Helping you #Make Sense of Sensors
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PRESSING AND STAMPING APPLICATIONS Contrinex’s robustness is well renowned in the Pressing and Stamping industries and therefore Contrinex supplies Inductive, Photoelectric, Machine Safety and RFID sensors optimised to this sector.
A manufacturer of cold-forming tools for joining sheet metal uses position sensing to control the operation of a manual punch-riveting tool. A high-pressure inductive sensor mounted directly into the wall of a small pneumohydraulic cylinder detects the position of the hydraulic ram, preventing the operating cycle from starting unless the ram is fully retracted. CUSTOMER APPLICATION Automotive technicians assembling prototype vehicle bodies during pre-production use manual punch-riveting tools to join individual sheet-metal parts. Several thousand joints are required per vehicle, and tools must be compact since space is often limited. Bad joints, which are very costly to repair, can occur if the technician does not set the tool correctly before triggering it. During use, the tool- head is often partly hidden from view, so a sensing system must confirm that the operating ram is fully retracted and prevent the tool from operating if the ram is not in the correct position. A pneumohydraulic cylinder drives the ram, and the compact nature of the tool limits the allowable sensor size. The sensing face is exposed to the high-pressure side of the hydraulic circuit, so the sensor must withstand continuous pressures up to 500 bar (7255 psi) and pressure spikes of 1000 bar (14,510 psi).
Customer Solution Robust inductive sensors from the Contrinex Extra Distance family, High Pressure range, withstand the high operating pressure of this application. The extended operating distance of patented Condist® technology allows the use of thick, hermetically sealed ceramic discs on the sensing faces without compromising the sensors’ performance. These lightweight M5- and M8-diameter embeddable sensors are 27 mm and 30 mm in length, respectively. The sensors are mounted directly into the wall of the cylinder and do not interfere with the normal operation of the tool. Sensing distances of 1mm (M5 sensor) and 1.5 mm (M8 sensor) eliminate any risk of internal mechanical damage through contact with the ram. The sensors have an industry-standard PNP normally-open configuration and connect with the customer’s control system via a flexible PUR-sheathed cable. Vacuum-encapsulated electronics ensure excellent resistance to shock and vibration, and no additional electrical or mechanical protection is required. Previously, users of the punch-riveting tools were unable to check the position of the operating ram with the tool in situ and either incurred downtime or risked costly bad joints. Contrinex high-pressure inductive sensors satisfy the manufacturer’s requirement for small, lightweight, ultra-reliable sensors with an attractive total cost of ownership.
APPLICATION - PUNCH-RIVETING TOOL
APPLICATION - DOUBLE-SHEET PRESS FEED PROTECTION
Continex’s Double-Sheet Inductive sensors have been specifically developed for more affordable detection of overlapping metal sheets. The specialist inductive sensor checks sheet metal blanks prior to being presented to the forming press – If the sensor detects that two or more sheets are stuck together, the press feed control system rejects the material and protects the press from damage. The sensors are a specialist version of Contrinex’s innovative, robust ‘700 Series’ family of inductive sensors. The double-sheet detection sensors enable discrimination between one and two conductive metal sheets of defined thickness, achieving a sensitivity of 0.8 – 1.2 mm per sheet. The one-piece, stainless-steel construction of these sensors makes them the most durable on the market. They withstand the impacts that are a common hazard close to moving sheet metal, ensuring minimal down-time to improve OEE.
Customer Solution A German producer of deep-drawn metal parts for the automotive industry uses Contrinex’s double-sheet sensing to prevent costly tool damage and downtime. Deep drawing and other metal-forming techniques are widely used in the automotive industry, which requires expensive press tools to produce complex profiles from sheet metal blanks. During high-volume production, an automated feeder loads sheets of steel or aluminium to the press. The metal sheets are lightly lubricated to reduce friction during deep drawing, but the thin film of oil can cause two sheets to stick together in the feeder. If the press operates with such double sheets loaded, the forming tool will be damaged, resulting in downtime and large repair costs. Therefore sensing systems are used to check the material before it is loaded. Previously, the customer had trailed alternative sensor technologies. All were excessively cumbersome and difficult to set up, and most were unable to detect double sheets reliably. Contrinex offers a rugged, compact metal-bodied sensor for the loading station, which checks each metal sheet as it is presented by the feeder. If it detects a double sheet, the material is rejected and the operating cycle inhibited, which reduces expensive damage to tooling and improves OEE.
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CUSTOMER VALUES • Reliable, continuous tool operation in time- sensitive production environments • Significant enhancement of tool function with minimal effect on size or weight • Low risk of internal damage due to best-in- class sensing distances • Industry-standard interface requires little modification to control systems
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PRODUCT ADVANTAGES • Sensor performance unaffected by 500 bar (7255 psi) operating pressure • Condist® technology of Extra Distance family delivers best-in-class sensing distances • Small, lightweight embeddable sensors with high-pressure capability • Rugged inductive sensor with metal housing and ceramic sensing face
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CUSTOMER VALUES • Reliable double-sheet detection eliminates tool damage and downtime • Compact, robust sensor ensures convenient, unobtrusive operation • Increased flexibility as a single sensor detects several different materials (eg Carbon steel, Stainless steel & Aluminium) • Reduced complexity as sensor connects directly to the customer’s control system
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PRODUCT ADVANTAGES • Sensor specially developed for detecting multiple overlapping metal sheets • Condet® technology makes performance independent of target material • Rugged inductive sensor with one-piece stainless steel construction • Extended sensing distance avoids risk of mechanical damage
PLUS Automation ® Limited © 2020 Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire. WR9 0LG
Helping you #MakeSenseofSensors
PRESS & STAMPING Inductive, Photoelectric, Machine Safety and RFID sensors optimised for Pressing and Stamping.
APPLICATION - PUNCH-RIVETING TOOL
Customer Solution Robust inductive sensors from the Contrinex Extra Distance family, High Pressure range, withstand the high operating pressure of this application. The extended operating distance of patented Condist® technology allows the use of thick, hermetically sealed ceramic discs on the sensing faces without compromising the sensors’ performance. These lightweight M5- and M8-diameter embeddable sensors are 27 mm and 30 mm in length, respectively. The sensors are mounted directly into the wall of the cylinder and do not interfere with the normal operation of the tool. Sensing distances of 1mm (M5 sensor) and 1.5 mm (M8 sensor) eliminate any risk of internal mechanical damage through contact with the ram. The sensors have an industry-standard PNP normally-open configuration and connect with the customer’s control system via a flexible PUR-sheathed cable. Vacuum- encapsulated electronics ensure excellent resistance to shock and vibration, and no additional electrical or mechanical protection is required. Previously, users of the punch-riveting tools were unable to check the position of the operating ram with the tool in situ and either incurred downtime or risked costly bad joints. Contrinex high-pressure inductive sensors satisfy the manufacturer’s requirement for small, lightweight, ultra- reliable sensors with an attractive total cost of ownership.
A manufacturer of cold-forming tools for joining sheet metal uses position sensing to control the operation of a manual punch-riveting tool. A high-pressure inductive sensor mounted directly into the wall of a small pneumohydraulic cylinder detects the position of the hydraulic ram, preventing the operating cycle from starting unless the ram is fully retracted. CUSTOMER APPLICATION Automotive technicians assembling prototype vehicle bodies during pre-production use manual punch-riveting tools to join individual sheet-metal parts. Several thousand joints are required per vehicle, and tools must be compact since space is often limited. Bad joints, which are very costly to repair, can occur if the technician does not set the tool correctly before triggering it. During use, the tool-head is often partly hidden from view, so a sensing system must confirm that the operating ram is fully retracted and prevent the tool from operating if the ram is not in the correct position. A pneumohydraulic cylinder drives the ram, and the compact nature of the tool limits the allowable sensor size. The sensing face is exposed to the high-pressure side of the hydraulic circuit, so the sensor must withstand continuous pressures up to 500 bar (7255 psi) and pressure spikes of 1000 bar (14,510 psi).
APPLICATION - DOUBLE-SHEET PRESS FEED PROTECTION
Continex’s Double-Sheet Inductive sensors have been specifically developed for more affordable detection of overlapping metal sheets. The specialist inductive sensor checks sheet metal blanks prior to being presented to the forming press – If the sensor detects that two or more sheets are stuck together, the press feed control system rejects the material and protects the press from damage. The sensors are a specialist version of Contrinex’s innovative, robust ‘700 Series’ family of inductive sensors. The double-sheet detection sensors enable discrimination between one and two conductive metal sheets of defined thickness, achieving a sensitivity of 0.8 – 1.2 mm per sheet. The one-piece, stainless-steel construction of these sensors makes them the most durable on the market. They withstand the impacts that are a common hazard close to moving sheet metal, ensuring minimal down-time to improve OEE.
Customer Solution A German producer of deep-drawn metal parts for the automotive industry uses Contrinex’s double-sheet sensing to prevent costly tool damage and downtime. Deep drawing and other metal-forming techniques are widely used in the automotive industry, which requires expensive press tools to produce complex profiles from sheet metal blanks. During high-volume production, an automated feeder loads sheets of steel or aluminium to the press. The metal sheets are lightly lubricated to reduce friction during deep drawing, but the thin film of oil can cause two sheets to stick together in the feeder. If the press operates with such double sheets loaded, the forming tool will be damaged, resulting in downtime and large repair costs. Therefore sensing systems are used to check the material before it is loaded. Previously, the customer had trailed alternative sensor technologies. All were excessively cumbersome and difficult to set up, and most were unable to detect double sheets reliably. Contrinex offers a rugged, compact metal-bodied sensor for the loading station, which checks each metal sheet as it is presented by the feeder. If it detects a double sheet, the material is rejected and the operating cycle inhibited, which reduces expensive damage to tooling and improves OEE.
+ CUSTOMER VALUES • Reliable double-sheet detection eliminates tool damage and downtime • Compact, robust sensor ensures convenient, unobtrusive operation  • Increased flexibility as a single sensor detects several different materials (eg Carbon steel, Stainless steel & Aluminium) • Reduced complexity as sensor connects directly to the customer’s control system PRODUCT ADVANTAGES • Sensor specially developed for detecting multiple overlapping metal sheets • Condet® technology makes performance independent of target material • Rugged inductive sensor with one-piece stainless steel construction • Extended sensing distance avoids risk of mechanical damage + + CUSTOMER VALUES • Reliable, continuous tool operation in time-sensitive production environments • Significant enhancement of tool function with minimal effect on size or weight • Low risk of internal damage due to best-in-class sensing distances • Industry-standard interface requires little modification to control systems PRODUCT ADVANTAGES • Sensor performance unaffected by 500 bar (7255 psi) operating pressure • Condist® technology of Extra Distance family delivers best-in-class sensing distances • Small, lightweight embeddable sensors with high-pressure capability • Rugged inductive sensor with metal housing and ceramic sensing face +
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