Consistent non-contact detection of 10μm float of shaft components
Automobile industry
An automotive parts manufacturer that produces special gears for major automakers.
A representative of the engineering department consulted us on "seating confirmation" in drilling the shaft parts for the gears.
Table of Contents
Client’s Issues
The client had a trouble with the small chips put between the "shaft part" and the "table" when drilling the part by a machine.
The "Air sensors" have been used to confirm the seating of the shaft part, however, because of the low repeatability 50µm, the uplifts by 10µm cutting chips cannot be detected reliably.
We received an inquiry looking for a sensor capable of accurate seating detection as a float of a mere 10μm can influence the accuracy of special gears, having seen our demo products at the JIMTOF Japan International Machine Tool Fair.
The main focus of the issues
A 10µm slight uplift by cutting chips should be detected.
Metrol’s suggestions
Although "air sensor" adopted on machine tools as a standard equipment is used for detecting machined workpieces, in fact, the most air sensors are intended for "existence detection" of workpieces and not suited for precise "seating confirmation".
Metrol's "Air Gap Sensor", on the other hand, demonstrates 0.5µm repeatability which is 10 times as precise as that of "air sensors".
By stable detection of 10µm uplifts by cutting chips, precise "seating confirmation" for precise machining of the gear is realized.
In addition, "Air Gap Sensor" is resistant to harsh working conditions by IP67 protective structure, by installing it inside the machine where cutting chips or mist exist,
・Air piping: 12 → 1.5m
・Response speed: 5 → 0.8 seconds
The considerable productivity of Air Micro Switch has been realized.
Improvements
Stably detected a 10 μm of slight uplift caused by cutting chips.
The response speed was reduced to 0.8 seconds, and the productivity improved.
Comment from Metrol representative
Conventional air sensors are damaged by machining cuttings or splattered coolant oil, meaning the sensor unit had to be installed external to the industrial machine.
The Air Gap Sensor introduced here has an IP67 rated protection structure allowing it to be installed inside machine tools for accurate seating or seating verification, without being affected by machining cuttings or coolant.
If you have any trouble with seating confirmation or the air sensors, please feel free to contact us.
For further information about the products used in this application
Air Gap Sensor [Short range detection type]
10µm gap caused by cutting chips can be detected stably without contact!
Realizes precise workpirce seating confirmation.
