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KAPP sensors are devices or assemblies that detect pressure signals and convert them into usable output electrical signals according to a defined relationship. Pressure sensors typically consist of a pressure-sensitive element and a signal processing unit. Depending on the type of pressure measured, pressure sensors can be classified as gauge pressure sensors, differential pressure sensors, and absolute pressure sensors. Pressure sensors are among the most commonly used sensors in industrial practice, widely applied in various industrial automation environments, including water conservancy and hydropower, railway transportation, smart buildings, production automation, aerospace, military industry, petrochemicals, oil wells, electric power, ships, machine tools, pipelines, and many other industries.

KAPP sensor classification

1) Linear displacement sensors: The function of a linear displacement sensor is to convert linear mechanical displacement into an electrical signal. To achieve this, a variable resistive track is typically fixed within the sensor housing, and different resistance values are measured by the movement of a wiper along the track. The sensor track is connected to a stable DC voltage, allowing a small microampere current to flow. The voltage between the wiper and the start terminal is proportional to the distance the wiper has moved. Using the sensor as a voltage divider minimizes the requirement for precise total track resistance, because resistance changes caused by temperature variations do not affect the measurement result. 2) Angular displacement sensors: Angular displacement sensors are used for obstacle detection: using angle sensors to control your wheels can indirectly detect obstacles. The principle is very simple: if the motor with the angle sensor is running but the gear does not turn, it indicates that your machine is blocked by an obstacle. This technique is very simple to use and highly effective; the only requirement is that the moving wheel must not slip on the floor (or slip excessively), otherwise you will not be able to detect obstacles. Connecting an idler gear to the motor can avoid this problem; this wheel is not driven by the motor but is driven by the movement of the device: during the rotation of the drive wheel, if the idler wheel stops, it indicates that you have encountered an obstacle.

KAPP sensor usage precautions

1) If the electronic scale has been used for a long time, and the seal has aged while accumulating many impurities, water mixtures and oil will seriously affect the contact resistance of the brush, causing the displayed numbers to fluctuate continuously. In this case, the electronic scale of the linear displacement sensor can be considered damaged and needs to be replaced. 2) If the power supply capacity is too small, various issues may arise; therefore, the power supply must have sufficient capacity. Insufficient capacity can cause the following situations: movement of the plasticizing unit causes fluctuations in the display of the mold-clamping electronic scale, or movement of the mold clamping causes fluctuations in the display of the injection electronic scale, resulting in significant measurement errors. If the solenoid valve drive power supply shares the same source as the linear displacement sensor power supply, the above situations are more likely to occur. In severe cases, voltage fluctuations can even be measured using the voltage range of a multimeter. If the issue is not caused by high-frequency interference, electrostatic interference, or poor neutral grounding, it is likely due to insufficient power supply capacity. 3) Frequency modulation interference and electrostatic interference can both cause the displayed numbers on the linear displacement sensor's electronic scale to fluctuate. The signal cables of the electronic scale must be routed in separate cable trays from the equipment's high-power lines. The electronic scale must be forcibly mounted using a grounding bracket, ensuring good contact between the electronic scale housing and ground. Signal cables must use shielded cables, and one end of the shield should be grounded at the electrical cabinet. When high-frequency interference is present, voltage measurements with a multimeter usually appear normal, but the displayed numbers continue to fluctuate; electrostatic interference produces similar symptoms. To verify whether electrostatic interference is the cause, briefly short-circuit the cover screw of the electronic scale to a metal part of the machine using a piece of power cable; once shorted, the electrostatic interference will be eliminated immediately. However, eliminating high-frequency interference is more difficult using this method. Variable frequency drives and robotic arms often generate high-frequency interference, so you can try stopping the high-frequency drive or the robotic arm to verify if high-frequency interference is the cause. 4) If the displayed data of the linear displacement sensor's electronic scale fluctuates regularly at a certain point during operation, or if there is no display, check whether the insulation of the connection cable is damaged, causing regular contact with the machine housing and resulting in a ground short circuit. 5) The supply voltage must be stable. Industrial voltage stability must comply with ±0.1[%]. For example, if the reference voltage is 10V, a fluctuation of ±0.01V is permissible; otherwise, it will cause continuous display fluctuations. However, if the amplitude of the display fluctuation does not exceed the amplitude of the voltage fluctuation, the electronic scale is functioning normally. 6) The alignment of the linear displacement sensor installation must be precise, but parallelism errors of ±0.5mm and angular errors of ±12° are permissible. However, if both parallelism and angular errors are excessive, the displayed numbers will fluctuate. In such cases, the parallelism and angle must be adjusted. 7) During connection, pay close attention: the three wires of the electronic scale must not be connected incorrectly, and the power and output lines must not be swapped. Incorrect wiring will result in significant linearity errors, making control difficult and reducing control precision, while the display is prone to fluctuation.

KAPP sensor applications

The geometric state parameters of train wheel flanges affect the speed and smoothness of train operation and are crucial for safe train operation. Traditional inspection methods are relatively complex, typically using specialized calipers for manual measurement, which leads to significant measurement errors due to manual data reading and prevents digital management of inspection data. With the development of China's railway industry, train speeds are increasing, making precise and rapid inspection of wheel flange state parameters and digital management increasingly important. The flange detector adopts modern sensor technology, a microcontroller processing system, and a concise, stable mechanical structure, enabling convenient and precise continuous rapid measurement of geometric state parameters, achieving digitization of parameters such as flange height and rim thickness. Many sensors are used for detecting flange height, width, rim thickness, and other aspects, with displacement sensors being of primary concern. There are many types of displacement sensors; the current novel sensor technology used for train wheel flange profile detection is called laser displacement sensors. Currently, laser triangulation is used for train wheel flange detection, offering high precision for short-distance measurements. The displacement sensor can be directly installed on the track for detection, or a laser reflective displacement sensor can be used as the measuring device. The laser sensor module scans the flange profile in a straight line while recording the entire flange data. A microprocessor can then derive the entire flange contour curve, thereby calculating flange width, flange height, 70mm wear volume, and wear area. The measured data can be uploaded to a computer to generate a database, utilizing advanced post-processing software for digital management of train wheel flanges. It can not only measure wheelset wear on trains in operation but also sort wheelsets on the production line based on dimensional compliance. The development of transportation relies on inspection technology, with instruments, meters, and sensor technology forming the core of inspection technology. In today's era of high-speed power development, people not only seek comfort and enjoyment but also prioritize safety. The development of sensor technology will bring greater safety to people's lives and transportation, and the advancement of sensor technology in China will also drive the development of world-class technologies in the transportation sector internationally.

Weidou Intelligent Technology specializes in selling German KAPP sensors, KAPP proximity sensors, KAPP distance sensors, KAPP vision sensors, KAPP displacement sensors, KAPP torque sensors, KAPP speed sensors, KAPP photoelectric sensors, KAPP position sensors, KAPP angle sensors, KAPP tactile sensors, KAPP temperature sensors, KAPP pressure sensors, KAPP flow sensors, KAPP level sensors, KAPP motion sensors, KAPP process sensors. Original German imports. Welcome inquiries and orders from users.