Sensors Applications
Volume 1
Sensors in Manufacturing
Sensors in Manufacturing. Edited by H. K. Tönshoff, I. Inasaki
Copyright © 2001 Wiley-VCH Verlag GmbH
ISBNs: 3-527-29558-5 (Hardcover); 3-527-60002-7 (Electronic)
Sensors Applications
Upcoming volumes:
· Sensors in Intelligent Buildings
· Sensors in Medicine and Health Care
· Sensors in Automotive Technology
· Sensors in Aerospace Technology
· Sensors in Environmental Technology
· Sensors in Household Appliances
Related Wiley-VCH titles:
W. Göpel, J. Hesse, J. N. Zemel
Sensors Vol. 1–9
ISBN 3-527-26538-4
H. Baltes, W. Göpel, J. Hesse
Sensors Update
ISSN 1432-2404
Sensors in Manufacturing. Edited by H. K. Tönshoff, I. Inasaki
Copyright © 2001 Wiley-VCH Verlag GmbH
ISBNs: 3-527-29558-5 (Hardcover); 3-527-60002-7 (Electronic)
Edited by
H. K. Tönshoff, I. Inasaki
Series Editors:
J. Hesse, J.W. Gardner, W. Göpel
Sensors Applications
Volume 1
Sensors in Manufacturing

Prof. I. Inasaki
Faculty of Science & Technology
Keio University
3-14-1 Hiyoshi, Kohoku-ku
Yokohama-shi
Japan
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the British Library.
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Bibliothek
© WILEY-VCH Verlag GmbH
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now an indispensable part of many industrial processes and systems. It is timely,
therefore, to launch a new series, Sensors Applications. WILEY-VCH again commis-
sioned Wolfgang Göpel and Joachim Hesse to plan the series, but sadly Wolfgang
Göpel suffered a fatal accident in June 1999 and did not live to see publication.
We are fortunate that Julian Gardner of the University of Warwick has been able
to take his place, but Wolfgang Göpel remains a co-editor posthumously and will
not be forgotten.
The series of Sensors Applications will deal with the use of sensors in the key
technical and economic sectors and systems: Sensors in Manufacturing, Intelligent
Buildings, Medicine and Health Care, Automotive Technology, Aerospace Technology,
Environmental Technology and Household Appliances. Each volume will be edited by
specialists in the field. Individual volumes may differ in certain respects as dic-
tated by the topic, but the emphasis in each case will be on the process or system
in question: which sensor is used, where, how and why, and exactly what the ben-
efits are to the user. The process or system itself will of course be outlined and
V
Preface to the Series
Sensors in Manufacturing. Edited by H. K. Tönshoff, I. Inasaki
Copyright © 2001 Wiley-VCH Verlag GmbH
ISBNs: 3-527-29558-5 (Hardcover); 3-527-60002-7 (Electronic)
the volume will close with a look ahead to likely developments and applications in
the future. Actual sensor functions will only be described where it seems neces-
sary for an understanding of how they relate to the process or system. The basic
principles can always be found in the earlier series of Sensors and Sensors Update.
The series editors would like to express their warm appreciation in the col-
leagues who have contributed their expertise as volume editors or authors. We are
deeply indebted to the publisher and would like to thank in particular Dr. Peter
Gregory, Dr. Jörn Ritterbusch and Dr. Claudia Barzen for their constructive assis-
tance both with the editorial detail and the publishing venture in general. We
trust that our endeavors will meet with the reader’s approval.

· Environmental consciousness in the manufacturing of today requires monitor-
ing emissions from the process.
This book deals with monitoring technologies in various manufacturing pro-
cesses, and aims to provide the latest developments in those fields together with
VII
Preface to Volume 1 of “Sensors Applications”
the necessary principles behind these developments. We are convinced that the
readers of this book, both in research institutes and in industry, can obtain infor-
mation necessary for their research and developmental work.
The editors wish to thank the specialists who contributed their expertise and
forbearance during the various stages of preparation. In addition to the assistance
of the authors, we would like to thank the staff of Wiley-VCH for their support.
Hannover and Yokohama, November 2000 Hans Kurt Tönshoff
Ichiro Inasaki
VIII
Preface to Volume 1 of “Sensors Applications”
List of Contributors
XVII
1 Fundamentals
1
1.1
Roles of Sensors in Manufacturing and Application Range
1
I. Inasaki, H. K. Tönshoff
1.1.1
Manufacturing
1
1.1.2
Unit Processes in Manufacturing
2

17
1.2.3.3
Electrical Sensors
17
1.2.3.4
Magnetic Sensors
18
1.2.3.5
Radiant Sensors
18
1.2.3.6
Chemical Sensors
18
1.2.4
New Trends – Signal Processing and Decision Making
19
1.2.4.1
Background
19
1.2.4.2
Sensor Fusion
21
1.2.5
Summary
23
1.2.6
References
23
1.3
Sensors in Mechanical Manufacturing – Requirements, Demands,

Digital Signal Processing
36
1.3.6
Identification and Decision Making
39
1.3.6.1
Strategy of Identification and Decision Making
39
1.3.6.2
Pattern Recognition
40
1.3.6.3
Neural Networks
41
1.3.6.4
Fuzzy Reasoning
42
1.3.7
Communication and Transmission Techniques
43
1.3.8
Human-Machine Interfaces
44
1.3.9
References
45
2 Sensors for Machine Tools and Robots
47
H.K. Tönshoff
2.1

Protractors
73
3.1.1.3
Micrometer Gages
73
3.1.1.4
Dial Gages
75
3.1.1.5
Dial Comparators
76
3.1.1.6
Lever-type Test Indicators
76
3.1.2
Electrical Measuring Methods
76
3.1.2.1
Resistive Displacement Sensors
77
3.1.2.2
Capacitive Displacement Sensors
77
3.1.2.3
Inductive Displacement Sensors
78
3.1.2.4
Magnetic Incremental Sensors
81
3.1.2.5

3.1.5.2
Shadow Casting Methods
91
3.1.5.3
Point Triangulation
91
3.1.5.4
Light-section Method
92
3.1.5.5
Fringe Projection
93
3.1.5.6
Theodolite Measuring Systems
93
3.1.5.7
Photogrammetry
94
3.1.5.8
Interferometric Distance Measurement
94
3.1.5.9
Interferometric Form Testing
95
3.1.5.10
Autofocus Method
96
3.1.6
Pneumatic Measuring Systems
96

104
3.2.2.4
Grazing Incidence X-ray Reflectrometry
105
3.2.3
Probe Measuring Methods
106
3.2.3.1
Scanning Electron Microscopy (SEM)
107
3.2.3.2
Scanning Tunneling Microscopy (STM)
108
3.2.3.3
Scanning Near-field Optical Microscopy (SNOM)
110
3.2.3.4
Scanning Capacitance Microscopy (SCM)
111
3.2.3.5
Scanning Thermal Microscopy (SThM)
111
3.2.3.6
Atomic Force Microscopy (AFM)
113
3.2.3.7
Magnetic Force Microscopy (MFM)
117
3.2.3.8
Lateral Force Microscopy (LFM)

Force Sensors
126
Contents
XI
3.3.3.2
Power Sensors
128
3.3.3.3
Temperature Sensors
129
3.3.3.4
Acoustic Emission Sensors
131
3.3.4
Sensors for Tools
134
3.3.5
Sensors for Workpieces
136
3.3.5.1
Eddy-current Sensors
136
3.3.5.2
Micro-magnetic Sensors
137
3.3.6
References
141
4 Sensors for Process Monitoring
143

Mixing and Blending of Metal Powders
159
4.1.2.3
Compacting of Metal Powders
162
4.1.2.4
The Sintering Process
166
4.1.2.5
References
171
4.2
Metal Forming
172
E. Doege, F. Meiners, T. Mende, W. Strache, J. W. Yun
4.2.1
Sensors for the Punching Process
172
4.2.1.1
Sensors and Process Signals
173
4.2.1.2
Sensor Locations
174
4.2.1.3
Sensor Applications
176
4.2.2
Sensors for the Sheet Metal Forming Process
181

4.3
Cutting Processes
203
I. Inasaki, B. Karpuschewski, H.K. Tönshoff
4.3.1
Introduction
203
ContentsXII