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IT Hall Sensors from Montronix
Montronix Hall sensors measure the current flow in all three phases of an AC motor without contact and detect even the smallest deviations in real time. In combination with the PS200-NG, these signals are evaluated immediately to reliably prevent tool breakage, overloads, and failures. The result: more process reliability, less downtime, and additional protection for your machines.
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What is the Hall Effect?
The Hall effect describes a physical principle in which a magnetic field is created when current flows through a conductor. If a sensor is placed laterally in this magnetic field, a measurable voltage is generated. This so-called Hall voltage is directly related to the current in the conductor.
Hall sensors use this effect to measure current without contact. They detect even the smallest current changes, even with fluctuating loads, and can be mounted directly on the machine. This technology has proven itself especially in industrial applications because it is safe, low-maintenance, and quick to use.
How do Hall sensors work?
A Hall sensor measures the magnetic field that is created when current flows through a conductor. The sensor is placed around the power cable without touching it. This allows it to detect any change in current flow without interrupting or altering the line.
In a three-phase motor, current flows through three separate wires. Montronix therefore always supplies three Hall sensors, each monitoring one wire. These sensors record the current values analogically and send them directly to the PS200-NG evaluation system. The system compares the current values with the stored references and reacts immediately to deviations.
Applications of Hall Sensors
Hall sensors measure current contactlessly, quickly, and reliably and can be used in countless applications, from high-precision industrial systems to modern everyday devices.
- Milling machines in metalworking: Monitors spindle power consumption to detect tool breakage or dull edges immediately and stop the machining process in time.
- Hydraulic pumps in industrial plants: Detects blockages or wear by registering even the smallest current changes in the drive motor before a failure occurs.
- Combine harvesters in agriculture: Measures the current consumption of conveyor and cutting units to report blockages caused by wet or oversized crops at an early stage.
- Conveyor belts in recycling plants: Detects current spikes caused by material jams or foreign objects and automatically triggers a shutdown.
- Electric motors in e-bikes: Measures motor current to dynamically regulate the support level and protect the battery from overload.
- Water pumps in building technology: Detects changes in motor current that indicate dry running or defective bearings, thus preventing damage to the pump system.
- Elevators in office buildings: Monitors drive motors to detect unusual load changes caused by blocked doors or mechanical defects.
- Wind turbines: Measures current flow in the generator to detect imbalances or bearing damage early and plan maintenance operations.
- Induction hobs in households: Controls the current flow to the coils to precisely control the heating power and use energy efficiently.
- Industrial robots in production lines: Detects current changes in the axis drives to immediately detect collisions or blockages and stop the robot.
Note: Montronix focuses on the use of Hall sensors in industrial environments, especially for process monitoring, machine safety, and efficiency improvement.
Contact us nowThe Hall Sensor PS200-NG:
Technical Features and Application Advantages at a Glance
Why Hall sensors are so crucial in production
In machining, the machine reacts sensitively to any change in the process. Even a small difference in the current curve can indicate material defects, dull tools, or incorrect settings. If the system detects these deviations too late, defective parts or damage to the spindle and drive can occur.
Hall sensors solve this problem directly at the source. They detect the current flow without contact in all three phases of an AC motor. The system detects the smallest fluctuations immediately and forwards them to the PS200-NG evaluation unit. This analyzes the signal and reports any deviation in real time. This way you avoid production errors and permanently protect the drive components from overload and failure.
Advantages of our system of Hall sensors and PS200-NG
Detect tool breakage at an early stage
The system detects current changes directly at the first sign of a break. If the tool jams or breaks, the current in the spindle increases immediately. The sensors report this process within microseconds and prevent consequential damage to the workpiece or machine.
Contactless current measurement without risk
The Hall sensors are ring-shaped; a motor connection cable is passed through the center of a Hall sensor, and the Hall sensor does not electrically touch the power cable. They measure the magnetic field around the cable and remain electrically isolated. This protects the system from interference, increases safety, and prevents voltage losses.
Real-time response
The PS200-NG processes the input signals immediately. The combination with the Hall sensors detects any current deviation faster than the machine control or a human. This fast response is especially protective in short machining cycles or with sensitive tools.
Full monitoring of all three phases
Three-phase motors are connected to the drive module of the control via three separate wires. Montronix supplies three sensors, each detecting one wire. This way you also detect a fault if it only occurs in one phase.
Easy retrofit
The sensors can be placed directly over the existing power cable. You do not have to cut the line or prepare special connections. Connection to the PS200-NG system is via pre-assembled connectors and works immediately.
Contact
Would you like to use Hall sensors in your production or test the PS200-NG system without obligation? Then send us your inquiry. We will advise you personally, deliver a complete set, and support you with integration.
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