GOAL

• Automate the QC testing of drive shafts on the balancing machine.
• Take data and derive TIR within two seconds.
• Must be integrated with existing PLC.

SOLUTION

A two-channel KµDA system was installed with the sensors mounted to monitor each end of the rotating drive shaft. The PLC provided an output wired to one of the three digital inputs on KµDA which was configured to trigger two (one for each end of the drive shaft) of the KµDA programmable functions.

KµDA performed these functions on each sensor:

• Captured two seconds worth of data.
• Derived the peak and valley values, then subtract them.
• Sent this value to one of the three analog outputs.
• Triggered one of the digital outputs if the analog value exceeded the acceptance specification.

BENEFITS OF USING KµDA

• KµDA configurations are stored on board.
• KµDA takes on many of the tasks of PLC s.
• KµDA operates with all the benefits of digital circuitry, without a PC.
• With the use of a local enunciator wired to the KµDA digital output, the indication of pass or fail resided at the balancing with the technician.

GOAL

• Implement a fast and accurate method to measure aluminum substrate thickness after lapping for sorting requirements.
• Must measure immediately after lapping. Disks will be wet and coated with residue. Cannot touch the disk.
• Must integrate with future process automation plans.

SOLUTION

A two-channel KµDA was integrated into a NEMA 4 rated tabletop system, with the sensors mounted a fixed distance apart on opposite sides of the disk. Using a disk of known thickness, the spacing between the sensors is derived and stored in KµDA.

The thickness of each disk placed in between the sensors is calculated by subtracting the sum of the output of both sensors from the stored sensor spacing value. KµDA is configured to provide the thickness as an analog output, which is displayed locally to the operator in engineering units.

BENEFITS OF USING KµDA

• KµDA configurations are stored on board. Once the configuration is set, KµDA operates without a PC.
• Performance can be verified as often as needed by checking the thickness of the known disk.
• KµDA is based on eddy current technology, so lapping residue, water, dirt, and grime are invisible.
• With built in digital I/O and RS-232/485, KµDA is ideal as a standalone system or easily integrated into any future automation process control platforms.

GOAL

• Measure/display the gap at each end of a roller pair.
• Provide local digital display for technicians making routine adjustments to the roll gap.
• Provide for implementation of a plant-wide data acquisition system to monitor system performance.

SOLUTION

A two-channel KµDA is integrated into a NEMA 4 rated enclosure with digital displays. A sensor is mounted to a lower roller bearing block and an aluminum target, to an upper block. With a known gap between the rollers, the sensor output is adjusted. Each sensor provides an analog voltage output proportional to the gap. KµDA calculates the difference between the sensor outputs and provides the difference between the gaps at each end of the roller. A limit output is triggered when this value exceeds a prescribed threshold, indicating a need for maintenance.

BENEFITS OF USING KµDA

• KµDA configurations are stored on board. Once the configuration is set, KµDA operates without a PC.
• KµDA is an eddy current system and unaffected by the cleanliness of the material being measured.
• RS-485 drop allows future integration into SPC/PM systems.

GOAL

• Monitor core movement in-situ during the injection molding process.
• Integrate into a plant-wide data acquisition and control system.
• Survive the high temperature and pressure of the mold environment.

SOLUTION

Kaman designed a custom sensor to meet the pressure (20,000 psi) and temperature (500° F) requirements. This sensor is characterized with KµDA electronics and embedded into the wall of the mold used for making medical waste buckets with stringent wall thickness specifications. The sensor face forms part of the mold wall and senses any movement of the core. The system alarms if movement is detected that exceeds the specified limit, triggering the material handler to discard any out-of-spec bucket. Via RS-232/485 interface, the data from each part is captured by the plant wide data acquisition system.

BENEFITS OF USING KµDA

• KµDA configurations can be stored and loaded as required by the plant wide data acquisition and control program. This allows an individual sensor to remain with the mold. When mold change is required to run different parts, the sensor in the new mold is attached to the KµDA and the control program loads the configuration for that sensor. All configuration data, calibration parameters, alarms, and functions are downloaded.
• KµDA is an eddy current system and unaffected by the presence of plastic in either liquid or solid form.
• Active temperature compensation allows for accurate readings regardless of the variation in temperature of the mold.