(0121) 58 222 58 SALES@PLUSAUTOMATION.CO.UK
© 2020 - PLUS AUTOMATION LIMITED®
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 SMART inductive sensors help industrial equipment designers find new ways to reduce cycle times without compromising safety or increasing cost. Automation engineers designing a monitoring system for pneumatic cylinders need to identify deviations from the optimal deceleration profile without increasing complexity or cost. The rugged, multi- mode Smart Sensors from Contrinex embedded into the cylinder, identify adverse trends in the deceleration profile, providing a cost-effective, unobtrusive fit-and-forget solution. CUSTOMER APPLICATION Industrial automation enables the optimisation of machine performance, with equipment designers always looking for ways to reduce cycle times without compromising safety at little or ideally no increased cost. Pneumatic systems are a typical challenge to engineers where they are commonly used to move parts between workstations using an optimal combination of cylinder size, travel speed and air consumption. The maximum piston travel speed for a given load is generally known, but optimising the rate of acceleration and, particularly, deceleration at each end of the travel brings additional factors into play. Stopping too suddenly generates high internal forces that may overload the cylinder, while insufficient deceleration results in a sudden impact when the load reaches the limit of the allowed travel. Cushioning, where an internal damping mechanism is designed into the cylinder, enables an optimum level of deceleration to be achieved, but requires an application- specific adjustment during commissioning. As a cylinder wears during service, its set-up becomes suboptimal, necessitating readjustment. Process engineers require a monitoring capability that identifies deviations from the specified deceleration profile; ideally, this should utilise existing sensors to avoid increased complexity and cost.
CUSTOMER SOLUTION The designers identified and specified a highly versatile, cost- effective solution to the problem, namely Contrinex’s SMART Sensors. The multiple sensing modes offered in a single inductive sensor provide all the answers in a compact and robust package, ideally suited to the demanding environment. A sensor is embedded at each end of the cylinder to provide high-resolution, real-time measurement of piston displacement and also provide a cumulative data store that allows process drift to be monitored. Designed with the needs of OEMs and system integrators in mind, Smart Sensors provide an unobtrusive fit-and-forget solution. As the piston approaches the deceleration zone, engineers use the Smart Sensor’s inbuilt one-shot timer feature to trigger a rapid succession of displacement measurements. Taken at known time intervals and recorded in the sensor’s data store, these measurements provide a velocity gradient during the deceleration phase that, plotted over multiple process cycles, identifies deviations from the piston’s optimal deceleration profile. Consequently, readjustment is scheduled only when necessary, minimising maintenance costs. Mounted immediately adjacent to the piston travel path, these embeddable, metal-cased M12 Smart Sensors, which have a nominal 6-mm sensing distance for carbon steel, are highly robust and resistant to vibration and mechanical shock. Capable of measuring both lateral and axial displacement directly, these devices also offer process engineers the option to monitor temperature, vibration and process cycle count. IO-Link connectivity, standard across the range, provides an industry-standard interface to the machine control system; the Smart Sensor’s dual-channel capability also enables a local alarm to be triggered by an event-based exception, for example, over-temperature or excessive piston travel. 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.
CUSTOMER VALUES MULTIPLE SENSING MODES IN A SINGLE EMBEDDABLE DEVICE, ELIMINATING INCREASED COMPLEXITY AND COST. ONE-SHOT TIMER FEATURE ALLOWS PROCESS ENGINEERS TO IDENTIFY DEVIATIONS FROM THE OPTIMAL DECELERATION PROFILE, MINIMISING MAINTENANCE EXPENSE. DUAL-CHANNEL CAPABILITY ENABLES A LOCAL ALARM TO BE TRIGGERED BY AN EVENT-BASED EXCEPTION, AVOIDING A PLANT-WIDE SHUT-DOWN. 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 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 DECENTRALISED DATA-PROCESSING AND DECISION MAKING 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
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 SENSOR PROVIDE ACCURATE POSITIONING OF LINEAR STAGES AND MAINTAIN 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
CONTRINEXS 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 CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk (0121) 58 222 58
Helping you #Make Sense of Sensors
Order Placement   Orders@PLUSAx.co.uk 0121 582 0835   Sales & Technical Product selection & application advice Sales@PLUSAx.co.uk 0121 58 222 58 Customer Service Price & Delivery / Lead time CustomerService@PLUSAx.co.uk 0121 582 0835 Contact Us
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
Contrinex SMART inductive sensors help industrial equipment designers find new ways to reduce cycle times without compromising safety or increasing cost. Automation engineers designing a monitoring system for pneumatic cylinders need to identify deviations from the optimal deceleration profile without increasing complexity or cost. The rugged, multi- mode Smart Sensors from Contrinex embedded into the cylinder, identify adverse trends in the deceleration profile, providing a cost-effective, unobtrusive fit-and-forget solution. CUSTOMER APPLICATION Industrial automation enables the optimisation of machine performance, with equipment designers always looking for ways to reduce cycle times without compromising safety at little or ideally no increased cost. Pneumatic systems are a typical challenge to engineers where they are commonly used to move parts between workstations using an optimal combination of cylinder size, travel speed and air consumption. The maximum piston travel speed for a given load is generally known, but optimising the rate of acceleration and, particularly, deceleration at each end of the travel brings additional factors into play. Stopping too suddenly generates high internal forces that may overload the cylinder, while insufficient deceleration results in a sudden impact when the load reaches the limit of the allowed travel. Cushioning, where an internal damping mechanism is designed into the cylinder, enables an optimum level of deceleration to be achieved, but requires an application- specific adjustment during commissioning. As a cylinder wears during service, its set-up becomes suboptimal, necessitating readjustment. Process engineers require a monitoring capability that identifies deviations from the specified deceleration profile; ideally, this should utilise existing sensors to avoid increased complexity and cost.
CUSTOMER SOLUTION The designers identified and specified a highly versatile, cost- effective solution to the problem, namely Contrinex’s SMART Sensors. The multiple sensing modes offered in a single inductive sensor provide all the answers in a compact and robust package, ideally suited to the demanding environment. A sensor is embedded at each end of the cylinder to provide high-resolution, real-time measurement of piston displacement and also provide a cumulative data store that allows process drift to be monitored. Designed with the needs of OEMs and system integrators in mind, Smart Sensors provide an unobtrusive fit-and-forget solution. As the piston approaches the deceleration zone, engineers use the Smart Sensor’s inbuilt one-shot timer feature to trigger a rapid succession of displacement measurements. Taken at known time intervals and recorded in the sensor’s data store, these measurements provide a velocity gradient during the deceleration phase that, plotted over multiple process cycles, identifies deviations from the piston’s optimal deceleration profile. Consequently, readjustment is scheduled only when necessary, minimising maintenance costs. Mounted immediately adjacent to the piston travel path, these embeddable, metal-cased M12 Smart Sensors, which have a nominal 6-mm sensing distance for carbon steel, are highly robust and resistant to vibration and mechanical shock. Capable of measuring both lateral and axial displacement directly, these devices also offer process engineers the option to monitor temperature, vibration and process cycle count. IO-Link connectivity, standard across the range, provides an industry-standard interface to the machine control system; the Smart Sensor’s dual-channel capability also enables a local alarm to be triggered by an event-based exception, for example, over-temperature or excessive piston travel. 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.
CUSTOMER VALUES MULTIPLE SENSING MODES IN A SINGLE EMBEDDABLE DEVICE, ELIMINATING INCREASED COMPLEXITY AND COST. ONE-SHOT TIMER FEATURE ALLOWS PROCESS ENGINEERS TO IDENTIFY DEVIATIONS FROM THE OPTIMAL DECELERATION PROFILE, MINIMISING MAINTENANCE EXPENSE. DUAL-CHANNEL CAPABILITY ENABLES A LOCAL ALARM TO BE TRIGGERED BY AN EVENT-BASED EXCEPTION, AVOIDING A PLANT-WIDE SHUT-DOWN. 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 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 CONTRINEXS WEBSITE, OR CALL US TO HELP GUIDE YOU THROUGH SELECTION, ANSWER QUESTIONS, OR TO HELP YOU #MAKESENSEOFSENSORS:

SMART INDUCTIVE SENSORS

CONTRINEXS 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 CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk 0121 58 222 58 Click for Brochure Smart Sensors Brochure