German MELFORM sensors MELFORM models MELFORM prices

MELFORM sensors are sensors that measure the operating speed of the measured object and convert it into an output signal. Speed sensors include linear speed sensors and rotational speed sensors. With technological development, traditional measurement equipment can no longer meet current needs and is gradually being phased out, while laser speed sensors are widely used. They play a significant role in product manufacturing processes; by connecting to a computer, they enable automated and intelligent measurement and control of the measured object. This is the product of the combination of modern measurement technology and computer technology.

MELFORM sensor classification

1) Contact sensors: The contacts of contact sensors act when two objects come into contact and press against each other. Common types include limit switches and two-dimensional matrix position sensors. Limit switches have a simple structure, reliable operation, and low cost. When an object moves and touches a limit switch, its internal contacts act to complete control. For example, if limit switches are installed at both ends of the X, Y, and Z axes of a machining center, the travel range can be controlled. Two-dimensional matrix position sensors are installed inside mechanical grippers to detect the contact position with an object. 2) Proximity sensors: A proximity switch is a switch that emits an "actuation" signal when an object approaches within a set distance, without requiring direct contact. There are many types of proximity switches, mainly electromagnetic, photoelectric, differential transformer, eddy current, capacitive, reed switch, and Hall effect types. The application of proximity switches on CNC machine tools mainly includes tool selection control for the tool turret, worktable travel control, and piston stroke control for hydraulic and pneumatic cylinders.

MELFORM sensor working principle

Crankshaft position sensors are usually installed at the front end of the crankshaft (at the pulley), at the rear end near the large flywheel, or in the middle of the crankshaft. In early vehicle models, they were also installed inside the distributor. They are one of the most important sensors in the control system. Their functions include: detecting engine speed, hence they are also called speed sensors; detecting the top dead center (TDC) position of the piston, hence they are also called TDC sensors. This includes detecting the TDC signals for each cylinder used to control ignition, and the TDC signal for the first cylinder used to control sequential fuel injection.

MELFORM sensor industry applications

1) Brushless DC motors: The position sensor is one of the three main components of a brushless DC motor system and is the main feature distinguishing it from brushed DC motors. Its function is to detect the position of the main rotor during motion, convert the position signal of the rotor magnet poles into an electrical signal, and provide correct commutation information to the logic switching circuit. This controls their conduction and cutoff, causing the current in the motor armature windings to commutate sequentially as the rotor position changes, forming a stepwise rotating magnetic field in the air gap that drives the permanent magnet rotor to rotate continuously. Brushless DC motors require position sensors to measure rotor position. The motor controller uses the position sensor signals to synchronize inverter commutation with the rotor, driving continuous motor operation. Although brushless DC motors can detect rotor position via the back electromotive force generated in the stator windings, thereby eliminating the need for position sensors, the motor speed is too low at startup, and the back EMF signal is too weak to be detected. Hall effect sensor chips used as position sensors for brushless DC motors are divided into switching and latching types. For electric bicycle motors, both types of Hall sensor chips can be used to accurately measure the position of the rotor magnets. The performance of brushless DC motors made with these two types of Hall sensor chips, including output power, efficiency, and torque, shows no difference, and they are compatible with the same motor controllers. The application of position sensors reduces motor operating noise, improves motor life and performance, and achieves energy savings. The application of position sensors undoubtedly provides a strong impetus to the development of the motor market. 2) Crankshaft and camshaft: The function of the position sensor is to collect crankshaft rotation angle and engine speed signals and input them to the electronic control unit (ECu) to determine ignition timing and fuel injection timing. To distinguish it from the crankshaft position sensor (CPS), the camshaft position sensor is generally denoted as CIS. The function of the camshaft position sensor is to collect the position signal of the camshaft and input it to ECU, so that ECU can identify the compression TDC of cylinder 1, thereby performing sequential fuel injection control, ignition timing control, and knock control. In addition, the camshaft position signal is used to identify the first ignition timing during engine start-up. Because the camshaft position sensor can identify which cylinder's piston is about to reach top dead center, it is called the cylinder identification sensor.

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