Sensors in Manufacturing - Sensors Application Book

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