(0121) 58 222 58 SALES@PLUSAUTOMATION.CO.UK
© 2020 - PLUS AUTOMATION LIMITED®
HELPING YOU #MAKE SENSE OF SENSORS
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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
CONTINUOUS PRODUCTION AS IN-PROCESS MEASUREMENT IS
HIGHLY ACCURATE WITH HIGH SAMPLING RATE
DEFECTS IDENTIFIED IN REAL TIME MINIMISES REJECT COSTS
NO RESTRICTIONS ON MOUNTING POSITION AS SENSORS ARE
VIBRATION-RESISTANT AND TEMPERATURE-STABLE
COMPATIBILITY WITH EXISTING IN-HOUSE SYSTEMS 0 TO 10V
LONG SENSING DISTANCE MINIMISES RISK OF MECHANICAL
DAMAGE TO THE SENSOR
PRODUCT ADVANTAGES
EXCEPTIONAL DETECTION ACCURACY, EXCELLENT
REPEATABILITY AND RESOLUTION IN THE MICRON RANGE (µM)
SAMPLING RATE OF 250HZ
CONDIST® TECHNOLOGY PROVIDES EXTENDED SENSING
RANGE ≤ 10 MM
RUGGED, VIBRATION-RESISTANT WITH METAL HOUSINGS
INDUSTRY-STANDARD 0 TO 10V ANALOGUE OUTPUTS
A manufacturer of industrial timing belts trusts Contrinex’s
analogue inductive sensors to measure the position of steel
reinforcing bands during continuous production.
Two long-range, high-resolution sensors, mounted above the
extruded belt profile, provide real-time positional data. The
customer’s process-control system monitors the sensor’s
analogue voltage outputs, alerting the operator and halting
production if the values are outside allowable limits.
CUSTOMER APPLICATION
To enhance the strength of industrial timing belts, steel
reinforcing wires are bonded into the belt carcass as part of a
continuous extrusion process. The distance between the
reinforcing wires and the belt teeth is a critical parameter,
influencing the accuracy of the belt’s fit and other operating
characteristics, including service life.
Engineers can check product quality at intervals by cutting
samples of extruded belts and taking optical measurements,
but this process is slow and only detects faults some time after
production is complete, leading to high reject costs.
The customer requires a real-time system with sensors that
reliable and accurately measure the position of the steel
reinforcement.
CUSTOMER SOLUTION
Contrinex M18-size analogue inductive sensors are ideal for this
application providing an analogue voltage output with a
sampling rate of at least 100Hz. The physical characteristics of
the belt dictate a sensing distance of up to 10 mm with micron
(µm) measurement accuracy. Contrinex’s patented Condist®
technology provides a highly stable sensing performance at
operating distances of ≤10 mm with exceptional detection
accuracy, excellent repeatability and resolution in the micron
range.
The sensors sample at 250Hz, enabling accurate measurement
of the position of the steel reinforcement in the fast moving
belt profile, and provide continuous, non-linearised 0 to 10V
analogue output signals. They are resistant to vibration and
variations in ambient temperature, allowing their positioning
immediately after the extrusion press in close proximity to the
moving belt.
Two sensors, set flush into a non-metallic plate, are mounted
directly above the surface of the belt as it runs over a guide
roller, giving a stable reference position. The lightly tensioned
belt clears the sensing face of the devices by a few tenths of a
millimetre. Connection to the customer’s control system is via
a flexible cable with an easily detachable M12 connector.
The introduction of Contrinex analogue inductive sensors
provide small, high-accuracy, ultra-reliable sensors with a low
total cost of ownership.
Rather than needing to destructively test belts to inspect the
position of the steel reinforcement and risking high reject
costs because of the infrequent nature of the sampling, the
production process is now continuously monitored.
CUSTOMER VALUES
ACCURATE HIGH-SPEED MEASUREMENT OF FAST-MOVING
MATERIAL
DISCRETE RAW-DATA OUTPUT WITH EXCEPTIONAL
RESOLUTION
REAL-TIME PROCESS MONITORING AND ADJUSTMENT
HIGHLY RELIABLE, COST-EFFECTIVE SOLUTION
PRODUCT ADVANTAGES
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT
HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL
RESOLUTION
CUSTOMER SOLUTION
Contrinex Analogue Output Inductive sensors are highly
accurate and provide the continuous voltage or current
outputs required for this application. The quasi-embeddable
sensors feature a chrome-plated brass body and PBTP sensing
face, with the M18-diameter sensor allowing sensing distances
up to 10mm (0.4”) with resolution in the µm range.
The sensor, mounted in the sensing head, moves rapidly back
and forth across the web and senses through the material of
the web as it feeds over the roller. It measures the distance
from its sensing face – which lies a known distance from the
bottom face of the head, to the top surface of the roller. It
delivers a precisely calibrated, near-linear, discrete output in
the range 0 to 10V or 4 to 20mA.
The Contrinex inductive sensor has a sealed cable entry,
ensuring fit-and-forget capability during extended periods of
operation, and connects with the machine’s control system via
a flexible PUR-sheathed cable. Using a custom-configured
software interface, output data is displayed numerically and
graphically on a screen, allowing real-time adjustment to the
production process when necessary.
Contrinex’s Analogue Output sensors provide a cost-effective
solution that satisfies the customer’s requirements for
accurate high-speed measurement with an exceptional
resolution. These analogue inductive sensors are used on an
almost unimaginable array of applications and industries.
.
A specialised textile-testing machine measures the thickness
of a moving textile web in real at a high-speed. As the web
passes over a roller, a precision Contrinex analogue inductive
sensor, positioned directly above the roller, rests lightly on the
top of the web. It senses the distance through the material to
the roller, precisely measuring the thickness of the material.
CUSTOMER APPLICATION
For the efficient manufacture of textiles and fabrics, the
thickness of the material needs to be measured immediately
after its formation to enable real-time adjustment of the
production process. Therefore, a manufacturer of specialised
textile-testing machines uses a high-accuracy sensor to
measure the thickness of a continuously produced sheet, or
web of material moving at up to 5m/s (16.4fps).
Measurements are required across the full width of the textile
web, which can be up to 4 metre (13ft) wide. To achieve this a
sensing head is mounted on a transverse-axis carriage which
lies immediately above a fixed roller, traversing the width of
the web as it passes over the roller. In this application, the
precision sensor is providing real-time measurements in the
range 0 to 4mm with a resolution of 0.02mm (0.0008”) or
better.
High-frequency measurement is provided to accommodate
the speed and width of the moving web. A continuous
analogue output is necessary as conventional digital sensors
do not provide the required resolution.
.
CUSTOMER VALUES
MAXIMUM VEHICLE UTILISATION WITH FEWER CONSTRAINTS
ON OPERATIONS
REAL-TIME INDICATION OF BEARING CONDITION AND WEAR
RATE
REDUCED MAINTENANCE COSTS WITH MINIMAL INCIDENCE OF
BREAKDOWNS
RELIABLE OPERATION IN A HIGHLY DEMANDING AND HARSH
ENVIRONMENT
PRODUCT ADVANTAGES
ANALOGUE DEVICE WITH EXTENDED 40MM SENSING RANGE
SMALL PHYSICAL SIZE (LESS THAN 50MM LENGTH)
EXCEPTIONAL ACCURACY AND RESOLUTION IN THE MICRON
RANGE
LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE
FLUCTUATIONS AND VIBRATIONS
Busy container seaports rely upon the ‘24/7’ operation of
specialist container-handling vehicles called Straddle Carriers
for loading, unloading and stacking containers. Often located
at ports, being beside the sea can mean that they have to work
in an aggressive and corrosive environment, requiring
frequent maintenance.
Because traditional, interval-based maintenance schedules are
not optimally efficient, condition-based intervention systems
which minimise the risk of breakdown, are popular. European
port operators therefore frequently rely upon Contrinex’s
rugged, analogue-output inductive sensors to monitor
components with a high risk of premature failure, maximising
vehicle utilisation and reducing maintenance costs.
CUSTOMER APPLICATION
A fleet of straddle carriers services a busy container port,
operating round the clock in a highly aggressive environment.
Frequent maintenance is necessary, but traditional, interval-
based maintenance schedules are not always optimal.
Condition-based intervention minimises the risk of
breakdowns, while imposing fewer constraints on day-to-day
operation; it also incurs cost only when necessary.
As a carrier moves over a container, a central spreader beam
lowers and locks onto the four corner fittings of the container.
Plain plastic bearings on the carrier legs guide the container as
it is raised; there is significant contamination from dirt and
other debris. Bearings wear rapidly in the all-weather
operating conditions.
A condition-monitoring system must measure bearing
thickness, repeatably and accurately, in realtime and with µm
resolution. Sensors must operate reliably in the harsh
environment with a minimum rating of IP67. Sensor length
must not exceed 70mm and a minimum sensing range of
30mm is mandatory.
CUSTOMER SOLUTION
Contrinex’s Analogue Inductive sensors, which feature ‘Extra
Distance’ technology are ideal for this demanding application.
These M30-diameter metal-bodied devices are IP67-rated and
provide an analogue voltage (0 to 10 volt) or current (4 to
20mA) output. The sensors are less than 50mm long with a
40mm sensing range, comfortably exceeding the specified
requirement.
A mild steel mounting plate, fixed immediately behind the
plastic bearing, locates each sensor with its sensing face in
contact with the rear surface of the bearing. As a container
passes over the front face of the bearing, the sensor measures
the distance to the metal container wall, and thus the bearing
thickness. Data is collected in real time with exceptional
accuracy and resolution in the micron range.
Data passes to on-board computers mounted on each carrier;
connection is via a flexible cable with an easily detachable M12
connector. At intervals, carriers transmit data wirelessly to a
central processor for detailed analysis.
The output gives a clear indication of the condition and wear
rate of each bearing, identifying any carrier requiring
maintenance. Consequently, the port operator has the means
to develop a genuine commercial advantage by eliminating
compromise from day-to-day operating processes
CONTRINEX’S BEST-IN-CLASS ANALOGUE INDUCTIVE SENSORS ARE ACCURATE TO MICRONS (µM)
AND TRUSTED IN A WIDE VARIETY OF CRITICAL SYSTEMS AND INNOVATIVE MACHINES.
ANALOGUE INDUCTIVE SENSORS
ANALOGUE INDUCTIVE SENSORS - EXCEPTIONAL ACCURACY & AFFORDABILITY
PRODUCT ADVANTAGES
EXCEPTIONAL ACCURACY & RESOLUTION IN MICRON RANGE
HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL
RESOLUTION, PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT
BEST-IN-CLASS TEMPERATURE STABILITY
VERY LONG SENSING RANGES UP TO 40MM
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE
FLUCTUATIONS AND VIBRATIONS
Contrinex’s analogue inductive sensors offer a reliable, repeatable, highly accurate means of measuring the position of a target
object. Best-in-class temperature stability and a measurement range of zero to 40mm make the sensors ideally suited for measuring
linear, angular and rotational position.
With detection accuracy in the micron range and the best long-range sensing capability on the market, Contrinex analogue sensors
offer world-class performance with an attractive total cost of ownership.
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
CONTINUOUS PRODUCTION AS IN-PROCESS MEASUREMENT IS
HIGHLY ACCURATE WITH HIGH SAMPLING RATE
DEFECTS IDENTIFIED IN REAL TIME MINIMISES REJECT COSTS
NO RESTRICTIONS ON MOUNTING POSITION AS SENSORS ARE
VIBRATION-RESISTANT AND TEMPERATURE-STABLE
COMPATIBILITY WITH EXISTING IN-HOUSE SYSTEMS 0 TO 10V
LONG SENSING DISTANCE MINIMISES RISK OF MECHANICAL
DAMAGE TO THE SENSOR
PRODUCT ADVANTAGES
EXCEPTIONAL DETECTION ACCURACY, EXCELLENT
REPEATABILITY AND RESOLUTION IN THE MICRON RANGE (µM)
SAMPLING RATE OF 250HZ
CONDIST® TECHNOLOGY PROVIDES EXTENDED SENSING
RANGE ≤ 10 MM
RUGGED, VIBRATION-RESISTANT WITH METAL HOUSINGS
INDUSTRY-STANDARD 0 TO 10V ANALOGUE OUTPUTS
A manufacturer of industrial timing belts trusts Contrinex’s
analogue inductive sensors to measure the position of steel
reinforcing bands during continuous production.
Two long-range, high-resolution sensors, mounted above the
extruded belt profile, provide real-time positional data. The
customer’s process-control system monitors the sensor’s
analogue voltage outputs, alerting the operator and halting
production if the values are outside allowable limits.
CUSTOMER APPLICATION
To enhance the strength of industrial timing belts, steel
reinforcing wires are bonded into the belt carcass as part of a
continuous extrusion process. The distance between the
reinforcing wires and the belt teeth is a critical parameter,
influencing the accuracy of the belt’s fit and other operating
characteristics, including service life.
Engineers can check product quality at intervals by cutting
samples of extruded belts and taking optical measurements,
but this process is slow and only detects faults some time after
production is complete, leading to high reject costs.
The customer requires a real-time system with sensors that
reliable and accurately measure the position of the steel
reinforcement.
CUSTOMER SOLUTION
Contrinex M18-size analogue inductive sensors are ideal for this
application providing an analogue voltage output with a
sampling rate of at least 100Hz. The physical characteristics of
the belt dictate a sensing distance of up to 10 mm with micron
(µm) measurement accuracy. Contrinex’s patented Condist®
technology provides a highly stable sensing performance at
operating distances of ≤10 mm with exceptional detection
accuracy, excellent repeatability and resolution in the micron
range.
The sensors sample at 250Hz, enabling accurate measurement
of the position of the steel reinforcement in the fast moving
belt profile, and provide continuous, non-linearised 0 to 10V
analogue output signals. They are resistant to vibration and
variations in ambient temperature, allowing their positioning
immediately after the extrusion press in close proximity to the
moving belt.
Two sensors, set flush into a non-metallic plate, are mounted
directly above the surface of the belt as it runs over a guide
roller, giving a stable reference position. The lightly tensioned
belt clears the sensing face of the devices by a few tenths of a
millimetre. Connection to the customer’s control system is via
a flexible cable with an easily detachable M12 connector.
The introduction of Contrinex analogue inductive sensors
provide small, high-accuracy, ultra-reliable sensors with a low
total cost of ownership.
Rather than needing to destructively test belts to inspect the
position of the steel reinforcement and risking high reject
costs because of the infrequent nature of the sampling, the
production process is now continuously monitored.
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:
ANALOGUE INDUCTIVE
SENSORS
CONTRINEX’S BEST-IN-CLASS ANALOGUE INDUCTIVE
SENSORS ARE ACCURATE TO MICRONS (µM) AND
TRUSTED IN A WIDE VARIETY OF CRITICAL SYSTEMS
AND INNOVATIVE MACHINES.
Busy container seaports rely upon the ‘24/7’ operation of
specialist container-handling vehicles called Straddle Carriers
for loading, unloading and stacking containers. Often located
at ports, being beside the sea can mean that they have to work
in an aggressive and corrosive environment, requiring
frequent maintenance.
Because traditional, interval-based maintenance schedules are
not optimally efficient, condition-based intervention systems
which minimise the risk of breakdown, are popular. European
port operators therefore frequently rely upon Contrinex’s
rugged, analogue-output inductive sensors to monitor
components with a high risk of premature failure, maximising
vehicle utilisation and reducing maintenance costs.
CUSTOMER APPLICATION
A fleet of straddle carriers services a busy container port,
operating round the clock in a highly aggressive environment.
Frequent maintenance is necessary, but traditional, interval-
based maintenance schedules are not always optimal.
Condition-based intervention minimises the risk of
breakdowns, while imposing fewer constraints on day-to-day
operation; it also incurs cost only when necessary.
As a carrier moves over a container, a central spreader beam
lowers and locks onto the four corner fittings of the container.
Plain plastic bearings on the carrier legs guide the container as
it is raised; there is significant contamination from dirt and
other debris. Bearings wear rapidly in the all-weather
operating conditions.
A condition-monitoring system must measure bearing
thickness, repeatably and accurately, in real-time and with µm
resolution. Sensors must operate reliably in the harsh
environment with a minimum rating of IP67. Sensor length
must not exceed 70mm and a minimum sensing range of
30mm is mandatory.
CUSTOMER SOLUTION
Contrinex Analogue Output Inductive sensors are highly
accurate and provide the continuous voltage or current
outputs required for this application. The quasi-embeddable
sensors feature a chrome-plated brass body and PBTP sensing
face, with the M18-diameter sensor allowing sensing distances
up to 10mm (0.4”) with resolution in the µm range.
The sensor, mounted in the sensing head, moves rapidly back
and forth across the web and senses through the material of
the web as it feeds over the roller. It measures the distance
from its sensing face – which lies a known distance from the
bottom face of the head, to the top surface of the roller. It
delivers a precisely calibrated, near-linear, discrete output in
the range 0 to 10V or 4 to 20mA.
The Contrinex inductive sensor has a sealed cable entry,
ensuring fit-and-forget capability during extended periods of
operation, and connects with the machine’s control system via
a flexible PUR-sheathed cable. Using a custom-configured
software interface, output data is displayed numerically and
graphically on a screen, allowing real-time adjustment to the
production process when necessary.
Contrinex’s Analogue Output sensors provide a cost-effective
solution that satisfies the customer’s requirements for
accurate high-speed measurement with an exceptional
resolution. These analogue inductive sensors are used on an
almost unimaginable array of applications and industries.
A specialised textile-testing machine measures the thickness
of a moving textile web in real at a high-speed. As the web
passes over a roller, a precision Contrinex analogue inductive
sensor, positioned directly above the roller, rests lightly on the
top of the web. It senses the distance through the material to
the roller, precisely measuring the thickness of the material.
CUSTOMER APPLICATION
For the efficient manufacture of textiles and fabrics, the
thickness of the material needs to be measured immediately
after its formation to enable real-time adjustment of the
production process. Therefore, a manufacturer of specialised
textile-testing machines uses a high-accuracy sensor to
measure the thickness of a continuously produced sheet, or
web of material moving at up to 5m/s (16.4fps).
Measurements are required across the full width of the textile
web, which can be up to 4 metre (13ft) wide. To achieve this a
sensing head is mounted on a transverse-axis carriage which
lies immediately above a fixed roller, traversing the width of
the web as it passes over the roller. In this application, the
precision sensor is providing real-time measurements in the
range 0 to 4mm with a resolution of 0.02mm (0.0008”) or
better.
High-frequency measurement is provided to accommodate
the speed and width of the moving web. A continuous
analogue output is necessary as conventional digital sensors
do not provide the required resolution.
CUSTOMER VALUES
MAXIMUM VEHICLE UTILISATION WITH FEWER CONSTRAINTS
ON OPERATIONS
REAL-TIME INDICATION OF BEARING CONDITION AND WEAR
RATE
REDUCED MAINTENANCE COSTS WITH MINIMAL INCIDENCE OF
BREAKDOWNS
RELIABLE OPERATION IN A HIGHLY DEMANDING AND HARSH
ENVIRONMENT
PRODUCT ADVANTAGES
ANALOGUE DEVICE WITH EXTENDED 40MM SENSING RANGE
SMALL PHYSICAL SIZE (LESS THAN 50MM LENGTH)
EXCEPTIONAL ACCURACY AND RESOLUTION IN THE MICRON
RANGE
LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE
FLUCTUATIONS AND VIBRATIONS
CUSTOMER SOLUTION
Contrinex’s Analogue Inductive sensors, which feature ‘Extra
Distance’ technology are ideal for this demanding application.
These M30-diameter metal-bodied devices are IP67-rated and
provide an analogue voltage (0 to 10 volt) or current (4 to
20mA) output. The sensors are less than 50mm long with a
40mm sensing range, comfortably exceeding the specified
requirement.
A mild steel mounting plate, fixed immediately behind the
plastic bearing, locates each sensor with its sensing face in
contact with the rear surface of the bearing. As a container
passes over the front face of the bearing, the sensor measures
the distance to the metal container wall, and thus the bearing
thickness. Data is collected in real time with exceptional
accuracy and resolution in the micron range.
Data passes to on-board computers mounted on each carrier;
connection is via a flexible cable with an easily detachable M12
connector. At intervals, carriers transmit data wirelessly to a
central processor for detailed analysis.
The output gives a clear indication of the condition and wear
rate of each bearing, identifying any carrier requiring
maintenance. Consequently, the port operator has the means
to develop a genuine commercial advantage by eliminating
compromise from day-to-day operating processes.
CUSTOMER VALUES
ACCURATE HIGH-SPEED MEASUREMENT OF FAST-MOVING
MATERIAL
DISCRETE RAW-DATA OUTPUT WITH EXCEPTIONAL
RESOLUTION
REAL-TIME PROCESS MONITORING AND ADJUSTMENT
HIGHLY RELIABLE, COST-EFFECTIVE SOLUTION
PRODUCT ADVANTAGES
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT
HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL
RESOLUTION
ANALOGUE INDUCTIVE SENSORS -
EXCEPTIONAL ACCURACY & AFFORDABILITY
PRODUCT ADVANTAGES
EXCEPTIONAL ACCURACY & RESOLUTION IN MICRON RANGE
HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL
RESOLUTION, PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT
BEST-IN-CLASS TEMPERATURE STABILITY
VERY LONG SENSING RANGES UP TO 40MM
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE
FLUCTUATIONS AND VIBRATIONS
Contrinex’s analogue inductive sensors offer a reliable,
repeatable, highly accurate means of measuring the position of
a target object. Best-in-class temperature stability and a
measurement range of zero to 40mm make the sensors ideally
suited for measuring linear, angular and rotational position.
With detection accuracy in the micron range and the best long-
range sensing capability on the market, Contrinex analogue
sensors offer world-class performance with an attractive total
cost of ownership.
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
