Q&A Improvement Case Studies
Using expensive Touch Probes for Updating the wear of Grinding Stone?! Looking for more economical solution…
Hello! I’m an engineer and designer of CNC Grinding machines.
Currently we are using Touch Probes for updating the wear of Grinding Stone but they cost more than 100,000 JPY per Probe, even it is a single detection of the Grinding Stone.
I am looking for contact-type sensors, as the Grinding Stone is stopped during the detection. Are there any economical sensors with the same repeatability of 1μm?
With 0.5μm repeatability at around 1/10 Price! Reducing your costs with the same specs!
Thank you very much for your inquiry! Metrol Precision Positioning Switches can also be used for wear updation of Grinding Stone in CNC Grinding Machines!
Cost of around 1/10 of other Touch Probes even with the same 0.5μm repeatability! Also, with IP67 Protective Structure for coolant and chips environment, it will contribute to reducing the cost for Grinding Stone Wear Updation!
Metrol Precision Switches have been used for detecting and updating the wear in Machining Centers and single measurement for NC Grinding machines!
Please feel free to contact us for further details! We are experiencing difficulties because the detection of double sheet metal feeding with expensive contact displacement sensors costs too much.
Hello, I am a user of sheet metal working equipment.
I engage in 0.5 mm-thick sheet metal working on spot welding lines. Although they happen very rarely, when feeding sheet metal on the line, double-feed errors do occur and these cause defective products.
Currently, to prevent this, we use contact displacement sensors with a repeatability of 1 μm and make them display the thickness to assess whether the number of fed sheets is one or more (if the thickness is greater than 0.5 mm, it is assessed as an error).
In this way, defective products have been prevented, but we have a problem because those sensors are too expensive.
Do you have any better solution?
Cost reduction, achieving the same precision as contact displacement sensors!
Thank you for your inquiry.
Is value indication really necessary in the detection of sheet metal double feeding? Contact displacement sensors with a display unit may be an over-engineered solution for positioning on automated lines.
Metrol precision positioning switches can achieve as high precision as contact displacement sensors at a low price without requiring expensive amplifiers. High repeatability of 1 μm is achieved at a low price. With precision positioning switches, double feed detection of sheet metals with a combined thickness of only 0.7 mm can easily be done. Radiation degrades photomicrosensors fast and we have to replace them every two or three months.
Hello, I am an engineer with an atomic laboratory. I design molecular accelerators used in a large-scale synchrotron radiation facility.
We use photomicrosensors in the positioning of a slit to narrow neutron beams. Sensors cannot be used inside the system because they are affected by radiation, so an intermediate mechanism is installed outside the system for detection.
However, we are experiencing difficulties with the following issues: 1) Sensors deteriorate because of slight radiation even outside the system and they need replacing every two or three months. 2) The precision of detection is naturally low because the detection is made via the intermediate mechanism. 3) The intermediate mechanism makes the system larger.
Are there any methods to position the slit with high precision even under radiation?
Leave precision positioning under radiation to precision positioning switches.
Thank you for your inquiry.
Leave positioning under radiation to precision positioning switches.
The Metrol radiation-compatible precision positioning switches are of the precision mechanical type made with materials that can be used under radiation. They do not include electronic components, so they are not damaged by radiation.
By incorporating the switches into the system and making them touch the slit directly, the following can be realized. 1) Elimination of labor required for replacement and repair, because the switches are immune from radiation 2) Repeatability of 1 μm 3) Size and cost reduction of the system requiring no intermediate mechanism
In addition to radiation environments, we have experience of precision positioning switches used in a high vacuum or magnetic fields. Q&A Improvement Case Studies
Contact displacement sensors used for measurement inside CNC cylindrical grinding machines cannot survive the harsh internal environment.
Hello, I am an engineer with a machine tool manufacturer. I design machines dedicated to semiconductor manufacturing (CNC cylindrical grinding machines).
We use contact displacement sensors with a value display function to measure the outer diameters of ingots before and after grinding.
The measured values are then fed back to the equipment for after-process inspection. However, we are experiencing difficulties because sensors are affected by coolant, scattering chips and dust inside the grinding machine and that causes malfunction.
In addition, the required display unit is costly.
To achieve 1 μm-precision measurements in adverse environments, contact-type devices are necessary. Do you have any solution for this?
Is value indication really necessary? Leave ON/OFF position signals to the digital scale of the equipment.
Thank you for your inquiry. Leave outer diameter measurement for workpieces inside CNC cylindrical grinding machines to Metrol.
Are displacement sensors with a value display function really necessary for the outer diameter measurement for ingots inside machine tools?
The Metrol touch probe-type precision positioning switch is designed exclusively for machine tools. By measuring high-precision ON/OFF position signals with a digital scale of the equipment, the outer diameter of ingots can be measured without using a value display unit.
In addition, the touch probe-type precision positioning switch is immune from coolant, scattering chips and dust and can achieve 1 μm repeatability in such adverse environments. It has been introduced widely for inner and outer diameter measurement and the centering of workpieces by major machine tool manufacturers.
Please try contacting Metrol about its precision positioning switches. Air sensor is low accuracy that confirming adhesion of Precision Component for PC cannot be done properly…
Hello, I am machining Precision Component for PC with Machining Center.
I use air sensor to confirm adhesion between the base and the fixture, but it cannot detect 10μm uplift as the sensor accuracy is 50μm. Also, installing air pipe is long that responsive speed is slow resulting in increasing tact time. I prefer installing the sensor close to the table inside, but coolant and chips might cause some trouble by doing so. Required accuracy is 10μm as to enable hard disk drive and disk motor fit each other well.
Air Micro Switch can steadily detects even 10μm uplift and improves precise machining for Precision Component for PC.
Thank you for your inquiry! If you are looking for seating confirmation of Precision Component for PC to the fixture in harsh environment, Metrol DPA-A2 is suitable for such application. DPA-A2 applies the principle of air micrometer and has ±1 micron repeatability, which is 10 times better than that of conventional air sensors’. By using the changes in air pressure, it can detect even 2 micron of “uplift” caused by chips reliably. IP67 enables to install in the machining area and shorten the tube pipe from 5m to 1m. Improves the response speed from 5 sec to 0.8 sec, and the tact time resulting in overall production efficiency! Metrol Air Micro Switch “DPA-A2” has been proved for its accurate and stable seating detection and confirmation of adhesion for engine die cast and watch base which require precise machining. If you are looking for Air Micro Switch that are better, please do not hesitate to contact us for DPA-A2!
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Looking for a solution for detecting 10μm of Power steering parts… 2013.10.11
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Using expensive Touch Probes for Updating the wear of Grinding Stone?! Looking for more economical solution…2013.10.11
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Air sensor is low accuracy that confirming adhesion of Precision Component for PC cannot be done properly…2013.09.04
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Contact displacement sensors used for measurement inside CNC cylindrical grinding machines cannot survive the harsh internal environment.2012.09.10
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Radiation degrades photomicrosensors fast and we have to replace them every two or three months.2012.09.10
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We are experiencing difficulties because the detection of double sheet metal feeding with expensive contact displacement sensors costs too much.2012.09.10
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False detection of photoelectric sensors results in damage to HDD disks. We are experiencing problems because of the production of defective disks.2012.09.10
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Radiation degrades optical fiber sensors. Are there any sensors durable under radiation exposure?2012.09.10
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The switch is not broken but false signals frequently occurs. It is necessary to detect the opening and closing of disk brake pads without fail!2012.09.10
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Is high-precision positioning for the driving part of equipment possible with stepper motors?2012.09.10
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The signal point of proximity sensors varies with changes of the external environment.2012.09.10
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Can small-diameter drills (ø 5 mm) length detection be made more reliable? Laser sensors are prone to fail in adverse environments.2012.09.10
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We need to correct the deviation of the X-Y axes of the table of semiconductor inspection devices.2012.09.10
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Can the double feeding of paper as thin as 0.1 mm really be prevented by microswitches?2012.09.10
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Is there any alternative to contact detection by installing an intermediate unit onto proximity sensors?2012.09.10
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We have some problems with the presence detection of wafers for semiconductor devices with photoelectric sensors.2012.09.10
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We need to correct the deviation of printing plates in micron increments.2012.09.10
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We are experiencing difficulties because proximity sensors cannot achieve high precision for bobbin positioning in automatic knitting machines. 2012.09.10
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Can 1 mm or smaller slight movements of diaphragms be detected stably with switches?2012.09.10
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There is no mounting space for a photoelectric sensor in workpiece detection with a robot.2012.09.10
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We are experiencing problems with connectors for optical fiber sensors inside vacuum film forming equipment.2012.09.10
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Optical fiber sensors detect objects falsely on conveyors.2012.09.10
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Are expensive touch probes necessary in end face measurement for grinders?2012.09.10
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Is the zero seek of carriers possible inside vacuum film forming equipment for FPDs?2012.09.10
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Mutual interference of neighboring proximity sensors prevents stable detection.2012.09.10
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False detection occurs because of condensation on the lens. We have difficulties because image sensors are easily affected by welding fumes.2012.09.10
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In workpiece seating confirmation, optical fiber sensors cannot reach trays inside vacuum film forming equipment.2012.09.10
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The intermediate mechanism installed for the detection of screws in pinholes with a proximity sensor costs too much.2012.09.10
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Expensive sensors for spring endurance testers? Are there any switches that can be used in automatic stop mechanisms?2012.09.10
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Are optical fiber sensors the best for glass substrate alignment inside vacuum film forming equipment for FPDs?2012.09.10
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Ultrasonic sensors cannot reliably detect 0.1 mm-thick sheets if the material type varies.2012.09.10
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The Z-axis of a desktop robot needs correction.2012.09.10
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Water drops on the liquid crystal glass cause false detection by optical fiber sensors.2012.09.10
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I have some problems with the precision of air sensors for seating confirmation.2012.09.10
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Can the slight movements of valve gates be detected at high temperatures during mold injection?
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Machine tools
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Looking for a solution for detecting 10μm of Power steering parts… 2013.10.11
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Using expensive Touch Probes for Updating the wear of Grinding Stone?! Looking for more economical solution…2013.10.11
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Air sensor is low accuracy that confirming adhesion of Precision Component for PC cannot be done properly…2013.09.04
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Contact displacement sensors used for measurement inside CNC cylindrical grinding machines cannot survive the harsh internal environment.2012.09.10
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Can small-diameter drills (ø 5 mm) length detection be made more reliable? Laser sensors are prone to fail in adverse environments.2012.09.10
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Are expensive touch probes necessary in end face measurement for grinders?2012.09.10
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I have some problems with the precision of air sensors for seating confirmation.
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Other industrial machinery
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The signal point of proximity sensors varies with changes of the external environment.2012.09.10
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Is there any alternative to contact detection by installing an intermediate unit onto proximity sensors?2012.09.10
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Mutual interference of neighboring proximity sensors prevents stable detection.2012.09.10
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The intermediate mechanism installed for the detection of screws in pinholes with a proximity sensor costs too much.2012.09.10
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Expensive sensors for spring endurance testers? Are there any switches that can be used in automatic stop mechanisms?
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Spinning
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