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Graphical analysis of the assembly of the cable encoder
SICK's cable encoder typically refers to the combination of an encoder and a cable box, such as models like BCG or PTF. If the customer specifies a particular encoder (e.g., DFS60 or AFM60) and a specific cable box (e.g., MRA*), the product is assembled by the customer upon arrival. This setup allows for greater customization based on the application requirements.
The basic structure of a cable encoder includes several key components: the encoder itself, a flange, a coupling, and a wire-pulling mechanism. The assembly process involves securing the encoder and flange with bolts, connecting the coupling while maintaining the correct distance between the coupling and the flange’s end face, and then fastening the flange to the wire-pulling mechanism. Proper alignment and spacing are crucial to ensure smooth operation and prevent mechanical failure.
For more advanced configurations, enhanced cable encoders may include additional components for improved performance. These setups often require precise installation procedures, including the use of specialized bushings to fit the encoder shafts and secure them to the wire-pulling mechanism.
In some cases, especially with smaller encoders like those with a 36mm outer diameter, a conversion flange may be necessary to mount the encoder onto the wire-pulling mechanism. A special bushing is still required to fit the encoder shaft, ensuring a secure and stable connection.
Installation in the field requires careful attention to environmental conditions. In dusty or humid environments, it is essential to protect the wire rope outlet of the cable pulling mechanism to prevent water droplets and dust from entering the system. Over time, dirt buildup can cause blockages and damage the internal components, ultimately affecting the performance of the entire cable encoder.
When pulling the cable, it's important to maintain linear motion to avoid excessive angular deviation—ideally no more than 3°. If the movement angle changes during operation, a guide wheel should be installed to reduce stress on the drawstring and allow for smoother retraction without angular restrictions.
After the cable has been pulled out, it should not be suddenly released, as this can cause damage due to the cable's natural rest force. Without external guidance, the cable may bend and become jammed inside the mechanism when retracted.
Never pull the drawstring directly with your hands, as this can cause bending and malfunctions during retraction. Also, avoid pulling the rope along sharp edges or near foreign objects, as this can lead to damage and affect the reliability of the system.
For certain models, such as the MRA-F130-R guide pulley, installation involves removing the existing dust cover and flange, installing a new flange with a rubber ring, and securing the guide pulley in place. This process ensures that the cable moves smoothly and remains protected from external contaminants.
Similarly, the MRA-F080-R guide pulley installation follows a similar procedure, with adjustments made to accommodate the smaller size of the cable box. Removing the dust cover, replacing the flange, and securing the guide pulley properly helps maintain the integrity of the system over time.
Proper installation and maintenance of SICK cable encoders are essential for reliable performance, especially in demanding industrial environments. Following these guidelines ensures optimal operation and extends the lifespan of the equipment.