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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:
CNC machining centres use automatic tool-changing spindles
to rapidly switch between different tools with characteristic
suited to different materials, work-pieces and cutting speeds.
To ensure that a new tool engages completely in order to
prevent damage to the tool, the work-piece or the spindle,
designers specified Contrinex’s NEW SMART inductive sensors.
Embedded within the body of the spindle, the sensor monitors
the position of the tool during changes, so that any non-
compliant measurement stop the process, triggering an alarm.
CUSTOMER APPLICATION
Modern machine-tool spindles offer CNC machine designers
huge flexibility, enabling individual machining centres to cope
with ranges of materials, batch sizes, work-pieces, tools and
cutting speeds that might previously have needed several
different machines. Successive cuts often call for different tool
characteristics, spindles with automatic tool-changing are key
to optimizing throughput.
A spring-loaded collet, actuated by a central drawbar that runs
the length of the spindle, retains the tool in position. Once the
tool to be changed is moved to its designated position in the
machine’s tool-storage magazine, an actuator pushes the
drawbar forward along its axis until the collet disengages,
releasing the tool. The spindle then moves to the location of
the new tool in the magazine and the process is reversed.
From time to time, the collet may fail to retract fully,
preventing the new tool from engaging completely. Failing to
detect and rectify the problem leads to expensive damage to
the tool, the workpiece and possibly the spindle. Spindle
manufacturers require a robust, fail-safe method of detecting
incomplete tool engagement in what is already a tightly
packed assembly.
CUSTOMER SOLUTION
Designers specified rugged inductive sensors from the
Contrinex Smart Sensor portfolio; a single metal-cased sensor,
embedded radially in the body of the spindle immediately
adjacent to the rear of the drawbar, performs the required
tasks. All Contrinex Smart Sensors feature IO-Link connectivity,
providing a single, industry-standard interface to the machine
control system.
The sensor operates as a high-precision distance-
measurement device; its target is a longitudinally inclined face
on the circumference of the drawbar. As the drawbar moves
forward, the distance to the inclined faces changes in direct
proportion to the distance moved. With a sensing distance of
up to 6 mm and a dynamic resolution of ±5.5 micrometres, the
sensor delivers a highly accurate 16-bit digital output, enabling
the drawbar position to be determined in real time.
At the time of initial calibration, the drawbar positions
corresponding to the two extremes of travel are recorded in
the sensor’s local data store. Thereafter, the sensor operates in
two distinct modes: During tool changes, the drawbar position
is monitored in real time, ensuring that its motion follows the
expected pattern; once the extreme of travel is reached in
either direction, the sensor de-energizes the actuator and
initiates the next stage of the process. Any non-compliant
measurements stop the process and trigger an alarm.
Contrinex inductive Smart Sensors are designed with the
needs of OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. On-board data storage
holds cumulative operating data for user-specified purposes,
including predictive maintenance. These highly versatile
sensors meet designers’ needs for a reliable, cost-effective and
compact solution that delivers ultimate peace of mind.
CUSTOMER VALUES
EMBEDDABLE INDUCTIVE SMART SENSOR MONITORS
DRAWBAR POSITION, DETECTING INCOMPLETE TOOL
ENGAGEMENT AND INHIBITING FURTHER MOTION BEFORE
DAMAGE OCCURS
SINGLE-SENSOR POSITIONAL-CONTROL SYSTEM IS NON-
COMPLEX AND HIGHLY AFFORDABLE
EMBEDDABLE M12 SENSOR FITS SNUGLY IN THE LIMITED
SPACE AVAILABLE
INDUSTRY-STANDARD IO-LINK CONNECTIVITY PROVIDES A
SINGLE INTERFACE TO THE MACHINE CONTROL SYSTEM
CUMULATIVE OPERATING DATA FOR PREDICTIVE
MAINTENANCE, INCLUDING TEMPERATURE AND OPERATING-
CYCLE COUNT, IS RECORDED IN ON-BOARD DATA STORAGE
SENSOR CONFIGURATIONS ARE STORED LOCALLY, ALLOWING
PLUG-AND-PLAY REPLACEMENT OF SENSORS WHEN NEEDED
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-AND-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ROBUST, METAL-CASED INDUCTIVE SMART SENSORS ARE
IDEAL FOR EASY INTEGRATION
MULTI-CHANNEL MONITORING CIRCUITRY ALLOWS USERS TO
DEFINE UP TO 5 CUSTOMIZED OUTPUT THRESHOLDS
SOPHISTICATED SENSING ELECTRONICS DELIVER DYNAMIC
LINEAR-DISTANCE MEASUREMENTS WITH A RESOLUTION IN
THE MICRON RANGE
HIGH-SPEED DEVICE-TO-DEVICE COMMUNICATION ENABLES
DECENTRALIZED DATA-PROCESSING AND DECISION MAKING
DEDICATED SERVICE-DATA BLOCKS HOLD DEVICE-SPECIFIC
DATA INCLUDING PRODUCT ID, LOCATION AND SERIAL
NUMBER
VISIBLE LED INDICATORS ENABLE SENSORS TO SELF-IDENTIFY
ON DEMAND, SIMPLIFYING COMMISSIONING AND TROUBLE-
SHOOTING ROUTINES
INDUSTRY-STANDARD -25°C TO +70°C OPERATING RANGE
Contrinex inductive sensors help automation companies build
high-speed assembly equipment and their new SMART
Inductive sensors can help by being able to measure, monitor,
configure and help predict.
High-speed automated systems frequently use linear transfers
stages between workstations to maximise speed and accuracy
while keeping cost down. Designers of these linear transfer
units required a single-sensor positional-control solution that
controls both high-speed movements as the slide approaches
the critical area, where it slows down and also to provide high-
precision final positioning.
To achieve this, Contrinex’s inductive SMART Sensors were
selected. A single smart sensor with IO-Link connectivity and
multiple user-configurable outputs performs both the
required tasks in a highly cost-effective manner.
CUSTOMER APPLICATION
Automation engineers often face a three-way balancing act
when designing equipment, trying to maximise speed and
accuracy while keeping cost at acceptable levels. Position
control is no exception – high-performance systems typically
rely on linear or rotary encoders to deliver the required
positional accuracy, and these can be expensive, particularly
when both coarse and fine positioning is needed.
Using a secondary sensor for coarse-positional control is a
commonly used, although inelegant, solution to the problem.
It also increases complexity and cost, while reducing the
overall reliability of the system. Alternatively, designers
maintain accuracy without increasing cost by reducing travel
speeds during coarse positioning, increasing the cycle time.
Neither approach is optimal.
Equipment manufacturers (OEMs) specifying high-speed
assembly equipment with multiple linear transfers between
workstations need an alternative solution. Using off-the-shelf
linear stages, they require a controlled, fast approach to the
critical areas and a slower, high-precision final positioning –
without increasing complexity or cost. An affordable single-
sensor solution is highly desirable.
CUSTOMER SOLUTION
The designers specified rugged inductive sensors from the
Contrinex SMART Sensor portfolio; a single sensor with IO-Link
connectivity and multiple user-configurable outputs performs
both the required tasks. Firstly, it initiates a controlled
deceleration as the carriage of a linear stage approaches the
specified workstation; it then switches to micrometer distance
resolution, positioning the stage accurately and precisely.
Contrinex inductive SMART Sensors are designed with the
needs of OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. A single metal-cased M12
sensor is embedded in one of the guide rails immediately
adjacent to each workstation. The sensor detects the presence
of the carriage as it begins to pass overhead, triggering the
deceleration and changing the sensing mode.
The sensor now operates as a high-precision distance-
measurement device; its target is an inclined face on the
underside of the carriage. As the carriage moves over the
sensor, the distance to the inclined faces changes in direct
proportion to the distance moved. With a sensing distance of
up to 6mm and a dynamic resolution of ±5.5 micrometres, the
sensor delivers a highly accurate 16-bit digital output, enabling
the carriage position to be determined in real-time.
Once the initial set-up is completed, each sensor’s
configuration is stored automatically on the local IO-Link
Master; this allows plug-and-play replacement of sensors
should the need arise, without any loss of functionality and
without any need for recalibration. These highly versatile
sensors meet designers’ needs for a highly reliable, cost-
effective and non-complex solution without compromising
operational performance.
CUSTOMER VALUES
EMBEDDABLE INDUCTIVE SMART SENSOR ENSURE ACCURATE
POSITIONING OF LINEAR STAGES WITHOUT COMPROMISING
OPERATIONAL SPEED
SINGLE-SENSOR POSITIONAL-CONTROL SYSTEM IS NON-
COMPLEX AND HIGHLY AFFORDABLE
COMPACT EMBEDDABLE M12 SENSORS FIT UNOBTRUSIVELY
AND EASILY INTO OFF-THE-SHELF LINEAR GUIDE RAILS
INDUSTRY-STANDARD IO-LINK CONNECTIVITY PROVIDES A
SINGLE INTERFACE TO THE MACHINE CONTROL SYSTEM.
SENSOR CONFIGURATIONS ARE STORED LOCALLY, ALLOWING
PLUG-AND-PLAY REPLACEMENT OF SENSORS WHEN NEEDED.
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-AND-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ON-BOARD DATA STORAGE HOLDS CUMULATIVE OPERATING
DATA FOR USER-SPECIFIED PURPOSES, INCLUDING PREDICTIVE
MAINTENANCE
ROBUST, METAL-CASED INDUCTIVE SMART SENSORS ARE
IDEAL FOR EASY INTEGRATION
MULTI-CHANNEL MONITORING CIRCUITRY ALLOWS USERS TO
DEFINE UP TO 5 CUSTOMISED OUTPUT THRESHOLDS
SOPHISTICATED SENSING ELECTRONICS DELIVER DYNAMIC
LINEAR-DISTANCE MEASUREMENTS WITH A RESOLUTION IN
THE MICRON RANGE
HIGH-SPEED DEVICE-TO-DEVICE COMMUNICATION ENABLES
DECENTRALIZED DATA-PROCESSING AND DECISION MAKING
DEDICATED SERVICE-DATA BLOCKS HOLD DEVICE-SPECIFIC
DATA INCLUDING PRODUCT ID, LOCATION AND SERIAL
NUMBER
VISIBLE LED INDICATORS ENABLE SENSORS TO SELF-IDENTIFY
ON DEMAND, SIMPLIFYING COMMISSIONING AND TROUBLE-
SHOOTING ROUTINES
INDUSTRY-STANDARD -25°C TO +70°C OPERATING RANGE
PRODUCT ADVANTAGES
SENSORS COMPATIBLE WITH INDUSTRY-STANDARD SMART
SENSOR PROFILE: IO-LINK SSP 3.3, DIGITAL MEASURING
SENSORS (DMS) WITH DISABLE FUNCTION
CLOUD-READY SENSORS WITH PERFORMANCE EQUIVALENT
TO A CONVENTIONAL ANALOG OUTPUT SENSOR, BUT WITH A
DIGITAL DATA OUTPUT
32-BIT PROCESS DATA INPUT (PDI) WITH 16-BIT VALUES FOR
DISTANCE, COUNTER AND TEMPERATURE, 8-BIT VALUES FOR
MEASUREMENT DATA SCALING AND 8-BIT VALUES FOR OUTPUT
SWITCHING SIGNAL, SWITCHING SIGNAL AND CONFIGURABLE
ALARM FLAGS. THE 8-BIT PROCESS DATA OUTPUT (PDO)
INCLUDES A DISABLE FUNCTION.
USER-DEFINABLE IO-LINK PARAMETERS: DISTANCE,
COUNTER, TEMPERATURE AND SWITCH-POINT MODE
(DEACTIVATED, SINGLE POINT, WINDOW MODE, TWO-POINT
MODE)
PRE-DEFINED PREDICTIVE MAINTENANCE FUNCTIONS:
OPERATING HOURS SINCE FIRST/LAST POWER-UP, SWITCHING
COUNTER SINCE FIRST/LAST POWER-UP, SENSOR AUTO-
DIAGNOSTIC ALARM
CONTRINEX’S NEW CLOUD-READY SMART SENSORS ARE PERFECT FOR LIVE DATA
MONITORING FROM THE HEART OF AN APPLICATION WITH FAST AND SIMPLE SET-UP.
SMART INDUCTIVE SENSORS
Contrinex’s new cloud-ready Smart Sensors are perfect for live data monitoring from the heart of an application. Simply by
configuring an IO-Link parameter, the user can output and display sensor data in real time on any cloud dashboard.
The Smart Sensors which were designed with the needs of OEMs and system integrators in mind, have all the answers when it
comes to reducing complexity and cost. By implementing multiple sensing modes in a single sensor, Contrinex has given
designers the freedom they’ve always dreamed about, offering exceptional versatility and simplified integration.
Let Contrinex Smart Sensors supercharge your IoT strategy; enjoy all the advantages of the industry-standard IO-Link SSP 3.3
interface, plus the option of high-speed sensor-based decision-making using SIO. The only limit is your imagination….
The recycling industry utilises automation to reduce the cost of
sorting and separating mixed-metal scrap. One such solution
is automated sorting, which requires sensors which both
operate accurately and at high speed to identify and separate
fast-moving streams of ferrous and non-ferrous material in a
single pass. Rugged inductive Smart Sensors from Contrinex,
are embedded immediately below the delivery belt to provide
continuous high-speed detection across the full width of a
conveyor belt.
CUSTOMER APPLICATION
The global recycling industry relies upon advances in
technology to automate waste-recovery operations. These
make it economic to recover an ever greater proportion of
domestic and industrial waste. Waste-management
companies are always looking for more affordable alternatives
for sorting and separating mixed-metal scrap as some of the
existing processes, while effective, are inflexible and expensive.
Advances in sensor technology and capabilities have seen the
introduction of induction sorting, a process that identifies and
separates different types of metallic material. A fast-moving
conveyor carries pre-sized waste over a bank of inductive
sensors mounted below the belt; the sensors detect and
identify any non-ferrous material, which is subsequently
ejected and separated by a targeted air-knife.
To take full advantage of the process, OEM equipment builders
require robust sensors that differentiate accurately and at high
speed between ferrous and non-ferrous material, allowing a
single bank of sensors to process mixed-metal waste in a
single pass. As the sensors may operate independently or in
combination with other sensing technologies, an industry-
standard communication interface is highly desirable.
CUSTOMER SOLUTION
Designers specified rugged inductive sensors from the
Contrinex Smart Sensor portfolio; an array of 50 metal-cased
sensors, embedded in a grid pattern immediately below the
belt, provides continuous detection across the full width of the
conveyor. Best-practice electronic design ensures that Smart
Sensors are individually shielded and EMC immune,
eliminating interference when multiple devices operate in
close proximity.
Mounted only a few millimetres from the target as it passes
overhead, these M18 devices, which have a nominal sensing
distance of 10 mm for carbon steel, generate analogue output
signals that vary according to the material type. The Smart
Sensors are easily able to accommodate the required range of
conveyor speeds.
IO-Link connectivity, standard across the range, provides an
industry-standard interface to the machine control system,
triggering the appropriate air-knives as pieces of non-ferrous
material reach the separator. During initial calibration, each
sensor’s configuration is stored automatically on the local IO-
Link Master; this allows plug-and-play replacement of sensors
should the need arise, without any loss of functionality and
without any need for recalibration.
Contrinex inductive Smart Sensors are designed with the
needs of OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. On-board data storage
holds cumulative operating data for user-specified purposes,
including predictive maintenance. These highly versatile
sensors meet designers’ needs for a robust and cost-effective
solution that delivers exceptional accuracy and reliability in a
particularly challenging environment.
CUSTOMER VALUES
HIGHLY ACCURATE, REPEATABLE SENSING PERFORMANCE IN
EMBEDDABLE INDUCTIVE SMART SENSORS DIFFERENTIATE
CLEARLY BETWEEN TARGET MATERIAL TYPES, DETECTING
NON-FERROUS METAL AND TRIGGERING SEPARATION
ACCURATELY AND RELIABLY
A SINGLE ARRAY OF SENSORS PROVIDES CONTINUOUS
DETECTION ACROSS THE FULL WIDTH OF A CONVEYOR
SMART SENSORS EASILY ABLE TO IDENTIFY MATERIAL ON
FAST-MOVING CONVEYORS THANKS TO HIGH SENSING SPEED
INDUSTRY-STANDARD IO-LINK CONNECTIVITY PROVIDES A
SINGLE INTERFACE TO THE MACHINE CONTROL SYSTEM
CUMULATIVE OPERATING DATA FOR PREDICTIVE
MAINTENANCE, INCLUDING TEMPERATURE AND OPERATING-
CYCLE COUNT, IS RECORDED IN ON-BOARD DATA STORAGE
SENSOR CONFIGURATIONS ARE STORED LOCALLY, ALLOWING
PLUG-AND-PLAY REPLACEMENT OF SENSORS WHEN NEEDED
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-AND-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ROBUST, METAL-CASED INDUCTIVE SMART SENSORS ARE
IDEAL FOR EASY INTEGRATION
MULTI-CHANNEL MONITORING CIRCUITRY ALLOWS USERS TO
DEFINE 5 CUSTOMISED OUTPUT THRESHOLDS
SOPHISTICATED SENSING ELECTRONICS DELIVER HIGH-
PRECISION ANALOGUE OUTPUT SIGNALS
HIGH-SPEED DEVICE-TO-DEVICE COMMUNICATION ENABLES
DECENTRALISED DATA-PROCESSING AND DECISION MAKING
SMART SENSORS ARE INDIVIDUALLY SHIELDED AND EMC
IMMUNE, ELIMINATING INTERFERENCE WHEN MULTIPLE
DEVICES OPERATE IN CLOSE PROXIMITY
DEDICATED SERVICE-DATA BLOCKS HOLD DEVICE-SPECIFIC
DATA INCLUDING PRODUCT ID, LOCATION & SERIAL NUMBER
VISIBLE LED INDICATORS ENABLE SENSORS TO SELF-IDENTIFY
ON DEMAND, SIMPLIFYING COMMISSIONING AND TROUBLE-
SHOOTING ROUTINES
INDUSTRY-STANDARD -25°C TO +70°C OPERATING RANGE
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
CNC machining centres use automatic tool-changing spindles
to rapidly switch between different tools with characteristic
suited to different materials, work-pieces and cutting speeds.
To ensure that a new tool engages completely in order to
prevent damage to the tool, the work-piece or the spindle,
designers specified Contrinex’s NEW SMART inductive sensors.
Embedded within the body of the spindle, the sensor monitors
the position of the tool during changes, so that any non-
compliant measurement stop the process, triggering an alarm.
CUSTOMER APPLICATION
Modern machine-tool spindles offer CNC machine designers
huge flexibility, enabling individual machining centres to cope
with ranges of materials, batch sizes, work-pieces, tools and
cutting speeds that might previously have needed several
different machines. Successive cuts often call for different tool
characteristics, spindles with automatic tool-changing are key
to optimizing throughput.
A spring-loaded collet, actuated by a central drawbar that runs
the length of the spindle, retains the tool in position. Once the
tool to be changed is moved to its designated position in the
machine’s tool-storage magazine, an actuator pushes the
drawbar forward along its axis until the collet disengages,
releasing the tool. The spindle then moves to the location of
the new tool in the magazine and the process is reversed.
From time to time, the collet may fail to retract fully,
preventing the new tool from engaging completely. Failing to
detect and rectify the problem leads to expensive damage to
the tool, the workpiece and possibly the spindle. Spindle
manufacturers require a robust, fail-safe method of detecting
incomplete tool engagement in what is already a tightly
packed assembly.
CUSTOMER SOLUTION
Designers specified rugged inductive sensors from the
Contrinex Smart Sensor portfolio; a single metal-cased sensor,
embedded radially in the body of the spindle immediately
adjacent to the rear of the drawbar, performs the required
tasks. All Contrinex Smart Sensors feature IO-Link connectivity,
providing a single, industry-standard interface to the machine
control system.
The sensor operates as a high-precision distance-
measurement device; its target is a longitudinally inclined face
on the circumference of the drawbar. As the drawbar moves
forward, the distance to the inclined faces changes in direct
proportion to the distance moved. With a sensing distance of
up to 6 mm and a dynamic resolution of ±5.5 micrometres, the
sensor delivers a highly accurate 16-bit digital output, enabling
the drawbar position to be determined in real time.
At the time of initial calibration, the drawbar positions
corresponding to the two extremes of travel are recorded in
the sensor’s local data store. Thereafter, the sensor operates in
two distinct modes: During tool changes, the drawbar position
is monitored in real time, ensuring that its motion follows the
expected pattern; once the extreme of travel is reached in
either direction, the sensor de-energizes the actuator and
initiates the next stage of the process. Any non-compliant
measurements stop the process and trigger an alarm.
Contrinex inductive Smart Sensors are designed with the
needs of OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. On-board data storage
holds cumulative operating data for user-specified purposes,
including predictive maintenance. These highly versatile
sensors meet designers’ needs for a reliable, cost-effective and
compact solution that delivers ultimate peace of mind.
CUSTOMER VALUES
EMBEDDABLE INDUCTIVE SMART SENSOR MONITORS
DRAWBAR POSITION, DETECTING INCOMPLETE TOOL
ENGAGEMENT AND INHIBITING FURTHER MOTION BEFORE
DAMAGE OCCURS
SINGLE-SENSOR POSITIONAL-CONTROL SYSTEM IS NON-
COMPLEX AND HIGHLY AFFORDABLE
EMBEDDABLE M12 SENSOR FITS SNUGLY IN THE LIMITED
SPACE AVAILABLE
INDUSTRY-STANDARD IO-LINK CONNECTIVITY PROVIDES A
SINGLE INTERFACE TO THE MACHINE CONTROL SYSTEM
CUMULATIVE OPERATING DATA FOR PREDICTIVE
MAINTENANCE, INCLUDING TEMPERATURE AND OPERATING-
CYCLE COUNT, IS RECORDED IN ON-BOARD DATA STORAGE
SENSOR CONFIGURATIONS ARE STORED LOCALLY, ALLOWING
PLUG-AND-PLAY REPLACEMENT OF SENSORS WHEN NEEDED
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-AND-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ROBUST, METAL-CASED INDUCTIVE SMART SENSORS ARE
IDEAL FOR EASY INTEGRATION
MULTI-CHANNEL MONITORING CIRCUITRY ALLOWS USERS TO
DEFINE UP TO 5 CUSTOMIZED OUTPUT THRESHOLDS
SOPHISTICATED SENSING ELECTRONICS DELIVER DYNAMIC
LINEAR-DISTANCE MEASUREMENTS WITH A RESOLUTION IN
THE MICRON RANGE
HIGH-SPEED DEVICE-TO-DEVICE COMMUNICATION ENABLES
DECENTRALIZED DATA-PROCESSING AND DECISION MAKING
DEDICATED SERVICE-DATA BLOCKS HOLD DEVICE-SPECIFIC
DATA INCLUDING PRODUCT ID, LOCATION AND SERIAL
NUMBER
VISIBLE LED INDICATORS ENABLE SENSORS TO SELF-IDENTIFY
ON DEMAND, SIMPLIFYING COMMISSIONING AND TROUBLE-
SHOOTING ROUTINES
INDUSTRY-STANDARD -25°C TO +70°C OPERATING RANGE
Contrinex inductive sensors help automation companies build
high-speed assembly equipment and their new SMART
Inductive sensors can help by being able to measure, monitor,
configure and help predict.
High-speed automated systems frequently use linear transfers
stages between workstations to maximise speed and accuracy
while keeping cost down. Designers of these linear transfer
units required a single-sensor positional-control solution that
controls both high-speed movements as the slide approaches
the critical area, where it slows down and also to provide high-
precision final positioning.
To achieve this, Contrinex’s inductive SMART Sensors were
selected. A single smart sensor with IO-Link connectivity and
multiple user-configurable outputs performs both the
required tasks in a highly cost-effective manner.
CUSTOMER APPLICATION
Automation engineers often face a three-way balancing act
when designing equipment, trying to maximise speed and
accuracy while keeping cost at acceptable levels. Position
control is no exception – high-performance systems typically
rely on linear or rotary encoders to deliver the required
positional accuracy, and these can be expensive, particularly
when both coarse and fine positioning is needed.
Using a secondary sensor for coarse-positional control is a
commonly used, although inelegant, solution to the problem.
It also increases complexity and cost, while reducing the
overall reliability of the system. Alternatively, designers
maintain accuracy without increasing cost by reducing travel
speeds during coarse positioning, increasing the cycle time.
Neither approach is optimal.
Equipment manufacturers (OEMs) specifying high-speed
assembly equipment with multiple linear transfers between
workstations need an alternative solution. Using off-the-shelf
linear stages, they require a controlled, fast approach to the
critical areas and a slower, high-precision final positioning –
without increasing complexity or cost. An affordable single-
sensor solution is highly desirable.
CUSTOMER SOLUTION
The designers specified rugged inductive sensors from the
Contrinex SMART Sensor portfolio; a single sensor with IO-Link
connectivity and multiple user-configurable outputs performs
both the required tasks. Firstly, it initiates a controlled
deceleration as the carriage of a linear stage approaches the
specified workstation; it then switches to micrometer distance
resolution, positioning the stage accurately and precisely.
Contrinex inductive SMART Sensors are designed with the
needs of OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. A single metal-cased M12
sensor is embedded in one of the guide rails immediately
adjacent to each workstation. The sensor detects the presence
of the carriage as it begins to pass overhead, triggering the
deceleration and changing the sensing mode.
The sensor now operates as a high-precision distance-
measurement device; its target is an inclined face on the
underside of the carriage. As the carriage moves over the
sensor, the distance to the inclined faces changes in direct
proportion to the distance moved. With a sensing distance of
up to 6mm and a dynamic resolution of ±5.5 micrometres, the
sensor delivers a highly accurate 16-bit digital output, enabling
the carriage position to be determined in real-time.
Once the initial set-up is completed, each sensor’s
configuration is stored automatically on the local IO-Link
Master; this allows plug-and-play replacement of sensors
should the need arise, without any loss of functionality and
without any need for recalibration. These highly versatile
sensors meet designers’ needs for a highly reliable, cost-
effective and non-complex solution without compromising
operational performance.
CUSTOMER VALUES
EMBEDDABLE INDUCTIVE SMART SENSOR ENSURE ACCURATE
POSITIONING OF LINEAR STAGES WITHOUT COMPROMISING
OPERATIONAL SPEED
SINGLE-SENSOR POSITIONAL-CONTROL SYSTEM IS NON-
COMPLEX AND HIGHLY AFFORDABLE
COMPACT EMBEDDABLE M12 SENSORS FIT UNOBTRUSIVELY
AND EASILY INTO OFF-THE-SHELF LINEAR GUIDE RAILS
INDUSTRY-STANDARD IO-LINK CONNECTIVITY PROVIDES A
SINGLE INTERFACE TO THE MACHINE CONTROL SYSTEM.
SENSOR CONFIGURATIONS ARE STORED LOCALLY, ALLOWING
PLUG-AND-PLAY REPLACEMENT OF SENSORS WHEN NEEDED.
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-AND-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ON-BOARD DATA STORAGE HOLDS CUMULATIVE OPERATING
DATA FOR USER-SPECIFIED PURPOSES, INCLUDING PREDICTIVE
MAINTENANCE
ROBUST, METAL-CASED INDUCTIVE SMART SENSORS ARE
IDEAL FOR EASY INTEGRATION
MULTI-CHANNEL MONITORING CIRCUITRY ALLOWS USERS TO
DEFINE UP TO 5 CUSTOMISED OUTPUT THRESHOLDS
SOPHISTICATED SENSING ELECTRONICS DELIVER DYNAMIC
LINEAR-DISTANCE MEASUREMENTS WITH A RESOLUTION IN
THE MICRON RANGE
HIGH-SPEED DEVICE-TO-DEVICE COMMUNICATION ENABLES
DECENTRALIZED DATA-PROCESSING AND DECISION MAKING
DEDICATED SERVICE-DATA BLOCKS HOLD DEVICE-SPECIFIC
DATA INCLUDING PRODUCT ID, LOCATION AND SERIAL
NUMBER
VISIBLE LED INDICATORS ENABLE SENSORS TO SELF-IDENTIFY
ON DEMAND, SIMPLIFYING COMMISSIONING AND TROUBLE-
SHOOTING ROUTINES
INDUSTRY-STANDARD -25°C TO +70°C OPERATING RANGE
CLICK HERE TO VIEW THIS SENSOR ON
CONTRINEX’S WEBSITE, OR CALL US TO HELP
GUIDE YOU THROUGH SELECTION, ANSWER
QUESTIONS, OR TO HELP YOU
#MAKESENSEOFSENSORS:
SMART INDUCTIVE SENSORS
CONTRINEX’S NEW CLOUD-READY SMART
SENSORS ARE PERFECT FOR LIVE DATA
MONITORING FROM THE HEART OF AN
APPLICATION WITH FAST AND SIMPLE SET-UP.
PRODUCT ADVANTAGES
SENSORS COMPATIBLE WITH INDUSTRY-STANDARD SMART
SENSOR PROFILE: IO-LINK SSP 3.3, DIGITAL MEASURING
SENSORS (DMS) WITH DISABLE FUNCTION
CLOUD-READY SENSORS WITH PERFORMANCE EQUIVALENT
TO A CONVENTIONAL ANALOG OUTPUT SENSOR, BUT WITH A
DIGITAL DATA OUTPUT
32-BIT PROCESS DATA INPUT (PDI) WITH 16-BIT VALUES FOR
DISTANCE, COUNTER AND TEMPERATURE, 8-BIT VALUES FOR
MEASUREMENT DATA SCALING AND 8-BIT VALUES FOR OUTPUT
SWITCHING SIGNAL, SWITCHING SIGNAL AND CONFIGURABLE
ALARM FLAGS. THE 8-BIT PROCESS DATA OUTPUT (PDO)
INCLUDES A DISABLE FUNCTION.
USER-DEFINABLE IO-LINK PARAMETERS: DISTANCE,
COUNTER, TEMPERATURE AND SWITCH-POINT MODE
(DEACTIVATED, SINGLE POINT, WINDOW MODE, TWO-POINT
MODE)
PRE-DEFINED PREDICTIVE MAINTENANCE FUNCTIONS:
OPERATING HOURS SINCE FIRST/LAST POWER-UP, SWITCHING
COUNTER SINCE FIRST/LAST POWER-UP, SENSOR AUTO-
DIAGNOSTIC ALARM
SMART INDUCTIVE SENSORS - CLOUD-READY
SMART SENSORS WITH FAST & SIMPLE SET-UP
Contrinex’s new cloud-ready Smart Sensors are perfect for live
data monitoring from the heart of an application. Simply by
configuring an IO-Link parameter, the user can output and
display sensor data in real time on any cloud dashboard.
Predictive maintenance features are available to help speed up
troubleshooting, reduce machine downtime and save cost. These
new smart sensors can be integrated into an enterprise resource
planning (ERP) or manufacturing execution system (MES).
Setup is fast and simple, as all data structures are compatible
with the IO-Link SSP 3.3 smart sensor profile for measuring
sensors with disable function.
CUSTOMER VALUES
HIGHLY ACCURATE, REPEATABLE SENSING PERFORMANCE IN
EMBEDDABLE INDUCTIVE SMART SENSORS DIFFERENTIATE
CLEARLY BETWEEN TARGET MATERIAL TYPES, DETECTING
NON-FERROUS METAL AND TRIGGERING SEPARATION
ACCURATELY AND RELIABLY
A SINGLE ARRAY OF SENSORS PROVIDES CONTINUOUS
DETECTION ACROSS THE FULL WIDTH OF A CONVEYOR
SMART SENSORS EASILY ABLE TO IDENTIFY MATERIAL ON
FAST-MOVING CONVEYORS THANKS TO HIGH SENSING SPEED
INDUSTRY-STANDARD IO-LINK CONNECTIVITY PROVIDES A
SINGLE INTERFACE TO THE MACHINE CONTROL SYSTEM
CUMULATIVE OPERATING DATA FOR PREDICTIVE
MAINTENANCE, INCLUDING TEMPERATURE AND OPERATING-
CYCLE COUNT, IS RECORDED IN ON-BOARD DATA STORAGE
SENSOR CONFIGURATIONS ARE STORED LOCALLY, ALLOWING
PLUG-AND-PLAY REPLACEMENT OF SENSORS WHEN NEEDED
PROVEN TECHNOLOGY ENSURES HIGHLY RELIABLE FIT-AND-
FORGET OPERATION WITH NO MANUAL INTERVENTION
PRODUCT ADVANTAGES
ROBUST, METAL-CASED INDUCTIVE SMART SENSORS ARE
IDEAL FOR EASY INTEGRATION
MULTI-CHANNEL MONITORING CIRCUITRY ALLOWS USERS TO
DEFINE 5 CUSTOMISED OUTPUT THRESHOLDS
SOPHISTICATED SENSING ELECTRONICS DELIVER HIGH-
PRECISION ANALOGUE OUTPUT SIGNALS
HIGH-SPEED DEVICE-TO-DEVICE COMMUNICATION ENABLES
DECENTRALISED DATA-PROCESSING AND DECISION MAKING
SMART SENSORS ARE INDIVIDUALLY SHIELDED AND EMC
IMMUNE, ELIMINATING INTERFERENCE WHEN MULTIPLE
DEVICES OPERATE IN CLOSE PROXIMITY
DEDICATED SERVICE-DATA BLOCKS HOLD DEVICE-SPECIFIC
DATA INCLUDING PRODUCT ID, LOCATION & SERIAL NUMBER
LEDS ENABLE SENSORS TO SELF-IDENTIFY ON DEMAND,
SIMPLIFYING COMMISSIONING & TROUBLE-SHOOTING
INDUSTRY-STANDARD -25°C TO +70°C OPERATING RANGE
The recycling industry utilises automation to reduce the cost of
sorting and separating mixed-metal scrap. One such solution
is automated sorting, which requires sensors which both
operate accurately and at high speed to identify and separate
fast-moving streams of ferrous and non-ferrous material in a
single pass. Rugged inductive Smart Sensors from Contrinex,
are embedded immediately below the delivery belt to provide
continuous high-speed detection across the full width of a
conveyor belt.
CUSTOMER APPLICATION
The global recycling industry relies upon advances in
technology to automate waste-recovery operations. These
make it economic to recover an ever greater proportion of
domestic and industrial waste. Waste-management
companies are always looking for more affordable alternatives
for sorting and separating mixed-metal scrap as some of the
existing processes, while effective, are inflexible and expensive.
Advances in sensor technology and capabilities have seen the
introduction of induction sorting, a process that identifies and
separates different types of metallic material. A fast-moving
conveyor carries pre-sized waste over a bank of inductive
sensors mounted below the belt; the sensors detect and
identify any non-ferrous material, which is subsequently
ejected and separated by a targeted air-knife.
To take full advantage of the process, OEM equipment builders
require robust sensors that differentiate accurately and at high
speed between ferrous and non-ferrous material, allowing a
single bank of sensors to process mixed-metal waste in a
single pass. As the sensors may operate independently or in
combination with other sensing technologies, an industry-
standard communication interface is highly desirable.
CUSTOMER SOLUTION
Designers specified rugged inductive sensors from the
Contrinex Smart Sensor portfolio; an array of 50 metal-cased
sensors, embedded in a grid pattern immediately below the
belt, provides continuous detection across the full width of the
conveyor. Best-practice electronic design ensures that Smart
Sensors are individually shielded and EMC immune,
eliminating interference when multiple devices operate in
close proximity.
Mounted only a few millimetres from the target as it passes
overhead, these M18 devices, which have a nominal sensing
distance of 10 mm for carbon steel, generate analogue output
signals that vary according to the material type. The Smart
Sensors are easily able to accommodate the required range of
conveyor speeds.
IO-Link connectivity, standard across the range, provides an
industry-standard interface to the machine control system,
triggering the appropriate air-knives as pieces of non-ferrous
material reach the separator. During initial calibration, each
sensor’s configuration is stored automatically on the local IO-
Link Master; this allows plug-and-play replacement of sensors
should the need arise, without any loss of functionality and
without any need for recalibration.
Contrinex inductive Smart Sensors are designed with the
needs of OEMs and system integrators in mind and provide an
unobtrusive fit-and-forget solution. On-board data storage
holds cumulative operating data for user-specified purposes,
including predictive maintenance. These highly versatile
sensors meet designers’ needs for a robust and cost-effective
solution that delivers exceptional accuracy and reliability in a
particularly challenging environment.
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
