Interesting applications from the automation industry
Sensors often play a very important role in automation technology. Sensitec MagnetoResistive sensors are used in many applications, such as simple switching functions in pneumatic cylinders, highly dynamic and high-resolution motor feedback systems or even in complex process monitoring. These deliver flawless, high-precision measurement results to the upstream control unit.
Due to the variety of requirements, all possibilities and benefits of magnetic sensor technology are fully utilized in automation. These include durability, precision and dynamics as well as high signal resolution, a broad temperature range and naturally also the possibility of extremely compact sensor integration.
In the following descriptions of use you will find various examples of how and where Sensitec MagnetoResistive sensors are used as a solution for measurement tasks.
Position and speed measurement Measurement system to record the angular position and speed of the motor shaft
Local solutions, high power density and cost efficiency are the demands that are also being called for in the field of development of electric motors. The high integration density and the simultaneous increasingly harsh conditions, pave the way for magnetic solutions. Dust, oil and grease cannot touch the magnetic measurement principle – integration without any housing is preferable to avoid unnecessary costs as well as the space saving. The high power density leads to higher temperatures and also to larger magnetic stray fields. The challenges for a customized measurement solution for recording speed and position are extremely complex and can only be solved reliably with a special design.
Angle measurement robots Angle measurement in the motors of robotic joints
The changing face of industrial robotics: The image of classic industrial robots – that perform their services on heavy and cumbersome components, locked in cages in order to protect the life and limb of the employees in the area should a malfunction occur – is a thing of the past in the new generation of robots. The trend is towards "collaborative work" – not just between people, but also between people and robots. If robots can indeed easily carry larger loads and operate as delicately as a human being using modern sensor components, then they can learn the motion sequences of people – “hand in hand” in the truest sense of the phrase. With their strength, they can assist people in adjusting and exact positioning of components in the mounting processes. More fields of use are being revealed practically every day.
Process controls & process documentation Process monitoring for mechanical riveted joints
It pops and is over in less than 500 µs: A nail-like "tac" joins two materials together - and the whole thing is absolutely perfect! The connection is stable – which can be seen very easily in a diagram – because the fusion process is monitored by sensors. But take a step back: What’s this all for?
Plastic bonded materials are increasingly being used in modern car body production, meaning that classic welding technology is no longer an option. Riveted joints have the disadvantage of requiring a counterpart in order to produce a safe connection. As a result, a new joining method has established itself, which closely resembles a nail connection. Due to the high demands for a demonstrably secure connection, the process must be monitored and documented.
This requires a measuring and evaluation system, which virtually completely records the joining process. The analysis is carried out using a systematic "fingerprint”. Driving in the tac too strongly or too weakly results in an unclean connection and can be clearly recognized by a number of points in a recorded distance-time diagram. The same is true for a correct, clean join.
At a speed of more than 50 m/s, the roughly 3-cm-long tac is "shot" into the materials - a highly dynamic process that places high demands on the sensor solution.
The compressed air driven driver piston for the tac features a 2-mm tooth structure. This is sealed with a non-magnetic material so that the piston has a smooth surface.
The sensor system, based on the GMR tooth sensors, was integrated in the piston guide.
The sensor signals are amplified and sensor parameters, such as offset and amplitude, are corrected.
Within the controller, the position of the piston can be determined using a simple arc tangent procedure and can be converted into a distance-time diagram in combination with the time.
The assembly is extremely durable and is implemented in the system so that it can withstand the strong shock loads despite harsh conditions.
Excellent sensor signals despite high dynamics in the process
Direct measurement principle on the driver piston is presented precisely via the tac-position
Distance-time diagram or “Finger print” of the process for high-quality proof of quality
Current measurement in drive controllers Typical high-resolution, 3-phase current measurement with galvanic isolation
There are numerous options with a wide range of technologies for typical 3-phase current measurement in the field of drive technology. In principle, the requirement consists of ensuring a secure galvanic isolation between the load circuit and the signal circuit. Furthermore, good dynamics, low power losses and low installation space are required for current measurement.
The better the current measurement, the higher the control quality of the overall system. However, cost-effectiveness is also required. A cheap transformer often requires extensive wiring – so all the pros and con of the overall system must always be weighed up.
Standard current sensor of the CDS4000 family with unipolar 5 V power supply.
3 sensors with compact outer geometry for all 3 phases.
The current sensors are fitted onto the PCB as a THT component and no addition cables leading through the converter core are required.
High signal bandwidth with 200 kHz
No iron core, very compact structure, hardly any internal losses
Current proportional analog output signal
Additional overcurrent output signal for direct shut down of the IGBTs
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