Air Gap Sensor [DPA-PLR2B Series]

Air Gap Sensor [3-point setting type] DPA-PLR2B Series

Automation of CNC Grinding Machines

The industry's first non-contact sensor for determining the “machine origin of the rotary wheel of NC grinders" with an accuracy of ±0.5µm, realizing full automation and unmanned operation of NC grinders.
The air gap sensor's "home positioning of the rotary grinding wheel" eliminates variations in the machine home point due to the skill level of the operator.

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Main Challenges

  • Automating the originating task for grinding wheels.
  • Reduced productivity because the wheel stops rotating each time during "grinding wheel positioning."
  • Standardize the grinding wheel originating process, which we currently rely on skilled workers, so that it can be done safely.
  • AE sensor detects by grinding the workpiece, so accuracy varies and stable measurement is difficult.
  • Automating the machining to reduce time because air-cutting is taking too long.
  • We want to reduce dressing frequency and prolong the life of expensive grinding stones.

Features

Non-contact detection of the machining origin of the rotary grinding wheel with ±0.5µⅿ repeatability

For super abrasive wheels such as diamond and CBN, non-contact detection with an accuracy of 1µⅿ is achieved without stopping the rotation of the grinding wheel.

Outputs 3 identification signals

The amount of air-cut is reduced by setting three thresholds:
(1) deceleration signal, (2) judgment signal, and (3) overtravel signal.
It is also possible to distinguish up to three different types of grinding wheels with as many grit sizes.

Grinding wheel diameter and thermal displacement compensation available

By detecting the grinding wheel from two directions, Z-axis and Y-axis, “grinding wheel wear” and “thermal displacement” in the machine axis direction can be detected and compensated.

Reduces machining cycle time

IP67 rating for protection against water, coolant, and dust, and the sensor can be installed inside the machine for shorter air piping.
Shorter pipe length improves signal response and contributes to shorter cycle time in mass production lines.
Coolant flooding tests and severe durability tests are conducted on machine tools assuming that they will be used in adverse environments.

Supply air self-diagnostic function

The self-diagnostic function outputs an alarm when an error occurs in the air supply pressure.
It notifies you of insufficient pressure, pressure fluctuation while the sensor is in use, and excessive pressure.

[Air Gap Sensor] Achieve automation of CNC grinder

Grinding wheel wear detection for CNC grinding machine [Pneumatic precision seating sensor]

Specification

Product name DPA-PLR2B
Poupose of use Seating confirmation of workpieces・Positioning of grinding machine grindstone
Signal points can be set 3 points
Hot to set the detection range The master values (master＃1, #2 and #3) are displayed and output.
*Master values are saved even when the power is turned off.
Detection range
 80 - 350μm （When using a recommended nozzle)
Repeatability  ±1μm (Detection range：80 - 150μm)
±3μm (Detection range：150 - 250μm)
±5μm(Detection range：250 - 350μm)
*Air pressure change: within ±1％
Protective structure IP67
Output mode NO（Normally Open）
Fluid Dry air（filtered to 5μm）
Setting pressure 150 - 200kPa
Consumption flow rate 24ℓ/min (max)
Connection port diameter Rc1/8
Recommended tube:SUP port φ6×φ4 tube
Recommended tube:OUT port φ4×φ2.5 tube
φ6×φ4 tube
*A diameter of the connection tube for leakage unit (accessory) is φ6. Please prepare a conversion adapter if you use a connection tube of φ4.
Response speed 0.8 seconds
(Tube length 1.5m / Time between the air pressure supply and the signal output of the sensor.)
Input specification Photocoupler input
DC24V±10％
Output specification Photocoupler output (Non-voltage floating output)
(collector emitter floating)
DC24V±10% 20mA (max)
Low level output voltage : less than 1.5V (at 15mA)
Cable Standard length 3m　Oil resistance φ5.5/16 cores　AWG28
Electrical response speed 10ms
LED lump Plsease see the manial
Accessory 0
Operating temperature range 0℃ - 60℃(no condensation)

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