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HELPING YOU #MAKE SENSE OF SENSORS

EXAMPLE APPLICATIONS

TO ILLUSTRATE THE WIDE-VARIETY OF APPLICATIONS SOLVED USING CONTRINEX SENSORS, WE HAVE POSTED A LARGE SELECTION OF EXAMPLE APPLICATIONS WHICH CAN BE SEEN BY CLICKING ON AN IMAGE. BELOW ARE A SELECTION OF SOME OF THESE APPLICATIONS:
CUSTOMER VALUES COST-EFFECTIVE, ACTIVE SAFEGUARDING IMPROVED WORKPLACE ERGONOMICS INCREASED PRODUCTIVITY ARISING FROM UNIMPEDED LOADING AND UNLOADING INDUSTRY-STANDARD INTERFACE REQUIRES MINIMAL MODIFICATION TO CONTROL SYSTEMS PRODUCT ADVANTAGES PERMANENT AUTOCONTROL NOT USUALLY FOUND ON TYPE 2 SAFETY DEVICES IP65 AND IP67 PROTECTION NON-CONTACT OPERATING PRINCIPLES EXCELLENT SAFETY RATING TO EN/ISO 13849-1 CAT. 2 PL C AND IEC 61508 SIL 1 AOPD (ACTIVE OPTOELECTRONIC PROTECTIVE DEVICE) WITH ALUMINIUM HOUSING AND M12 CABLE CONNECTOR
CUSTOMER SOLUTION The company’s risk assessment confirms that Type 2 AOPDs (active optoelectronic protective devices) would ensure appropriate operator protection. Designed for applications where the risk has been evaluated as moderate, Safetinex IEC 61496 Type 2 light curtains from Contrinex are rated to EN/ISO 13849-1 Category 2, Performance Level PL c and IEC 61508 Safety Integrity Level SIL 1, making them ideal for the application. The heat-staking press is housed in an open-fronted enclosure with clear impact-resistant walls. The light curtain has an operating range of up to 12 metres and a resolution of 30 mm, ideal for hand protection; it safeguards the open front area of the press, allowing easy access when required. The protected height is 795mm, ensuring safe operation without impeding the operator during loading and unloading. Manufactured with rugged extruded aluminium housings and IP65 + IP67 protection, these units are well-suited to the production environment and will withstand shocks and vibrations. Industry-standard PNP normally-open configuration allows connection to the customer’s control system via an integral 5- pin M12 cable connector. These units have an integrated alignment LED and permanent autocontrol – a feature not usually found on Type 2 safety devices. The new sensors take up much less space than the mechanical guards they replaced, improving workplace ergonomics. Loading and unloading is no longer impeded, increasing productivity while actively safeguarding operators. Safetinex Type 2 light curtains provide a reliable and cost- effective solution.
CONTRINEX SENSORS ARE RENOWNED FOR PERFORMANCE AND RELIABILITY BY AUTOMOTIVE OEMS & THEIR SUPPLIERS AROUND THE WORLD.. CONTRINEXS INNOVATIVE PRODUCTS ARE OFTEN DEVELOPED WITH AUTOMOTIVE MIND - EXAMPLES INCLUDE THE UNIQUELY ROBUST 700 SERIES INDUCTIVES, METAL-ENCASED & EMBEDDABLE RFID TRANSPONDERS, MACHINE SAFETY SENSORS AND A WIDE PORTFOLIO OF PHOTOELECTRIC SENSORS. - EXPERTS IN MINIATURISATION, CONTRINEX SENSORS ARE POPULAR FOR JIGS, GAUGES & ASSEMBLY.

AUTOMOTIVE MANUFACTURING

& ASSEMBLY APPLICATIONS

Click for Brochure 700 Series - Extreme Robust Click for Brochure High Temperature Inductive & RFID Click for Brochure 700 Series -  Weld Immune Click for Brochure Miniature Photoelectric
CUSTOMER VALUES UNINTERRUPTED PRODUCTION AS PART IDENTIFICATION IS HIGHLY RELIABLE NO RISK OF SYSTEM DEGRADATION AS TAGS ARE RESISTANT TO HIGH TEMPERATURES LOW MAINTENANCE COSTS IN VIEW OF TRANSPONDERS EXTENDED SERVICE LIFE NO RISK OF PAINT CONTAMINATION OWING TO SILICONE-FREE TAG CONSTRUCTION PRODUCT ADVANTAGES LCP-HOUSED TRANSPONDERS OPERATE AT TEMPERATURES UP TO 250OC (482ºF) CONIDENT® TECHNOLOGY IS HIGHLY TOLERANT OF SURFACE CONTAMINATION EXTENDED SENSING DISTANCES UP TO 56MM
A manufacturer of automotive-suspension coil springs uses Radio Frequency Identification (RFID) technology to identify parts and monitor process status in an automated paint shop. Parts travel on dedicated transport frames; each transport frame, suspended from an overhead conveyor, is fitted with a high-frequency, high-temperature RFID tag. During the paint- curing cycle, temperatures may rise to 250°C (482°F) for more than 30 minutes. Contrinex high-temperature transponders operate reliably in this range. CUSTOMER APPLICATION Automotive suspension components require highly durable surface finishes. A German manufacturer of suspension coil springs operates an automated paint-processing plant that degreases, spray-paints and heat-cures parts. Springs travel through the plant on dedicated transport frames. RFID tags, mounted on the frames, identify individual parts. Throughout the process, read/write modules (RWMs), compatible with ISO/IEC 15693, interrogate the tags and update a centralized control system. During the heat-curing process, the entire transport frame, complete not only with parts but also with transponder, passes through the curing oven. Curing temperatures reach 250°C (482°F) for more than 30 minutes. Temperatures this high are beyond the capabilities of many RFID tags. In the past, complex mechanical arrangements were needed to shield devices from elevated-temperature areas. The customer requires RFID tags that not only withstand the high-temperature environment but also offer complete reliability and a service life of at least 2000 temperature cycles. Compliance with ISO/IEC 15693 is mandatory to ensure compatibility with existing RWMs.
Customer Solution Contrinex high-temperature high-frequency (HF) RFID tags are ideal for this application. These 50mm-diameter ConIdent® passive transponders with liquid-crystal polymer (LCP) housings are purpose-designed for operation at temperatures up to 250°C (482°F). They require no internal power source and are fully compliant with ISO/IEC 15693, ensuring compatibility with the customer’s existing equipment. The tags, mounted directly onto the transport frames, withstand repeated exposure to elevated temperatures and easily achieve the required service life. ConIdent® technology is also highly tolerant of surface contamination, and the tags ensure continuous error-free operation in spite of unavoidable soiling with paint overspray. These Contrinex RFID tags also boast silicone-free construction – an essential anti- contamination requirement for paint-shop applications. Contrinex transponders not only withstand the environment, they accommodate the variability of a transport frame’s travel path. Since the frame is not constrained from moving about its vertical axis, the exact path of the tag may vary from frame to frame – often by several millimetres. The system allows for this movement and produces reliable results that are independent of the exact tag position. Contrinex RFID tags provide accurate and highly reliable part identification in a demanding high-temperature environment. The customer enjoys extended service life and robustness not available from alternative transponders, together with excellent value for money.
CUSTOMER VALUES PROVEN TECHNOLOGY TO ENSURE HIGHLY RELIABLE FIT-&- FORGET POKA YOKE QUALITY CONTROL WITH NO MANUAL INTERVENTION UNOBTRUSIVE SYSTEM THAT DOES NOT IMPACT UPON THE WELDING STATION CYCYLE TIMES FAST & EASY SWAP OUT IN CASE OF DAMAGE TO THE SENSOR PRODUCT ADVANTAGES COMPACT & ROBUST, ALUMINIUM EXTRUDED HOUSING - 40 X 20.5MM) DIVERSE PORTFOLIO OFFERS EXCEPTIONAL RANGE OF SIZES - 100 TO 2,000MM HEIGHT AND 0.9 TO 25MM RESOLUTION FAST & EASY INTEGRATION WITH M12 CONNECTORS LOW COST, HIGH PERFORMANCE AND LONG SENSING RANGE
During manufacture of mechanical assemblies for automotive production, an operator uses a manually operated machine to weld metal parts together. After welding, the operator drops the assembly in a transport bin ready for dispatch. As each assembly is placed in the bin, an infra-red light detection grid sensor detects its presence and confirms that the welding cycle has been completed correctly CUSTOMER APPLICATION In an automotive 1st tier supplier manufacturing plant, an operator loads small parts by hand onto a resistance-welding machine and initiates the PLC-controlled welding cycle. After welding, the operator drops the completed assembly into a metal bin used to transport parts directly to the customer. From time to time, unwelded parts are placed in the bin, resulting in rejection of entire batches of assemblies by the customer. Manual inspection of each assembly is impractical; a sensor system must detect the presence of each item as it is dropped into the bin and check that the corresponding welding cycle has been completed. The sensing system must not increase the process cycle-time and must detect parts as they are dropped into the open bin, which is approximately 120cm (4ft) long and 90cm (3ft) wide. Parts are around 15cm (6in) long and a sensor with a rapid response time is necessary to detect fast-moving items.
Customer Solution The Contrinex DGI range of infrared light detection grids is well-suited for this application. Comprising separate sender- and receiver-units and constructed with rugged one-piece aluminium-profile housings, these versatile sensor systems are ideal for the busy production environment. With response times from 0.8 to 4.8 milliseconds which are faster than safety light-curtains and a choice of resolutions from 0.9 to 25mm dependent upon the size of the light grid, the DGI light detection grids range exceed the demanding customer specification for rapid response and reliable detection of the small parts. The 8m range between sender and receiver and their compact design enables easy mounting at each end of the transport bin without impeding the operator or increasing the process cycle time. The DGI light detection grid sender only requires a power supply connection and the receiver features two Push-Pull (PNP + NPN), Light-ON+ Dark-ON, 4-pin M12 outputs, simplifying installation. The system detects the presence of any item passing through the light curtain and immediately interrogates the PLC to confirm that a welding cycle has been completed since detection of the preceding item. If no welding cycle is registered, the system interrupts the process and sounds an alarm, alerting the operator.
CUSTOMER VALUES RAPID, RELIABLE DETECTION OF A SMALL, FAST-MOVING TARGET WITH AN ERRATIC PATH ELIMINATION OF DOWNTIME ARISING FROM BROKEN CABLES HIGHLY COST-EFFECTIVE SOLUTION TO A POTENTIALLY COSTLY PROBLEM PRODUCT ADVANTAGES SYSTEM SWITCHING FREQUENCY OF UP TO 4000 HZ EXCEPTIONALLY RELIABLE DETECTION ACROSS A 90MM X 20MM ENVELOPE DIFFUSE DETECTOR WITH SIMPLE SET-UP AND TEACH-IN FUNCTION
During manufacture of automotive parking-brake cable, multiple strands of steel wire are twisted together, forming a single cable. After twisting, cable passes to the next process in an unsupported, continuous length. Occasionally, the cable breaks, compromising safety and damaging equipment. Although the cable’s exact path is unpredictable, a multi- beam fibre-optic sensor detects its presence, interrupting the process if it breaks. CUSTOMER APPLICATION During production of automotive parking-brake cable in a Portuguese factory, strands of steel wire are twisted together, forming a single cable with a nominal diameter of 3mm (0.1in). The process operates continuously, and twisted cable passes between successive work-stations in an unbroken length. Between operations, the cable is largely unsupported, assuming the form of a suspended catenary. Occasionally, a manufacturing defect causes the cable to break. In this event, safety is compromised and, unless processing is halted, machine breakdowns occur. A sensor system must detect the presence of the cable as it passes from one operation to the next, interrupting the process if it breaks. Because the cable is unsupported, its path is unpredictable and its exact position at any time, particularly in the vertical plane, is unknown. The sensor system must detect the presence of the cable reliably at any point within an envelope 90mm (3.5in) high and 20mm (0.75in) wide.
Customer Solution A Contrinex photoelectric sensor system, comprising a DIN- rail-mounted fibre-optic amplifier coupled with a multi-beam diffuse sensing head, provides an optimal solution for this application. With maximum switching frequencies of up to 4000 Hz and sensing distances of up to 150mm (6in), multi- beam fibre-optic sensors are ideal for detecting fast-moving targets. The PBTP construction of the sensing head ensures excellent mechanical protection in the production environment. The 28mm-wide sensing face of the multi-beam sensor detects targets across its entire width, providing a detection envelope that comfortably accommodates the customer’s 90mm x 20mm requirement. Initial set-up is accomplished by means of a manual teach-in function and integral signal- strength LCD, following which the system operates without manual intervention. A 2m-long fibre cable allows remote mounting of the fibre- optic amplifier; connection to the customer’s control system is via an industry-standard PNP interface and an integral M8 cable connector, allowing easy removal and replacement when necessary. The system tolerates high ambient-light conditions and detection of a broken cable is both highly reliable and immediate. If the cable breaks, the system interrupts the process and sounds an alarm, alerting the operator. Downtime arising from broken cables has been eliminated since the system has been operational.
CUSTOMER VALUES RELIABLE DOUBLE-SHEET DETECTION ELIMINATES TOOL DAMAGE AND DOWNTIME COMPACT, ROBUST SENSOR ENSURES CONVENIENT, UNOBTRUSIVE OPERATION INCREASED FLEXIBILITY AS A SINGLE SENSOR DETECTS SEVERAL DIFFERENT MATERIALS (EG CARBON STEEL, STAINLESS STEEL & ALUMINIUM) REDUCED COMPLEXITY AS SENSOR CONNECTS DIRECTLY TO THE CUSTOMERS CONTROL SYSTEM PRODUCT ADVANTAGES SENSOR SPECIALLY DEVELOPED FOR DETECTING MULTIPLE OVERLAPPING METAL SHEETS CONDET® TECHNOLOGY MAKES PERFORMANCE INDEPENDENT OF TARGET MATERIAL RUGGED INDUCTIVE SENSOR WITH ONE-PIECE STAINLESS STEEL CONSTRUCTION EXTENDED SENSING DISTANCE AVOIDS RISK OF MECHANICAL DAMAGE
Contrinex’s innovative sensors provide affordable detection of overlapping metal sheets. They can protect a press-line by checking that two metal blanks are not presented to the forming press, or alternatively ensure two pieces of metal are present for example in an automotive welding assembly – Sometimes two’s too many, but sometimes you just need two. CUSTOMER APPLICATION A producer of deep-drawn metal parts for the automotive industry uses Contrinex’s double-sheet sensing to prevent costly tool damage and downtime. Deep drawing and other metal-forming techniques are widely used in the automotive industry, which requires expensive press tools to produce complex profiles from sheet metal blanks. During high-volume production, an automated feeder loads sheets of steel or aluminium to the press. The metal sheets are lightly lubricated to reduce friction during deep drawing, but the thin film of oil can cause two sheets to stick together in the feeder. If the press operates with such double sheets loaded, the forming tool will be damaged, resulting in downtime and large repair costs. Therefore sensing systems are used to check the material before it is loaded. Previously, the customer had trailed alternative sensor technologies. All were excessively cumbersome and difficult to set up, and most were unable to detect double sheets reliably.
Customer Solution Contrinex offers a rugged, compact stainless-steel -bodied sensor for the loading station, which checks each metal sheet as it is presented by the feeder. If it detects a double sheet, the material is rejected and the operating cycle inhibited, which reduces expensive damage to tooling and improves OEE. The sensor enables discrimination between single and double metal sheets of a defined thickness of steel or aluminium in the size range of 0.8 – 1.2mm thick. A specialist version of Contrinex’s uniquely robust ‘700 Series’ family of inductive sensors, they share the benefits of being both impact and abrasion resilient and having a case machined from a single-piece of stainless-steel – These are the sensors whose robustness is demonstrated by using them to hammer in nails. The reliability of their performance and robustness enable you to minimise downtime and improve the OEE of Press-lines or verify assembly operations.
During semi-automated heat staking of assemblies manufacturers use light curtains to preserve operator safety without compromising production throughput. The active optoelectronic protective device (AOPD), mounted directly in front of each bench-mounted heat-press, prevents the press- head from descending if it detects any intrusion in the working area, halting the operating cycle immediately. CUSTOMER APPLICATION Heat-staking is a popular process for fastening metal parts to plastic moldings, and is commonly used by manufacturers during the production of sub-assemblies. At each station, an operator loads a molding and one or more metal parts into a slide-mounted assembly fixture. Once the components are correctly inserted, the operator pushes the slide into position beneath the press-head, triggering the automated heat- staking cycle. The heated press-head, which may reach temperatures in excess of 350oC (660oF), descends toward the pre-positioned components. It applies heat and pressure to specific areas of the molding, causing a controlled thermal deformation that creates a permanent joint between the metal parts and the molding. Following a pre-determined dwell period, the head returns to the raised position, ending the cycle; the operator withdraws the slide and removes the assembly from the fixture. Existing mechanical safety barriers are cumbersome and inconvenient; throughput is constrained as a result of the time taken to open and close the guards during each cycle. The company requires an alternative safety guard that provides effective hand protection while allowing unobstructed loading and unloading. It must be simple, space-saving and operate reliably in the production environment.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL WORK TO HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk (0121) 58 222 58
#Make Sense of Sensors
Order Placement   Orders@PLUSAx.co.uk 0121 582 0835   Sales & Technical Product selection & application advice Sales@PLUSAx.co.uk 0121 58 222 58 Customer Service Price & Delivery / Lead time CustomerService@PLUSAx.co.uk 0121 582 0835 Contact Us
CUSTOMER VALUES COST-EFFECTIVE, ACTIVE SAFEGUARDING IMPROVED WORKPLACE ERGONOMICS INCREASED PRODUCTIVITY ARISING FROM UNIMPEDED LOADING AND UNLOADING INDUSTRY-STANDARD INTERFACE REQUIRES MINIMAL MODIFICATION TO CONTROL SYSTEMS PRODUCT ADVANTAGES PERMANENT AUTOCONTROL NOT USUALLY FOUND ON TYPE 2 SAFETY DEVICES IP65 AND IP67 PROTECTION NON-CONTACT OPERATING PRINCIPLES EXCELLENT SAFETY RATING TO EN/ISO 13849-1 CAT. 2 PL C AND IEC 61508 SIL 1 AOPD (ACTIVE OPTOELECTRONIC PROTECTIVE DEVICE) WITH ALUMINIUM HOUSING AND M12 CABLE CONNECTOR
CUSTOMER SOLUTION The company’s risk assessment confirms that Type 2 AOPDs (active optoelectronic protective devices) would ensure appropriate operator protection. Designed for applications where the risk has been evaluated as moderate, Safetinex IEC 61496 Type 2 light curtains from Contrinex are rated to EN/ISO 13849-1 Category 2, Performance Level PL c and IEC 61508 Safety Integrity Level SIL 1, making them ideal for the application. The heat-staking press is housed in an open-fronted enclosure with clear impact-resistant walls. The light curtain has an operating range of up to 12 metres and a resolution of 30 mm, ideal for hand protection; it safeguards the open front area of the press, allowing easy access when required. The protected height is 795mm, ensuring safe operation without impeding the operator during loading and unloading. Manufactured with rugged extruded aluminium housings and IP65 + IP67 protection, these units are well-suited to the production environment and will withstand shocks and vibrations. Industry-standard PNP normally-open configuration allows connection to the customer’s control system via an integral 5- pin M12 cable connector. These units have an integrated alignment LED and permanent autocontrol – a feature not usually found on Type 2 safety devices. The new sensors take up much less space than the mechanical guards they replaced, improving workplace ergonomics. Loading and unloading is no longer impeded, increasing productivity while actively safeguarding operators. Safetinex Type 2 light curtains provide a reliable and cost- effective solution.

AUTOMOTIVE

MANUFACTURING

& ASSEMBLY

APPLICATIONS

RENOWNED FOR PERFORMANCE AND RELIABILITY BY AUTOMOTIVE OEMS AND THEIR SUPPLY BASE, CONTRINEX SENSORS ARE TRUSTED AROUND THE WORLD. CONTRINEXS INNOVATIVE PRODUCTS ARE OFTEN DEVELOPED WITH AUTOMOTIVE MIND - EXAMPLES INCLUDE THE UNIQUELY ROBUST 700 SERIES INDUCTIVES, METAL-ENCASED & EMBEDDABLE RFID TRANSPONDERS, MACHINE SAFETY SENSORS AND A WIDE PORTFOLIO OF PHOTOELECTRIC SENSORS. - EXPERTS IN MINIATURISATION, CONTRINEX SENSORS ARE POPULAR FOR JIGS & ASSEMBLY.
Click for Brochure Miniature Photoelectric
A manufacturer of automotive-suspension coil springs uses Radio Frequency Identification (RFID) technology to identify parts and monitor process status in an automated paint shop. Parts travel on dedicated transport frames; each transport frame, suspended from an overhead conveyor, is fitted with a high-frequency, high-temperature RFID tag. During the paint- curing cycle, temperatures may rise to 250°C (482°F) for more than 30 minutes. Contrinex high-temperature transponders operate reliably in this range. CUSTOMER APPLICATION Automotive suspension components require highly durable surface finishes. A German manufacturer of suspension coil springs operates an automated paint-processing plant that degreases, spray-paints and heat-cures parts. Springs travel through the plant on dedicated transport frames. RFID tags, mounted on the frames, identify individual parts. Throughout the process, read/write modules (RWMs), compatible with ISO/IEC 15693, interrogate the tags and update a centralized control system. During the heat-curing process, the entire transport frame, complete not only with parts but also with transponder, passes through the curing oven. Curing temperatures reach 250°C (482°F) for more than 30 minutes. Temperatures this high are beyond the capabilities of many RFID tags. In the past, complex mechanical arrangements were needed to shield devices from elevated-temperature areas. The customer requires RFID tags that not only withstand the high-temperature environment but also offer complete reliability and a service life of at least 2000 temperature cycles. Compliance with ISO/IEC 15693 is mandatory to ensure compatibility with existing RWMs.
Customer Solution Stack-feeders deliver base plates, electrical printed circuit boards and other planar components to the assembly lines. In Contrinex high-temperature high-frequency (HF) RFID tags are ideal for this application. These 50mm-diameter ConIdent® passive transponders with liquid-crystal polymer (LCP) housings are purpose-designed for operation at temperatures up to 250°C (482°F). They require no internal power source and are fully compliant with ISO/IEC 15693, ensuring compatibility with the customer’s existing equipment. The tags, mounted directly onto the transport frames, withstand repeated exposure to elevated temperatures and easily achieve the required service life. ConIdent® technology is also highly tolerant of surface contamination, and the tags ensure continuous error-free operation in spite of unavoidable soiling with paint overspray. These Contrinex RFID tags also boast silicone-free construction – an essential anti- contamination requirement for paint-shop applications. Contrinex transponders not only withstand the environment, they accommodate the variability of a transport frame’s travel path. Since the frame is not constrained from moving about its vertical axis, the exact path of the tag may vary from frame to frame – often by several millimetres. The system allows for this movement and produces reliable results that are independent of the exact tag position. Contrinex RFID tags provide accurate and highly reliable part identification in a demanding high-temperature environment. The customer enjoys extended service life and robustness not available from alternative transponders, together with excellent value for money.
CUSTOMER VALUES RAPID, RELIABLE DETECTION OF A SMALL, FAST-MOVING TARGET WITH AN ERRATIC PATH ELIMINATION OF DOWNTIME ARISING FROM BROKEN CABLES HIGHLY COST-EFFECTIVE SOLUTION TO A POTENTIALLY COSTLY PROBLEM PRODUCT ADVANTAGES SYSTEM SWITCHING FREQUENCY OF UP TO 4000 HZ EXCEPTIONALLY RELIABLE DETECTION ACROSS A 90MM X 20MM ENVELOPE DIFFUSE DETECTOR WITH SIMPLE SET-UP AND TEACH-IN FUNCTION
Customer Solution The Contrinex DGI range of infrared light detection grids is well-suited for this application. Comprising separate sender- and receiver-units and constructed with rugged one-piece aluminium-profile housings, these versatile sensor systems are ideal for the busy production environment. With response times from 0.8 to 4.8 milliseconds which are faster than safety light-curtains and a choice of resolutions from 0.9 to 25mm dependent upon the size of the light grid, the DGI light detection grids range exceed the demanding customer specification for rapid response and reliable detection of the small parts. The 8m range between sender and receiver and their compact design enables easy mounting at each end of the transport bin without impeding the operator or increasing the process cycle time. The DGI light detection grid sender only requires a power supply connection and the receiver features two Push-Pull (PNP + NPN), Light-ON+ Dark-ON, 4-pin M12 outputs, simplifying installation. The system detects the presence of any item passing through the light curtain and immediately interrogates the PLC to confirm that a welding cycle has been completed since detection of the preceding item. If no welding cycle is registered, the system interrupts the process and sounds an alarm, alerting the operator.
Click for Brochure 700 Series - Extreme Robust Click for Brochure High Temperature Inductive & RFID Click for Brochure 700 Series -  Weld Immune
CUSTOMER VALUES UNINTERRUPTED PRODUCTION AS PART IDENTIFICATION IS HIGHLY RELIABLE NO RISK OF SYSTEM DEGRADATION AS TAGS ARE RESISTANT TO HIGH TEMPERATURES LOW MAINTENANCE COSTS IN VIEW OF TRANSPONDERS EXTENDED SERVICE LIFE NO RISK OF PAINT CONTAMINATION OWING TO SILICONE-FREE TAG CONSTRUCTION PRODUCT ADVANTAGES LCP-HOUSED TRANSPONDERS OPERATE AT TEMPERATURES UP TO 250OC (482ºF) CONIDENT® TECHNOLOGY IS HIGHLY TOLERANT OF SURFACE CONTAMINATION EXTENDED SENSING DISTANCES UP TO 56MM
CUSTOMER VALUES PROVEN TECHNOLOGY TO ENSURE HIGHLY RELIABLE FIT-&- FORGET POKA YOKE QUALITY CONTROL WITH NO MANUAL INTERVENTION UNOBTRUSIVE SYSTEM THAT DOES NOT IMPACT UPON THE WELDING STATION CYCYLE TIMES FAST & EASY SWAP OUT IN CASE OF DAMAGE TO THE SENSOR PRODUCT ADVANTAGES COMPACT & ROBUST, ALUMINIUM EXTRUDED HOUSING - 40 X 20.5MM) DIVERSE PORTFOLIO OFFERS EXCEPTIONAL RANGE OF SIZES - 100 TO 2,000MM HEIGHT AND 0.9 TO 25MM RESOLUTION FAST & EASY INTEGRATION WITH M12 CONNECTORS LOW COST, HIGH PERFORMANCE AND LONG SENSING RANGE
During manufacture of mechanical assemblies for automotive production, an operator uses a manually operated machine to weld metal parts together. After welding, the operator drops the assembly in a transport bin ready for dispatch. As each assembly is placed in the bin, an infra-red light detection grid sensor detects its presence and confirms that the welding cycle has been completed correctly CUSTOMER APPLICATION In an automotive 1st tier supplier manufacturing plant, an operator loads small parts by hand onto a resistance-welding machine and initiates the PLC-controlled welding cycle. After welding, the operator drops the completed assembly into a metal bin used to transport parts directly to the customer. From time to time, unwelded parts are placed in the bin, resulting in rejection of entire batches of assemblies by the customer. Manual inspection of each assembly is impractical; a sensor system must detect the presence of each item as it is dropped into the bin and check that the corresponding welding cycle has been completed. The sensing system must not increase the process cycle-time and must detect parts as they are dropped into the open bin, which is approximately 120cm (4ft) long and 90cm (3ft) wide. Parts are around 15cm (6in) long and a sensor with a rapid response time is necessary to detect fast-moving items.
During manufacture of automotive parking-brake cable, multiple strands of steel wire are twisted together, forming a single cable. After twisting, cable passes to the next process in an unsupported, continuous length. Occasionally, the cable breaks, compromising safety and damaging equipment. Although the cable’s exact path is unpredictable, a multi- beam fibre-optic sensor detects its presence, interrupting the process if it breaks. CUSTOMER APPLICATION During production of automotive parking-brake cable in a Portuguese factory, strands of steel wire are twisted together, forming a single cable with a nominal diameter of 3mm (0.1in). The process operates continuously, and twisted cable passes between successive work-stations in an unbroken length. Between operations, the cable is largely unsupported, assuming the form of a suspended catenary. Occasionally, a manufacturing defect causes the cable to break. In this event, safety is compromised and, unless processing is halted, machine breakdowns occur. A sensor system must detect the presence of the cable as it passes from one operation to the next, interrupting the process if it breaks. Because the cable is unsupported, its path is unpredictable and its exact position at any time, particularly in the vertical plane, is unknown. The sensor system must detect the presence of the cable reliably at any point within an envelope 90mm (3.5in) high and 20mm (0.75in) wide.
Customer Solution A Contrinex photoelectric sensor system, comprising a DIN- rail-mounted fibre-optic amplifier coupled with a multi-beam diffuse sensing head, provides an optimal solution for this application. With maximum switching frequencies of up to 4000 Hz and sensing distances of up to 150mm (6in), multi- beam fibre-optic sensors are ideal for detecting fast-moving targets. The PBTP construction of the sensing head ensures excellent mechanical protection in the production environment. The 28mm-wide sensing face of the multi-beam sensor detects targets across its entire width, providing a detection envelope that comfortably accommodates the customer’s 90mm x 20mm requirement. Initial set-up is accomplished by means of a manual teach-in function and integral signal- strength LCD, following which the system operates without manual intervention. A 2m-long fibre cable allows remote mounting of the fibre- optic amplifier; connection to the customer’s control system is via an industry-standard PNP interface and an integral M8 cable connector, allowing easy removal and replacement when necessary. The system tolerates high ambient-light conditions and detection of a broken cable is both highly reliable and immediate. If the cable breaks, the system interrupts the process and sounds an alarm, alerting the operator. Downtime arising from broken cables has been eliminated since the system has been operational.
Contrinex’s innovative sensors provide affordable detection of overlapping metal sheets. They can protect a press-line by checking that two metal blanks are not presented to the forming press, or alternatively ensure two pieces of metal are present for example in an automotive welding assembly – Sometimes two’s too many, but sometimes you just need two. CUSTOMER APPLICATION A producer of deep-drawn metal parts for the automotive industry uses Contrinex’s double-sheet sensing to prevent costly tool damage and downtime. Deep drawing and other metal-forming techniques are widely used in the automotive industry, which requires expensive press tools to produce complex profiles from sheet metal blanks. During high-volume production, an automated feeder loads sheets of steel or aluminium to the press. The metal sheets are lightly lubricated to reduce friction during deep drawing, but the thin film of oil can cause two sheets to stick together in the feeder. If the press operates with such double sheets loaded, the forming tool will be damaged, resulting in downtime and large repair costs. Therefore sensing systems are used to check the material before it is loaded. Previously, the customer had trailed alternative sensor technologies. All were excessively cumbersome and difficult to set up, and most were unable to detect double sheets reliably.
CUSTOMER VALUES RELIABLE DOUBLE-SHEET DETECTION ELIMINATES TOOL DAMAGE AND DOWNTIME COMPACT, ROBUST SENSOR ENSURES CONVENIENT, UNOBTRUSIVE OPERATION INCREASED FLEXIBILITY AS A SINGLE SENSOR DETECTS SEVERAL DIFFERENT MATERIALS (EG CARBON STEEL, STAINLESS STEEL & ALUMINIUM) REDUCED COMPLEXITY AS SENSOR CONNECTS DIRECTLY TO THE CUSTOMERS CONTROL SYSTEM PRODUCT ADVANTAGES SENSOR SPECIALLY DEVELOPED FOR DETECTING MULTIPLE OVERLAPPING METAL SHEETS CONDET® TECHNOLOGY MAKES PERFORMANCE INDEPENDENT OF TARGET MATERIAL RUGGED INDUCTIVE SENSOR WITH ONE-PIECE STAINLESS STEEL CONSTRUCTION EXTENDED SENSING DISTANCE AVOIDS RISK OF MECHANICAL DAMAGE
Customer Solution Contrinex offers a rugged, compact stainless-steel -bodied sensor for the loading station, which checks each metal sheet as it is presented by the feeder. If it detects a double sheet, the material is rejected and the operating cycle inhibited, which reduces expensive damage to tooling and improves OEE. The sensor enables discrimination between single and double metal sheets of a defined thickness of steel or aluminium in the size range of 0.8 – 1.2mm thick. A specialist version of Contrinex’s uniquely robust ‘700 Series’ family of inductive sensors, they share the benefits of being both impact and abrasion resilient and having a case machined from a single-piece of stainless-steel – These are the sensors whose robustness is demonstrated by using them to hammer in nails. The reliability of their performance and robustness enable you to minimise downtime and improve the OEE of Press-lines or verify assembly operations.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk 0121 58 222 58
During semi-automated heat staking of assemblies manufacturers use light curtains to preserve operator safety without compromising production throughput. The active optoelectronic protective device (AOPD), mounted directly in front of each bench-mounted heat-press, prevents the press- head from descending if it detects any intrusion in the working area, halting the operating cycle immediately. CUSTOMER APPLICATION Heat-staking is a popular process for fastening metal parts to plastic moldings, and is commonly used by manufacturers during the production of sub-assemblies. At each station, an operator loads a molding and one or more metal parts into a slide-mounted assembly fixture. Once the components are correctly inserted, the operator pushes the slide into position beneath the press-head, triggering the automated heat- staking cycle. The heated press-head, which may reach temperatures in excess of 350oC (660oF), descends toward the pre-positioned components. It applies heat and pressure to specific areas of the molding, causing a controlled thermal deformation that creates a permanent joint between the metal parts and the molding. Following a pre-determined dwell period, the head returns to the raised position, ending the cycle; the operator withdraws the slide and removes the assembly from the fixture. Existing mechanical safety barriers are cumbersome and inconvenient; throughput is constrained as a result of the time taken to open and close the guards during each cycle. The company requires an alternative safety guard that provides effective hand protection while allowing unobstructed loading and unloading. It must be simple, space-saving and operate reliably in the production environment.