Overcoming the limitations of linear measurement systems

Sensor technology Overcoming the limitations of linear measurement systems

2024-12-13 From Kübler | Translated by AI 4 min Reading Time

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From simple object detection to ultra-precise distance and position change measurements: Kübler expands its linear measurement technology with industrial radar sensors.

Radar sensors allow for precise width measurement of steel beams.(Image: Kübler) — Radar sensors allow for precise width measurement of steel beams.
(Image: Kübler)

For the detection of linear positions, distances, and movements, sensor specialist Kübler already offers a wide product portfolio based on various technologies: from magnetic sensor systems to optical sensor systems with code strips and sensor heads, to draw-wire encoders or measuring wheel systems, which can be combined with the company's extensive range of Sendix encoders.

However, all these systems have one thing in common: a mechanical connection must always be established over the entire measuring range to the application. Additionally, no other objects may be present along the measurement path, even temporarily. To extend the range of applications beyond these limitations, Kübler has newly added radar sensors as a non-contact technology to its product portfolio. In addition to the actual position information, radar offers numerous possibilities to capture and process additional information about the measuring range through the echo curve generated by the sensor.

Gallery

The RAD7x family of radar sensors is characterized by high performance.(Image: Kübler)

Application example: Determining the bridge condition.(Image: Kübler)

Application example: Detecting passing trains.(Image: Kübler)

Application example: Position detection in cranes.(Image: Kübler)

Gallery with 8 images

Since the measurement system consists only of the sensor without any connection to the measured object, many advantages arise in applications. Both the sensor and the measured object can be freely moved in use. This enormous flexibility makes the radar sensor interesting for a wide range of industries and applications in terms of mounting and alignment.

Precisely measure under the harshest environmental conditions

In logistics, mobile automation, agricultural technology, and the steel industry, as well as in many other sectors, customers cannot always rely on technologies that require a mechanical connection within the measuring range. Through the non-contact radar sensor technology combined with smart tools, it is possible to achieve precise and reliable measurement results even under the roughest weather conditions, despite short-term disturbances such as a bird flying through the measuring area or objects tangentially touching the measuring range.

Another major advantage is the high robustness. Unlike optical technologies such as laser distance sensors, radar is insensitive to dust, dirt, water vapor, or interfering and stray light. Also, background noise or air movements, which can be problematic for ultrasonic measurement, for example, are negligible.

In this way, radar sensors can unfold their full potential, especially in outdoor applications. However, even under harsh environmental conditions, such as those characterized by heat, dust, and vibrations in the steel industry, positions and distances, as well as profiles like the width measurement of still glowing materials, can be reliably detected.

Unstoppable

Radar waves can measure through non-conductive materials such as plastics, glass, or cardboard. This offers many further possibilities to make the sensor system even more robust and thus more reliable. An additional protective housing or cover, critical measurement objects behind a protective wall—the diverse possibilities that radar technology offers are unique.

The RAD5x sensor family from Kübler is based on an extremely compact M30 housing design. In addition to analog interfaces and switching outputs, the RAD5x is also available with IO-Link as a communication and parameterization interface. Additional interfaces such as CANopen are planned. With a linearity of ±0.20 inches and repeatability of up to ±0.04 inches, many precise measurement tasks can already be realized with this sensor family. With an opening angle of ±7.5° (15°), the sensors reliably detect objects and measure distances and positions accurately, even when oriented at an angle to a measuring object.

The RAD5x sensor family also offers order variants specifically for use in distance measurement. When it comes to measuring precisely with the narrowest possible beam angle (radar pointer), it is advisable to choose the ±3° (6°) option. A measurement rate of 100 Hz ensures not only the required precision but also the appropriate measuring speed.

Can it be a bit more precise?

For higher performance, the RAD78 radar sensors with Profinet interface and an integrated web server provide a solution. With a linearity of ±0.03 inches and repeatability of ±0.004 inches, these sensors can measure not only extremely precisely but also very quickly, with a high measurement rate of up to 500 Hz. Besides being used as stand-alone product solutions, they are also developed for use in system solutions. Two radar sensors can be intelligently combined to achieve precise profile or width measurement of steel slabs, for example.

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Maximum accuracy is finally achieved with the RAD78UP product. Within the maximum measuring range, a reference point/zero point can be established. Relative positional change is then measured from this point with a linearity of ±0.1% of the recorded value, achieving accuracy down to the lower micron range. This offers completely new possibilities for condition monitoring applications in various fields.

An example of this: The condition of bridges in Germany is well known. Thanks to ultra-precise radar sensors, conditions and even the smallest movements of bridges can be monitored as part of condition monitoring concepts to prevent major damage with timely repairs.

Smart software tools that visualize the echo curve (what the radar sensor sees) in real time not only simplify the commissioning of radar sensors but also assist in the process of easily adjusting the sensors to specific application requirements. Switch points or filters can be set to exclude disturbances, such as a bird flying through the sensor's measuring range in the example of a monitored bridge.

Foundation for intelligent system solutions

The RAD7x series radar sensors are also suitable for complex measurement system solutions, where, for example, the profile or width of objects is measured from two directions. Especially when capturing material dimensions in the steel industry, where sometimes still glowing objects must be measured, the high robustness complements these technical capabilities perfectly.

In a nutshell: Wherever other linear measurement systems reach their limits, radar sensors are the optimal solution. When the sensor or the measured object is in motion, when the measured object cannot be accessed directly, when precise measurement is required under the harshest environmental conditions—then the time has come for radar sensors.