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HELPING YOU #MAKE SENSE OF SENSORS

EXAMPLE APPLICATIONS

TO ILLUSTRATE THE WIDE-VARIETY OF APPLICATIONS SOLVED USING CONTRINEX SENSORS, WE HAVE POSTED A LARGE SELECTION OF EXAMPLE APPLICATIONS WHICH CAN BE SEEN BY CLICKING ON AN IMAGE. BELOW ARE A SELECTION OF SOME OF THESE APPLICATIONS:
CONTRINEXS PHOTOELECTRIC, INDUCTIVE, RFID AND MACHINE SAFETY SENSORS EXCEL IN A WIDE RANGE OF PACKAGING MACHINERY APPLICATIONS , BEING TRUSTED ACROSS MANY INDUSTRIES. BEST-IN-CLASS SENSOR PERFORMANCE, PLUS FEATURES LIKE PREVENTATIVE-MAINTENANCE OUTPUTS; UNIQUE UV TRANSPARENT-OBJECT DETECTION; IP69K CIP-WASHDOWN INDUCTIVE, SAFETY & RFID SENSORS, ALL FEATURE WITHIN THE WORLDS LARGEST SELECTION OF IO-LINK SENSORS.
PACKAGING Applications
Click for Brochure Miniature Photo & Inductive Sensors Click for Brochure C23PA Photoelectrics Click for Brochure IO-Link RFID
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick-and- place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and-place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and-place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary-packaging station, a plant- wide control system prevents operation of the pick-and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom-formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non-contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and-place sequence if no bags are queued for packing.
CUSTOMER SOLUTION Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm-diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE QUALITY CHECKS ON A NON- CONTACT BASIS IMPROVED QUALITY ARISING FROM REAL-TIME DETECTION OF INCORRECTLY PACKED CARTONS INCREASED PRODUCTIVITY AS STABILITY ALARM FLAGS PREVENTATIVE-MAINTENANCE NEEDS SINGLE SENSOR ACCOMMODATES A RANGE OF CARTON SIZES WITHOUT REPOSITIONING REMOTE ADJUSTMENT VIA IO-LINK REDUCES CHANGEOVER TIME BETWEEN PRODUCTS PRODUCT ADVANTAGES MAXIMUM SENSING RANGE OF 300MM WITH PINPOINT RED LED BEST-IN-CLASS BACKGROUND-SUPPRESSION BLACK/WHITE BEHAVIOUR IO-LINK CONNECTIVITY AVAILABLE AT NO EXTRA COST ON PNP VERSIONS DUAL OUTPUT WITH STABILITY ALARM
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE DETECTION ON A NON- CONTACT BASIS REAL-TIME REJECTION OF UNIDENTIFIED OR UNTRACEABLE PRODUCTS REMOTE SET-UP VIA IO-LINK REDUCES NEED FOR MANUAL INTERVENTION PRODUCT ADVANTAGES Operating range up to 12mm with three-COLOUR RGB EMISSION TECHNOLOGY AUTOMATIC SELECTION OF BEST EMISSION COLOUR IO-LINK CONNECTIVITY AVAILABLE AT NO EXTRA COST HIGH SWITCHING FREQUENCY UP TO 10KHZ VERSATILE INDUSTRY-STANDARD PUSH-PULL 4-WIRE OUTPUT HIGH TOLERANCE TO OBJECT POSITION VARIATION AROUND 12 MM
During high-volume production of confectionery, sealed cartons of bagged candy travel by conveyor to a labelling station. Conrinex’s versatile photoelectric contrast sensor, mounted beside the conveyor, checks the label alignment and confirms the presence of print markings as each carton leaves the labelling area. If a label is blank, illegible or wrongly positioned, the carton is diverted to a holding area for investigation. CUSTOMER APPLICATION In the food-processing industry, packaged consumer products require labelling – both for identification and for batch control – before final packing. During confectionery production, sealed cartons of bagged candy travel by conveyor from carton- taping stations to a label printer-applicator, before passing to the final packing area. The printer-applicator, which is located at one side of the conveyor, produces a continuous feed of printed labels from roll-stock. As each carton passes the applicator head, the label- stock advances, peeling a single label and applying it to the side of the carton. From time to time, misfeeds or malfunctions occur within the printer-applicator, which consequently applies labels that are either blank, illegible or wrongly positioned. Failure to detect these errors results in unidentified or untraceable products arriving at subsequent operations or, critically, at the customer’s premises. A highly reliable non-contact sensor system is needed. The sensor must detect the alignment of labels and confirm the presence of print markings as cartons leave the printer- applicator, rejecting any defective cartons.
CUSTOMER SOLUTION A photoelectric contrast sensor from the Contrinex Cubic Small range is ideal for this application. This versatile device incorporates a single-lens autocollimator, delivering a narrow optical beam that allows detection of very small features. The choice of red, green or blue LED light, auto-selectable during set-up, ensures optimal contrast resolution. Immediately after the applicator, a single sensor is mounted beside the conveyor; adjustable mounting brackets makes for easy positioning. As the label on each carton passes the detection point, changes in contrast trigger the sensor. The transition from carton surface to label body identifies the position and alignment of the label itself, while the well- defined contrast between printed content and the label body ensures reliable detection of even the smallest print marks. If the label is wrongly aligned or the print markings missing, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. An operating range up to 12mm allows adequate clearance between sensor and target, while the compact 40mm x 50mm x 15mm PBTB plastic housing is both mechanically robust and small enough to accommodate any space constraints. Set-up is accomplished either using a three-button keypad on the sensor, or via IO-Link, a standardized point-to-point serial connection protocol. Photoelectric contrast sensors are available with industry-standard push-pull 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry.
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE TESTING OF A RANGE OF DIFFERENT-SIZED CONTAINERS TESTING IS COMPLETED AT PRODUCTION-LINE SPEED IMMEDIATE IDENTIFICATION OF MISSING CLOSURES ELIMINATION OF MANUAL INSPECTION AND POTENTIAL BATCH REJECTION PRODUCT ADVANTAGES EXTENDED SENSING DISTANCES UP TO 40MM UNMATCHED COMBINATION OF 40MM SENSING DISTANCE IN M30-DIAMETER DEVICE
CUSTOMER SOLUTION Contrinex Extra Distance inductive sensors are ideal for this application, with the M30-diameter units operating reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable and fast detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of 40mm sensing distance in an M30-diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions can occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time or potential rejection by customers. An in-line sensor system inspecting each container could confirm the presence of a foil closure, rejecting any faulty items. Each production line processes containers in batches. The system must accommodate containers whose heights vary by up to 20mm, without adjustment of sensors between batches as successive batches may comprise containers of differing sizes.
CUSTOMER SOLUTION Contrinex ultrasonic sensors are ideal for presence- and level- sensing applications, and a diffuse sensor from the Compact range (housing size M30) is an excellent choice for this application. Operating range for this metal-bodied, IP65-rated device is between 20cm and 130cm; detection is independent of the target’s color, shape, material or surface structure. Contrinex Compact ultrasonic sensors feature an integral S12 cable connector, allowing rapid disconnection and removal when required. The variable size and shape of meat residue makes it difficult for an uncompensated sensor to detect contamination consistently and reliably; potentiometer adjustment, provided by many manufacturers, is inadequate for this application. Contrinex CONPROG software for Windows®, connected via the APE-0000-001 PC interface, compensates perfectly. Using CONPROG, the operator characterizes the target area of the box during set-up, setting the exact operating parameters of the sensor and ensuring reliable detection. Sensor data is stored, allowing like-for-like sensor replacement without additional set-up. The sensor’s three-wire PNP normally-open output communicates directly with the customer PLC. On detection of a contaminated box, a mechanical diverter shunts the box to a separate conveyor for manual emptying.
A meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact-based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
CUSTOMER VALUES IMPROVED SENSOR RELIABILITY DERIVED FROM EXACT CHARACTERISATION OF TARGET INCREASED PRODUCTIVITY ARISING FROM ELIMINATION OF BREAKDOWNS REDUCED SENSOR MAINTENANCE RESULTING FROM NON- CONTACT OPERATION INDUSTRY-STANDARD INTERFACE REQUIRES LITTLE MODIFICATION TO CONTROL SYSTEMS PRODUCT ADVANTAGES ECOLAB-CERTIFIED PHOTOELECTRIC SENSORS WITH BACKGROUND-SUPPRESSION MODE CHARACTERISED SENSORS DETECT TARGETS OF VARIABLE SIZE AND SHAPE LONG-DISTANCE, NON-CONTACT OPERATING PRINCIPLES IP65 PROTECTION ALLOWS OPERATION IN HYGIENIC ENVIRONMENTS RUGGED ULTRASONIC SENSOR WITH METAL HOUSING AND METAL CABLE CONNECTOR
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE QUALITY CHECKS ON A NON- CONTACT BASIS IMPROVED QUALITY ARISING FROM REAL-TIME DETECTION OF INCORRECTLY PACKED CARTONS INCREASED PRODUCTIVITY AS STABILITY ALARM FLAGS PREVENTATIVE-MAINTENANCE NEEDS SINGLE SENSOR ACCOMMODATES A RANGE OF CARTON SIZES WITHOUT REPOSITIONING REMOTE ADJUSTMENT VIA IO-LINK REDUCES CHANGEOVER TIME BETWEEN PRODUCTS PRODUCT ADVANTAGES MAXIMUM SENSING RANGE OF 300MM WITH PINPOINT RED LED BEST-IN-CLASS BACKGROUND-SUPPRESSION BLACK/WHITE BEHAVIOUR IO-LINK CONNECTIVITY AVAILABLE AT NO EXTRA COST ON PNP VERSIONS DUAL OUTPUT WITH STABILITY ALARM
Contrinex’s C23 photoelectric sensor family is small but powerful and so ideal for conveyor and packaging applications. An example application for the C23 is the food processing industry, where ‘shingling’, or overlapped layering, is a common technique for optimizing space during secondary packaging operations. As shown in the video, biscuits are sealed in gusseted bags with a triangular profile, and packed in alternating, overlapping layers into a preformed cardboard box. Once each box is full, it passes to a case-sealing station prior to palletisation and dispatch. From time to time, an incorrectly formed layer occurs, where a bag might be damaged or misaligned. The C23 photoelectric sensor with Background Suppression is used to provide non- contact sensing of the height of the top layer of bags, rejecting any over-filled cartons. CUSTOMER APPLICATION In the food processing industry, shingling, or overlapped layering, is a common technique for optimising space utilisation during secondary packaging operations. Confectionery, sealed in gusseted bags with predominantly triangular profiles, is packed in alternating, overlapping layers in preformed cardboard cartons. Once each carton is full, it passes to a case-sealing station prior to palletisation and dispatch. Pre-aligned bags of confectionery arrive at the packing station in regularly spaced rows. At each station, a multi-axis pick-and- place packing robot lifts a row of bags, aligns it and lowers it into a preformed carton. Successive layers overlap each other, ensuring that space within the carton is fully utilised. Once the predetermined number of layers has been packed, the carton is conveyed to the sealing station. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non- contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
CUSTOMER SOLUTION Rugged photoelectric sensors with background suppression from the Contrinex C23 range are ideal for this application. A pinpoint red LED with a 10mm-diameter light spot at the maximum sensing range of 300mm ensures highly reliable detection of objects of almost any colour against light or dark backgrounds. These sensors are well suited to both the task and the environment. Immediately after packing, a single sensor is mounted centrally above the conveyor. As each carton passes below on its way to the sealing station, the sensor detects the top surface of the packed bags. If the height of the top layer falls outside preset limits, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Locating sensors optimally is simple thanks to a custom- designed range of multi-position mounting brackets. An operating range between 15mm and 250mm accommodates a variety of carton sizes without any need to reposition the sensor. A simple electrical adjustment via an onboard potentiometer suffices, while remote adjustment via IO-Link, a standardized point-to-point serial connection protocol, is available as standard at no extra cost for PNP versions
Click for Brochure Transparent-object Detection
A meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact-based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
CUSTOMER VALUES A SINGLE SENSOR SOLUTION TO CHECK DIFFERENT CAN TYPES RELIABLE QUALITY OF DELIVERIES DIRECT INTERFACE TO A CONTROLLER 0–10 VDC OR 4–20 MA LONG SERVICE LIFE SIMPLE INSTALLATION NON-VISUAL SOLUTION PRODUCT ADVANTAGES PRECISION ANALOGUE OUTPUT 0–10 VDC OR 4–20 MA LONG SENSING DISTANCES COMPARED TO MARKET STANDARD EXCELLENT TEMPERATURE STABILITY VERY GOOD REPEATING ACCURACY SENSING RANGE UP TO 40 MM RESOLUTION IN µM RANGE CURRENT AND VOLTAGE OUTPUTS IN SAME DEVICE SEVERAL SWITCH POINTS WITH A SINGLE DEVICE
Customer Solution Ecolab-certified, diffuse-mode photoelectric sensors with background suppression from the Contrinex C23 product family are ideally suited to this application. These miniature cubic devices, mounted above product conveyors immediately after each buffering station, detect the presence of cheese portions as they pass underneath. Positioning sensors is simple thanks to a range of adjustable stainless steel mounting brackets. An industry-standard PNP normally open output with an M8 connector ensures optimum flexibility. Additionally, IO-Link, a standardized point-to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost, offering the advantages of digital communication without the need for special cabling. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Robust sensor construction, featuring miniature (20mm x 30mm x 10mm) plastic housings, ensures reliable operation in the demanding washdown environment; Contrinex C23 devices are rated to IP67. An operating range between 15mm and 250mm, adjustable via a teach button or via IO-Link, accommodates the range of portion sizes without compromise. A brief one- or two-step teach procedure simplifies initial set- up. One-button operation allows process engineers to teach the target object and, optionally, the background, each time a new portion size is introduced. Once taught, sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO-Link, eliminating the need for manual adjustment. These rugged miniature sensors meet the customer’s need for reliable operation with little or no manual intervention, while unplanned sanitization is avoided. The solution is highly cost- effective with minimal non-productive time; throughput is maintained at or above target levels.
Contrinex’s small, but powerful C23PA photoelectric sensors are trusted to ensure conveyors deliver cheese portions to packaging stations, with in-line buffering stations regulating their flow to match packaging throughput. The miniature Ecolab-certified sensors detect the presence of each portion after buffering, triggering the packaging cycle. Sensitivity parameters for each portion size, stored on the sensor’s inbuilt memory, may be updated remotely using IO-Link, removing the need for a manual intervention and eliminating the need for unplanned sanitisation between batches. CUSTOMER APPLICATION A Swiss manufacturer of premium dairy products produces a range of individually packaged cheese portions in a high- volume hygienic production facility. Once cut to size, cheese portions travel on a food-grade conveyor to a packaging station; the duration of the packaging cycle is dependent on the type of cheese and the portion size. Prior to packaging, a buffering station produces a regular flow of portions with a predetermined spacing to suit the packaging throughput. The two operations must be synchronized; the manufacturer requires a sensor system that detects the presence of each cheese portion as it leaves the buffering station, triggering the packaging cycle. Sensors must be food-grade certified and withstand the aggressive cleaning agents used during washdown routines. They must also accommodate the full range of portion sizes without the need for manual adjustment, as this would necessitate sanitisation each time the portion size changes. Maximising throughput is an additional priority; rapid changeover between product batches is essential.
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
CUSTOMER VALUES ECOLAB-CERTIFIED SENSORS ARE IDEAL FOR HYGIENIC PRODUCTION FACILITIES WIDE OPERATING RANGE ACCOMMODATES FULL RANGE OF PORTION SIZES SENSITIVITY PARAMETERS ARE RETRIEVED OR UPDATED REMOTELY VIA IO-LINK UNNECESSARY SANITIZATION BETWEEN BATCHES IS AVOIDED SIMPLE ONE- OR TWO-STEP TEACH PROCEDURE OPTIMISES INITIAL SENSOR SET-UP STABILITY ALARM HIGHLIGHTS REDUCED SENSITIVITY, AVOIDING UNPLANNED STOPPAGES DOWNTIME IS AVOIDED BY ELIMINATING THE NEED FOR TECHNICIANS TO ATTEND MACHINES PRODUCT ADVANTAGES ECOLAB-CERTIFIED PHOTOELECTRIC SENSORS WITH BACKGROUND-SUPPRESSION MODE IO-LINK SERIAL-CONNECTION PROTOCOL ENABLED ON PNP VERSIONS AT NO ADDITIONAL COST PRE-TAUGHT SENSITIVITY PARAMETERS STORED ON INBUILT SENSOR MEMORY REMOTE SENSITIVITY RETRIEVAL OR UPDATE VIA IO-LINK ROBUST SENSORS WITH MINIATURE (20MM X 30MM X 10MM) PLASTIC HOUSINGS
A sensing range up to 1200 mm, adjustable via a teach button or via IO-Link, accommodates a wide range of machine geometries. Sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO-Link, eliminating the need for manual adjustment. These rugged miniature sensors meet the customer’s need for reliable operation with little or no manual intervention. The solution is highly cost-effective with minimal non-productive time; throughput is maintained at or above target levels.
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CUSTOMER VALUES SAFE DETECTION OF THE THINNEST TRANSPARENT MATERIALS MAXIMUM OPERATING RESERVE OWING TO HIGH ABSORPTION FACTOR OF UV LIGHT BY TRANSPARENT PLASTICS ELIMINATION OF MULTIPLE SWITCHING ON A SINGLE TARGET RELIABLE OPERATION WITHOUT THE NEED FOR MANUAL INTERVENTION VERY LOW SENSITIVITY TO DUST, LIQUID DROPLETS AND SPLASHES PRODUCT ADVANTAGES REMOTE SENSITIVITY RETRIEVAL OR UPDATE VIA IO-LINK IO-LINK SERIAL-CONNECTION PROTOCOL ENABLED ON PNP VERSIONS AT NO ADDITIONAL COST PRE-TAUGHT SENSITIVITY PARAMETERS STORED ON INBUILT SENSOR MEMORY HIGHLY TOLERANT OF CONTAMINATION BY DUST, LIQUID DROPLETS OR SPLASHES
During the automated packaging of fast-moving products, thermoformed transparent plastic tray bases are common. Contrinex’s small C23 transparent-object sensor with patented UV technology detects the presence of each set of transparent trays after it is formed, initiating a subsequent operation and, optionally, triggering a counting circuit. The Ecolab- certification of these sensors make them suitable for the packaging of food and medical products. CUSTOMER APPLICATION A manufacturer of packaging machines for the medical industry produces automated blister-packaging lines for pharmaceutical and surgical products. Medical blister-packs comprise a recessed, semi-rigid tray base, vacuum-formed in- line from a clear thermoplastic material and sealed with a metal or plastic film after the desired products are loaded. Typically, blister-packaging lines for surgical products operate in sterile conditions; minimal manual intervention is permitted, as contamination may enter the environment. If defective bases are identified and rejected after forming, the flow of tray bases to the loading station is not continuous. In this event, a sensor system must inhibit the loading cycle until a base is in position. Sensors must detect the presence of transparent tray bases swiftly and reliably, enabling the loading cycle to proceed with minimal delay as soon as a tray is present at the loading station. Standard photoelectric sensors, which use visible red- light sources, proved unreliable as they are unable to differentiate reliably between ‘tray present’ and ‘tray not present’ conditions. An alternative sensor is required which will detect the presence of a transparent plastic target under normal operating conditions
CUSTOMER SOLUTION Transparent-object sensors with ultraviolet LED-light sources from the Contrinex C23 product series are ideally suited to this application. These miniature cubic devices, mounted above product conveyors, detect the presence of transparent tray bases as they arrive at the loading station. Positioning sensors is simple thanks to a range of adjustable mounting brackets, and auto-collimated optics ensure there are no blind zones. Contrinex transparent-object sensors utilize a patented reflex operating principle with polarized ultraviolet light at 275 nm. At this wavelength, absorption of the polarized UV light by a range of commonly used plastics is maximized. Custom- designed UV reflectors, using high-tech plastic materials with excellent reflective properties in the ultraviolet range, provide a range of sizes and geometries that simplify installation. An industry-standard PNP normally open output ensures optimum flexibility. Additionally, IO-Link, a standardized point- to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost. An additional option is to have a second output to provide the stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. The robust sensors which are only 20mm x 30mm x 10mm feature Ecolab-certified plastic housings. A sensing range up to 1200 mm, adjustable via a teach button or via IO-Link, accommodates a wide range of machine geometries. Sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO- Link, eliminating the need for manual adjustment. The robust sensors which are only 20mm x 30mm x 10mm feature Ecolab-certified plastic housings, are corrosion- resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry.
CUSTOMER VALUES UV SENSORS ENSURE RELIABLE DETECTION OF TRANSPARENT, IRREGULARLY SHAPED PLASTIC TARGETS ELIMINATION OF MULTIPLE SWITCHING ON A SINGLE TARGET WIDE OPERATING RANGE ACCOMMODATES FULL RANGE OF MACHINE GEOMETRIES SIMPLE ONE- OR TWO-STEP TEACH PROCEDURE OPTIMISES INITIAL SET-UP SENSITIVITY PARAMETERS ARE RETRIEVED OR UPDATED REMOTELY VIA IO-LINK STABILITY ALARM HIGHLIGHTS REDUCED SENSITIVITY FOR EXAMPLE FOR PREVENTATIVE MAINTENANCE PRODUCT ADVANTAGES ULTRAVIOLET REFLEX PHOTOELECTRIC SENSORS FOR TRANSPARENT OBJECT DETECTION VERY LOW SENSITIVITY TO TARGET SHAPE ROBUST, ECOLAB APPROVED SENSORS WITH IP67-RATED SMALL PLASTIC HOUSINGS
Thermoforming lines produce transparent plastic trays from continuous reels of material. Contrinex’s transparent-object sensors with patented UV technology are used to detect the presence of the transparent plastic sheet as it is unwound from the reel, ensuring the material is correctly tensioned as it enters the loading station. False detection is avoided, ensuring reliable operation with little or no downtime. CUSTOMER APPLICATION Thermoforming equipment is often used in the production of plastic packaging and is particularly suitable for the continuous production of blister-packs. The process involves the in-line vacuum-forming of clear thermoplastic material into semi-rigid blister-trays which, after insertion of the desired products, are sealed with film. Configurable thermoforming lines are ideal for the high-speed production of such blister- trays from continuous reel-stock material. Coupling a standalone reel-feeder to the loading station of a modular line is quick and simple. In operation, a set of drive rollers draws thermoplastic sheet from the stock reel, creating a continuous loop of material between the feeder and the loading station. Maintaining the size of the loop between defined limits ensures the material is correctly tensioned as it enters the loading station. Sensors detect the presence of the transparent material as the loop size varies, initiating or inhibiting operation of the feeder if the loop becomes too small or too large, respectively. Photoelectric sensors using visible-light sources are unreliable in such an application as they cannot reliably differentiate between ‘material present’ and ‘material not present’ under normal operating conditions.
CUSTOMER SOLUTION Contrinex C23 transparent-object reflex sensors with ultraviolet LED-light sources are ideally suited to this application. These miniature cubic devices, mounted between the reel feeder and the loading station, detect the presence of the transparent material loop as its size varies. Positioning the sensors and reflectors is simple using a range of adjustable mounting brackets, and auto-collimated optics which ensure there are no blind zones. Contrinex transparent-object sensors utilise a patented reflex operating principle with polarised ultraviolet light at 275 nm. At this wavelength, absorption of the polarised UV light by a range of commonly used plastics is maximised. Custom- designed UV reflectors, using high-tech plastic materials with excellent reflective properties in the ultraviolet range, are available in a range of sizes and geometries which simplify installation. An industry-standard PNP normally open output ensures optimum flexibility. Additionally, IO-Link, a standardized point- to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost. An additional option is to have a second output to provide the stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. The robust sensors which are only 20mm x 30mm x 10mm feature Ecolab-certified plastic housings, are corrosion- resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry.
CUSTOMER SOLUTION Contrinex fork light-barrier sensors combine simplicity of installation, compact and robust construction and multi-mode operation. They offer high-resolution, high-speed sensing plus IO-Link connectivity, being ideal for position sensing and presence detection. The versatile, metal-cased devices offer designers the choice of four discrete operating modes and switching frequencies up to 14,000Hz. With a standard resolution of 0.3 mm (down to 0.1 mm in high-resolution mode), with the convenience of a push- pull output. The industry-standard IO-Link communication protocol, provides a choice of manual or remote set-up and adjustment, enabling the sensor to be automatically reconfigured between different product production runs. simplifying installation while saving time and money. The product range offers a choice of fork openings from 10 mm to 120 mm, to suit a wide variety of applications and environments, whilst saving time and money.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging.
CUSTOMER APPLICATION In the continuous production of fast-moving items, line stoppages are both costly and time consuming. After filling, sealing and capping, bottles of ketchups and sauces are labelled and packaged. Previously, if a plastic cap was missing it could go undetected, risking an entire batch of production potentially being rejected. Contrinex’s highly versatile photoelectric fork sensor, is positioned directly over the conveyor to sense the presence of a cap on each bottle prior to labelling, triggering an alarm if a cap is missing.
PRODUCT ADVANTAGES HIGH FREQUENCY UP TO 14 KHZ 4 SELECTABLE MODES BETWEEN PRODUCTION BATCHES: STANDARD, HIGH RESOLUTION, POWER, SPEED IO-LINK V1.1 COMMUNICATION PROTOCOL SENSITIVITY ADJUSTMENT ALLOWING DETECTION OF TRANSPARENT OBJECTS PRECISE ALIGNMENT REQUIRES NO ON-SITE ADJUSTMENT
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL WORK TO HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
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#Make Sense of Sensors
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PACKAGING Applications
CONTRINEXS PHOTOELECTRIC, INDUCTIVE, RFID AND MACHINE SAFETY SENSORS ARE TRUSTED ACROSS THE MANY ASPECTS OF FOOD & BEVERAGE MANUFACTURING AND PACKAGING. IMPROVE MACHINE PERFORMANCE WITH SUPERIOR SENSOR PERFORMANCE, PLUS ADDED FEATURES LIKE PREVENTATIVE-MAINTENANCE OUTPUTS; IP69K CIP-WASHDOWN INDUCTIVE; SAFETY & RFID SENSORS; UV TRANSPARENT-OBJECT DETECTION; PLUS THE WORLDS LARGEST SELECTION OF IO-LINK SENSORS PROVIDING ADDITIONAL PERFORMANCE DATA IN A CONSISTENT MANNER AND EASY IOT / INDUSTRY 4 CONNECTIVITY. .
Click for Brochure Miniature Photo & Inductive Sensors Click for Brochure C23PA Photoelectrics Click for Brochure IO-Link RFID Click for Brochure Transparent-object Detection
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick-and- place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and-place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and-place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary-packaging station, a plant- wide control system prevents operation of the pick-and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom-formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non-contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and-place sequence if no bags are queued for packing.
CUSTOMER SOLUTION Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm-diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE QUALITY CHECKS ON A NON- CONTACT BASIS IMPROVED QUALITY ARISING FROM REAL-TIME DETECTION OF INCORRECTLY PACKED CARTONS INCREASED PRODUCTIVITY AS STABILITY ALARM FLAGS PREVENTATIVE-MAINTENANCE NEEDS SINGLE SENSOR ACCOMMODATES A RANGE OF CARTON SIZES WITHOUT REPOSITIONING REMOTE ADJUSTMENT VIA IO-LINK REDUCES CHANGEOVER TIME BETWEEN PRODUCTS PRODUCT ADVANTAGES MAXIMUM SENSING RANGE OF 300MM WITH PINPOINT RED LED BEST-IN-CLASS BACKGROUND-SUPPRESSION BLACK/WHITE BEHAVIOUR IO-LINK CONNECTIVITY AVAILABLE AT NO EXTRA COST ON PNP VERSIONS DUAL OUTPUT WITH STABILITY ALARM
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE DETECTION ON A NON- CONTACT BASIS REAL-TIME REJECTION OF UNIDENTIFIED OR UNTRACEABLE PRODUCTS REMOTE SET-UP VIA IO-LINK REDUCES NEED FOR MANUAL INTERVENTION PRODUCT ADVANTAGES Operating range up to 12mm with three-COLOUR RGB EMISSION TECHNOLOGY AUTOMATIC SELECTION OF BEST EMISSION COLOUR IO-LINK CONNECTIVITY AVAILABLE AT NO EXTRA COST HIGH SWITCHING FREQUENCY UP TO 10KHZ VERSATILE INDUSTRY-STANDARD PUSH-PULL 4-WIRE OUTPUT HIGH TOLERANCE TO OBJECT POSITION VARIATION AROUND 12 MM
During high-volume production of confectionery, sealed cartons of bagged candy travel by conveyor to a labelling station. Conrinex’s versatile photoelectric contrast sensor, mounted beside the conveyor, checks the label alignment and confirms the presence of print markings as each carton leaves the labelling area. If a label is blank, illegible or wrongly positioned, the carton is diverted to a holding area for investigation. CUSTOMER APPLICATION In the food-processing industry, packaged consumer products require labelling – both for identification and for batch control – before final packing. During confectionery production, sealed cartons of bagged candy travel by conveyor from carton- taping stations to a label printer-applicator, before passing to the final packing area. The printer-applicator, which is located at one side of the conveyor, produces a continuous feed of printed labels from roll-stock. As each carton passes the applicator head, the label- stock advances, peeling a single label and applying it to the side of the carton. From time to time, misfeeds or malfunctions occur within the printer-applicator, which consequently applies labels that are either blank, illegible or wrongly positioned. Failure to detect these errors results in unidentified or untraceable products arriving at subsequent operations or, critically, at the customer’s premises. A highly reliable non-contact sensor system is needed. The sensor must detect the alignment of labels and confirm the presence of print markings as cartons leave the printer- applicator, rejecting any defective cartons.
CUSTOMER SOLUTION A photoelectric contrast sensor from the Contrinex Cubic Small range is ideal for this application. This versatile device incorporates a single-lens autocollimator, delivering a narrow optical beam that allows detection of very small features. The choice of red, green or blue LED light, auto-selectable during set-up, ensures optimal contrast resolution. Immediately after the applicator, a single sensor is mounted beside the conveyor; adjustable mounting brackets makes for easy positioning. As the label on each carton passes the detection point, changes in contrast trigger the sensor. The transition from carton surface to label body identifies the position and alignment of the label itself, while the well- defined contrast between printed content and the label body ensures reliable detection of even the smallest print marks. If the label is wrongly aligned or the print markings missing, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. An operating range up to 12mm allows adequate clearance between sensor and target, while the compact 40mm x 50mm x 15mm PBTB plastic housing is both mechanically robust and small enough to accommodate any space constraints. Set-up is accomplished either using a three-button keypad on the sensor, or via IO-Link, a standardized point-to-point serial connection protocol. Photoelectric contrast sensors are available with industry-standard push-pull 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry.
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE TESTING OF A RANGE OF DIFFERENT-SIZED CONTAINERS TESTING IS COMPLETED AT PRODUCTION-LINE SPEED IMMEDIATE IDENTIFICATION OF MISSING CLOSURES ELIMINATION OF MANUAL INSPECTION AND POTENTIAL BATCH REJECTION PRODUCT ADVANTAGES EXTENDED SENSING DISTANCES UP TO 40MM UNMATCHED COMBINATION OF 40MM SENSING DISTANCE IN M30-DIAMETER DEVICE
CUSTOMER SOLUTION Contrinex Extra Distance inductive sensors are ideal for this application, with the M30-diameter units operating reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable and fast detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of 40mm sensing distance in an M30-diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions can occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time or potential rejection by customers. An in-line sensor system inspecting each container could confirm the presence of a foil closure, rejecting any faulty items. Each production line processes containers in batches. The system must accommodate containers whose heights vary by up to 20mm, without adjustment of sensors between batches as successive batches may comprise containers of differing sizes.
A sensing range up to 1200 mm, adjustable via a teach button or via IO-Link, accommodates a wide range of machine geometries. Sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO-Link, eliminating the need for manual adjustment. These rugged miniature sensors meet the customer’s need for reliable operation with little or no manual intervention. The solution is highly cost-effective with minimal non-productive time; throughput is maintained at or above target levels.
CUSTOMER VALUES UV SENSORS ENSURE RELIABLE DETECTION OF TRANSPARENT, IRREGULARLY SHAPED PLASTIC TARGETS ELIMINATION OF MULTIPLE SWITCHING ON A SINGLE TARGET WIDE OPERATING RANGE ACCOMMODATES FULL RANGE OF MACHINE GEOMETRIES SIMPLE ONE- OR TWO-STEP TEACH PROCEDURE OPTIMISES INITIAL SET-UP SENSITIVITY PARAMETERS ARE RETRIEVED OR UPDATED REMOTELY VIA IO-LINK STABILITY ALARM HIGHLIGHTS REDUCED SENSITIVITY FOR EXAMPLE FOR PREVENTATIVE MAINTENANCE PRODUCT ADVANTAGES ULTRAVIOLET REFLEX PHOTOELECTRIC SENSORS FOR TRANSPARENT OBJECT DETECTION VERY LOW SENSITIVITY TO TARGET SHAPE ROBUST, ECOLAB APPROVED SENSORS WITH IP67-RATED SMALL PLASTIC HOUSINGS
Thermoforming lines produce transparent plastic trays from continuous reels of material. Contrinex’s transparent-object sensors with patented UV technology are used to detect the presence of the transparent plastic sheet as it is unwound from the reel, ensuring the material is correctly tensioned as it enters the loading station. False detection is avoided, ensuring reliable operation with little or no downtime. CUSTOMER APPLICATION Thermoforming equipment is often used in the production of plastic packaging and is particularly suitable for the continuous production of blister-packs. The process involves the in-line vacuum-forming of clear thermoplastic material into semi-rigid blister-trays which, after insertion of the desired products, are sealed with film. Configurable thermoforming lines are ideal for the high-speed production of such blister- trays from continuous reel-stock material. Coupling a standalone reel-feeder to the loading station of a modular line is quick and simple. In operation, a set of drive rollers draws thermoplastic sheet from the stock reel, creating a continuous loop of material between the feeder and the loading station. Maintaining the size of the loop between defined limits ensures the material is correctly tensioned as it enters the loading station. Sensors detect the presence of the transparent material as the loop size varies, initiating or inhibiting operation of the feeder if the loop becomes too small or too large, respectively. Photoelectric sensors using visible-light sources are unreliable in such an application as they cannot reliably differentiate between ‘material present’ and ‘material not present’ under normal operating conditions.
CUSTOMER SOLUTION Contrinex C23 transparent-object reflex sensors with ultraviolet LED-light sources are ideally suited to this application. These miniature cubic devices, mounted between the reel feeder and the loading station, detect the presence of the transparent material loop as its size varies. Positioning the sensors and reflectors is simple using a range of adjustable mounting brackets, and auto-collimated optics which ensure there are no blind zones. Contrinex transparent-object sensors utilise a patented reflex operating principle with polarised ultraviolet light at 275 nm. At this wavelength, absorption of the polarised UV light by a range of commonly used plastics is maximised. Custom- designed UV reflectors, using high-tech plastic materials with excellent reflective properties in the ultraviolet range, are available in a range of sizes and geometries which simplify installation. An industry-standard PNP normally open output ensures optimum flexibility. Additionally, IO-Link, a standardized point- to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost. An additional option is to have a second output to provide the stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. The robust sensors which are only 20mm x 30mm x 10mm feature Ecolab-certified plastic housings, are corrosion- resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry.
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CUSTOMER VALUES SAFE DETECTION OF THE THINNEST TRANSPARENT MATERIALS MAXIMUM OPERATING RESERVE OWING TO HIGH ABSORPTION FACTOR OF UV LIGHT BY TRANSPARENT PLASTICS ELIMINATION OF MULTIPLE SWITCHING ON A SINGLE TARGET RELIABLE OPERATION WITHOUT THE NEED FOR MANUAL INTERVENTION VERY LOW SENSITIVITY TO DUST, LIQUID DROPLETS AND SPLASHES PRODUCT ADVANTAGES REMOTE SENSITIVITY RETRIEVAL OR UPDATE VIA IO-LINK IO-LINK SERIAL-CONNECTION PROTOCOL ENABLED ON PNP VERSIONS AT NO ADDITIONAL COST PRE-TAUGHT SENSITIVITY PARAMETERS STORED ON INBUILT SENSOR MEMORY HIGHLY TOLERANT OF CONTAMINATION BY DUST, LIQUID DROPLETS OR SPLASHES
During the automated packaging of fast-moving products, thermoformed transparent plastic tray bases are common. Contrinex’s small C23 transparent-object sensor with patented UV technology detects the presence of each set of transparent trays after it is formed, initiating a subsequent operation and, optionally, triggering a counting circuit. The Ecolab- certification of these sensors make them suitable for the packaging of food and medical products. CUSTOMER APPLICATION A manufacturer of packaging machines for the medical industry produces automated blister-packaging lines for pharmaceutical and surgical products. Medical blister-packs comprise a recessed, semi-rigid tray base, vacuum-formed in- line from a clear thermoplastic material and sealed with a metal or plastic film after the desired products are loaded. Typically, blister-packaging lines for surgical products operate in sterile conditions; minimal manual intervention is permitted, as contamination may enter the environment. If defective bases are identified and rejected after forming, the flow of tray bases to the loading station is not continuous. In this event, a sensor system must inhibit the loading cycle until a base is in position. Sensors must detect the presence of transparent tray bases swiftly and reliably, enabling the loading cycle to proceed with minimal delay as soon as a tray is present at the loading station. Standard photoelectric sensors, which use visible red- light sources, proved unreliable as they are unable to differentiate reliably between ‘tray present’ and ‘tray not present’ conditions. An alternative sensor is required which will detect the presence of a transparent plastic target under normal operating conditions
CUSTOMER SOLUTION Transparent-object sensors with ultraviolet LED-light sources from the Contrinex C23 product series are ideally suited to this application. These miniature cubic devices, mounted above product conveyors, detect the presence of transparent tray bases as they arrive at the loading station. Positioning sensors is simple thanks to a range of adjustable mounting brackets, and auto-collimated optics ensure there are no blind zones. Contrinex transparent-object sensors utilize a patented reflex operating principle with polarized ultraviolet light at 275 nm. At this wavelength, absorption of the polarized UV light by a range of commonly used plastics is maximized. Custom- designed UV reflectors, using high-tech plastic materials with excellent reflective properties in the ultraviolet range, provide a range of sizes and geometries that simplify installation. An industry-standard PNP normally open output ensures optimum flexibility. Additionally, IO-Link, a standardized point- to-point serial connection protocol for sensors and actuators, is enabled on PNP versions at no additional cost. An additional option is to have a second output to provide the stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. The robust sensors which are only 20mm x 30mm x 10mm feature Ecolab-certified plastic housings. A sensing range up to 1200 mm, adjustable via a teach button or via IO-Link, accommodates a wide range of machine geometries. Sensitivity parameters are stored on the sensor’s inbuilt memory and may be retrieved or updated remotely via IO- Link, eliminating the need for manual adjustment. The robust sensors which are only 20mm x 30mm x 10mm feature Ecolab-certified plastic housings, are corrosion- resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry.
CUSTOMER SOLUTION Contrinex ultrasonic sensors are ideal for presence- and level- sensing applications, and a diffuse sensor from the Compact range (housing size M30) is an excellent choice for this application. Operating range for this metal-bodied, IP65-rated device is between 20cm and 130cm; detection is independent of the target’s color, shape, material or surface structure. Contrinex Compact ultrasonic sensors feature an integral S12 cable connector, allowing rapid disconnection and removal when required. The variable size and shape of meat residue makes it difficult for an uncompensated sensor to detect contamination consistently and reliably; potentiometer adjustment, provided by many manufacturers, is inadequate for this application. Contrinex CONPROG software for Windows®, connected via the APE-0000-001 PC interface, compensates perfectly. Using CONPROG, the operator characterizes the target area of the box during set-up, setting the exact operating parameters of the sensor and ensuring reliable detection. Sensor data is stored, allowing like-for-like sensor replacement without additional set-up. The sensor’s three-wire PNP normally-open output communicates directly with the customer PLC. On detection of a contaminated box, a mechanical diverter shunts the box to a separate conveyor for manual emptying.
A meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact-based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
CUSTOMER VALUES IMPROVED SENSOR RELIABILITY DERIVED FROM EXACT CHARACTERISATION OF TARGET INCREASED PRODUCTIVITY ARISING FROM ELIMINATION OF BREAKDOWNS REDUCED SENSOR MAINTENANCE RESULTING FROM NON- CONTACT OPERATION INDUSTRY-STANDARD INTERFACE REQUIRES LITTLE MODIFICATION TO CONTROL SYSTEMS PRODUCT ADVANTAGES ECOLAB-CERTIFIED PHOTOELECTRIC SENSORS WITH BACKGROUND-SUPPRESSION MODE CHARACTERISED SENSORS DETECT TARGETS OF VARIABLE SIZE AND SHAPE LONG-DISTANCE, NON-CONTACT OPERATING PRINCIPLES IP65 PROTECTION ALLOWS OPERATION IN HYGIENIC ENVIRONMENTS RUGGED ULTRASONIC SENSOR WITH METAL HOUSING AND METAL CABLE CONNECTOR
CUSTOMER VALUES RELIABLE, REPEATABLE IN-LINE QUALITY CHECKS ON A NON- CONTACT BASIS IMPROVED QUALITY ARISING FROM REAL-TIME DETECTION OF INCORRECTLY PACKED CARTONS INCREASED PRODUCTIVITY AS STABILITY ALARM FLAGS PREVENTATIVE-MAINTENANCE NEEDS SINGLE SENSOR ACCOMMODATES A RANGE OF CARTON SIZES WITHOUT REPOSITIONING REMOTE ADJUSTMENT VIA IO-LINK REDUCES CHANGEOVER TIME BETWEEN PRODUCTS PRODUCT ADVANTAGES MAXIMUM SENSING RANGE OF 300MM WITH PINPOINT RED LED BEST-IN-CLASS BACKGROUND-SUPPRESSION BLACK/WHITE BEHAVIOUR IO-LINK CONNECTIVITY AVAILABLE AT NO EXTRA COST ON PNP VERSIONS DUAL OUTPUT WITH STABILITY ALARM
Contrinex’s C23 photoelectric sensor family is small but powerful and so ideal for conveyor and packaging applications. An example application for the C23 is the food processing industry, where ‘shingling’, or overlapped layering, is a common technique for optimizing space during secondary packaging operations. As shown in the video, biscuits are sealed in gusseted bags with a triangular profile, and packed in alternating, overlapping layers into a preformed cardboard box. Once each box is full, it passes to a case-sealing station prior to palletisation and dispatch. From time to time, an incorrectly formed layer occurs, where a bag might be damaged or misaligned. The C23 photoelectric sensor with Background Suppression is used to provide non- contact sensing of the height of the top layer of bags, rejecting any over-filled cartons. CUSTOMER APPLICATION In the food processing industry, shingling, or overlapped layering, is a common technique for optimising space utilisation during secondary packaging operations. Confectionery, sealed in gusseted bags with predominantly triangular profiles, is packed in alternating, overlapping layers in preformed cardboard cartons. Once each carton is full, it passes to a case-sealing station prior to palletisation and dispatch. Pre-aligned bags of confectionery arrive at the packing station in regularly spaced rows. At each station, a multi-axis pick-and- place packing robot lifts a row of bags, aligns it and lowers it into a preformed carton. Successive layers overlap each other, ensuring that space within the carton is fully utilised. Once the predetermined number of layers has been packed, the carton is conveyed to the sealing station. From time to time, one or more incorrectly formed layers occur. Individual bags may be missing from a row on arrival at the packing station, or may be damaged or misaligned. A non- contact sensor is needed to sense the height of the top layer of bags, rejecting any defective cartons. It must be reliable and require minimal maintenance.
CUSTOMER SOLUTION Rugged photoelectric sensors with background suppression from the Contrinex C23 range are ideal for this application. A pinpoint red LED with a 10mm-diameter light spot at the maximum sensing range of 300mm ensures highly reliable detection of objects of almost any colour against light or dark backgrounds. These sensors are well suited to both the task and the environment. Immediately after packing, a single sensor is mounted centrally above the conveyor. As each carton passes below on its way to the sealing station, the sensor detects the top surface of the packed bags. If the height of the top layer falls outside preset limits, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs. Locating sensors optimally is simple thanks to a custom- designed range of multi-position mounting brackets. An operating range between 15mm and 250mm accommodates a variety of carton sizes without any need to reposition the sensor. A simple electrical adjustment via an onboard potentiometer suffices, while remote adjustment via IO-Link, a standardized point-to-point serial connection protocol, is available as standard at no extra cost for PNP versions.
Click for Video
A meat-processing plant uses non-contact ultrasonic presence sensing to increase productivity and eliminate breakdowns when washing empty meat bins. A single ultrasonic sensor, mounted above the conveyor on which the bins travel, checks for meat residues, rejecting any contaminated bins before the wash station. Old, contact-based systems were unreliable, resulting in breakdowns and frequent interruptions to the washing process. CUSTOMER APPLICATION During production, an industrial meat-processing company conveys meat portions around its factory in food-grade plastic bins. After completion of each batch, empty bins are washed prior to reuse. Some bins contain sizeable pieces of meat which, if undetected, accumulate in the washing machine, causing blockages and breakdowns. The resulting interruptions to production are unacceptably frequent. A reliable sensor system must detect the presence of meat residues in bins as they travel along the conveyor. The sensor should identify all non-trivial residues and divert contaminated bins before they enter the washing station. The system should require little or no regular maintenance, and a non-contact sensor, suitable for a hygienic environment, is preferred. Old systems with spring-loaded wand-actuators in contact with the box are unreliable and require regular adjustment; the contact probes need frequent, time-consuming cleaning. The new system has to operate on a fit-and-forget basis.
CUSTOMER VALUES A SINGLE SENSOR SOLUTION TO CHECK DIFFERENT CAN TYPES RELIABLE QUALITY OF DELIVERIES DIRECT INTERFACE TO CONTROLLER 0–10 VDC OR 4–20 MA LONG SERVICE LIFE SIMPLE INSTALLATION NON-VISUAL SOLUTION PRODUCT ADVANTAGES PRECISION ANALOGUE OUTPUT 0–10 VDC OR 4–20 MA LONG SENSING DISTANCES COMPARED TO MARKET STANDARD EXCELLENT TEMPERATURE STABILITY VERY GOOD REPEATING ACCURACY SENSING RANGE UP TO 40 MM RESOLUTION IN µM RANGE CURRENT AND VOLTAGE OUTPUTS IN SAME DEVICE SEVERAL SWITCH POINTS WITH A SINGLE DEVICE
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk 0121 58 222 58
CUSTOMER SOLUTION Contrinex fork light-barrier sensors combine simplicity of installation, compact and robust construction and multi-mode operation. They offer high-resolution, high-speed sensing plus IO-Link connectivity, being ideal for position sensing and presence detection. The versatile, metal-cased devices offer designers the choice of four discrete operating modes and switching frequencies up to 14,000Hz. With a standard resolution of 0.3 mm (down to 0.1 mm in high-resolution mode), with the convenience of a push- pull output. The industry-standard IO-Link communication protocol, provides a choice of manual or remote set-up and adjustment, enabling the sensor to be automatically reconfigured between different product production runs. simplifying installation while saving time and money. The product range offers a choice of fork openings from 10 mm to 120 mm, to suit a wide variety of applications and environments, whilst saving time and money.
A food-processing plant trusts Contrinex’s sensors to help it ensure plastic bottles, filled with liquid food products, are hermetically sealed and its customers kept safe. Prior to the containers being capped, a long-distance inductive sensor, positioned directly over the packaging line confirms the presence of an aluminium-foil seal over the top of every container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilised as seals for plastic containers filled with ketchup, mustard and other table sauces. At a food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging.
CUSTOMER APPLICATION In the continuous production of fast-moving items, line stoppages are both costly and time consuming. After filling, sealing and capping, bottles of ketchups and sauces are labelled and packaged. Previously, if a plastic cap was missing it could go undetected, risking an entire batch of production potentially being rejected. Contrinex’s highly versatile photoelectric fork sensor, is positioned directly over the conveyor to sense the presence of a cap on each bottle prior to labelling, triggering an alarm if a cap is missing.
PRODUCT ADVANTAGES HIGH FREQUENCY UP TO 14 KHZ 4 SELECTABLE MODES BETWEEN PRODUCTION BATCHES: STANDARD, HIGH RESOLUTION, POWER, SPEED IO-LINK V1.1 COMMUNICATION PROTOCOL SENSITIVITY ADJUSTMENT ALLOWING DETECTION OF TRANSPARENT OBJECTS PRECISE ALIGNMENT REQUIRES NO ON-SITE ADJUSTMENT