Keyence's Security Sensor Utilization Guide to Change Automatic Machine Design

Here, it is a revolutionary product that has begun to be popular in recent FA machinesMr. Keens' "Line type Cylinder Sensor"It is a note about.

There are many problems in pneumatic control, such as complicated sensor position adjustment at the time of facility start-up and unexpected chocolate stop due to speed change due to packing deterioration during operation.There are many potential practical challenges. i can solve such a problem.Mr. Keens' line type cylinder sensorThis is a summary of the key points of the project.

In designing an automatic machine, I encountered conflicting issues such as shortening cycle times and mitigating end impact, as well as my own on-site mechanical design experience.Based on this information, we investigate and supplement the missing parts with reliable primary information such as official technical information of manufacturers and JIS standards. I would appreciate it if it would be helpful.

Basics and Usage of Keyence Cylinder Sensors

Basic knowledge of line detection, which is the principle of operation

Keyence's CS-L series takes a completely new approach to understanding the piston position of pneumatic cylinders.While conventional sensors detect whether a magnet inside a piston has passed through a specific point, this product provides a high-density line-by-line sensor.A line detection method is adopted that captures a wide range of changes in the magnetic field using a large number of detection elements.This makes it possible to visualize the current position of the piston as a continuous line at all times.

the internal processor processes the read magnetic field information at high speed、The absolute position of the piston is determined with an extremely high resolution of 0.1 mm.In addition, based on this continuous position data, the stroke time from the start of the cylinder to the end is measured in milliseconds.or、Advanced functions such as calculating the impact level at the end of the collision as a quantitative numerical value using a unique algorithmWe have a wide range of products and services to meet the needs of our customers. It can be understood that the device has evolved from a simple contact output device to a device that can monitor the dynamic state of the cylinder.

The overwhelming difference in the conventional comparison in terms of

It is represented by the M9B of SMC, which is widely adopted in the field of automatic machine designThe conventional auto switch is a contact-type detection method that switches on and off with a specific set magnetic flux density as a threshold.These have very high reliability, but in the position adjustment at the time of equipment start-up、When the operator slides the sensor body while manually moving the cylinder, finds the boundary where the LED lights up, and then fixes it with a very small set screw, the sensor is turned on.It was essential to work in an analog and personal way.

On the other hand, after the sensor of the keyence is moved to any position where you want to output the piston, the sensor is moved to the position where you want to output the piston, and then the sensor is moved to the position where you want to output the piston, the sensor is moved to the position where you want to output the piston,、Just press the set button on the sensor body once to complete the teaching.In addition, when detecting 2 points of the forward end and the backward end of the cylinder in the conventional method, 2 sensors are installed and programmable logic is applied from each of them.The wiring had to be routed individually to the input unit of the controller. In the new system, control output and detailed state data of multiple locations can be transmitted at once from 1 device via 1 communication cable.There is a clear difference that the amount of physical wiring is dramatically reduced.

Reference Source：Keyence Official Catalog

The full range of benefits that designers should know

The biggest advantage from a mechanical design perspective is the ability to reduce the tact time of the equipment and the down time after operation to the limit.As mentioned above, since the stroke time and impact level can be continuously monitored, a mechanism to issue a warning when these values exceed pre-set thresholdsIt is easy to build only one. This prevents equipment abnormalities such as wear of the packing and mechanical hooking.、A predictive maintenance system is realized that detects chocolate stops and parts damage before they actually occur.

and the benefits that we can't miss、SP-C series, a dedicated smart cushion valveIt is an overwhelming performance improvement when linked with.Based on the real-time position information of the piston acquired by the sensor, it has a function to automatically switch between the high-speed flow path and the deceleration flow path inside the valve.It's a good idea.This allows the cylinder to move up to its limit speed and to slow down properly only just before it hits the ground to absorb the impact.It's a good idea. It is also equipped with an auto stroke control function that automatically corrects the start timing of the cushion according to changes in air pressure and aging.It is no longer necessary to set a slow cylinder speed that is expected too much of the total rate. Therefore,、It is thought that it will be possible to operate the equipment at a cycle time close to the theoretical limit.

What are the disadvantages to understand before deployment?

While it is a multi-functional, high-performance device, there are some concerns. The most important consideration is the increase in the initial deployment cost of the system as a whole. In addition to the high price of a single sensor compared to a simple contact switch, it is necessary to use an IO-Link master and a dedicated high-performance amplifier to demonstrate its true value.It is also necessary to prepare the infrastructure of peripheral communication equipment such as smart valves at the same time.There is a risk that the investment effect will not be satisfactory because of overspecifications in a simple mechanism whose purpose is only to confirm the position.

It also requires closer collaboration with electrical and software design personnel than ever before. In addition to simply assigning inputs and outputs, there is a time required to create a program that receives and processes various parameters. As a physical constraint, by the presence of the dead area described later、The sensor body may overhang relative to the strokeTherefore, in some cases it is not suitable for installation in extremely small spaces. Based on these factors, it is important to calmly assess the balance between the required specifications and costs required by the project.

Keyence Cylinder Sensor Design Differences

Applicable cylinder geometry and slot standards

In the actual machine design, pneumatic cylinders of various manufacturers are selected according to the application and thrust, but in order to apply this device,It is necessary to check in advance the compatibility with the shape of the sensor mounting groove provided on the cylinder body. Keyence's CS-L series is standard compatible with 2 types of slot standards that have become mainstream in the global factory automation market.It's a good idea.

Reference Source: Keyence Official Catalog

The lineup includes C-slots with slot widths of about 3.6 mm to 5.1 mm and T-slots with slot widths of about 6.5 mm to 8.0 mm.This is the first time that I've ever seen a video of a woman in a public place. Even for cylinders that do not have these standard slots, a dedicated conversion bracket is used to widen the range of support. For example, a band-type bracket that is wound around the outer periphery of a round cylinder is used, and a dedicated conversion bracket is used for a CKD cylinder with a special T-slot.The C-slot sensor can be mounted via a socket. In the case of tie rod cylinders, we prepare a switch bracket for tie rod provided by each cylinder manufacturer and adapt it to the slot shape.In this step, we will select the sensor that will be used for the measurement.

Advantages of direct mounting from above

As a design ingenuity to greatly improve assembly work and maintainability、A quick access mechanism that can be fitted vertically from above with respect to the slot is mentioned.　　Some conventional auto switches have a structure that must be inserted by sliding laterally along the groove of the slot from the end face of the cylinder.There are a lot of things to do. In the case of such a structure, it is necessary to have a dense device layout, in which the front and rear of the cylinder is sandwiched with a solid bracket or the perimeter is covered with a cover.and do、When the sensor failed, the cylinder itself had to be completely removed from the device for replacement.

If it is a structure that can be installed directly, the attachment and removal of the sensor can be completed only by access from above without interfering with the surrounding structure. In addition, it comes with a component called a small memory block to prevent misalignment during replacement.By fixing this in the slot in advance, in the unlikely event that the sensor body is damaged, it is possible to set the new sensor against the memory block.It is possible to restore to the exact same physical reference position just by placing it, and it is possible to save the trouble of the readjustment.

Requirements for PNP wiring that are essential for information linkage

The Japanese automation industry has been using NPN output, which is a negative common for many years, but with the wave of globalization, it is becoming increasingly difficult to achieve a European standard platform.The transition to PNP output is progressing. In Keyence's cylinder sensors, the choice of this output format is not only a difference in electrical wiring, but also a very important factor that determines the function of the device itself.This will be a major decision for the company.

The biggest advantage of this product is the monitoring of stroke time, calculation of impact level, dedicated communication with smart valve manifolds, etc., and IO-Link communicationThe M8 connector type model of the PNP specification must always be selected in order to use it. The NPN's rose-wire type models are also available, although they can be output as contacts, but can be used in a series of advanced multi-information applications.It does not support the AL communication function. At the initial stage of creating a bill of materials, it is necessary to align specifications with the electrical circuit designer and determine the correct wiring requirements for network cooperationThis is the key to the smooth progress of the project.

Importance of Digital Recording based on JIS Standards

In some cases, compliance with Japanese industrial standards is strongly required as a standard to ensure the quality and safety of various production facilities operating in Japan.JIS B 8377-1 concerning pneumatic systems stipulates that when a cylinder with a switch is shipped or delivered, the operation of the switch is checked from the viewpoint of quality assurance.It is clearly stated that it is good to check the work and magnetic force at the final assembly stage and leave a record of it.

In a system in which the sensor of the keyence is linked with the control panel etc., the setting value of the output position taught and the measured stroke are measured.It is possible to directly export operation data such as crash time and impact level to USB memory or higher network in CSV format. Based on the above points, the ability to submit the operation records recommended by the JIS standard to customers as reliable digital data without human error is an important factor for the equipment.It can be said that it is a strong backing that dramatically increases the reliability and added value of the whole.

Cautions and Conclusions of Keyence Cylinder Sensors

Design countermeasures for magnetic interference and dead zones

Physical constraints must not be overlooked in the process of actually drawing drawings and placing parts. The first thing to consider is the existence of the dead zone. Due to the characteristics of the line detection method, there are areas at both ends of the sensor body that cannot accurately read the magnetic field. Therefore, it is necessary to select a sensor with dimensions that have a margin of 5 millimeters or more relative to the actual stroke length of the cylinder. For example, even a cylinder with a stroke length of 30 mm、Since the total length of the sensor body is about 53.5 mm, when applied to a cylinder with a short stroke, the sensor protrudes greatly from the rear end of the cylinder, and it is possible to reduce the size of the cylinder.Careful clearance design is required so as not to interfere with the surrounding mechanical components.

On the other hand, 2 cylinder sensors can be used for long-stroke cylinders.

In addition, countermeasures against magnetic interference are necessary as a universal physical phenomenon in the design of pneumatic circuits using general magnetic sensors. Although it is not mentioned in the official manual as an extreme prohibited matter, if multiple air cylinders are arranged in parallel with extreme compactness, adjacent air cylinders will be placed in parallel with each other.The magnetic flux leaking from the piston magnet of the cylinder in contact with each other affects each other's sensitive detection elements, causing malfunction and a decrease in resolution.Risk is considered. To ensure that the pitch between the actuators is sufficiently secured as much as mechanically allowed, or to ensure that the power line of the large-capacity servo motor generates a strong magnetic field is close to the power line.It may be important to keep in mind the safety design that is faithful to the basics of noise countermeasures, such as avoiding the placement of noise in the system.

Factors in which the cost of implementation is a trade-off

The balance between budget and performance is always a topic of discussion when meeting design requirements. With state-of-the-art sensing technology and communications infrastructure, Keyence's solutions provide a more efficient and efficient system than traditional auto-switches alone.The initial deployment cost to build will inevitably be high. We offer full space for simple single-shot jigs and low-end equipment where cost reduction is the top priority due to sufficient margin for cycle time.It is possible to consider the over-quality to be introduced in a single package.

On the other hand, we are also developing equipment such as high-speed assembly lines for semiconductor manufacturing equipment and automotive components, where the reduction of tact time by 0.1 seconds brings huge lifetime benefits, and equipment such as high-speed assembly lines for automotive components.In critical environments where 24-hour unattended operation is assumed and sudden downtime due to aging of the packing can lead to serious lossesThe ratings are reversed.The maximization of production efficiency by stroke control and maintenance-free by predictive maintenance reduce the running cost.It has the potential to recover the difference in initial investment in a very short period of time.In short, it is the designer's skill to accurately estimate the long-term value that the equipment will bring to the end user and determine where it can justify the cost increase.It will be a place to show.

Use with conventional and hybrid configurations

Replacing all pneumatic cylinders with the latest line-type sensors in the dark is not a realistic optimal solution both on a budget and in terms of installation space.It is not.In an automatic machine with a wide variety of actuators, simple and inexpensive points such as SMC's non-contact switches, which have been popular for a long time, are required.It is a practical best practice to use the right person in the right place with the detection sensor.

Reference Source: Keyence Official Catalog

The main shaft mechanism, which requires both speed and shock mitigation due to severe cycle time constraints, and the stop position can be frequently adjusted according to the workpiece size in a multi-product mixed flow line.The CS-L series of the keyence is applied to control the full specifications at frequently fluctuating points. On the other hand, the clamping mechanism simply presses the workpiece from the side, and the auxiliary cylinder simply pulls and inserts the positioning pin.Conventional contact switches are placed where stroke monitoring is not required.

Keyence cylinder sensors for optimal design

• It adopts a line detection method that continuously grasps the position by a line instead of a point
• Determine the absolute position of the piston in microns with a resolution of 0.1 mm
• The teaching of the output position is completed just by pressing the button 1 time, and the adjustment man-hours are reduced
• Quantitative visualization of cylinder stroke time and impact level at end
• It directly contributes to predictive maintenance of equipment by issuing a warning when the set value is exceeded
• 1. Multiple points of output and various data communication are possible with the cable, and the wiring can be saved.
• It is compatible with both the C-slot and T-slot, which are global standards
• The special bracket can be flexibly applied to cylinders with special shapes such as round and tie rods
• It is possible to detach the sensor without disassembling the device by the direct mounting mechanism from the top.
• By utilizing the attached memory block, the position reproducibility at the time of exchange can be kept extremely high
• In order to use advanced serial communication function, wiring selection of PNP specification is essential condition.
• Record of switch operation recommended by JIS standard can be easily saved as digital data
• The size selection of the dimension with the margin takes into account the dead area existing at both ends of the sensor
• The line type is adopted for the critical spindle mechanism, and the conventional type is arranged for the auxiliary mechanism.
• Build a hybrid design that centrally manages all input/output information with a dedicated unit

That's it.