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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, 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 SENSORS 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 During manufacture of computer motherboards use a soldering reflow process to secure components in place on the PCBs. Following assembly, boards are conveyed into a reflow oven, where the temperature increases progressively to achieve a predetermined thermal profile, melting the solder paste on the boards. As each board leaves the oven, a sensor must trigger the customer’s control system and activate a transfer mechanism, moving the board automatically to the next process stage. The ambient temperature immediately adjacent to the oven may reach 80°C (176°F), which has caused unacceptable rates of sensor failure in the past. Sensors must operate continuously in this environment with ultra-high reliability. Extended sensing distances are highly desirable for this application as several types of motherboard, each with different component heights, pass through the oven. Long- distance sensing also allows the sensor to be positioned further from the hot PCBs.
CUSTOMER SOLUTION Contrinex 500 Series Extended Sensing Distance Inductive sensors are ideal for this demanding application. Condist® technology delivers best-in-class operating distances and sensors have a continuous rating to 70°C (158°F). Trials confirmed highly stable performance even in the elevated ambient temperatures around the reflow oven. Vacuum- encapsulated electronics ensure excellent resistance to thermal shock and vibration. Extra Distance sensors are mounted vertically on steel brackets attached to the exterior of the reflow ovens, and sense the presence of each motherboard as it passes beneath the sensing face. The operating distance is set at 10mm, eliminating the risk of collision with components on the board, and an M12-threaded metal housing allows easy positional adjustment when necessary. Extra Distance sensors with an industry-standard NPN normally-open configuration connect with the customer’s control system via a flexible PVC sheathed cable. No additional electrical or mechanical protection is required in spite of 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. Sensor replacement costs were excessive. Contrinex inductive sensors have been reliable and long-lived, providing a professional sensing solution with an attractive total cost of ownership.
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 CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk (0121) 58 222 58
Helping you #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
CLICK ON AN IMAGE TO VIEW THE BROCHURE, READ APPLICATION EXAMPLES BELOW, CLICK HERE TO VIEW THIS SENSOR ON CONTRINEXS 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.
Click for Brochure 500 & 600 Series Catalogue Extract Click for Brochure 500 Series -  Extended Distance
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 SENSORS 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 During manufacture of computer motherboards use a soldering reflow process to secure components in place on the PCBs. Following assembly, boards are conveyed into a reflow oven, where the temperature increases progressively to achieve a predetermined thermal profile, melting the solder paste on the boards. As each board leaves the oven, a sensor must trigger the customer’s control system and activate a transfer mechanism, moving the board automatically to the next process stage. The ambient temperature immediately adjacent to the oven may reach 80°C (176°F), which has caused unacceptable rates of sensor failure in the past. Sensors must operate continuously in this environment with ultra-high reliability. Extended sensing distances are highly desirable for this application as several types of motherboard, each with different component heights, pass through the oven. Long- distance sensing also allows the sensor to be positioned further from the hot PCBs..
CUSTOMER SOLUTION Contrinex 500 Series Extended Sensing Distance Inductive sensors are ideal for this demanding application. Condist® technology delivers best-in-class operating distances and sensors have a continuous rating to 70°C (158°F). Trials confirmed highly stable performance even in the elevated ambient temperatures around the reflow oven. Vacuum- encapsulated electronics ensure excellent resistance to thermal shock and vibration. Extra Distance sensors are mounted vertically on steel brackets attached to the exterior of the reflow ovens, and sense the presence of each motherboard as it passes beneath the sensing face. The operating distance is set at 10mm, eliminating the risk of collision with components on the board, and an M12-threaded metal housing allows easy positional adjustment when necessary. Extra Distance sensors with an industry-standard NPN normally-open configuration connect with the customer’s control system via a flexible PVC sheathed cable. No additional electrical or mechanical protection is required in spite of 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. Sensor replacement costs were excessive. Contrinex inductive sensors have been reliable and long-lived, providing a professional sensing solution with an attractive total cost of ownership.
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.
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