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Quick Set-up Instructions 1
Theory of Operation 2
Specifications 3
7. Gain Adjustment VR 8
Calibration Instructions 9
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QUICK SET-UP INSTRUCTIONS
1. Carefully unpack the instrument and lay the contents on a table. You should have
the following:
NOTE: This detector has been factory calibrated, and as such, DO NOT adjust
the (3) gain potentiometers.
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Theory of Operation
When a normal object is passed through the parallel light beams, the light volume
produces a null (A1-A2).
When an object with a lump or bump is passed through the beams, the values A1 and A2
become unbalanced. The difference between A1 and A2 is in proportion to the size of the
flaw (lump/bump). When these features exceed a preset value an alarm is output.
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SPECIFICATIONS:
NOTE: The optical shield is typically used for very fine wire <0.2 mm. For larger wire,
the two shields may be removed.
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TM – 1003W Controls and Connections
Standard Model
7. Gain Adjusting VR
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1. Power Source Connector (3 Terminal ± 15VDC Regulated Power Supply)
Terminal #
1 0V (Black)
2 +15V 0.07A (White)
3 –15V 0.02A (Red)
Terminal #
1 = + (White)
2 = – (Black)
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3. Variation Detection Lamp
Will be illuminated at each detection for 0.5 sec for the standard relay model.
A dual parallel Photo- optic slit technique combined with Infrared light source is used to
measure rapid light volume changes created when a sudden change in product diameter
occurs. This diameter change is caused by the flaw, bump, neck down, color skip, etc.
The light volume received is converted to a “Real time” analog signal, which is then
analyzed through a differential circuit. The actual throughput speed is limited by the
design of the circuits used, i.e. light modulation and filtering techniques. However, 5 µm
defects can be characterized at speed greater than 15 m/sec.
The sketch below illustrates how a defect may appear as it passes through the TM defect
detectors two parallel photo- optic slits. And although the defect height may be the same,
the actual light volume received can be different due to defect size characteristics. As
such allowances should be made to adjust the TM sensitivity lower for these variations.
In figure A the defect creates a shadow that takes up the entire photo- optic slit. The
defect is detected as a 0.5 mm high defect.
In figure B the defect is detected as a 0.25 mm high defect.
In figure C the defect is detected as a 0.125 mm high defect.
Using the above comparison, it is suggested that the TM – 1003W’s sensitivity be set to
the lowest possible setting (without false triggering) for very small defect detection on
small diameter wire and optical fibers.
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4b. Calculating Defect Size for Proper Sensitivity Adjustment
1. The formula for calculating a defect size which is smaller than the TM 0.5mm
optical slit width shall be:
Length (mm) x Width (mm)
0.5mm
2. Deviated Projection: When the point of the projection (Defect) leans by a
certain degree against the emitted beam direction, as shown below, the
detected height becomes smaller than the actual one. To prevent from
misdetection, the actual variation width (height) shall be calculated using the
following formula:
h= ½ φ • (cos α - 1) + Hcos α
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4d. Alarm Sensitivity Adjustment (Digital Dial Model)
To set the sensitivity on the digital dial model set the dial display to the defect to
detect from 20 to 999 µm. Example to detect a defect ≥0.04 mm set the dial to 040.
7. Gain Adjusting VR
The TM – 1003W has been calibrated at the factory and should require a
calibration check at yearly intervals to ensure optimum performance. DAS
Distribution Inc. provides this annual service as part of a 17-point inspection test.
(See Test Certificate on Page 16)
Takikawa also offers an optional calibration gage kit (P/N: TMG – 05) for this
purpose, should the user wish to check the linearity of the recorder output only.
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Calibration Instructions
1. Remove the detection area protection covers and clean the emitter/ receiver
lenses with alcohol and a lint free cotton cloth, or optical glass cleaner. Ensure
that there is no left over residue on the lens.
2. Re attach the protection covers and attach the 0.5 mm gage pin (P/N: TMG –
05) to the TM – 1003W center detecting area.
4. Press the cable trigger button and note that the 0.5mm gage pin moves
horizontally through the center portion of the detecting area. The in and out
movement of the pin must be done quickly (within 0.5 sec. or less) to
accurately simulate a 0.5mm defect.
5. While moving the gage pin in and out monitor the output reading on the
oscilloscope. A 0.5mm defect should produce an output pulse of 2.5V.
6. Adjust the number 1 gain potentiometer so that the output pulse is within
±0.1V of 2.5V. Note that when the gage pin is retracted there will be a “dent”
signal. Disregard this signal. Calibration is done with the gage pin projection
only.
7. Repeat the above steps for recorder outputs 2 and 3 using their respective gain
potentiometers.
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TMG-05 Gage Unit
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Sensor Output Values
Defect size Output
inches Meters Millimeters Microns Voltage
0.040000 0.001016 1.016000 1016.00 5.079997
0.039000 0.0009906 0.990600 990.60 4.952997
0.038000 0.0009652 0.965200 965.20 4.825997
0.037000 0.0009398 0.939800 939.80 4.698997
0.036000 0.0009144 0.914400 914.40 4.571998
0.035000 0.0008890 0.889000 889.00 4.444998
0.034000 0.0008636 0.863600 863.60 4.317998
0.033000 0.0008382 0.838200 838.20 4.190998
0.032000 0.0008128 0.812800 812.80 4.063998
0.031000 0.0007874 0.787400 787.40 3.936998
0.030000 0.0007620 0.762000 762.00 3.809998
0.029000 0.0007366 0.736600 736.60 3.682998
0.028000 0.0007112 0.711200 711.20 3.555998
0.027000 0.0006858 0.685800 685.80 3.428998
0.026000 0.0006604 0.660400 660.40 3.301998
0.025000 0.0006350 0.635000 635.00 3.174998
0.024000 0.0006096 0.609600 609.60 3.047998
0.023000 0.0005842 0.584200 584.20 2.920998
0.022000 0.0005588 0.558800 558.80 2.793998
0.021000 0.0005334 0.533400 533.40 2.666999
0.020000 0.0005080 0.508000 508.00 2.539999
0.019000 0.0004826 0.482600 482.60 2.412999
0.018000 0.0004572 0.457200 457.20 2.285999
0.017000 0.0004318 0.431800 431.80 2.158999
0.016000 0.0004064 0.406400 406.40 2.031999
0.015000 0.0003810 0.381000 381.00 1.904999
0.014000 0.0003556 0.355600 355.60 1.777999
0.013000 0.0003302 0.330200 330.20 1.650999
0.012000 0.0003048 0.304800 304.80 1.523999
0.011000 0.0002794 0.279400 279.40 1.396999
0.010900 0.0002769 0.276860 276.86 1.384299
0.010800 0.0002743 0.274320 274.32 1.371599
0.010700 0.0002718 0.271780 271.78 1.358899
0.010600 0.0002692 0.269240 269.24 1.346199
0.010500 0.0002667 0.266700 266.70 1.333499
0.010400 0.0002642 0.264160 264.16 1.320799
0.010300 0.0002616 0.261620 261.62 1.308099
0.010200 0.0002591 0.259080 259.08 1.295399
0.010100 0.0002565 0.256540 256.54 1.282699
0.010000 0.0002540 0.254000 254.00 1.269999
0.009900 0.0002515 0.251460 251.46 1.257299
0.009800 0.0002489 0.248920 248.92 1.244599
0.009700 0.0002464 0.246380 246.38 1.231899
0.009600 0.0002438 0.243840 243.84 1.219199
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Defect size Output
inches Meters Millimeters Microns Voltage
0.009500 0.0002413 0.241300 241.30 1.206499
0.009400 0.0002388 0.238760 238.76 1.193799
0.009300 0.0002362 0.236220 236.22 1.181099
0.009200 0.0002337 0.233680 233.68 1.168399
0.009100 0.0002311 0.231140 231.14 1.155699
0.009000 0.0002286 0.228600 228.60 1.142999
0.008000 0.0002032 0.203200 203.20 1.015999
0.007000 0.0001778 0.177800 177.80 0.889000
0.006000 0.0001524 0.152400 152.40 0.762000
0.005000 0.000127 0.127000 127.00 0.635000
0.004000 0.0001016 0.101600 101.60 0.508000
0.003000 0.0000762 0.076200 76.20 0.381000
0.002000 0.0000508 0.050800 50.80 0.254000
0.001000 0.0000254 0.025400 25.40 0.127000
0.000900 2.286E-05 0.022860 22.86 0.114300
0.000800 2.032E-05 0.020320 20.32 0.101600
0.000700 1.778E-05 0.017780 17.78 0.088900
0.000600 1.524E-05 0.015240 15.24 0.076200
0.000500 0.0000127 0.012700 12.70 0.063500
0.000400 1.016E-05 0.010160 10.16 0.050800
0.000300 7.62E-06 0.007620 7.62 0.038100
0.000200 5.08E-06 0.005080 5.08 0.025400
0.000100 2.54E-06 0.002540 2.54 0.012700
0.000090 2.286E-06 0.002286 2.29 0.011430
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Optional Comparator Module
Function:
This module is used if two different size defects need to be detected. The module
mounts on the side of the TM –1003W and plugs in to the monitor terminal and
recorder output terminals.
Specifications
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Installation
2. Plug the Comparator module into the Level monitor and recorder output
terminals. Secure the module to the TM – 1003W with the two screws
removed in step 1.
3. Attach the power and relay cobles to the TM unit and the comparator module.
4. Set the voltage for the smaller variation by using a Digital Multimeter in the
Lo terminal and adjusting the Potentiometer on the TM – 1003W.
5. Switch the meter to the Hi terminals and set the voltage for the larger variation
by adjusting the potentiometer on the comparator module.
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