Sensors in manufacturing

Taken as a whole, this series covers all major fields of application for commercial sensors, as well as their manufacturing techniques and major types. As such the series does not treat bulk sensors, but rather places strong emphasis on microsensors, microsystems and integrated electronic sensor packages. Each of the individual volumes is tailored to the needs and queries of readers from the relevant branch of industry.

A treatment of on-line monitoring techniques for optimizing various manufacturing processes while also making them safer. The book looks at the latest developments in sensors for quality control or preventing downtime, as well as environmental protection in the form of emission monitoring and waste reduction. Although the text concentrates on practical applications, it also provides readers with the necessary basic principles.

I. Inasaki and H. K. TonshoffD. DornfeldT. MoriwakiH. K. TonshoffA. WeckenmannA. WeckenmannB. KarpuschewskiH. D. Haferkamp and M. Niemeyer and J. WeberR. WertheimE. Doege and F. Meiners and T. Mende and W. Strache and J.W. YunI. Inasaki and B. Karpuschewski and H.K. TonshoffI. Inasaki and B. KarpuschewskiV. Kral and O. HillersT. MasuzawaH.D. Haferkamp and F.v. Alvensleben and M. Niemeyer and W. Specker and M. ZeltK.-D. Bouzakis and N. Vidakis and G. ErkensP. Mayr and H. Klumper-WestkampE. BrinksmeierH. K. TonshoffM. WeckF. Klocke

List of Contributors	p. XVII
1 Fundamentals	p. 1
1.1 Roles of Sensors in Manufacturing and Application Range	p. 1
1.1.1 Manufacturing	p. 1
1.1.2 Unit Processes in Manufacturing	p. 2
1.1.3 Sensors	p. 3
1.1.4 Needs and Roles of Monitoring Systems	p. 4
1.1.5 Trends	p. 5
1.1.6 References	p. 6
1.2 Principles of Sensors for Manufacturing	p. 6
1.2.1 Introduction	p. 6
1.2.2 Basic Sensor Classification	p. 10
1.2.3 Basic Sensor Types	p. 13
1.2.4 New Trends--Signal Processing and Decision Making	p. 19
1.2.5 Summary	p. 23
1.2.6 References	p. 23
1.3 Sensors in Mechanical Manufacturing--Requirements, Demands, Boundary Conditions, Signal Processing, Communication	p. 24
1.3.1 Introduction	p. 24
1.3.2 Role of Sensors and Objectives of Sensing	p. 24
1.3.3 Requirements for Sensors and Sensing Systems	p. 27
1.3.4 Boundary Conditions	p. 31
1.3.5 Signal Processing and Conversion	p. 32
1.3.6 Identification and Decision Making	p. 39
1.3.7 Communication and Transmission Techniques	p. 43
1.3.8 Human-Machine Interfaces	p. 44
1.3.9 References	p. 45
2 Sensors for Machine Tools and Robots	p. 47
2.1 Position Measurement	p. 47
2.2 Sensors for Orientation	p. 58
2.3 Calibration of Machine Tools and Robots	p. 60
2.4 Collision Detection	p. 62
2.5 Machine Tool Monitoring and Diagnosis	p. 65
2.6 References	p. 70
3 Sensors for Workpieces	p. 71
3.1 Macro-geometric Features	p. 71
3.1.1 Mechanical Measurement Methods	p. 72
3.1.2 Electrical Measuring Methods	p. 76
3.1.3 Electromechanical Measuring Methods	p. 83
3.1.4 Optoelectronic Measurement Methods	p. 86
3.1.5 Optical Measuring Methods	p. 90
3.1.6 Pneumatic Measuring Systems	p. 96
3.1.7 Further Reading	p. 98
3.2 Micro-geometric Features	p. 98
3.2.1 Tactile Measuring Method	p. 99
3.2.2 Optical Measuring Methods	p. 101
3.2.3 Probe Measuring Methods	p. 106
3.2.4 Further Reading	p. 123
3.3 Sensors for Physical Properties	p. 123
3.3.1 Introduction	p. 123
3.3.2 Laboratory Reference Techniques	p. 125
3.3.3 Sensors for Process Quantities	p. 125
3.3.4 Sensors for Tools	p. 134
3.3.5 Sensors for Workpieces	p. 136
3.3.6 References	p. 141
4 Sensors for Process Monitoring	p. 143
4.1 Casting and Powder Metallurgy	p. 143
4.1.1 Casting	p. 143
4.1.2 Powder Metallurgy	p. 159
4.2 Metal Forming	p. 172
4.2.1 Sensors for the Punching Process	p. 172
4.2.2 Sensors for the Sheet Metal Forming Process	p. 181
4.2.3 Sensors for the Forging Process	p. 191
4.2.4 References	p. 202
4.3 Cutting Processes	p. 203
4.3.1 Introduction	p. 203
4.3.2 Problems in Cutting and Need for Monitoring	p. 203
4.3.3 Sensors for Process Quantities	p. 204
4.3.4 Tool Sensors	p. 220
4.3.5 Workpiece Sensors	p. 225
4.3.6 Chip Control Sensors	p. 228
4.3.7 Adaptive Control Systems	p. 231
4.3.8 Intelligent Systems for Cutting Processes	p. 233
4.3.9 References	p. 234
4.4 Abrasive Processes	p. 236
4.4.1 Introduction	p. 236
4.4.2 Problems in Abrasive Processes and Needs for Monitoring	p. 236
4.4.3 Sensors for Process Quantities	p. 237
4.4.4 Sensors for the Grinding Wheel	p. 244
4.4.5 Workpiece Sensors	p. 249
4.4.6 Sensors for Peripheral Systems	p. 256
4.4.7 Sensors for Loose Abrasive Processes	p. 262
4.4.8 Adaptive Control Systems	p. 265
4.4.9 Intelligent Systems for Abrasive Processes	p. 268
4.4.10 References	p. 271
4.5 Laser Processing	p. 272
4.5.1 Introduction	p. 272
4.5.2 Parameter Monitoring Sensors	p. 273
4.5.3 Quality Monitoring Sensors	p. 275
4.5.4 Conclusion	p. 276
4.5.5 References	p. 277
4.6 Electrical Discharge Machining	p. 277
4.6.1 Introduction	p. 277
4.6.2 Principle of EDM	p. 278
4.6.3 Process Control	p. 279
4.6.4 Sensing Technology	p. 279
4.6.5 Evaluation of Machinery Accuracy	p. 283
4.7 Welding	p. 286
4.7.1 Introduction	p. 286
4.7.2 Geometry-oriented Sensors	p. 287
4.7.3 Welding Process-oriented Sensors	p. 295
4.7.4 Summary	p. 305
4.7.5 References	p. 305
4.8 Coating Processes	p. 307
4.8.1 Coating Process Monitoring	p. 307
4.8.2 Sensors in Vapor Deposition Processes	p. 311
4.8.3 References	p. 325
4.9 Heat Treatment	p. 326
4.9.1 Introduction	p. 326
4.9.2 Temperature Monitoring	p. 326
4.9.3 Control of Atmospheres	p. 329
4.9.4 Carburizing	p. 329
4.9.5 Nitriding	p. 331
4.9.6 Oxidizing	p. 332
4.9.7 Control of Structural Changes	p. 334
4.9.8 Quenching Monitoring	p. 337
4.9.9 Control of Induction Heating	p. 339
4.9.10 Sensors for Plasma Processes	p. 341
4.9.11 Conclusions	p. 341
4.9.12 References	p. 341
5 Developments in Manufacturing and Their Influence on Sensors	p. 343
5.1 Ultra-precision Machining: Nanometric Displacement Sensors	p. 343
5.1.1 Optical Scales	p. 343
5.1.2 Laser Interferometers	p. 348
5.1.3 Photoelectric Transducers	p. 351
5.1.4 Inductive Sensors	p. 352
5.1.5 Autocollimators	p. 352
5.1.6 References	p. 353
5.2 High-speed Machining	p. 354
5.3 Micro-machining	p. 357
5.4 Environmental Awareness	p. 363
5.4.1 Measurement of Emissions in the Work Environment	p. 364
5.4.2 Dry Machining and Minimum Lubrication	p. 367
5.4.3 Turning of Hardened Materials	p. 369
5.4.4 Using Acoustic Emission to Detect Grinding Burn	p. 372
5.4.5 References	p. 375
List of Symbols and Abbreviations	p. 377
Index	p. 383

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