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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 Industry-standard IO-Link interface ensures reliable out-of-the-box connectivity Dual-mode read-write modules deliver ultimate flexibility Standard I/O mode operation provides decentralized, local intelligence IO-Link mode operation provides centralized intelligence Plant-wide commonality of RWM hardware minimizes spares inventory holding Integral M12 connectors ensure easy installation and replacement PRODUCT ADVANTAGES IO-Link V1.1 compatibility Robust metal housings with PBTB sensing faces Sensing distances up to 60mm Reconfigurable remotely or via Master Tag
Bulk-handling and pneumatic transport system designers use RFID technology to eliminate connection errors at manual hose-coupling stations for fluidizable materials. Coupling stations, with IO-Link enabled read/write modules (RWMs) mounted on each outlet pipe, use manual quick- release hoses to feed materials to multiple machines. RFID tags, mounted integrally within each hose coupling and blanking cap, identify the mating parts uniquely, allowing individual outlet/hose combinations to be verified at the time of connection. CUSTOMER APPLICATION Bulk-handling systems across diverse industries, including food processing, plastics and pharmaceuticals, rely heavily on pneumatic conveying systems for transporting powders, granulates and other fluidizable materials. Pneumatic conveyors offer quick, reliable high-volume transportation with minimum degradation of the transported material. Coupling stations offer a simple and cost-effective means of connecting several material sources, typically silos or storage bins, to multiple processing machines. A pipe from each source enters the bottom of the coupling station, where it branches, providing multiple outlets for each material. Quick- release hoses, connected manually to the corresponding outlets, feed materials to machines. Unused outlets are capped.
CONTRINEXS PHOTOELECTRIC, INDUCTIVE, RFID AND MACHINE SAFETY SENSORS ARE TRUSTED ACROSS THE MANY ASPECTS OF FOOD & BEVERAGE MANUFACTURING AND PACKAGING. IMPROVE MACHINE PERFORMANCE WITH SUPERIOR SENSOR PERFORMANCE, PLUS ADDED FEATURES LIKE PREVENTATIVE-MAINTENANCE OUTPUTS, IP69K CIP-WASHDOWN INDUCTIVE, SAFETY & RFID SENSORS, UV TRANSPARENT-OBJECT DETECTION, PLUS THE WORLDS LARGEST SELECTION OF IO-LINK SENSORS PROVIDING ADDITIONAL PERFORMANCE DATA IN A CONSISTENT MANNER AND EASY IOT / INDUSTRY 4 CONNECTIVITY.
Food & Beverage Applications
Customer Solution Ecolab-certified, diffuse-mode photoelectric sensors with background suppression from the Contrinex C23 product family are ideally suited to this application. These miniature cubic devices, mounted above product conveyors immediately after each buffering station, detect the presence of cheese portions as they pass underneath. Positioning sensors is simple thanks to a range of adjustable stainless steel mounting brackets. An industry-standard PNP normally open output with an M8 connector ensures optimum flexibility. Additionally, IO-Link, a standardized point-to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost, offering the advantages of digital communication without the need for special cabling. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Robust sensor construction, featuring miniature (20mm x 30mm x 10mm) plastic housings, ensures reliable operation in the demanding washdown environment; Contrinex C23 devices are rated to IP67. An operating range between 15mm and 250mm, adjustable via a teach button or via IO-Link, accommodates the range of portion sizes without compromise. A brief one- or two-step teach procedure simplifies initial set- up. One-button operation allows process engineers to teach the target object and, optionally, the background, each time a new portion size is introduced. Once taught, sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO-Link, eliminating the need for manual adjustment. These rugged miniature sensors meet the customer’s need for reliable operation with little or no manual intervention, while unplanned sanitization is avoided. The solution is highly cost-effective with minimal non-productive time; throughput is maintained at or above target levels.
Contrinex’s small, but powerful C23PA photoelectric sensors are trusted to ensure conveyors deliver cheese portions to packaging stations, with in-line buffering stations regulating their flow to match packaging throughput. The miniature Ecolab-certified sensors detect the presence of each portion after buffering, triggering the packaging cycle. Sensitivity parameters for each portion size, stored on the sensor’s inbuilt memory, may be updated remotely using IO-Link, removing the need for a manual intervention and eliminating the need for unplanned sanitisation between batches. CUSTOMER APPLICATION A Swiss manufacturer of premium dairy products produces a range of individually packaged cheese portions in a high- volume hygienic production facility. Once cut to size, cheese portions travel on a food-grade conveyor to a packaging station; the duration of the packaging cycle is dependent on the type of cheese and the portion size. Prior to packaging, a buffering station produces a regular flow of portions with a predetermined spacing to suit the packaging throughput. The two operations must be synchronized; the manufacturer requires a sensor system that detects the presence of each cheese portion as it leaves the buffering station, triggering the packaging cycle. Sensors must be food-grade certified and withstand the aggressive cleaning agents used during washdown routines. They must also accommodate the full range of portion sizes without the need for manual adjustment, as this would necessitate sanitisation each time the portion size changes. Maximising throughput is an additional priority; rapid changeover between product batches is essential.
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick- and-place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and-place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and-place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary-packaging station, a plant- wide control system prevents operation of the pick-and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom-formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non-contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and- place sequence if no bags are queued for packing
CUSTOMER SOLUTION Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm-diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent
CUSTOMER VALUES Reliable, repeatable in-line quality checks on a non- contact basis Improved quality arising from real-time detection of incorrectly packed cartons Increased productivity as stability alarm flags preventative-maintenance needs• Single sensor accommodates a range of carton sizes without repositioning Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES Maximum sensing range of 300mm with pinpoint red LED Best-in-class background-suppression black/white behaviour IO-Link connectivity available at no extra cost on PNP versions• Dual output with stability alarm
CUSTOMER VALUES Safe, reliable operation in a hostile washdown environment No risk of cross-contamination between processing and cleaning sequences Easy integration with existing plant-wide control system Cost-effective solution requiring minimal maintenance PRODUCT ADVANTAGES IP68/ IP69K rated housing, food-compatible body Exceptional resistance to shock and vibration Affordable high-performance sensor with excellent reliability
During manufacture of dairy products, raw milk travels between successive processes through stainless-steel pipework. Rotary-shaft control valves maintain process sequences correctly, ensuring that no cross-contamination occurs during CIP cleaning after each batch is completed. Robust washdown inductive sensors, mounted on existing rotary actuators, monitor control-valve status around the clock, providing real-time positional feedback to a plant-wide control system in a simple, cost-effective manner. CUSTOMER APPLICATION At a European dairy-processing plant, milk products, made from pasteurized or raw milk, require hygienic transportation between successive operations. Process engineers use stainless-steel pipework to transport liquid ingredients from one operation to the next. Fluid flow is managed using control valves fitted with electrical, hydraulic or pneumatic actuators. Multiple rotary-shaft valves deliver raw milk from holding tanks to each process station in sequence, maintaining specified flow rates and volumetric limits. Once processing of each batch is completed and all process vessels are drained, closed-loop CIP cleaning commences. Accurate, repeatable valve sequencing is essential to prevent any chance of cross- contamination between processing and cleaning sequences. A robust, highly reliable sensor system, capable of withstanding the harsh washdown regimes in force, is needed to monitor control-valve positions during processing. Where possible, sensors must be mounted on existing rotary actuators, and real-time communication with existing plant- wide control systems is mandatory.
Customer Solution Sensing the position of a rotary-valve actuator is a routine task for Contrinex Classics washdown inductive sensors. These sensors interface directly with a range of industrial process controllers and provide cost-effective confirmation of control-valve status around the clock. A purpose-designed bracket, mounted on the top surface of each actuator, holds two sensors; these are positioned with the sensing faces vertically aligned, one above the other, and facing the actuator shaft. NAMUR-compatible (VDE/VDI 3845) mountings on the actuators provide a known datum for the sensors. A solid plastic disc, mounted on the shaft, carries two or more stainless-steel targets, positioned at 90 degrees to each other around the outer peripheral surface of the disc. Each target occupies either an upper or a lower position corresponding to height of one of the sensors. As the shaft rotates, opening and closing the valve, the targets pass in front of the sensing faces, triggering the sensors. These M12-diameter devices, rated to IP68/IP69K, have all- metal bodies with PBTB sensing faces and vacuum- encapsulated electronics; each features an industry-standard PNP normally open output. Fully embeddable, and with a sensing range up to 2mm, they are well suited to the hostile operating conditions of a washdown environment. Each sensor has an integral M12 connector, interfacing with the customer’s control system via a TPE-S-sheathed cable. Reliability is excellent; the system is simple and cost-effective.
Human error can result in hoses being connected to the wrong outlet, causing costly errors if undetected; systems designers require real-time confirmation that the correct hose has been connected to each outlet, or, where no connection is specified, that a blanking cap is in place. An industry-standard interface is highly desirable; ultra-high- speed communication is not essential.
Customer Solution IO-Link-enabled high-frequency (HF) read-write modules (RWMs) and RFID tags from Contrinex are ideal for this application. An IO-Link-enabled RWM, mounted on each outlet pipe, is connected to a plant-wide control system via two industry-standard 8-way IO-Link master hubs. An RFID tag, mounted integrally within each hose coupling, identifies the hose uniquely, allowing the outlet/hose combination to be verified at the time of connection. Blanking caps also carry unique RFID tags to confirm that unused outlets are capped. The mechanical design of the RWM and tag mountings ensures that the coupling or cap can only be locked in place once the components are aligned accurately. With data- transfer rates up to 38.4k baud, the sensors provide data in real time, triggering an immediate alarm in the event of a connection error. Contrinex IO-Link RWMs are configurable to operate in one of two discrete modes: IO-Link mode allows remote communication via the standard protocol; alternatively, if local control is preferred, standard I/O mode allows the device to function as an intelligent presence-sensing sensor. Process engineers can switch RWMs between modes either remotely, using the IO-Link protocol itself, or locally, using a pre- configured RFID tag (a Master Tag) which is simply placed on top of the RWM during the RWM startup process. With sensing distances up to 60 mm, robust M18- and M30- threaded metal housings and integral M12 connectors, Contrinex RWMs are ideally suited to the environment of a busy industrial processing plant. They are compatible with all ISO/IEC 15693 approved RFID tags, allowing designers ultimate flexibility and excellent value for money.
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
CUSTOMER VALUES Ecolab-certified sensors are ideal for hygienic production facilities Wide operating range accommodates full range of portion sizes Sensitivity parameters are retrieved or updated remotely via IO-Link Unnecessary sanitization between batches is avoided Simple one- or two-step teach procedure optimises initial sensor set-up Stability alarm highlights reduced sensitivity, avoiding unplanned stoppages Downtime is avoided by eliminating the need for technicians to attend machines PRODUCT ADVANTAGES Ecolab-certified photoelectric sensors with background-suppression mode IO-Link serial-connection protocol enabled on PNP versions at no additional cost Pre-taught sensitivity parameters stored on inbuilt sensor memory Remote sensitivity retrieval or update via IO-Link Robust sensors with miniature (20mm x 30mm x 10mm) plastic housings
CUSTOMER VALUES Reliable, repeatable in-line testing of a range of different-sized containers Testing is completed at production-line speed Immediate identification of missing closures Elimination of manual inspection and potential batch rejection PRODUCT ADVANTAGES Extended sensing distances up to 40mm Unmatched combination of 40mm sensing distance in M30-diameter device
CUSTOMER SOLUTION Contrinex Extra Distance inductive sensors are ideal for this application, with the M30-diameter units operating reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable and fast detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of 40mm sensing distance in an M30-diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions can occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time or potential rejection by customers. An in-line sensor system inspecting each container could confirm the presence of a foil closure, rejecting any faulty items. Each production line processes containers in batches. The system must accommodate containers whose heights vary by up to 20mm, without adjustment of sensors between batches as successive batches may comprise containers of differing sizes.
Customer Solution Contrinex ultrasonic sensors are ideal for presence- and level- sensing applications, and a diffuse sensor from the Compact range (housing size M30) is an excellent choice for this application. Operating range for this metal-bodied, IP65-rated device is between 20cm and 130cm; detection is independent of the target’s color, shape, material or surface structure. Contrinex Compact ultrasonic sensors feature an integral S12 cable connector, allowing rapid disconnection and removal when required. The variable size and shape of meat residue makes it difficult for an uncompensated sensor to detect contamination consistently and reliably; potentiometer adjustment, provided by many manufacturers, is inadequate for this application. Contrinex CONPROG software for Windows®, connected via the APE-0000-001 PC interface, compensates perfectly. Using CONPROG, the operator characterizes the target area of the box during set-up, setting the exact operating parameters of the sensor and ensuring reliable detection. Sensor data is stored, allowing like-for-like sensor replacement without additional set-up. The sensor’s three-wire PNP normally-open output communicates directly with the customer PLC. On detection of a contaminated box, a mechanical diverter shunts the box to a separate conveyor for manual emptying.
A meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact-based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
CUSTOMER VALUES Improved sensor reliability derived from exact characterisation of target Increased productivity arising from elimination of breakdowns Reduced sensor maintenance resulting from non- contact operation Industry-standard interface requires little modification to control systems PRODUCT ADVANTAGES Ecolab-certified photoelectric sensors with background-suppression mode Characterised sensors detect targets of variable size and shape Long-distance, non-contact operating principles IP65 protection allows operation in hygienic environments Rugged ultrasonic sensor with metal housing and metal cable connector
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CUSTOMER VALUES Reliable, repeatable in-line quality checks on a non- contact basis Improved quality arising from real-time detection of incorrectly packed cartons Increased productivity as stability alarm flags preventative-maintenance needs• Single sensor accommodates a range of carton sizes without repositioning Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES Maximum sensing range of 300mm with pinpoint red LED Best-in-class background-suppression black/white behaviour IO-Link connectivity available at no extra cost on PNP versions• Dual output with stability alarm
Contrinex’s C23 photoelectric sensor family is small but powerful and so ideal for conveyor and packaging applications. An example application for the C23 is the food processing industry, where ‘shingling’, or overlapped layering, is a common technique for optimizing space during secondary packaging operations. As shown in the video, biscuits are sealed in gusseted bags with a triangular profile, and packed in alternating, overlapping layers into a preformed cardboard box. Once each box is full, it passes to a case-sealing station prior to palletisation and dispatch. From time to time, an incorrectly formed layer occurs, where a bag might be damaged or misaligned. The C23 photoelectric sensor with Background Suppression is used to provide non-contact sensing of the height of the top layer of bags, rejecting any over-filled cartons. CUSTOMER APPLICATION In the food processing industry, shingling, or overlapped layering, is a common technique for optimising space utilisation during secondary packaging operations. Confectionery, sealed in gusseted bags with predominantly triangular profiles, is packed in alternating, overlapping layers in preformed cardboard cartons. Once each carton is full, it passes to a case-sealing station prior to palletisation and dispatch. Pre-aligned bags of confectionery arrive at the packing station in regularly spaced rows. At each station, a multi-axis pick-and-place packing robot lifts a row of bags, aligns it and lowers it into a preformed carton. Successive layers overlap each other, ensuring that space within the carton is fully utilised. Once the predetermined number of layers has been packed, the carton is conveyed to the sealing station. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non-contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
CUSTOMER SOLUTION Rugged photoelectric sensors with background suppression from the Contrinex C23 range are ideal for this application. A pinpoint red LED with a 10mm-diameter light spot at the maximum sensing range of 300mm ensures highly reliable detection of objects of almost any colour against light or dark backgrounds. These sensors are well suited to both the task and the environment. Immediately after packing, a single sensor is mounted centrally above the conveyor. As each carton passes below on its way to the sealing station, the sensor detects the top surface of the packed bags. If the height of the top layer falls outside preset limits, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Locating sensors optimally is simple thanks to a custom- designed range of multi-position mounting brackets. An operating range between 15mm and 250mm accommodates a variety of carton sizes without any need to reposition the sensor. A simple electrical adjustment via an onboard potentiometer suffices, while remote adjustment via IO-Link, a standardized point-to-point serial connection protocol, is available as standard at no extra cost for PNP versions
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Food & Beverage Applications
CONTRINEXS PHOTOELECTRIC, INDUCTIVE, RFID AND MACHINE SAFETY SENSORS ARE TRUSTED ACROSS THE MANY ASPECTS OF FOOD & BEVERAGE MANUFACTURING AND PACKAGING. IMPROVE MACHINE PERFORMANCE WITH SUPERIOR SENSOR PERFORMANCE, PLUS ADDED FEATURES LIKE PREVENTATIVE-MAINTENANCE OUTPUTS, IP69K CIP-WASHDOWN INDUCTIVE, SAFETY & RFID SENSORS, UV TRANSPARENT-OBJECT DETECTION, PLUS THE WORLDS LARGEST SELECTION OF IO-LINK SENSORS PROVIDING ADDITIONAL PERFORMANCE DATA IN A CONSISTENT MANNER AND EASY IOT / INDUSTRY 4 CONNECTIVITY. .
During the production of individually packaged cheese portions, conveyors deliver product to packaging stations. In- line buffering stations regulate flow to match packaging throughput; miniature Ecolab-certified sensors detect the presence of each portion after buffering, triggering the packaging cycle. Sensitivity parameters for each portion size, stored on the sensor’s inbuilt memory, may be updated remotely without manual intervention, eliminating the need for unplanned sanitisation between batches. CUSTOMER APPLICATION A Swiss manufacturer of premium dairy products produces a range of individually packaged cheese portions in a high- volume hygienic production facility. Once cut to size, cheese portions travel on a food-grade conveyor to a packaging station; the duration of the packaging cycle is dependent on the type of cheese and the portion size. Prior to packaging, a buffering station produces a regular flow of portions with a predetermined spacing to suit the packaging throughput. The two operations must be synchronized; the manufacturer requires a sensor system that detects the presence of each cheese portion as it leaves the buffering station, triggering the packaging cycle. Sensors must be food-grade certified and withstand the aggressive cleaning agents used during washdown routines. They must also accommodate the full range of portion sizes without the need for manual adjustment, as this would necessitate sanitization each time the portion size changes. Maximising throughput is an additional priority; rapid changeover between product batches is essential. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non-contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
CUSTOMER SOLUTION Ecolab-certified, diffuse-mode photoelectric sensors with background suppression from the Contrinex C23 product family are ideally suited to this application. These miniature cubic devices, mounted above product conveyors immediately after each buffering station, detect the presence of cheese portions as they pass underneath. Positioning sensors is simple thanks to a range of adjustable stainless steel mounting brackets. An industry-standard PNP normally open output with an M8 connector ensures optimum flexibility. Additionally, IO-Link, a standardized point-to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost, offering the advantages of digital communication without the need for special cabling. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Robust sensor construction and Ecolab-certified miniature (20mm x 30mm x 10mm) plastic housings which are corrosion-resistant and impervious to water ingress ensure reliable operation in the demanding washdown environment; Contrinex C23 devices are rated to IP67. An operating range between 15mm and 250mm, adjustable via a teach button or via IO-Link, accommodates the range of portion sizes without compromise. A brief one- or two-step teach procedure simplifies initial set- up. One-button operation allows process engineers to teach the target object and, optionally, the background, each time a new portion size is introduced. Once taught, sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO-Link, eliminating the need for manual adjustment. These rugged miniature sensors meet the customer’s need for reliable operation with little or no manual intervention, while unplanned sanitization is avoided. The solution is highly cost-effective with minimal non-productive time; throughput is maintained at or above target levels. An additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry.
CUSTOMER VALUES Reliable, repeatable in-line quality checks on a non- contact basis Improved quality arising from real-time detection of incorrectly packed cartons Increased productivity as stability alarm flags preventative-maintenance needs Single sensor accommodates a range of carton sizes without repositioning Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES Maximum sensing range of 300mm with pinpoint red LED Best-in-class background-suppression black/white behaviour IO-Link connectivity available at no extra cost on PNP versions Dual output with stability alarm
CUSTOMER VALUES Industry-standard IO-Link interface ensures reliable out-of-the-box connectivity Dual-mode read-write modules deliver ultimate flexibility Standard I/O mode operation provides decentralized, local intelligence IO-Link mode operation provides centralized intelligence Plant-wide commonality of RWM hardware minimizes spares inventory holding Integral M12 connectors ensure easy installation and replacement PRODUCT ADVANTAGES IO-Link V1.1 compatibility Robust metal housings with PBTB sensing faces Sensing distances up to 60mm Reconfigurable remotely or via Master Tag
A manufacturer of automated conveyor systems uses RFID technology to monitor the location of items and to route them to their chosen destinations. As an basket, fitted with an RFID transponder tag, travels through the warehouse, IO- Link-enabled high-frequency read-write modules (RWMs) monitor its position and read pre-set data stored in the tag. Local logic capability enables a read-write module to trigger a conveyor diverter, routing the item without reference to a centralised PLC-based control system. CUSTOMER APPLICATION An OEM manufacturer of automated conveyor systems for the distribution sector uses RFID technology to monitor the location of items as they pass through a warehouse. Designers also required local control of two-way conveyor diverters to route items to the correct destination;. Therefore generic information stored on each RFID transponder tag determines the required diverter position and thus an item’s destination. Location monitoring relies on a plant-wide PLC-based control system. An industry-standard interface with the RFID modules is highly desirable as this allows the use of existing libraries of PLC function blocks, avoiding the need for custom PLC code. Ultra-high-speed communication is not essential as conveyor speeds are moderate. Local diverter switching relies solely on the information contained in an item’s RFID tag; communication with the centralized system is unnecessary. Response time must be no more than 200 milliseconds to allow the diverter to operate before the item reaches the switch point.
Customer Solution IO-Link-enabled high-frequency (HF) read-write modules (RWMs) and RFID tags from Contrinex are ideal for this application. An IO-Link-enabled RWM, mounted on each outlet pipe, is connected to a plant-wide control system via two industry-standard 8-way IO-Link master hubs. An RFID tag, mounted integrally within each hose coupling, identifies the hose uniquely, allowing the outlet/hose combination to be verified at the time of connection. Blanking caps also carry unique RFID tags to confirm that unused outlets are capped. The mechanical design of the RWM and tag mountings ensures that the coupling or cap can only be locked in place once the components are aligned accurately. With data- transfer rates up to 38.4k baud, the sensors provide data in real time, triggering an immediate alarm in the event of a connection error. Contrinex IO-Link RWMs are configurable to operate in one of two discrete modes: IO-Link mode allows remote communication via the standard protocol; alternatively, if local control is preferred, standard I/O mode allows the device to function as an intelligent presence-sensing sensor. Process engineers can switch RWMs between modes either remotely, using the IO-Link protocol itself, or locally, using a pre- configured RFID tag (a Master Tag) which is simply placed on top of the RWM during the RWM startup process. With sensing distances up to 60 mm, robust M18- and M30- threaded metal housings and integral M12 connectors, Contrinex RWMs are ideally suited to the environment of a busy industrial processing plant. They are compatible with all ISO/IEC 15693 approved RFID tags, allowing designers ultimate flexibility and excellent value for money.
CUSTOMER VALUES Reliable, repeatable in-line quality checks on a non- contact basis Improved quality arising from real-time detection of incorrectly packed cartons Increased productivity as stability alarm flags preventative-maintenance needs• Single sensor accommodates a range of carton sizes without repositioning Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES Maximum sensing range of 300mm with pinpoint red LED Best-in-class background-suppression black/white behaviour IO-Link connectivity available at no extra cost on PNP versions• Dual output with stability alarm
Contrinex’s C23 photoelectric sensor family is small but powerful and so ideal for conveyor and packaging applications. An example application for the C23 is the food processing industry, where ‘shingling’, or overlapped layering, is a common technique for optimizing space during secondary packaging operations. As shown in the video, biscuits are sealed in gusseted bags with a triangular profile, and packed in alternating, overlapping layers into a preformed cardboard box. Once each box is full, it passes to a case-sealing station prior to palletisation and dispatch. From time to time, an incorrectly formed layer occurs, where a bag might be damaged or misaligned. The C23 photoelectric sensor with Background Suppression is used to provide non-contact sensing of the height of the top layer of bags, rejecting any over-filled cartons. CUSTOMER APPLICATION In the food processing industry, shingling, or overlapped layering, is a common technique for optimising space utilisation during secondary packaging operations. Confectionery, sealed in gusseted bags with predominantly triangular profiles, is packed in alternating, overlapping layers in preformed cardboard cartons. Once each carton is full, it passes to a case-sealing station prior to palletisation and dispatch. Pre-aligned bags of confectionery arrive at the packing station in regularly spaced rows. At each station, a multi-axis pick-and-place packing robot lifts a row of bags, aligns it and lowers it into a preformed carton. Successive layers overlap each other, ensuring that space within the carton is fully utilised. Once the predetermined number of layers has been packed, the carton is conveyed to the sealing station. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non-contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
CUSTOMER SOLUTION Rugged photoelectric sensors with background suppression from the Contrinex C23 range are ideal for this application. A pinpoint red LED with a 10mm-diameter light spot at the maximum sensing range of 300mm ensures highly reliable detection of objects of almost any colour against light or dark backgrounds. These sensors are well suited to both the task and the environment. Immediately after packing, a single sensor is mounted centrally above the conveyor. As each carton passes below on its way to the sealing station, the sensor detects the top surface of the packed bags. If the height of the top layer falls outside preset limits, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Locating sensors optimally is simple thanks to a custom- designed range of multi-position mounting brackets. An operating range between 15mm and 250mm accommodates a variety of carton sizes without any need to reposition the sensor. A simple electrical adjustment via an onboard potentiometer suffices, while remote adjustment via IO-Link, a standardized point-to-point serial connection protocol, is available as standard at no extra cost for PNP version.
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick- and-place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and-place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and-place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary-packaging station, a plant- wide control system prevents operation of the pick-and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom-formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non-contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and- place sequence if no bags are queued for packing
CUSTOMER SOLUTION Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm-diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent
CUSTOMER VALUES Safe, reliable operation in a hostile washdown environment No risk of cross-contamination between processing and cleaning sequences Easy integration with existing plant-wide control system Cost-effective solution requiring minimal maintenance PRODUCT ADVANTAGES IP68/ IP69K rated housing, food-compatible body Exceptional resistance to shock and vibration Affordable high-performance sensor with excellent reliability
During manufacture of dairy products, raw milk travels between successive processes through stainless-steel pipework. Rotary-shaft control valves maintain process sequences correctly, ensuring that no cross-contamination occurs during CIP cleaning after each batch is completed. Robust washdown inductive sensors, mounted on existing rotary actuators, monitor control-valve status around the clock, providing real-time positional feedback to a plant-wide control system in a simple, cost-effective manner. CUSTOMER APPLICATION At a European dairy-processing plant, milk products, made from pasteurized or raw milk, require hygienic transportation between successive operations. Process engineers use stainless-steel pipework to transport liquid ingredients from one operation to the next. Fluid flow is managed using control valves fitted with electrical, hydraulic or pneumatic actuators. Multiple rotary-shaft valves deliver raw milk from holding tanks to each process station in sequence, maintaining specified flow rates and volumetric limits. Once processing of each batch is completed and all process vessels are drained, closed-loop CIP cleaning commences. Accurate, repeatable valve sequencing is essential to prevent any chance of cross- contamination between processing and cleaning sequences. A robust, highly reliable sensor system, capable of withstanding the harsh washdown regimes in force, is needed to monitor control-valve positions during processing. Where possible, sensors must be mounted on existing rotary actuators, and real-time communication with existing plant- wide control systems is mandatory.
Customer Solution Sensing the position of a rotary-valve actuator is a routine task for Contrinex Classics washdown inductive sensors. These sensors interface directly with a range of industrial process controllers and provide cost-effective confirmation of control-valve status around the clock. A purpose-designed bracket, mounted on the top surface of each actuator, holds two sensors; these are positioned with the sensing faces vertically aligned, one above the other, and facing the actuator shaft. NAMUR-compatible (VDE/VDI 3845) mountings on the actuators provide a known datum for the sensors. A solid plastic disc, mounted on the shaft, carries two or more stainless-steel targets, positioned at 90 degrees to each other around the outer peripheral surface of the disc. Each target occupies either an upper or a lower position corresponding to height of one of the sensors. As the shaft rotates, opening and closing the valve, the targets pass in front of the sensing faces, triggering the sensors. These M12-diameter devices, rated to IP68/IP69K, have all- metal bodies with PBTB sensing faces and vacuum- encapsulated electronics; each features an industry-standard PNP normally open output. Fully embeddable, and with a sensing range up to 2mm, they are well suited to the hostile operating conditions of a washdown environment. Each sensor has an integral M12 connector, interfacing with the customer’s control system via a TPE-S-sheathed cable. Reliability is excellent; the system is simple and cost-effective.
CUSTOMER VALUES Reliable, repeatable in-line testing of a range of different-sized containers Testing is completed at production-line speed Immediate identification of missing closures Elimination of manual inspection and potential batch rejection PRODUCT ADVANTAGES Extended sensing distances up to 40mm Unmatched combination of 40mm sensing distance in M30-diameter device
CUSTOMER SOLUTION Contrinex Extra Distance inductive sensors are ideal for this application, with the M30-diameter units operating reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable and fast detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of 40mm sensing distance in an M30-diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions can occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time or potential rejection by customers. An in-line sensor system inspecting each container could confirm the presence of a foil closure, rejecting any faulty items. Each production line processes containers in batches. The system must accommodate containers whose heights vary by up to 20mm, without adjustment of sensors between batches as successive batches may comprise containers of differing sizes.
Customer Solution Contrinex ultrasonic sensors are ideal for presence- and level- sensing applications, and a diffuse sensor from the Compact range (housing size M30) is an excellent choice for this application. Operating range for this metal-bodied, IP65-rated device is between 20cm and 130cm; detection is independent of the target’s color, shape, material or surface structure. Contrinex Compact ultrasonic sensors feature an integral S12 cable connector, allowing rapid disconnection and removal when required. The variable size and shape of meat residue makes it difficult for an uncompensated sensor to detect contamination consistently and reliably; potentiometer adjustment, provided by many manufacturers, is inadequate for this application. Contrinex CONPROG software for Windows®, connected via the APE-0000-001 PC interface, compensates perfectly. Using CONPROG, the operator characterizes the target area of the box during set-up, setting the exact operating parameters of the sensor and ensuring reliable detection. Sensor data is stored, allowing like-for-like sensor replacement without additional set-up. The sensor’s three-wire PNP normally-open output communicates directly with the customer PLC. On detection of a contaminated box, a mechanical diverter shunts the box to a separate conveyor for manual emptying.
A meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact- based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
CUSTOMER VALUES Improved sensor reliability derived from exact characterisation of target Increased productivity arising from elimination of breakdowns Reduced sensor maintenance resulting from non- contact operation Industry-standard interface requires little modification to control systems PRODUCT ADVANTAGES Ecolab-certified photoelectric sensors with background-suppression mode Characterised sensors detect targets of variable size and shape Long-distance, non-contact operating principles IP65 protection allows operation in hygienic environments Rugged ultrasonic sensor with metal housing and metal cable connector