(0121) 58 222 58 SALES@PLUSAUTOMATION.CO.UK
© 2021 - 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
HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES
SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES
SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER
(0 – 10 VDC OR 4 – 20 MA)
LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE
PRODUCT ADVANTAGES
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
LONG SENSING RANGE OF 40MM
PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION
IN µM RANGE
EXCELLENT TEMPERATURE STABILITY & VERY GOOD
REPEATING ACCURACY
SEVERAL SWITCH POINTS WITH A SINGLE DEVICE
LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION
Analogue inductive sensors from Contrinex’s 509 Series are
ideal for this application because their Condist® oscillator
technology ensures excellent environmental stability,
especially to temperature. This is key in providing sensing
distances up to 3 times the standard (in this case 40 mm from
the M30 sized sensor).
This extra sensing distance ability enables them to obtain a
good signal not only through multiple layers of cardboard but
also from different conductive metals at varying distances,
depending on the can type.
The customer mounted the M30 sized inductive analogue
sensors which yield the greatest sensing distance above and
below the passing lanes of cans so that the double layer of
cans in each carton can be checked through the cardboard
walls of the box.
The continuous analogue current or voltage output from
these sensors is connected directly to a PLC with a high-speed
analogue input card. Resolution is in the µm range and repeat
accuracy is very good. The solution excels because it is durable,
adaptable, reliable and simple to install.
.
To ensure that sealed cardboard cartons have the required
number of tinned food cans inside them, a packaging
company trusts Contrinex’s analogue inductive sensors. Using
an analogue sensor enables this final pre-shipment quality
check to process different sizes of can as well as manage with
different material grades of can.
CUSTOMER APPLICATION
Canned products and their labels are protected during
delivery by being tightly packed into sturdy sealed cardboard
boxes. This poses a challenge to food packaging companies
because retailers, particularly supermarkets require absolute
accuracy in the contents of the carton, but at final inspection,
the carton is already sealed and so the contents can not be
visually inspected.
Therefore to eliminate the risk that product faults that may
have occurred during upstream processes are shipped out to
the customers, the packing company needed a way to verify
what tins are inside the sealed box. Because the packaging
line handles a variety of cans of different sizes and materials, a
conventional on-off switching inductive proximity sensor could
not be used.
An additional challenge is that the sensor needs to be part of a
verification process integrated into a fast-moving automated
packaging and pre-shipment line, accepting or rejecting each
carton instantly.
.
CUSTOMER VALUES
HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES
SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES
SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER
(0 – 10 VDC OR 4 – 20 MA)
LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE
PRODUCT ADVANTAGES
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
LONG SENSING RANGE OF 40MM
PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION
IN µM RANGE
EXCELLENT TEMPERATURE STABILITY & VERY GOOD
REPEATING ACCURACY
SEVERAL SWITCH POINTS WITH A SINGLE DEVICE
LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION
Contrinex analogue inductive sensors from their Extra
Distance 509 Series family are perfect for the position and
distance measurement requirements of this application. The
sensors provide an analogue value for the entire motion
sequence of the x-ray inspection. Their excellent resolution in
µm range is particularly suitable for measuring gaps and
angles, detecting motion and controlling travel smoothly.
The sensors are positioned to measure both the pipe carriage
position, which represents the system’s zero-point and is
therefore critical for correct operation and the distance
between the x-ray source and the pipe surface which is critical
to x-ray result quality.
The analogue sensors output a continuous voltage or current
analogue signal which reflects the gap between the damping
element and the sensing surface.
With Contrinex’s patent-protected Condist technology, these
high-performance analogue sensors provide a sensing range
that is more than twice the distance offered by competitors.
The M30 versions used in this application offer a sensing range
of 0 to 40 mm and so they can provide the flexibility required
for testing the numerous pipe diameters being manufactured.
The solution excels because it is durable, adaptable, reliable
and was also fast and simple to install.
.
The integrity of weld seams in pipes used to transport oil or
gas across land or sea is ensured using x-ray testing. The x-ray
test systems used for this require precision control of the
distance between the x-ray source and the surface of the pipe
because this is critical for the quality of the imaging data.
CUSTOMER APPLICATION
A producer of pipes ranging in diameter from 50mm to 2m
has a x-ray testing systems integrated to the end of their
production lines to ensure the pipes they manufacture will not
leak and are impermeable. Pipes for pipelines for example
must resist long-term exposure to harsh environments and
withstand high pressures and fluctuations in temperature.
Therefore, they must be guaranteed to be free from material
faults and weak points, such as flaws in the weld seam, like
trapped air or slag in the metal.
The final inspection of the pipe involves the pipes entering an
x-ray test room, which is a radiation-proof bunker. The x-ray
source is positioned precisely over the pipe, while a flat panel
forms the opposite pole of the system. The flat panel is located
inside a large pipe or below a small one.
Accurate positioning of pipe, the flat panel and the x-ray
source is crucial to achieving optimum test results and
therefore accurate and reliable sensors are critical to
production efficiency.
.
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
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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
HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES
SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES
SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER
(0 – 10 VDC OR 4 – 20 MA)
LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE
PRODUCT ADVANTAGES
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
LONG SENSING RANGE OF 40MM
PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION
IN µM RANGE
EXCELLENT TEMPERATURE STABILITY & VERY GOOD
REPEATING ACCURACY
SEVERAL SWITCH POINTS WITH A SINGLE DEVICE
LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION
Analogue inductive sensors from Contrinex’s 509 Series are
ideal for this application because their Condist® oscillator
technology ensures excellent environmental stability,
especially to temperature. This is key in providing sensing
distances up to 3 times the standard (in this case 40 mm from
the M30 sized sensor).
This extra sensing distance ability enables them to obtain a
good signal not only through multiple layers of cardboard, but
also from different conductive metals at varying distances,
depending on the can type.
The customer mounted the M30 sized inductive analogue
sensors which yield the greatest sensing distance above and
below the passing lanes of cans, so that the double layer of
cans in each carton can be checked through the cardboard
walls of the box.
The continuous analogue current or voltage output from
these sensors is connected directly to a PLC with a high-speed
analogue input card. Resolution is in the µm range and repeat
accuracy is very good. The solution excels because it is durable,
adaptable, reliable and simple to install.
.
To ensure that sealed cardboard cartons have the required
number of tinned food cans inside them, a packaging
company trusts Contrinex’s analogue inductive sensors. Using
an analogue sensor enables this final pre-shipment quality
check to process different sizes of can as well as manage with
different material grades of can.
CUSTOMER APPLICATION
Canned products and their labels are protected during
delivery by being tightly packed into sturdy sealed cardboard
boxes. This poses a challenge to food packaging companies
because retailers, particularly supermarkets require absolute
accuracy in the cartons contents, but at final inspection the
carton is already sealed and so the contents can not be visually
inspected.
Therefore to eliminate the risk that product faults that may
have occurred during upstream processes are shipped out to
the customers, the packing company needed a way to verify
what tins are inside the sealed box. Because of the packaging
line handles a variety of cans of different sizes and materials, a
conventional on-off switching inductive proximity sensor could
not be used.
An additional challenge is that the the sensor needs to be part
of a verification process integrated into a fast-moving
automated packaging and pre-shipment line, accepting or
rejecting each carton instantly.
.
CUSTOMER VALUES
HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES
SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES
SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER
(0 – 10 VDC OR 4 – 20 MA)
LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE
PRODUCT ADVANTAGES
CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE
ANALOGUE SIGNAL
LONG SENSING RANGE OF 40MM
PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION
IN µM RANGE
EXCELLENT TEMPERATURE STABILITY & VERY GOOD
REPEATING ACCURACY
SEVERAL SWITCH POINTS WITH A SINGLE DEVICE
LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION
Contrinex analogue inductive sensors from their Extra
Distance 509 Series family are perfect for the position and
distance measurement requirements of this application. The
sensors provide an analogue value for the entire motion
sequence of the x-ray inspection. Their excellent resolution in
µm range is particularly suitable for measuring gaps and
angles, detecting motion and controlling travel smoothly.
The sensors are positioned to measure both the pipe carriage
position, which represents the system’s zero-point and is
therefore critical for correct operation and the distance
between the x-ray source and the pipe surface which is critical
to x-ray result quality.
The analogue sensors output a continuous voltage or current
analogue signal which reflects the gap between the damping
element and the sensing surface.
With Contrinex’s patent-protected Condist technology, these
high-performance analogue sensors provide a sensing range
that is more than twice the distance offered by competitors.
The M30 versions used in this application offer a sensing range
of 0 to 40 mm and so they can provide the flexibility required
for testing the numerous pipe diameters being manufactured.
The solution excels because it is durable, adaptable, reliable
and was also fast and simple to install.
.
The integrity of weld seams in pipes used to transport oil or
gas across land or sea is ensured using x-ray testing. The x-ray
test systems used for this require precision control of the
distance between the x-ray source and the surface of the pipe
because this is critical for the quality of the imaging data.
CUSTOMER APPLICATION
A producer of pipes ranging in diameter from 50mm to 2m
has a x-ray testing systems integrated to the end of their
production lines to ensure the pipes they manufacture will not
leak and are impermeable. Pipes for pipelines for example
must resist long-term exposure to harsh environments and
withstand high pressures and fluctuations in temperature.
Therefore, they must be guaranteed to be free from material
faults and weak points, such as flaws in the weld seam, like
trapped air or slag in the metal.
The final inspection of the pipe involves the pipes entering an
x-ray test room, which is a radiation-proof bunker. The x-ray
source is positioned precisely over the pipe, while a flat panel
forms the opposite pole of the system. The flat panel is located
inside a large pipe or below a small one.
Accurate positioning of pipe, the flat panel and the x-ray
source is crucial to achieving optimum test results and
therefore accurate and reliable sensors are critical to
production efficiency.
.
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
