Product category:
Rotary Position, Tilt and Angular Sensors
News Release from: Newall Measurement Systems | Subject: Digital Spherosyn encoders
Edited by the Engineeringtalk Editorial
Team on 11 March 2003
Encoders aid in speciality steels
production
Digital Spherosyn encoders and readouts are helping Scunthorpe based Corus Bi-Steel dramatically improve the performance of the unique Bi-Steel manufacturing system.
Digital Spherosyn encoders and readouts, designed, developed and manufactured in the UK by Newall Measurement Systems, are helping Scunthorpe based Corus Bi-Steel dramatically improve the performance of the unique Bi-Steel manufacturing system In particular, positional accuracy during production has been increased tenfold, and setup times have been halved, leading to enhanced repeatability, productivity and final product quality
This article was originally published on Engineeringtalk on 31 Jan 2002 at 8.00am (UK)
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Corus business unit worked closely with Newall Measurement Systems to develop the new manufacturing system.
This is the only machine of its kind in the world and is used to produce Bi-Steel, which is a patented composite material used as a cost effective replacement for traditional reinforced concrete or heavily stiffened steel in the construction of military and commercial buildings, industrial and research facilities and offshore structures.
One of the principal advantages of Bi-Steel is that large sections can be fabricated quickly and inexpensively off-site, thereby reducing on-site erection time and cost; perhaps as importantly, although relatively light and easy to transport, Bi-Steel structures are extremely strong, making them widely used in areas where blast protection is required.
Key to the success of this process is the speed, accuracy and repeatability with which Bi-Steel panels can be manufactured, to ensure that they can be assembled easily on-site without the need for rework or modification.
In essence, Bi-Steel is constructed from pairs of steel plates permanently connected by an array of transverse steel bars, producing panels that can be straight or curved and up to 740mm in cross section and up to 18 x 2m in size.
Further reading
Linear encoder cuts positioning costs
Machine-tool builders, system integrators, machine designers and engineering companies are managing to cut costs and increase productivity with the help of Newall's Spherosyn Digital linear encoder.
Single-axis digital readout system
Newall's SA100 single-axis digital readout system is specifically designed to increase productivity and machine tool efficiency within the machinery and metrology industries.
Encoder measures hostile machine movements
The Magnasyn encoder system features a supple, magnetically encoded tape scale, which is ideal for both rotary and linear applications.
The new Bi-Steel manufacturing system is fully automated and comprises three sections: entry side, weld head and exit side.
Each pair of plates is fed through rollers on the entry side to the welding head, where columns of bars are individually friction welded using an innovative double-ended process, with the plates indexing forward as each column is completed.
The exit side of the system provides the crucial guidance mechanism to control both the alignment of the plates and, as the welded panel indexes forward, the degree of curvature.
Positional accuracy is therefore crucial if each panel is to be manufactured within tolerance and it is at this stage that Newall Measurement Systems' digital Spherosyn encoders and readouts play a crucial role.
Previously Corus had used traditional vernier scales as a method of controlling panel alignment.
However, as Bi-Steel Manufacturing Engineer, John Campbell, explains, "The Bi-Steel system has been continuously improved, as we have developed new ways to control the manufacturing process, and although the original manual scale alignment mechanism provided reasonable results it quickly became apparent that we needed to enhance both accuracy and repeatability, while reducing setup times if we were to continue to meet the rigorous demands of our customers".
The company considered a number of measuring options, including glass scale encoders, but discarded these as being either insufficiently accurate or too fragile for use in what is a relatively demanding environment.
Ultimately, Corus selected Newall Measurement Systems as a partner for the project, "for the proven quality, reliability and performance of their products".
The exit side of the system is essentially a complex multi-axis guide and alignment frame, with Spherosyn linear encoders being used on each side of the frame to measure the position of guides to within +/-5um/m.
Each encoder operates on the principle of electromagnetic induction, with an energised electromagnetic reading head, incorporating four pickup coils, passing along a stainless steel tube that is filled with high precision, graded steel balls.
As the head moves along the tube the pickup coils detect variations in the induced field, with the four signals being combined and processed to determine the exact position of the head.
Digital output from each Spherosyn encoder is then fed directly to Newall Measurement Systems' DPG2000 DROs, one mounted on each side of the alignment frame.
In addition, Newall has supplied two SA100R DROs for connection to a pair of rotary encoders, also used on the frame, to show angular readings.
John Cambell is delighted with the improvements that the Newall Measurement Systems' encoders and DROs have delivered.
"The products are both rugged and reliable, being more than capable of withstanding the stresses imposed in a demanding manufacturing environment; in addition, as they are produced in the UK, we are able to deal direct with the manufacturer, which has resulted in an effective working partnership and helped us gain more benefit than would otherwise have been the case.
Ultimately, the new measurement system has cut set up times by 50%, leading to increased productivity, and given us a tenfold improvement in accuracy, so that we are able to ensure straight-line dimensional tolerances are less than 1.0mm over a 3.0m panel". Request a free brochure from Newall Measurement Systems ...
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