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APPLICATION - WIND TURBINE BLADE ROTATION VELOCITY MEASUREMENT
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.
Customer Solution Rugged Full Inox 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.
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.
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).
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. Finally, to ensure reliable detection of the stainless-steel collar, an M8- diameter sensor from the Extreme range (Full Inox family) was chosen. Its one-piece AISI 303 (V2A) stainless-steel construction is combined with an extended operating distance of 6mm. 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.
APPLICATION - COMPONENT PRESENCE CHECK IN HOSE ASSEMBLIES
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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
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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
APPLICATION - FORKLIFT ATTACHMENTS
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 Swiss 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 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.
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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
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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
APPLICATION - POSITION SENSING OF REAR-WHEEL STEERING
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 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.
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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
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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
700 SERIES ‘EXTREME 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. CLICK HERE to view this product family on Contrinex’s website, or call us to help guide you through selection, or answer your questions. Below are links to additional information and application stories.
APPLICATION - HOOKLIFT TRUCK INTERLOCK SENSING
APPLICATION - ROTARY INDEXING TABLE & ROBOT ASSEMBLY
Hooklift 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; sensors must be mechanically robust and withstand harsh outdoors conditions. CUSTOMER APPLICATION A specialist vehicle builder manufactures hydraulic hooklift systems for commercial trucks. A hooklift 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. Hooklift trucks operate all year round, often in harsh environments such as demolition and construction sites. Hooklift 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 Solution Rugged Full Inox 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.
Fault-free assembly is ensured and downtime minimised by using automated facilities for high volume assembly. Rugged inductive sensors detect the presence and position of equipment or components at each stage to ensure that parts are correctly aligned and ready for the next operation. The sensors must be accurate and responsive. In addition, an IO-Link interface offers the advantages of digital communication without the need for special cabling. CUSTOMER APPLICATION Highly reliable automation and machine-control systems are used to eliminate assembly faults and improve efficiency in an assembly operation. Whilst the repetitive assembly tasks are well-suited to being done by robots, these robots can be too slow at picking and placing the assembled parts and therefore a rotary indexing table is used to move the assemblies between the robots. The rotary indexing table speeds up the transfer of PCBs between assembly robots and also on and off conveyors, increasing the production throughput and reducing the number of assembly robots required – Sensors are used to automate these processes and these sensors must be able to operate continuously at high speed, performing tasks including: presence detection to initiate the cassette-change cycle in a stack feeder; position control for a rotary indexing table; pick-and- place gripper control; and presence monitoring on a conveyor system.
Customer Solution Stack-feeders deliver base plates, electrical printed circuit boards and other planar components to the assembly lines. In each stack-feeder, a vertical cassette holds as many as 50 individual parts and a single inductive sensor monitors the status of each cassette. Once the final part is discharged from the stack, the cassette moves to its end position, triggering the sensor and initiating the cassette-change cycle.
PROMOTIONAL VIDEO DEMONSTRATION VIDEO
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CUSTOMER VALUES • Single-piece AISI 304 (V2A) stainless-steel (V4A ‘Washdown’ versions also available for Food & Bev, Marine & corrosive environments) • Rugged, hermetically sealed embeddable sensors • High resistance to harsh operating conditions • Extended service life and reduced maintenance workload for sensor replacements • Corrosion-resistant stainless-steel sensors reduce in-field failures • Highly cost-effective solution to improve OEE
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PRODUCT ADVANTAGES • World class performance, even in extreme environments • Extremely robust one-piece, stainless-steel housing • Virtually indestructible - Vibration and shock resistant • IP 68 and IP 69K, Corrosion resistant & sea water resistant • Pressure resistant up to 100 bar (1451 psi) • Long sensing distances • Factor 1 (consistent sensing) with both ferrous & non-ferrous materials • IO-Link serial-connection protocol enabled on PNP versions at no additional cost • Food-grade stainless steel (V4A / AISI 316L) ‘Washdown’ versions • Large choice of sensors styles from 4mm to 30mm diameter plus cubic options.
 APPLICATION FLYER
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.
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.
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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
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PRODUCT ADVANTAGES • One-piece AISI 304 (V2A) stainless-steel body • State-of-the-art ASIC technology ensures exceptional in-service reliability10 mm sensing range available in physically small sensor • Excellent resistance to extreme operating conditions
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.
Contrinex C23 embeddable inductive sensors, featuring a one-piece stainless-steel housing, are both robust and highly reliable. A 7mm sensing distance allows ample operating clearance, minimizing the risk of mechanical collision. Their implementation into the assembly equipment is made easier by the choice of industry-standard PNP or NPN outputs with either a PUR cable or an M8 pigtail connector. Additionally, IO-Link, a standardised point-to-point serial connection protocol for sensors and actuators, is provided at no additional cost, offering the advantages of digital communication without the need for special cabling, making them ideal for Industry 4 applications. Designed for demanding applications, Contrinex’s rugged C23 inductive sensors offer best-in-class switching frequency of 180Hz and exceptional robustness including impact and abrasion resistance, making them a versatile, cost-effective and highly reliable solution. These uniquely robust sensors are typically demonstrated by Contrinex as being able to repeatedly being used to hammer in nails. Even when their front face is dented, the sensor continues to operate correctly. .
Conveyors deliver a continuous stream of parts to the rotary indexing table, which transports them in sequence to each assembly station. As the table rotates, sensors located at precise intervals around its periphery detect its exact angular position, bringing it to a halt once parts are correctly positioned for the next operation. At each assembly station, automated pick-and-place equipment add components to the assembly. Dedicated transport mechanisms – including vacuum lifters, electromagnetic clamps and mechanical grippers – insert items swiftly and accurately in their designated positions. Embeddable inductive sensors play a key role in confirming the secure closure of custom-designed grippers before fragile, high- value parts are lifted. Manufactured in V4A/ AISI 316L stainless steel and rated to IP68/ IP69K, these small inductive sensors can be fully embedded into a steel surface such as part of the rotary table or an assembly jig or bench, further reducing the potential for mechanical damage. On completion of the final assembly stage, finished PCBs are discharged to a linear conveyor system. They travel to subsequent processing stages, including testing and packing. C23 Full Inox sensors mounted directly above these conveyors, detect each unit as it passes below. This check not only confirms the presence of the assembled item at the expected height above the conveyor but also measures throughput by activating a counting circuit in the customer’s control system. Continuous operation is the norm in automated assembly plants. However, minor adjustments or tool changes may be required from time to time. In non-safety-critical areas, access hatches allow maintenance technicians to carry out these tasks without needing to interrupt production across an entire plant. Multiple sensors, mounted at intervals around the periphery of a hatch, ensure that appropriate warning signals are activated whenever the opening is not fully secured. The Contrinex C23 series of Full Inox inductive sensors have the capability of communicating remotely with a plant-wide control system, thanks to the implementation of the IO-Link protocol. In a typical automated plant, each assembly line runs continuously throughout the day, with remote diagnostics eliminating the need for manual intervention in almost every situation. Designed to simplify integration, IO-Link sensors are compatible with all IO-Link master versions, allowing set-up and diagnostics to be conducted centrally. Interrogating a device returns its manufacturer ID and product ID, allowing systems integrators to determine remotely that the right sensor is in the correct location. Contrinex C23 inductive sensors additionally feature an on-demand self-test function that confirms full capability at all times. For the C23 inductive series, alternating between normally open and normally closed functionality via remote output-mode configuration is a standard feature of the IO-Link protocol. Systems designers also can modify the output signal. Delaying the switching pulse accommodates any travel time between a sensor and its corresponding actuation point, while stretching the pulse ensures that slave devices with lengthy response times trigger reliably, even at high throughput rates. Finally, each sensor provides an output-status check derived from its factory calibration data. If the output signal from a sensor falls outside a range that corresponds to a sensing distance between 80% and 100% of its nominal value, an alarm flag is triggered, highlighting the need for investigation. For plant managers under pressure, peace-of-mind is a valuable benefit. The no-cost option of the industry-standard IO-Link protocol ensures that best-in-class performance is coupled with ultimate ease of use in even the most demanding circumstances.
700 SERIES ‘EXTREME 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. CLICK HERE to view this product family on Contrinex’s website, or call us to help guide you through selection, or answer your questions. Below are links to additional information and application stories.
APPLICATION - INDEXING TABLE & ROBOT ASSEMBLY
Fault-free assembly is ensured and downtime minimised in automated facilities for high volume consumer goods 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. 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.
APPLICATION - HOOKLIFT TRUCK INTERLOCK SENSING
Hooklift 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; sensors must be mechanically robust and withstand harsh outdoors conditions. CUSTOMER APPLICATION A specialist vehicle builder manufactures hydraulic hooklift systems for commercial trucks. A hooklift 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. Hooklift trucks operate all year round, often in harsh environments such as demolition and construction sites. Hooklift 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 Solution Rugged Full Inox 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.
PROMOTIONAL VIDEO DEMONSTRATION VIDEO
+ CUSTOMER VALUES • Single-piece AISI 304 (V2A) stainless-steel  (V4A ‘Washdown’ versions also available for Food & Bev, Marine & corrosive environments) • Rugged, hermetically sealed embeddable sensors • High resistance to harsh operating conditions PRODUCT ADVANTAGES • World class performance, even in extreme environments • Extremely robust one-piece, stainless-steel housing • Virtually indestructible - Vibration and shock resistant • IP 68 and IP 69K, Corrosion resistant & sea water resistant  • Pressure resistant up to 100 bar (1451 psi) • Long sensing distances + APPLICATION FLYER + CUSTOMER VALUES • Extended service life and reduced maintenance workload for sensor replacements • Corrosion-resistant stainless-steel sensors reduce in-field failures • Highly cost-effective solution to improve OEE PRODUCT ADVANTAGES • Factor 1 (consistent sensing) with both ferrous & non-ferrous materials  • IO-Link serial-connection protocol enabled on PNP versions at no additional cost • Food-grade stainless steel (V4A / AISI 316L) ‘Washdown’ versions • Large choice of sensors styles from 4mm to 30mm diameter plus cubic options. +
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Helping you #MakeSenseofSensors
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.
Fault-free assembly is ensured and downtime minimised in automated facilities for high volume consumer goods 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. Sensors must be accurate and responsive. In addition, an IO-Link interface offers the advantages of digital communication without the need for special cabling.
Conveyors deliver a continuous stream of parts to the rotary indexing table, which transports them in sequence to each assembly station. As the table rotates, sensors located at precise intervals around its periphery detect its exact angular position, bringing it to a halt once parts are correctly positioned for the next operation. At each assembly station, automated pick-and-place equipment add components to the assembly. Dedicated transport mechanisms – including vacuum lifters, electromagnetic clamps and mechanical grippers – insert items swiftly and accurately in their designated positions. Embeddable inductive sensors play a key role in confirming the secure closure of custom-designed grippers before fragile, high-value parts are lifted.
Manufactured in V4A/ AISI 316L stainless steel and rated to IP68/ IP69K, these small inductive sensors can be fully embedded into a steel surface such as part of the rotary table or an assembly jig or bench, further reducing the potential for mechanical damage. On completion of the final assembly stage, finished PCBs are discharged to a linear conveyor system. They travel to subsequent processing stages, including testing and packing. C23 Full Inox sensors mounted directly above these conveyors, detect each unit as it passes below. This check not only confirms the presence of the assembled item at the expected height above the conveyor but also measures throughput by activating a counting circuit in the customer’s control system. Continuous operation is the norm in automated assembly plants. However, minor adjustments or tool changes may be required from time to time. In non-safety-critical areas, access hatches allow maintenance technicians to carry out these tasks without needing to interrupt production across an entire plant. Multiple sensors, mounted at intervals around the periphery of a hatch, ensure that appropriate warning signals are activated whenever the opening is not fully secured. The Contrinex C23 series of Full Inox inductive sensors have the capability of communicating remotely with a plant- wide control system, thanks to the implementation of the IO-Link protocol. In a typical automated plant, each assembly line runs continuously throughout the day, with remote diagnostics eliminating the need for manual intervention in almost every situation. Designed to simplify integration, IO-Link sensors are compatible with all IO-Link master versions, allowing set-up and diagnostics to be conducted centrally. Interrogating a device returns its manufacturer ID and product ID, allowing systems integrators to determine remotely that the right sensor is in the correct location. Contrinex C23 inductive sensors additionally feature an on-demand self-test function that confirms full capability at all times. For the C23 inductive series, alternating between normally open and normally closed functionality via remote output- mode configuration is a standard feature of the IO-Link protocol. Systems designers also can modify the output signal. Delaying the switching pulse accommodates any travel time between a sensor and its corresponding actuation point, while stretching the pulse ensures that slave devices with lengthy response times trigger reliably, even at high throughput rates. Finally, each sensor provides an output-status check derived from its factory calibration data. If the output signal from a sensor falls outside a range that corresponds to a sensing distance between 80% and 100% of its nominal value, an alarm flag is triggered, highlighting the need for investigation. For plant managers under pressure, peace- of-mind is a valuable benefit. The no-cost option of the industry-standard IO-Link protocol ensures that best-in-class performance is coupled with ultimate ease of use in even the most demanding circumstances.