Draw Wire Sensors - Applications

Draw wire sensors are used throughout industry and research. They are easily mounted and can be installed subsequently. WayCon’s wide product range of draw wire sensors can be configured for many different applications.

Typical areas of application of these sensors are: automated gates, floodgates, packaging industry, cutting plants, welding plants, mobile cranes, lift truck and scissors lifts.

More information about the measurement principle of draw wire sensors can be found on this subpage. An overview of the characteristics of draw wire sensors can be found here.

Draw Wire Transducer - stroke measurement

Forklift trucks are commonly used, where a large quantity of goods have to be stored at limited space. Especially in logistics centres storage racks with a height of 12 to 50 m are used. Through this the storage space is expanded to support hundreds of thousands pallet bays. A forklift truck manoeuvres these pallets through narrow hallways and stack them at the intended spaces. To ensure the smooth and secure storage of the pallets, the control of the forklift have to be carried out by a sensor.

Our draw wire sensor SX80 is used to monitor the stroke of the forklift and allows the precise positioning of the pallets. This guarantees that the pallets don’t damage the goods or the racks.

Draw Wire Transducer - embankment dam

Embankment dams help to store large water quantities. They have to withstand considerable water pressure, while allowing a certain water flow. The “Three Gorges Dam” in the Yangtze River in China is a good example for this. It is located near the town of Sandouping approx. 40 km upriver in the province of Hubei. The hydroelectric power station in the dam is the largest in the world and generates 22.5 GW.

The monitoring of the floodgates is essential for the save operation of the dam. The floodgates are opened and closed by hydraulic cylinders, that have to withstand the considerable water pressure. Draw wire transducers like the SX300 are used to measure the stroke of these hydraulic cylinders. Draw wire sensors can control and monitor the traverse speed directly inside the cylinder. Due to the pressure-tight case of the SX300, the transducer can be mounted on the front side of the cylinder. The draw wire is extended with the piston of the cylinder. The draw wire is coiled single-layered, which allows the conversion from a linear movement into a rotary movement. This rotation is directed into the pressure-free area and detected by an encoder.

Draw Wire Transducer - wind turbine

The blades of wind turbines have to withstand powerful wind in a height of 60 m above ground. To withstand this stress the blades are tested thoroughly. During these tests an increasing force is applied to the blades. Draw wire transducers are used to detect the bending of the blades. For this draw wire sensors are mounted to the blade at multiple point with extended draw wire. Due to this the bending is detected across the whole blade. The results of this measurement will be outlined in an FEM model, which will be used for the optimal construction of the rotor.

Draw Wire Transducer - mobile crane

Mobile cranes transport heavy loads at construction sites. The advantages over stationary cranes are that the can be deployed more time-efficiently and cost-efficiently. They also need less room than stationary cranes.

The draw wire sensors SX120 and MH120 are used to measure the load torque to prevent the cranes from turning over.

The extension of the crane supports is calculated with values measured by the draw wire sensors. Other values like crane height, the rotation angle and lifting load are important for the calculation of the extension. The correct calculation is essential for the compliance of the guide values. These guide values and the usage of redundant draw wire sensors ensure the safety of people and equipment.

Position measurement at MRI scanner

Cameras of MRI scanners create high resolution pictures from five different angles. These angles arise from: horizontal camera position, horizontal table position, vertical table position, the height position of the X-ray tube and the height position of the camera. Draw wire sensors register these positions, so that the control system of the X-ray machine can align the X-ray tubes according to the camera. The pictures are created digitally and fully automated, due to this the monitoring of the positions through sensors is essential.

Ship salvage

After a ship accident the retrieval is a difficult and costly procedure. The wrecked ship has to be erected evenly, otherwise it might overturn again or burst. To erect a ship air tanks can be mounted to the ship to correct the incline. Even a sunken ship or submarine can be retrieved that way.

Draw wire transducers are used to measure the position of these air tanks. The sensors ensure that the wrecked ship is erected evenly.

Raising of a building

To increase living space, houses might be raised to increase the height of a cellar. This method is more cost-efficient than the construction of new buildings. Also the clearance can be adjusted which is used to correct constructional requirements.

To raise a house, hydraulic lifting platforms are installed in the cellar. It is very important to raise the building evenly, otherwise it might be damaged. To guarantee this draw wire transducers are used in the hydraulic cylinders to measure the stroke.

Optimization of sports equipment

Sports equipment serve to improve to health and fitness of the user. It is of great importance that the equipment does not demand too little or too much from the user. The optimal demand can be controlled via data measured by position sensors. Draw wire transducers measure the movement patterns, which will be analysed in subsequent systems. In combination with force sensors the data is used to optimize the exercise.

Especially top athletes need these optimizations.

Automated cutting and supply machinery

In today’s automation, positioning systems are indispensable. An example for this is automated cutting and supply machinery. For the positioning WayCon developed the SX draw wire sensors. These allow the reliable positioning of production or sawing parts even in harsh environments. The need for maintenance can be registered earlier and the automation by means of sensors and control units saves time.

The draw wire transducers SX are more robust and compact than other sensors. This makes them perfect for harsh environments. Despite the small housing of the SX sensors, they come equipped with dual industrial ball-bearings and are ideally suited for high cycle numbers. The robust mechanic and high-quality electronic guarantee the permanent use even with a requirement of protection class IP67.

Lifting of bridges

Bridges and especially their supports are under a continues load. This leads to constant maintenance. To renew the support, the bridge need to be lifted. The lifting needs to be carried out equally and synchronised, because even small displacement can damage the bridge.

Draw wire transducers monitor and control the lifting motion of the hydraulic lifts. The sensors measure the stroke of the hydraulic cylinders and displacements are registered in time to prevent damage. The stroke measurement takes place inside the hydraulic cylinders.


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