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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 RELIABLE, CONTINUOUS TOOL OPERATION IN TIME-SENSITIVE PRODUCTION ENVIRONMENTS SIGNIFICANT ENHANCEMENT OF TOOL FUNCTION WITH MINIMAL EFFECT ON SIZE OR WEIGHT LOW RISK OF INTERNAL DAMAGE DUE TO BEST-IN-CLASS SENSING DISTANCES INDUSTRY-STANDARD INTERFACE REQUIRES LITTLE MODIFICATION TO CONTROL SYSTEMS PRODUCT ADVANTAGES SENSOR PERFORMANCE UNAFFECTED BY 500 BAR (7255 PSI) OPERATING PRESSURE CONDIST® TECHNOLOGY OF EXTRA DISTANCE FAMILY DELIVERS BEST-IN-CLASS SENSING DISTANCES SMALL, LIGHTWEIGHT EMBEDDABLE SENSORS WITH HIGH- PRESSURE CAPABILITY RUGGED INDUCTIVE SENSOR WITH METAL HOUSING AND CERAMIC SENSING FACE
A manufacturer of cold-forming tools for joining sheet metal uses position sensing to control the operation of a manual punch-riveting tool. A high-pressure inductive sensor mounted directly into the wall of a small pneumohydraulic cylinder detects the position of the hydraulic ram, preventing the operating cycle from starting unless the ram is fully retracted. CUSTOMER APPLICATION Automotive technicians assembling prototype vehicle bodies during pre-production use manual punch-riveting tools to join individual sheet-metal parts. Several thousand joints are required per vehicle, and tools must be compact since space is often limited. Bad joints, which are very costly to repair, can occur if the technician does not set the tool correctly before triggering it. During use, the tool-head is often partly hidden from view, so a sensing system must confirm that the operating ram is fully retracted and prevent the tool from operating if the ram is not in the correct position. A pneumohydraulic cylinder drives the ram, and the compact nature of the tool limits the allowable sensor size. The sensing face is exposed to the high-pressure side of the hydraulic circuit, so the sensor must withstand continuous pressures up to 500 bar (7255 psi) and pressure spikes of 1000 bar (14,510 psi).
CUSTOMER SOLUTION Robust inductive sensors from the Contrinex Extra Distance family, High Pressure range, withstand the high operating pressure of this application. The extended operating distance of patented Condist® technology allows the use of thick, hermetically sealed ceramic discs on the sensing faces without compromising the sensors’ performance. These lightweight M5- and M8-diameter embeddable sensors are 27 mm and 30 mm in length, respectively. The sensors are mounted directly into the wall of the cylinder and do not interfere with the normal operation of the tool. Sensing distances of 1mm (M5 sensor) and 1.5 mm (M8 sensor) eliminate any risk of internal mechanical damage through contact with the ram. The sensors have an industry-standard PNP normally-open configuration and connect with the customer’s control system via a flexible PUR-sheathed cable. Vacuum-encapsulated electronics ensure excellent resistance to shock and vibration, and no additional electrical or mechanical protection is required. Previously, users of the punch-riveting tools were unable to check the position of the operating ram with the tool in situ and either incurred downtime or risked costly bad joints. Contrinex high-pressure inductive sensors satisfy the manufacturer’s requirement for small, lightweight, ultra- reliable sensors with an attractive total cost of ownership.
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.
During semi-automated pressing 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.
CONTRINEX SENSORS ARE RENOWNED FOR THEIR UNIQUE ROBUSTNESS, PERFORMANCE AND RELIABILITY ON PRESS & STAMPING LINES. A WIDE RANGE OF SENSORS OPTIMISED FOR THESE HARSH ENVIRONMENTS INCLUDE METAL-ENCASED & EMBEDDABLE RFID TRANSPONDERS, MACHINE SAFETY SENSORS, A WIDE CHOICE OF PHOTOELECTRIC SENSORS, DOUBLE-SHEET DETECTION, PLUS THE UNIQUELY ROBUST 700 SERIES INDUCTIVE SENSORS.

PRESS & ASSEMBLY APPLICATIONS

Click for Brochure 700 Series - Extreme Robust Click for Brochure Light Grid Catalogue Extract Click for Brochure 700 Series-Double-sheet Detection Click for Brochure Miniature Photoelectric
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 assemble metal parts together. After assembly 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 an assembly machine and initiates the PLC-controlled cycle. After assembly the operator drops the completed assembly into a metal bin used to transport parts directly to the customer. From time to time, un-assembled 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 infra-red 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 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.
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 RELIABLE, CONTINUOUS TOOL OPERATION IN TIME-SENSITIVE PRODUCTION ENVIRONMENTS SIGNIFICANT ENHANCEMENT OF TOOL FUNCTION WITH MINIMAL EFFECT ON SIZE OR WEIGHT LOW RISK OF INTERNAL DAMAGE DUE TO BEST-IN-CLASS SENSING DISTANCES INDUSTRY-STANDARD INTERFACE REQUIRES LITTLE MODIFICATION TO CONTROL SYSTEMS PRODUCT ADVANTAGES SENSOR PERFORMANCE UNAFFECTED BY 500 BAR (7255 PSI) OPERATING PRESSURE CONDIST® TECHNOLOGY OF EXTRA DISTANCE FAMILY DELIVERS BEST-IN-CLASS SENSING DISTANCES SMALL, LIGHTWEIGHT EMBEDDABLE SENSORS WITH HIGH- PRESSURE CAPABILITY RUGGED INDUCTIVE SENSOR WITH METAL HOUSING AND CERAMIC SENSING FACE
A manufacturer of cold-forming tools for joining sheet metal uses position sensing to control the operation of a manual punch-riveting tool. A high-pressure inductive sensor mounted directly into the wall of a small pneumohydraulic cylinder detects the position of the hydraulic ram, preventing the operating cycle from starting unless the ram is fully retracted. CUSTOMER APPLICATION Automotive technicians assembling prototype vehicle bodies during pre-production use manual punch-riveting tools to join individual sheet-metal parts. Several thousand joints are required per vehicle, and tools must be compact since space is often limited. Bad joints, which are very costly to repair, can occur if the technician does not set the tool correctly before triggering it. During use, the tool-head is often partly hidden from view, so a sensing system must confirm that the operating ram is fully retracted and prevent the tool from operating if the ram is not in the correct position. A pneumohydraulic cylinder drives the ram, and the compact nature of the tool limits the allowable sensor size. The sensing face is exposed to the high-pressure side of the hydraulic circuit, so the sensor must withstand continuous pressures up to 500 bar (7255 psi) and pressure spikes of 1000 bar (14,510 psi).
CUSTOMER SOLUTION Robust inductive sensors from the Contrinex Extra Distance family, High Pressure range, withstand the high operating pressure of this application. The extended operating distance of patented Condist® technology allows the use of thick, hermetically sealed ceramic discs on the sensing faces without compromising the sensors’ performance. These lightweight M5- and M8-diameter embeddable sensors are 27 mm and 30 mm in length, respectively. The sensors are mounted directly into the wall of the cylinder and do not interfere with the normal operation of the tool. Sensing distances of 1mm (M5 sensor) and 1.5 mm (M8 sensor) eliminate any risk of internal mechanical damage through contact with the ram. The sensors have an industry-standard PNP normally-open configuration and connect with the customer’s control system via a flexible PUR-sheathed cable. Vacuum-encapsulated electronics ensure excellent resistance to shock and vibration, and no additional electrical or mechanical protection is required. Previously, users of the punch-riveting tools were unable to check the position of the operating ram with the tool in situ and either incurred downtime or risked costly bad joints. Contrinex high-pressure inductive sensors satisfy the manufacturer’s requirement for small, lightweight, ultra- reliable sensors with an attractive total cost of ownership.
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.

PRESS & ASSEMBLY

APPLICATIONS

CONTRINEX SENSORS ARE RENOWNED FOR THEIR UNIQUE ROBUSTNESS, PERFORMANCE AND RELIABILITY ON PRESS & STAMPING LINES. A WIDE RANGE OF SENSORS OPTIMISED FOR HARSH ENVIRONMENTS INCLUDE METAL-ENCASED & EMBEDDABLE RFID TRANSPONDERS, MACHINE SAFETY SENSORS, A WIDE CHOICE OF PHOTOELECTRIC SENSORS, DOUBLE-SHEET DETECTION, PLUS THE ROBUST 700 SERIES.
Click for Brochure Miniature Photoelectric
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 Light Grid Catalogue Extract Click for Brochure 700 Series-Double-sheet Detection
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 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.
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 pressing 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.