中英文文献翻译—什么是智能传感器

What is a smart sensorOne of the biggest advances in automation has been the development and spread of smart sensors. But what exactly is a "smart" sensor? Experts from six sensor manufacturers define this term.A good working "smart sensor" definition comes from Tom Griffiths, product manager, Honeywell Industrial Measurement and Control. Smart sensors, he says, are "sensors and instrument packages that are microprocessor driven and include features such as communication capability and on-board diagnostics that provide information to a monitoring system and/or operator to increase operational efficiency and reduce maintenance costs."No failure to communicate"The benefit of the smart sensor," says Bill Black, controllers product manager at GE Fanuc Automation, "is the wealth of information that can be gathered from the process to reduce downtime and improve quality." David Edeal, Temposonics product manager, MTS Sensors, expands on that: "The basic premise of distributed intelligence," he says, is that "complete knowledge of a system, subsystem, or component's state at the right place and time enables the ability to make'optimal' process control decisions."Adds John Keating, product marketing manager for the Checker machine vision unit at Cognex, "For a (machine vision) sensor to really be 'smart,' it should not require the user to understand machine vision."A smart sensor must communicate. "At the most basic level, an 'intelligent' sensor has the ability to communicate information beyond the basic feedback signals that are derived from its application." says Edeal. This can be a HART signal superimposed on a standard 4-20 mA process output, a bus system, orwireless arrangement. A growing factor in this area is IEEE 1451, a family of smart transducer interface standards intended to give plug-and-play functionality to sensors from different makers.Diagnose, programSmart sensors can self-monitor for any aspect of their operation, including "photo eye dirty, out of tolerance, or failed switch," says GE Fanuc's Black. Add to this, says Helge Hornis, intelligent systems manager, Pepperl+Fuchs, "coil monitoring functions, target out of range, or target too close." It may also compensate for changes in operating conditions. "A 'smart' sensor," says Dan Armentrout, strategic creative director, Omron Electronics LLC, "must monitor itself and its surroundings and then make a decision to compensate for the changes automatically or alert someone for needed attention."Many smart sensors can be re-ranged in the field, offering "settable parameters that allow users to substitute several 'standard' sensors," says Hornis. "For example, typically sensors are ordered to be normally open (NO) or normally closed (NC). An intelligent sensor can be configured to be either one of these kinds."Intelligent sensors have numerous advantages. As the cost of embedded computing power continues to decrease, "smart" devices will be used in more applications. Internal diagnostics alone can recover the investment quickly by helping avoid costly downtime.Sensors: Getting into PositionAs the saying goes, 'No matter where you go, there you are.' Still, most applications require a bit more precision and repeatability than that, so here's advice on how to select and locate position sensors.The article contains online extra material.What's the right position sensor for a particular application? It depends on required precision, repeatability, speed, budget, connectivity, conditions, and location, among other factors. You can bet that taking the right measurement is the first step to closing the loop on any successful application.Sensor technologies that can detect position are nearly as diverse as applications in providing feedback for machine control and other uses. Spatial possibilities are linear, area, rotational, and three-dimensional. In some applications, they're used in combination. Sensing elements are equally diverse.Ken Brey, technical director, DMC Inc., a Chicago-based system integrator, outlined some the following position-sensing options.Think digitallyFor digital position feedback:∙Incremental encoders are supported by all motion controllers; come in rotary and linear varieties and in many resolutions; are simulated by many other devices; and require a homing process to reference the machine toa physical marker, and when power is turned off.∙Absolute encoders are natively supported by fewer motion controllers; can be used by all controllers that have sufficient available digital inputs;report a complete position within their range (typically one revolution);and do not require homing.∙Resolvers are more immune to high-level noise in welding applications;come standard on some larger motors; simulate incremental encoders when used with appropriate servo amps; and can simulate absolute encoders with some servo amps.∙Dual-encoder feedback, generally under-used, is natively supported by most motion controllers; uses one encoder attached to the motor and another attached directly to the load; and is beneficial when the mechanical connection between motor and load is flexible or can slip.∙Vision systems , used widely for inspection, can also be used for position feedback. Such systems locate objects in multiple dimensions, typically X, Y, and rotation; frequently find parts on a conveyor; and are increasing in speed and simplicity.A metal rolling, stamping, and cut-off application provides an example of dual-encoder feedback use, Brey says. 'It required rapid and accurate indexing of material through a roll mill for a stamping process. The roll mill creates an inconsistent amount of material stretch and roller slip,' Brey explains.'By using the encoder on the outgoing material as position feedback and the motor resolver as velocity feedback in a dual-loop configuration, the system was tuned stable and a single index move provided an accurate index length. It was much faster and more accurate than making a primary move, measuring the error, then having to make a second correction move,' he says.Creative, economicalSam Hammond, chief engineer, Innoventor, a St. Louis, MO-area system integrator, suggests that the application's purpose should guide selection of position sensors; measurements and feedback don't have to be complex. 'Creative implementations can provide simple, economical solutions,' he says. For instance, for sequencing, proximity sensors serve well in many instances.Recent sensor applications include the AGV mentioned in lead image and the following.∙In a machine to apply the top seals to tea containers, proximity and through-beam sensors locate incoming packages. National Instruments vision system images are processed to find location of a bar code on a pre-applied label, and then give appropriate motor commands to achieve the desired position (rotation) setting to apply one of 125 label types.Two types of position sensors were used. One was a simple inductive proximity sensor, used to monitor machine status to ensure various motion components were in the right position for motion to occur. The camera also served as a position sensor, chosen because of its multi purpose use, feature location, and ability to read bar codes.∙ A progressive-die stamping machine operates in closed loop. A linear output proximity sensor provides control feedback for optimizing die operation; a servo motor adjusts die position in the bend stage. A linear proximity sensor was selected to give a dimensional readout from the metal stamping operation; data are used in a closed-loop control system.∙Part inspection uses a laser distance measurement device to determine surface flatness. Sensor measures deviation in return beams, indicating different surface attributes to 10 microns in size. An encoder wouldn't have worked because distance was more than a meter. Laser measurement was the technology chosen because it had very high spatial resolution, did not require surface contact, and had a very high distance resolution.An automotive key and lock assembly system uses a proximity sensor for detecting a cap in the ready position. A laser profile sensor applied with a robot measures the key profile.What to use, where?Sensor manufacturers agree that matching advantages inherent to certain position sensing technologies can help various applications.David Edeal, product marketing manager, MTS Sensors Div., says, for harsh factory automation environments, 'the most significant factors even above speed and accuracy in customer's minds are product durability and reliability. Therefore, products with inherently non-contact sensing technologies (inductive, magnetostrictive, laser, etc.) have a significant advantage over those that rely on physical contact (resistive, cable extension, etc.)'Other important factors, Edeal says, are product range of use and application flexibility. 'In other words, technologies that can accommodate significant variations in stroke range, environmental conditions, and can provide a wide range of interface options are of great value to customers who would prefer to avoid sourcing a large variety of sensor types. All technologies are inherently limited with respect to these requirements, which is why there are so many options.'Edeal suggest that higher cost of fitting some technologies to a certain application creates a limitation, such as with linear variable differential transformers. 'For example, LVDTs with stroke lengths longer than 12 inches are rare because of the larger product envelope (about twice the stroke length) and higher material and manufacturing costs. On the other hand, magnetostrictive sensing technology has always required conditioning electronics. With the advent of microelectronics and the use of ASICs, we have progressed to a point where, today, a wide range of programmable output types (such as analog, encoder, and fieldbus) are available in the same compact package. Key for sensor manufacturers is to push the envelope to extend the range of use (advantages) while minimizing the limitations (disadvantages) of their technologies.'Listen to your appDifferent sensor types offer distinct advantages for various uses, agrees Tom Corbett, product manager, Pepperl+Fuchs. 'Sometimes the application itself is the deciding factor on which mode of sensing is required. For example, a machine surface or conveyor belt within the sensing area could mean the difference between using a standard diffused mode sensor, and using a diffused mode sensor with background suppression. While standard diffused mode models are not able to ignore such background objects, background suppression models evaluate light differently to differentiate between the target surface and background surfaces.'Similarly, Corbett continues, 'a shiny target in a retro-reflective application may require use of a polarized retro-reflective model sensor. Whereas a standard retro-reflective sensor could falsely trigger when presented with a shiny target, a polarized retro-reflective model uses a polarizing filter to distinguish the shiny target from the reflector.'MTS' Edeal says, 'Each technology has ideal applications, which tend to magnify its advantages and minimize its disadvantages. For example, in the wood products industry, where high precision; varied stroke ranges; and immunity to high shock and vibration, electromagnetic interference, and temperature fluxuations are critical, magnetostrictive position sensors are the primary linear feedback option. Likewise, rotary optical encoders are an ideal fit for motor feedback because of their packaging, response speed, accuracy, durability, and noise immunity. When applied correctly, linear position sensors can help designers to ensure optimum machine productivity over the long haul.'Thinking broadly first, then more narrowly, is often the best way to design sensors into a system. Edeal says, 'Sensor specifications should be developed by starting from the machine/system-level requirements and working back toward the subsystem, and finally component level. This is typically done, but whatoften happens is that some system-level specifications are not properly or completely translated back to component requirements (not that this is a trivial undertaking). For example, how machine operation might create unique or additional environmental challenges (temperature, vibration, etc.) may not be clear without in-depth analysis or past experience. This can result in an under-specified sensor in the worst situation or alternatively an over-specified product where conservative estimates are applied.'Open or closedEarly in design, those involved need to decide if the architecture will be open-loop or closed-loop. Paul Ruland, product manager, AutomationDirect, says, 'Cost and performance are generally the two main criteria used to decide between open-loop or closed-loop control in electromechanical positioning systems. Open-loop controls, such as stepping systems, can often be extremely reliable and accurate when properly sized for the system. The burden of tuning a closed-loop system prior to operation is not required here, which inherently makes it easy to apply. Both types can usually be controlled by the same motion controller. A NEMA 23 stepping motor with micro-stepping drive is now available for as little as $188, compared to an equivalent servo system at about $700.'Edeal suggests, 'Control systems are created to automate processes and there are many good examples of high-performance control systems that require little if any feedback. However, where structural system (plant) or input (demand or disturbance) changes occur, feedback is necessary to manage unanticipated changes. On the process side, accuracy—both static and dynamic—is important for end product quality, and system stability and repeatability (robustness) are important for machine productivity.'For example,' Edeal says, 'in a machining or injection molding application, the tool, mold or ram position feedback is critical to the final dimension ofthe fabricated part. With rare exceptions, dimensional accuracy of the part will never surpass that of the position sensor. Similarly, bandwidth (response speed) of the sensor may, along with response limitations of the actuators, limit production rates.'Finally, a sensor that is only accurate over a narrow range of operating conditions will not be sufficient in these types of environments where high shock and vibration and dramatic temperature variations are common.'The latestWhat are the latest position sensing technologies to apply to manufacturing and machining processes and why?Ruland says, 'Some of the latest developments in positioning technologies for manufacturing applications can be found in even the simplest of devices, such as new lower-cost proximity switches. Many of these prox devices are now available for as little as $20 and in much smaller form factors, down to 3 mm diameter. Some specialty models are also available with increased response frequencies up to 20 kHz. Where mounting difficulties and cost of an encoder are sometimes impractical, proximity switches provide an attractive alternative; many position control applications can benefit from increased performance, smaller package size, and lower purchase price and installation cost.'Corbett concurs. 'Photoelectric sensors are getting smaller, more durable, and flexible, and are packed with more standard features than ever before. Some new photoelectrics are about half the size of conventional cylindrical housings and feature welded housings compared with standard glued housings. Such features are very desirable in manufacturing and machining applications where space is critical and durability is a must. And more flexible connectivity and mountingoptions—side mount or snout mount are available from the same product—allow users to adapt a standard sensor to their machine, rather than vice versa.'Another simple innovation, Corbett says, is use of highly visible, 360-degree LED that clearly display status information from any point of view. 'Such enhanced LED indicates overload and marginal excess gain, in addition to power and output. Such sensors offer adjustable sensitivity as standard, but are available with optional tamperproof housings to prevent unauthorized adjustments.'Photoelectric SensorsPhotoelectric sensors are typically available in at least nine or more sensing modes, use two light sources, are encapsulated in three categories of package sizes, offer five or more sensing ranges, and can be purchased in various combinations of mounting styles, outputs, and operating voltages. It creates a bewildering array of sensor possibilities and a catalog full of options.This plethora of choices can be narrowed in two ways: The first has to do with the object being sensed. Second involves the sensor's environment.Boxed inThe first question to ask is: What is the sensor supposed to detect? "Are we doing bottles? Or are we detecting cardboard boxes?" says Greg Knutson, a senior applications engineer with sensor manufacturer Banner Engineering.Optical properties and physical distances will determine which sensing mode and what light source work best. In the case of uniformly colored boxes, for example, it might be possible to use an inexpensive diffuse sensor, which reflects light from the box.The same solution, however, can't be used when the boxes are multicolored and thus differ in reflectivity. In that case, the best solution might be an opposed or retroreflective mode sensor. Here, the system works by blocking a beam. When a box is in position, the beam is interrupted and the box detected. Without transparent boxes, the technique should yield reliable results. Several sensors could gauge boxes of different heights.Distance plays a role in selecting the light source, which can either be an LED or a laser. LED is less expensive. However, because LED are a more diffuse light source, they are better suited for shorter distances. A laser can be focused on a spot, yielding a beam that can reach long distances. Tight focus can also be important when small features have to be sensed. If a small feature has to be spotted from several feet, it may be necessary to use a laser.Laser sensors used to cost many times more than LED. That differential has dropped with the plummeting price of laser diodes. There's still a premium for using a laser, but it's not as large as in the past.Environmental challengesOperating environment is the other primary determining factor in choosing a sensor. Some industries, such food and automotive, tend to be messy, dangerous, or both. In the case of food processing, humidity can be high and a lot of fluids can be present. Automotive manufacturing sites that process engines and other components may include grit, lubricants, and coolants. In such situations, the sensor's environmental rating is of concern. If the sensor can't handle dirt, then it can't be used. Such considerations also impact the sensing range needed because it may be necessary to station the sensor out of harm's way and at a greater distance than would otherwise be desirable. Active alarming and notification may be useful if lens gets dirty and signal degrades.Similar environmental issues apply to the sensor's size, which can range from smaller than a finger to something larger than an open hand. A smaller sensor can be more expensive than a larger one because it costs more to pack everything into a small space. Smaller sensors also have a smaller area to collect light and therefore tend to have less range and reduced optical performance. Those drawbacks have to be balanced against a smaller size being a better fit for the amount of physical space available.Sensors used in semiconductor clean room equipment, for example, don't face harsh environmental conditions, but do have to operate in tight spaces. Sensing distances typically run a few inches, thus the sensors tend to be small. They also often make use of fiber optics to bring light into and out of the area where changes are being detected.Mounting, pricingAnother factor to consider is the mounting system. Frequently, sensors must be mechanically protected with shrouds and other means. Such mechanical and optical protection can cost more than the sensor itself—a consideration for the buying process. If vendors have flexible mounting systems and a protective mounting arrangement for sensors, the products could be easier to implement and last longer.List prices for standard photoelectric sensors range from $50 or so to about $100.Laser and specialty photoelectric sensors cost between $150 and $500. Features such as a low-grade housing, standard optical performance, and limited or no external adjustments characterize the lower ends of each category. The higher end will have a high-grade housing, such as stainless steel or aluminum, high optical performance, and be adjustable in terms of gain or allow timing and otheroptions. Low-end products are suitable for general applications, while those at the higher end may offer application-specific operation at high speed, high temperature, or in explosive environments.Finally, keep in mind that one sensing technology may not meet all of the needs of an application. And if needs change, a completely different sensor technology may be required. Having to switch to a new approach can be made simpler if a vendor offers multiple technologies in the same housing and mounting footprint, notes Ed Myers, product manager at sensor manufacturer Pepperl+Fuchs. If that's the case, then one technology can be more easily swapped out for another as needs change.译文什么是智能传感器自动化领域所取得的一项最大进展就是智能传感器的发展与广泛使用。