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microelectronic systems (MEMS) technology applied to sensing. "By printing thin-film IR absorbers surrounded by free-standing thermal isolation structures," continues Dunich, "this MEMS-based technology [measures] radiated power to remotely determine an object's temperature." One such sensor is the second generation AMG88 Series Grid-EYE Sensor from Panasonic. This device is an uncooled IR sensor with an 8x8 thermopile array in a reflow-compatible surface mount (SMD) package that includes MEMS sensor chip, RF-shielded metal cover, digital ASIC with I2C interface, and 60 degree silicon lens etched out of a silicon wafer (the lens is less than 0.01 inches high)—all in a package measuring 11.6mm x 8mm x 4.3mm, which is, according to Panasonic, about 70 percent smaller than competitive products. Each of the array's 64 pixel sensing elements converts the thermal energy into a proportional output signal. These temperature signals are amplified, converted from analog to digital, referenced against an ambient temperature value and then transmitted to a microprocessor. "The microprocessor maps the temperatures into a complete thermal represen- tation of the entire field of view," explains Dunich. "From this thermal grid, it is possible to detect moving people as well as the direction they are moving and the presence of motionless people." Grid-EYE sensors detect objects up to 7 m and have frame rates up to 10 fps. Ultrasonic sensors also exist on the plant floor. For instance, UC-F77 from Pepperl+Fuchs is about 1.25 inches high and can detect objects up to 31.5 feet away. "It has an extremely small deadband, meaning even objects in close proximity to the sensor are reliably detected," says Product Manager Carsten Heim. Helping matters is that the sensor's switch points, output mode, output logic and sound beam width are programmable by buttons on the sensor. The sensor includes automatic synchronization, which allows up to 10 sensors to operate in the same cycle or multiplex mode without external inter- vention. Continues Heim, "This prevents cross-talk between sensors mounted close [to] each other and ensures the shortest possible response time." The sensor comes in both thru-hole and surface-mount versions. Is this all worth it? You betcha! As stated in a SICK brochure entitled "Guide for Safe Machinery": "Safety is a basic human need." SIDEBAR TOPIC Sensor costs • Set-up and maintenance of multiple sensing technologies • Re-teaching at every production change-over • Analog signal converting • Replacement of damaged sensors • Installation and wiring • Machine commissioning • Failure analysis • Numerous sensor variants Why sensors fail • Low margin due to dust • Mechanical damage during production • Incorrect set-up or instruction • Cable break • Swapped cable • Material or target change during production change-over • Contamination • Component failure • Short circuit Cost of downtime • Loss of production • Manufacturing scrappage • Establishing cause of failure (mechanical/electrical) • Sensor replacement costs • Safety issues • Impact on other equipment Maintenance options • Advanced diagnostic information • Preventative not reactive maintenance • Planned downtime possible • Taking control of your plant • Reduced maintenance costs Increased productivity • Reducing unplanned downtime improves productivity • Take control of your production process • Make fact-based decisions with advanced diagnostic information • Faster production change-over due to multiple sensor profiles • Faster device changeover due to auto device configuration Source: Rockwell Automation Integrated Smart Sensor Solutions Can Help Provide At Least 5-10 Percent Production Increase 38 SAFETY