ZEROTRONIC inclination sensor

The sensors of the ZEROTRONIC family are very precise and robust inclination sensors with a measuring range from ±0.5° bis ±60°.

The inclination sensors of the ZEROTRONIC family have established themselves in the market as the benchmark when it comes to high-precision inclination measurement in demanding applications.

 

Working digitally, they compensate for temperature changes and allow data communication over long distances without any loss of data. The inclination sensors of the ZEROTRONIC family are therefore perfectly suited for the monitoring and alignment of objects and machines over a long period of time, even in a rough environments. Together with the wylerDYNAM software, measuring values of the ZEROTRONIC sensors can be registered and documented continuously.

 

The inclination sensors of the ZEROTRONIC family have the following features:

  • Measuring ranges of ±0.5 to ±60 degrees
  • High resolution and high precision
  • Excellent temperature stability at temperatures from -40°C up to + 75°C (depending on the requirement, an optional extended temperature calibration might be required)
  • Synchronized registration of measuring values for several sensors
  • High immunity to shock
  • High immunity to electromagnetic fields             

Thanks to these outstanding features, ZEROTRONIC sensors are used worldwide in a wide variety of demanding applications in almost all industries and fields such as aviation, shipbuilding, rail, aerospace, automotive, machine tool, telecommunication, defense, and civil engineering. 

 


The ZEROTRONIC family

Depending on the measuring range, two different types of sensors are used:

  • Measuring range from ±0.5° to ±10°: Inclination sensor ZEROTRONIC 3 
  • Measuring range from ±30° to ±60°:  Inclination sensor ZEROTRONIC C

Differences between the two types of inclination sensors:

  • The larger pendulum of the ZEROTRONIC 3 provides a significantly better signal-to-noise ratio for smaller inclinations. The ZEROTRONIC 3 is therefore perfectly suited for high-precision applications where only small inclinations are measured
  • The smaller mass of the pendulum of the ZEROTRONIC C provides a higher stability if the sensor is permanently inclined. It is therefore suited for larger measuring ranges.
  • Only ZEROTRONIC 3 provides the option of analog output 

CALIBRATION OF DIGITAL SYSTEMS

Each single sensor is individually calibrated over the complete measuring range as well as over the complete temperature range the sensor is going to be used in. These calibration values are stored as reference points in the EPROM of the sensor.

Two temperature calibrations are available:

  • The standard temperature calibration is well suited for sensors that are used in a typical laboratory or a machine shop environment: temperatures around 20° C and slow temperature changes.
  • The HTR-calibration (High Temperature Range) is suited for those sensors that are exposed to outdoor conditions. These sensors are calibrated at various temperatures, which ensures that they function well across the entire temperature range the sensor can be used, which is from – 40 °C to + 85 °C. Thanks to the extended and more elaborate temperature calibration, the HTR- sensors show a substantially lower temperature coefficient, which is about 1/5 of the value of a standard temperature calibration (see technical specification).

 

Remark:

Even with an HTR-calibration it has to be ensured that the sensors are protected against direct sunlight and that temperature changes are impacting the sensors evenly from all sides.

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Calibration Certificate:

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ZEROTRONIC-sensors can be delivered with an internationally recognised Calibration Certificate against a surcharge


Various

Also the following expressions are common for an inclination sensor:

  • Tilt sensor
  • Digital inclinometer
  • Digital inclination sensor
  • Inclination sensors
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Technical Specifications for ZEROTRONIC sensors type 3 and type C

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Technical Specifications for ZEROTRONIC sensors type 3

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Technical Specifications for ZEROTRONIC sensors type C

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*Remarks:

ME = Full-scale errors (are mainly due to drift of zero)
MW = Read Out (errors are mainly due to change of gain) no filter = raw values

no filter = raw values
with filter = floating average over 10 values
HTR-calibration will reduce temperature coefficient by approx. 5 times
TA = ambient temperature


ALIGNMENT OF THE ETCS-RADAR ON A LOCOMOTIVE

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Subject:

The Doppler-Radar which is measuring the exact speed of a train is an important part of the ETCS train control system in Europe. 2 such radars are mounted under each locomotive. To ensure a correct functioning, they must be precisely aligned.  

Measuring task: 

Precise alignment and regular checking of the parallelity of the lower side of the radars to the rail.

SHIP BUILDING / DETERMINATION OF DEVIATIONS IN PARALLELISM

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Subject:

Precise inclination measurement on unstable bases as they exist on a moored vessel on the water are a huge challenge. 

Measuring task:

On a large ship moored in a harbor, the deviations from parallelism for several platforms must be determined. Based on this, the platforms shall be aligned afterwards. This should be done as efficiently and precisely as possible

RESEARCH - DEVELOPMENT / MEASUREMENT OF A ROAD SURFACE

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Measuring task / Goal:

Based on the above mentioned information a standard road surface shall be recorded in a form which enables the integration in a software. This software will control and monitor a testing station in a way that that car test can be performed under laboratory conditions fully integrating the road surface profile. In order to establish this standard road profile, several dozen kilometres long, in an efficient way, the profile shall be monitored and recorded in the longitudinal direction by the aid of inclinometers during driving.

more

CIVIL ENGINEERING / MONITORING OF BRIDGES

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Subject:

The deformation of a highway bridge must be continuously monitored, not only during construction but also afterwards, when the bridge is put into service.

Measuring task:

In order to get significant values regarding the deformation of the bridge, several points on the bridge must be monitored simultaneously. 

PRINTING INDUSTRY / ADJUSTMENT OF STANDS AND PRINTING CYLINDERS

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Subject:

A modern multi-color printing system consists of several separate units, one unit per primary color. To achieve high-quality print products, these units must be precisely aligned and adjusted when assembled.

Measuring task:

Each single color unit provides horizontal and/or vertical reference faces, which must be used during the manufacturing process in the production plant as well as for the adjustment of the printing line. The positions of the reference faces must be adjusted in accordance to each other, measured, and a record must be printed. The positions of the printing cylinders must be precisely aligned to each other (horizontally).

POWER SUPPLY SECTOR / ALIGNMENT OF LARGE PUMP SHAFTS

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Subject:

During maintenance works on the pumps of the cooling circuit of a cooling tower in nuclear power plants, quick and precise methods for the required alignment works are indispensable. Large electro motors with vertical axis drive evenly large centrifugal pumps situated one floor below.

Measuring task:

  • The horizontal positions of the connecting lines between the bearing faces on the bearing ring for the stator must be checked. The flatness and the horizontal position of the bearing ring must be assured.
  • The pump housing, one floor below, must be adjusted horizontally as well.
  • The center points of the pump shaft and the drive shaft of the motor must be aligned to each other in order to assure that the transmission shaft can work free of any bending moment.

AIRCRAFT INDUSTRY / ALIGNMENT OF COMPONENTS IN AN AIRCRAFT

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Subject:

During assembly, maintenance and repair of a large transport aircraft various components of the equipment must be precisely aligned to a reference platform. 

Measuring Task:

Two radar platforms must be aligned precisely parallel to the reference platform. The measurements must be carried out while other teams are working on the same aircraft.

MACHINE TOOLS / SPINDLE ALIGNMENT

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Subject:

The main spindle of a milling machine can be set for vertical as well as for horizontal milling. To change between the two settings, the milling head rotates on a bearing set at 45°. 

Measuring task:

The deviation from the right angle between the two working positions “horizontal” and “vertical” must not exceed 2 arcsec. 

The measurement (and correction) is first made during assembly, and again during final inspection of the finished machine. 

MEASUREMENT OF THE FLATNESS IN AN OVEN WITH LIMITED HEIGHT

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Subject:

A bio-technical company must measure the flatness of plates in an oven (at room temperature), to ensure that all objects stored in that oven are horizontally aligned. Distance between plates are only 100 mm. Size of each plate is 800 mm x 800 mm.

Normally a BlueSYSTEM Sigma together with wylerSPEC is used for flatness measurement. For this application here the height of the instruments exceeds the space available.

Measuring task:

Flatness measurement of the plates in the oven with precision inclination measurement instruments, despite the limited space available.

CONTINUOUS MONITORING OF AN OBJECT, WHICH IS EXPOSED TO STRONG TEMPERATURE CHANGES

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Subject:

On a radar installation which is exposed to significant temperature changes as well as to direct sunlight, precise, reliable and continuous inclination measurements should be carried out. 

All high-precision instruments are sensitive to temperature changes. Significant temperature changes inhibit precision measurements and can even prevent them.

Measuring task:

Precise and continuous monitoring of the inclination of the base of the radar station. 

MEASUREMENT OF THE ABSOLUTE POSITION OF A Guideway

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Subject:

The straightness of a guide way can be measured very easily and very precisely with the software wylerSPEC. Since the straightness is independent of the absolute position of the guide way in space, it is enough to measure “relative”. On the other hand, when adjusting a machine, it can be very helpful to know the exact position of the guide way in space.

Measuring task:

For a guide way, not only its straightness but also its deviation from the horizontal plane shall be measured. Furthermore, it should be shown where and how much the guideway should be corrected to adjust it horizontally.

ALIGNMENT OF AN INJECTION MOLDING MACHINE WITH WIRELESS INCLINATION SENSORS

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Subject:

Each injection molding machine must be properly aligned during commissioning. This process uses 5 precision spirit levels and requires 2 technicians. One of them is reading the spirit levels and the other one is adjusting the 6 supports. This is an iterative and tedious work, since all 5 spirit levels must be re-checked after every adjustment. The available height on each of the 5 measuring points is limited to 120 mm.

Measuring task: 

The customer is searching for a more efficient solution for this process during in-house commissioning as well as for the commissioning

at the customers premises. If possible, the adjustment should be done by one single technician. To assure that no instrument is accidentally pulled down, a wireless solution is favored.

MONITORING OF A HISTORICAL BUILDING IN KOREA

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Subject:

An old and historically significant wooden building in the center of Seoul shall be preserved despite aggressive environmental influences, like the exhaust gases from cars.

Measuring task:

The building shall be continuously monitored with inclination sensors.

MONITORING OF A HIGH RACK WAREHOUSE / Part 1

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Subject:

Automatic high rack warehouses can reach very large dimensions:

80 m length, 45 m width and 30 m height are no exceptions. Despite these dimensions and despite the high speed of the transportation system, each bin must be placed very accurately at its predefined location. In order to reach such accuracy, the alignment of the racks is of key importance. The exact verticality of each rack has therefore to be ensured. Already smallest deviations will change the distance to the transportation system and could cause errors. The bins could get blocked and get damaged or even fall. 

Measuring task / Goal:

The verticality of each rack in the high rack warehouse must be monitored permanently.

POSITIONING OF A HEAVY PART WITH AN OVERHEAD CRANE

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Subject:

In a large production hall, a heavy part shall be positioned in the correct height with an overhead crane in order to allow a stress-free mounting. First tests show that the building is not stable enough: Depending on the weight of the part, vertical offsets are measured which are larger than the required positioning 

accuracy.

Measuring task: 

In order to achieve the required accuracy, the bending of thebuilding respectively of the overhead crane should be measured.From these values, the vertical correction of the crane should be calculated.

MACHINE TOOLS / ANGULAR POSITIONING ERROR OF A- AND C-AXIS

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Subject:

Machine centers capable of machining freely designed shapes, require, next to the linear axes X, Y and Z, the rotary axes A and C as well. In order to manufacture work pieces with adequate precision, the rotary axes A and C must provide the same high angular positioning accuracy as the linear axes. 

Measuring task: 

To measure deviation from nominal angle at different angular positions. To avoid errors due to the mass of the machine components, the measurement should be collected as close as possible to the cutting position. 

The measured values shall be used as corrective factors in the CNC controller. Uncertainty of measurement should not exceed 2 arcsec. 

INCLINATION MEASURING OF A SATELLITE DURING A SYSTEM TEST IN A TEMPERATURE VACUUM CHAMBER

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Subject:

Testing of a satellite in a temperature and vacuum chamber under conditions like in space: temperatures from –30°C to +60°C and vacuum. 

Measuring task:

Level all systems of a satellite to each other. A precise surface on the satellite serves as horizontal reference point. The inclination of this horizontal reference must be within ±0.001 mm/m. 

ADJUSTMENT OF A CEMENT OVEN DRIVE

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Subject:

Cement is manufactured in a so-called turn-tube oven. The oven itself is a about 50 to 70 m long, slightly tilted steel tube with a diameter of 4 to 5 m which turns around its longitudinal axis (max. 20 rpm).

Measuring task:

The inclination of the cement-oven drive- gear wheel (diameter approx. 1.5 m) should be the same as the inclination of the turn-tube oven gear wheel (diameter approx. 6 m). The required accuracy is 0.01° = 0.2 mm/m.

CONTROLLED CRADLE TO LIFT AND PLACE PAYLOAD FAIRING OF A ROCKET

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Subject:

The payload fairing covers the goods transported and provides aerodynamic to the leading end of the rocket. As the payload fairing is a highly complex unit, no scratches or even dents are acceptable. To lift and to position the payload fairing a cradle is used. 

Measuring task:

The balancing and weight distribution cross at the head of the cradle should be monitored in both axes. Deviation from horizontal alignment must be visualized at the cranes control panel.

Thresholds are defined regarding misalignment. Overshooting these limits must activate an alarm and disrupt the lifting actions. 

ALIGNMENT OF THE HOLES OF FLANGES

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Subject:

A pipe must be welded in between two vertical flanges with holes. These pipes have a length between 2m and 10m and a diameter between 400mm and 1000mm. 

The material of the flanges and the tubes is either aluminum or stainless steel.

Measuring task:

Before the welding process, the holes of the 2 flanges must be aligned in such a way that the holes on the left have less than ±15arcsec deviation from the holes on the right side after the welding process.

ZEROTRONIC SENSORS IN STRONG MAGNETIC FIELDS

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Measuring task / Goal:

The user of a particle accelerator would like to accurately measure and adjust the parts of his accelerator. The strong magnetic fields allow only the use of non-magnetic material. Only instruments that are not sensitive to heavy magnetic fields can be used.

more

PITCH AND ROLL MEASUREMENT WITH 2D-ZEROTRONIC MEASURING UNIT AND MT-SOFT-SOFTWARE

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Subject:

Alignment of a turning lathe with an oblique bed and establishing a pitch and roll measuring protocol for the longitudinal and transversal axis.

Measuring task:

The machine should first be very accurately levelled in both X- and Y-direction.

Afterwards a pitch and roll measuring report with numerical and graphical information is required.

CIVIL ENGINEERING / MONITORING OF VERTICAL MOVEMENTS IN NATURAL GROUND

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Subject / Measuring task

When excavating tunnels passing under e.g. existing railway installations, or roads where several owners are involved, the question of liability is raised regarding potential damage done to these structures. 

The owners then often ask for a permanent monitoring of the site to get early warnings as well as proof. 

MEASUREMENT AND CERTIFICATION OF THE TORQUE-RESISTANCE ON AN ENGINE-SHAFT

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Subject:

The torque-resistance of an engine shaft is decisive for the reliability and durability of the engine. However, to measure this resistance for long shafts is a challenging task.

Measuring task:

The torsion of an engine-axis mounted on a testing-rig with a base of 12m x 12m must be measured precisely by recording the change of the twist-inclination and by putting it in relation to the applied torque.

MONITORING OF AN OFFSHORE WIND TURBINE TRIPOD DURING PLACEMENT AND ANCHORING IN THE SEA

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Subject:

An offshore wind turbine requires a stable and exactly horizontal base. To achieve this, the tripod, on which afterwards the wind turbine will be mounted, must be monitored during the anchoring process.

Measuring task:

The position of the Tripod must be monitored during the anchoring rocess with inclination sensors mounted at the upper end of the Tripod. The sensors must withstand the high accelerations occurring during the ramming process. The measured data must be transmitted wireless to the boat controlling the whole process.

RAILWAY CONSTRUCTION

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Subject:

The requirements in railway construction are increasing continuously. Specifically, high speed tracks put very high demand on track geometry and therewith on track construction. A tamping machine requires exact information about the condition and position of the track ahead to make the required corrections and to work precisely and efficiently

Measuring task:

The positioning errors of the track shall be measured with a mobile measuring unit. The measuring data shall then be used by the tamping machine.

ALIGNMENT OF SOLAR PANELS

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Subject:

Solar panels must be perfectly adjusted to the sun to ensure best possible performance.

Measuring task:

The inclination of each single solar panel must be verified periodically. A measuring range of up to ±60° is required.

CALIBRATION OF ROBOTS

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Subject:

The precision of an industry robot is directly depending on the precise alignment of each single axis.

Measuring task / Goal:

The offset of each axis has to be measured not only in 

production, after mounting the robot, but also after the 

installation at customer site. These offsets are then to be known and compensated by the process control system.