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The sensor for precise thickness measurements of plastics

In its sensor housing, the combiSENSOR combines an eddy current displacement sensor and a capacitive displacement sensor. This unique sensor concept enables one-sided thickness measurement of electrically non-conductive materials on metallic objects. Its field of application is the thickness measurement of plastic film or of plastic coating on metal plates. Connected to the sensor via a cable, the controller processes and calculates the signals in order to put them out via interfaces.
Unit of Measure

Specifications

Controller Model

 N/A KSS6420 KSS6430
Maximum Offset Measuring Range1 N/A 5 mm
Analog Bandwidth2 N/A 1 kHz3 dB

Adjustable Digital Bandwidth

 N/A 2.6 to 3900 Sa/s

Linearity Full Scale Output (FSO)

 N/A ±0.05 %

Direct Current (DC) Power Supply

 N/A 12 to 36 V4.5 W

Trigger Voltage

 N/A 5 V

Trigger Type

 N/A Transistor-Transistor Logic (TTL)

Target Geometry

 N/A Minimum Diameter 200 mm (Reference material ground electrode: VA steel (1.4571) or aluminum. Changes of the ground electrode (material or geometry) require a recalibration of sensor and controller by the manufacturer.) Straight Surface
Minimum Target Thickness3 N/A 40 µm

Maximum Target Thickness

 N/A 3 mm

Minimum Diameter Measurement Surface

 N/A 45 mm

Sensor Protection Class

 N/A Ingress Protection (IP54)

Controller Protection Class

 N/A Ingress Protection (IP40)

Sensor Weight

 N/A 80 g

Controller Weight

 N/A 750 g

SCAC3/5 Connector

 N/A Signal Output (5-Pole Plug)

Web Interface

 N/A The web interface for sensor and controller configuration opens via Ethernet.

Calculation of the Dielectric Constant

 N/A If the thickness of the Insulator D and the offset distance from the ground electrode are known, the controller calculates the dielectric constant of the insulator.

Thickness Measurement

 N/A If the dielectric constant εr and the offset distance from the ground electrode are known, the controller calculates the insulator thickness D from the sensor signals.

Resolution

Static Resolution at 100 Hertz (Hz) Full Scale Output (FSO) for KSS6420 Controller

 N/A 0.0018 %

Static Resolution at 100 Hertz (Hz) Full Scale Output (FSO) for KSS6430 Controller

 N/A 0.0004 %

Dynamic Resolution at 3.9 Kilohertz (kHz) Full Scale Output (FSO) for KSS6420 Controller

 N/A 0.0075 %

Dynamic Resolution at 3.9 Kilohertz (kHz) Full Scale Output (FSO) for KSS6430 Controller

 N/A 0.0015 %

Note for Resolution

 N/A Difference signal of the digital output, measured with offset distance = 50% FSO

Temperature Stability

Sensor Temperature Stability

 N/A 10 to 60 ºC± 50 ppm

Temperature Stability for KSS6420 and KSS6430 Controllers

 N/A ± 50 ppm

Temperature Range

Controller Operating Temperature

 N/A 10 to 60 ºC

Sensor Operating Temperature

 N/A -10 to +85 ºC

Sensor Cable Operating Temperature

 N/A -10 to 125 ºC

Sensor Cable Storage Temperature Range

 N/A -10 to 100 ºC

Controller Storage Temperature

 N/A 0 to 75 ºC

Output

Analog Output

 N/A Capacitive, Eddy Current and Differential Signal: 0-10V (Short Circuit Proof) Internal Sensor Temperature Signal (Not Scaled)

Ethernet Output

 N/A Capacitive, Eddy Current, Differential and Internal Temperature Signal: 24Bit

EtherCAT Output

 N/A Capacitive, Eddy Current, Differential and Internal Temperature Signal: Float

Dimensions

Controller Width

 N/A 75 mm

Controller Length

 N/A 125 mm

Controller Height

 N/A 90 mm

Sensor Diameter

 N/A 30 mm

Sensor Height

 N/A 26 mm

Overall Sensor Height

 N/A 37 mm

Scope of Supply

Scope of Supply

 N/A
  • KSH sensor
  • Sensor cable 1 m
  • Controller
  • PC6200 3/4 supply and trigger cable (3 m)

Accessories

Accessories

 N/A SCAC3/5 signal output cable analog (3 m)

Features

Features

 N/A
  • One-sided thickness measurement in one axis
  • Integrated temperature measurement
  • Special plug for fast sensor connection
  • Thickness measurement based on εr
  • Determination of εr with known thickness
  • Ease of use via web interface

Application

Application

 N/A
  • Non-contact thickness measurement of plastic films
  • Non-contact thickness measurement of coated metals
  • Measurement of the applied adhesive
  • Lateral profile due to a traversing axis

Additional Information

Additional Information

 N/A Calculation of the two sensor signals provides compensation of mechanical changes such as thermal expansion, deflections or eccentricity in the measurement device. Due to the redundancy of this combined sensor principle, the measured thickness value remains unaffected by any changes in the measurement setup. Due to the high temperature stability, the combiSENSOR provides high measurement accuracy even with fluctuating temperatures.

Measuring principle
The construction of the eddy current measurement coil and the capacitive measurement electrodes is concentric. Both sensors measure against the same spot. The signal of the capacitive displacement sensor is a function of the offset, the thickness of the insulator (D) and the dielectric constant of the insulator material (εr). At the same time the eddy current displacement sensor measures the distance to the ground electrode (e.g. metal sheet or metal roller positioned behind the film). The controller outputs both single signals as well as the difference between capacitive sensor and eddy current sensor. Also the dielectric constant can be calculated with known thickness and offset distance.
  • 1 The ideal offset distance is between 40 and 90% FSO
  • 2 Only valid when sampling rate = 3900 Sa/s
  • 3 Insulator thickness below 40µm on request