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Product category: Linear Position Sensors
News Release from: Newall Measurement Systems | Subject: DPG 2000 DRO and Microsyn linear encoder
Edited by the Engineeringtalk Editorial Team on 16 October 2002

Open and shut case for steel-ball
technology

The design of a novel automotive electric window measurement system led Philip James to use linear encoders rather than the usual fixed-position digital indicators.

Confronted by the challenge of designing and manufacturing a unique final assembly-testing unit for the automotive industry, Philip James Precision Engineers required both an accurate and compact measuring system Newall Measurement Systems' steel-ball linear encoder and digital display offered the perfect solution

By investing in the latest CNC machinery, Philip James Precision Engineers has developed a range of services that not only includes subcontracted manufacturing and assembly-based support but also machine-tool design.

This expansion means the firm now handles contracts from a range of industries including those from the automotive, aviation and machine-tool sectors.

Philip James's move into more front-end work means the company is getting involved in projects at the earlier stages of development.

Philip Whitehouse, Joint Managing Director of Philip James, explains that his customers - typically OEMs - see this characteristic as a significant differentiating factor.

"Many of our customers use us because we offer both design and manufacturing services.

Lots of people manufacture, not many people do both".

James says this was key to securing a particularly challenging job with the UK subsidiary of a German manufacturer of electric window mechanisms.

"Our involvement with Brose started with conceptual designs for a new gauging system for final testing of components of a window movement mechanism.

In particular, the system checks that the mechanism reaches the top, bottom and delivery positions - ensuring that the window will open and close correctly".

James explains it is vitally important that the tests take place within the dimensions of the car door and as such a set of gauges is created specifically for the production of a single car model.

Unusually, however, the gauge created by Philip James amalgamates both the front and rear window-measuring mechanisms so that the quality control process can take place on a single gauge with left and right sides.

James believes this is the first time a window-testing system has been designed in such a way and admits conventional technologies were unsuitable.

"Previously we would have used digital dial test indicators to conduct variable measurement checks, but Brose required a more compact, economic and accurate system and the digital indicators simply wouldn't have done the job".

James recalls that a fresh approach, incorporating a linear encoder rather than a number of fixed-position digital indicators, was needed.

Newall Measurement Systems was contacted and a new amalgamated gauge design was produced featuring Newall's DPG 2000 digital display and Microsyn linear encoder.

James says Newall's ability to produce compact and robust measuring components made it the ideal supplier for the new window gauge project.

"Without Newall's compact linear encoder, combining the front and rear measuring facilities would be impossible.

This has clear financial implications, but also solves the problem of having multiple indicators which can be easily damaged or removed and therefore need resetting to a master".

James goes on to explain that the Microsyn linear encoder, incorporating steel-ball technology, enables the gauge to check linear measurements anywhere across the electric window mechanism, a function unattainable with digital dial test indicators which measure movement in specified areas only.

Unlike glass scales, Newall's linear encoder is also extremely robust as it relies on electro-magnetic technology interacting with a passive reference scale that is sealed within a stainless steel tube.

This makes the encoder tolerant to vibration and magnetic interference and impervious to virtually all shop conditions.

This functionality is bolstered by Newall's DPG 2000 digital display, which offers a single point of reference rather than the eight previously provided by the digital test indicators.

What's more, it's the right the way up.

"Many digital indicators don't have swivel faces", James explains, "which means lower-tier gauges have to be read upside down.

Newall's display is easy to read and acts as a single source of information, which cuts down the potential for mistakes".

Although Philip James uses Newall's technology on its machine tools, this is the first occasion that the company has employed a steel-ball, Microsyn encoder on a client's end product.

The compact and robust nature of the Newall components has impressed James: "We've known about Newall for about 20 years, but until the Brose job came along we were unaware of the Microsyn encoder's unique cost and space-savings characteristics". Request a free brochure from Newall Measurement Systems ...

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