The development and status quo of the automobile manufacturing industry
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Automobile products are a highly integrated final product. They are different from ordinary products. They are built under a huge social and economic system project. They need specialization and socialization, and they need related industrial products. In recent years, the automobile consumer market has expanded rapidly in China, and automakers have expanded their production scale to accommodate this huge market.
In terms of automobile production technology, in recent years, the automation level of the domestic automobile manufacturing industry has been greatly improved, and the obvious trend is to improve assembly precision and improve production efficiency. As a means of positioning and detection, a variety of sensors have been popularized in all aspects of the production line, especially the inductive sensors widely used by the vehicle manufacturers for positioning, real-time monitoring of the operating state of the entire line. However, for different manufacturers and multiple series of sensors on the market, how to choose the most suitable products for automotive applications is the key.
Discussion on the characteristics of inductive sensor products
For inductive sensors, everyone is not unfamiliar, it is a common way to locate metal objects at close range. Because it is mainly done by the Hall effect, it is also called a Hall sensor.
The internal structure is composed of two parts: the front end is composed of a core wrapped around the transmitting and receiving coils, and the rear end is a circuit part, which is integrally packaged in a plastic or metal casing. During operation, an alternating magnetic field is generated in the core portion of the electromagnet, which causes an eddy current effect on the surface of the adjacent metal object, thereby weakening the LC oscillation circuit, and the amplifying circuit portion analyzes the weak LC oscillation circuit of the electromagnet core receiving coil, and gives a corresponding output.
Different dimensions, the rated detection distance is generally up to 100mm. Under normal conditions, each manufacturer's nominal detection distance is the rated detection distance measured under laboratory conditions. In practical applications, considering the environmental factors of various aspects, the reliable detection distance is about 80% of the rated detection distance, but there are certain requirements for the measured object. Due to the magnetic permeability and size of the material to be tested at the application site, under normal circumstances, the requirements of the standard object are not met, and the detection distance of the sensor will be further attenuated, which is why many users feel that the detection distance of the inductor sensor is higher than that of the manufacturer. The reason for the nominally small size. In the case of such non-standard testing, the differences between manufacturers and their different series of products are large. In addition, in more depth, there are differences in anti-electromagnetic interference, ambient temperature, voltage disturbances, and installation requirements.
Choosing the right sensor will greatly improve the stability and reliability of the equipment operation, and the greatest possibility to reduce the failure or damage of the sensor and reduce unnecessary maintenance investment. In the manufacturing process, the automotive industry uses a large number of inductive sensors as positioning detection. How to choose the most suitable products for this industry is particularly important.
Requirements for inductive sensors for stable operation of automotive production lines
With the demand for automobiles in the Chinese market, as well as the improvement of vehicle performance requirements. Automakers have higher standards for their production lines on new projects. On the one hand, it is necessary to meet the requirements of the automobile manufacturing process; in addition, it is necessary to ensure a stable and smooth operation of the entire line, and to minimize maintenance and commissioning time to ensure high production efficiency.
As we all know, the automobile manufacturing process mainly includes four main parts: stamping, welding, painting, and final assembly. Inductive sensors are used in large quantities in each part. In particular, in the welding, painting and assembly shop, many inductive sensors are distributed in the accumulation chain conveyor line, which plays the role of slip detection or sub-track detection.
Take a new car factory built for example. The plant uses a large number of ELCO (Yike) C40 series inductive sensors to locate the slippery. This series of sensors is square, with a detection surface size of 40*40mm and a rated detection distance of 40mm.
ELCO C40 Series Sensors
There are two main factors to consider when choosing this series of sensors:
1. Far-distance detection distance: Sliding warp sometimes has a certain vibration during the movement, and the sensor needs a certain detection distance to ensure that the measured part of the slippery cannot be damaged due to vibration from the detection area or hitting the sensor.
2. Moderate size: Generally speaking, the detection distance and volume of the inductive sensor are directly proportional. For a detection distance of 40 mm, the square housing size of the 40*40 mm inspection surface is very suitable.
In addition to the selection of the main parameters, more details should be considered to match the on-site conditions, so that the sensor and the field environment and equipment are more closely matched.
First, the attenuation of the distance is detected. Sliding is iron, suitable for inductive sensor detection; while the size of the tested part is slightly smaller than the standard test object size (the standard measured object size is 3 times the rated detection distance. In this application, the standard size should be 120*120mm ), in this case, there will be a certain attenuation, the above sensors are better in this respect, and the attenuation is extremely small.
Second, the site's anti-interference ability. This is a problem that cannot be ignored. Ordinary inductive sensors are easily interfered by motors or inverters. Many technicians only select sensors that are highly resistant to electromagnetic interference for applications in the vicinity. However, in the automobile manufacturing workshop, the factory building is large, and the on-site technicians are accustomed to using the walkie-talkie to communicate, especially when talking with the walkie-talkie while walking, they will inadvertently approach the sensor, resulting in a short-term failure. ELCO is very concerned about the C40 series of products in this regard, to improve its overall electromagnetic compatibility, to avoid the occurrence of malfunctions.
Furthermore, the installation aspect. With the popularity of inductive sensors, sensors are not only improved in electrical performance, but their mechanical design is becoming more and more human. In this application, the C40's inductive sensor sensing surface can be easily adjusted to five directions. It does not need any tool assistance, and it does not need to cut off the power supply and output plug-in, just by manual operation. It is convenient for the installation and use of different detection directions, and the humanized installation is realized to the greatest extent. Reduces the stocking of multiple approximate products and reduces the time for installation and maintenance.
Finally, the guarantee of stable operation. The C40 has an IP67 protection rating and eliminates any oil and dust erosion during use in the depot. In addition, the vibration is long-lasting when the slider passes over the track, and the excellent shock resistance of the C40 also plays a very important role in this application.
In this project, ELCO's sensor technology solution for the auto manufacturer is a relatively successful case according to its working conditions. Overall, it provides a stable and reliable detection link for automatic control in the project.
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