WIEGAND WIRE ENERGY HARVESTING COMPONENTS

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POSITAL’s Wiegand assemblies offer a compact and efficient way of harvesting power for electronic circuits in electromechanical devices, eliminating the need for backup batteries. 

The operating principle of POSITAL’s Wiegand modules is simple. A “Wiegand wire” is a short length of specially prepared Vicalloy (vanadium-iron-cobalt) wire. When exposed to a changing external magnetic field (e.g. a nearby permanent magnet mounted on a rotating shaft) the Wiegand wire will initially retain its original magnetic polarity, and then abruptly ‘flip’ its polarity when the change to the external magnetic field reaches a certain threshold. This sudden change in the magnetic state of the core induces a current pulse in a copper coil wound around the Vicalloy core. This current pulse is very short-lived, but the energy harvested from the mechanical movement of the magnet can be captured and used to activate a low-power electronic circuit. An important feature of the Wiegand effect is that the amount of electric power generated with each reversal of the magnetic polarization is constant and completely independent of the rate of change of the external magnetic field, even if this happens very slowly. POSITAL Wiegand modules have been used to reliably power rotation counters in tens of millions of devices, including multi-turn rotary encoders, gas and water meters.

  • Production Since 1974 – Started by John R. Wiegand
  • Proven In Encoders & Water Meters Since > 10 Years
  • Used In Access Cards For > 30 Years
  • Power Supply For Future IoT Applications
  • High Energy Output of ~170 nJ

“The process for making Wiegand wire from raw Vicalloy wire was invented by John Wiegand in the 1970’s” comments Christian Fell, Chief of Technology Development for POSITAL-FRABA. “It involves a complex set of steps, including cold-working the wire through a combination of stretching and twisting, then heat-treating the product to lock in the desired characteristics.” POSITAL acquired the original wire-conditioning machinery and intellectual property from the Wiegand estate in 2013. Fell continues: “This acquisition has meant that we have reliable supply of Wiegand wire. It also gave us an opportunity to refine the manufacturing process for improved product quality. Thanks to our research, we can now produce wires that reliably generate 190 nanojoules of energy at 7 volts with each polarity flip”.

Wiegand assemblies are a core component in POSITAL’s IXARC multiturn absolute rotary encoders, providing a maintenance-free method for powering the counter that records the number of complete rotations that the device experiences. POSITAL also offers Wigand assemblies to other manufacturers. These consist of a 15mm length of Wiegand wire surrounded by a copper coil, all contained in an SMD-mountable plastic structure. Wiegand wire production is carried out at locations in the U.S. and Europe, ensuring a stable, reliable supply chain. These assemblies can be used wherever low-cost, zero-maintenance, battery-free energy harvesting systems are needed to energize electronic counters and other low-power electronic devices.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

LOW-COST KIT ENCODERS FOR STEPPER MOTORS

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POSITAL has expanded its line of kit-style encoders for feedback for servo and stepper motors with new models that utilize the same mounting form factor as incremental kit encoders from US Digital, Broadcom and other manufacturers.

  • Mechanical Drop In Replacement for Easy Upgrade to Absolute Position Control
  • Same Footprints as US Digital’s E5 Models and Broadcom’s (Avago) HEDS-5500 Models
  • Now Available with SSI and BiSS C Communication Interfaces
  • Identical Assembly Procedure – No Training Required
  • Various Hub Diameters from 4 mm to 10 mm (and 1/4 to 3/8 inch)
  • Magnetic Technology Which Is Generally More Robust Than Optical
  • Improved Connectivity via M12 Connector Additionally Available

See our Cross Reference Guide

POSITAL kit encoders provide absolute position feedback so that the control system always has complete information on the physical position of the mechanical components that it is directing. “Absolute position feedback is a natural way of providing accurate position control” comments Jim Stevens, market specialist for robotics at POSITAL. “Almost any position feedback application could be absolute-based. Many current systems were designed around incremental encoders because incremental feedback devices were historically much less expensive than their absolute counterparts.” However, with the introduction of POSITAL’s absolute kit encoders at prices much more in line with incremental devices, system designers no longer have to work around the shortcomings of incremental feedback in an absolute position world.

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Multiturn Absolute Kit Encoders Provide Robust Solution

Multiturn Absolute Kit Encoders from POSITAL are based on magnetic sensing technology which provides a very robust encoder solution. The multiturn counting system is powered by Wiegand wire energy harvesting technology, which enables the absolute encoder to maintain true absolute position over power cycles and rotation of the encoder during power off conditions.

With 17 bits (131072 positions) of single turn resolution and 16 bits (65536 turns) of multiturn range, KCD Absolute kit encoders from POSITAL are ideal for position control applications.

FAQ Kit Encoders

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

FRABA GROUP GROWS WORLDWIDE BY 12.4%

Fresh ideas and innovative products continue to pay off for the international FRABA Group. With a 12.4% increase in sales for Fiscal 2018 (year-end: Dec 31), the corporation, which includes the POSITAL (position and motion control sensors) and VITECTOR (safety technology for industrial doors) brands, posted another year of double-digit growth. Global sales reached € 35 million (US$ 39 million), while the number of employees in Europe, Asia and the USA rose by 4.5%, to 230.

New ideas and innovation lead to strong numbers

Key factors for the increase in personnel were the opening of a new sales office in Shanghai, in response to strong demand from China, and a further increase in the size of the development team at the group’s central R&D center. This research unit, located in Aachen, Germany, works closely with its neighbor, the highly regarded North-Rhein Westphalia Technical University, and other national and international partners in the fields of engineering and applied electronics. Currently there are 40 researchers and developers on board – from 28 countries. Physicists, mathematicians, computer scientists and engineers collaborate on interdisciplinary projects. “Our R&D staff work closely with our sales engineers in the field to drive the innovation that is at the core of our brand,” says Christian Leeser, CEO of the FRABA Group. “This is why we are committed to invest around 10% of our global sales in R&D –– year after year.”

Over the past 15 years, FRABA has established itself as a trendsetter, leading the transition from complex optical encoders to robust and less expensive precision magnetic encoders. These products are offered in both stand-alone versions and as integrated motor feedback kits. Throughout 2018, several significant milestones were achieved. To meet the growing demand in the ‘energy harvesting’ market, the global production capacity for SMD Wiegand sensors was doubled to one million units per annum. Following the successful rollout of magnetic kit encoders for servomotors, last fall saw the addition of magnetic kits specially tailored for stepper motors. This US-driven initiative has added absolute position feedback to low-cost stepper motors, significantly improving their performance levels. The latest breakthrough is the world’s first battery-free, Wiegand-based multiturn hollow shaft kit encoder . Pre-launched at the global SPS show In Nuremberg last November, sales of this innovative device – geared at robot manufacturers and the motor sector – started this month. “With all these initiatives lined up, we are confident to achieve further growth in 2019,” says Leeser.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

NEW HOLLOW SHAFT MULTI-TURN KIT ENCODERS FOR POSITION CONTROL APPLICATIONS

Slim Form Factor for Motor and Machine Manufacturers

POSITAL is introducing a new family of absolute rotary encoders for servomotors, stepper motors, robot joints and anywhere else a hollow center design is needed to achieve an optimal mechanical layout. Both single and multi-turn variants are available; for multi-turn models, the rotation counter is self-powered, using POSITAL’s Wiegand energy-harvesting technology. This eliminates the need for backup batteries and lowers maintenance costs.

  • Hollow Center Design for Optimal Mechanical Layout on Robotic Joints and Drives Shafts
  • 30 mm or 50 mm Internal Diameter Sizes Available
  • Battery-less Rotation Counter Based on Energy-Harvesting Technology
  • Capacitive Measurement System Allows for High Accuracy Even in Harsh Environments
  • Non-Proprietary Interfaces of SSI and BiSS C Standards

Capacitive Measurement Technology

These new products make use of a capacitive measurement system. Each encoder has two principle components, a stator and rotor, both containing specially shaped conductive surfaces. These surfaces, which function as capacitor plates, are positioned in close proximity. As the rotor turns, the patterns of the conductive surfaces change their relative position, causing changes to capacitive coupling in the system. This in turn causes changes to the amplitude and phase angle of a high-frequency electrical signal generated by exciter circuits in the stator. Special ASIC devices capture and decode these signal variations to determine the rotor’s angular position to a high level of precision.

Read more on the technology here.

The new POSITAL hollow shaft kit encoders offer excellent accuracy (+/- 0.02°) and dynamic response (up to 6000 RPM), making them suitable for use in critical motion control systems. However, what makes them especially useful in many applications is their shape. Both stator and rotor elements are in the form of disks with large central openings. This makes them an ideal choice in space-limited situations, such as servomotors, stepper motors or the joints in robotic arms , where it is desirable to have an embedded position sensor fitting around a central shaft or axle.

POSITAL hollow shaft kit encoders will be available in two sizes, with 30 mm or 50 mm internal diameters. Non-proprietary SSI and BiSS C communications interfaces are supported.

Energy Harvesting – No Battery

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The energy harvesting system is based on the Wiegand effect and eliminates the need for backup batteries or complex gear systems. 

Read More about the Wiegand Effect

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

TILTIX Inclinometers

LINARIX Linear Sensors Group

Inclinometers, also called tilt sensors are designed to measure the angle of an object with respect to the force of gravity. These tilt or level meters determine pitch and/or roll angle and output these values via the appropriate electrical interface. Inclinometers are easy to integrate to an application, because there is no need for mechanical linkages other than just the installation itself – a real advantage for design engineers. Posital developed several inclinometer types to have a suitable solution for different applications for each industry. Accurate measurement of the degree of tilt or inclination from a horizontal position is very important for many motion control systems or to ensure safety. 

  • Well Protected up to IP69K
  • Rugged and Compact Design
  • Measurement Range ±80° (Dual Axis) or 360° (Single Axis)

Dynamic Inclinometers

These inclinometers are equipped with a 3D MEMS accelerometer and a 3D MEMS gyroscope. A smart algorithm combines the signal of accelerometer and gyroscope to eliminate the effect of accelerations (e.g. due to rapid motion of the equipment), vibrations and shocks. 

  • Compensation of External Accelerations
  • Clean Measurement During Dynamic Movements
  • Accuracy 0.3°
  • Interfaces: CANopen

Static Inclinometers

These inclinometers are equipped with a 2D MEMS accelerometer as sensor cell. This type of inclinometer achieves a high accuracy in a static system or when the machine is only in a slow motion. 

  • Accuracy 0.1° or 0.5°
  • Interfaces: CANopen, Analog Current, Analog Voltage, RS232, SSI, J1939, DeviceNet

Installation and Mounting Options

Dependent on the application and machine it may be necessary to mount the inclinometer horizontally to monitor the tilt angle of two axes or to install the sensor vertically to measure one axis.

dual_axes

dual axis sensor is used for horizontal mounting and is ideal for leveling applications. This version got two outputs, one for the X-Axis and one for the Y-Axis. Each of the axes show the tilt angle with respect to the field of gravity.

single_axis

single axis tilt measurement version with one axis output is intended for vertical mounting.

Applications

Inclinometer offer an easy and efficient way of monitoring spatial orientation without the need for mechanical linkages – a real advantage for design engineers.

Static inclinometers can significantly improve operating safety in mobile machines, platform monitoring or medical applications by continuously monitoring the tilt or inclination angles. Inclinometers are much easier and thus less expensive to install compared to Rotary Encoders, which makes them ideal for applications like solar trackers. 

The dynamic inclinometer outputs a clean measurement signal and can be used reliably on mobile equipment such as construction machinery, mining equipment, agricultural machinery, cranes, and anywhere else where sudden movements, shocks and vibrations are likely to be encountered.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

TILTIX Inclinometer with M MODBUS RTU Interface

POSITAL’s TILTIX inclinometers are now also available with Modbus RTU support
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  • Full 360° Single Axis or Dual Axis ±80°
  • Shock Immunity up to 100 g
  • Tough Fiber-reinforced PBT and Heavy Duty Die-cast Aluminum Housings Available.
  • Programmable Measurement Resolution, Zero Setting and Direction via API

Robust and Cost Efficient Tilt Monitoring

POSITAL TILTIX inclinometers are now available with a new communication interface, Modbus RTU. Modbus RTU protocols, which are openly published and royalty-free, have emerged as a de-facto standard for simple, robust and cost-efficient data acquisition and control systems built around standard PLCs. Modbus RTU nodes can be connected together through RS-485 serial connections with up to 32 devices connected to the bus.

Industries

TILTIX inclinometers with Modbus RTU interface are ideal for solar energy systems where it is necessary to monitor the spatial orientation of multiple collectors or reflectors. They can also be used in production machineries like textile manufacturing, paper manufacturing or for material handling equipment and in many other applications where a practical, low-cost position control solution is required.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

POSITAL AT SPS IPC DRIVES 2018

POSITAL AT SPS IPC DRIVES 2018

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From November 27 to November 29 we will be exhibiting at SPS IPC Drives in Nuremberg, the most important exhibition for the professionals in the Automation world.

You can find us in hall 7A booth 146. Make sure to try out our freshly baked waffles with cherries and cream!

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THIS YEAR’S HIGHLIGHTS ARE

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Kit Encoders for Servo and Stepper Motors

POSITAL’s new family of kit encoders provide the manufacturers of motors and other machinery with rugged, accurate and cost-efficient tools for building rotary position feedback into their products. The new kit encoders are based on POSITAL’s highly successful self-contained magnetic rotary encoders. Now however, the core components of these instruments are available as separate assemblies that can be readily integrated into other products.

POSITAL offfers now also through hollow kit encoders which are designed for installations where there are benefits to having the measurement element fit around a machine’s shaft or axle. The kit portfolio expanded to also include compact incremental optical kit encoders which are optimized for speed control of small drives, low power motors and stepper motors. These devices are simple, robust and easy to install,

  • Absolute Multiturn Without Battery or Gear
  • 17 Bit Resolution
  • Multiple Interfaces: BiSS-C, BiSS Line (One Cable Technology), SSI, Incremental
  • Quick, Simple Assembly and Disassembly
  • Mounting Compatibility with Common Incremental Kit Encoders

Read More

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Wiegand Sensors – Magnetic Pulse Generator

Wiegand sensor products from POSITAL reflect the knowledge from a full decade of experience using Wiegand-effect base revolution counters. The high performace sensors are assembled using SMD mounting technology and can be used for revolution counters in absolute rotary encoders as well as in other applications, e.g. gas or water meters.

  • Production Since 1974 – Started by John R. Wiegand
  • Proven In Encoders & Water Meters Since > 10 Years
  • Used In Access Cards For > 30 Years
  • Power Supply For Future IoT Applications
  • High Energy Output of ~170 nJ

Read More

tiltix_aks
Inclinometers with Dynamic Acceleration Compensation

POSITAL has introduced new versions of its TILTIX inclinometers that can provide reliable tilt measurement for moving equipment. These new devices use a combination of electro-mechanical accelerometers and gyroscopes to provide accurate measurements, even if the instruments are subject to strong accelerations.

  • Compensation of External Accelerations
  • Clean Measurement During Dynamic Movements
  • Optional Output of Acceleration and Rate of Rotation
  • Well Protected up to IP69K
  • Compact and Robust Die-cast Housing with Integrated T-Coupler
  • Wide Temperature Range from -40 to +85°C

Read More

Reference: click here.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

CLOSED-LOOP MOTOR FEEDBACK WITH THE ABSOLUTE ADVANTAGE

CLOSED-LOOP MOTOR FEEDBACK WITH THE
ABSOLUTE ADVANTAGE

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Upgrade Your Existing Motion Control Application

POSITAL has expanded its line of kit-style encoders for feedback for servo and stepper motors with new models that utilize the same mounting form factor as incremental kit encoders from US Digital, Broadcom and other manufacturers.

  • Mechanical Drop In Replacement for Easy Upgrade to Absolute Position Control
  • Same Footprints as US Digital’s E5 Models and Broadcom’s (Avago) HEDS-5500 Models
  • Identical Assembly Procedure – No Training Required
  • Various Hub Diameters from 4 mm to 10 mm (and 1/4 to 3/8 inch)
  • Magnetic Technology Which Is Generally More Robust Than Optical
  • Improved Connectivity via M12 Connector Additionally Available

See our Cross Reference Guide

POSITAL kit encoders provide absolute position feedback so that the control system always has complete information on the physical position of the mechanical components that it is directing. “Absolute position feedback is a natural way of providing accurate position control” comments Jim Stevens, market specialist for robotics at POSITAL. “Almost any position feedback application could be absolute-based. Many current systems were designed around incremental encoders because incremental feedback devices were historically much less expensive than their absolute counterparts.” However, with the introduction of POSITAL’s absolute kit encoders at prices much more in line with incremental devices, system designers no longer have to work around the shortcomings of incremental feedback in an absolute position world.
Incremental encoders are effective for speed control. However, to monitor absolute position, the controller needs to maintain a complete count of the number of pulses received from the encoder. This can lead to problems. If, for example, the pulse count becomes corrupted due to a power outage, or if the control system fails to update the pulse count when the machine moves, positional accuracy is lost. The usual remedy is to “re-home” the machine by returning it to a known reference position and zeroing the pulse counts. By contrast, absolute encoders measure position directly. After a power outage, the controller can re-establish complete knowledge of the position of mechanical components by simply polling the sensors and reading their rotational position.
prq_exp

Multiturn Absolute Kit Encoders Provide Robust Solution

Multiturn Absolute Kit Encoders from POSITAL are based on magnetic sensing technology which provides a very robust encoder solution. The multiturn counting system is powered by Wiegand wire energy harvesting technology, which enables the absolute encoder to maintain true absolute position over power cycles and rotation of the encoder during power off conditions.

With 17 bits (131072 positions) of single turn resolution and 16 bits (65536 turns) of multiturn range, KCD Absolute kit encoders from POSITAL are ideal for position control applications.

FAQ Kit Encoders

Reference: click here.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

NEW CANOPEN MAGNETIC ABSOLUTE ROTARY ENCODER WITH CONNECTION CAP

NEW CANOPEN MAGNETIC ABSOLUTE ROTARY ENCODER
WITH CONNECTION CAP

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Intuitive Configuration of CANopen encoders for factory automation

POSITAL’s IXARC magnetic absolute encoders with CANopen interfaces are now available with an optional “connection cap” that makes device configuration and troubleshooting simpler and more intuitive.

  • Robust measurement technology
  • 30% more compact than the optical version
  • Diagnostics via LEDs
  • On site configuration of the address and baud rate via rotary switches
  • Hardware setup of the termination resistor
  • Up to 16 bit Single-Turn, 32 bit for Multi-Turn; battery-free
  • Flexible installation (cable gland, connector), easy in maintenance
  • Separation or combination of power and communication cables
  • High protection degree up to IP 66/67

For previous generation IXARC magnetic encoders with CANopen interfaces, device setup was accomplished by updating software parameters, requiring special tools and expertise. The new connection cap interfaces contain three rotary switches that enable the installer to define the node ID and baud-rate directly with a small screwdriver. There are also diagnostic LEDs on the backside that indicate device and network status. With eight screw terminals inside the cap, the user can easily install cables for power supply and bus-in bus-out. A slide switch can be set to activate a termination resistor when the device is located at the end of the network, reducing installation costs.

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Excellent Choice for a Variety of Industries

IXARC magnetic absolute encoders with CANopen interfaces are ideal for a wide range of motion control and factory automation applications. Compared to optical encoders, they are almost 30% more compact, with superior resistance to shock and vibration loads. Available IP 66/67 protection makes these devices suitable for harsh environmental conditions. Single- and multi-turn models are available; for multi-turn versions, the rotation counter is self-powered, with no need for backup batteries and a measurement range of four billion revolutions (32 bits). A variety of connection cap options are available, including cable glands for cables of various lengths and M12 connectors for use with pre-assembled cables. Connection caps with two or three connectors make it possible to connect multiple devices in series (daisy chain), without T-couplers.

Reference: click here.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com

FRABA GROUP CELEBRATES 100TH BIRTHDAY WITH STRONG FINANCIAL PERFORMANCE AND MARKET GROWTH

FRABA GROUP CELEBRATES 100TH BIRTHDAY WITH STRONG FINANCIAL PERFORMANCE AND MARKET GROWTH

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The international FRABA Group, which is about to mark the 100th anniversary of its founding, has enjoyed a year of significant growth in sales and profitability. In fiscal 2017 (ending December 31) turnover increased by 21.5% over the previous year, with total sales revenues of € 31.5 million. Growth has been driven by strong performance of the Group’s two product-oriented business units: POSITAL (industrial position/motion sensors) and VITECTOR(safety/security systems for large motorized doors). FRABA now has 220 employees, located at offices in Europe, Asia and the USA.

“Our success has been the result of hard work and careful planning” comments Christian Leeser, majority shareholder and CEO of the FRABA Group. “Innovative products, such as our high-resolution IXARC magnetic rotary encoders and the motor feedback Kit Encoders have been well received by the market”. Leeser continues: “Our future success will be supported by our Aachen-based R&D center, which is making significant progress in the development of innovative signal processing algorithms for of our magnetic encoder products and improved performance from our Wiegand wire energy harvesting technologies.”
While the VITECTOR business experienced significant growth, especially in North America, the largest area of advance was in the production of compact Wiegand devices for energy harvesting. In 2017, production of these ‘mini-power plants’ (which convert rotary motion into electrical energy through a magnetic process) more than doubled. FRABA, which is the exclusive producer of Wigand wire, makes use of this technology in its self-powered rotation counters for multi-turn encoders. It also supplies Wiegand modules, packaged as surface-mountable devices, to manufacturers of gas and water meters. Here, the energy harvesting capability is used to eliminate the need for external power or batteries. There are now more than 500,000 Wiegand devices in use worldwide.
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Reference: click here.

D&D Engineering – “W’ere YOUR Sensor Guys”
3835 E. Thousand Oaks Blvd. Suite 464 Westlake Village, CA 91362  – Voice: (818) 772-8720 Fax: (818) 772-2477 Toll Free: (888) 333-6474
Email: sales@sensorguys.com Website: www.sensorguys.com