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Position and Speed Sensor MiniCoder GEL 2442

Mini Coder Gel 2442 - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders Mini Coder Gel 2442

Functional Description

  • Measurement of speed and position by proximity sensing
    of precision target wheel
  • Scanning by means of magnetoresistive sensor elements
  • Measuring unit consisting of sensor and precision target
    wheel for installation on shafts with diameters ranging
    from 8 mm to more than 500 mm

Applications

  • Speed detection in HSC spindles (High-Speed-Cutting)
  • Measurement of speed and position of milling and
    grinding spindles in machine tools for the machining of
    metal, wood, glass, stone and aluminium
  • Angle measurement in radar equipment
  • Electronic synchronization of helical spindles in
    dry-running vaccum pumps
  • Measurement of speed in test stands

Special features

  • Sufficient scope for construction due to customer specific
    production of precision target wheels
  • Internal production of target wheels with module 0.3
    and 0.5 from speeds from 0 to more than 70,000 min-1
  • Safety integrated certificate
  • Output signal 1 Vpp with high signal quality (sin/cos)
  • Cable outlet axial or radial
  • Sensor fully encapsulated
  • Very compact

Measuring Principle

  • Integrated MR-sensors for contactless scanning of
    target wheel
  • Sensor signals internally amplified and temperaturecompensated
  • Frequency range from zero to max. 200 kHz

Output Signals

  • Outputs short-circuit-proof
  • Signal Forms:

  • - two signals phase-shifted by 90 for sense-of-rotation detection
    - sine-wave signal 1 Vpp - all signals aditionally available as inverted signals - option: reference pulse
Output level 1 VPP as differential signals
Output signals two sine-wave signals, by 90 out of phase, and their inverse signals
short-cicuit-proof, option: reference pulse
Output frequency 0 ... 200 kHz for CL = 5 nF
Offset (static) ±. 20 mV
Amplitude tolerance -20 ... +10 %
Amplitude ratio UA/UB 0.9 ... 1.1
Supply voltage UB 5 V DC ± 5%
Power consumption without load ≤ 0.3 W
Permissible air gap 0.15 mm ± 0.02 mm with module 0.3
0.20 mm ± 0.03 mm with module 0.5
Width of target wheel min 4.0 mm
Material of target wheel ferromagnetic steel
Operating temperature range -30C ... +85C
Ambient and storage temperature range -40C ... +120C
Protection class IP 68
Electromagnetic compatibility EN 61000-6-1 to 4*)
Insulation strength according to EN 60439-1 500 V
Vibration resistance (IEC 68-2-6) 200 m/s2
Shock resistance (IEC 68-T2-27) 2000 m/s2
weight 30 g
Housing material polyphenylene sulfide (PPS), glassfibre reinforced
Connection 9-core cable, cross section 0.15 mm2, outside diameter 5 mm(-0.3), min. bending radius 25 mm

The technical data provided are valid for the operating temperature range.

* Important: Where possible, connections to the cable screen should be made coaxially. Connections to the cable screen using single wire cores should be kept as short as possible.

Dimensional drawing, Boring and milling diagram

Mini Coder Gel 2442 - Dimension Drawings - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Boring & Milling Diagram

Mini Coder Gel 2442 - Boring Milling Diagram - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Type code, Description

Mini Coder Gel 2442 - Typecode - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


K = signal pattern sine/cosine-signals 1 VSS (pin layout)

Mini Coder Gel 2442 - Signal Pattern sine/cosine - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


N = reference mark (flag)

A metal flag integrated in the target wheel is detected when its position is exactly between two teeth. This reference signal can be used as a positon reference. This is required, for instance, for the automatic changing of a tool in a milling or grinding spindle.

Mini Coder Gel 2442 - Reference mark (flag) - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


M = reference mark (groove)

Depending on size and geometry of the target wheel, the target wheel version with a reference tab can only be used up to certain speeds. For speeds beyond 30.000 min-1, a MiniCoder detecting a reference groove integrated in the target wheel is used. For technical reasons, the target wheel is in this case composed of two parts.

Mini Coder Gel 2442 - Reference mark (groove) - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


Z = Reference mark (flag over groove)

This MiniCoder version can be used for scanning a target wheel manufactured in one piece. The system permits reaching speeds of more than 70.000 min-1. The reference flag is in alignment with a tooth of the pulse track.

Mini Coder Gel 2442 - Z Reference mark - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


1 = Internal multiplier

When the MiniCoder is used, the interpolation of the 1 VPP output signals is generally perfomed in the respective control unit used. If the control unit does not have this feature, Lenord + Bauer is in a position of supplying the GEL 214 series with independent interpolation electronics which converts the 1 VPP output signals into TTL square-wave signals (maximum interpolation factor = 512). Please ask for the corresponding documentation or just take a look at our website at www.lenord.de from where the above documentation can also be downloaded.




G =Axial cable outlet
Mini Coder Gel 2442 - G =Axial cable outlet - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


R = Radial cable outlet
Mini Coder Gel 2442 - R = Radial cable outlet - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


3 = Module 0.3

The module describes the relation between the number of teeth and the outer diameter of a target wheel. The smaller the module the smaller the outer diameter for the same number of teeth. The air gap to be observed between sensor and target wheel is less with module 0.3 than with module 0.5.


da= m (z+2)

da = outer diameter m = module z = number of teeth

The MiniCoder must be ordered compatible with the target wheel.


5 = Module 0.5 Mini Coder Gel 2442 - Module 0.5 - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

module air gap d
adjustment
dimension
distance tolerance
0.3 0.15 ± 0.02 mm
0.5 0.20 ± 0.03 mm



Connection type K = cable end open

The MiniCODER are manufactured with open cable end. The following cable length are available (30/150/250/600 cm).

Mini Coder Gel 2442 - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Important: Fit the cable screening as coaxially to the earth cable as possible. When fitting the cable screening onto an earth cable, the earth cable should be run as short as possible.

Mini Coder Gel 2442 - Connection Type K table - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders


Connection type A = 17-pole male plug, straight type, B = 17-pole male plug, elbow type

Ready-made cable variants with 17-pole male connector (straight type, elbow type) are available on the market.

Mini Coder Gel 2442 - Connection type A = 17-pole male plug, straight type

Mini Coder Gel 2442 - Connection type B = 17-pole male plug, elbow type

Important: Fit the cable screening as coaxially to the earth cable as possible. When fitting the cable screening onto an earth cable, the earth cable should be run as short as possible.

Mini Coder Gel 2442 Examples and Table - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

The examples illustrated show different ways of connecting the cable screen. Depending on the control type and the connecting cable used, a different screen connection may be necessary.

_ _ _ = Cable length (cm)

For connection type K= cable end open, 4 cable length are available: 30, 150, 250, 600 cm. For ready-made connecting cables with male connectors, the length of the cable is to specified in cm.

Cable type: PUR cable 9 x 0.15 mm2 screened
Screen not connected on MiniCoder side
Outside diameter: 5 mm ( 0.3)
Min. bending radius: 25 mm

M = cable for temperature sensor (2 m)

Variants A and B (see page 7) can be delievered on request with the cable for the temperature sensor connected to the mating connector.


Cable type: TEFLON cable 9 x 0.14 mm2
Outside diameter: 2.8 mm (+ 0.1)
Min. bending radius: 20 mm E-= Additional screen connection on sensor head.

This screen connection is connected to the screen of the sensor cable. In order to improve electromagnetic compatibility (EMC), the screen connection should be connected to the flange on which the MiniCoder is mounted.

Custom-made target wheels, Standard target wheels

Custom-made target wheel

Target wheel are made to individual specifications on request of the customer. Please send us a dimensional drawing of your target wheel (if possible, as a dxf-file) the inquiry form on page a 11 to info@lenord.de.

Target Wheels

For detecting rotary movements, the MiniCoders and target wheels form a complete unit. The target wheel size and hence , its diameter are directly dependent on the module and the number of teeth, i.e.:

z = (da/ m) - 2

da = m (z+2)

Standard target wheels (see table) are available at short notice ex factory.

Table - standard target wheels
Number of teeth
z
module
m
[mm]
OD - Θ
da
[mm]
ID - Θ
standard
[mm]
ID - Θ di max.
[mm]
collar - Θ
dr
[mm]
100 0.5 51.0 12 H7 30 H7 47
125 0.5 63.5 12 H7 35 H7 60
128 0.5 65.0 12 H7 35 H7 61
200 0.5 101.0 12 H7 70 H7 97
250 0.3 75.6 12 H7 45 H7 72
250 0.5 126 25 H7 85 H7 122
256 0.3 77.4 12 H7 50 H7 74
256 0.5 129 25 H7 90 H7 125
360 0.3 108.6 25 H7 70 H7 105
500 0.3 150.6 25 H7 110 H7 147
512 0.3 154.2 25 H7 110 H7 151


Mini Coder Gel 2442 - Dimensional Drawing Target Wheel - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Type code for standard target wheels Mini Coder Gel 2442 Target Wheel typecode - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Mechanical Data - Custom-Made Target Wheels

Mini Coder Gel 2442 Target wheels - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Mini Coder Gel 2442 Mounting Bores - Lenord & Bauer Rail Speed Sensors and Rotary Pulse Encoders

Lenord & Bauer: Rail Speed Sensors & Rotary Pulse Encoder

Other products relating to GEL 2442 are: GEL 2432, GEL 2443, GEL 2444