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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
LESS HANDLING
ELIMINATE VISUAL INSPECTION
FEWER RETURNS
PROCESS VERIFICATION
PRODUCT ADVANTAGES
LONG OPERATING DISTANCE (3X STANDARD VALUE)
EXCELLENT SENSING STABILITY ON SMALL & THIN TARGETS
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
The automotive industry demands parts that are verified to be
100% correct and therefore a supplier of injection moulded
parts trusts Contrinex inductives from their Extra Distance 500
Series to check that threaded inserts have been correctly
mounted inside moulded plastic parts.
CUSTOMER APPLICATION
To enable the fast screw assembly required by automotive
plants it is common to embed threaded inserts, typically made
of brass, into plastic mouldings.
These nut-like elements are crucial to ensuring the correct
final assembly process of the car and so the supplier must be
able to ensure they are all present. It is not uncommon for
automotive companies to return several days’ worth of
production parts to a supplier and levy substantial fines if even
a minor error is found.
The design of the moulded plastic parts which are used in
automotive air filtration systems is problematic because it
prevents visual checking the presence of the inserts and so a
reliable test mechanism had to be found.
CUSTOMER SOLUTION
Contrinex DW-AS-513-M30-002 Extra Distance inductives are
used in a checking fixture to detect if any inserts are missing
or incorrectly mounted. The solution exploits the unique
sensing capabilities of the Condist® technology in these 500
Series sensors, utilising their longer sensing distances and
better stability to environmental influences. The long
operating distance and high sensing stability enable the
detection of small inserts through a thick layer of plastic.
The test fixture is designed to accept a finished moulding and
is equipped with sensors at each of the insert locations. Each
sensor can detect the presence of the corresponding metal
insert through moulded plastic and so confirm compliance
with the specifications. The sensor’s PNP Normally Open
output provides a logical GO – NO GO feed to a micro-
controller.
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.
CONTRINEX IS RENOWNED FOR THE LONG SENSING DISTANCES OF ITS ‘500’ SERIES INDUCTIVE SENSORS -
THESE HIGH-PERFORMANCE SENSORS ARE AVAILABLE IN A WIDE VARIETY OF SIZES AND SPECIFICATIONS.
500 SERIES - ‘EXTENDED DISTANCE’ INDUCTIVES
500 SERIES ‘EXTENDED DISTANCE’ INDUCTIVES - EXTRA SENSING DISTANCES AT EXCELLENT PRICES
PRODUCT ADVANTAGES
EXCELLENT PRICE PERFORMANCE RATIO - EXTENDED SENSING
DISTANCE
A LARGE VARIETY OF PRODUCT SHAPES AND SIZES
A CHOICE OF SENSING DISTANCES (PLUS THE SISTER 600
SERIES OFFERING MORE AFFORDABLE SHORTER DISTANCES
AND THE MINIATURE FAMILY PROVIDING SMALLER SIZES)
DEVIATION IN OPERATING DISTANCE ≤2%
OUTSTANDING TEMPERATURE COMPENSATION
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
Contrinex’s 500 Series of inductive sensors offer extended sensing range with excellent accuracy and exceptional reliability at an
economical price. Available in sizes from M8 to M30, plus C44 (40 x 40mm), with optional Ø 6.5 plain and 8 mm square-section
models, the 500 Series is ideal for position-sensing and presence-sensing applications in almost any industry.
Embeddable or non-embeddable variants are available, with either hard-wired, hermetically sealed connecting cables or integral
metal connectors. Highly repeatable results are supplied at operating temperatures between -25°C and +70°C and the included IO-
Link interface makes integration to Industry 4.0 easier and more powerful.
CUSTOMER VALUES
COST EFFECTIVE SOLUTION
NON CONTACT / NON-MARRING OF PACKAGING
ELIMINATES SHIPMENT OF DAMAGED OR SOILED PRODUCT
LONG PERFORMANCE HISTORY
PRODUCT ADVANTAGES
LONG OPERATING DISTANCE (3X STANDARD VALUE)
EASY MOUNTING AND ADJUSTMENT
SECURE DISTANCE BETWEEN MOVING OBJECT AND SENSOR
HIGH SWITCHING FREQUENCY
EXCELLENT SENSING STABILITY ON SMALL & THIN TARGETS
IO-LINK INTERFACE INCLUDED - IDEAL FOR INDUSTRY 4
CUSTOMER SOLUTION
Contrinex’s rugged Extra-Distance inductive sensors from the
‘500 Series’ are ideal for this application, being robust and
accurate. These highly reliable, IP67 rated, M30-diameter
sensors have a chrome-plated brass body with a PBTP sensing
face and vacuum-encapsulated electronics. Well suited to
operating in a hostile environment, the 3x sensing distance of
22mm enables fully contactless operation in this relatively high
speed packaging process.
A sensor array is placed over the conveyor and travel path of
the cardboard cases. For each lane of bottles in a case, an M30
diameter inductive sensor is mounted on the array. A non-
embeddable sensor is chosen as it most closely equates to the
size of the bottle cap and yields the greatest sensing distance
for the available target area and is sufficient to allow for minor
variations in the height of the case as it passes under the
sensor bridge. This not only ensures reliable sensing, but also
keeps the sensor at a safe distance from any impact, avoiding
consequent downtime, with the sensors interfaced with a
controller that makes the logical decision to accept the
package or reject and divert it.
A drinks producer needs to conduct a final,inspection check of
cases of bottles after the lid of the corrugated cardboard case
has been closed and sealed. A bottle count is performed by
verifying the position of bottle caps through layers of
cardboard at the top of each sealed case.
CUSTOMER APPLICATION
Bottles which are packed into corrugated cardboard cases
require both the verification of the placement and number of
bottles in the case, ideally after they have had their lids hot-
glued closed. A concern is that a bottle can break on impact
with the bottom of the case, contaminating the machinery
and subsequent packages. Bottles can also be absent or
wrongly positioned or a cap might be missing from a bottle.
Whilst a vision systems could be used, this would need to be
done before the lid of the case is closed, whereas verification of
the closed case would be preferable.
The absence of a bottle cap in a specified position is a good
indicator of a missing or shattered bottle and so the challenge
is therefore to detect bottle caps through multiple layers of
corrugated cardboard material of varying thickness and
density.
CUSTOMER VALUES
RUGGED INDUCTIVES ENSURE ACCURATE POSITIONING OF
MATERIALS, ELIMINATING FAULTS
MINIATURE EXTRA-DISTANCE SENSOR FITS SAFELY &
UNOBTRUSIVELY INTO IN-LINE WELDING STATION
IMMEDIATE AVAILABILITY OF DIVERSE SENSOR RANGE ENABLES
RAPID INCREASE IN PRODUCTION CAPACITY
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-&-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
SUITABLE FOR EASY INTEGRATION
DIVERSE PORTFOLIO OFFERS EXCEPTIONAL RANGE OF SIZES
AND SENSING DISTANCES
RELIABLE, COMPACT VIBRATION-RESISTANT SENSORS
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
OEM equipment builders have long relied on Contrinex as a
single source of high-performance and reliable sensors for
integration within their machines. The ability to supply the
sensors from stock was also essential in this instance, as the
machine was built to manufacture essential N95 face masks.
The sensors synchronise material feeds in the machine during
the assembly process and ensure the part-completed mask is
positioned correctly. Designers specified rugged inductive
sensors with IO-Link connectivity to prevent costly machine
malfunctions.
CUSTOMER APPLICATION
Reliability is essential in automated production, and nowhere
more than in the hard-pressed healthcare supply sector. At the
time of the global COVID-19 crisis, OEM equipment builders
rushed to increase capacity for producing personal protective
equipment (PPE). Manufacturers of N95 face masks, a high-
volume item of PPE, faced unprecedented demand worldwide.
While a single N95 mask is a relatively low-cost item, fast-
moving production lines mean that any interruption to
continuous operation is disproportionately expensive. Machine
malfunctions not only cause lost production time but also
result in costly manual intervention, and must be prevented.
Purpose-built machines for manufacturing N95 masks must
dovetail several material feeds prior to assembly; they must
also ensure that part-completed masks are positioned
correctly during the process. Successive workstations
incorporate multiple position-sensing and presence-detection
sensors that monitor the status of material feeds and cutter
position, as well as checking part alignment for welding and
printing. It is highly desirable to source these devices from a
single manufacturer, minimizing spares inventory and
ensuring a common interface throughout an entire machine.
CUSTOMER SOLUTION
OEM designers specified rugged inductive sensors from the
Contrinex Basic and Miniature ranges. Not only did the
available selection match the functional requirement exactly,
the immediate availability of all the required devices from
stock eliminated delays in ramping up capacity. All the
specified sensors feature IO-Link connectivity, providing a
single, industry-standard interface to the machine control
system.
Contrinex inductive sensors are designed with the needs of
OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. With a sensing distance of
4 mm, the two metal-cased M12 sensors used to monitor the
positions of the steel fabric cutter and the printing head are
robust and reliable. The M8 device that detects the feed
position of the aluminium fixing strip has a V2A stainless-steel
housing and an extended sensing distance of 2 mm, fitting
snugly in the limited space available.
The extra-distance miniature M5 sensor fitted at the welding
station has a nickel-silver housing and was selected because of
its 2.5-mm sensing distance, eliminating any danger of
accidental collision during operation. Connection to all the
specified sensors is via a PVC-sheathed cable with a 3-pin
connector or 2-metre flying lead; alternative lengths are
available.
These highly versatile sensors meet designers’ needs for
trouble-free operation using sensors from a single
manufacturer. The solution is highly reliable, cost-effective
and, critically, available without delay, allowing the immediate
increase in machine-building capacity required by the OEM
customer.
CUSTOMER VALUES
UNINTERRUPTED PRODUCTION AS CIRCUIT-BOARD DETECTION
IS HIGHLY RELIABLE
MINIMAL REPLACEMENT SENSOR COSTS AS A RESULT OF
SENSOR’S LONG SERVICE LIFE
LOW RISK OF THERMAL OR MECHANICAL DAMAGE BECAUSE OF
EXTENDED OPERATING DISTANCE
PRODUCT ADVANTAGES
SENSOR PERFORMANCE UNAFFECTED BY ELEVATED
TEMPERATURES
CONDIST® TECHNOLOGY OF EXTRA DISTANCE FAMILY
DELIVERS BEST-IN-CLASS OPERATING DISTANCES
EXTENDED SENSING RANGE ≤ 10MM
RUGGED INDUCTIVE SENSOR WITH METAL HOUSING
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
A manufacturer of computer Printed Circuit Boards (PCBs)
uses presence detection immediately after a soldering reflow
process to trigger a subsequent operation. A long-distance
inductive sensor is mounted above the exit conveyor of the
reflow oven and detects each motherboard as it passes out of
the oven. The customer’s control system accepts the sensor’s
switched output, initiating the next process stage.
CUSTOMER APPLICATION
Reflow soldering ovens are an essential part of the electronic
assemble process, being used to secure components in place
on printed circuit boards. PCBs which have had solder paste
screen-printed onto them are populated with electronic
components and connectors before being conveyed into a
reflow oven. As the PCB is conveyed through the oven, the
temperature increases progressively according to a
predetermined thermal profile which melts the solder paste so
that it flows around and secures the components, as well as
ensuring a robust electrical connection.
As each PCB leaves the oven, a sensor must trigger the
factory’s control system to activate an automated transfer
mechanism to move the board to the next processing stage.
The ambient temperature of 80°C immediately adjacent to the
exit of the oven was causing an unacceptable rate of failure in
other manufacturer’s sensors and so Contrinex was
approached to see if its sensors could operate with total
reliability.
CUSTOMER SOLUTION
Contrinex’s 500 series of inductive sensors which provide
extended sensing distances were ideal for this application.
They were able to detect the metal within the PCB and also
allow sufficient space for the PCBs with tall components to
pass underneath. The longer-distance sensing also enables the
sensor to be positioned further away from the heat being
radiated off the hot boards.
Best-in-class operating distances, vacuum-encapsulated
electronics and excellent resistance to thermal shock and
vibration from Contrinex’s Condist® technology enable these
sensors to provide a continuous 70°C temperature rating.
The inductive sensors are mounted vertically on steel brackets
attached to the exterior of the reflow ovens. They are
positioned 10mm above the PCBs and their M12-threaded
metal housing enables easy adjustment. The 500 series
sensors proved to be reliable even in the elevated ambient
temperatures around the reflow oven, without needing to use
more expensive specialised high-temperature sensors, an area
in which Contrinex also excels, offering inductive sensors rated
to operate in temperatures up to 230°C.
The factory’s control system required an NPN sensor with a
normally open configuration and other than fitting protective
sheathing over the sensor’s PVC cable, no additional electrical
or mechanical protection was required despite the adverse
operating conditions.
Previously, sensors from other manufacturers did not detect
boards reliably and had unacceptably short service lives,
causing frequent interruptions to production. Whilst the
sensors were not particularly expensive, the cost of engineers
replacing them and interruptions to the manufacturing
process was high. The switch to Contrinex inductive sensors
provided a reliable sensing solution enabling the customer to
achieve the level of machine availability and effectiveness,
OEE, that they desired. The total cost of ownership was
extremely attractive because the 500 Series extended range
inductive sensor cost less than the cost of two of the
competitor's sensors.
CUSTOMER VALUES
SIMPLE SENSOR SYSTEM ELIMINATES MANUAL CHECKING
EXTENDED SENSING RANGE ALLOWS ACCURATE, CONTACTLESS
OPERATION
ROBUST CONSTRUCTION WITHSTANDS CONTAMINATION AND
WATER INGRESS
HIGHEST PRECISION, TEMPERATURE STABILITY AND RELIABILITY
PRODUCT ADVANTAGES
22MM SENSING RANGE AVAILABLE IN PHYSICALLY SMALL
SENSOR
HIGH RESISTANCE TO HARSH OPERATING CONDITIONS
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
SUITABLE FOR EASY INTEGRATION
IO-LINK INTERFACE INCLUDED - IDEAL FOR INDUSTRY 4
CUSTOMER SOLUTION
Rugged Extra-Distance inductive sensors from Contrinex’s 500
Series are ideal for this application. Highly reliable and rated to
IP67, these units are robust and accurate. A one-piece M30-
diameter chrome-plated brass body with PBTP sensing face
and vacuum-encapsulated electronics make this device well
suited to the hostile environment, and the sensing distance of
22mm allows fully contactless operation.
On each jack, a single sensor is fitted on a metal bracket that is
welded to the side of the cylinder; a bearing plate, mounted on
the end of the ram, distributes the load onto the bridge
section. During operation, the ram extends, lifting the section;
when it reaches the desired height, the sensor detects the
position of a small metal target mounted on the bearing plate,
halting the ram.
The sensor is configured with an industry-standard PNP
normally-open interface, and connection to the jack’s
hydraulic control system is via an integral M12 connector and
PVC-sheathed cable; this allows easy removal and
replacement during routine maintenance. The sensor is
impervious to water ingress, mud and dirt; reliability has been
excellent. Contrinex inductive sensors deliver a cost-effective
solution that satisfies the customer’s requirements for a
simple, fit-and-forget system.
Modern road bridges are typically constructed using mobile
cranes to lift prefabricated bridge beam onto support
columns. Heavy-duty hydraulic cylinders support the ends of
each section to enable accurate height adjustment prior to
final positioning. Engineers require rugged sensor systems
that detect the position of each cylinder accurately. These
sensors need to be mechanically robust and must withstand
harsh outdoors conditions.
CUSTOMER APPLICATION
A specialist lifting company uses heavy-duty hydraulic
cylinder-jacks to position prefabricated bridge sections during
roadway construction. A bridge single section requires up to
20 jacks for accurate positioning, with each jack having a
capacity up to 1,000 tons with a stroke up to 30mm (1.25 in).
On-site conditions are harsh with cylinders exposed to water,
mud and dirt, and may also be subject to mechanical shock
and vibration.
The company requires rugged sensors that operate reliably
and accurately in the demanding environment. Historically,
engineers checked the position of each cylinder manually; this
was both time-consuming and subject to human error.
Previously trialled sensors were insufficiently robust,
necessitating frequent adjustment or replacement, and had
inadequate sensing distances.
A simple, contactless system must provide fit-and-forget
operation with extended maintenance intervals. The sensors
need to be mechanically robust and must withstand
prolonged exposure to the harsh outdoor conditions of a
construction site. An industry-standard interface is highly
desirable to avoid the need for specialised control systems.
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 CONTRINEX’S EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
CUSTOMER VALUES
LESS HANDLING
ELIMINATE VISUAL INSPECTION
FEWER RETURNS
PROCESS VERIFICATION
PRODUCT ADVANTAGES
LONG OPERATING DISTANCE (3X STANDARD VALUE)
EXCELLENT SENSING STABILITY ON SMALL & THIN TARGETS
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
The automotive industry demands parts that are verified to be
100% correct and therefore a supplier of injection moulded
parts trusts Contrinex inductives from their Extra Distance 500
Series to check that threaded inserts have been correctly
mounted inside moulded plastic parts.
CUSTOMER APPLICATION
To enable the fast screw assembly required by automotive
plants it is common to embed threaded inserts, typically made
of brass, into plastic mouldings.
These nut-like elements are crucial to ensuring the correct
final assembly process of the car and so the supplier must be
able to ensure they are all present. It is not uncommon for
automotive companies to return several days’ worth of
production parts to a supplier and levy substantial fines if even
a minor error is found.
The design of the moulded plastic parts which are used in
automotive air filtration systems is problematic because it
prevents visual checking the presence of the inserts and so a
reliable test mechanism had to be found.
CUSTOMER SOLUTION
Contrinex DW-AS-513-M30-002 Extra Distance inductives are
used in a checking fixture to detect if any inserts are missing
or incorrectly mounted. The solution exploits the unique
sensing capabilities of the Condist® technology in these 500
Series sensors, utilising their longer sensing distances and
better stability to environmental influences. The long
operating distance and high sensing stability enable the
detection of small inserts through a thick layer of plastic.
The test fixture is designed to accept a finished moulding and
is equipped with sensors at each of the insert locations. Each
sensor can detect the presence of the corresponding metal
insert through moulded plastic and so confirm compliance
with the specifications. The sensor’s PNP Normally Open
output provides a logical GO – NO GO feed to a micro-
controller.
CLICK ON AN IMAGE TO VIEW THE BROCHURE,
READ APPLICATION EXAMPLES BELOW, CLICK
HERE TO VIEW THIS SENSOR ON CONTRINEX’S
WEBSITE, OR CALL US TO HELP GUIDE YOU
THROUGH SELECTION, ANSWER QUESTIONS, OR
TO HELP YOU #MAKESENSEOFSENSORS:
500 SERIES - ‘EXTENDED
DISTANCE’ INDUCTIVES
CONTRINEX IS RENOWNED FOR THE LONG SENSING
DISTANCES OF ITS ‘500’ SERIES INDUCTIVE SENSORS -
THESE HIGH-PERFORMANCE SENSORS ARE AVAILABLE
IN A WIDE VARIETY OF SIZES AND SPECIFICATIONS.
OEM equipment builders have long relied on Contrinex as a
single source of high-performance and reliable sensors for
integration within their machines. The ability to supply the
sensors from stock was also essential in this instance, as the
machine was built to manufacture essential N95 face masks.
The sensors synchronise material feeds in the machine during
the assembly process and ensure the part-completed mask is
positioned correctly. Designers specified rugged inductive
sensors with IO-Link connectivity to prevent costly machine
malfunctions.
CUSTOMER APPLICATION
Reliability is essential in automated production, and nowhere
more than in the hard-pressed healthcare supply sector. At the
time of the global COVID-19 crisis, OEM equipment builders
rushed to increase capacity for producing personal protective
equipment (PPE). Manufacturers of N95 face masks, a high-
volume item of PPE, faced unprecedented demand worldwide.
While a single N95 mask is a relatively low-cost item, fast-
moving production lines mean that any interruption to
continuous operation is disproportionately expensive. Machine
malfunctions not only cause lost production time but also
result in costly manual intervention, and must be prevented.
Purpose-built machines for manufacturing N95 masks must
dovetail several material feeds prior to assembly; they must
also ensure that part-completed masks are positioned
correctly during the process. Successive workstations
incorporate multiple position-sensing and presence-detection
sensors that monitor the status of material feeds and cutter
position, as well as checking part alignment for welding and
printing. It is highly desirable to source these devices from a
single manufacturer, minimizing spares inventory and
ensuring a common interface throughout an entire machine.
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 VALUES
RUGGED INDUCTIVES ENSURE ACCURATE POSITIONING OF
MATERIALS, ELIMINATING FAULTS
MINIATURE EXTRA-DISTANCE SENSOR FITS SAFELY &
UNOBTRUSIVELY INTO IN-LINE WELDING STATION
IMMEDIATE AVAILABILITY OF DIVERSE SENSOR RANGE ENABLES
RAPID INCREASE IN PRODUCTION CAPACITY
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-&-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
SUITABLE FOR EASY INTEGRATION
DIVERSE PORTFOLIO OFFERS EXCEPTIONAL RANGE OF SIZES
AND SENSING DISTANCES
RELIABLE, COMPACT VIBRATION-RESISTANT SENSORS
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
Customer Solution
OEM designers specified rugged inductive sensors from the
Contrinex Basic and Miniature ranges. Not only did the
available selection match the functional requirement exactly,
the immediate availability of all the required devices from
stock eliminated delays in ramping up capacity. All the
specified sensors feature IO-Link connectivity, providing a
single, industry-standard interface to the machine control
system.
Contrinex inductive sensors are designed with the needs of
OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. With a sensing distance of
4 mm, the two metal-cased M12 sensors used to monitor the
positions of the steel fabric cutter and the printing head are
robust and reliable. The M8 device that detects the feed
position of the aluminium fixing strip has a V2A stainless-steel
housing and an extended sensing distance of 2 mm, fitting
snugly in the limited space available.
The extra-distance miniature M5 sensor fitted at the welding
station has a nickel-silver housing and was selected because of
its 2.5-mm sensing distance, eliminating any danger of
accidental collision during operation. Connection to all the
specified sensors is via a PVC-sheathed cable with a 3-pin
connector or 2-metre flying lead; alternative lengths are
available.
These highly versatile sensors meet designers’ needs for
trouble-free operation using sensors from a single
manufacturer. The solution is highly reliable, cost-effective
and, critically, available without delay, allowing the immediate
increase in machine-building capacity required by the OEM
customer.
500 SERIES ‘EXTENDED DISTANCE’
INDUCTIVES - EXTRA SENSING DISTANCES
AT EXCELLENT PRICES
PRODUCT ADVANTAGES
EXCELLENT PRICE PERFORMANCE RATIO - EXTENDED SENSING
DISTANCE
A LARGE VARIETY OF PRODUCT SHAPES AND SIZES
A CHOICE OF SENSING DISTANCES (PLUS THE SISTER 600
SERIES OFFERING MORE AFFORDABLE SHORTER DISTANCES
AND THE MINIATURE FAMILY PROVIDING SMALLER SIZES)
DEVIATION IN OPERATING DISTANCE ≤2%
OUTSTANDING TEMPERATURE COMPENSATION
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
Contrinex’s 500 Series of inductive sensors offer extended
sensing range with excellent accuracy and exceptional reliability
at an economical price. Available in sizes from M8 to M30, plus
C44 (40 x 40mm), with optional Ø 6.5 plain and 8 mm square-
section models, the 500 Series is ideal for position-sensing and
presence-sensing applications in almost any industry.
Embeddable or non-embeddable variants are available, with
either hard-wired, hermetically sealed connecting cables or
integral metal connectors. Highly repeatable results are
supplied at operating temperatures between -25°C and +70°C
and the included IO-Link interface makes integration to
Industry 4.0 easier and more powerful.
CUSTOMER VALUES
SIMPLE SENSOR SYSTEM ELIMINATES MANUAL CHECKING
EXTENDED SENSING RANGE ALLOWS ACCURATE, CONTACTLESS
OPERATION
ROBUST CONSTRUCTION WITHSTANDS CONTAMINATION AND
WATER INGRESS
HIGHEST PRECISION, TEMPERATURE STABILITY AND RELIABILITY
PRODUCT ADVANTAGES
22MM SENSING RANGE AVAILABLE IN PHYSICALLY SMALL
SENSOR
HIGH RESISTANCE TO HARSH OPERATING CONDITIONS
ROBUST, METAL-CASED INDUCTIVE PROXIMITY SENSORS
SUITABLE FOR EASY INTEGRATION
IO-LINK INTERFACE INCLUDED - IDEAL FOR INDUSTRY 4
CUSTOMER SOLUTION
Rugged Extra-Distance inductive sensors from Contrinex’s 500
Series are ideal for this application. Highly reliable and rated to
IP67, these units are robust and accurate. A one-piece M30-
diameter chrome-plated brass body with PBTP sensing face
and vacuum-encapsulated electronics make this device well
suited to the hostile environment, and the sensing distance of
22mm allows fully contactless operation.
On each jack, a single sensor is fitted on a metal bracket that is
welded to the side of the cylinder; a bearing plate, mounted on
the end of the ram, distributes the load onto the bridge
section. During operation, the ram extends, lifting the section;
when it reaches the desired height, the sensor detects the
position of a small metal target mounted on the bearing plate,
halting the ram.
The sensor is configured with an industry-standard PNP
normally-open interface, and connection to the jack’s
hydraulic control system is via an integral M12 connector and
PVC-sheathed cable; this allows easy removal and
replacement during routine maintenance. The sensor is
impervious to water ingress, mud and dirt; reliability has been
excellent. Contrinex inductive sensors deliver a cost-effective
solution that satisfies the customer’s requirements for a
simple, fit-and-forget system.
Modern road bridges are typically constructed using mobile
cranes to lift prefabricated bridge beam onto support
columns. Heavy-duty hydraulic cylinders support the ends of
each bridge section to enable accurate height adjustment
prior to final positioning. Engineers require rugged sensor
systems that detect the position of each cylinder accurately.
These sensors need to be mechanically robust and must
withstand harsh outdoors conditions.
CUSTOMER APPLICATION
A specialist lifting company uses heavy-duty hydraulic
cylinder-jacks to position prefabricated bridge sections during
roadway construction. A bridge single section requires up to
20 jacks for accurate positioning, with each jack having a
capacity up to 1,000 tons with a stroke up to 30mm (1.25 in). On
site conditions are harsh with cylinders exposed to water, mud
and dirt, and may also be subject to mechanical shock and
vibration.
The company requires rugged sensors that operate reliably
and accurately in the demanding environment. Historically,
engineers checked the position of each cylinder manually; this
was both time-consuming and subject to human error.
Previously trialled sensors were insufficiently robust,
necessitating frequent adjustment or replacement, and had
inadequate sensing distances.
A simple, contactless system must provide fit-and-forget
operation with extended maintenance intervals. The sensors
need to be mechanically robust and must withstand
prolonged exposure to the harsh outdoor conditions of a
construction site. An industry-standard interface is highly
desirable to avoid the need for specialised control systems.
CUSTOMER VALUES
UNINTERRUPTED PRODUCTION AS CIRCUIT-BOARD DETECTION
IS HIGHLY RELIABLE
MINIMAL REPLACEMENT SENSOR COSTS AS A RESULT OF
SENSOR’S LONG SERVICE LIFE
LOW RISK OF THERMAL OR MECHANICAL DAMAGE BECAUSE OF
EXTENDED OPERATING DISTANCE
PRODUCT ADVANTAGES
SENSOR PERFORMANCE UNAFFECTED BY ELEVATED
TEMPERATURES
CONDIST® TECHNOLOGY OF EXTRA DISTANCE FAMILY
DELIVERS BEST-IN-CLASS OPERATING DISTANCES
EXTENDED SENSING RANGE ≤ 10MM
RUGGED INDUCTIVE SENSOR WITH METAL HOUSING
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
A manufacturer of computer Printed Circuit Boards (PCBs)
uses presence detection immediately after a soldering reflow
process to trigger a subsequent operation. A long-distance
inductive sensor is mounted above the exit conveyor of the
reflow oven and detects each motherboard as it passes out of
the oven. The customer’s control system accepts the sensor’s
switched output, initiating the next process stage.
CUSTOMER APPLICATION
Reflow soldering ovens are an essential part of the electronic
assemble process, being used to secure components in place
on printed circuit boards. PCBs which have had solder paste
screen-printed onto them are populated with electronic
components and connectors before being conveyed into a
reflow oven. As the PCB is conveyed through the oven, the
temperature increases progressively according to a
predetermined thermal profile which melts the solder paste so
that it flows around and secures the components, as well as
ensuring a robust electrical connection.
As each PCB leaves the oven, a sensor must trigger the
factory’s control system to activate an automated transfer
mechanism to move the board to the next processing stage.
The ambient temperature of 80°C immediately adjacent to the
exit of the oven was causing an unacceptable rate of failure in
other manufacturer’s sensors and so Contrinex was
approached to see if its sensors could operate with total
reliability.
CUSTOMER SOLUTION
Contrinex’s 500 series of inductive sensors which provide
extended sensing distances were ideal for this application.
They were able to detect the metal within the PCB and also
allow sufficient space for the PCBs with tall components to
pass underneath. The longer-distance sensing also enables the
sensor to be positioned further away from the heat being
radiated off the hot boards.
Best-in-class operating distances, vacuum-encapsulated
electronics and excellent resistance to thermal shock and
vibration from Contrinex’s Condist® technology enable these
sensors to provide a continuous 70°C temperature rating.
The inductive sensors are mounted vertically on steel brackets
attached to the exterior of the reflow ovens. They are
positioned 10mm above the PCBs and their M12-threaded
metal housing enables easy adjustment. The 500 series
sensors proved to be reliable even in the elevated ambient
temperatures around the reflow oven, without needing to use
more expensive specialised high-temperature sensors, an area
in which Contrinex also excels, offering inductive sensors rated
to operate in temperatures up to 230°C.
The factory’s control system required an NPN sensor with a
normally open configuration and other than fitting protective
sheathing over the sensor’s PVC cable, no additional electrical
or mechanical protection was required despite the adverse
operating conditions.
Previously, sensors from other manufacturers did not detect
boards reliably and had unacceptably short service lives,
causing frequent interruptions to production. Whilst the
sensors were not particularly expensive, the cost of engineers
replacing them and interruptions to the manufacturing
process was high. The switch to Contrinex inductive sensors
provided a reliable sensing solution enabling the customer to
achieve the level of machine availability and effectiveness,
OEE, that they desired. The total cost of ownership was
extremely attractive because the 500 Series extended range
inductive sensor cost less than the cost of two of the
competitor's sensors.
CUSTOMER VALUES
COST EFFECTIVE SOLUTION
NON CONTACT / NON-MARRING OF PACKAGING
ELIMINATES SHIPMENT OF DAMAGED OR SOILED PRODUCT
LONG PERFORMANCE HISTORY
PRODUCT ADVANTAGES
LONG OPERATING DISTANCE (3X STANDARD VALUE)
EASY MOUNTING AND ADJUSTMENT
SECURE DISTANCE BETWEEN MOVING OBJECT AND SENSOR
HIGH SWITCHING FREQUENCY
EXCELLENT SENSING STABILITY ON SMALL & THIN TARGETS
IO-LINK INTERFACE INCLUDED - IDEAL FOR INDUSTRY 4
CUSTOMER SOLUTION
Contrinex’s rugged Extra-Distance inductive sensors from the
‘500 Series’ are ideal for this application, being robust and
accurate. These highly reliable, IP67 rated, M30-diameter
sensors have a chrome-plated brass body with a PBTP sensing
face and vacuum-encapsulated electronics. Well suited to
operating in a hostile environment, the 3x sensing distance of
22mm enables fully contactless operation in this relatively high
speed packaging process.
A sensor array is placed over the conveyor and travel path of
the cardboard cases. For each lane of bottles in a case, an M30
diameter inductive sensor is mounted on the array. A non-
embeddable sensor is chosen as it most closely equates to the
size of the bottle cap and yields the greatest sensing distance
for the available target area and is sufficient to allow for minor
variations in the height of the case as it passes under the
sensor bridge. This not only ensures reliable sensing, but also
keeps the sensor at a safe distance from any impact, avoiding
consequent downtime, with the sensors interfaced with a
controller that makes the logical decision to accept the
package or reject and divert it.
A drinks producer needs to conduct a final,inspection check of
cases of bottles after the lid of the corrugated cardboard case
has been closed and sealed. A bottle count is performed by
verifying the position of bottle caps through layers of
cardboard at the top of each sealed case.
CUSTOMER APPLICATION
Bottles which are packed into corrugated cardboard cases
require both the verification of the placement and number of
bottles in the case, ideally after they have had their lids hot-
glued closed. A concern is that a bottle can break on impact
with the bottom of the case, contaminating the machinery
and subsequent packages. Bottles can also be absent or
wrongly positioned or a cap might be missing from a bottle.
Whilst a vision systems could be used, this would need to be
done before the lid of the case is closed, whereas verification of
the closed case would be preferable..
The absence of a bottle cap in a specified position is a good
indicator of a missing or shattered bottle and so the challenge
is therefore to detect bottle caps through multiple layers of
corrugated cardboard material of varying thickness and
density.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS,
WE WORK TO HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE
PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEX’S
EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
