CONTROL systems GmbH - … piezo as an analog sensor offers a highly practical ... Vibration &...

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© by unidor TR systems GmbH www.unidor.depiezoCONTROL

Measuring with Piezo

Deformations & sound in solids measuredprecisely with piezo

If your application requires the precise measuring of deformation, sound and vibration, then piezo technol-ogy, is not only an option but your first choice.

The piezo as an analog sensor offers a highly practical way to determine difficile physical events in solids such as tools and equipment. Together with the piezo signal amplifier PSA, event the smallest signals are detected accurately and converted to digital and bus-compatible measured values that can be processed by a SPC, CNC, by IPC or PC.

This applies in general to all models and types of piezo-electrical sensors such as plugs, disks or squares. Piezo disks are ideal because they require very littlespace, are easy to install and low-cost.

Hands-on example for using piezoCONTROL with a tool.

Handling of the PSA measuring signal

Stationary or mobile: the piezo combi measuring sys-tem piezoCONTROL delivers accurate data for measur-ing, checking, controlling and analyzing of mechanical processes and is a handy tool for various applications.

ForcePressureTorsion

ElongationCompression DeformationOscillation

Vibration & Sound

AutomationMachine construction

Tool and mold constructionPlant engineering and construction

Vehicle constructionShipbuilding

Civil engineeringQuality assurance QS

Inspection and test systemsSafety technology

© by unidor TR systems GmbH www.unidor.de piezoCONTROL

3The PiezoSignalAmplifier PSA

The PSA Amplifier

The piezo signal amplifier PSA ec4 is a perfect 4-channel amplifier specifically designed for piezoelectric sensors such as pressure, force, acceleration or torsion sensors in all tech-nical areas and applications.

The robust aluminum housing and the high degree of pro-tection (IP67) make the PSA the ideal tool, especially in in-dustrial environments, guaranteeing continuous and safe function.

The EtherCAT®-compatible PSA has 4 analog precision piezo measuring channels (charge amplifier), including two digital inputs and outputs each. The intelligent charge amplifier is triggered via EtherCAT SPC, or PC. Due to the extremely low drift of the input stage and the digital processing of the charge signal, not only extremely precise but also quasi-static measurements are possible.

1) Fine resolution in 0.2 or 0.8 pC available as well

Piezo 1Piezo 2Piezo 3Piezo 4

INP 1INP 2OUT 1OUT 2

IN

OUT

24 VDC IN

OUT24 VDC

PiezoSignalAmplifier PSA ec4

126 mm

60 m

m

unidor TRsystems GmbH, PSA Beschriftung 2Piezo 42 input +3 shield4 input -

Piezo 32 input +3 shield4 input -



2 +24 V3 GND4 outputOUT 2

2 +24 V3 GND4 outputOUT 1

2 +24 V3 GND4 inputINP 2

2 +24 V3 GND4 inputINP 1

1 Tx+2 Rx+3 Rx-4 Tx-EtherCAT IN

EtherCAT OUT1 Tx+2 Rx+3 Rx-4 Tx-

24V Us 124V Up 2

GNDs 3GNDp 4

Power IN

Power OUT24V Us 124V Up 2

GNDs 3GNDp 4

Key Technical PSA ec4 Data

Charge amplifier 4, digital

Sample rate 100 000 samples/sec

Resolution 1 fine: 2 pC

coarse: 22 pC

Slew rate 2 fine 50 pC/uS

coarse 550 pC/uS

Digital input 2 x | 24 V

Digital output 2 x | 24 V/0,5 A

Fieldbus interface EtherCAT® slave

Power Up/Us 24 VDC ±10%, 0,25 A

Temperature 0 ... + 55 °C

Protection class IP 67

Dimensions in mm 60 x 126 x 35 (W/L/H)

EtherCAT® Trademark Beckhoff

4


Measuring Principle and Bus Topologyab

s. for

ce c

urve

forc

e cu

rve

scaled

to ±

50,000

pC

Trigge

r

+100,000 pc

+50,000 pc

+50,000 pc

–100,000 pc

0 pc

0

1

+10 V+50,000 pC

-50,000 pC–10 V

start measuring stop measuring

pull

press

Communicating with the PSA

The process diagram can be absolute or scaled. As long as the trigger is log 0, the output signal is always zero re-gardless of the input signal. The signal analysis starts with the trigger signal ‚log 1‘ and ends with ‚log 0‘.

The 2 absolute measurement shows the actual process progression of the piezo output signal in ± pC (pico cou-lombs) as long as the trigger signal is ‘log 1’.

The 3 scaled measurement is in the range of ± 10 V or ± 32 767 digits, i.e. depicted in 16 bit ADC. Scaling of the coulomb/voltage is freely selectable.

A precise and quick process depiction are ensured with 100,000 samples/sec and channel. We deliver the piezo sig-nal amplifier PSA ec4 also fully calibrated with calibration certificate.

The Bus Topology

4 The example shows the integration of the PSA amplifiers in the topology of the EtherCAT fieldbus, including the con-nection to the control systems PC or SPC.

2

3

Piez

o 1

Piez

o 2

Piez

o 3

Piez

o 4

INP

1IN

P 2

OUT

1O

UT 2

INP

OUT

24 V

DC

IN

24 V

DC

OUT O

UT

Piez

oSig

nalA

mpl

ifier P

SA 4

ec

Piez

o 1

Piez

o 2

Piez

o 3

Piez

o 4

INP

1IN

P 2

OUT

1O

UT 2

INP

OUT

24 V

DC

IN

24 V

DC

OUT O

UT

Piez

oSig

nalA

mpl

ifier P

SA 4

ec

EtherCAT

power supply

PSA Fieldbus box

SPS

PLC

IPC

4


5

piezo disk (e.g. Ø 10 mm)

connection cable shieldsignal

simply position piezo disk and glue in place. Done



connection cable shieldsignal

simply position piezo disk and glue in place. Done

glue

Installing the Piezo Disk

Finding a suitable spot for the piezo disk is easy due to its very size. For more complex measurement tasks, several measuring points are to be determined to analyze the pro-cess progression, i.e. several piezo disks must be affixed.

The easiest way to affix the piezo disk at a suitable measur-ing point is to use glue and a mechanical component to keep the disk in place. Empirical determination of the ideal position of the disk for the respective measuring task is usually best since the task and the process technology may differ in each case.

The piezo disk can also be countersunk 2 if the height of the disk (about 2 mm) interferes in any way with the task at hand. The final encapsulation protects and fixes the disk additionally.

Interference-immune Coaxial Cable

The PSA/piezo connection is established with a coaxial cable. We usually ship each piezo disk with 300-cm coaxial cable. This makes it possible to adjust the cable easily to the required cable length.

Piezo connection plugs for PSA

length up to 10 m

adapter

ready-made cable

ready-made cable

Piezo connection

Easy Piezo Installation

2

3

6


Products and Technology

119 53

ø 3 mm (M3)

PiezoSignalAmplifier PSA 4ec

Power 24VDC (IN/OUT)EtherCAT® (IN/OUT)4 piezo sensors (input)2 Digital inputs (24 VDC)2 Digital outputs (24 VDC/0.5A)

Piezo in different variations

Piezo plug in different variations

20 ø

10 ø

Piezo disk in ø 10, ø 15, ø 20 mmCoax cable length 300 cm

Power supply unit230 VAC, 24 VDC/3 Awith power cable

Power cablefrom power supply unit to PSA amplifier

PSA cablefrom AC adapter to PSA amplifier

EtherCAT cable

Component Overview


7Controlling, Measuring, Visualizing: smartLINE

240,0

Mounting frame for quick smartLINE fastening

215,0

66,0

smartLINE: Top DesignsmartLINE features not only the best currently offered by PC technology but also stands out for its forward-looking, modern, and very compact design. smartLINE is quickly installed and designed especially for use in rugged indus-trial environments.

The PC is mounted in just a few minutes when using the included mounting adapter.

smartLINE: Top Technology

PC board CORE 2 DUO

CPU: ATOM D510, 1.66 GHz

1 GB internal RAM

4 GB flash memory, without mechanical drive

Windows 7 embedded

10.4“ LCD display, 1024 x 768 pixels, touch-resistive

Power + 24 VDC/

EtherNET, EtherCAT, 2 USB, power (IN/OUT)

All connections are pluggable

Anodized aluminum enclosure with mounting adapter

Ultra compact: only 240 x 215 x 66 mm (W/D/H)

Super easy installation for table or wall mounting

Well suited for rugged industrial applications

The Dream-Team: Combi Measuring System

PSA and smartLINE are the perfect match. Communica-tion is quickly established via EtherCAT as is linking with all EtherCAT bus components.

The Windows 7 operating system used in the smartLINE is the ideal platform for your own or external programs to control, visualize, measure, and analyze.

Whether compact and handy Combi Measuring System or automation subsystem, whether stationary or mobile: smartLINE is technically and especially price-wise the clear winner.

unidor TRsystems GMBH • 75179 Pforzheim • Freiburger Str. 3

Phone +49 (0) 7231/3152 0 • Fax +49 (0) 7231/3152 99 • [email protected]

CONTROL systems GmbH - … piezo as an analog sensor offers a highly practical ... Vibration &...

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