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After repairing a number of OEM sensors, it was determined
that a replacement was in fact, easier and more reliable than repair on a
number of available sensors.
The project started with Sauer-Sunstrand*
type sensors.
The inherent problem with them is that they were never
designed to be repaired. The design is a wonderful performer when it is intact,
but is difficult to save if the connector has been dislodged. The mounting of
the connector directly connects to a circuit board and usually destroys the
board when the connector takes a hit. Adding to the problem is the fact that it
is sealed in epoxy that, while protecting it from the elements, makes it about
a 5 hour job just to get to the electronics. This design (flaw?) is still used
on the latest models we've seen.
As development continued, we realized
that Blaw-Knox UltraIII sensors had problems of their own. The sensor element
design originated at Poloroid* for use in their line of instant cameras. While
they were marvelous at detecting distance, they were not designed for
"environmental" use. Efforts have been made to make them survive in moist
environments, most have not solved the problem, requiring frequent element
replacement. The elements are affordable, but you have to consider the costs of
down-time, travel back to the shop for spares, and the repair time on the bench
and later waiting while the sealant dries. This cycle continues most anytime
they get exposed to moisture. Then there is the problem of non-replacable
cables....
The Controlled Suroundings replacement sensor, the GEN Series, is
based on some of the newest sensor technology available. They are modular, and
can be easily rebuilt when severly damaged.
Development is an
ongoing process. The product line is an example of that. The Original
Replacement and the Tube are evolutions of the original idea to make a durable
but repairable sensor. Examples of both of these have been in service for over
3 seasons. The next step in this process is now being released to the public.
The Gen 7 is the culmination of many of the observations during the testing.
The Gen 7 not only solves the maintainablity concern, it adds the solution to
the root problem of mechanical damage. The Gen 7 packaging allows for movement
in instances of collision. Some managers claim that their crews were good and
didn't have damage to their sensors. If you can go two years without a
collision, great, but when you eventually have one, its going to cost you if
you stay OEM. Logic dictates that when you load and unload, when you pave
narrowing lanes, and just operate every day, sooner or later, your going to
forget to move the sensor out of the way before you pull in.
The new
Gen 7 allow the same sensor to be used on both Analog (variable) systems, and
Digital (on/off) systems. The only difference is the cable that allows the
sensor to connect to the appropriate machine. Current applications include
Cedar Rapids* , Blaw-Knox*, and CAT* pavers with the same sensor. The sensor
package now has enhanced moisture protection as a standard feature.
The
Gen 7 mounting arrangement is improved greatly over previous systems. It allows
for many options depending which brand of screed you choose.
The Gen 7
is modular and versatile. With simple reprogramming, it can be adapted to
almost any distance measuring application in the range of 6" - 25' . The mounts
can be custom made at very low cost for unique situations. Batch plant hopper
level, Back-up detector for your haulers, Follow or lead distance for a
transfer machine, Grade and Slope, etc. could all be done with the same sensor.
These features can allow you to add efficiency to your systems for many diverse
functions.
All of this and a lower cost of ownership! |
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