InteliSENS DGk2000-i4 Series

Diameter Gauge

The InteliSENS® DGk dual axis diameter gauge does much more than measure diameter. LED and CCD technology, with our specially designed optics, provide superfast high-accuracy diameter and position measurement, analyzing your product’s surface in precise detail.

This technology has no moving parts, no wear, and no drift. The FPGA processor used in the DGk diameter gauges enables superfast measurements: 10000 scans per second as standard, and, optionally, 20000 scans per second. Additional options add functionality to measure, control, and alarm and report on product quality.

As with all Proton i4 products, each gauge has digital and industrial inputs and outputs for easy integration in your production lines.

Precise, high-resolution measurement
No moving parts for high reliability and low maintenance
Full integration with PLC, and gauging equipment
Industry 4.0 data communications
SMFD flaw detection
PID controller
FFT analysis; SPC; Statistics
Analogue output

Category: Diameter Measurement

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Performance

	DGk2015-i4	DGk2030-i4	DGk2060-i4	DGk2120-i4	DGk2200-i4
Minimum Diameter	0.2 mm 0.008″	0.2 mm 0.008″	0.3 mm 0.012″	5 mm 0.20″	5 mm 0.20″
Maximum Diameter	15 mm 0.59″	30 mm 1.18″	60 mm 2.36″	120 mm 4.72″	180 mm 7.08″
Accuracy †	1 μm	1 μm	± 3 μm + 0.01% of object	± 50 μm + 0.05% of object	± 50 μm + 0.05% of object
Resolution	0.01 μm	0.01 μm	0.01 μm	0.01 μm	0.01 μm
Scan Speed	10,000 scans/s (20,000 option)	10,000 scans/s (20,000 option)	10,000 scans/s (20,000 option)	3,000 scans/s	3,000 scans/s

†: object centered in the optical gate.

Measurement Technology

Unlike traditional laser diameter gauges, which use a mechanically scanned laser beam, the InteliSENS® DGK-i4 diameter gauge uses an entirely solid-state technique. A LED light source is used to generate a broad collimated light beam that fully illuminates the measurement zone. The shadow generated by an object inserted into this light beam is imaged by a CCD, and the resulting electrical signal is digitally processed to measure diameter. This solid-state approach results in the following advantages over traditional laser diameter gauges:

• Higher measurement speeds (not limited by mechanical scan time).
• Higher reliability and MTBF of the gauge as it suffers no wear from moving parts.
• No laser precautions are required as a non-laser light source is used.

Connectivity

Analogue Speed input 0 -10vdc
Required for Helix Mode, Tolerance Location and Optional SMFD, Statistics and PI
Feedback Diameter Control options.

250kHz max frequency, 30v or 50v max pulses on two distinct inputs.
Required for Helix Mode, Tolerance Location and Optional SMFD, Statistics and PI
Feedback Diameter Control options

2 x Logic Inputs

User configurable function: Reset; External Alarm 1; External Alarm 2; Line Reverse Direction: 24 Vdc

4 x normally open Relays
Maximum 1 A / 24 VDC.
Gauge OK, Upper Tolerance, Lower Tolerances, Single Measurement Flaw Detection (SMFD)

1 x RS232 / RS422 / RS485
MODBUS RTU; PROTON ASCII code or Label; USB using RS232 – USB Converter Cable; RS485 MODBUS RTU; PROTON ASCII code (not available with PROFIBUS)

1 x CANBUS
Proprietary CAN protocol to connect CDi4 display interface, including CS5G / via CS1000

1 x iBUS
Connect to a PLC using PROFIBUS, PROFINET, EtherNet/IP [all included: select one to use].
Data update rate up to 500/sec.
Flexible Data Configuration, Big Endian, Little Endian.

1 x Ethernet
Ethernet Modbus TCP (or ‘Ethernet TCP/IP’); Ethernet UDP
OPC UA compatibility: OPC UA 1.03
Connect DGk gauges to your OPC UA data collection system.

1 x Wifi
Wi-Fi for gauge configuration and diagnostics.

Gauge Head Add on Hardware

3 analogue (±10 V) outputs can be set to X, Y, Z axis output for 2 and 3 axis gauges. Average diameter, diameter error, ovality and ovality error.

Feedback Control monitors the actual measured diameter compared to a Preset Value and provides a Control Output Signal that can be used to trim the motor output and maintain the product diameter within the Preset Value.

Gauge Head Add on Software

The DGK10k scanning option upgrades the standard gauge to a Super High scan rate, Ideal when used with SMFD Single Measurement Flaw Detection. Each scan takes just 1ms to obtain and output a new diameter reading.

Maximum, Minimum, Mean, Standard Deviation, Cp, Cpk is collected during a selectable time or length period. The results are updated on the SiDi CDi4 Universal Display, PCIS Software and can be transmitted digitally.

Statistical Process Control (SPC) enhances the Feedback Control option. Statistical Process Control, “measures” Process Capability and automatically adjusts the control set point to maximize material savings while maintaining control within upper and lower limits

Fast Fourier Transform (FFT) analyzes the diameter data for periodicity. Providing Amplitude verses Frequency data and a graphical representation on the SiDi CDi4 Universal Display Unit or PCIS Software.

Single Measurement Flaw Detection (SMFD) analyzes each individual measurement and compares it with the running average. If a Single Measurement is greater than the running average and above or below a threshold value a Flaw is Detected.

Electrical and Operating Requirements

DGK2030 / DGK2060

DGK2120 / DGK2200 / DGK2300 / DGK2400

Power Supply 18-30 Vdc	Power Consumption 30 Watts	Operating Temerature 5c – 45c (41-113F)	Environmental Protection IP 65
Power Supply 100 – 240 Vac (50 – 60 Hz)	Power Consumption 100 Watts	Operating Temerature 5c – 45c (41-113F)	Environmental Protection IP 65