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marposs Dittel SENSITRON6 Installation And Operation Manual

Ae evaluation and control unit, 1 sensor
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SENSITRON6
AE Evaluation and Control Unit
Installation- and Operation Manual
Covers SENSITRON6 - 1 Sensor
Date of issue:
March 2018
Revision:
6
Article no.:
ODNFL20EN02 (D65029)
Dittel Messtechnik GmbH is certified according to DIN EN ISO 9001 and DIN EN ISO 14001
A/N O830L204002
(A/N F65003)

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  • Page 1 SENSITRON6 AE Evaluation and Control Unit Installation- and Operation Manual Covers SENSITRON6 - 1 Sensor A/N O830L204002 (A/N F65003) Date of issue: March 2018 Revision: Article no.: ODNFL20EN02 (D65029) Dittel Messtechnik GmbH is certified according to DIN EN ISO 9001 and DIN EN ISO 14001...

  • Page 2: Manual Revision History

    Update of DITTEL’s Agencies November 2009 DECLARATION OF CONFORMITY added January 2010 Acquisition of full ownership by MARPOSS S.p.A., Italy August 2012 Changes due to new requirements for CE-Conformity check and July 2013 acquisition of full ownership by MARPOSS S.p.A., Italy.

  • Page 3: Table Of Contents

    SENSITRON6 – 1 Sensor AE Evaluation and Control Unit Table of Contents Manual Revision History ..............2 Table of Contents ................3 For Your Safety ................5 General ......................5 Intended Use ....................6 Used Symbols ....................6 Introduction ..................7 General Information ..................
  • Page 4 SENSITRON6 – 1 Sensor AE Evaluation and Control Unit Automatic Operation ..............37 Prerequisite ....................38 Shortening the Air Grinding Time ..............39 Monitoring the Dressing Process ..............39 Appendix A Troubleshooting Guide ........... 41 Cleaning – Maintenance – Environmental Protection ... 43 Appendix B Cleaning .......................

  • Page 5: For Your Safety

    SENSITRON6 – 1 Sensor 1 For Your Safety For Your Safety General  The SENSITRON6 – 1 Sensor is a state-of-the-art AE Evaluation and Control Unit developed and produced according to recognised safety directives, rules, standards, and regulations. To preserve this standard and in order to maintain safety, you as a user must adhere to this Operation Manual.

  • Page 6: Intended Use

    SENSITRON6 – 1 Sensor 1 For Your Safety SENSITRON6 – 1 Sensor. So if the SENSITRON6 – 1 Sensor is sold, disposed of, or rented out, always include this Installation- and Operation Manual with the device. Intended Use  Use the SENSITRON6 – 1 Sensor exclusively to measure acoustic emission signals and to monitor grinding and dressing processes! ...

  • Page 7: Introduction

    SENSITRON6 – 1 Sensor 2 Introduction Introduction This manual contains information relative to the installation, setting, and operation of the AE Evaluation and Control Unit SENSITRON6 - 1 Sensor – the successor of our former SENSITRON2. General Information Consistent high quality, automation, increased productivity reduction of downtimes –...

  • Page 8: Application Of The Sensitron6

    SENSITRON6 – 1 Sensor 2 Introduction Application of the SENSITRON6 - 1 Sensor 2.2.1 General During any grinding or dressing process, the grinding wheel and workpiece/dressing wheel both produce a noise (Acoustic Emission = AE) whose spectral frequency distribution is, for the main proportion, in the ultrasonic range.

  • Page 9: Touch Dressing

    SENSITRON6 – 1 Sensor 2 Introduction F irs t c o n ta c t In fe e d m o n ito re d b y S E N S IT R O N 6 S a fe ty P o s itio n T o le ra n c e o f w o rk p ie c e ra d iu s W o rk p ie c e...

  • Page 10: Monitoring The Dressing Process

    SENSITRON6 – 1 Sensor 2 Introduction 2.2.4 Monitoring the Dressing Process  IWF-TU Braunschweig The SENSITRON6 – 1 Sensor in conjunction with the machine control is able to recognise whether the dressing unit is in touch over the whole width of the grinding wheel. If the dresser loses contact, the noise emission decreases and a HIGH-signal is fed via pin 4 of connector #11 to the machine control.

  • Page 11: Crash Control

    SENSITRON6 – 1 Sensor 2 Introduction 2.2.5 Crash Control The SENSITRON6 – 1 Sensor includes a Crash Control (collision monitoring) and therefore an additional safety device. Should the detection of the very first contact of the grinding wheel and the workpiece or dressing roller fail, the Crash Control reacts instantaneously.
  • Page 12 SENSITRON6 – 1 Sensor 2 Introduction DITTEL – ODNFL20EN02 of 52 March 2018...

  • Page 13: Installation

    SENSITRON6 – 1 Sensor 3 Installation Installation Mechanical Installation 3.1.1 AE Evaluation and Control Unit SENSITRON6 - 1 Sensor  The SENSITRON6 electronic unit should be mounted in a location that allows observation of the display by the machine operator. ...
  • Page 14 SENSITRON6 – 1 Sensor 3 Installation SENSITRON6 - 1 Sensor Fig. 3-1 Dimensions DITTEL – ODNFL20EN02 of 52 March 2018...

  • Page 15: Installation And Application Of Ae Sensors

    SENSITRON6 – 1 Sensor 3 Installation 3.1.2 Installation and Application of AE Sensors  Contact MARPOSS S.p.A. or your nearest MARPOSS Agency for application assistance!  Dimensions and illustration of our standard AE sensors are available on request. Risk of injuries by rotating parts! ...

  • Page 16: Ae Sensor 'S' Or Magnetic Type Ae Sensor 'Mgp1

    SENSITRON6 – 1 Sensor 3 Installation AE Sensor ‘S’ or Magnetic Type AE Sensor ‘MGP1’ These AE sensors consist of one part and are connected directly to the AE Evaluation and Control Unit. The AE signal is picked up via the base plate.

  • Page 17: Ae Fluid Sensor

    SENSITRON6 – 1 Sensor 3 Installation AE Fluid Sensor This AE Sensor consists of one part and is connected directly to the SENSITRON6 – 1 Sensor. The AE signal is picked up via the coolant stream. Fluid-Sensor  The AE Fluid Sensor must be attached so that its measuring coolant stream directly hits the process to be monitored.

  • Page 18: Electrical Installation

    SENSITRON6 – 1 Sensor 3 Installation Electrical Installation 3.2.1 General  To ensure proper function of the AE Evaluation and Control Unit SENSITRON6 - 1 Sensor use only connection cables or extension cables supplied by DITTEL.  To reduce electrical interference make sure that the unit SENSITRON6 –...
  • Page 19 SENSITRON6 – 1 Sensor 3 Installation 3.2.2 24 Vdc Supply  Wiring the supply must be made by qualified staff of the customer!  Power the device from a 24 Vdc supply only! The power source must comply with EN 60950 SELV (Safety Extra Low Voltage). Applying a higher voltage can cause the destruction of the device.

  • Page 20: Connector # 11, Hardwire Interface Of Process Monitoring

    SENSITRON6 – 1 Sensor 3 Installation 3.2.3 Connector # 11, Hardwire Interface of Process Monitoring Type: Standard DB-25 Connector, female Static interface to the Automation System. Via the inputs, the Automation System using HIGH or LOW signals can control the SENSITRON6. Via the outputs, the Automation System receives various messages from the SENSITRON6 - 1 Sensor as HIGH or LOW signals.
  • Page 21 SENSITRON6 – 1 Sensor 3 Installation Selecting Parameter Set see following Truth Table Selecting Parameter Set see following Truth Table Reserved Do not wire! Reserved Do not wire! Reserved Do not wire! Ground 0 Vdc (Ground) of Machine Control Reserved Do not wire! Reserved Do not wire!
  • Page 22 SENSITRON6 – 1 Sensor 3 Installation Specification of digital Inputs: Connector # 11, In p u t 3 K 9 specification of all digital inputs: A ll d ig it a l F r o m M a c h in e C N C C o n tr o l In p u t s : 2 0 G r o u n d...

  • Page 23: Port # 9

    SENSITRON6 – 1 Sensor 3 Installation 3.2.4 Port # 9 Type: Standard DB-9 Connector, female Software Interface to DITTEL testing equipment! For DITTEL testing purposes only! 3.2.5 AE Sensor Input # S1 Type: 3-pole Miniature Socket To connect an AE sensor. Pin # Signal + AE Sensor...
  • Page 24 SENSITRON6 – 1 Sensor 3 Installation DITTEL – ODNFL20EN02 of 52 March 2018...

  • Page 25: Functional Description Of Indicators, Connectors And Keys

    SENSITRON6 – 1 Sensor 5 Starting Up Functional Description of Indicators, Connectors and Keys This Section includes a functional description of the LED indicators, keys and connectors located on the front or rear panel of the SENSITRON6 - 1 Sensor, together with operating instructions and hints.
  • Page 26 SENSITRON6 – 1 Sensor 5 Starting Up Shift Key S1 - S2: Pressing the key changes:  the active Parameter Set from S1 to S2 and vice versa,  the yellow LED indicator (LED S1 or LED S2 lights correspondingly), ...
  • Page 27 SENSITRON6 – 1 Sensor 5 Starting Up (Low = 70 kHz - 100 kHz), or  after previously pressing the Shift Key O - F - C three times, it decreases the Crash Gain in steps of 1 dB (min 0 dB), each value readable on the red 2-digit display.
  • Page 28 SENSITRON6 – 1 Sensor 5 Starting Up Rear Panel:  No serviceable parts inside!  The internal fuse is resettable (Polyswitch)! 24 V dc Input The SENSITRON6 is powered by 24 Vdc either from the machine control supply or from other suitable 24 Vdc sources, provided that it is according to EN 60950 SELV (Safety Extra Low Voltage).

  • Page 29: Starting Up

    SENSITRON6 – 1 Sensor 5 Starting Up Starting Up This Section contains a description of starting up the SENSITRON6 - 1 Sensor the first time. Since every machine tool differs in basic noise, as well as its Acoustic Emission Signal when dressing or grinding, the evaluation circuit of the SENSITRON6 must be adapted to the conditions and characteristics of the machine tool used.

  • Page 30: Starting Up

    SENSITRON6 – 1 Sensor 5 Starting Up Starting Up  Start the grinding machine and/or the dressing spindle and let it run with operational speed.  Clamp the workpiece and feed the grinding wheel just in front of the workpiece, or feed the dresser just in front of the grinding wheel.

  • Page 31: Selecting The Parameter Set

    SENSITRON6 – 1 Sensor 5 Starting Up Selecting the Parameter Set All parameters which are necessary to monitor a process by AE are saved in a Parameter Set. For example, by changing the Parameter Set during a grinding process it is possible to change the limits, the offset, or the gain.

  • Page 32: Setting The Ae Gain

    SENSITRON6 – 1 Sensor 5 Starting Up Setting the AE Gain  Continue operating the grinding wheel or dresser in idle!  By pressing the UP- or DOWN Key adjust to eight (8) green illuminated LEDs on the Analogue Display. ...

  • Page 33: Setting The Offset

    SENSITRON6 – 1 Sensor 5 Starting Up Setting the Offset  Setting the Offset is absolutely necessary when: the basic noise level exceeds the LIMIT (more than 10 lit LEDs) when running the machine tool in idle!  As a rule, when using rotating sensors like M- or R-Sensors, a high Offset value is very useful.

  • Page 34: Setting The Frequency Range

    SENSITRON6 – 1 Sensor 5 Starting Up Setting the Frequency Range  This setting determines the Frequency Range of the AE Signal to be picked up.  The setting “L” = Low (70 kHz to 100 kHz) is particularly suitable when measuring AE Signals by means of Magnet-Sensors or S- Sensors on the headstock.

  • Page 35: Setting The Crash Gain

    SENSITRON6 – 1 Sensor 5 Starting Up Setting the Crash Gain  The AE signal and the Crash Signal are picked up by the same sensor. To detect a collision (crash) the signal is fed through a special filter.  Make sure that during normal grinding or dressing cycles the signal does not exceed the Crash Limit.

  • Page 36: Selecting The Second Parameter Set

    SENSITRON6 – 1 Sensor 5 Starting Up Selecting the second Parameter Set  Select the second Parameter Set , e.g. S2, by pressing the Shift Key S1 - S2. The corresponding LED lights yellow. Sensor LED must be off, if not, refer to Appendix A, Troubleshooting.

  • Page 37: Automatic Operation

    SENSITRON6 – 1 Sensor 6 Automatic Operation Automatic Operation This Section includes descriptions of different processes, controlled by a Machine Control.  Make sure that the Acoustic Emission signal after the touch of grinding wheel and workpiece is considerably higher (more than 10 lit LEDs) than the basic noise! Otherwise the machine control gets no save signal for changing or stopping the grinding wheel infeed.

  • Page 38: Prerequisite

    SENSITRON6 – 1 Sensor 6 Automatic Operation Prerequisite  SENSITRON6 is connected to a 24 Vdc source of adequate power.  One AE Sensor is mounted carefully on the machine and plugged into the input S1 on the rear of the electronic unit SENSITRON6. ...

  • Page 39: Shortening The Air Grinding Time

    SENSITRON6 – 1 Sensor 6 Automatic Operation Shortening the Air Grinding Time With a SENSITRON6 it is possible, to feed in the grinding wheel or dresser without noticeable delay of time towards workpieces with slightly differing diameters. These differences may be caused by tolerances, runout errors, (particularly with slender, hardened parts) or diameters out of tolerance.
  • Page 40 SENSITRON6 – 1 Sensor 6 Automatic Operation DITTEL – ODNFL20EN02 of 52 March 2018...

  • Page 41: Appendix A Troubleshooting Guide

     check Sensor mounting, verify firm seating, choose another position on the machine tool. If you still have problems with the operation or function despite the above mentioned instructions, please consult your local MARPOSS service centre (see last page of this manual). DITTEL – ODNFL20EN02...
  • Page 42 SENSITRON6 – 1 Sensor Appendix A DITTEL – ODNFL20EN02 of 52 March 2018...

  • Page 43: Appendix B Cleaning - Maintenance - Environmental Protection

    SENSITRON6 – 1 Sensor Appendix B Cleaning – Maintenance – Environmental Appendix B Protection B.1 Cleaning The outside surface - primarily the front panel - should be cleaned as soon as spots, grease or dirt are visible. Using a clean, lint-free cloth lightly moistened with a mild cleaning detergent, remove all foreign matter from the case and front panel.

  • Page 44: Environmental Protection

    SENSITRON6 – 1 Sensor Appendix B B.3 Environmental Protection After the implementation of the European Directive 2012/19/EU in the national legal system, the following applies: Electrical and electronic devices may not be disposed of with domestic waste. Consumers are obliged by law to return electrical and electronic devices at the end of their service lives to the public collecting points set up for this purpose or point of sale.

  • Page 45: Appendix C Technical Specifications Sensitron6

    SENSITRON6 – 1 Sensor Appendix C Technical Specifications SENSITRON6 - 1 Sensor Appendix C 24 Vdc ± 6 Vdc, ripple  5% (DIN 19 240), Supply, nominal range: must comply with EN 60950 SELV. Power Consumption: ca. 6 Watt Internal Fuse: Resettable (Poly Switch RUE 160) External Fuse: IEC 60127 type, 4 Amps, Time-Lag (T4A),...
  • Page 46 SENSITRON6 – 1 Sensor Appendix C Response Time of the  3 ms System: Limit output signal  50 ms (Connector # 11, pin 4): Hardwire Interface All digital inputs and outputs are optically isolated, Port # 11: 24 Vdc CNC compatible -30 Vdc …...

  • Page 47: Appendix D Glossary - Abbreviations - Index

    SENSITRON6 – 1 Sensor Appendix D Glossary – Abbreviations – Index Appendix D D.1 Glossary Acoustic Emission AE is defined as the spontaneous release of localized strain energy in a stressed material resulting, for example, from touching a workpiece by a grinding wheel. It can be recorded by transducers (sensors) on the surface.

  • Page 48: Abbreviation

    SENSITRON6 – 1 Sensor Appendix D D.2 Abbreviation Acoustic Emission Human Machine Interface: SINUMERIK operator functionality for operation, programming and Article Number MARPOSS S.p.A: simulation: HMI has the same (Dittel Messtechnik GmbH) meaning as MMC Wire gauge (US) International Electrotechnical Commission...

  • Page 49: Index

    SENSITRON6 – 1 Sensor Appendix D D.3 Index 24 Vdc Input ............ 26 Hardwire Interface ........19, 44 24 Vdc supply ..........18 I/0 LED ............23 AE Gain ............43 Analogue Display ........25, 28 Parameter Set ........... 29, 34 Mounting the AE Sensor .........
  • Page 50 SENSITRON6 – 1 Sensor Declaration of Conformity DITTEL – ODNFL20EN02 of 52 March 2018...

  • Page 51: Copyright - Service Information

    Service Information Should any unusual problem arise or further information be desired, please contact your nearest MARPOSS representative. We welcome your comments concerning this Operator's Manual. Although every effort has been made to keep it free of errors, some may occur. When...
  • Page 52 Wheel Balancer and Acoustic Emission sensors, products and applications. MARPOSS is worldwide leader in precision equipment for measurement and control in the production environment. MARPOSS is present with 80 offices in 25 Countries: for current address of our sales offices, please check at: www.marposs.com/worldwide_addresses.php/eng...

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