Helping you #Make Sense of Sensors
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ROBOT & GRIPPER APPLICATIONS Robots are an essential tool for fault-free assembly and Contrinex’s large product portfolios provide sensors for robots, grippers and associated machinery. Examples include miniature sensors for inclusion inside grippers and tooling, RFID tags that can be embedded into tooling, and machine safety guarding.
Robots utilise small multi-finger grippers to enable pick and place and assembly operations. A problem faced by robot manufacturers and system integrators is managing the collision hazard potentially caused by a malfunction or an unplanned human intervention. Contrinex’s new MiniDist module enables a miniature distance sensor to be embedded in the outward-facing surfaces of the robot gripper jaws, monitoring the position of potential obstructions during travel, preventing accidents. CUSTOMER APPLICATION Collision avoidance is an absolute priority for automation engineers implementing robotic handling systems. At worst, a collision can result in injury to a human co-worker; at best, damage to static infrastructure or other equipment. Either way, the implications are serious for any organization, an accident is costly and potentially tragic. While anti- collision measures will typically be coded into software routines, this is not always sufficient. In a manufacturing cell, robotic handling systems build electromechanical sub-assemblies before presenting them for automated testing. At each stage, parts are transported between operations by compact, multi-finger robot grippers, which are programmed individually according to the geometry of both the parts and the production equipment. As the products develop over time, the routines that control their manufacture also evolve. If conflicts between neighbouring robots aren’t eliminated completely, or if unplanned human intervention occurs, there’s an unacceptable risk of an accident. A cost-effective hardware solution is required to provide overriding anti-collision protection if this situation arises
Customer Solution Production engineers specified grippers fitted with Contrinex MiniDist photoelectric sensor modules as a reliable and cost-effective means of measuring the proximity of obstructions in real time. When transporting parts between operations, these miniature distance sensors, embedded in the outward-facing surfaces of the gripper jaws, monitor the position of potential obstructions during travel. MiniDist Brut sensors are designed with the needs of OEMs and system integrators in mind and provide an unobtrusive fit-and-forget solution. These miniature devices weigh only 3.1 grams, and with a compact 4mm x 4mm x 11m envelope and no external housing, they allow easy integration in tight spaces with insufficient room for traditional devices. With sensing distances of up to 40mm, MiniDist devices offer designers highly versatile options when specifying equipment. An industry-standard PNP analog output ensures optimum flexibility, with an output range of 0.3V to 3V allowing scope for in-situ adjustment. Connection is via a 4-wire PVC-sheathed cable with a 2m standard length; alternative options are available on request. These highly versatile miniature sensors meet the customer’s need for reliable operation while preventing accidents. The solution is both highly reliable and cost-effective while eliminating collision hazards; production throughput is maintained at or above target levels without compromising the safety of people or equipment.
APPLICATION - DISTANCE MEASUREMENT PHOTOELECTRIC MODULE IN GRIPPER
APPLICATION - ROTARY INDEXING TABLE & ROBOT ASSEMBLY
Fault-free assembly is ensured and downtime minimised by using automated facilities for high volume assembly. Rugged inductive sensors detect the presence and position of equipment or components at each stage to ensure that parts are correctly aligned and ready for the next operation. The sensors must be accurate and responsive. In addition, an IO-Link interface offers the advantages of digital communication without the need for special cabling. CUSTOMER APPLICATION Highly reliable automation and machine-control systems are used to eliminate assembly faults and improve efficiency in an assembly operation. Whilst the repetitive assembly tasks are well-suited to being done by robots, these robots can be too slow at picking and placing the assembled parts and therefore a rotary indexing table is used to move the assemblies between the robots. The rotary indexing table speeds up the transfer of PCBs between assembly robots and also on and off conveyors, increasing the production throughput and reducing the number of assembly robots required – Sensors are used to automate these processes and these sensors must be able to operate continuously at high speed, performing tasks including: presence detection to initiate the cassette- change cycle in a stack feeder; position control for a rotary indexing table; pick-and-place gripper control; and presence monitoring on a conveyor system.
Customer Solution Stack-feeders deliver base plates, electrical printed circuit boards and other planar components to the assembly lines. In each stack-feeder, a vertical cassette holds as many as 50 individual parts and a single inductive sensor monitors the status of each cassette. Once the final part is discharged from the stack, the cassette moves to its end position, triggering the sensor and initiating the cassette-change cycle.
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CUSTOMER VALUES • Embedded miniature distance sensors ensure reliable detection of potential obstructions, eliminating collision hazards • Miniature, housing-free photoelectric distance sensors suitable for easy integration • Reliable, compact vibration-resistant sensors • -25°C to +65°C operating range
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PRODUCT ADVANTAGES • Compact 4mm x 4mm x 11mm sensor envelope with no external housing allows easy integration in tight spaces • Sensing distances of up to 40mm • Industry-standard PNP analogue output with a range of 0.3V to 3V • Proven technology ensures fit-and-forget operation with no manual intervention
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CUSTOMER VALUES • Reliable, repeatable testing of complete trays of knobs in a single cycle • Testing is completed in standard transit trays with no additional handling • Immediate identification of faulty assemblies • Elimination of batch rejection by the customer
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PRODUCT ADVANTAGES • Extended sensing distances up to 12mm • Exceptional packing density with 44mm clearance • Reliable sensing of small targets through plastic tray material • IO- Link connectivity – Ideal for preventative maintenance and Industry 4.0 implementations
Contrinex C23 embeddable inductive sensors, featuring a one-piece stainless-steel housing, are both robust and highly reliable. A 7mm sensing distance allows ample operating clearance, minimizing the risk of mechanical collision. Their implementation into the assembly equipment is made easier by the choice of industry-standard PNP or NPN outputs with either a PUR cable or an M8 pigtail connector. Additionally, IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost, offering the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications. Designed for demanding applications, Contrinex’s rugged C23 inductive sensors offer best-in-class switching frequency of 180Hz and exceptional robustness including impact and abrasion resistance, making them a versatile, cost-effective and highly reliable solution. These uniquely robust sensors are typically demonstrated by Contrinex as being able to repeatedly being used to hammer in nails. Even when their front face is dented, the sensor continues to operate correctly.
Conveyors deliver a continuous stream of parts to the rotary indexing table, which transports them in sequence to each assembly station. As the table rotates, sensors located at precise intervals around its periphery detect its exact angular position, bringing it to a halt once parts are correctly positioned for the next operation. At each assembly station, automated pick-and-place equipment add components to the assembly. Dedicated transport mechanisms – including vacuum lifters, electromagnetic clamps and mechanical grippers – insert items swiftly and accurately in their designated positions. Embeddable inductive sensors play a key role in confirming the secure closure of custom-designed grippers before fragile, high- value parts are lifted. Manufactured in V4A/ AISI 316L stainless steel and rated to IP68/ IP69K, these small inductive sensors can be fully embedded into a steel surface such as part of the rotary table or an assembly jig or bench, further reducing the potential for mechanical damage. On completion of the final assembly stage, finished PCBs are discharged to a linear conveyor system. They travel to subsequent processing stages, including testing and packing. C23 Full Inox sensors mounted directly above these conveyors, detect each unit as it passes below. This check not only confirms the presence of the assembled item at the expected height above the conveyor but also measures throughput by activating a counting circuit in the customer’s control system. Continuous operation is the norm in automated assembly plants. However, minor adjustments or tool changes may be required from time to time. In non-safety-critical areas, access hatches allow maintenance technicians to carry out these tasks without needing to interrupt production across an entire plant. Multiple sensors, mounted at intervals around the periphery of a hatch, ensure that appropriate warning signals are activated whenever the opening is not fully secured. The Contrinex C23 series of Full Inox inductive sensors have the capability of communicating remotely with a plant-wide control system, thanks to the implementation of the IO-Link protocol. In a typical automated plant, each assembly line runs continuously throughout the day, with remote diagnostics eliminating the need for manual intervention in almost every situation. Designed to simplify integration, IO-Link sensors are compatible with all IO-Link master versions, allowing set-up and diagnostics to be conducted centrally. Interrogating a device returns its manufacturer ID and product ID, allowing systems integrators to determine remotely that the right sensor is in the correct location. Contrinex C23 inductive sensors additionally feature an on-demand self-test function that confirms full capability at all times. For the C23 inductive series, alternating between normally open and normally closed functionality via remote output-mode configuration is a standard feature of the IO-Link protocol. Systems designers also can modify the output signal. Delaying the switching pulse accommodates any travel time between a sensor and its corresponding actuation point, while stretching the pulse ensures that slave devices with lengthy response times trigger reliably, even at high throughput rates. Finally, each sensor provides an output-status check derived from its factory calibration data. If the output signal from a sensor falls outside a range that corresponds to a sensing distance between 80% and 100% of its nominal value, an alarm flag is triggered, highlighting the need for investigation. For plant managers under pressure, peace-of- mind is a valuable benefit. The no-cost option of the industry-standard IO-Link protocol ensures that best-in-class performance is coupled with ultimate ease of use in even the most demanding circumstances.
During automated production of solar cells, compact two-finger robot grippers transport trays of silicon wafers between operations. To avoid impacts on the wafer’s surfaces, process engineers require reliable confirmation that gripper jaws are fully open before the gripper descends to pick up a tray. Contrinex’s Ultra-miniature inductive proximity sensors, mounted directly above the top faces of the gripper fingers, sense the position of the jaws in the fully open position, eliminating avoidable scrap costs. CUSTOMER APPLICATION Eliminating avoidable scrap costs has to be at the top of any production engineer’s to-do list, particularly when rectifying component damage also means interrupting a fast-moving automated production line. When the component in question is a costly photovoltaic silicon wafer, designers often turn to automated handling systems, although relying on these to achieve perfect alignment isn’t always the answer. In a manufacturing cell, handling systems assemble solar cells before presenting them for automated testing. To start, trays of silicon wafers are transported between operations by two-finger edge-grippers. If gripper malfunctions occur, scrap costs can mount rapidly, with mechanical damage caused by impacts on the wafer surfaces being a common cause. Analysis showed that open/close errors account for a significant proportion of gripper malfunctions. Software routines alone can’t identify the position of the gripper fingers; attempts to pick up a wafer tray with the jaws only partially open result in fingers impacting on the wafer surfaces. A cost-effective hardware solution is required to provide overriding inhibition of picking routines if this situation arises.
Customer Solution Designers specified two-finger grippers fitted with Contrinex Ultra- miniature inductive sensors as a reliable and cost-effective means of detecting the position of the jaws at the extremes of travel. Before the gripper descends to pick up a tray, these miniature proximity sensors, mounted directly above the top faces of the gripper fingers, sense the position of the jaws in the fully open position. Ultraminiature inductive sensors are designed with the needs of OEMs and system integrators in mind and provide an unobtrusive fit-and- forget solution. These miniature devices weigh only 25 grams, and with a compact 3mm-diameter x 22mm V2A stainless-steel housing, they allow easy integration in tight spaces with insufficient room for traditional devices. With a sensing distance of 1mm, MiniDist devices offer designers attractive alternatives when specifying equipment. Industry-standard PNP and NPN outputs with normally open or normally closed options ensure optimum flexibility when interfacing with a wide range of control systems. Connection is via a PUR-sheathed cable with a 3-pin connector or 2-meter flying lead; alternative lengths are available. These highly versatile miniature sensors meet designers’ needs for reliable operation while preventing accidental damage. The solution is both highly reliable and cost-effective while eliminating avoidable scrap costs; payback is rapid, while production throughput is maintained at target levels without increasing the cost of quality. The inclusion of IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost. It offers the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications.
APPLICATION - MINIATURE SENSORS ON GRIPPERS FOR FRAGILE WAFERS
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CUSTOMER VALUES • Miniature sensors to ensure reliable detection • Miniature sensors suitable for easy integration • Reliable, compact vibration-resistant sensors • -25°C to +70°C operating range
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PRODUCT ADVANTAGES • Compact 3mm-diameter x 22mm, 25 gram V2A stainless-steel housing • Sensing distances of 1mm • IO-Link interface included for free– Industry 4 • Proven technology ensures fit-and-forget operation with no manual intervention
ROBOT & GRIPPER APPLICATIONS Robots are an essential tool for fault-free assembly and Contrinex’s large product portfolios provide sensors for robots, grippers and associated machinery. Examples include miniature sensors for inclusion inside grippers and tooling, RFID tags that can be embedded into tooling, and machine safety guarding.
APPLICATION - DISTANCE MEASUREMENT MODULE INTEGRATED INTO GRIPPER
Customer Solution Production engineers specified grippers fitted with Contrinex MiniDist Brut photoelectric sensor modules as a reliable and cost-effective means of measuring the proximity of obstructions in real time. When transporting parts between operations, these miniature distance sensors, embedded in the outward-facing surfaces of the gripper jaws, monitor the position of potential obstructions during travel. MiniDist sensors are designed with the needs of OEMs and system integrators in mind and provide an unobtrusive fit- and-forget solution. These miniature devices weigh only 3.1 grams, and with a compact 4mm x 4mm x 11mm envelope and no external housing, they allow easy integration in tight spaces with insufficient room for traditional devices. With sensing distances of up to 40mm, MiniDist devices offer designers highly versatile options when specifying equipment. An industry-standard PNP analog output ensures optimum flexibility, with an output range of 0.3V to 3V allowing scope for in-situ adjustment. Connection is via a 4-wire PVC-sheathed cable with a 2m standard length; alternative options are available on request. These highly versatile miniature sensors meet the customer’s need for reliable operation while preventing accidents. The solution is both highly reliable and cost- effective while eliminating collision hazards; production throughput is maintained at or above target levels without compromising the safety of people or equipment.
Robots utilise small multi-finger grippers to enable pick and place and assembly operations. A problem faced by robot manufacturers and system integrators is managing the collision hazard potentially caused by a malfunction or an unplanned human intervention. Contrinex’s new MiniDist module enables a miniature distance sensor to be embedded in the outward-facing surfaces of the robot gripper jaws, monitoring the position of potential obstructions during travel, preventing accidents. CUSTOMER APPLICATION Collision avoidance is an absolute priority for automation engineers implementing robotic handling systems. At worst, a collision can result in injury to a human co-worker; at best, damage to static infrastructure or other equipment. Either way, the implications are serious for any organization, an accident is costly and potentially tragic. While anti-collision measures will typically be coded into software routines, this is not always sufficient. In a manufacturing cell, robotic handling systems build electromechanical sub-assemblies before presenting them for automated testing. At each stage, parts are transported between operations by compact, multi-finger robot grippers, which are programmed individually according to the geometry of both the parts and the production equipment. As the products develop over time, the routines that control their manufacture also evolve. If conflicts between neighbouring robots aren’t eliminated completely, or if unplanned human intervention occurs, there’s an unacceptable risk of an accident. A cost-effective hardware solution is required to provide overriding anti-collision protection if this situation arises.
APPLICATION - ROTARY INDEX TABLE & ROBOT ASSEMBLY
Fault-free assembly is ensured and downtime minimised by using automated facilities for high volume assembly. Rugged inductive sensors detect the presence and position of equipment or components at each stage to ensure that parts are correctly aligned and ready for the next operation. The sensors must be accurate and responsive. In addition, an IO-Link interface offers the advantages of digital communication without the need for special cabling. CUSTOMER APPLICATION Highly reliable automation and machine-control systems are used to eliminate assembly faults and improve efficiency in an assembly operation. Whilst the repetitive assembly tasks are well-suited to being done by robots, these robots can be too slow at picking and placing the assembled parts and therefore a rotary indexing table is used to move the assemblies between the robots. The rotary indexing table speeds up the transfer of PCBs between assembly robots and also on and off conveyors, increasing the production throughput and reducing the number of assembly robots required – Sensors are used to automate these processes and these sensors must be able to operate continuously at high speed, performing tasks including: presence detection to initiate the cassette-change cycle in a stack feeder; position control for a rotary indexing table; pick-and-place gripper control; and presence monitoring on a conveyor system.
PLUS Automation ® Limited © 2020 Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire. WR9 0LG
Helping you #MakeSenseofSensors
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
+ CUSTOMER VALUES • Reliable, repeatable detection of three discrete parts in a single operation • Elimination of unsafe occurrences due to faulty hose assemblies • Highly cost-effective solution to a previously insoluble problem PRODUCT ADVANTAGES • Exceptional sensing distances in small sensor envelopes • Correction factor of 1.0 for brass allows extended sensing distance • Sensors operate in close proximity without interference + + CUSTOMER VALUES • Embedded miniature distance sensors ensure reliable detection of potential obstructions, eliminating collision hazards • Miniature, housing-free photoelectric distance sensors suitable for easy integration • Reliable, compact vibration-resistant sensors • -25°C to +65°C operating range PRODUCT ADVANTAGES • Compact 4mm x 4mm x 11mm sensor envelope with no external housing allows easy integration in tight spaces • Sensing distances of up to 40mm • Industry-standard PNP analogue output with a range of 0.3V to 3V • Proven technology ensures fit-and-forget operation with no manual intervention +
Customer Solution Stack-feeders deliver base plates, electrical printed circuit boards and other planar components to the assembly lines. In each stack-feeder, a vertical cassette holds as many as 50 individual parts and a single inductive sensor monitors the status of each cassette. Once the final part is discharged from the stack, the cassette moves to its end position, triggering the sensor and initiating the cassette- change cycle.
BROCHURES VIDEOS MATERIAL HANDLING APP
Contrinex C23 embeddable inductive sensors, featuring a one-piece stainless-steel housing, are both robust and highly reliable. A 7mm sensing distance allows ample operating clearance, minimizing the risk of mechanical collision. Their implementation into the assembly equipment is made easier by the choice of industry- standard PNP or NPN outputs with either a PUR cable or an M8 pigtail connector. Additionally, IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost, offering the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications. Designed for demanding applications, Contrinex’s rugged C23 inductive sensors offer best-in-class switching frequency of 180Hz and exceptional robustness including impact and abrasion resistance, making them a versatile, cost-effective and highly reliable solution. These uniquely robust sensors are typically demonstrated by Contrinex as being able to repeatedly being used to hammer in nails. Even when their front face is dented, the sensor continues to operate correctly.
Conveyors deliver a continuous stream of parts to the rotary indexing table, which transports them in sequence to each assembly station. As the table rotates, sensors located at precise intervals around its periphery detect its exact angular position, bringing it to a halt once parts are correctly positioned for the next operation. At each assembly station, automated pick-and-place equipment add components to the assembly. Dedicated transport mechanisms – including vacuum lifters, electromagnetic clamps and mechanical grippers – insert items swiftly and accurately in their designated positions. Embeddable inductive sensors play a key role in confirming the secure closure of custom-designed grippers before fragile, high-value parts are lifted. Manufactured in V4A/ AISI 316L stainless steel and rated to IP68/ IP69K, these small inductive sensors can be fully embedded into a steel surface such as part of the rotary table or an assembly jig or bench, further reducing the potential for mechanical damage. On completion of the final assembly stage, finished PCBs are discharged to a linear conveyor system. They travel to subsequent processing stages, including testing and packing. C23 Full Inox sensors mounted directly above these conveyors, detect each unit as it passes below. This check not only confirms the presence of the assembled item at the expected height above the conveyor but also measures throughput by activating a counting circuit in the customer’s control system. Continuous operation is the norm in automated assembly plants. However, minor adjustments or tool changes may be required from time to time. In non-safety-critical areas, access hatches allow maintenance technicians to carry out these tasks without needing to interrupt production across an entire plant. Multiple sensors, mounted at intervals around the periphery of a hatch, ensure that appropriate warning signals are activated whenever the opening is not fully secured. The Contrinex C23 series of Full Inox inductive sensors have the capability of communicating remotely with a plant-wide control system, thanks to the implementation of the IO-Link protocol. In a typical automated plant, each assembly line runs continuously throughout the day, with remote diagnostics eliminating the need for manual intervention in almost every situation. Designed to simplify integration, IO-Link sensors are compatible with all IO-Link master versions, allowing set- up and diagnostics to be conducted centrally. Interrogating a device returns its manufacturer ID and product ID, allowing systems integrators to determine remotely that the right sensor is in the correct location. Contrinex C23 inductive sensors additionally feature an on-demand self- test function that confirms full capability at all times. For the C23 inductive series, alternating between normally open and normally closed functionality via remote output- mode configuration is a standard feature of the IO-Link protocol. Systems designers also can modify the output signal. Delaying the switching pulse accommodates any travel time between a sensor and its corresponding actuation point, while stretching the pulse ensures that slave devices with lengthy response times trigger reliably, even at high throughput rates. Finally, each sensor provides an output-status check derived from its factory calibration data. If the output signal from a sensor falls outside a range that corresponds to a sensing distance between 80% and 100% of its nominal value, an alarm flag is triggered, highlighting the need for investigation. For plant managers under pressure, peace-of-mind is a valuable benefit. The no-cost option of the industry-standard IO-Link protocol ensures that best-in-class performance is coupled with ultimate ease of use in even the most demanding circumstances.
APPLICATION - MINIATURE SENSORS ON GRIPPERS FOR FRAGILE WAFERS
Customer Solution Designers specified two-finger grippers fitted with Contrinex Ultra-miniature inductive sensors as a reliable and cost- effective means of detecting the position of the jaws at the extremes of travel. Before the gripper descends to pick up a tray, these miniature proximity sensors, mounted directly above the top faces of the gripper fingers, sense the position of the jaws in the fully open position. Ultraminiature inductive sensors are designed with the needs of OEMs and system integrators in mind and provide an unobtrusive fit-and-forget solution. These miniature devices weigh only 25 grams, and with a compact 3mm- diameter x 22mm V2A stainless-steel housing, they allow easy integration in tight spaces with insufficient room for traditional devices. With a sensing distance of 1mm, MiniDist devices offer designers attractive alternatives when specifying equipment. Industry-standard PNP and NPN outputs with normally open or normally closed options ensure optimum flexibility when interfacing with a wide range of control systems. Connection is via a PUR-sheathed cable with a 3- pin connector or 2-meter flying lead; alternative lengths are available. These highly versatile miniature sensors meet designers’ needs for reliable operation while preventing accidental damage. The solution is both highly reliable and cost- effective while eliminating avoidable scrap costs; payback is rapid, while production throughput is maintained at target levels without increasing the cost of quality. The inclusion of IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost. It offers the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications.
During automated production of solar cells, compact two- finger grippers transport trays of silicon wafers between operations. To avoid impacts on the wafer’s surfaces, process engineers require reliable confirmation that gripper jaws are fully open before the gripper descends to pick up a tray. Contrinex’s Ultra-miniature inductive proximity sensors, mounted directly above the top faces of the gripper fingers, sense the position of the jaws in the fully open position, eliminating avoidable scrap costs. CUSTOMER APPLICATION Eliminating avoidable scrap costs has to be at the top of any production engineer’s to-do list, particularly when rectifying component damage also means interrupting a fast-moving automated production line. When the component in question is a costly photovoltaic silicon wafer, designers often turn to automated handling systems, although relying on these to achieve perfect alignment isn’t always the answer. In a manufacturing cell, handling systems assemble solar cells before presenting them for automated testing. To start, trays of silicon wafers are transported between operations by two-finger edge-grippers. If gripper malfunctions occur, scrap costs can mount rapidly, with mechanical damage caused by impacts on the wafer surfaces being a common cause. Analysis showed that open/close errors account for a significant proportion of gripper malfunctions. Software routines alone can’t identify the position of the gripper fingers; attempts to pick up a wafer tray with the jaws only partially open result in fingers impacting on the wafer surfaces. A cost-effective hardware solution is required to provide overriding inhibition of picking routines if this situation arises
+ CUSTOMER VALUES • Miniature sensors ensure reliable detection • Miniature sensors for easy integration • Reliable, compact vibration-resistant sensors • -25°C to +70°C operating range PRODUCT ADVANTAGES • Compact 3mm-diameter x 22mm, 25 gram V2A stainless-steel housing• Sensing distances of 1mm• IO-Link interface included for free– Industry 4• Proven technology ensures fit-and-forget operation with no manual intervention +