In the more than 20 years CPI has been developing the world’s most robust and durable underwater draw wire position sensors, it’s fair to say we’ve learned a few things. For subsea hydraulic cylinders and hydraulic accumulators the use of specialized draw wire sensors like ours are likely to be the system designer’s best choice. Our unique measurement technology can cover stroke lengths anywhere from 1 meter to almost 30 meters (100 ft) while completely submerged in water or hydraulic fluid. They can operate inside or outside of a hydraulic cylinder. Our sensors have functioned everywhere from the corrosive salt water of rig raisers in the Gulf, to the corrosive chlorinated water of a Las Vegas Swimming pool!
The primary requirements of these applications end up being the durability and reliability of these sensors in their underwater environments but a close second is the requirement for accuracy and precision in the sensor as it mechanically extends and retracts over as much as a 100 meter length. The engineering and experience that has gone into this has been some of the most interesting developmental aspects of our sensors. Stay tuned you engineering types, this is a story you’ll appreciate. The Accuracy of Submerged Draw Wire Sensors The CPI SL-6000 is capable of subsea piston position sensing of strokes up to 30 meters (100 feet)Generally we start the conversation by telling our customers that we have a nominal 12 bit accuracy. For most applications this is plenty good enough, however it turns out that the actual resolution of the draw wire sensors is better than that over the majority of its operating range. Here’s why: One-Sided Accuracy – A characteristic of all draw wire sensors is that they are backlash-compensated. All draw wire sensors operate with a recoil spring (power spring) which provides the rewinding force for the cable. This spring force is always keeping the mechanical system of the draw wire in tension. That is, the small mechanical errors due to part tolerances in the draw wire mechanism are always held in a one-sided tension when the cable is being drawn out, or when it is being rewound back in. This provides two benefits: First, the errors associated with mechanical tolerances are not random, but are constrained by the tension. Second, the errors associated with mechanical tolerances are minimized, again because they are held to one side, against the tension of the spring. Change of direction – Another characteristic of all draw wire sensors is hysteresis, or lag, when the direction of the cable is changed (i.e. from pulling out to rewinding, or vice versa). This change of direction hysteresis is when the backlash compensation tension changes. This is due to the change of cable direction. The degree of influence that this factor imposes on true sensor accuracy depends on the application. In slow-moving systems the hysteresis error may be minimal. In fast-moving systems the hysteresis error may be magnified. Core resolution – CPI subsea draw wire sensor systems are built around probe-type, non-contacting transducers. These transducers are generally very accurate in their base format. However in applications requiring extreme accuracy, we can use a core transducer with a higher base resolution. In this way, CPI can provide subsea linear sensors with ranges of up to 30 meters, and accuracies of significantly better than 12-bits. This is especially true for the one-sided accuracy, as outlined above. It’s all about the Tradeoffs isn’t it? CPI’s SL1490MSA major challenge in subsea sensor design is the packaging and protection of the electronics payload of the core sensor. While the metallurgy of the gearing and wire allow operation directly in liquid the short magnetostrictive sensor must be of the sealed variety. There are cost tradeoffs associated with the deployment of the extremely accurate subsea capable systems described above. Luckily we have options developed over many years that make the appropriate tradeoffs necessary to work in your application as cost effectively as possible. If you have a wet or subsea application for the world’s most robust long stroke linear position sensor, our engineers will work with you to configure the most appropriate design for your application. For many of us the idea of fire and ice might conjure up memories of the first book in Game of Thrones. Throughout that tortured story, “winter is coming,” but the forces of dragon fire threaten to keep it at bay, mostly.
Still, the idea of using “fire” to combat ice, isn’t very new. And its actually a short trip from fire breathing dragons flying around, to the idea of using thermal switches to control hot engine bleed air to de-ice a plane wing, right? Practically the same thing!The bleed air application for CPI Thermal Switches.While CPI has recently been engaged in bleed air applications for de-icing various commercial and military aircraft, the bleed air type application is even more general than that. In any application requiring reliable high-temperature sensing that redirects or provides airflow, CPI thermals are often selected. Here’s just a few bleed-air applications that use our thermals.
Snapstat Thermal Switches (0-300F) Surface mount options, low profile, can be mounted on engine block or other surfaces easily. Extremely resistent to shock and vibration, long life. Plugstat Thermal Switches (0-650F) Tight tolerances and a small differential set these bimetallic thermals apart. They are slow make-break devices and come with a hermetically sealed option. Rod & Tube Thermal Switches (0 – 1750F) – For your highest temperature thermal switch requirements, used over galley stoves, in fuel cells and APU’s for thermal runaway detection among other applications. For more information about how CPI Thermal Switches solve problems of fire and ice, call our team today! With the 2024 work truck show in full swing, the broad category of “Work Trucks” or “vocational trucks” is very much on our minds.
These trucks include vehicles from ambulances to class 8 heavy trucks weighing over 33,000 pounds . Unlike cars and your consumer oriented pickup truck, these vehicles really work for a living, and are built for a complex purpose beyond getting you from here to there. As a manufacturer of some of the worlds most durable and reliable waterproof safety switches and hi-temp thermal switches, CPI brings both deep and broad experience to the problems of safety and component survival on systems for all kinds of work trucks. The CPI switches and sensors designed into these trucks of every type represent a small, but critically important component of overall safety system operation. No matter what safety system your work truck design requires, reliability, durability, and long life will be maximized with a CPI hardened limit switch solution. Made in the USA you will also find a reliable supplier who is not subject to disruptive manufacturing and export policies of foreign governments. Work Truck Applications for CPI SwitchesIt seems like every day a new manufacturer reaches out to us for an interesting application of one of our hardened switches. Both our Thermal and our waterproof switch products have been used in work trucks and military vehicles for decades owing to their relatively small form factor, mounting versatility, and of course their operational toughness. Here’s just a few examples of problems we solve on work trucks around the world. Dump Trucks – Using our E1 switches to detect when the dump body is raised prevents inadvertent take off when the body is raised. (Don’t laugh, it has happened. See Here!) Emergency Vehicles – Often use our E1 limit switches for Outrigger Deployment detection to insure the stabilizer is locked into place. Heated Dump Box – Our M1 Thermal switches have been used on Salt trucks provided to the DPW to prevent freezing or melting during dispense by keeping the salt box at the optimal temperature through exhaust redirection. Bucket Trucks – Bucket truck manufacturers have used a wide variety of our E1 limit switches as part of safety systems controlling the boom hydraulics and buckets. Our control panels have been used to provide operator control through our panel mounted waterproof pendant switches. Door Interlock Switches – Anywhere that a door open or closed needs to be detected in a robust or outdoor setting, is a perfect home for our B-Series waterproof switch mounted inside one of our simulated roller actuator brackets. We’ve been used for hood down, door closed, hatch closed, or arm locked, kinds of applications on dozens of different commercial and military vehicles. Agricultural Sprayers – Use our J4 ball switch to sense that sprayer arms are locked owing to its ability to withstand highly corrosive spray fertilizers. Sanitation Trucks – Use our waterproof limit switches pre-mounted into a stainless steel control panel to control compressor and lift gate operations on the vehicle. Cranes – Cranes of all types and sizes have made use of our E1 waterproof limit switches in anti-two-block safety systems owing to their robustness and small form factor. They also use our J4 ball switch in hydraulic valve position detection applications using our specialized valve mounting brackets. Forklifts and Construction Vehicles – Our operator controlled, Waterproof Pendant Switches are the perfect solutions to things like backup alarms and siren control. Or put this in any of dozens of mounting brackets we can provide and let the machine activate it. Our K1005 using our E1057 mounting bracket is a great example of this. Military Vehicles – In applications like Door Alarms, and Neutral Safety detection, our J4 ball switch has been designed into tough vehicles for its durability, reliability, and small form factor. Work Trucks Need to prioritize reliability in switching solutions.On Work Trucks costing upwards of $100,000, its seems silly to take a chance on safety system sensors, with cheap, offshore produced switches. All CPI switches are designed and made in the USA right here in our East Hanover NJ Factory. Despite this, our switches often cost less in quantity than comparable switches by Honeywell, Eaton, and Otto. We love solving problems of safety and sensing with our switches. Please give us a call today. https://cpi-nj.com This blog was originally published at: https://www.cpi-nj.com/work-truck-safety-switch-applications/ For over 70 years, CPI has been providing thermal and waterproof switches to the military & law enforcement industries in a wide variety of applications. There are a few major reasons the military comes to us for their toughest switch applications.
The list below is just a sample of the many military applications in which our switches are used.
Additionally we provide complete qualification documentation for our parts in new applications. Call us today to discuss your application or visit https://cpi-nj.com The Work Truck Association™ has released the full Work Truck Week® 2024 schedule for North America’s largest yearly work truck event. It runs March 5–8, 2024, at the Indiana Convention Center in Indianapolis.
Over 500 companies will be there sporting the latest trucks, equipment and trends. In breakout sessions attendees can learn new ideas and solutions that can impact their operations, and connect with the people and companies they need to thrive. CPI will be talking to companies there, both old friends and new ones, who are pushing the envelope on systems and functionality in these typically tough outdoor commercial vehicles. You know us, somebody says “tough” and “outdoor” and we’re there! We’re particularly excited about the breakout sessions discussing the move to electric vehicles and subsystems. The exclusive commercial vehicle Chassis Update Sessions return with 12 commercial vehicle OEMs and three EV manufacturers sharing vehicle changes and upfitting solutions. Some of these may even include eAxel solutions that use CPI Switches! CPI is Working Hard On Work TrucksCPI is no stranger to the work truck industry and our presence at the show will serve as a reminder that there is really only one place to go for tough, made in the USA, waterproof switches and thermal switches for work truck systems. We’ve showcased this a lot over there years, here are just a few of the hundreds of unique applications CPI components find homes in, on work trucks.
Thanks! This blog was originally published at https://www.cpi-nj.com/work-truck-show-2024/ Harsh duty thermal switches like CPI’s have seen an evolution for over 70 years. Their tough operating capability and high degree of accuracy and dependability have made them ideal for military and tough commercial applications in aviation, construction, mining and refinery operations and naval vessels for decades.
But what many folks don’t fully realize is that they are problem solvers for a wide variety of more common commercial applications. A recent application comes to us from the developers of after-market additions to specialized work trucks. This application highlights both the flexibility and reliability of our switch for thermal detection in a tough environment. Thermal Management in Heated Dump Box ApplicationsAt Truck & Trailer Specialities in Dutton Michigan, they’ve been providing work-truck upfit services for almost 50 years for the public works and commercial trucking industry. Specializing in snow and ice truck build ups, TTS represents the highest level of quality and craftsmanship in their build outs which are designed to last. So when they needed to change the design of their temperature monitoring for their heated salt dump box, they found a thermal switch that has the same focus on quality and performance. In this application the exhaust from the engine is directed into cavities in the salt box so that the salt and sand does not freeze. If the engine goes into regen mode however, it can exceed 650 degrees and the flow of air is too hot and must be redirected. In this case, a thermal switch must close and activate a flapper that closes in the exhaust pipe, directing exhaust from the engine out the top of the stack. “This was a perfect application for our M1 thermal switch,” notes Pete Gagliardi, CPI sales engineer. ” The M1 fits inside the exhaust pipe and is programmed with a set point that detects the rise in temperature and closes well before the exhaust air gets too hot.” The M1 Thermal switch is part of our “Plug Stat” line of thermal switches with a programmable temperature detection range from 0 to 650F. Made of all stainless steel with either wire or connector configurations, the switch fits perfectly inside the engine exhaust feed. The M1 comes in all electrical configurations such as close on rise, or open on rise, etc… “The switch works as designed and was delivered to the customer,” notes Pete. “This will now be their solution for thermal feedback designs on these heated dump beds.” Cost Effective for Commercial Applications.CPI’s Plugstat Line of thermal switches are cost effective for most commercial applications, and indeed very few other thermal switches have anywhere near such robust operating characteristics at this price point. For samples and discussions related to set point and mounting concerns contact our engineering team today. This blog was originally published at https://www.cpi-nj.com/thermal-switches-in-work-truck-applications/ The mass production of food products is a fascinating business, requiring the specification of many different types of technology in many different operating environments. In some cases, massive amounts of raw food product has to be carefully cooked and packaged and kept at certain temperatures for certain amounts of time, all done in a hygienic way so as not to poison folks and such.
A great example that recently came to our attention was for a rotary conveyor in a huge freezer shown above. In this case, the food is already cooked and simply needs to be moved around within cold storage via trays that ride on a track. In this environment, moisture, condensation, and icing is an unavoidable problem and the machinery occasionally gets off track – literally. CPI Cold Operating Limit SwitchesUnlike typical commercial switches and sensors that run from 0 to 70 C, even basic CPI limit switches are fully IP68 rated and sealed in Santoprene which gives them a default temperature rating of -40C to 100C. But long and deep experience has taught us that cold and wet environments pose unique problems for switch operation that even switches with low temperature ratings may have challenges overcoming. In one such experience it was found that switches that were actuated for long periods of time would “freeze” in place upon release due to the deformity of the thermoplastic boot which could not be pushed back into its original state upon release. In cases that exist at the edge of cold temperature operation, CPI recommends our military grade limit switch where the temperature range goes all the way down to -65F. These switches are encased in neoprene rubber which avoids the semi-permanent deformity that is possible with thermoplastic seals. And with CPI’s USA based, in house manufacturing team, the cost of producing these in quantity is on par with their Santoprene cousins. In the case of our rotary conveyor, a series of CPI E1100 angle mount brackets using our B series momentary switch provide feedback to the rotary controller when the system is off the track. In this application our switches are daisy-chained so that any detection of a failed conveyor will immediately pause the conveyor, while requiring only one monitoring point at the controller. CPI Tastes Good on Food Processing EquipmentIn the mass production of food products, CPI limit switches have been used for position and safety sensing in both hot and cold environments. They not only take the heat/cold, but they do it for a really really long time. Call our team today, lets see what we can cook up for you! This blog was originally published at https://www.cpi-nj.com/conveying-food/ Lately it feels like there is a race between the widespread improvement and adoption of renewable energy sources, and the worst effects of a rapidly warming planet. We’re not there yet but the dedicated and intelligent work of so many individuals and companies who announce exciting advances every day, gives us hope that we may yet win the race.
It turns out that CPI Thermal switches have a part to play in a number of renewable energy technologies that form part of the overall solution for green energy production. Because of our Thermal Switch capabilities related to both cold and hot temperature detection, CPI switches get designed in to many systems. Here’s just a few ways in which CPI is doing it’s part to help the green energy movement. Ocean Based Windmill Farms Large wind turbines, especially ocean based, can be protected from cold related failure by use of special anti-freeze fluids, that create heated gearboxes or trigger internally heated electronics which can also fail in extreme cold.This is a proven application for CPI thermal switches which have been used in power grid applications including windmills to detect cold weather conditions which might affect the operation of components. in one such application windmills depend on critical voltage converters to translate the mechanical energy of the turbine to electrical energy. These converters have a lower limit on the temperature under which they can safely operate. Our switch is used as a cold temperature indicator that the converter controller software reads. If the temperature hits the low temperature set point (in this case -3C) it is a signal that the internal heating system for the voltage converter has failed to turn on. To prevent a failure, our switch sends a signal to raise a fault and shut down the converter. In other applications the same switch closure is used to turn on local heating elements which prevent the gearbox and associated electronics from reaching freezing temperatures which may exceed their ratings. The switch closure can also be used in windmills to enable the flow of antifreeze by turning on pumps and generating alarms when various temperature thresholds are reached. Fuel CellsThe promise of hydrogen based fuel cells is certainly one of the most exciting energy technologies on the cusp of mainstream acceptance. Fuel cells are expected to be over a 40 billion dollar industry by 2030 as advances in technology and adoption continue. Reactions within a fuel cell are carefully temperature controlled to allow for maximum efficiency in energy conversion. That’s where our AD173 bimetallic thermal switch comes in. This switch has a small form factor that can detect temperatures from –18C to 148C with tolerances as tight as 2.8C.Deployed at a 35F set point, our AD series switches have been used to initiate anti-freeze protection extending the useful temperature range of outdoor fuel cells. Electric Bus Charging SolutionsPrototype electric buses employ magnetic charging solutions that actually charge the bus while its sitting at each bus stop. Because of the high electromagnetic field in use, CPI developed special versions of our AD190 Thermal Switch with a dielectric resistance up to 5000 VAC. Their double snap action and hermetic sealing option, make them perfect for this application. Nuclear Energy Thermal SensingNuclear energy may be the overlooked child in the green energy revolution. While this is somewhat understandable given public perceptions of the danger of Nuclear Power plants and the difficulty dealing with used fuel rods. Still most experts consider modern nuclear power plant reactor designs to be exceedingly safe, and that the energy generated will be an important stopgap energy solution on the way to a completely green world. While temperature measurement inside an active reactor are the province of extremely specialized thermocouples due to high neutron bombardment, it turns out there are a boatload of other temperature measurements that could be perfect for a robust, standalone, high precision thermal switch product like those that CPI makes. Here’s just a few examples:
CPI Thermals Can be Customized for Your ApplicationIf you have an emerging or existing application in the renewable energy area, we want to be your partner. Changes to our thermal switches for a specific requirement can be readily made by our engineering team. Set points for your switches are programmable for you in our factory and lead lengths and terminations are fully customizable as are electrical parameters and other elements. Call our engineering team today to discuss your application. This blog was originally published at https://www.cpi-nj.com/renewable-energy-applications-use-cpi-thermals/ Sometimes clients come to us because they have a small need for switches on an outdoor application and want to design in a sealed switch that they won’t ever have to worry about. A switch that is truly waterproof, with reliability over tens of thousands of actuations, and just the right tactile feel. Applications on jet ski’s and speedboats come to mind. Or motors on specialized enduro-mountain bikes, motorized fishing reels for the handicapped and push-to-talk helmet mounted buttons for cops. Dozens more like this. All small but important CPI customers because they just didn’t want to mess around with the switch. They wanted a bulletproof implementation from the get-go.
Some of the environmental stress these applications experience can be severe for sure, but a whole different set of environmental challenges exist in the commercial mobile space. This is the place which CPI switches were exactly designed for. Some of these apps represent the most difficult operating environments you will find on the planet. The Non-Automotive Commercial Mobile Vehicle ProblemConsider the use of limit switches on a backhoe loader or other construction vehicles like a crane or dump truck. These vehicles can employ strong hydraulic movement on loader arms, dump bodies, or stabilizers with limit switches exposed to the outdoor elements constantly. This means rain, wind, dust, oil and other chemicals, even power washing. Add to that extreme temperatures, high vibration, constant use and physical abuse by operators and machines alike. Many times, these switches function as a critical safety sensor and so failure in the field can be expensive to resolve and dangerous to leave unresolved. Here are just a few examples: Next Gen Telehandler using J4 Plunger Switch – For this brand-new design, our manufacturer uses outriggers (or stabilizers) to insure stability of the extended platform. The critical safety related nature of this application, and the need to be small form yet durable made CPI the best choice. These plunger switches act as position sensors for the stabilizers with operating parameters held to +-1mm in the CPI switch design. Agricultural Harvester using waterproof Limit Switch E1245-501 – In this value-add addition to a popular harvester model, our client ads our simulated roller limit switch to the side of the harvester. This sensor allows them to determine when the crop harvester head is in the locked or floating position. Key to this design win was the reliability and immunity to chemicals and high pressure water our switches exhibit. Dump Body Detection using E1092 simulated roller bracket with B-Series Switches – Driving down the highway with the dump body raised is both comical and dangerous. The installation of a simple CPI limit switch like our 1092 simulated roller actuator is commonly used to make sure all kinds of things are closed, from dump truck bodies, to safety doors, to engine hoods, and submarine hatches. Switch closure parameters such as force and electromechanical endurance as well as extended temperature ranges can be specified. And no matter what you pick, its always sealed and completely waterproof. You can read more about this dump truck raised body application at this link. Other applications for Construction vehicles Include: Back-up Alarm Switch Brake Over-Temp Cab Closed Interlock Door Interlock Seat Position Door Switch Dump Body Detect Switch Horn Switch Idle Validation Detect Lift Up/Down Control Lift Up/Down Control Operator Presence Switch Park Brake Switch Remote Horn Signal Switch For more information on any of these applications please call a sales engineer at 973-887-9400 CPI – We’re Different on the InsideInside our unassuming santoprene (or neoprene) sealed “pendant” switch, lies a world of experience and field proven technology in switching and sensing. Working for up to 1 million cycles in the environments we reliably operate in, takes a lot of careful thought in both design and manufacturing, and a lot of understanding about how small mods in materials and construction can make big changes in operating characteristics. The other way we’re different on the inside is our company operating philosophy. With all our manufacturing, engineering and design done at a single USA based corporate campus, our ability to make changes, customize, consult, ensure quality and be nimble in delivery are unmatched by any offshore solution to high performance switching you will find anywhere else in the world. With our USA based operations, your supply chain will be unaffected by the policies and hostilities of foreign made products in unstable countries with ever changing export rules. And in quantity, our pricing is usually competitive with those offshore products. But with CPI you will also get a reliable, accessible and incredibly responsive USA based supply partner. That’s worth something. Call (973) 887-9400 or visit https://cpi-nj.com today to discuss your next limit switch design challenge. This blog was originally posted at https://www.cpi-nj.com/defining-harsh-environments-for-commercial-vehicles/ CPI Thermal Switches are solving fire and heat detection applications for a large variety of Military and Non-Military Applications. Typically used for these applications is our Rod & Tube line of Thermal switches owing to several important operational characteristics. For one, these switches are certified to RTCA DO-160C which represents the harshest conditions you are likely to encounter in an avionics application. The list of specific testing area’s includes the following:
One other important part of the DA42 is the CPI X2003-506 thermal switch used in the engine compartment fire detection systems. “The X2003 is really made for fire detection applications,” says Pete Gagliardi, CPI’s regional sales engineer, “a slow make/break device with a set point from 0F to 1750F that is ultra reliable and accurate.” A Look at CPI Rod & Tube Thermal SwitchesThe X2003 thermal switch belongs to a class of stand alone Rod & Tube style, bi-metal Thermal Switchproducts where contact movement is achieved via differences in the coefficients of expansion of two materials, in this case the outer tube and the inner rod. This family of switches is characterized by very rapid response time and very high temperature sensing which operate completely independently of any external control system. The switch has seen many deployments in aircraft over the years, where remote sensors and control systems are not a good or reliable option. These thermal switches can be procured in multiple rod lengths and multiple contact configurations. They have been used in helicopter engine exhaust, plastics extrusion, aircraft brake applications, among many other demanding applications for the industrial, aerospace, and military industries. CPI Thermal Switches Fly Safely in Aircraft Applications.In addition to fire detection, CPI thermals have a long history of success in military and non-military avionics applications. Here are just a few: Especially popular for fire and heat detection on aircraft are our rod and tube thermals because of their ability to operate with set points up to 1750F. Snapstat thermal switches boast a set point range: 0°F-300°F (-17.8°C-148°C) and are perfect for panel or pcb mounting. They have also been qualified in a hermetically sealed option that has dielectric resistance up to 5000 VAC. For more information call a CPI engineer today. https://www.cpi-nj.com/cpi-thermals-help-young-pilots-fly-safe/ |
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