Wireless limit switches are favored by the market
Author: Todd Hanso, director of wireless solutions, Honeywell Sensing and Control Date: 2013-09-06
Wireless limit switches reduce equipment downtime and lost productivity due to proximity sensors
Wireless technology drives factory automation revolution, reducing costs and reducing downtime
Switches and sensors can be used to detect that components, doors, and guards are properly locked before the equipment is operational. These locks are critical to ensure the accuracy of the production, the smoothness and safety of the equipment during operation. But all wired devices – whether limit switches or proximity sensors – are not only limited in area but also prone to wear and require ongoing maintenance.
Currently, proximity sensors are widely used in factory floors simply because they are less expensive than traditional electromechanical switches. However, many manufacturers have found that proximity sensors require passive maintenance from time to time, resulting in a disruption in the production process.
In the case of multi-axis machining (such as engine casting machining), the fixture will continuously rotate the part to be machined to be properly seated, which causes the wire of the proximity sensor to continuously move and withstand stress, which causes the cable to gradually wear and eventually break. Once the cable breaks, the equipment and workers enter the idle state due to cable replacement (usually 15 to 20 minutes per replacement). If the cable is replaced every 3 months (as some manufacturers do), the cumulative productivity loss will be staggering. If you can predict when maintenance is needed, preventive maintenance measures can avoid downtime due to maintenance.
Similarly, the metal chips that the coolant carries from the processing area are in constant contact with the wires, constantly eroding the cable jacket, causing "short circuit" or continuity problems. The cable must be replaced at this point, resulting in a loss of productivity.
In addition, one of the biggest problems manufacturers face with sensors and devices is the number of connection points. Each connection point is a potential source of failure. If these connection points are eliminated, manufacturers can reduce the number and timing of interruptions in their production processes.
All of these issues can be easily solved with the wireless limit switch. Extensive application on the factory floor proves that wireless technology (especially 802.15.4.2.4 Ghz) is a reliable solution. Integrating wireless technology into the switch provides the advantage that the switch does not consume power, but only performs control functions - this extends battery life to two years or longer under normal operating conditions. The built-in diagnostics function in the RF (Radio Frequency) circuit provides a low battery indication to replace a battery that is not working properly before the workflow is interrupted. This is very important because both the sensor and the RF (radio frequency) circuit consume a lot of power and require regular battery replacement.
The wireless switch can be easily retrofitted to applications that use standard wired or proximity sensors. Of course, no matter which wireless device is used, an RF (Radio Frequency) signal needs to be sent and must be converted to a standard input signal (PNP, NPN or relay) available to the control system. This is done through a wireless receiver installed in the device control panel. The receiver's output is directly connected to the controller input card in a conventional wired manner. The controller cannot distinguish whether the standard input is from a wireless device or a wired device. The only difference is that additional diagnostic inputs for monitoring battery life and signal strength are now added.
Wireless technology has revolutionized the field of factory automation by reducing switch installation costs and providing greater application flexibility. By eliminating the need for cables, manufacturers can significantly reduce maintenance costs, avoid downtime caused by connector and cable integrity, and dramatically increase productivity. With the continuous release of new solutions and more applications of wireless technology, the use of wireless devices to solve application problems will lead the new trend of factory automation technology. For more information on Honeywell Sensing and Control. Please visit http://sensing.honeywell.com.cn/ or send an email to infochina.
Source: Honeywell Sensing and Control
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