESENTATION : New Tech Direct Position M it i Di t P iti Monitoring Linear Encoder Systems y – Sensor head moves with load – Sensor head reads actual position of load Reported Position: 10.0000” Actual Position: 10.0000 10 0000” Load Carriage Sensor head Linear Encoder Scale Motor WWW.BALLUFF.COM
  27. 27. PRESENTATION : New Tech 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 WWW.BALLUFF.COM
  28. 28. WWW.BALLUFF.COM Sensors survivability It’s not by chance WWW.BALLUFF.COM
  29. 29. PRESENTATION : New Tech Welding Function Common Process Issues that Stop Production Sensor Impact Improvement WWW.BALLUFF.COM
  30. 30. PRESENTATION : New Tech Welding Function Common Process Issues that Stop Production Slag Buildup Improvement TM WWW.BALLUFF.COM
  31. 31. PRESENTATION : New Tech Welding Function Common Process Issues that Stop Production Cable Damage Improvement WWW.BALLUFF.COM
  32. 32. PRESENTATION : New Tech Welding Function Common Process Issues that Stop Production Improper Mounting Improvement TM Bunker Block WWW.BALLUFF.COM
  33. 33. PRESENTATION : New Tech Welding Function Common Process Issues that Stop Production Heat Damage Improvement Bunker BlockTM + High Temp Sensors WWW.BALLUFF.COM
  34. 34. PRESENTATION : New Tech SMARTLevel Technology Proximity Sensors that detect more than just metal Now with technology to auto-tune difficult fill applications li ti WWW.BALLUFF.COM
  35. 35. PRESENTATION : New Tech 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. field reliable SMARTLevel sensors do not require any setup SMARTL l d t i t 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 R b stness WWW.BALLUFF.COM
  36. 36. PRESENTATION : New Tech Trouble with Standard Capacitive Sensors C-Wall + C-Ground Foam / Material Wall Build-up Conductive Target (e.g. water) SENSOR Standard Capacitive Sensors cannot distinguish between the true level and material build-up, foaming or filming. Result: - Inconsistent and false triggering Ground - Frequent readjustments - Replacements - Maintenance cleaning procedures WWW.BALLUFF.COM
  37. 37. PRESENTATION : New Tech 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 Detects highly conductive Reduce cost -Free of routine maintenance -Self-adjusting for most applications -Reduced material and engineering efforts WWW.BALLUFF.COM
  38. 38. PRESENTATION : New Tech Standard vs SMARTLevel vs. Standard Sensor Operation Principle Amplifier with Oscillator No Oscillation without presence of an object Oscillation Function of distance + coverage + dielectric factor Oscillation Cylindrical Sensor from top view WWW.BALLUFF.COM
  39. 39. PRESENTATION : New Tech Standard vs SMARTLevel vs. Wall SMARTLevel oscillator amplitude Amplifier Oscillator C-FIX C-COMP C-FIX The additionally introduced wall material causes an increase in C-COMP – which leads to a hi h oscillator amplitude. Th sensor does not active hi h l d t higher ill t lit d The d t ti the output at increasing oscillator amplitudes – unlike the standard capacitive sensors. The result is the ability to compensate and self-adjust. WWW.BALLUFF.COM
  40. 40. PRESENTATION : New Tech Standard vs SMARTLevel vs. Conductive Wall Liquid SMARTLevel oscillator amplitude Oscillator Amplifier C-FIX C-FIX C-COMP C-GND The increase of C-GND reduces the output voltage and pulls the oscillator to 0V – the trigger condition is reached and the sensor output will be activated. t t ill b ti t d WWW.BALLUFF.COM
  41. 41. PRESENTATION : New Tech Standard vs SMARTLevel vs. 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. WWW.BALLUFF.COM
  42. 42. PRESENTATION : New Tech Agenda • 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 loop • Sensors survivability: it’s not by chance • SmartLevel: a fusion for capacitive and conductance technologies WWW.BALLUFF.COM

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