1、FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 1 1. GENERAL: 1.1 This Standard describes the requirements for switching type proximity sensors intended for general use throughout Ford Motor Company. 1.2 1.3 1.4 1.5 Definitions shall be per NEMA Standard ICS 2-229. 1.6 Other st
2、andards referenced in this document include the following: This Standard includes and supplements the requirements of NEMA ICS 2-229, “Proximity Switches“, type 1, non-beam break, sensing class .Ol, inductive, dimensional class .Ol, cylindrical, styles IC12, IC18 and IC30, and dimensional class .02,
3、 rectangular, styles IR35, IR40 and IR80. Other types, classes and styles are not included. All of the requirements of ICS 2-229 shall apply. Use of the word “shall“ herein is understood as a requirement; the word “should“ as a recommendation. Proximity sensors intended for hazardous locations shall
4、 conform to Underwriters Laboratories Standards (UL) and/or Factory Mutual Standards (FM) for such service. - UL 508, Industrial Control Equipment. - NEMA ICS 2-229, Proximity Switches. - NEMA ICS 2-230, Components for Solid-State Logic Systems. - NEMA FBl, Fittings and Supports for Conduit and Cabl
5、e Assemblies. - Ford Manufacturing Standard M-3C83A, Soluble Oil - Petroleum Base. - Ford Manufacturing Standard M-6C12A, Fire Resistant Hydraulic Fluid. 2. ENCLOSURES: 2.1 Proximity sensors shall withstand five cycles (of five seconds with a five inch flame and five seconds without) and shall extin
6、guish itself within one (1) minute, with no drip and no degradation of enclosure integrity per UL 508. 2.2 1 Impact resistance shall be 6.785 (5ft-lbs) per UL 508, Industrial 1 Control Equipment. Crush resistance shall be 445N (100 lbf) per UL 1 508. 2.3 Gasket material shall be impervious to solids
7、 and fluids normally encountered in industrial service. See Section 7.4.1, Environmental Testing. FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 2 2.4 Dimensional styles R40 and R80 shall include the following additional requirements: 2.4.1 Mounting holes for the style R40 sen
8、sor shall be external to the compartment enclosing the basic sensor or terminal blocks and shall be located as specified in Figure 1 (page 5). The holes shall be accessible from the outside without removal of the sensor cover. Hole diameter shall accommodate not less than a number lo/32 socket head
9、cap screw. 2.4.2 2.4.3 2.4.4 2.4.5 The sensor shall have a tapered threaded opening for one-half inch standard pipe thread conforming to NRMA FBl, Fittings and Supports for Conduit and Cable Assemblies. The conduit entrance shall withstand a torque of 22.6 Nm 200 lb-in per UI. 508. Adequate wiring s
10、pace shall be provided to terminate the conductors. Terminals shall accommodate type MTW conductors, AWG 16, 65 strands, through AWG 14, 19 strands. The conductor strands shall be clamped between two non-rotating surfaces. A saddle or pressure plate shall be captive to and ride with the terminal scr
11、ew. A green grounding screw with a saddle or pressure plate shall be provided within the sensor enclosure and shall be accessible for wiring, where applicable. Exception: The ground symbol is acceptable alternate to green color on screw. An embossed bulls-eye or permanent scribe on the sensing surfa
12、ce shall indicate the center of the sensing surface to show proper sensing direction. 2.4.6 Means in addition to the retaining screws shall be provided to prevent rotational movement of removable sensing heads. 2.4.7 The sensing head and enclosure cover retaining screws and gaskets shall be captive
13、to their respective parts. 3. INDICATORS: A light source indicator shall be provided and be visible through but not protrude above the enclosure. The indicator shall be illuminated when the target is present or the output device (thyristor, SCR, reed) is conducting, but under no other condition. An
14、additional indicator for “Power On“ is also acceptable, but not required. FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 3 4. 4.1 4.2 5. 5.1 5.2 6. SENSITIVITY AND SHIELDING: 6.1 Output ratings of switching type proximity sensors shall conform with ICS 2-229. Nominal operating
15、 distances (Sn) shall be 2 mm (1 in), 5 mm (0.2 in) and 10 mm (0.4 in) respectively as specified for classes IC12, IC18 and IC30. Class IR35, IR40 and IRS0 shall have nominal operating distances (Sn) of 10 mm (0.4 in), 10 mm (0.4 in) and 40 mm (1.6 in) respectively. 6.2 6.3 NOMINAL INPUT RATINGS: Th
16、e supply voltage shall be a nominal 120 VAC, 60 Hz unless otherwise specified. DC types may be supplied where specified in writing by the requisitioning activity. The sensor shall operate in compliance with this Standard over a voltage range of +lO% to -15% of the nominal supply voltage. This voltag
17、e range may be the result of gradual or instantaneous supply variations. OUTPUT RATINGS: Leakage current shall not exceed 1.7 mA rms when connected to a load impedance of 10k ohms or higher, and not greater than 2.0 mA rms when connected to a lower impedance, within the supply voltage range specifie
18、d in Section 4.0. Outputs shall be capable of controlling an inductive load operating at 0.90 Amperes inrush current with a 45% power factor, and 0.18 Amperes sealed at 26% power factor within the supply voltage range specified in section 4.0. Metal masses adjacent to any side of the sensor, other t
19、han the sensing surface, shall not have any effect on its state of operation. Exception: IR 80 style. Current or voltage transients or electromagnetic interference (EMI) caused by adjacent devices (e.g.: solenoids, transformers, welders or induction heaters), or radio frequency interference (RFI) pi
20、cked up by wiring connected to the proximity sensor shall not cause spurious operation or affect the design efficiencies of the sensor output. Operation shall not be affected when subjected to the electrical noise immunity tests (except 50 micro second rise time) as outlined in NEMA Standard ICS 2-2
21、30. FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 4 6.4 Proximity sensors shall be capable of being mounted side-by-side (on centers greater than three times the width of the sensing surface) without affecting sensing distance or creating interference. 6.5 Sensors mounted wit
22、h their sensing surfaces directly opposite each other, but no closer than six times the nominal sensing distance (Sn x 6) shall not affect the operating characteristics of either sensor. 6.6 Proximity sensors shall be immune to radio frequency interference (RFI) as outlined in the following paragrap
23、hs. They will be tested for sensitivity in the 27, 150, 410, 465 and 800 MHz communication bands. 6.6.1 6.6.2 6.6.3 6.6.4 6.7 6.8 The RF1 tests will be conducted with a typical hand-held transceiver having a rated power of five watts (batteries fully charged). The tests will be performed with the ta
24、rget at the nominal sensing distance (Sn), and also at 200% of the distance (Sn x 2.0) (non-conducting state) from the sensor. The test will be conducted with the proximity sensor connected to a programmable controller input rated 120 volts AC, causing a current flow of 6 to 25 mA. A relay coil or l
25、amp is not acceptable as an alternate load. The test will be performed with the switch in both the non-conducting and conducting states. With the circuit described in 6.6.3 fully operational, the switch shall not turn ON when no target is present, or turn OFF when a target is present, when the trans
26、mitter is keyed and the antenna is held parallel, within 6.3 mm (0.25 in), to any part of the sensor body except the sensing face. The antenna will then be moved parallel to and within 6.3 mm (0.25 in) of the cable or wiring conductors connected to the sensor for a distance of four feet along the ca
27、ble without causing switch operation. There shall be no output pulse from the proximity switch per ICS 2-229 when power is applied or is disconnected, when target is in position as described in section 6.6.2. No means shall be provided on the sensor to change the nominal sensing distance (Sn) as mea
28、sured from the sensing face. FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 5 7. RELIABILITY TEST: 7.1 Four proximity sensors of the same make and model shall achieve a minimum life of 30 million operations without adjustment or repair. Two sensors will be tested with ferrous
29、targets and two with aluminum targets. 7.2 The test will be conducted at approximately 360 operations per minute with the load as specified in section 5.2. Operation will be obtained from a rotating shaft at 90 rpm, with four standard metal targets 19 mm x 140 mm (0.75 x 5.5 in), 1.5 mm (0.060 in) t
30、hick mounted on a plastic disc 325 mm x 19 mm (12.75 x 0.75 in) thick. Target distance from the sensor will be the nominal sensing distance (Sn) for ferrous targets and 50% Sn for nonferrous (aluminum) metallic targets. 7.3 Tolerance to environmental conditions shall meet or exceed those specified i
31、n ICS 2-229 including -20 C to +70 C. 7.4 Two sensors will be installed in a heat chamber at +70 C and two in a liquid spray chamber at ambient temperature. When the life of the sensors has reached 15 million operations, they will be changed to the opposite environmental chamber for the next 15 mill
32、ion operations. 7.4.1 DURING TEST, THE SENSORS WILL BE SUBJECTED TO THE FOLLGWING: 7.4.2 a) Oil and cutting compounds (M-3C83A)* b) Hydraulic fluids (M-6C12A)* * See Ford Manufacturing Standards (Section MC). Two additional switches will be checked for proper operation and then immersed in cutting o
33、il (M-3C83A) for a period of thirty days. At the completion of the soak test, the switches will again be tested for proper operation. 7.5 Sensors will be vibration tested from 5 to 100 Hz in each of three mutually perpendicular axes, with an excursion of .75 mm (0.030 in) peak to peak and a sweep ti
34、me of 5 minutes, logarithmic ramp. The total loading will not exceed 5.5 Gs for a maximum of one minute. The sensor output shall not change state during this test. FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 6 7.6 Before sensors will be accepted for retest after a failure,
35、the supplier shall provide evidence of appropriate modifications or redesign in writing which precludes the previous failure. m 9007LbCl llll53558 b-t0 m FORD MANUFACTURING STANDARDS ES2 JUNE 1994 PROXIMITY SENSORS ES2 Page 7 Figure 1. Dimensions (Rectangular IR40 Only) inches (millimeters) F- 1 c +
36、 ALTERNATE SENSING SURFACE POSITIONS . ,201 DIA. (2) HOLES (5.1) - l/2 N.P.T. SENSING SURFACE r I I V-1.63 -4 (41.5) MAX. t 1 (1 c 1.00 (25.4) f E ( A- ! I 4.72 L20s0) Dimensions (Rectanaular IR40 Onlv inches (millimeters) Unless otherwise specified, tolerances are +/- 1 of the last digit shown, FOR
37、D MANUFACTURING STANDARDS ES2 JUNE 19% PROXIMITY SENSORS ES2 Page 8 Figure 2. Dimensions (Cylindrical) millimeters Sensing face Across flats SW - Dimensions (Cvlindrical) millimeters Form Bodv Nut d -1 iI min I, max m (+/- 0.15) SWh12 & max 1) IC12 M12xl zi 80 4 20 IC18 M18xl 100 4 28 IC30 M30x1.5 50 100 36 5 42 I d3 min. = 1.13 SW Unless otherwise specified, tolerances ore +/- 1 of the last digit shown. I 1 NOTE: Denotes area of change in previous issue. I
