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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:
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
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.
CONTRINEX HELP KEEP YOU CALM UNDER PRESSURE WITH THEIR RANGES OF ‘EXTRA’ & HIGH’
PRESSURE SENSORS WHICH ARE TRUSTED IN A WORLD OF CHALLENGING APPLICATIONS.
INDUCTIVE SENSORS DESIGNED FOR ‘Extra’ PRESSURE (200 BAR) AND
‘High’ PRESSURE (500 BAR / 1000 BAR PEAK)- ‘COOL UNDER PRESSURE’
PRODUCT ADVANTAGES
EXTRA - PRESSURE RESISTANT UP TO 200 BAR
HIGH - HIGHEST OPERATING AND PEAK PRESSURES (500
BAR, 1000 BAR PEAK)
EXTRAORDINARY LIFE TIME UNDER PRESSURE CYCLE
EXCEPTIONAL RELIABILITY IN MINIATURE PACKAGES
EXTRA - SUITABLE FOR HIGH VACUUM APPLICATIONS
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
Dependable, accurate presence- and position-sensing at pressures up to 200 bar for the ‘EXTRA’ range or 500 bar (1,000 bar peak)
for the ‘HIGH PRESSURE’ range of sensors.
The EXTRA PRESSURE inductive sensors deliver can operate continuously in permanently pressurised conditions and at water
depths up to 1,000 metres. Their combination of a stainless-steel housing and a permanently bonded ceramic or sapphire-glass
sensing face guarantees robustness and exceptional reliability in miniature packages sized from ø3 to M8.
Contrinex HIGH PRESSURE inductive sensors are suitable for continuous duty at pressures up to 500 bar (1,000 bar peak pressure),
ensuring reliable, accurate sensing in the most demanding pneumatic and hydraulic applications. Available with classic metal
housing or one-piece, stainless-steel construction, high-pressure sensors detect the smallest parts and are ideal for piston-control
applications where space is at a premium.
EXTRA & HIGH PRESSURE INDUCTIVE SENSORS
CUSTOMER VALUES
RELIABLE OPERATION DESPITE HIGH-OPERATING PRESSURES
EASE OF MOUNTING
REDUCED MAINTENANCE COSTS
INCREASED EFFICIENCY
PRODUCT ADVANTAGES
PRACTICALLY UNLIMITED NUMBER OF PRESSURE CYCLES
ACROSS THE PRESSURE RANGE – 10 TIMES GREATER
LONGEVITY THAN THE MARKET STANDARD
PEAK PRESSURE UP TO 1000 BAR (14500 PSI)
LONG OPERATING DISTANCES DESPITE PRESSURE RESISTANT
HOUSING
RESISTANCE TO DYNAMIC STRESSES
Manufacturers of mobile concrete pumping trucks trust
Contrinex’s High Pressure sensors to monitor the piston
position in the hydraulic drive cylinder.
These sensors provide exceptional reliability despite the
challenges of pressure cycles and high pressure peaks,
increasing longevity and efficiency and reducing maintenance
costs for these concrete pump.
An additional benefit is that these sensors are part of
Contrinex’s Extra Distance family and so combine long
operating distances despite the pressure resistant housing.
CUSTOMER APPLICATION
Concrete pumps use a double-piston pump and require two
feed cylinders that pump concrete at a working pressure of up
to 400 bar (5800 psi). These feed cylinders are driven by pairs
of hydraulic cylinder pairs which operate in push-pull
opposition. To achieve the maximum possible efficiency, the
timing of this push-pull operation must be precisely
coordinated. It is therefore essential to monitor the cylinder
limit position with sensors that are resistant to high-pressure.
The dynamic stresses on all components built into the
hydraulic system are very high, due to constantly changing
pressure cycles during pump operation.
Concrete pump failures are extremely costly because they can
cause construction problems and stoppages and risk
compromising the building being constructed.
If the breakdown is due to problems in the hydraulic system,
all the hydraulic oil must be drained to correct the fault. Then,
after refilling and before start-up, several time-consuming de-
aeration cycles must take place before the pump is fully fit for
service again. This prolongs the construction stoppage.
The customer’s requirements for longevity and resistance to
high peak pressures are essential to guarantee the smooth
operation of such systems.
CUSTOMER SOLUTION
Contrinex High Pressure sensors (series 500P) withstand the
necessary pressure levels (peak pressure up to 1000 bar - 14500
psi) due to a patented process whereby a solid ceramic disk is
built into the stainless steel housing.
These sensors are fully resistant to dynamic stresses. A
patented technology ensures that all electronics, including the
ferrite core and coil, are located on the unpressurised side of
the housing. This results in an unusually long life under
pressure cycle stresses.
To monitor cylinder limit positions in the concrete pump, two
sensors are installed and connected to the control system. Due
to their longevity, which is ten times greater than the market
standard, maintenance costs are reduced to a minimum.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL WORK TO HELP YOU
SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS
USING CONTRINEX’S EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
EXTRA & HIGH PRESSURE
INDUCTIVE SENSORS
CONTRINEX HELP KEEP YOU CALM UNDER PRESSURE
WITH THEIR RANGES OF ‘EXTRA’ & HIGH’ PRESSURE
SENSORS WHICH ARE TRUSTED IN A WORLD OF
CHALLENGING APPLICATIONS.
CUSTOMER VALUES
FAST AND EASY UPGRADE OF MECHANICAL LIMIT SWITCHES
TOOL-FREE MOUNTING
ROTATABLE SENSING FACE, MOUNTABLE IN FIVE DIRECTIONS
SIGNIFICANT REDUCTION IN DOWNTIME
PRODUCT ADVANTAGES
LONG OPERATING DISTANCE UP TO 40 MM
HIGHLY FLEXIBLE, RELIABLE AND ECONOMICAL
SUITABLE FOR HARSH ENVIRONMENTS AND TEMPERATURES
FROM -25°C TO +85°C
LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE
FLUCTUATIONS AND VIBRATIONS
HIGH SWITCHING FREQUENCIES, RELIABLE SWITCHING
CHANGEOVER OUTPUTS
4 LED INDICATORS• IO-LINK INTERFACE
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 (14,510psi).
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.
INDUCTIVE SENSORS DESIGNED FOR
‘Extra’ PRESSURE (200 BAR) AND
‘High’ PRESSURE (500 BAR / 1000 BAR PEAK)
- ‘COOL UNDER PRESSURE’
PRODUCT ADVANTAGES
EXTRA - PRESSURE RESISTANT UP TO 200 BAR
HIGH - HIGHEST OPERATING AND PEAK PRESSURES (500
BAR, 1000 BAR PEAK)
EXTRAORDINARY LIFE TIME UNDER PRESSURE CYCLE
EXCEPTIONAL RELIABILITY IN MINIATURE PACKAGES
EXTRA - SUITABLE FOR HIGH VACUUM APPLICATIONS
IO-LINK INTERFACE INCLUDED – IDEAL FOR INDUSTRY 4
Dependable, accurate presence- and position-sensing at
pressures up to 200 bar for the ‘EXTRA’ range or 500 bar (1,000
bar peak) for the ‘HIGH PRESSURE’ range of sensors.
The EXTRA PRESSURE inductive sensors deliver can operate
continuously in permanently pressurised conditions and at
water depths up to 1,000 metres. Their combination of a
stainless-steel housing and a permanently bonded ceramic or
sapphire-glass sensing face guarantees robustness and
exceptional reliability in miniature packages sized from ø3 to
M8.
Contrinex HIGH PRESSURE inductive sensors are suitable for
continuous duty at pressures up to 500 bar (1,000 bar peak
pressure), ensuring reliable, accurate sensing in the most
demanding pneumatic and hydraulic applications. Available
with classic metal housing or one-piece, stainless-steel
construction, high-pressure sensors detect the smallest parts
and are ideal for piston-control applications where space is at a
premium.
CUSTOMER VALUES
RELIABLE OPERATION DESPITE HIGH-OPERATING PRESSURES
EASE OF MOUNTING
REDUCED MAINTENANCE COSTS
INCREASED EFFICIENCY
PRODUCT ADVANTAGES
PRACTICALLY UNLIMITED NUMBER OF PRESSURE CYCLES
ACROSS THE PRESSURE RANGE – 10 TIMES GREATER
LONGEVITY THAN THE MARKET STANDARD
PEAK PRESSURE UP TO 1000 BAR (14500 PSI)
LONG OPERATING DISTANCES DESPITE PRESSURE RESISTANT
HOUSING
RESISTANCE TO DYNAMIC STRESSES
Manufacturers of mobile concrete pumping trucks trust
Contrinex’s High-Pressure sensors to monitor the piston
position in the hydraulic drive cylinder.
These sensors provide exceptional reliability despite the
challenges of pressure cycles and high-pressure peaks,
increasing longevity and efficiency and reducing maintenance
costs for these concrete pump.
An additional benefit is that these sensors are part of
Contrinex’s Extra Distance family and so combine long
operating distances despite the pressure resistant housing.
CUSTOMER APPLICATION
Concrete pumps use a double-piston pump and require two
feed cylinders that pump concrete at a working pressure of up
to 400 bar (5800 psi). These feed cylinders are driven by pairs
of hydraulic cylinder pairs which operate in push-pull
opposition. To achieve the maximum possible efficiency, the
timing of this push-pull operation must be precisely
coordinated. It is therefore essential to monitor the cylinder
limit position with sensors that are resistant to high-pressure.
The dynamic stresses on all components built into the
hydraulic system are very high, due to constantly changing
pressure cycles during pump operation.
Concrete pump failures are extremely costly because they can
cause construction problems and stoppages and risk
compromising the building being constructed.
If the breakdown is due to problems in the hydraulic system,
all the hydraulic oil must be drained to correct the fault. Then,
after refilling and before start-up, several time-consuming de-
aeration cycles must take place before the pump is fully fit for
service again. This prolongs the construction stoppage.
The customer’s requirements for longevity and resistance to
high peak pressures are essential to guarantee the smooth
operation of such systems.
CUSTOMER SOLUTION
Contrinex High-Pressure sensors (series 500P) withstand the
necessary pressure levels (peak pressure up to 1000 bar - 14500
psi) due to a patented process whereby a solid ceramic disk is
built into the stainless steel housing.
These sensors are fully resistant to dynamic stresses. A
patented technology ensures that all electronics, including the
ferrite core and coil, are located on the unpressurised side of
the housing. This results in an unusually long life under
pressure cycle stresses.
To monitor cylinder limit positions in the concrete pump, two
sensors are installed and connected to the control system. Due
to their longevity, which is ten times greater than the market
standard, maintenance costs are reduced to a minimum.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS,
WE WORK TO HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE
PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEX’S
EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
