And the increasingly thin automated production of silicon steel sheets has also brought certain challenges to sensors:

Due to the extremely thin thickness of the metal sheet, the inductance change caused by it is extremely weak, which poses a challenge for traditional inductive proximity sensors in detection. In addition, the material properties of ultra-thin metal sheets, such as conductivity, magnetic permeability, and dielectric constant, may also have a significant impact on the detection process, further increasing the uncertainty of the detection. Therefore, the detection of ultra-thin metal sheets requires more precise and sensitive detection techniques, taking into account the comprehensive influence of multiple factors to ensure the accuracy and reliability of the detection results.

In this issue, Xiao Ming will share the unparalleled application of AKUSENSE in detecting ultra-thin metal sheets

Scenario requirement - Detecting the presence of silicon steel sheets

On the silicon steel mesh belt/conveyor belt, a sensor needs to be installed above the conveyor belt to detect whether each metal sheet is successfully produced and transported to the next process. This helps to detect blockages, fractures, and other issues on the production line in a timely manner, avoiding production interruptions.

Testing difficulties:

0.1mm thickness, thinner than A4 paper!

Why is it difficult for traditional inductive proximity sensors to stably detect very thin metal sheets?

The main reasons can be summarized as follows:

1. Thickness limit for metal sheets

Inductive proximity sensors have certain requirements for the thickness of metals when detecting them. Especially for magnetic metals such as iron, nickel, etc., their thickness usually needs to be greater than 1mm to ensure effective detection. Thin metal sheets, such as foils with a thickness less than 0.01mm, although theoretically able to achieve the same detection distance as magnetic materials, in practical applications, due to their thin thickness, they may not be able to trigger the oscillator and amplifier inside the sensor to generate sufficient signal changes.

2. Limitations of detection principle - inductance variation

Inductive proximity sensors work by detecting changes in inductance caused by changes in the relative position between the probe and the target. When the metal sheet is too thin, the inductance change it causes may be very weak and difficult for sensors to accurately capture and identify.

Optimal detection area: There is an optimal area between the sensor and the target, which makes the position and inductance changes close to linear and has less noise interference. For very thin metal sheets, it may not be stable within this optimal area, resulting in poor detection performance.

3. Influence of material properties - attenuation factor

Different metal materials have different attenuation factors, which can affect the detection performance of sensors for metals. For very thin metal sheets, their material properties may be more complex and unstable, further increasing the difficulty of detection.

Conductivity and dielectric constant: Although inductive proximity sensors are mainly used for detecting metals, the conductivity and dielectric constant of the material can also affect the detection distance and sensitivity. For non-magnetic and low conductivity metal sheets, their detection difficulty may be greater.

4. External environmental interference - electromagnetic interference

In practical applications, inductive proximity sensors may be subject to interference from the surrounding electromagnetic environment, resulting in unstable or distorted detection signals. For very thin metal sheets, this interference may be more significant, further reducing the accuracy and reliability of detection.

solution

Select Akusense non decaying inductive proximity sensor TC series, the sensor can be installed above the silicon steel sheet streamline, and when no silicon steel sheet is detected, a signal will be sent to remind the operator to handle the abnormality in a timely manner

The sensor adopts high-frequency oscillation circuit and advanced signal processing algorithm, with high sensitivity, capable of accurately sensing the presence of ultra-thin metal sheets and outputting precise detection signals.

1. No attenuation detection capability

Stable detection distance: The all metal non attenuation proximity sensor can maintain a non attenuation detection distance when detecting different metals, which means that even when facing ultra-thin metal sheets, the sensor can stably output detection signals without signal attenuation due to the thin thickness of the metal sheet.

Strong adaptability: The sensor can be applied to various metal materials, including copper, iron, aluminum, stainless steel, etc., without the need to adjust detection parameters for different metals, improving the flexibility and universality of detection.

2. High precision detection

High sensitivity: The sensor adopts high-frequency oscillation circuit and advanced signal processing algorithm, which can accurately sense the presence of ultra-thin metal sheets and output accurate detection signals.

Strong anti-interference ability: Sensors have strong anti-interference ability, which can resist adverse factors such as electromagnetic interference and mechanical vibration in industrial environments, ensuring the accuracy and reliability of detection results.

3. Easy to integrate and maintain

Small size and light weight: The all metal non decaying proximity sensor has a small size and light weight, making it easy to integrate with other equipment on the production line and reducing the impact on the production process.

Low maintenance cost: The sensor structure is simple, easy to maintain, and reduces the operating costs of the enterprise.

4. Widely applicable scenarios

Suitable for harsh environments: Meiji TC series all metal non decaying proximity sensors can work stably in harsh industrial environments, such as high temperature, humidity, vibration, etc., providing a reliable solution for the detection of ultra-thin metal sheets.

Multi industry applications: Sensors are widely used in industries such as machine tools, metallurgy, chemical engineering, textiles, and printing. They can be an important component of limit, counting, positioning control, and automatic protection in automatic control systems.