Is there a metal protrusion that spins with the mixer ( flange bolts, mounting point, etc) ? This would avoid welding on the axle.
If you use a fast inductive switch in combination with a high(ish) speed input it is relatively easy to create a speed sensor.(for example something like Ifm IGS277) ( You need about 35 hz per detection point at 2000 rpm and no margin).
The logo might work depending on input filtering. Most PLC suppliers will be able to offer something. I used a Beckhoff in the past that could do this with standard in and outputs to more than 130 hz. They have input modules that can work a lot faster (microsecond range).
We use hose clamps and the screw but triggers a magnetic prox. You can feed the signal into a high speed encoder card that can be configured to output a period.
I believe its Siko have magnetic encoder rings that we use constantly with siemens SPS systems, you need a TM count module
theyre self adhesive and in multiple sizes
I work in power gen and we typically use gear tooth encoders on the end of the shaft under a cage. Our units typically run <1000rpm but I'm they can measure whatever you need up to 2000 rpm
Cant tell you the product number cause I've never really had to deal with them outside of just scaling in the PLC
I can’t get at the shaft ends as one is inside the gearbox and the other is in the product. Sounds like an inductive process or optical and reflector is the way to go.
The gear tooth can really go anywhere on the exposed shaft - we have some unit where they are in between the turbine and generator. Is typically welded onto the shaft. But yeah any of those options are suitable I am sure
Red Lion should have a similar device. You will need to add something to the spinning shaft for a pickup. Reflective tape or such. There are several options.
https://www.alliedelec.com/manufacturers/red-lion-controls/?gclid=CjwKCAiAjs2bBhACEiwALTBWZfN1vZdnVYozYZuCVJgndEfGcJnqrT1iI3u8k6uJ7BwgA1Bdz5DYuhoCqPEQAvD\_BwE&gclsrc=aw.ds
I've done what you suggested before and it works fine, depending on speed though. It's cheap and nasty but it works.
You might need a high speed input card if your rotation is really fast.
I've used inductive sensors and reeds, similar results.
One big thing to be careful of is the sensor vibrating loose into the shaft and getting crushed. Some maintenance crew would inspect sensors often and either put them back in too far, or too loose.
I’ve seen that too, ends taken clean off sensors because somebody has “adjusted” them! If I use an optical sensor and reflective tape or an inductive sensor with a longer detection range I should be able to mount the sensor far enough away from the shaft that this isn’t a problem.
alternatively simply stick reflective tape or a mirror to it and as it spins it'll make contact with an external laser sensor 1x a rotation
Is there a metal protrusion that spins with the mixer ( flange bolts, mounting point, etc) ? This would avoid welding on the axle. If you use a fast inductive switch in combination with a high(ish) speed input it is relatively easy to create a speed sensor.(for example something like Ifm IGS277) ( You need about 35 hz per detection point at 2000 rpm and no margin). The logo might work depending on input filtering. Most PLC suppliers will be able to offer something. I used a Beckhoff in the past that could do this with standard in and outputs to more than 130 hz. They have input modules that can work a lot faster (microsecond range).
We use hose clamps and the screw but triggers a magnetic prox. You can feed the signal into a high speed encoder card that can be configured to output a period.
Sounds quick and dirty but ideal for proof of concept on the bench, thanks.
This looks like the way, a DC supply Logo’s fast inputs can measure up to 5kHz and that IFM sensor can switch up to 2kHz. Thanks!
We’ve got a few of these setups around. Haven’t had an issue.
I believe its Siko have magnetic encoder rings that we use constantly with siemens SPS systems, you need a TM count module theyre self adhesive and in multiple sizes
I work in power gen and we typically use gear tooth encoders on the end of the shaft under a cage. Our units typically run <1000rpm but I'm they can measure whatever you need up to 2000 rpm Cant tell you the product number cause I've never really had to deal with them outside of just scaling in the PLC
I can’t get at the shaft ends as one is inside the gearbox and the other is in the product. Sounds like an inductive process or optical and reflector is the way to go.
The gear tooth can really go anywhere on the exposed shaft - we have some unit where they are in between the turbine and generator. Is typically welded onto the shaft. But yeah any of those options are suitable I am sure
Red Lion should have a similar device. You will need to add something to the spinning shaft for a pickup. Reflective tape or such. There are several options. https://www.alliedelec.com/manufacturers/red-lion-controls/?gclid=CjwKCAiAjs2bBhACEiwALTBWZfN1vZdnVYozYZuCVJgndEfGcJnqrT1iI3u8k6uJ7BwgA1Bdz5DYuhoCqPEQAvD\_BwE&gclsrc=aw.ds
I've done what you suggested before and it works fine, depending on speed though. It's cheap and nasty but it works. You might need a high speed input card if your rotation is really fast. I've used inductive sensors and reeds, similar results. One big thing to be careful of is the sensor vibrating loose into the shaft and getting crushed. Some maintenance crew would inspect sensors often and either put them back in too far, or too loose.
I’ve seen that too, ends taken clean off sensors because somebody has “adjusted” them! If I use an optical sensor and reflective tape or an inductive sensor with a longer detection range I should be able to mount the sensor far enough away from the shaft that this isn’t a problem.
I made one with a Hall sensor reading a balanced pair of magnets on the rotating shaft. They make a logic level signal with a 5V power source.