Helping you #Make Sense of Sensors
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OFF-HIGHWAY & RAIL APPLICATIONS The Off-Highway and Rail industries demand robustness and low-cost, which makes Contrinex sensors ideal and very popular across these industry sectors.
OFF HIGHWAY, RAIL & VEHICLE APPLICATIONS
Hook loader trucks utilise a hydraulic system for loading and unloading a demountable container. Once the container is correctly positioned on the vehicle’s load bed, interlocks engage with its base, securing it in position. Contrinex’s rugged sensor systems detect full engagement of the interlocks, ensuring the truck is safely loaded before driving away. Therefore the sensors must be mechanically robust and able to withstand harsh outdoors conditions. CUSTOMER APPLICATION A specialist vehicle builder manufactures hydraulic hook-lift systems for commercial trucks. A hook loader truck employs a series of hydraulic rams to hook, lift and pull a demountable container onto the vehicle’s load bed; a full container may weigh up to 30 tons. Hook loader trucks operate all year round, often in harsh environments such as demolition and construction sites. Hook-lift systems are typically semi-automated. The driver positions the truck, engages the hook with the container and initiates the lifting sequence. Once the container is pulled onto the load bed, two interlock mechanisms, mounted on the truck chassis, actuate and engage with the container body. Once the interlocks are fully engaged, the container is secure and the truck may be driven safely. A highly reliable sensor system must detect the position of the interlocks, ensuring that they are fully engaged before the truck drives away. Sensors must be robust and must withstand water, mud, dirt and ice. They may also be subject to mechanical shock and vibration.
APPLICATION - TRAM PANTAGRAPH DETECTION
When a tram reaches a road junction, wire-switches, installed on the overhead conductor cables, control its direction of travel, with switches in either the default “straight-through” or “turnout” positions. As the tram passes a switch in the turnout position, Contrinex photoelectric sensors mounted on the overhead cables detect the presence of the pantograph current collector so that the control system can then reset the switch to the default position. CUSTOMER APPLICATION In urban tram transportation systems, wire-switches installed on the overhead conductor cables at road junctions, control the direction of travel for the trams. The switches default to the straight-through position so that when a bus approaches a turn, the driver uses a remote trigger to change the switch to the turnout position. After the bus completes the turn, the switch reverts to the straight-through position. If a triggered switch reverts to the straight-through position prematurely, the pantagraph current collector may become disengaged, damaging the switch. Therefore tram operators install safety systems to prevent premature switching. Typically, these utilise timer circuits and a predetermined delay or mechanical sensors that rely on physical contact with the current collector, but neither system is reliable. A Swiss manufacturer of trolley-bus control systems requires a highly reliable, rugged sensor system that will detect the presence of a current collector as it passes a switch. The system must operate with minimal maintenance and withstand the varied weather conditions of an outdoor environment in Switzerland and therefore they selected Contrinex sensors .
Customer Solution Contrinex’s C23 through-beam photoelectric sensors offer high- performance, small size and high-stability. A purpose-designed metal bracket, mounted above the conductor cable, holds the transmitter and receiver units in alignment on either side of the cable. As the pantagraph current collector passes between the two units it breaks the beam, triggering the sensor and returning the switch to the straight-through position. The C23 photoelectric sensors are virtually impervious to the harsh, outdoor environment and their small physically size (30 x 20 x 10mm) eliminates the risk of accidental damage arising from a mechanical collision. The rugged construction and vacuum-encapsulated electronics within the sensor minimise the effects of vibration, ensuring a long service life. Each unit is connected to the trolley-bus control systems via a PVC- sheathed cable with a hermetically sealed entry. The receiver has an industry-standard PNP interface. The one-piece mounting bracket allows easy removal and replacement of the complete assembly during routine maintenance. Operational results have been excellent and the Contrinex sensors have proved highly reliable, eliminating switching errors and reducing maintenance costs significantly.
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CUSTOMER VALUES • Exceptional reliability in a harsh outdoor environment • Automatic operation with optimal space utilisation • Elimination of switching errors during year- round operation • Significantly reduced maintenance costs
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PRODUCT ADVANTAGES • Sensing range up to 12,000 mm • Long sensing range in small sensor • Exceptional resistance to vibration during operation
APPLICATION - HOOK LOADER TRUCKS
APPLICATION - FORKLIFT ATTACHMENTS
A container manufacturer uses a modified forklift, fitted with two sets of forks, for unloading bulk cargo. The lower forks support the container while the upper forks control the lid. When unloading, the lid opens and the lower forks rotate, tipping out the contents. A robust inductive sensor senses the position of the lid, ensuring it opens fully before emptying. CUSTOMER APPLICATION Containers are often used when transporting bulk cargo, including wood chip and biomass, by rail. A Swiss manufacturer of bulk-cargo containers has developed an innovative unloading system that uses only a modified forklift, eliminating the need for specialist handling equipment. The forklift has two pairs of lifting forks. The main forks, mounted conventionally, support the weight of the container as it is unloaded from a freight wagon; a second pair, mounted vertically above the lower pair, opens and closes the lid of the container. During opening, the upper forks lift the lid a short distance before tilting it vertically, leaving the top of the container completely unobstructed. The lower forks then rotate about a horizontal axis, tilting the container end-over-end and tipping the contents out. A robust and reliable sensor system is required to detect the vertical position of the lid before rotation begins. An extended sensing distance is essential to eliminate the possibility of mechanical damage.
Customer Solution Contrinex inductive sensors are robust, reliable and offer extended sensing distances; the Full Inox Extreme range is ideal for this application. A one-piece M30-diameter stainless-steel body and vacuum-encapsulated electronics make this device particularly suitable for the mechanically demanding environment, and the sensing distance of 20mm eliminates any possibility of accidental collision in operation. A metal bracket is mounted externally on the actuating mechanism for the upper forks; the embeddable sensor is mounted immediately adjacent to one of the forks and detects the position of the actuating arm as it drives the fork into the vertical position. The AISI 303/V2A stainless-steel housing and sensing face are corrosion-resistant and impervious to water ingress; the sensor is IP68- and IP69K-rated. Configured with an industry-standard PNP normally-open interface, the Contrinex M30 Extreme sensor connects to the forklift’s lower-fork tilt- control systems via a flexible PUR-sheathed cable. A sealed cable entry ensures fit-and-forget capability during extended periods of operation in an outdoor environment. The Full Inox inductive sensor detects the vertical position of the forklift’s upper forks effectively and repeatably, ensuring safe, reliable operation of the unloading system. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for extreme robustness and extended sensing distance.
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CUSTOMER VALUES • Elimination of human error by inhibiting lifting until arm is fully retracted • Highly reliable sensing performance in highly demanding conditions • Corrosion-resistant sensors withstand water, ice, mud and salt • Highly cost-effective solution to a potentially serious problem
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PRODUCT ADVANTAGES • Corrosion-resistant single-piece AISI 303 (V2A) stainless-steel body • High resistance to harsh operating conditions • Rugged, hermetically sealed IP68, IP69K, embeddable sensors
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CUSTOMER VALUES • Safe, reliable performance in a demanding outdoor environment • No likelihood of accidental damage arising in operation • Cost-effective solution, maintenance free
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PRODUCT ADVANTAGES • Corrosion-resistant stainless-steel sensor rated to IP68 and IP69K • Cost-effective high-performance sensor with exceptional reliability • Best-in-class 20mm sensing distance in M30- diameter housing
These rugged miniature sensors have a sensing range up to 30m, for Through-beam applications. They are very reliable and cost-effective with the additional benefit of offering a range of low-cost stainless-steel mounting and protection brackets, making them ideal for a wide variety of applications.
Customer Solution Rugged Full Inox inductive sensors from the Contrinex Extreme 700 Series are designed for demanding or even exceptionally demanding environments, making them ideal for this application. Highly reliable and IP68 / IP69K rated, these embeddable units feature one-piece V2A (AISI 304) stainless-steel construction with vacuum-encapsulated electronics, making them well suited to the hostile operating conditions. During operation, a double-ended ram drives a pair of interlock bolts into position. On either side of the truck, two M18-diameter sensors are mounted in the wall of each bolt housing; one detects the bolt as it reaches the fully engaged position; the other detects it in the fully retracted position. A second ram drives a rotating lock mechanism to engage with the vehicle chassis; a further two sensors detect the position of a cam on the locking shaft as it rotates. Each sensor is configured with an industry-standard PNP normally- open interface, and connection to the truck’s hydraulic control system is via an integral M12 connector and PUR-sheathed cable. This allows easy removal and replacement during routine maintenance. Rugged sensor construction ensures excellent resistance to shock and vibration and a sensing distance of up to 10mm eliminates any risk of accidental collision with moving parts. These devices are corrosion- resistant and impervious to water ingress, mud, ice and salt. 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.
PLUS Automation ® Limited © 2020 Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire. WR9 0LG
Helping you #MakeSenseofSensors
These rugged miniature sensors have a sensing range up to 30m, for Through-beam applications. They are very reliable and cost-effective with the additional benefit of offering a range of low-cost stainless-steel mounting and protection brackets, making them ideal for a wide variety of applications.
OFF-HIGHWAY, RAIL & VEHICLE APPLICATIONS The Off-Highway and Rail industries demand robustness and low-cost, which makes Contrinex sensors ideal and very popular across these industries.
APPLICATION - HOOK LOADER TRUCKS
Customer Solution Rugged Full Inox inductive sensors from the Contrinex Extreme 700 Series are designed for demanding or even exceptionally demanding environments, making them ideal for this application. Highly reliable and IP68 / IP69K rated, these embeddable units feature one-piece V2A (AISI 304) stainless-steel construction with vacuum-encapsulated electronics, making them well suited to the hostile operating conditions. During operation, a double-ended ram drives a pair of interlock bolts into position. On either side of the truck, two M18-diameter sensors are mounted in the wall of each bolt housing; one detects the bolt as it reaches the fully engaged position; the other detects it in the fully retracted position. A second ram drives a rotating lock mechanism to engage with the vehicle chassis; a further two sensors detect the position of a cam on the locking shaft as it rotates. Each sensor is configured with an industry-standard PNP normally-open interface, and connection to the truck’s hydraulic control system is via an integral M12 connector and PUR-sheathed cable. This enables easy removal and replacement during routine maintenance. Rugged sensor construction ensures excellent resistance to shock and vibration and a sensing distance of up to 10mm eliminates any risk of accidental collision with moving parts. These devices are corrosion-resistant and impervious to water ingress, mud, ice and salt. 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.
Hook loader trucks utilise a hydraulic system for loading and unloading a demountable container. Once the container is correctly positioned on the vehicle’s load bed, interlocks engage with its base, securing it in position. Contrinex’s rugged sensor systems detect full engagement of the interlocks, ensuring the truck is safely loaded prior to driving away. Therefore the sensors must be mechanically robust and able to withstand harsh outdoors conditions. CUSTOMER APPLICATION A specialist vehicle builder manufactures hydraulic hook-lift systems for commercial trucks. A hook loader truck employs a series of hydraulic rams to hook, lift and pull a demountable container onto the vehicle’s load bed; a full container may weigh up to 30 tons. Hook-lift trucks operate all year round, often in harsh environments such as demolition and construction sites. Hook-lift systems are typically semi-automated. The driver positions the truck, engages the hook with the container and initiates the lifting sequence. Once the container is pulled onto the load bed, two interlock mechanisms, mounted on the truck chassis, actuate and engage with the container body. Once the interlocks are fully engaged, the container is secure and the truck may be driven safely. A highly reliable sensor system must detect the position of the interlocks, ensuring that they are fully engaged before the truck drives away. Sensors must be robust and must withstand water, mud, dirt and ice. They may also be subject to mechanical shock and vibration.
APPLICATION - FORKLIFT TRUCK ATTACHMENTS
A container manufacturer uses a modified forklift, fitted with two sets of forks, for unloading bulk cargo. The lower forks support the container while the upper forks control the lid. When unloading, the lid opens and the lower forks rotate, tipping out the contents. A robust inductive sensor senses the position of the lid, ensuring it opens fully before emptying. CUSTOMER APPLICATION Containers are often used when transporting bulk cargo, including wood chip and biomass, by rail. A Swiss manufacturer of bulk-cargo containers has developed an innovative unloading system that uses only a modified forklift, eliminating the need for specialist handling equipment. The forklift has two pairs of lifting forks. The main forks, mounted conventionally, support the weight of the container as it is unloaded from a freight wagon; a second pair, mounted vertically above the lower pair, opens and closes the lid of the container. During opening, the upper forks lift the lid a short distance before tilting it vertically, leaving the top of the container completely unobstructed. The lower forks then rotate about a horizontal axis, tilting the container end-over-end and tipping the contents out. A robust and reliable sensor system is required to detect the vertical position of the lid before rotation begins. An extended sensing distance is essential to eliminate the possibility of mechanical damage.
Customer Solution Contrinex inductive sensors are robust, reliable and offer extended sensing distances; the Full Inox Extreme range is ideal for this application. A one-piece M30-diameter stainless-steel body and vacuum-encapsulated electronics make this device particularly suitable for the mechanically demanding environment, and the sensing distance of 20mm eliminates any possibility of accidental collision in operation. A metal bracket is mounted externally on the actuating mechanism for the upper forks; the embeddable sensor is mounted immediately adjacent to one of the forks and detects the position of the actuating arm as it drives the fork into the vertical position. The AISI 303/V2A stainless- steel housing and sensing face are corrosion-resistant and impervious to water ingress; the sensor is IP68- and IP69K-rated. Configured with an industry-standard PNP normally-open interface, the Contrinex M30 Extreme sensor connects to the forklift’s lower-fork tilt-control systems via a flexible PUR-sheathed cable. A sealed cable entry ensures fit- and-forget capability during extended periods of operation in an outdoor environment. The Full Inox inductive sensor detects the vertical position of the forklift’s upper forks effectively and repeatably, ensuring safe, reliable operation of the unloading system. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for extreme robustness and extended sensing distance.
+ CUSTOMER VALUES • Safe, reliable performance in a demanding outdoor environment • No likelihood of accidental damage arising in operation • Cost-effective solution, maintenance free PRODUCT ADVANTAGES • Corrosion-resistant stainless-steel sensor rated to IP68 and IP69K • Cost-effective high-performance sensor with exceptional reliability • Best-in-class 20mm sensing distance in M30-diameter housing + + CUSTOMER VALUES • Elimination of human error by inhibiting lifting until arm is fully retracted • Highly reliable sensing performance in highly demanding conditions • Corrosion-resistant sensors withstand water, ice, mud and salt • Highly cost-effective solution to a potentially serious problem PRODUCT ADVANTAGES • Corrosion-resistant single-piece AISI 303 (V2A) stainless-steel body • High resistance to harsh operating conditions • Rugged, hermetically sealed IP68, IP69K embeddable sensors +
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
APPLICATION - TRAM PANTAGRAPH DETECTION
When a tram reaches a road junction, wire-switches, installed on the overhead conductor cables, control its direction of travel, with switches in either the default “straight-through” or “turnout” positions. As the tram passes a switch in the turnout position, Contrinex photoelectric sensors mounted on the overhead cables detect the presence of the pantograph current collector so that the control system can then reset the switch to the default position. CUSTOMER APPLICATION In urban tram transportation systems, wire-switches installed on the overhead conductor cables at road junctions, control the direction of travel for the trams. The switches default to the straight-through position so that when a bus approaches a turn, the driver uses a remote trigger to change the switch to the turnout position. After the bus completes the turn, the switch reverts to the straight-through position. If a triggered switch reverts to the straight-through position prematurely, the pantagraph current collector may become disengaged, damaging the switch. Therefore tram operators install safety systems to prevent premature switching. Typically, these utilise timer circuits and a predetermined delay or mechanical sensors that rely on physical contact with the current collector, but neither system is reliable. A Swiss manufacturer of trolley-bus control systems requires a highly reliable, rugged sensor system that will detect the presence of a current collector as it passes a switch. The system must operate with minimal maintenance and withstand the varied weather conditions of an outdoor environment in Switzerland and therefore they selected Contrinex sensors.
Customer Solution Contrinex’s C23 through-beam photoelectric sensors offer high-performance, small size and high-stability. A purpose- designed metal bracket, mounted above the conductor cable, holds the transmitter and receiver units in alignment on either side of the cable. As the pantagraph current collector passes between the two units it breaks the beam, triggering the sensor and returning the switch to the straight-through position. The C23 photoelectric sensors are virtually impervious to the harsh, outdoor environment and their small physically size (30 x 20 x 10mm) eliminates the risk of accidental damage arising from a mechanical collision. The rugged construction and vacuum-encapsulated electronics within the sensor minimise the effects of vibration, ensuring a long service life. Each unit is connected to the trolley-bus control systems via a PVC-sheathed cable with a hermetically sealed entry. The receiver has an industry-standard PNP interface. The one-piece mounting bracket allows easy removal and replacement of the complete assembly during routine maintenance. Operational results have been excellent and the Contrinex sensors have proved highly reliable, eliminating switching errors and reducing maintenance costs significantly.
+ CUSTOMER VALUES • Exceptional reliability in outdoor environment • Automatic operation in optimal space  • Elimination of switching errors during year-round operation • Significantly reduced maintenance costs PRODUCT ADVANTAGES • Sensing range up to 12,000 mm • Long sensing range in small sensor • Exceptional resistance to vibration during operation +