Help Identifying the spindle speed proximity sensor

[Jim Caudill]

I posted this question as an "add-on" to another topic involving spindle syncronization. I then realized that I might get a better response if my question wasn't buried in an older post.

I have a KM3-P with the BX controller (one of a few made). I have determined that my proximity sensor is bad and am trying to obtain a new one. The main stumbling block is whether it is an NPN or PNP. I know the body is 8mm in diameter and aproximately 50mm long with 3 wires exiting the sensor (blue, black, & brown). There are no other markings other than the insulator at the end of the sensor is green in color. Since the voltage going to the sensor is 15vdc, I am assuming that a 10-30vdc sensor will work. A Turck or other brand part number would be great. The only numbers I can find in my Hurco documentation is "4PRS" for this sensor.

Any help would be greatly appreciated.

Wiring diagram: the numbers refer to pins on the edge connector of the spindle servo card
Blowup of relevant section:

Spindle card by Voltak:
Installed:

Actual sensor:

[Al_The_Man]

Looks PNP shielded type.
The only thing that is unknown, unless you know the result when actuated is if it is N.C. or N.O. most are N.O. and the diagram also shows N.O. if drawn correctly.
In a pinch you could find it out by simulating the input by disconnecting the present switch and jumper from the + to the input with a Push button etc.
Turk, Omron, Allen-Bradley, Honeywell are some substitute options.
Al.

[Al_The_Man]

My Turk catalogue is a bit dated but they show a 8mm x 30mm 1-G08k-AP6X N.O. PNP
This is about the fastest they make at 5000Hz.
10v-30vdc.
Al.

[Jim Caudill]

Al, you're the man! I really appreciate your input. Just in the way of expanding the Hurco knowledgebase, here is what has been deduced:
The Hurco speed sensing proximity sensor is a barrel that is 8mm in diameter and aprox 50mm long with 3 wires (blue, brown, & black) coming out of the back. The sensor is connected to a 15vdc circuit and is NO (normally open). It is functioning as a PNP device and sensing "gear teeth" mounted on the spindle shaft. The number of teeth on the gear is 30, and thus will produce 120,000 pulses per minute when the spindle is at its maximum of 4,000 rpm. Since the sensor are rated in hz, dividing 120,000 by 60 produces a pulse rate of 2khz. I didn't measure the distance between the sensor and the gear teeth, but would estimate it to be around .020" (or .5mm). Standard sensing range for most 8mm barrels is 1.5mm, so no extra sensing range is required. Typical DC voltages for these sensor is 10-30vdc, so most any of them will work for this 15vdc application.

In summary, 10-30vdc, PNP, NO, 8mm diameter, under 50mm long, normal sensing range (1.5mm), at least 2khz switching, with 3 wire epoxied lead (they are normally 2meters long - but only has to be 2feet long).

Pics showing the angle bracket for mounting the sensor and the spindle gear with 30 teeth:


Overview of gaining access to the sensor:111111 Wiring connections for the sensor:
11111

Location of the connector:

[Jim Caudill]

I ordered from a company in Georgia called "Automation Direct". Their part number is AE1-AP-1A and cost $18.50 plus shipping. They indicate the part is made in Italy and is in-stock for immediate shipment.

Here are some equivalent part numbers:
Turck - Bi 1.5-EG08-AP6X catalog #S4602240
Omron - E2E-X1R5F1-N (SS)
Pepperl & Fuchs - NBB1.5-8GM50-E2
Sick Optic - IM08-01B5PS-ZW1
Siemens - 3RG40 11-0AG05 (SS)

This is a 3khz switching, PNP, NO, 10 to 30vdc, stainless steel, inductive sensor, 8mm in diameter, 40mm long, with a potted 2 meter long 3-wire cable.

It also has a signal LED in the base which will not be visible once installed.

The Turck sensor from my supplier was $92.76 plus shipping and a 1 week wait.

PLC direct wanted around $93 for the sensor also.

[skullworks]

Note those holes on either side of the Quill ballscrew. They go thru to the ram dovetail. Blowing off parts will allow "Chips" to get into this ballscrew area.

On the KM3 and KM3P mills I worked on we fitted some scotchbrite pads as filters for these holes to keep stuff out but allow it to breathe.

I was doing alot of Poco (EDM Tungsten graphite) and G10 parts and I did not want that dust anywhere near that ballscrew.

You might want to look into plugging these for your own peace of mind.



( To the OSHA weenies, Long Last the Open machines! )

[dan_barber]

Originally Posted by Jim Caudill I ordered from a company in Georgia called "Automation Direct". Their part number is AE1-AP-1A and cost $18.50 plus shipping. They indicate the part is made in Italy and is in-stock for immediate shipment. Here are some equivalent part numbers: Turck - Bi 1.5-EG08-AP6X catalog #S4602240 Omron - E2E-X1R5F1-N (SS) Pepperl & Fuchs - NBB1.5-8GM50-E2 Sick Optic - IM08-01B5PS-ZW1 Siemens - 3RG40 11-0AG05 (SS) This is a 3khz switching, PNP, NO, 10 to 30vdc, stainless steel, inductive sensor, 8mm in diameter, 40mm long, with a potted 2 meter long 3-wire cable. It also has a signal LED in the base which will not be visible once installed. The Turck sensor from my supplier was $92.76 plus shipping and a 1 week wait. PLC direct wanted around $93 for the sensor also.

It looks like a Datasensor. Datasensor brand sensors are manufactured by Datalogic an Italian Company that private label lot of well known sensors. Their sensors are very cheap. IDEC is the rep firm in the USA.