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HELPING YOU #MAKE SENSE OF SENSORS

EXAMPLE APPLICATIONS

TO ILLUSTRATE THE WIDE-VARIETY OF APPLICATIONS SOLVED USING CONTRINEX SENSORS, WE HAVE POSTED A LARGE SELECTION OF EXAMPLE APPLICATIONS WHICH CAN BE SEEN BY CLICKING ON AN IMAGE. BELOW ARE A SELECTION OF SOME OF THESE APPLICATIONS:
CUSTOMER VALUES SAFE, RELIABLE PERFORMANCE IN A DEMANDING OUTDOOR ENVIRONMENT NO LIKELIHOOD OF ACCIDENTAL DAMAGE ARISING IN OPERATION COST-EFFECTIVE SOLUTION, MAINTENANCE FREE PRODUCT ADVANTAGES CORROSION-RESISTANT STAINLESS-STEEL SENSOR RATED TO IP68 AND IP69K COST-EFFECTIVE HIGH-PERFORMANCE SENSOR WITH EXCEPTIONAL RELIABILITY BEST-IN-CLASS 20MM SENSING DISTANCE IN M30-DIAMETER HOUSING
CUSTOMER SOLUTION Contrinex inductive sensors are robust, reliable and offer extended sensing distances; the Full Inox Extreme range is ideal for this application. A one-piece M30-diameter stainless- steel body and vacuum-encapsulated electronics make this device particularly suitable for the mechanically demanding environment, and the sensing distance of 20mm eliminates any possibility of accidental collision in operation. A metal bracket is mounted externally on the actuating mechanism for the upper forks; the embeddable sensor is mounted immediately adjacent to one of the forks and detects the position of the actuating arm as it drives the fork into the vertical position. The AISI 303/V2A stainless-steel housing and sensing face are corrosion-resistant and impervious to water ingress; the sensor is IP68- and IP69K-rated. Configured with an industry-standard PNP normally-open interface, the Contrinex M30 Extreme sensor connects to the forklift’s lower-fork tilt-control systems via a flexible PUR- sheathed cable. A sealed cable entry ensures fit-and-forget capability during extended periods of operation in an outdoor environment. The Full Inox inductive sensor detects the vertical position of the forklift’s upper forks effectively and repeatably, ensuring safe, reliable operation of the unloading system. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for extreme robustness and extended sensing distance.
A container manufacturer uses a modified forklift, fitted with two sets of forks, for unloading bulk cargo. The lower forks support the container while the upper forks control the lid. When unloading, the lid opens and the lower forks rotate, tipping out the contents. A robust inductive sensor senses the position of the lid, ensuring it opens fully before emptying. CUSTOMER APPLICATION Containers are often used when transporting bulk cargo, including wood chip and biomass, by rail. A manufacturer of bulk-cargo containers has developed an innovative unloading system that uses only a modified forklift, eliminating the need for specialist handling equipment. The forklift has two pairs of lifting forks. The main forks, mounted conventionally, support the weight of the container as it is unloaded from a freight wagon; a second pair, mounted vertically above the lower pair, opens and closes the lid of the container. During opening, the upper forks lift the lid a short distance before tilting it vertically, leaving the top of the container completely unobstructed. The lower forks then rotate about a horizontal axis, tilting the container end-over-end and tipping the contents out. A robust and reliable sensor system is required to detect the vertical position of the lid before rotation begins. An extended sensing distance is essential to eliminate the possibility of mechanical damage.
CUSTOMER VALUES HIGHLY COST EFFECTIVE SOLUTION - SUBSTANTIALLY LOWER COST THAN OTHER DOUBLE-SHEET DETECTION SOLUTIONS SIMPLE SETUP AND USE ELIMINATES MACHINE JAMS, BREAKAGE OF TOOLING AND SO ELIMINATES PRODUCTION DOWNTIME CORROSION-RESISTANT SENSORS WITHSTAND CLEANING PRODUCT ADVANTAGES UNIQUE TECHNOLOGY DEFIES LIMITS OF TRADITIONAL INDUCTIVE SENSOR TECHNOLOGY EXTREMELY ROBUST, IMPACT AND ABRASION RESISTANT IP68/ IP69K STAINLESS-STEEL RATED HOUSING CORROSION-RESISTANT, V2A/ AISI 304 STAINLESS-STEEL, FOOD-COMPATIBLE BODY IO-LINK INTERFACE INCLUDED IDEAL FOR INDUSTRY 4
A manufacturer of metal cans needs to ensure that the press that applies and crimps the bottom onto the can body is fed with only one bottom. Therefore a fast, non-contact and robust checking mechanism is required. CUSTOMER APPLICATION A conveyor with a stainless-steel glide plate backed by a permanent magnet ensures that the can bottoms travel perfectly flat on the belt which transports them to the assembly stage. If double-bottoms are fed into the assembly stage, damage can be done to the press, tools can be broken, and even the press becoming jammed will cause production downtime. To check that only one bottom is being fed to the assembly stage whilst they are attached magnetically to the fast-moving belt, requires a non-contact sensing solution. The thin gauge of steel used to produce the can bottoms (~0.33 mm thick) is too small for the customer’s normal automatic double-sheet detector to work reliably.
CUSTOMER SOLUTION Contrinex’s Extreme 700 Series sensors provide a robust and simple, cost effective solution. They utilise their Condet® technology to detect the mass of a target by inducing a voltage in it, whereas a traditional inductive sensor would induce the voltage only in the target’s surface. The stainless-steel bodied sensor (DW-Ax-70X-M12) is mounted approximately 4 – 5 mm above the dome of a can bottom. On its own, the 0.33mm thick steel doom presents insufficient mass to switch the sensor at this distance, however the presence of a second bottom piece increases target mass sufficiently to switch the sensor. The inductive sensor triggers a rejection shoot whenever two bottoms are detected as being stacked together and so provide a robust and reliable system to protect the assembly press.
CUSTOMER VALUES COST SAVING DUE TO REDUCED DOWNTIME CAUSED BY SENSOR DAMAGE AND REPLACEMENT SAFE, RELIABLE PERFORMANCE IN A DEMANDING ENVIRONMENT FOR INCREASED PROCESS SECURITY COST-EFFECTIVE SOLUTION, MAINTENANCE FREE PRODUCT ADVANTAGES MECHANICALLY RUGGED, CORROSION-RESISTANT STAINLESS- STEEL SENSOR RATED TO IP68 AND IP69K COST-EFFECTIVE HIGH-PERFORMANCE SENSOR WITH EXCEPTIONAL RELIABILITY BEST-IN-CLASS 20MM SENSING DISTANCE IN M30-DIAMETER HOUSING FACTOR 1: IDENTICAL OPERATING DISTANCES ON STEEL AND ALUMINIUM
CUSTOMER SOLUTION Contrinex’s DW-AS-703-M30-002 inductive sensor is ideal for this application. The 700 Series sensor’s long sensing distances (20 mm in this case) detect equally well on both steel and aluminium, which is often called ‘factor 1’ sensing. The sensor selected detects the absence or presence of a model-dependent metal part that identifies the model. If the wrong model is identified, an alarm is generated to warn the operator. The Condet detection technology protects it from environmental and material influences. and its all-metal, AISI 303/V2A stainless-steel housing and sensing face protect it from corrosion and water ingress. The 700 series of inductive sensors are much more resistant to mechanical stresses than conventional sensors which makes them ideal for this application since the process involves the movement of large metal parts. The sensor used for identification should be rugged enough to withstand heavy impacts as the loading process is performed manually by an operator, so movements and positions are imprecise, while mechanical shocks to the sensor can be expected and a long sensing distance is required. .
An automotive manufacturer uses simple, low-cost inductive sensors to identify which style of chassis it receives in the body shop, to define what further processing should take place. CUSTOMER APPLICATION The customer manufactures a wide range of vehicles and so as each body arrives at the body shop, operators use pulleys and clamps to lift it onto the line. Since the same body shop handles more than one type, reliable confirmation is required before any work takes place. The customer, therefore, wants identification to take place as soon as the metal body is clamped into the lift at the reception point. There are two variations of the chassis. Identifying them confirms that the model corresponds to the operator's production order. Since the process involves the movement of large metal parts, the sensor used for identification should be rugged enough to withstand heavy impacts. The loading process is performed manually by an operator, so movements and positions are imprecise, while mechanical shocks to the sensor can be expected. A long sensing distance is required.
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.
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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.
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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.
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Helping you #Make Sense of Sensors
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CUSTOMER VALUES SAFE, RELIABLE PERFORMANCE IN A DEMANDING OUTDOOR ENVIRONMENT NO LIKELIHOOD OF ACCIDENTAL DAMAGE ARISING IN OPERATION COST-EFFECTIVE SOLUTION, MAINTENANCE FREE PRODUCT ADVANTAGES CORROSION-RESISTANT STAINLESS-STEEL SENSOR RATED TO IP68 AND IP69K COST-EFFECTIVE HIGH-PERFORMANCE SENSOR WITH EXCEPTIONAL RELIABILITY BEST-IN-CLASS 20MM SENSING DISTANCE IN M30-DIAMETER HOUSING
CUSTOMER SOLUTION Contrinex inductive sensors are robust, reliable and offer extended sensing distances; the Full Inox Extreme range is ideal for this application. A one-piece M30-diameter stainless- steel body and vacuum-encapsulated electronics make this device particularly suitable for the mechanically demanding environment, and the sensing distance of 20mm eliminates any possibility of accidental collision in operation. A metal bracket is mounted externally on the actuating mechanism for the upper forks; the embeddable sensor is mounted immediately adjacent to one of the forks and detects the position of the actuating arm as it drives the fork into the vertical position. The AISI 303/V2A stainless-steel housing and sensing face are corrosion-resistant and impervious to water ingress; the sensor is IP68- and IP69K-rated. Configured with an industry-standard PNP normally-open interface, the Contrinex M30 Extreme sensor connects to the forklift’s lower-fork tilt-control systems via a flexible PUR- sheathed cable. A sealed cable entry ensures fit-and-forget capability during extended periods of operation in an outdoor environment. The Full Inox inductive sensor detects the vertical position of the forklift’s upper forks effectively and repeatably, ensuring safe, reliable operation of the unloading system. Contrinex inductive sensors deliver a cost-effective solution that satisfies the customer’s requirements for extreme robustness and extended sensing distance.
A container manufacturer uses a modified forklift, fitted with two sets of forks, for unloading bulk cargo. The lower forks support the container while the upper forks control the lid. When unloading, the lid opens and the lower forks rotate, tipping out the contents. A robust inductive sensor senses the position of the lid, ensuring it opens fully before emptying. CUSTOMER APPLICATION Containers are often used when transporting bulk cargo, including wood chip and biomass, by rail. A manufacturer of bulk-cargo containers has developed an innovative unloading system that uses only a modified forklift, eliminating the need for specialist handling equipment. The forklift has two pairs of lifting forks. The main forks, mounted conventionally, support the weight of the container as it is unloaded from a freight wagon; a second pair, mounted vertically above the lower pair, opens and closes the lid of the container. During opening, the upper forks lift the lid a short distance before tilting it vertically, leaving the top of the container completely unobstructed. The lower forks then rotate about a horizontal axis, tilting the container end-over-end and tipping the contents out. A robust and reliable sensor system is required to detect the vertical position of the lid before rotation begins. An extended sensing distance is essential to eliminate the possibility of mechanical damage.
CUSTOMER VALUES HIGHLY COST EFFECTIVE SOLUTION - SUBSTANTIALLY LOWER COST THAN OTHER DOUBLE-SHEET DETECTION SOLUTIONS SIMPLE SETUP AND USE ELIMINATES MACHINE JAMS, BREAKAGE OF TOOLING AND SO ELIMINATES PRODUCTION DOWNTIME CORROSION-RESISTANT SENSORS WITHSTAND CLEANING PRODUCT ADVANTAGES UNIQUE TECHNOLOGY DEFIES LIMITS OF TRADITIONAL INDUCTIVE SENSOR TECHNOLOGY EXTREMELY ROBUST, IMPACT AND ABRASION RESISTANT IP68/ IP69K STAINLESS-STEEL RATED HOUSING CORROSION-RESISTANT, V2A/ AISI 304 STAINLESS-STEEL, FOOD-COMPATIBLE BODY IO-LINK INTERFACE INCLUDED IDEAL FOR INDUSTRY 4
A manufacturer of metal cans needs to ensure that the press that applies and crimps the bottom onto the can body is fed with only one bottom. Therefore a fast, non-contact and robust checking mechanism is required. CUSTOMER APPLICATION A conveyor with a stainless-steel glide plate backed by a permanent magnet ensures that the can bottoms travel perfectly flat on the belt which transports them to the assembly stage. If double-bottoms are fed into the assembly stage, damage can be done to the press, tools can be broken, and even the press becoming jammed will cause production downtime. To check that only one bottom is being fed to the assembly stage whilst they are attached magnetically to the fast-moving belt, requires a non-contact sensing solution. The thin gauge of steel used to produce the can bottoms (~0.33 mm thick) is too small for the customer’s normal automatic double-sheet detector to work reliably.
CUSTOMER SOLUTION Contrinex’s Extreme 700 Series sensors provide a robust and simple, cost effective solution. They utilise their Condet® technology to detect the mass of a target by inducing a voltage in it, whereas a traditional inductive sensor would induce the voltage only in the target’s surface. The stainless-steel bodied sensor (DW-Ax-70X-M12) is mounted approximately 4 – 5 mm above the dome of a can bottom. On its own, the 0.33mm thick steel doom presents insufficient mass to switch the sensor at this distance, however the presence of a second bottom piece increases target mass sufficiently to switch the sensor. The inductive sensor triggers a rejection shoot whenever two bottoms are detected as being stacked together and so provide a robust and reliable system to protect the assembly press.
CUSTOMER VALUES COST SAVING DUE TO REDUCED DOWNTIME CAUSED BY SENSOR DAMAGE AND REPLACEMENT SAFE, RELIABLE PERFORMANCE IN A DEMANDING ENVIRONMENT FOR INCREASED PROCESS SECURITY COST-EFFECTIVE SOLUTION, MAINTENANCE FREE PRODUCT ADVANTAGES MECHANICALLY RUGGED, CORROSION-RESISTANT STAINLESS- STEEL SENSOR RATED TO IP68 AND IP69K COST-EFFECTIVE HIGH-PERFORMANCE SENSOR WITH EXCEPTIONAL RELIABILITY BEST-IN-CLASS 20MM SENSING DISTANCE IN M30-DIAMETER HOUSING FACTOR 1: IDENTICAL OPERATING DISTANCES ON STEEL AND ALUMINIUM
CUSTOMER SOLUTION Contrinex’s DW-AS-703-M30-002 inductive sensor is ideal for this application. The 700 Series sensor’s long sensing distances (20 mm in this case) detect equally well on both steel and aluminium, which is often called ‘factor 1’ sensing. The sensor selected detects the absence or presence of a model-dependent metal part that identifies the model. If the wrong model is identified, an alarm is generated to warn the operator. The Condet detection technology protects it from environmental and material influences. and its all-metal, AISI 303/V2A stainless-steel housing and sensing face protect it from corrosion and water ingress. The 700 series of inductive sensors are much more resistant to mechanical stresses than conventional sensors which makes them ideal for this application since the process involves the movement of large metal parts. The sensor used for identification should be rugged enough to withstand heavy impacts as the loading process is performed manually by an operator, so movements and positions are imprecise, while mechanical shocks to the sensor can be expected and a long sensing distance is required.
An automotive manufacturer uses simple, low-cost inductive sensors to identify which style of chassis it receives in the body shop, to define what further processing should take place. CUSTOMER APPLICATION The customer manufactures a wide range of vehicles and so as each body arrives at the body shop, operators use pulleys and clamps to lift it onto the line. Since the same body shop handles more than one type, reliable confirmation is required before any work takes place. The customer, therefore, wants identification to take place as soon as the metal body is clamped into the lift at the reception point. There are two variations of the chassis. Identifying them confirms that the model corresponds to the operator's production order. Since the process involves the movement of large metal parts, the sensor used for identification should be rugged enough to withstand heavy impacts. The loading process is performed manually by an operator, so movements and positions are imprecise, while mechanical shocks to the sensor can be expected. A long sensing distance is required.
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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 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
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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.
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