2008 Strategic Marketing and Communications Plan

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Transcript 2008 Strategic Marketing and Communications Plan

KAMAN APPLICATION NOTE
ThreadChecker™ Universal
Checks the presence or absence
of threads using non-contact
eddy current technology
800-552-6267 | www.kamansensors.com |
[email protected]
800-552-6267 | www.kamansensors.com
| [email protected]
Copyright 2010
Copyright 2010
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Basic eddy current operation
Slide 4
Thread detection basics
Slide 5
Thread detection in operation
Slides 6-11
Application concerns
Slide 12-19
Teaching the ThreadCheckerTM
Slide 20
Electrical installation
Slide 21
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Copyright 2010
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Inductive ‘eddy current’
principles of operation
Normal displacement operation
• An oscillating electro-magnetic field is
magnetic field radiating from the end of the
sensor.
• The sensor uses the portion of the electro-
produced in the sensor tip.
• As the target moves from position A to
position B the output voltage decreases.
• Any conductive material engaging this
field will have ‘eddy current’ induced in the
surface setting up a corresponding electromagnetic field.
• As the gap between the sensor and the
conductive target material changes, the
influence of the eddy current field on the
sensor field changes.
• The electronics produces an analog
voltage proportional to the gap between the
sensor and the target.
10
VDC
A
B
0
VDC
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A B
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Thread detection using
eddy current technology
• Instead of using the axial portion of the
electro-magnetic field, thread detection uses
the radial portion of the field.
Thread presence/absence
operation
10
VDC
• The sensor uses the portion of the electromagnetic field radiating radially from the
sensor.
• An untapped hole results in a lower voltage
output than that of a tapped hole.
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A
B
0
VDC
A
B
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
IN OPERATION
Thread Detection Zone 1
• Sensor in air.
• Output saturated high.
Zone
1
2
10 VDC
3
4
5
6
0 VDC
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
IN OPERATION
Thread Detection Zone 2
• Sensor enters the tapped hole.
Zone
1
2
3
4
5
6
• Radial portion of the electromagnetic field engages the threaded
hole.
10 VDC
0 VDC
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• Output begins to decrease.
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
IN OPERATION
Thread Detection Zone 3
• Sensor is completely in threaded section
of the tapped hole.
Zone
1
2
• Electro-magnetic field is fully engaged.
10 VDC
3
4
5
6
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Copyright 2010
• Output indicates pitch diameter
of threads.
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
IN OPERATION
Thread Detection Zone 4
• Sensor transitions to untapped section
of the hole.
Zone
1
2
• Electro-magnetic field transitions from
threads to tap drill diameter.
10 VDC
3
4
5
6
0 VDC
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Copyright 2010
• Output decreases.
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
IN OPERATION
Thread Detection Zone 5
• Sensor’s electro-magnetic field is completely in untapped section of the hole.
• Output indicates untapped hole diameter.
Zone
1
2
3
4
5
6
10 VDC
0 VDC
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
IN OPERATION
Thread Detection Zone 6
• Sensor’s electro-magnetic field begins
to engage bottom of the hole
Zone
1
2
• Output continues to decrease as it does
in a normal displacement measurement.
10 VDC
3
4
5
6
0 VDC
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
APPLICATION CONCERNS
• Thread pitch Coarse threads are easier to detect. Finer threads require tighter insertion repeatability
• Pitch diameter vs. sensor diameter Bigger gaps provide less sensitivity.
Smaller gaps require tighter insertion repeatability
• Axial insertion repeatability Long thread length is easier. Short thread lengths require tighter insertion repeatability.
• Radial insertion repeatability Big hole/small sensor is easier. Less gap requires tighter insertion repeatability.
• Thermal environmental changes Sensor temperature changes can/will cause a change in the output.
• Cut vs. cold form threads Cut threads are easier to detect. Formed threads requires tighter insertion repeatability
• Base material As this is an eddy current device, the base material must be electrically conductive.
• Sensor damage potential Spring-loaded sensor mounts minimize damage potential during operation.
800-552-6267 | www.kamansensors.com | [email protected]
Copyright 2010
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Thread pitch
• Eddy currents induced in the surface
follow the contour of the threads.
• Output voltage indicates the average of
the major and minor thread diameters,
essentially the pitch diameter of the threads.
.174”
.159”
• The coarser the threads, the greater the
voltage difference between tapped and
untapped holes.
• Finer threads warrant tighter radial
insertion repeatability of the sensor.
10-32 threaded
hole .0075” radial
differential.
.189”
.169”
.149”
10-24 threaded
hole .010” radial
differential.
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Pitch diameter
vs. sensor diameter
• Although the output is linear, the
sensitivity is greater close in to the sensor
and less farther out.
• Too small a gap can cause rubbing
between the sensor body and thread ID
resulting in irreparable damage to the
sensor.
• Too large a gap and eccentricity between
the sensor and hole becomes an error
source.
• It is best to stay within the published
recommendations for the thread size being
checked.
800-552-6267 | www.kamansensors.com | [email protected]
Copyright 2010
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Axial insertion
repeatability
• The output changes as the
sensor enters the tapped hole.
• If not fully inserted, minor
depth changes will result in
output changes.
• Longer thread lengths
provide best reliability.
Repeatabiliy
Zone
10 VDC
10 VDC
Thread
Thread
No Thread
No Thread
0 VDC
Repeatability
Zone
Depth
0 VDC
• Thread lengths shorter than
the electro-magnetic field
length require very
repeatable axial insertion.
Repeatability
Zone
Depth
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Radial insertion repeatability
• The output changes as the sensor moves
laterally in a hole, tapped or untapped.
• Hole/sensor eccentricity can be an error
source.
• Better radial insertion repeatability X will
provide greater headroom Y resulting in
more reliable operation.
10 VDC
Y
Thread
No Thread
X
0 VDC
CL
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Thermal sensitivity
• Spec is 0.05%/deg C
• Output is 0-10 VDC
10 VDC
• With thread voltage @ 4.500 VDC and
unthreaded voltage at 4.300 VDC when taught,
the switch is set to trip at 4.400 VDC.
• 4.300 VDC x . 05% = .00215 VDC change per
degree C. Hence a 10 degree C change in
ambient temperature could result in an
untapped hole voltage of 4.3215 VDC, now
only .0785 VDC from the switch point instead
of the original 0.100 VDC.
0 VDC
• At wider gaps, the voltage value is higher
resulting in a higher voltage shift, getting even
closer to the switch point.
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
0.250”
0.230” (Avg)
Cold
Form
Threads
0.224”
(Drill Diameter)
• Hole diameter for cold form threads is larger than cut
threads.
• The difference between the hole diameter and average
(basically pitch) diameter is much less with cold formed
threads.
0.250”
0.225” (Avg)
Cut
Threads
Cut vs. cold form threads
0.201”
(Drill Diameter)
• Cold working can change the properties of the material
somewhat, affecting the sensor output. This is more of a
concern with ferrous materials.
• Cold form threads typically can be 60% of full depth
vs. 75 % of full depth for the same strength in cut
threads. This can reduce the drill diameter to average
diameter distance even more.
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Base material
• The most influential difference is seen
between ferrous and non-ferrous material.
• The second major influence is conductivity.
• Within ferrous and non-ferrous categories,
‘teaching’ the sensor the new material is
sufficient to accommodate the variation in
conductivity.
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KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Sensor damage potential
• The coil in the sensor is only ~0.010” from the
OD of the PEEK sensor tip just below the conical
section. Exercise care to avoid the sensor tip
rubbing on the inside of the hole.
• Plunging the sensor into a broken tap is obviously
going to cause irrepairable damage. Using a spring
loaded sensor mount will help minimize this
potential.
• The sensor and electronics are rated IP67. The
cabling in PUR jacketed, and the sensor is made of
PEEK and stainless steel. This combination holds
up very well to a wide variety of coolants and
lubricants.
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Copyright 2010
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Teaching the ThreadCheckerTM
• Push the teach button once to put the microprocessor
in ‘teach’ mode. The ‘Thread’ LED will be yellow and
flash rapidly.
• Insert the sensor into a threaded hole, and push the
teach button once. The ‘Thread’ LED will be yellow
and flash slowly.
• Insert the sensor into an unthreaded hole, and push
the teach button once. The ‘Thread’ LED will be red
indicating no thread.
Teach
Pushbutton
Power On
LED
Thread
LED
• Alternate between threaded and unthreaded holes,
and verify the ‘Thread’ LED is green when the sensor
is in the threaded hole and red when the sensor is in
the unthreaded hole (or not in a hole at all).
• If desired, the polarity of the switched output can be
inverted by holding the teach button for 10 seconds.
800-552-6267 | www.kamansensors.com | [email protected]
Copyright 2010
KAMAN APPLICATION NOTE | THREADCHECKER UNIVERSAL™
Electrical installation
• Brown – 15-30VDC input
• White – switched output NPN
• Black – analog output
• Blue – ground
• Input power is reverse polarity
and short circuit protected
• Switched output 30VDC max,
80mA max, 3KHz
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Copyright 2010