Helping you #Make Sense of Sensors
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ASSEMBLY EQUIPMENT APPLICATIONS Fault-free assembly is ensured and downtime minimised by using automated assembly. Contrinex’s large product portfolios provide choice and innovation for assembly equipment manufacturers. The wide variety of sensors offered make them fast and easy to implement for the equipment builder.
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.
APPLICATION - RUGGED INDUCTIVES IN ASSEMBLY OF N95 FACE MASKS
APPLICATION - ROTARY INDEXING TABLE & ROBOT ASSEMBLY
Fault-free assembly is ensured and downtime minimised by using automated facilities for high volume assembly. Rugged inductive sensors detect the presence and position of equipment or components at each stage to ensure that parts are correctly aligned and ready for the next operation. The sensors must be accurate and responsive. In addition, an IO-Link interface offers the advantages of digital communication without the need for special cabling. CUSTOMER APPLICATION Highly reliable automation and machine-control systems are used to eliminate assembly faults and improve efficiency in an assembly operation. Whilst the repetitive assembly tasks are well-suited to being done by robots, these robots can be too slow at picking and placing the assembled parts and therefore a rotary indexing table is used to move the assemblies between the robots. The rotary indexing table speeds up the transfer of PCBs between assembly robots and also on and off conveyors, increasing the production throughput and reducing the number of assembly robots required – Sensors are used to automate these processes and these sensors must be able to operate continuously at high speed, performing tasks including: presence detection to initiate the cassette- change cycle in a stack feeder; position control for a rotary indexing table; pick-and-place gripper control; and presence monitoring on a conveyor system.
Customer Solution Stack-feeders deliver base plates, electrical printed circuit boards and other planar components to the assembly lines. In each stack-feeder, a vertical cassette holds as many as 50 individual parts and a single inductive sensor monitors the status of each cassette. Once the final part is discharged from the stack, the cassette moves to its end position, triggering the sensor and initiating the cassette-change cycle.
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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
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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 for free– Industry 4
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CUSTOMER VALUES • Reliable, repeatable testing of complete trays of knobs in a single cycle • Testing is completed in standard transit trays with no additional handling • Immediate identification of faulty assemblies • Elimination of batch rejection by the customer
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PRODUCT ADVANTAGES • Extended sensing distances up to 12mm • Exceptional packing density with 44mm clearance • Reliable sensing of small targets through plastic tray material • IO- Link connectivity – Ideal for preventative maintenance and Industry 4.0 implementations
Contrinex C23 embeddable inductive sensors, featuring a one-piece stainless-steel housing, are both robust and highly reliable. A 7mm sensing distance allows ample operating clearance, minimizing the risk of mechanical collision. Their implementation into the assembly equipment is made easier by the choice of industry-standard PNP or NPN outputs with either a PUR cable or an M8 pigtail connector. Additionally, IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost, offering the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications. Designed for demanding applications, Contrinex’s rugged C23 inductive sensors offer best-in-class switching frequency of 180Hz and exceptional robustness including impact and abrasion resistance, making them a versatile, cost-effective and highly reliable solution. These uniquely robust sensors are typically demonstrated by Contrinex as being able to repeatedly being used to hammer in nails. Even when their front face is dented, the sensor continues to operate correctly.
Conveyors deliver a continuous stream of parts to the rotary indexing table, which transports them in sequence to each assembly station. As the table rotates, sensors located at precise intervals around its periphery detect its exact angular position, bringing it to a halt once parts are correctly positioned for the next operation. At each assembly station, automated pick-and-place equipment add components to the assembly. Dedicated transport mechanisms – including vacuum lifters, electromagnetic clamps and mechanical grippers – insert items swiftly and accurately in their designated positions. Embeddable inductive sensors play a key role in confirming the secure closure of custom-designed grippers before fragile, high- value parts are lifted. Manufactured in V4A/ AISI 316L stainless steel and rated to IP68/ IP69K, these small inductive sensors can be fully embedded into a steel surface such as part of the rotary table or an assembly jig or bench, further reducing the potential for mechanical damage. On completion of the final assembly stage, finished PCBs are discharged to a linear conveyor system. They travel to subsequent processing stages, including testing and packing. C23 Full Inox sensors mounted directly above these conveyors, detect each unit as it passes below. This check not only confirms the presence of the assembled item at the expected height above the conveyor but also measures throughput by activating a counting circuit in the customer’s control system. Continuous operation is the norm in automated assembly plants. However, minor adjustments or tool changes may be required from time to time. In non-safety-critical areas, access hatches allow maintenance technicians to carry out these tasks without needing to interrupt production across an entire plant. Multiple sensors, mounted at intervals around the periphery of a hatch, ensure that appropriate warning signals are activated whenever the opening is not fully secured. The Contrinex C23 series of Full Inox inductive sensors have the capability of communicating remotely with a plant-wide control system, thanks to the implementation of the IO-Link protocol. In a typical automated plant, each assembly line runs continuously throughout the day, with remote diagnostics eliminating the need for manual intervention in almost every situation. Designed to simplify integration, IO-Link sensors are compatible with all IO-Link master versions, allowing set-up and diagnostics to be conducted centrally. Interrogating a device returns its manufacturer ID and product ID, allowing systems integrators to determine remotely that the right sensor is in the correct location. Contrinex C23 inductive sensors additionally feature an on-demand self-test function that confirms full capability at all times. For the C23 inductive series, alternating between normally open and normally closed functionality via remote output-mode configuration is a standard feature of the IO-Link protocol. Systems designers also can modify the output signal. Delaying the switching pulse accommodates any travel time between a sensor and its corresponding actuation point, while stretching the pulse ensures that slave devices with lengthy response times trigger reliably, even at high throughput rates. Finally, each sensor provides an output-status check derived from its factory calibration data. If the output signal from a sensor falls outside a range that corresponds to a sensing distance between 80% and 100% of its nominal value, an alarm flag is triggered, highlighting the need for investigation. For plant managers under pressure, peace-of- mind is a valuable benefit. The no-cost option of the industry-standard IO-Link protocol ensures that best-in-class performance is coupled with ultimate ease of use in even the most demanding circumstances.
During automated production of solar cells, compact two-finger grippers transport trays of silicon wafers between operations. To avoid impacts on the wafer’s surfaces, process engineers require reliable confirmation that gripper jaws are fully open before the gripper descends to pick up a tray. Contrinex’s Ultra-miniature inductive proximity sensors, mounted directly above the top faces of the gripper fingers, sense the position of the jaws in the fully open position, eliminating avoidable scrap costs. CUSTOMER APPLICATION Eliminating avoidable scrap costs has to be at the top of any production engineer’s to-do list, particularly when rectifying component damage also means interrupting a fast-moving automated production line. When the component in question is a costly photovoltaic silicon wafer, designers often turn to automated handling systems, although relying on these to achieve perfect alignment isn’t always the answer. In a manufacturing cell, handling systems assemble solar cells before presenting them for automated testing. To start, trays of silicon wafers are transported between operations by two-finger edge-grippers. If gripper malfunctions occur, scrap costs can mount rapidly, with mechanical damage caused by impacts on the wafer surfaces being a common cause. Analysis showed that open/close errors account for a significant proportion of gripper malfunctions. Software routines alone can’t identify the position of the gripper fingers; attempts to pick up a wafer tray with the jaws only partially open result in fingers impacting on the wafer surfaces. A cost-effective hardware solution is required to provide overriding inhibition of picking routines if this situation arises.
Customer Solution Designers specified two-finger grippers fitted with Contrinex Ultra- miniature inductive sensors as a reliable and cost-effective means of detecting the position of the jaws at the extremes of travel. Before the gripper descends to pick up a tray, these miniature proximity sensors, mounted directly above the top faces of the gripper fingers, sense the position of the jaws in the fully open position. Ultraminiature inductive sensors are designed with the needs of OEMs and system integrators in mind and provide an unobtrusive fit-and- forget solution. These miniature devices weigh only 25 grams, and with a compact 3mm-diameter x 22mm V2A stainless-steel housing, they allow easy integration in tight spaces with insufficient room for traditional devices. With a sensing distance of 1mm, MiniDist devices offer designers attractive alternatives when specifying equipment. Industry-standard PNP and NPN outputs with normally open or normally closed options ensure optimum flexibility when interfacing with a wide range of control systems. Connection is via a PUR-sheathed cable with a 3-pin connector or 2-meter flying lead; alternative lengths are available. These highly versatile miniature sensors meet designers’ needs for reliable operation while preventing accidental damage. The solution is both highly reliable and cost-effective while eliminating avoidable scrap costs; payback is rapid, while production throughput is maintained at target levels without increasing the cost of quality. The inclusion of IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost. It offers the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications.
APPLICATION - MINIATURE SENSORS IN ASSEMBLY OF FRAGILE WAFERS
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CUSTOMER VALUES • Miniature sensors to ensure reliable detection • Miniature sensors suitable for easy integration • Reliable, compact vibration-resistant sensors • -25°C to +70°C operating range
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PRODUCT ADVANTAGES • Compact 3mm-diameter x 22mm, 25 gram V2A stainless-steel housing • Sensing distances of 1mm • IO-Link interface included for free– Industry 4 • Proven technology ensures fit-and-forget operation with no manual intervention
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
ASSEMBLY EQUIPMENT APPLICATIONS Fault-free assembly is ensured and downtime minimised by using automated assembly. Contrinex’s large product portfolios provide choice and innovation for assembly equipment manufacturers.
APPLICATION - RUGGED INDUCTIVES IN ASSEMBLY OF N95 FACE MASKS
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.
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.
APPLICATION - ROTARY INDEX TABLE & ROBOT ASSEMBLY
Fault-free assembly is ensured and downtime minimised by using automated facilities for high volume assembly. Rugged inductive sensors detect the presence and position of equipment or components at each stage to ensure that parts are correctly aligned and ready for the next operation. The sensors must be accurate and responsive. In addition, an IO-Link interface offers the advantages of digital communication without the need for special cabling. CUSTOMER APPLICATION Highly reliable automation and machine-control systems are used to eliminate assembly faults and improve efficiency in an assembly operation. Whilst the repetitive assembly tasks are well-suited to being done by robots, these robots can be too slow at picking and placing the assembled parts and therefore a rotary indexing table is used to move the assemblies between the robots. The rotary indexing table speeds up the transfer of PCBs between assembly robots and also on and off conveyors, increasing the production throughput and reducing the number of assembly robots required – Sensors are used to automate these processes and these sensors must be able to operate continuously at high speed, performing tasks including: presence detection to initiate the cassette-change cycle in a stack feeder; position control for a rotary indexing table; pick-and-place gripper control; and presence monitoring on a conveyor system.
+ CUSTOMER VALUES • Reliable, repeatable detection of three discrete parts in a single operation • Elimination of unsafe occurrences due to faulty hose assemblies • Highly cost-effective solution to a previously insoluble problem PRODUCT ADVANTAGES • Exceptional sensing distances in small sensor envelopes • Correction factor of 1.0 for brass allows extended sensing distance • Sensors operate in close proximity without interference + + 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 for free – Industry 4  +
Customer Solution Stack-feeders deliver base plates, electrical printed circuit boards and other planar components to the assembly lines. In each stack-feeder, a vertical cassette holds as many as 50 individual parts and a single inductive sensor monitors the status of each cassette. Once the final part is discharged from the stack, the cassette moves to its end position, triggering the sensor and initiating the cassette- change cycle.
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Helping you #MakeSenseofSensors
Contrinex C23 embeddable inductive sensors, featuring a one-piece stainless-steel housing, are both robust and highly reliable. A 7mm sensing distance allows ample operating clearance, minimizing the risk of mechanical collision. Their implementation into the assembly equipment is made easier by the choice of industry- standard PNP or NPN outputs with either a PUR cable or an M8 pigtail connector. Additionally, IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost, offering the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications. Designed for demanding applications, Contrinex’s rugged C23 inductive sensors offer best-in-class switching frequency of 180Hz and exceptional robustness including impact and abrasion resistance, making them a versatile, cost-effective and highly reliable solution. These uniquely robust sensors are typically demonstrated by Contrinex as being able to repeatedly being used to hammer in nails. Even when their front face is dented, the sensor continues to operate correctly.
Conveyors deliver a continuous stream of parts to the rotary indexing table, which transports them in sequence to each assembly station. As the table rotates, sensors located at precise intervals around its periphery detect its exact angular position, bringing it to a halt once parts are correctly positioned for the next operation. At each assembly station, automated pick-and-place equipment add components to the assembly. Dedicated transport mechanisms – including vacuum lifters, electromagnetic clamps and mechanical grippers – insert items swiftly and accurately in their designated positions. Embeddable inductive sensors play a key role in confirming the secure closure of custom-designed grippers before fragile, high-value parts are lifted. Manufactured in V4A/ AISI 316L stainless steel and rated to IP68/ IP69K, these small inductive sensors can be fully embedded into a steel surface such as part of the rotary table or an assembly jig or bench, further reducing the potential for mechanical damage. On completion of the final assembly stage, finished PCBs are discharged to a linear conveyor system. They travel to subsequent processing stages, including testing and packing. C23 Full Inox sensors mounted directly above these conveyors, detect each unit as it passes below. This check not only confirms the presence of the assembled item at the expected height above the conveyor but also measures throughput by activating a counting circuit in the customer’s control system. Continuous operation is the norm in automated assembly plants. However, minor adjustments or tool changes may be required from time to time. In non-safety-critical areas, access hatches allow maintenance technicians to carry out these tasks without needing to interrupt production across an entire plant. Multiple sensors, mounted at intervals around the periphery of a hatch, ensure that appropriate warning signals are activated whenever the opening is not fully secured. The Contrinex C23 series of Full Inox inductive sensors have the capability of communicating remotely with a plant-wide control system, thanks to the implementation of the IO-Link protocol. In a typical automated plant, each assembly line runs continuously throughout the day, with remote diagnostics eliminating the need for manual intervention in almost every situation. Designed to simplify integration, IO-Link sensors are compatible with all IO-Link master versions, allowing set- up and diagnostics to be conducted centrally. Interrogating a device returns its manufacturer ID and product ID, allowing systems integrators to determine remotely that the right sensor is in the correct location. Contrinex C23 inductive sensors additionally feature an on-demand self- test function that confirms full capability at all times. For the C23 inductive series, alternating between normally open and normally closed functionality via remote output- mode configuration is a standard feature of the IO-Link protocol. Systems designers also can modify the output signal. Delaying the switching pulse accommodates any travel time between a sensor and its corresponding actuation point, while stretching the pulse ensures that slave devices with lengthy response times trigger reliably, even at high throughput rates. Finally, each sensor provides an output-status check derived from its factory calibration data. If the output signal from a sensor falls outside a range that corresponds to a sensing distance between 80% and 100% of its nominal value, an alarm flag is triggered, highlighting the need for investigation. For plant managers under pressure, peace-of-mind is a valuable benefit. The no-cost option of the industry-standard IO-Link protocol ensures that best-in-class performance is coupled with ultimate ease of use in even the most demanding circumstances.