Shaping the future with custom sensor solutions for OEM series applications

As a leading manufacturer of precision sensors, Micro-Epsilon is shaping the future with sensors. The company’s displacement sensors are used where accuracy and performance are crucial to success – in modern machine building and in advanced automation, as well as in satellite technology and in the production of next-generation batteries and semiconductors, says Glenn Wedgbrow, Business Development Manager at Micro-Epsilon UK.

Micro-Epsilon offers a wide and powerful product portfolio combined with in-depth technical industry and application knowledge. As a partner, the company supports its customers with sustainable solutions and long-term cooperation. Due to the bundled know-how within the entire Micro-Epsilon group of companies, the business is able to react with high flexibility to customer requirements to develop application solutions with high demands on measurement technology.

Competence and expertise

With over 27 companies, the Micro-Epsilon Group is a powerful worldwide alliance with technological expertise gained from more than 55 years of sensor development and over 400 active patents and patent applications. Each of these companies has a clearly defined focus on development and series production, automation and application consulting. This is to provide customers with solutions, development, production and service from a single source.

For series projects, Micro-Epsilon offers a wide range of measuring techniques, decades of development expertise and production capacities for large volumes. If necessary, the company can adapt its sensors to specific customer requirements to achieve maximum efficiency, both technically and economically. Engineering teams coordinate all measurement requirements and relevant components together with the customer. This ensures optimum functionality with maximum cost efficiency – from design to series production.

Technology expertise for series production

Micro-Epsilon transforms high-tech into industrial series products by combining the key competencies in the Group. The accumulation of sophisticated technologies and automated production facilities enable the company to build a high-performance portfolio that is also suitable for OEM applications with high volumes, responding quickly to customer requests and offering optimised solutions within a short timeframe.

The company’s sensor products are used in numerous industries where they solve measurement tasks with maximum precision and reliability. This improves quality and adds value for customers. The company consistently improves its knowledge to optimise customers’ machines, systems and processes. The accumulation of knowledge and experience allows it to speak the language of its customers. In this way, targeted solutions can be developed for future-oriented applications – from aerospace and machine building, to energy technology, mobile machinery, semiconductors and automation.

The following examples help illustrate how Micro-Epsilon displacement sensors (linear inductive, eddy current and capacitive) can be customised for OEM series applications. 

1. Linear inductive displacement sensors

OEM sensor design for valve lift
The DR-85-BUE is optimised for series production and is used in process valves with a range of 85 mm.

The induSENSOR series of linear inductive displacement sensors from Micro-Epsilon can be customised to suit customer specific requirements, including simplified sensor systems for low cost series production; simple PCB solutions for deep integration; modular concepts for high flexibility; customised sensor designs; adapted measuring ranges; integrated or external electronics; and various target options, for example, sleeve, plunger or magnet.

These sensors are also suitable for demanding environments including applications with high ambient pressure; high temperature environments; contaminated installation and measuring rooms; and special requirements for shock and vibration resistance.

Application examples

Magneto-inductive sensor module:

  • Low-cost product optimized for controller-based  evaluation (rectangular signal/time measurement)
  • Distance measurement on magnets
  • Reduced to pure measurement technology without protective measures such as EMC, voltage stabilization, housing, etc.
  • Measuring range: 40 mm
  • Application: e.g. white goods, household appliances, sports equipment, measuring modules
  • Usual quantities: > 5,000 pieces / year

Sensor for valve lift measurement:

  • Optimised for series production
  • Deep integration into the overall system with individual form factor
  • Only 50% of the sensor electronics are integrated directly in the sensor, the micro-controller already provided by the customer forms the second half of the sensor electronics. LEDs are also installed on the sensor, which the customer needs for other tasks in the application
  • High vertical range of manufacture at Micro-Epsilon
  • Measuring range: 85 mm
  • Application: e.g. process valves
  • Usual quantities: > 20,000 pieces / year

Inductive proximity sensor:

  • Aviation-certified, hermetically sealed
  • Sensor without electronics for determining switching points
  • Adapted to electronics from a third-party manufacturer
  • Self-locking mounting system
  • Measuring range: 4 mm
  • Application: e.g. chassis, door lock
  • Usual quantities: > 5,000 pieces / year

Miniature displacement sensor with external controller:

  • Miniature variant of a catalogue sensor (EDS)
  • Pressure up to 350 bar, temperature up to 165°C
  • Optimised in terms of size and weight
  • Measuring range: 28 mm
  • Application: e.g. miniature actuators, hydraulic cylinders, pneumatics, motorsports.

2. Eddy current displacement sensors

Three Eddy Current Sensor OEM designs
The eddyNCDT series of eddy current displacement sensors from Micro-Epsilon can be customised to suit specific customer requirements.

The eddyNCDT series of eddy current displacement sensors from Micro-Epsilon can be customised to suit specific customer requirements. Available options include changed offset distance and measuring range; housing and mounting options for sensor and controller; pressure-resistant sensors up to 2000 bar; sensors with integrated or external electronics, miniature designs; various materials for coil, housing or circuit boards; individual cable lengths and special adaptation to the measuring object.

The eddyNCDT sensors are also suitable for particularly demanding environments including applications with high ambient pressure; high temperature environments; vacuum areas up to UHV; contaminated installation and measuring rooms; special requirements for vibration resistance; and assembly with ECT technology is possible.

Application examples

Robust eddy current sensor in injection moulding technology:

  • Robust plastic housing, hermetically sealed
  • Pressure up to 100 bar possible
  • Dimensional stability up to 250°C
  • Withstands shock and vibration
  • Resistance to oil, water, cooling lubricant or similar contact material – high EMC stability
  • Best repeatability due to optimised injection moulding technology
  • Optional: use with or without housing possible
  • Application: drive technology and automation, wear measurements, robot positioning

Embedded Coil Technology (ECT) sensors for demanding environments:

  • Temperature, pressure and media resistance
  • Temperature stability up to 350°C
  • Can be used in clean or harsh environments
  • Vacuum suitability up to UHV
  • Customised geometry adaptations possible
  • Applications: alignment of mirror segments on telescopes, semiconductor production in ultra-high vacuum
  • High-pressure applications in deep sea, high-temperature applications in material test benches

High speed measurements with nanometre resolution:

  • Flexible frequency response up to 50 kHz (-3dB)
  • Deep integration into customer system possible
  • Nanometer resolution even with high bandwidth
  • Miniature electronics for the best possible machine integration
  • 1 to 4 channel applications (single A, B or differential A-B)
  • Output signal not linear, but high resolution and speed
  • Application: Fast steering mirror, engraving heads, high-resolution stages (X, Y, Z, ...)

3. Capacitive sensors for displacement, distance & position

OEM version of capacitive sensor in thin strip form
Flex board technology provides the necessary flexibility to adapt sensors to curvature and to measure in confined spaces.

The capaNCDT series of capacitive displacement sensors from Micro-Epsilon can be customised to suit specific customer requirements. Possible modifications include: sensor design (e.g. flange, thread); cable lengths; plugs and couplings; sensors with integrated electronics (active sensors); signal output electronics (e.g. analogue, Ethernet, EtherCAT, PROFINET, etc.).

The capaNCDT sensors are also suitable for particularly demanding OEM projects including environments from cryogenic to extremely hot temperatures; vacuum ranges up to UHV; applications in clean rooms (cleanliness requirements, outgassing behaviour); maximum self-sufficiency due to high long-term stability and maintenance-free base; use in magnetic and electric fields; product modularity allows individual compilation for evaluation and series requirements at short notice.

Application examples

Quantity-optimised CSR sensors:

  • Individual form factor adapted to the space available in the system
    • Rectangular electrode instead of round electrode
    • Version in flat metal housing
  • Quantity price-optimised
  • 160°C operating temperature
  • Focus on maximum repeatability for the best possible process control
  • Suitable for all DT6xxx controllers
  • Application: e.g. machine / system levelling, alignment of platforms, parallelism control of platforms

Flex board technology:

Provides the necessary flexibility to adapt sensors to curvature and to measure in confined spaces. Thin flex sensor with flex conductor and ccx cable:

  • Optimised for minimum sensor thickness < 0.3 mm
  • Equipped with fastening wings
  • Flex conductor connection for positioning
  • Maximum total length of sensor incl. flex conductor up to the sensor cable transition: 400 mm
  • Application: test bench measurement, gap distances in new high-performance e-motors for the automotive industry

Miniature sensor system for complete integration close to the measuring point:

  • Miniature electronics with a small footprint 50 x 27 x 8.5 mm
  • Targeted position control < 0.5 µm with the aid of a switching signal
  • Quick teach-in of the switching position via the upper and lower limit buttons
  • Control range (measuring range) 500 µm
  • Application: system is fully integrated into e.g. surgical microscopes and serves to stabilise the tripods.

For more information on displacement sensors for OEM series applications, please visit Precise distance sensors & displacement measuring systems | Micro-Epsilon or call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email info@~@micro-epsilon.co.uk  

Further Information

OEM SENSORS
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