Micronor Fiber Optic Sensors July 12, 2011 - ferret.com.au · 14. R&D Projects: Mini Encoder,...

MICRONOR 3/6/2014 Slide: 1

MICRONOR automation components

Company and Fiber Optic Sensor

Presentation

Micronor, Inc.

750 Mitchell Road, Newbury Park, CA 91320 USA

TEL 805.499.0114 FAX 805.499.6585

Dennis Horwitz, Technical Sales Manager

[email protected]


Presentation Outline

1. Sensing and Controlling Rotary Motion Overview

2. Micronor Overview

3. Position Sensor Technologies and Product Overview

4. Fiber Optic Sensor Overview

5. MR320 series Fiber Optic Incremental Encoder (100ppr-1024ppr)

6. MR330 series Fiber Optic 13-bit Absolute Position Sensor

7. MR380 series Fiber Optic Emergency Stop Switch

8. MR382 series Fiber Optic U-Beam Slot Sensor

9. FOTEMP Fiber Optic Temperature Sensors

10. Some Real-World Fiber Optic Encoder Applications

11. Guidelines for Designing Fiber Optic Links For Harsh Environments

12. MR398 Series Fiber Optic Junction Boxes and Sample Link Designs

13. Important Things To Know About Fiber Optic Sensors

14. R&D Projects: Mini Encoder, Commutation Sensor, Wheel Speed Sensor

15. Conclusion


1. About MICRONOR

• MICRONOR has served the industrial automation market since 1968 with mechanical motion sensing products.

• June 2003, MICRONOR opens facility in Newbury Park, California New facility designs and manufactures innovative fiber optic sensor systems

• In 2005 MICRONOR receives contract from AFRL to work on fiber optic commutation sensor.

• Micronor core competencies

– Fiber Optic Sensors

• FO Encoders: Absolute and Incremental

• FO Control Sensors: Emergency Stop and Slot Sensor

• FO Temperature Sensors

• FO Commutation sensor

• FO Wheel Speed Sensor

– Position Sensors (Resolvers , Encoders, Rotary Limit Switches)

– Integrated Feedback Units

– Motorized Potentiometers

– Cam Timers

– Manual Pulse Generators and Handheld Pendants


2. Sensing & Controlling Rotary Motion

Measure & Control:

•Rotational Speed

•Direction

•Angular Position

•Temperature

CNC Machine

Paper Press


Absolute

Encoder

Incremental

Encoder

• Real-time speed or velocity

• Real-time acceleration

• Relative position

• Absolute position

• Measuring speed or velocity

• Measuring acceleration


Custom Feedback Units • Available as a modular system which can include

– Encoders

– Absolute Multi-Turn Position

– Resolvers

– Potentiometers

– Limit switches

• Control elements and analog/digital sensors can be integrated

• Consolidation of components results in compact, integrated device

• Re-engineering design service for replacing obsolete feedback units from other manufacturers

• Custom engineered units for extreme conditions including wind-generators, aviation, military applications

Dual Geared

Resolver

Yaw Sensor with Absolute

Multi-Turn Sensor and

Limit Switches


3. Fiber Optic Sensors

Remote sensing and measuring of a physical quantity using

photonics for both sensing and transmission.

Since most Fiber Optic Sensors are not of transducer(1) type

they require an interrogator.

Sensor

•Amplitude Modulator

•Bragg Gratings

•Interferometers

•Spectrum Modulators

•Etc.

Interrogator

Source

Receiver

Signal

Processing

User Interface

Fiber Connection

(1) transducer – a device that converts one form of energy into another.

Non Electric – No Interference


What Types of Applications

Are Candidates For Fiber Optic Encoders?

High Importance(5) Medium Importance(3) Low Importance(1)

ATTRIBUTES

CNC

Machinery

Steel

Mill

Aerial

Tram

Wind

Turbine

Oil Rig or

Petrochemical

Plant Mines Aerospace

Inherent Reliability

Immunity to Lightning and

Static Discharges

Immunity to EMI/RFI

Immunity to Ground Loops

Inherent Safety

Cable Lengths

Lightweight

Resolution

Power Consumption

Extreme Temperatures

Radiation Exposure

Total Score (Max=55 pts) 21 23 33 34 39 41 45

Candidate for FO

Encoder?


• Passive optical sensor design

• Incremental resolution up to 1024 pulses per revolution (ppr)

• Immune to EMI and RFI

• Immune to Lightning and Atmospheric Static

• Outdistances copper – encoder links to 2500+ meters

• Intrinsically Safe Sensor “op is”

• ATEX Classified “Simple Mechanical Apparatus”

• Non-metallic MRI compatible Model MR328

• Wide Temperature Range : -60°C to +150°C

5. Fiber Optic Incremental Encoders


• Proven coarse WDM (Wavelength Division Multiplexing) technology

• Two optical paths (850nm and 1300nm) are combined and operate in both

directions over just one industry-standard 62.5/125 multimode fiber

How The Encoder System Works


Optical signals at two distinct separate wavelengths sense the direction of a

moving graduated disk. The two signals provide us with directional information

Fiber optics allows information to be passed in opposite directions without

causing interference. This makes it possible to send the interrogation light beam

to the sensor and receive the modulated signal back over the same optical fiber.

Inside The Fiber Optic Encoder


• Passive optical sensor design

• Absolute angular position over 0-360° with 13-bit resolution

• Multi-turn tracking capability to 12 bits (4096 turns)

• Immune to EMI, RFI, lightning and atmospheric discharge

• Outdistances copper – encoder links up to 300 meters

• Intrinsically Safe Sensor “op is”

• ATEX Classified “Simple Mechanical Apparatus”

• Non-metallic MRI Compatible Model MR338

• Wide Temperature Range: -60°C to +80°C

6. Fiber Optic Absolute Position Sensor


MR330 Absolute Fiber Optic Position Sensor

Click Here for Link To YouTube video

http://www.youtube.com/watch?v=WyxB4NDHals


Light

Source

Optical

Receiver

Micro

Processor

Sensor modulates the optical

spectrum with position

specific information

Controller sends a

broadband light pulse

for position interrogation

Controller receives modulated

light spectrum and converts to

electrical signals

Embedded firmware extracts

the position information from

the spectral information

Measured

Position

Actual

Position

How The MR330 Works


Sensor Head

Optical Fiber

Link

Controller

Linear Spectral

distribution of light on the

sensor disk

Spectrum has bit

pattern embedded

How The MR330 Works


Code disk mounted on rotating shaft

Optical head fully assembled

Input & output fiber

dispersion grating

Inside The MR330 Sensor


7. MR380 Fiber Optic Emergency Stop

• Inherently Safe E-Stop switch system

allows placement of operator override

switches beyond limits of conventional

electromechanical E-Stop switches

• For extended distances

• For hazardous locations such as

mines and chemical plants


MR380 Controller Interface


8. MR382 Fiber Optic Slot Sensor

• Inherently Safe slot sensor provides

turn-key proximity or gear speed

sensor solution for applications where

conventional electronics-based

sensors cannot be used

• For extended distances

• For hazardous locations such as

mines and petrochemical plants


MR382 Block Diagram


MR382 Controller Interface


How To Use The MR382 Slot Sensor


• Passive optical design

• Temperature Range : -200°C to +300°C

• Fast response

• Immune to EMI, RFI, lightning and atmospheric static

• Intrinsically Safe

• Link length to 2000 meters

9. Fiber Optic Temperature Sensors


How The FO Temperature Sensor

Works

Spectrum

Analyzer

Micro -

Processor

Broadband

Light Source GaAs

Material

Temperature

output


Principle of the Fiber Optic

Temperature Sensor

Optical beam probes the wavelength dependence of the

intrinsic band-gap of GaAs.

The band-gap of GaAs is dependent of absolute temperature. Egap = 1.423eV 300°K = 872nm

dEgap/dT = - 0.452meV/°K ≈ 0.315nm/°K


Portland Tram (Portland, OR) uses MR316 encoders to monitor drive speed and

synchronization of cable system for aerial cable car system. Fiber Optic Encoders were

chosen for their immunity to lightening and ability to transmit over long distances.

10. Successful Applications


Steel Rolling Mill

Unbending Rollers:

AC Drives With

MR312 Fiber Optic

Encoder Feedback


Marine Application

Dredge Depth Measurement

MR326 Encoder measures length of cable pay-out.

MR320 Controller adapted to Marine NMEA standard

$--DPT,1234.12,<CR><LF>


Functional MRI (fMRI) Research

Angular Position of Pedal

Measured via MR318

“Non-Metallic” MRI-

Compatible Encoder

Goal: Evaluate effectiveness of various

treatments and therapies on stroke and

other brain-impaired patients.


Mass Spectrometer

Position Sensor is used to

adjust focus and direction of

particle beam.

The sensor resides at some

30kV potential with the fiber

bringing the position signal to

normal ground voltage potential

Fiber Optic Sensor eliminates

complicated electrical isolation

amplifiers.


High Speed Train Pantograph

Pantographs start to skip at high speeds.

Pressure is pneumatically controlled.

Micronor MR320 incremental encoder is

used for position feedback. Isolation

provided by using fiber optic sensor.


32

Features

Pantograph Angle Sensor


Features

Application

qualified for 25kV-railway network

4 or more fibers

available with 9/125 µm or 62,5/125 or 50/125µm fiber

IEC 61952, IEC 62217, IEC 60383, IEC 60060-1

integrated terminal enclosure

EPR Cable (Ethylene Propylene Rubber)

Cable tensile strength 700N, short term 1000N

cable weight 50kg/km

railway network installations

railway sensor and test stations

electric power industry

high Voltage laboratory

particle accelerators

INSULATOR WITH INTEGRATED FIBER OPTIC CABLE

FOR RAILWAY APPLICATIONS


11. Guidelines For Designing

Fiber Optic Cable Links

For Harsh Environments

• Choose appropriate connector types

• Choose appropriate cable type consistent with the application, industry

standards and operating environment (tactical, festoon, mining, mud

oil resistant, shipboard, aerospace, etc.)

• Design link with purposeful interconnection points for ease of

installation and troubleshooting

Non-Environmental

Standard Duplex LC Environmental-Grade IP67

ODVA Industrial IP-LC


12. MR398 Series Fiber Optic

Environmental Junction Boxes

• Turn-key environmental solution for all types of interconnects whether

environmental or non-environmental rated

• Indoor/Outdoor rated UL-approved, UV-stabilized polycarbonate housing

• Other connector configurations and housings available upon request

MR398-JBPC-CC

For Duplex LC to Duplex LC

MR398-JBPC-CD

For Duplex LC to ODVA

MR398-JBPC-DD

For ODVA to ODVA


Konecranes Fiber Optic Encoder Link (4 encoders per crane)

Version A – Using ODVA Industrial LC Segments

FOJB1

FOJB2

Industrial LC Receptacle (Environmental Rated)

Industrial LC Plug (Environmental Rated)

FOJB1

FOJB1

Standard Duplex LC (Non-Environmental)

FOJB1

10-12 Fiber Festoon Cable With 5-6 Pairs

Terminated with Std

Duplex LC on each end

NOTE: 1-2

extra pairs for spares

10-12 Fiber Cable OD=

18mm (0.71 in)

Mfgr:

Optical Cable Corporation

FOJB2

Control Cabinet

Festoon ~250 ft

~100 ft

~50 ft

4x MR324-F38PC1R5 Sensor with DxLC Pigtail

4x MR320 Controller

5 ft (1.5m)


Konecranes Fiber Optic Encoder Link Configuration

Version B - All Duplex LC Breakout Connections

FOJB1

FOJB2

Standard Duplex LC Plug (Non-Environmental)

FOJB1

FOJB1

Standard Duplex LC to Duplex LC interconnection using standard Duplex LC mating/bulkhead adapter.

FOJB1

12 Fiber Festoon Cable With 6 Pairs Terminated

with Standard Duplex LC on

each end

NOTE: 2 spare fiber pairs are

provided

107m

~10m

4x MR324-F38PC1R5

Control Cabinet

4x MR320 Controller

FOJB3

~5m

1.5m


IHI Simplex Fiber Optic Encoder Link (One encoder per crane)

FOJB

Industrial LC Receptacle (Environmental Rated)

Industrial LC Plug (Environmental Rated)

= Standard Duplex LC (Non-Environmental)

ODVA to ODVA Cable 160m

MR332-Y10D00 Absolute Sensor

with ODVA Receptacle

MR330-1 Controller

~3-10m

FOJB

Duplex LC to Duplex LC Cable

150m

MR332-Y10D00 Absolute Sensor

with ODVA Receptacle

MR330-1 Controller

10m

FOJB


13. Important Things To Know About

Fiber Optic Sensors

• Sensors based on light amplitude modulation are inaccurate

Solution: Wavelength-based technologies such Micronor CWDM-based

incremental encoder and Optical Spectrum Modulated position sensor are proven.

• Sensors must be tolerant to non-conforming fiber links

Changes in optical link quality must not affect sensor measurement. We

converted from a one fiber design to always use a transmit and receive fiber.

• Connectors and Cabling are an essential part of the system

• Training for all personnel is an essential investment


14. R&D Projects

• Mini Incremental Encoder has been prototypes. Currrent resolution is

128ppr, goal is 1024ppr

• Mini Absolute Encoder based on Size 11 (1.1” OD) form factor

• Fiber Optic Commutation Sensor has been prototyped and

environmentally tested for US Air Force program

• Fiber Optic Wheel Speed Sensor has been prototyped and tested by an

Aircraft Wheel & Brake OEM


MR302 Mini Encoder (24mm OD)


MR302 Mini Encoder (Size 11)


Fiber Optic Commutation Sensor

• For brushless DC motor drive

• Passive optical design

• Hall-type ABC 3-phase outputs

• Operates up to 30,000 RPM and higher

• Immune to EMI, RFI, lightning and atmospheric static

• Outdistances copper – links up to 2000 meters

• Intrinsically Safe

• Wide Temperature Range : -60°C to +150°C

0° 180° 360° Electrical degree

A

B

C

Hall Sensor Signals


How The Commutation Sensor Works

0° 180° 360° Electrical degree

A

B

C

Hall Sensor Signals

• A sensing disk is attached to the rotor of the motor and

aligned with the poles. Each segment on the disk has a

unique wavelength dependent signature imprinted.

• The position of the disk is monitored by sensing the

wavelength signature on the disk via one fiber optic line

carrying light with four distinctly different wavelengths.

• The light from the fiber is focused onto the disk and the

reflected signature is used to determine the position of

the rotor.

F5

F4

F3

F2

F1

F0 F5

F0

F4

F3

F2

F1

Controller

Fiber Optic Cable

XMTR

RCVR

Timing

Signal

Decsc.

System

Monitor


Commutation Sensor Optical Pick-Up

Colored Disk

Fiber GI

62.5µm/125µm

0.275NA

3mm

Prism

Filter

1.5mm

Optical Filter Disk

25mm


Rear Cover with Optical Pick-Up Assembly

Tie down for cable strength member.

Guide channel for fiber

Fiber connection, fiber routing and contamination

protection present packaging challenges for the

fiber optic sensor designer.


Commutation Sensor Tests Performed

Water Spray Freeze & Dew Exposure

Shock & Vibration Dust Exposure

Temperature

TD5140 Temperature Behaviour

-100

-50

0

50

100

150

200

Tim

e 1 2 3 4 5 6 7 8 9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

Time [hours]

Te

mp

era

ture

-25

-24

-23

-22

-21

-20

-19

-18

-17

-16

-15 T_Sensor

T_Oven

T_Ambient

Power


Fiber Optic Aircraft Wheel Sensor

• Performs in Harsh Environment

• Weight savings from both sensor and

cabling

• EMI-Immunity is ideal for use with

Electric Brake systems

• Accurately monitors aircraft

movement and position during taxi

phase

• Successful Dynamometer tests by

A/C wheel and brake OEM.

Prototype of Fiber

Optic Wheel Speed

Sensor


Fiber Optic Wheel Speed Sensor

Vibration Test

Ve

locit

y (R

ad

/se

c)

Ve

locit

y (R

ad

/se

c)

Time (sec)


15. Conclusion

• Passive Fiber Optic Sensors outperform electronic sensors in challenging

environments

• Fiber Optic technology offers an intrinsic solution to EMI/RFI concerns

• No ground loops

• Immune to lightning

• Not affected by - and will not interfere with magnetic fields

• Interference-free transmission over longer distances than copper

• Resistant to radiation (X-rays etc)

• Simplified installation and wiring – does not require remote power,

special purpose multi-conductor shielded electrical cables, isolation

barriers or remote environmental electrical cabinets


your partner for fiber optic sensing

we supply the sensors

and

application support

Micronor, Inc.

750 Mitchell Road, Newbury Park, CA 91320 USA

TEL 805.499.0114 FAX 805.499.6585

Robert Rickenback, Chief Engineer

[email protected]

Dennis Horwitz, Technical Sales Manager

[email protected]

mailto:[email protected]




Micronor Fiber Optic Sensors July 12, 2011 - ferret.com.au · 14. R&D Projects: Mini Encoder,...

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Transcript of Micronor Fiber Optic Sensors July 12, 2011 - ferret.com.au · 14. R&D Projects: Mini Encoder,...