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Piezoelectric sensing helps "industry 4.0"

Abstract: what is the most effective method to optimize and control the production chain in industrial manufacturing? According to mcmus consulting, for many manufacturers, the most effective solution is to use piezoelectric sensors to monitor the dynamic manufacturing process

what is the most effective method to optimize and control the production chain in industrial manufacturing? According to mcmus consulting, for many manufacturers, the most effective solution is to use piezoelectric sensors to monitor the dynamic manufacturing process

the vision of "industry 4.0" has become a reality in many industrial application fields, such as automobile manufacturing, medical technology, electrical engineering and so on. Now, due to the development of digitalization, machines and systems, unprecedented optimization of all production processes has become possible

continuous control of the production chain with the goal of zero defect production is essential for any modern production enterprise to occupy a place in the future market

just a few years ago, almost all products were tested after the production line (that is, after the completion of the manufacturing process). In contrast, nowadays, more and more products can be actually monitored in the production process, or in the "" state, which is also a way to save costs. For manufacturing processes such as connection, assembly and testing, sensor technology based on piezoelectric principle is the fundamental element to optimize the production process with zero defect production as the goal. This technology is very suitable for measuring physical variables such as force, pressure, acceleration and torque

basic working principle of piezoelectric sensor

the physical principle of piezoelectric sensor is the "piezoelectric effect" discovered by Pierre and Jacques Curie in 1880. Under the action of mechanical load (Greek "pie zein": compression or extrusion), piezoelectric materials will generate charges. In 1950, Walter P. Kistler applied for the patent of piezoelectric signal charge amplifier, taking an important step in the application of piezoelectric effect

the piezoelectric effect is particularly significant for quartz crystals: when properly treated quartz is subjected to mechanical load, it will produce a charge signal proportional to the force (Fig. 1). Therefore, compared with other technologies, the use of piezoelectric effect to capture the measured signal does not depend on strain and displacement

make good use of the piezoelectric effect of quartz crystal. When subjected to mechanical load, it will produce an electrical signal proportional to the force

in this case, the size of the quartz element only determines the maximum allowable measurement amplitude. Therefore, the signal generated by large sensors is equivalent to that of small sensors with the same structure. Then, the downstream amplifier is used to set the required measurement range. Only one sensor is needed to make accurate measurement within decades without changing the mechanical structure

for example, Kistler of Switzerland has developed a piezoelectric force sensor with ICP output. In this case, the original signal has been converted into an output voltage of 5 or 10 V in the sensor

due to the very high rigidity of quartz crystal, the measurement deviation is very small, usually in the range of thousands of Newton/micron, so that the measurement system has a high natural frequency, which is very critical for the measurement of high dynamic processes. Another important factor is that quartz and crystal have no fatigue or long-term effects such as zero shift or linear change. In some cases, the use of piezoelectric sensors may be limited due to charge drift caused by physical reasons. According to the amplitude of the measured variable and the design of the measurement technology, quasi-static measurement lasting for several minutes or even hours can still be carried out

using the quartz sensor technology developed by Qishile, the dynamic force can be measured directly or indirectly. In Figure 2, for direct measurement, the sensor is completely placed in the force flux (1) and measures the dynamically changing force throughout the process. This method can obtain high measurement accuracy, and it is almost independent of the force application point. If the sensor cannot be directly positioned in the force flux, only part of the force can be measured (3). The rest of the force is applied to the structure on which it is installed (called a force shunt). Through the inter force measurement, the strain sensor is used to indirectly measure the process force through the structural strain (2)

according to the installation conditions, various sensors can be used to provide the best production monitoring: 1. Direct measurement (measuring the whole process force passing through the sensor). 2. Indirect measurement (measuring a small part of the force passing through the sensor). 3. Shunt measurement (indirect measurement of force by bending of C-type Press)

Application of piezoelectric sensors in scientific research and industry

in addition to considering the overall economy, the installation conditions become more and more important. Size is often a key factor in the selection of force sensors. Quartz sensors are very stable, solid and compact. They can usually be installed at measuring points that cannot be used by other technologies

these features are not only widely used in research and development, but also increasingly used in production lines and industrial testing technology

for example, for the aging and load research of automotive components, China's national standards stipulate the pressure of locks, doors, hood, trunk deck, seats and springs, so it is important to understand the main functions of the tension machine. Force, tension, collision and durability tests need to have long-term stable dynamic force measurement. In this case, the quartz force sensor is superior to other sensors at present because there is no sign of aging of quartz. Therefore, calibration can usually be limited to the period specified by quality assurance systems such as DIN EN ISO 9001:2015

these advantages can save time and cost. For some applications, quartz force sensor can provide a variety of technical advantages, and because of its low life cycle cost, it has the advantage of significantly reducing the cost

Qishile maxymos XY display can monitor and evaluate product quality or manufacturing steps according to configuration files. With the help of evaluation objects (EOS), users can evaluate curves for specific monitoring tasks

piezoelectric force sensor can be used to measure dynamic force (such as stamping process of sheet metal parts). In addition, they can also be used to measure quasi-static processes such as bearings in the engine cylinder block. In this case, the equipment can apply force more safely. Even if the peak value of mechanical force may permanently destroy the traditional measurement system, this piezoelectric measurement technology will not be damaged

the system developed by Qishile company has the ability to analyze and archive the injection molding process, ensure the selection of products according to the nature of the items that our company needs to experiment, and ensure the quality of products. Cavity pressure is the most informative process variable, because it can immediately reflect the process conditions in the process of manufacturing mold parts. Therefore, the sensor and system can detect qualified parts or waste products as early as possible according to the mold cavity pressure

process integrated quality assurance system solution

in order to make the data captured by the high-sensitivity piezoelectric sensor get practical application, the data is visualized, evaluated, recorded and archived in the appropriate monitoring system. When these measurement systems are integrated into the production line, production defects can be found as soon as possible, so as to reduce the risk of financial losses caused by part failures

in terms of assembly process, maxymos system of Qishile company can reliably monitor the production process (Figure 3), so it can maximize the production efficiency and achieve the goal of zero defect production. The features of the system include flexibility and user-friendly operation interface. It can be used for automatic connection and pressing process, as well as manual operation like manual pressing process. In addition to production and assembly, the application of Qishile's sensors and XY displays also includes the verification of the final product function

focus on enhanced cost-effectiveness

the sensor technology based on the piezoelectric principle has significantly improved the process reliability in the company's production chain. Coupled with the continuous improvement of productivity, it has opened up a way to zero defect production and maximize process efficiency. From a commercial point of view, the purpose of this high-precision technology is to create a good foundation for economic success in the highly competitive markets around the world

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