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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:
The sensor is configured with an industry-standard PNP normally-open interface, and connection to the turbine’s control systems is via an integral M12 connector and PUR- sheathed cable. This allows easy removal and replacement during routine maintenance. The sensor is corrosion-resistant and impervious to water ingress. Reliability has been excellent. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for a simple, fit-and-forget system.
A range of multi-purpose off-road tractors allows the driver to choose between two-wheel or four-wheel steering. When selecting two-wheel steering using the front wheels only, the rear axle is locked in the straight-ahead position. Before the axle is locked, rugged inductive sensors from Contrinex detect the straight-ahead position accurately and reliably, ensuring precise alignment of the tractor’s steering geometry. CUSTOMER APPLICATION Modern multi-purpose off-road utility vehicles are exceptionally versatile, offering four-wheel drive and both front and rear-wheel steering. Reliable operation all year round, on all types of terrain and in all weather conditions, is essential as typical tasks include bulk-load transportation and agricultural engineering. Extreme conditions often demand increased manoeuvrability; for maximum control, the driver can engage four-wheel steering when required. When reverting to the default two- wheel steering configuration, the rear axle must be locked in the straight-ahead position to prevent misalignment of the rear wheels. A rugged, reliable and accurate sensor system is required to detect the straight-ahead position of the rear axle before it is locked. The sensor must withstand significant mechanical shock and vibration and must also be impervious to water ingress. Additionally, it should accommodate the extremes of temperature experienced during all-year-round operation.
CUSTOMER VALUES Reliable, repeatable sensing performance in demanding operating conditions Fit-and-forget operation with minimal maintenance Technically elegant, cost-effective solution requiring minimal re-engineering PRODUCT ADVANTAGES 2mm sensing distance eliminates the possibility of accidental damage to the sensor Rugged, robust stainless-steel sensor with integral M8 connector Affordable high-performance sensor with exceptional reliability - Fit-and-forget operation with minimal maintenance
Configured with an industry-standard PNP normally-open interface, the sensor features an integral M8 connector and connects to the vehicle’s central controller via a flexible PVC- sheathed cable. Adding the sensor requires minimal modification to the vehicle’s control systems, and maintenance is simple and speedy. The sensor detects the straight-ahead position of the vehicle’s rear axle repeatably and accurately, ensuring correct, reliable engagement of two-wheel steering. Contrinex inductive sensors provide the customer with a cost-effective fit-and- forget solution to a challenging problem.
CUSTOMER SOLUTION Inductive sensors from the Contrinex ‘Basic’ range are rugged, reliable and accommodate the required extremes of temperature; with an M8-sized sensor being ideal for this application. A V2A/AISI 303 stainless-steel body and vacuum- encapsulated electronics, make it particularly suitable for the mechanically demanding environment, and it is rated for operation at temperatures between -25ºC (-13ºF) and 70ºC (158ºF). A narrow flange is attached to each end of the vehicle’s hydraulic power-steering rack. The sensor is mounted immediately below one end of the rack and detects the position of the flange as it passes over the sensing face. The sensing distance of 2mm eliminates any possibility of accidental collision with the flange.
CUSTOMER VALUES Simple sensor system providing contactless operation Robust construction withstands corrosion and water ingress Exceptionally reliable, fit-and-forget operation in a remote, harsh environment PRODUCT ADVANTAGES Extremely robust, impact and abrasion resistant IP68/ IP69K rated housing. Corrosion-resistant, one-piece AISI 304 (V2A) stainless-steel body State-of-the-art ASIC technology ensures exceptional in-service reliability 10 mm sensing range available in physically small sensor Excellent resistance to extreme operating conditions
A single sensor is mounted in each turbine head, immediately adjacent to the main mounting ring for the blade assembly. As the blades rotate, so does the mounting ring, and the sensor detects the presence of each mounting bolt as it passes the sensing face. The angular spacing of the bolts is known. Measuring the time that elapses between successive signals thus allows the rotation velocity of the blades to be calculated.
WATCH THE VIDEO TO SEE THE UNIQUE ROBUSTNESS DEMONSTRATED
WATCH THE VIDEO TO SEE THE UNIQUE ROBUSTNESS SURVIVE A HAMMERING
700 SERIES EXTREME ROBUST STAINLESS-STEEL INDUCTIVE SENSORS - ‘HAMMER HOME AN ADVANTAGE
PRODUCT ADVANTAGES World class performance in extreme environments Corrosion-resistant, AISI 304 V2A stainless-steel body Extremely robust one-piece, stainless-steel housing - impact and abrasion resistant - IP68/ IP69K rated Factor 1 with both ferrous and non-ferrous materials including aluminium & brass for extended sensing Can operate in close proximity without interference IO-Link interface included – Ideal for Industry 4
Exceptional performance combined with unique robustness make Contrinex’s Full stainless-steel EXTREME inductive sensors the solution where reliability is valued. Thanks to their housing being machined from a single piece of V2A/AISI 303 stainless-steel and a hermetically sealed cable entry, Extreme sensors are corrosion-resistant, impervious to oil, and pressure-resistant to 100 bar. Rugged, reliable and highly accurate, the EXTREME range is at home in the most challenging applications. Developed to withstand the harshest industrial operating conditions, Extreme sensors are rated to IP68 and IP69K, delivering fit- and-forget performance with minimal downtime. With operating distances up to 40 mm, the Extreme range senses both ferrous and non-ferrous materials with Factor 1 performance, and is available in sizes from M8 to M30 and C23.
CUSTOMER SOLUTION Rugged Full stainless-steel inductive sensors from the Contrinex Extreme range are ideal for this application. Highly reliable and rated to IP68 or IP69K, these units provide a cost- effective alternative to tradition rotary-encoder technology. A one-piece M18-diameter AISI 304 (V2A) stainless-steel body and vacuum-encapsulated electronics make this device particularly suitable for the hostile environment, and the sensing distance of 10 mm allows fully contactless operation.
Modern wind turbines operate continuously in remote, highly demanding environments. Exceptional reliability is essential as opportunities for maintenance are limited. Turbine rotation velocity is a key operating parameter and manufacturers require robust sensor systems that provide accurate measurement in real-time. Contrinex’s rugged inductive sensors provide presence-sensing systems which withstand harsh exposed conditions, both onshore and offshore, while delivering the required accuracy and reliability. CUSTOMER APPLICATION A manufacturer of wind turbines provides engineering support for systems installed around the globe. The company’s field-service capability is backed by 24-hour remote data monitoring, allowing early detection of potential problems. Given the remote location of most wind farms, monitoring systems must be exceptionally reliable, as site attendance is infrequent. Turbine rotation velocity is a key operating parameter, and the company requires robust sensor systems that provide accurate data in real-time. Traditional rotary-encoder technology is unsuitable as sensors do not withstand prolonged exposure to outdoor, often salt-laden, environments. In addition, turbine rotation speeds are relatively low, typically requiring more complex mechanical encoders. The company requires a simple, contactless system that provides fit-and-forget operation with extended maintenance intervals. Sensors must be mechanically robust and must withstand prolonged exposure to harsh outdoor conditions including seawater. An industry-standard interface is highly desirable to avoid the need for specialised control systems.
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 stainless steel 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 stainless-steel 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.
CUSTOMER VALUES Elimination of human error prevents truck being driven in an unsafe condition. Highly reliable sensing performance in highly demanding conditions Corrosion-resistant sensors withstand water, ice, mud and salt Highly cost-effective solution to a potentially serious problem PRODUCT ADVANTAGES Extremely robust, impact and abrasion resistant IP68/ IP69K rated housing. Corrosion-resistant, V2A/ AISI 304 stainless-steel, food-compatible body. Long operating distance of 7mm in a small & slim stainless-steel 20x 32x 8mm housing. Robust, metal-cased inductive proximity sensors suitable for easy integration Factor 1 - Consistent sensing, irrespective of whether the target is steel or aluminium. Reliable, compact vibration-resistant sensors IO-Link interface included – Ideal for Industry 4
Stainless-steel-braided hydraulic hoses for water heaters undergo over-pressure testing at the final stage of manufacture. Before pressure is applied, a multi-sensor system checks each hose assembly to ensure that the correct mechanical parts have been fitted. Applying high pressure to an incomplete assembly could result in catastrophic failure, damaging test equipment and putting operators at risk of injury. CUSTOMER APPLICATION A manufacturer of stainless-steel-braided high-pressure hoses for water heaters carries out mandatory over-pressure testing on every hose assembly. If either of the mechanical unions fitted to the ends of each hose is incorrectly assembled, it will leak under pressure. Occasionally, a component is omitted entirely, making a hose liable to fail catastrophically under high pressure. To avoid damaging test equipment and endangering personnel, a sensor system must confirm the presence of three critical parts on each union before testing commences. Each extra test extends the process cycle time. The customer requires a single test fixture capable of carrying out three presence checks concurrently, minimizing the additional cost. The three critical parts, made from stainless steel, carbon steel and brass, respectively, are positioned in close proximity when assembled. Access is limited; the three sensors must be small, yet sense these materials reliably at distances up to 6mm (0.25in)
Finally, to ensure reliable detection of the stainless-steel collar, an M8-diameter sensor from the Extreme range (Full stainless-steel family) was chosen. Its one-piece AISI 303 (V2A) stainless-steel construction is combined with an extended operating distance of 6mm.
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 Reliable, compact vibration-resistant sensors IO-Link interface included – Ideal for Industry 4
Customer Solution By mounting three separate M8- and C5-sized Contrinex inductive sensors in a single fixture, all the demands of this application can be met in full. Each sensor is chosen for its combination of size, sensing distance and reliable detection of one of the three different materials. To detect the brass union nut, an M8-diameter sensor from the Basic range (Extra Distance family) with a 4mm sensing distance is an excellent choice. Fully embeddable with chrome-plated nickel-silver bodies and PBTP sensing faces, this sensor has a correction factor of 1.0 for brass, outperforming competitors. For detecting the steel spring, a 5mm-square-section sensor from the Miniature range (Classics family) is an ideal option. Embedding the sensor makes optimal use of its 1.5mm sensing distance, and its chrome-plated brass body is well- suited to the environment.
Each sensor is configured with an industry-standard PNP normally-open interface and features a hermetically sealed cable entry. All three are connected to the customer’s control equipment via PUR-sheathed cables. Delivering the required detection capabilities and sensing distances in small-bodied sensors enables Contrinex to solve a previously insoluble problem.
Hook loader trucks utilise a hydraulic system for loading and unloading a demountable container. Once the container is correctly positioned on the vehicle’s load bed, interlocks engage with its base, securing it in position. Contrinex’s rugged sensor systems detect full engagement of the interlocks, ensuring the truck is safely loaded prior to driving away. Therefore, the sensors must be mechanically robust and able to withstand harsh outdoor conditions. CUSTOMER APPLICATION A specialist vehicle builder manufactures hydraulic hook-lift systems for commercial trucks. A hook loader truck employs a series of hydraulic rams to hook, lift and pull a demountable container onto the vehicle’s load bed; a full container may weigh up to 30 tons. Hook loader trucks operate all year round, often in harsh environments such as demolition and construction sites. Hook-lift systems are typically semi-automated. The driver positions the truck, engages the hook with the container and initiates the lifting sequence. Once the container is pulled onto the load bed, two interlock mechanisms, mounted on the truck chassis, actuate and engage with the container body. Once the interlocks are fully engaged, the container is secure and the truck may be driven safely. A highly reliable sensor system must detect the position of the interlocks, ensuring that they are fully engaged before the truck drives away. Sensors must be robust and must withstand water, mud, dirt and ice. They may also be subject to mechanical shock and vibration.
CUSTOMER VALUES Efficient, fault-free assembly. No sensor-related downtime. Digital communication without needing special cabling. Outstanding process monitoring & control capabilities. Fast, easy set-up and reconfiguration. PRODUCT ADVANTAGES Extremely robust, impact and abrasion resistant IP68/ IP69K rated housing. Corrosion-resistant, V4A/ AISI 316L stainless-steel, food-compatible body on C23 and available as an option on cyclindrical sensors. Long operating distance of 7mm in a small & slim stainless-steel 20x 32x 8mm housing. Robust, metal-cased inductive proximity sensors suitable for easy integration Factor 1 - Consistent sensing, irrespective of whether the target is steel or aluminium. Reliable, compact vibration-resistant sensors IO-Link interface included – Ideal for Industry 4
Fault-free assembly is ensured, downtime minimised and assembly speed increased 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.
Click for Video Click for Demo Video
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. 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
THE INNOVATIVE INDUCTIVE SENSOR FAMILY, WHICH IS SO IMPACT AND ABRASION RESISTANT THAT YOU CAN USE IT TO HAMMER IN NAILS - IMAGINE HOW THEY CAN REDUCE MACHINE DOWN-TIME.

700 SERIES - ‘EXTREME ROBUST

STAINLESS-STEEL INDUCTIVE SENSORS

CUSTOMER SOLUTION Rugged Full stainless-steel inductive sensors from the Contrinex Extreme 700 Series are designed for demanding or even exceptionally demanding environments, making them ideal for this application. Highly reliable and IP68 / IP69K rated, these embeddable units feature one-piece V2A (AISI 304) stainless-steel construction with vacuum-encapsulated electronics, making them well suited to the hostile operating conditions. During operation, a double-ended ram drives a pair of interlock bolts into position. On either side of the truck, two M18-diameter sensors are mounted in the wall of each bolt housing; one detects the bolt as it reaches the fully engaged position; the other detects it in the fully retracted position. A second ram drives a rotating lock mechanism to engage with the vehicle chassis; a further two sensors detect the position of a cam on the locking shaft as it rotates. Each sensor is configured with an industry-standard PNP normally-open interface, and connection to the truck’s hydraulic control system is via an integral M12 connector and PUR-sheathed cable. This allows easy removal and replacement during routine maintenance.
Rugged sensor construction ensures excellent resistance to shock and vibration and a sensing distance of up to 10mm eliminates any risk of accidental collision with moving parts. These devices are corrosion-resistant and impervious to water ingress, mud, ice and salt. Reliability has been excellent. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for a simple, fit- and-forget system.
Helping you #Make Sense of Sensors
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CLICK ON AN IMAGE TO VIEW THE BROCHURE OR A VIDEO, READ APPLICATION EXAMPLES BELOW, 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:

700 SERIES - ‘EXTREME

ROBUST STAINLESS-STEEL

INDUCTIVE SENSORS

THE INNOVATIVE INDUCTIVE SENSOR FAMILY, WHICH IS SO IMPACT AND ABRASION RESISTANT THAT YOU CAN USE IT TO HAMMER IN NAILS - IMAGINE HOW THEY CAN REDUCE MACHINE DOWN-TIME.
Fault-free assembly is ensured, downtime minimised and assembly speed increased 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 Rugged Full stainless-steel inductive sensors from the Contrinex Extreme 700 Series are designed for demanding or even exceptionally demanding environments, making them ideal for this application. Highly reliable and IP68 / IP69K rated, these embeddable units feature one-piece V2A (AISI 304) stainless-steel construction with vacuum-encapsulated electronics, making them well suited to the hostile operating conditions. During operation, a double-ended ram drives a pair of interlock bolts into position. On either side of the truck, two M18-diameter sensors are mounted in the wall of each bolt housing; one detects the bolt as it reaches the fully engaged position; the other detects it in the fully retracted position. A second ram drives a rotating lock mechanism to engage with the vehicle chassis; a further two sensors detect the position of a cam on the locking shaft as it rotates. Each sensor is configured with an industry-standard PNP normally-open interface, and connection to the truck’s hydraulic control system is via an integral M12 connector and PUR-sheathed cable. This allows easy removal and replacement during routine maintenance.
Hook loader trucks utilise a hydraulic system for loading and unloading a demountable container. Once the container is correctly positioned on the vehicle’s load bed, interlocks engage with its base, securing it in position. Contrinex’s rugged sensor systems detect full engagement of the interlocks, ensuring the truck is safely loaded prior to driving away. Therefore, the sensors must be mechanically robust and able to withstand harsh outdoor conditions. CUSTOMER APPLICATION A specialist vehicle builder manufactures hydraulic hook-lift systems for commercial trucks. A hook loader truck employs a series of hydraulic rams to hook, lift and pull a demountable container onto the vehicle’s load bed; a full container may weigh up to 30 tons. Hook loader trucks operate all year round, often in harsh environments such as demolition and construction sites. Hook-lift systems are typically semi-automated. The driver positions the truck, engages the hook with the container and initiates the lifting sequence. Once the container is pulled onto the load bed, two interlock mechanisms, mounted on the truck chassis, actuate and engage with the container body. Once the interlocks are fully engaged, the container is secure and the truck may be driven safely. A highly reliable sensor system must detect the position of the interlocks, ensuring that they are fully engaged before the truck drives away. Sensors must be robust and must withstand water, mud, dirt and ice. They may also be subject to mechanical shock and vibration.
Click for Brochure C23 Cubic - 700 Series - Extreme Click for Brochure 700 Series -  Extreme Robust
CUSTOMER VALUES Efficient, fault-free assembly. No sensor-related downtime. Digital communication without needing special cabling. Outstanding process monitoring & control capabilities. Fast, easy set-up and reconfiguration. PRODUCT ADVANTAGES Extremely robust, impact and abrasion resistant IP68/ IP69K rated housing. Corrosion-resistant, V4A/ AISI 316L stainless-steel, food-compatible body. Long operating distance of 7mm in a small & slim stainless-steel 20x 32x 8mm housing. Robust, metal-cased inductive proximity sensors suitable for easy integration Factor 1 - Consistent sensing, irrespective of whether the target is steel or aluminium. Reliable, compact vibration-resistant sensors IO-Link interface included for free – Ideal for Industry 4
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. 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
Click for Video Click for Demo Video
A range of multi-purpose off-road tractors allows the driver to choose between two-wheel or four-wheel steering. When selecting two-wheel steering using the front wheels only, the rear axle is locked in the straight-ahead position. Before the axle is locked, rugged inductive sensors from Contrinex detect the straight-ahead position accurately and reliably, ensuring precise alignment of the tractor’s steering geometry. CUSTOMER APPLICATION Modern multi-purpose off-road utility vehicles are exceptionally versatile, offering four-wheel drive and both front and rear-wheel steering. Reliable operation all year round, on all types of terrain and in all weather conditions, is essential as typical tasks include bulk-load transportation and agricultural engineering. Extreme conditions often demand increased manoeuvrability; for maximum control, the driver can engage four-wheel steering when required. When reverting to the default two- wheel steering configuration, the rear axle must be locked in the straight-ahead position to prevent misalignment of the rear wheels. A rugged, reliable and accurate sensor system is required to detect the straight-ahead position of the rear axle before it is locked. The sensor must withstand significant mechanical shock and vibration and must also be impervious to water ingress. Additionally, it should accommodate the extremes of temperature experienced during all-year-round operation.
CUSTOMER VALUES Reliable, repeatable sensing performance in demanding operating conditions Fit-and-forget operation with minimal maintenance Technically elegant, cost-effective solution requiring minimal re-engineering PRODUCT ADVANTAGES 2mm sensing distance eliminates the possibility of accidental damage to the sensor Rugged, robust stainless-steel sensor with integral M8 connector Affordable high-performance sensor with exceptional reliability - Fit-and-forget operation with minimal maintenance
Configured with an industry-standard PNP normally-open interface, the sensor features an integral M8 connector and connects to the vehicle’s central controller via a flexible PVC- sheathed cable. Adding the sensor requires minimal modification to the vehicle’s control systems, and maintenance is simple and speedy. The sensor detects the straight-ahead position of the vehicle’s rear axle repeatably and accurately, ensuring correct, reliable engagement of two-wheel steering. Contrinex inductive sensors provide the customer with a cost-effective fit-and- forget solution to a challenging problem.
CUSTOMER SOLUTION Inductive sensors from the Contrinex ‘Basic’ range are rugged, reliable and accommodate the required extremes of temperature; with an M8-sized sensor being ideal for this application. A V2A/AISI 303 stainless-steel body and vacuum- encapsulated electronics, make it particularly suitable for the mechanically demanding environment, and it is rated for operation at temperatures between -25ºC (-13ºF) and 70ºC (158ºF). A narrow flange is attached to each end of the vehicle’s hydraulic power-steering rack. The sensor is mounted immediately below one end of the rack and detects the position of the flange as it passes over the sensing face. The sensing distance of 2mm eliminates any possibility of accidental collision with the flange.
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 stainless steel 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 stainless-steel 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.
CUSTOMER VALUES Elimination of human error prevents truck being driven in an unsafe condition. Highly reliable sensing performance in highly demanding conditions Corrosion-resistant sensors withstand water, ice, mud and salt Highly cost-effective solution to a potentially serious problem PRODUCT ADVANTAGES Extremely robust, impact and abrasion resistant IP68/ IP69K rated housing. Corrosion-resistant, V4A/ AISI 316L stainless-steel, food-compatible body. Long operating distance of 7mm in a small & slim stainless-steel 20x 32x 8mm housing. Robust, metal-cased inductive proximity sensors suitable for easy integration Factor 1 - Consistent sensing, irrespective of whether the target is steel or aluminium. Reliable, compact vibration-resistant sensors IO-Link interface included for free – Ideal for Industry 4
Stainless-steel-braided hydraulic hoses for water heaters undergo over-pressure testing at the final stage of manufacture. Before pressure is applied, a multi-sensor system checks each hose assembly to ensure that the correct mechanical parts have been fitted. Applying high pressure to an incomplete assembly could result in catastrophic failure, damaging test equipment and putting operators at risk of injury. CUSTOMER APPLICATION A manufacturer of stainless-steel-braided high-pressure hoses for water heaters carries out mandatory over-pressure testing on every hose assembly. If either of the mechanical unions fitted to the ends of each hose is incorrectly assembled, it will leak under pressure. Occasionally, a component is omitted entirely, making a hose liable to fail catastrophically under high pressure. To avoid damaging test equipment and endangering personnel, a sensor system must confirm the presence of three critical parts on each union before testing commences. Each extra test extends the process cycle time. The customer requires a single test fixture capable of carrying out three presence checks concurrently, minimizing the additional cost. The three critical parts, made from stainless steel, carbon steel and brass, respectively, are positioned in close proximity when assembled. Access is limited; the three sensors must be small, yet sense these materials reliably at distances up to 6mm (0.25in)
Finally, to ensure reliable detection of the stainless-steel collar, an M8-diameter sensor from the Extreme range (Full stainless-steel family) was chosen. Its one-piece AISI 303 (V2A) stainless-steel construction is combined with an extended operating distance of 6mm.
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 Reliable, compact vibration-resistant sensors IO-Link interface included for free – Ideal for Industry 4
Customer Solution By mounting three separate M8- and C5-sized Contrinex inductive sensors in a single fixture, all the demands of this application can be met in full. Each sensor is chosen for its combination of size, sensing distance and reliable detection of one of the three different materials. To detect the brass union nut, an M8-diameter sensor from the Basic range (Extra Distance family) with a 4mm sensing distance is an excellent choice. Fully embeddable with chrome-plated nickel-silver bodies and PBTP sensing faces, this sensor has a correction factor of 1.0 for brass, outperforming competitors. For detecting the steel spring, a 5mm-square-section sensor from the Miniature range (Classics family) is an ideal option. Embedding the sensor makes optimal use of its 1.5mm sensing distance, and its chrome-plated brass body is well- suited to the environment.
Each sensor is configured with an industry-standard PNP normally-open interface and features a hermetically sealed cable entry. All three are connected to the customer’s control equipment via PUR-sheathed cables. Delivering the required detection capabilities and sensing distances in small-bodied sensors enables Contrinex to solve a previously insoluble problem.
700 SERIES EXTREME ROBUST STAINLESS-STEEL INDUCTIVE SENSORS - ‘HAMMER HOME AN ADVANTAGE
PRODUCT ADVANTAGES World class performance in extreme environments Corrosion-resistant, AISI 304 V2A stainless-steel body Extremely robust one-piece, stainless-steel housing - impact and abrasion resistant - IP68/ IP69K rated Factor 1 with both ferrous and non-ferrous materials including aluminium & brass for extended sensing Can operate in close proximity without interference IO-Link interface included – Ideal for Industry 4
Exceptional performance combined with unique robustness make Contrinex’s Full stainless-steel EXTREME inductive sensors the solution where reliability is valued. Thanks to their housing being machined from a single piece of V2A/AISI 303 stainless-steel and a hermetically sealed cable entry, Extreme sensors are corrosion-resistant, impervious to oil, and pressure- resistant to 100 bar. Rugged, reliable and highly accurate, the EXTREME range is at home in the most challenging applications. Developed to withstand the harshest industrial operating conditions, Extreme sensors are rated to IP68 and IP69K, delivering fit-and-forget performance with minimal downtime. With operating distances up to 40 mm, the Extreme range senses both ferrous and non-ferrous materials with Factor 1 performance, and is available in sizes from M8 to M30 and C23.
WATCH THE VIDEO TO SEE THE UNIQUE ROBUSTNESS DEMONSTRATED
WATCH THE VIDEO TO SEE THE UNIQUE ROBUSTNESS SURVIVE A HAMMERING
The sensor is configured with an industry-standard PNP normally-open interface, and connection to the turbine’s control systems is via an integral M12 connector and PUR- sheathed cable. This allows easy removal and replacement during routine maintenance. The sensor is corrosion-resistant and impervious to water ingress. Reliability has been excellent. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for a simple, fit-and-forget system.
CUSTOMER VALUES Simple sensor system providing contactless operation Robust construction withstands corrosion and water ingress Exceptionally reliable, fit-and-forget operation in a remote, harsh environment PRODUCT ADVANTAGES Extremely robust, impact and abrasion resistant IP68/ IP69K rated housing. Corrosion-resistant, one-piece AISI 304 (V2A) stainless-steel body State-of-the-art ASIC technology ensures exceptional in-service reliability 10 mm sensing range available in physically small sensor Excellent resistance to extreme operating conditions
A single sensor is mounted in each turbine head, immediately adjacent to the main mounting ring for the blade assembly. As the blades rotate, so does the mounting ring, and the sensor detects the presence of each mounting bolt as it passes the sensing face. The angular spacing of the bolts is known. Measuring the time that elapses between successive signals thus allows the rotation velocity of the blades to be calculated.
CUSTOMER SOLUTION Rugged Full stainless-steel inductive sensors from the Contrinex Extreme range are ideal for this application. Highly reliable and rated to IP68 or IP69K, these units provide a cost- effective alternative to tradition rotary-encoder technology. A one-piece M18-diameter AISI 304 (V2A) stainless-steel body and vacuum-encapsulated electronics make this device particularly suitable for the hostile environment, and the sensing distance of 10 mm allows fully contactless operation.
Modern wind turbines operate continuously in remote, highly demanding environments. Exceptional reliability is essential as opportunities for maintenance are limited. Turbine rotation velocity is a key operating parameter and manufacturers require robust sensor systems that provide accurate measurement in real-time. Contrinex’s rugged inductive sensors provide presence-sensing systems which withstand harsh exposed conditions, both onshore and offshore, while delivering the required accuracy and reliability. CUSTOMER APPLICATION A manufacturer of wind turbines provides engineering support for systems installed around the globe. The company’s field-service capability is backed by 24-hour remote data monitoring, allowing early detection of potential problems. Given the remote location of most wind farms, monitoring systems must be exceptionally reliable, as site attendance is infrequent. Turbine rotation velocity is a key operating parameter, and the company requires robust sensor systems that provide accurate data in real-time. Traditional rotary-encoder technology is unsuitable as sensors do not withstand prolonged exposure to outdoor, often salt-laden, environments. In addition, turbine rotation speeds are relatively low, typically requiring more complex mechanical encoders. The company requires a simple, contactless system that provides fit-and-forget operation with extended maintenance intervals. Sensors must be mechanically robust and must withstand prolonged exposure to harsh outdoor conditions including seawater. An industry-standard interface is highly desirable to avoid the need for specialised control systems.
Rugged sensor construction ensures excellent resistance to shock and vibration and a sensing distance of up to 10mm eliminates any risk of accidental collision with moving parts. These devices are corrosion-resistant and impervious to water ingress, mud, ice and salt. Reliability has been excellent. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for a simple, fit- and-forget system.