RJG T-445 Product Manual

Analog single-channel strain gage button sensors

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PRODUCT MANUAL

Lynx™ Analog Single‑Channel

Strain Gage Button Sensors

T‑445

Training and Technology for Injection Molding

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Page 1 PRODUCT MANUAL PRODUCT MANUAL Lynx™ Analog Single‑Channel Strain Gage Button Sensors T‑445 Training and Technology for Injection Molding...
Page 2 PRINT DATE 10.16.2023 REVISION NO.
Page 3: Table Of Contents
PRODUCT MANUAL Lynx™ Analog Single‑Channel Strain Gage Button Sensors T‑445 INTRODUCTION DISCLAIMER PRIVACY ALERTS PRODUCT DESCRIPTION APPLICATIONS SINGLE‑CHANNEL SENSORS PROCESS MONITORING PROCESS CONTROL OPERATION INDIRECT/UNDER‑PIN EJECTOR PIN SIZES ANALOG STRAIN GAGE SENSORS DIMENSIONS SENSOR CABLE LENGTHS Product Manual | Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445...
Page 4 NON‑STANDARD INSTALLATIONS STATIC (NON‑MOVING) EJECTOR PINS MULTIPLE EJECTOR PINS MAINTENANCE CLEANING TESTING & CALIBRATION TESTING SENSORS CALIBRATION COMMON FACTORS AFFECTING SENSOR RECALIBRATION WARRANTY RJG, INC. STANDARD THREE‑YEAR WARRANTY PRODUCT DISCLAIMER Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 5 PRODUCT MANUAL Lynx™ Analog Single‑Channel Strain Gage Button Sensors T‑445 TROUBLESHOOTING INSTALLATION ERRORS EJECTOR PIN ISSUES SENSOR HEAD ISSUES CASE AND CABLE ISSUES WIRING FAILURE RESISTANCE READINGS PIN ASSIGNMENT PINOUT SCHEMATIC SENSOR AND EJECTOR PIN SIZE SELECTION CHARTS CUSTOMER SUPPORT RELATED PRODUCTS COMPATIBLE PRODUCTS ANALOG SINGLE‑CHANNEL STRAIN GAGE SENSOR CABLE T‑520...
Page 6 NOTES Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 7: Introduction
This guide must be kept available for reference at all times. DISCLAIMER PRIVACY Inasmuch as RJG, Inc. has no control Designed and developed by RJG, Inc. over the use to which others may put Manual design, format and structure this material, it does not guarantee that copyright 2023 RJG, Inc.
Page 8 NOTES Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 9: Product Description
PROCESS CONTROL relieved connector. The exclusive Lynx™ technology sensors A primary goal of molding machine control, are designed for use with the RJG eDART® flashed part detection, and/or gate seal process control and monitoring system. detection dictates a sensor placement near APPLICATIONS the gate end of the part.
Page 10: Operation Indirect/Under-Pin
SG/LX1‑S electronics Gate 3 case mounted on the outside of the mold. The SG/LX1‑S adapter is connected to the RJG, Inc. eDART System, which records and displays the sensor’s measurement for operator aid in process monitoring and control.
Page 11: Dimensions
DIMENSIONS SENSOR CABLE LENGTHS Length must be longer than needed to facilitate safe installation and removal of connector from tool to prevent tension on the lead wire; generally, 2–3” (50–75 mm) of slack is sufficient. Use good sense to determine the appropriate cable length required for each application.
Page 12 NOTES Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 13: Installation
INSTALLATION INSTALLATION OVERVIEW B Plate or Cavity Insert The sensor’s Bendix connector is mounted on the outside of the mold. A channel is machined into the mold for the sensor cable and sensor head. The sensor head is Ejector Pin placed under the ejector pin.
Page 14: Angled Ejector Pins
INSTALLATION OVERVIEW (continued) ANGLED EJECTOR PINS Ejector pins that are located onto angled surfaces of a part can utilize sensors depending upon the angle of the pin. The threshold for angled pin and sensor compatibility is 30° at right). Any pin that is at an angle greater than this and not symmetrical must not be used for sensing cavity pressure.
Page 15: Installation Specifications
INSTALLATION SPECIFICATIONS DETAIL A Product Manual | Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445...
Page 16: Sensor Pocket Machining
INSTALLATION SPECIFICATIONS (continued) SENSOR POCKET MACHINING Sensor pockets are machined into the ejector plate. The pockets must be concentric 0.635” +0.005/‑0.0 (16,13 mm +0,13/‑0,0 [ at right]), and 0.50” +0.003/‑ 0.0 (12,7 mm +0,08/‑0,0 [ at right]) tall. • Use a “dead sharp” end mill to achieve correct radius—sensor pocket corner radius MAX R 0.005”...
Page 17 INSTALLATION SPECIFICATIONS (continued) Product Manual | Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445...
Page 18: Sensor Cables
INSTALLATION SPECIFICATIONS (continued) SENSOR CABLES Machine a cable channel width of 0.25” (6,0 mm) and depth of 0.38” (9,5 mm). 1. Sensor Cable Bend The sensor cable must not be bent within 1.50” (38,1 mm) MIN of center of the sensor head. 2.
Page 19: Sensor Cable Retention
INSTALLATION SPECIFICATIONS (continued) Sensor cable retention strategies must be considered during the mold design phase. Cables are often not the exact size needed, or do not easily remain in the cable channels during assembly and must be retained using one or more of the following methods. Cable Pocket Cover—Washer Style Cable Clip Cable Pocket...
Page 20 If excess cable pockets are present, it may be useful to provide a cover ( right) for the cable pocket with which to retain extra cable. Though RJG does not currently provide a solution specifically for this application, plastic or metal discs with a centrally‑located hole, retained by a...
Page 21: Non-Standard Installations
NON‑STANDARD INSTALLATIONS STATIC (NON‑MOVING) EJECTOR PINS STATIC PIN INSTALLATION While cavity pressure sensor installation with moving, or “working” ejector pins is recommended, in some situations a non‑moving or “static” pin must be utilized; static ejector pins may be used in the ejector plate as described previously in “Installation Specifications”...
Page 22 Many silicone‑based lubricants can assistance. Minimum orders are usually $50 damage silicone O‑rings. for in‑stock items. RJG, Inc. recommends P‑80 THIX lubricant 7. Tolerancing from International Products Corporation Tolerancing usually has little impact on (http://www.ipcol.com/shopexd.asp?id=31).
Page 23 NON‑STANDARD INSTALLATIONS (continued) O‑Ring Selection Table Groove Pin DIA Width Max. Nominal Pin DIA O‑Ring # Groove DIA Tol‑ Bore DIA Bore Tol‑ Min. DIA Toler‑ Material Width (G) Toler‑ Angle Pin Size (in.) (IDXCS) DIA (C) erance erance ance (in.) ance (±) (°) (±)
Page 24 NON‑STANDARD INSTALLATIONS (continued) O‑Ring Selection Table (continued) Groove Pin DIA Width Max. Nominal Pin DIA O‑Ring # Groove DIA Tol‑ Bore DIA Bore Tol‑ Min. DIA Toler‑ Material Width (G) Toler‑ Angle Pin Size (in.) (IDXCS) DIA (C) erance erance ance (in.) ance (±) (°)
Page 25 NON‑STANDARD INSTALLATIONS (continued) O‑Ring Selection Table (continued) Groove Pin DIA Width Max. Nominal Pin DIA O‑Ring # Groove DIA Tol‑ Bore DIA Bore Tol‑ Min. DIA Toler‑ Material Width (G) Toler‑ Angle Pin Size (in.) (IDXCS) DIA (C) erance erance ance (in.) ance (±) (°)
Page 26 NON‑STANDARD INSTALLATIONS (continued) Sensor Readings Data from the same mold is pictured below (typical results—not guaranteed). Without O‑Ring Installation With O‑Ring Installation Above Left: Three sensors are reading too Above Right: The template and solid lines low due to contamination—without O‑rings after four months of continuous production;...
Page 27: Multiple Ejector Pins
NON‑STANDARD INSTALLATIONS (continued) MULTIPLE EJECTOR PINS PIN, SENSOR, & PLATE INSTALLATION Ejector pins are often grouped in small areas that do not allow for traditional cavity pressure senor installation. Read and follow all instructions, and refer to the provided figures to properly install sensors with multiple ejector pins.
Page 28 NOTES Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 29: Maintenance
MAINTENANCE Strain gage sensors require little maintenance. CLEANING The eDART Raw Data Viewer can be used to test T‑445 sensors. The Raw Data Viewer Pull sensors from the mold and clean out displays the status of the sensor, either the pockets and channels when a mold Valid, No Reply, Stale, or Invalid.
Page 30: Calibration
2% is more than sufficient, and is used force range (less than 40% of full scale) by RJG as the specification for repaired show less calibration shift than sensors that sensors.
Page 31: Warranty
The higher the mold temperature, the WARRANTY greater the potential for calibration shift. Below 212 °F (100 °C), calibration usually RJG, Inc. is confident in the quality and remains stable. Sensors running at robustness of the T‑445 cavity pressure 300–400 °F (150–200 °C) have a greater sensors, and so are offering a three‑year...
Page 32 NOTES Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 33: Troubleshooting
TROUBLESHOOTING INSTALLATION ERRORS EJECTOR PIN ISSUES 1. Pin size, expected pressure,and/or expected temperature not appropriate for selected sensor. • Refer to “Sensor and Ejector Pin Size” on page 29. 2. Ejector pin is located behind mold surface with angle greater than 30° at right).
Page 34: Sensor Head Issues
INSTALLATION ERRORS (continued) SENSOR HEAD ISSUES 1. Ejector Pin head diameter is larger than sensor pocket diameter ( at right). • Counterbore the ejector plate, or chamfer the pin head to ensure that the pin rests only on the sensor nub. 2.
Page 35: Case And Cable Issues
2. Sensor case is mounted on surface that exceeds temperature rating. • Do not mount the Lynx case on surface that exceeds the recommended temperature rating. Contact RJG, Inc. Customer support for high‑temperature applications. 3. Lynx case is drilled to accommodate alternate mounting ( at right).
Page 36: Wiring Failure
WIRING FAILURE The most common cause of failure are short circuits or broken wires. Measure wire resistances and refer to the following tables to determine if the sensor has had a wiring failure. RESISTANCE READINGS PIN ASSIGNMENT PINOUT RESISTANCE GREY CABLE YELLOW CABLE pin A to pin C 260–365 W...
Page 37: Sensor And Ejector Pin Size
SELECTION CHARTS The charts below are only a guide. In order to assure correct sensor selection for an application, please contact RJG. Locate the pin size that will be used and match it to the location on the part (near the end of fill or near the gate).
Page 38 SENSOR AND EJECTOR PIN SIZE (continued) 2. Metric Units RECOMMENDED SENSOR FOR EXPECTED PLASTIC PRESSURE/PIN SIZE Pin Size 5,000 psi 10,000 psi 15,000 psi 20,000 psi 9,0 mm T‑445 9,5 mm T‑445 10,0 mm T‑445 T‑445 11,0 mm T‑445 T‑445 12,0 mm T‑445 T‑445...
Page 39: Customer Support
CUSTOMER SUPPORT Contact RJG’s Customer Support team by phone or email. RJG, Inc. Customer Support P: 800.472.0566 (Toll Free) P: +1.231.933.8170 www.rjginc.com/support Product Manual | Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445...
Page 40 NOTES Lynx™ Analog Single‑Channel Strain Gage Button Sensor T‑445e | Product Manual...
Page 41: Related Products
RELATED PRODUCTS COMPATIBLE PRODUCTS The T‑445 line of senors are compatible with other RJG, Inc. products for use with the eDART process control and monitoring system. ANALOG SINGLE‑CHANNEL STRAIN GAGE SENSOR CABLE T‑520 The Analog Single‑Channel Strain Gage Sensor Cable T‑520 ( at right) interfaces the RJG, Inc.
Page 42: Similar Products
SIMILAR PRODUCTS RJG, Inc. offers a wide array of cavity pressure sensors for each application— strain gage, single‑channel, multi‑channel, and digital. LYNX SINGLE‑CHANNEL STRAIN GAGE BUTTON SENSOR LS‑B‑159‑4000 The Lynx Single‑Channel Strain Gage Button Sensor LS‑B‑159‑4000 ( at right) provides the same strain gage technology, indirect installation style, and force rating as the T‑445 sensor, but with Lynx™...
Page 44 P +39 335 178 4035 P +01 231 947‑3111 sales@it.rjginc.com F +01 231 947‑6403 it.rjginc.com sales@rjginc.com www.rjginc.com MEXICO RJG MEXICO SINGAPORE RJG (S.E.A.) PTE LTD Chihuahua, Mexico Singapore, Republic of P +52 614 4242281 Singapore sales@es.rjginc.com P +65 6846 1518 es.rjginc.com sales@swg.rjginc.com en.rjginc.com...