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AUTOMOTIVE APPLICATIONS Contrinex supplies a vast number of automotive manufacturers and suppliers around the World and in the UK.
A manufacturer of automotive-suspension coil springs uses Radio Frequency Identification (RFID) technology to identify parts and monitor process status in an automated paint shop. Parts travel on dedicated transport frames; each transport frame, suspended from an overhead conveyor, is fitted with a high-frequency, high-temperature RFID tag. During the paint-curing cycle, temperatures may rise to 250°C (482°F) for more than 30 minutes. Contrinex high-temperature transponders operate reliably in this range. CUSTOMER APPLICATION Automotive suspension components require highly durable surface finishes. A German manufacturer of suspension coil springs operates an automated paint-processing plant that degreases, spray-paints and heat-cures parts. Springs travel through the plant on dedicated transport frames. RFID tags, mounted on the frames, identify individual parts. Throughout the process, read/write modules (RWMs), compatible with ISO/IEC 15693, interrogate the tags and update a centralized control system. During the heat-curing process, the entire transport frame, complete not only with parts but also with transponder, passes through the curing oven. Curing temperatures reach 250°C (482°F) for more than 30 minutes. Temperatures this high are beyond the capabilities of many RFID tags. In the past, complex mechanical arrangements were needed to shield devices from elevated-temperature areas. The customer requires RFID tags that not only withstand the high- temperature environment but also offer complete reliability and a service life of at least 2000 temperature cycles. Compliance with ISO/IEC 15693 is mandatory to ensure compatibility with existing RWMs.
Customer Solution Contrinex high-temperature high-frequency (HF) RFID tags are ideal for this application. These 50mm-diameter ConIdent® passive transponders with liquid-crystal polymer (LCP) housings are purpose- designed for operation at temperatures up to 250°C (482°F). They require no internal power source and are fully compliant with ISO/IEC 15693, ensuring compatibility with the customer’s existing equipment. The tags, mounted directly onto the transport frames, withstand repeated exposure to elevated temperatures and easily achieve the required service life. ConIdent® technology is also highly tolerant of surface contamination, and the tags ensure continuous error-free operation in spite of unavoidable soiling with paint overspray. These Contrinex RFID tags also boast silicone-free construction – an essential anti-contamination requirement for paint-shop applications. Contrinex transponders not only withstand the environment, they accommodate the variability of a transport frame’s travel path. Since the frame is not constrained from moving about its vertical axis, the exact path of the tag may vary from frame to frame – often by several millimetres. The system allows for this movement and produces reliable results that are independent of the exact tag position. Contrinex RFID tags provide accurate and highly reliable part identification in a demanding high-temperature environment. The customer enjoys extended service life and robustness not available from alternative transponders, together with excellent value for money.
APPLICATION - RFID MONITORING OF PAINT CURING LINE
APPLICATION - LIGHT CURTAIN DETECTS PRESENCE OF PARTS
During manufacture of mechanical assemblies for automotive production, an operator uses a manually operated machine to weld metal parts together. After welding, the operator drops the assembly in a transport bin ready for dispatch. As each assembly is placed in the bin, an infrared light curtain detects its presence and confirms that the welding cycle has been completed correctly CUSTOMER APPLICATION In a Portuguese manufacturing plant, an operator loads small parts by hand onto a resistance-welding machine and initiates the PLC- controlled welding cycle. After welding, the operator drops the completed assembly into a metal bin used to transport parts directly to the customer. From time to time, unwelded parts are placed in the bin, resulting in rejection of entire batches of assemblies by the customer. Manual inspection of each assembly is impractical; a sensor system must detect the presence of each item as it is dropped into the bin and check that the corresponding welding cycle has been completed. The sensing system must not increase the process cycle-time and must detect parts as they are dropped into the open bin, which is approximately 120cm (4ft) long and 90cm (3ft) wide. Parts are around 15cm (6in) long and a sensor with a rapid response time is necessary to detect fast-moving items. Customer Solution The Contrinex range of Safetinex infrared light curtains, developed for use in high-reliability safety systems, is well-suited for this application. Comprising separate sender- and receiver-units and constructed with rugged one-piece aluminium-profile housings, these versatile sensor systems are ideal for the busy production environment. With a response time of less than 25 milliseconds and a resolution of 14mm, the Safetinex range satisfies the demanding customer specification for rapid response and reliable detection of the small parts. The compact design allows easy mounting at each end of the transport bin without impeding the operator or increasing the process cycle time. Safetinex light curtains require no direct connection between sender and receiver; The system provides two separate OSSD (Output Signal Switching Device) PNP outputs, and integral M12 connectors allow easy removal and replacement of individual units for maintenance. Connection to the customer’s PLC is via flexible PVC-sheathed cables. The system detects the presence of any item passing through the light curtain and immediately interrogates the PLC to confirm that a welding cycle has been completed since detection of the preceding item. If no welding cycle is registered, the system interrupts the process and sounds an alarm, alerting the operator.
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CUSTOMER VALUES • Uninterrupted production as part identification is highly reliable • No risk of system degradation as tags are resistant to high temperatures • Low maintenance costs in view of transponders’ extended service life • No risk of paint contamination owing to silicone-free tag construction
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PRODUCT ADVANTAGES • LCP-housed transponders operate at temperatures up to 250oC (482ºF) • ConIdent® technology is highly tolerant of surface contamination • Extended sensing distances up to 56mm
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CUSTOMER VALUES • Reliable, repeatable detection of fast-moving parts • Testing is completed in-cycle without increasing cycle time • Elimination of batch rejection by the customer • Highly cost-effective solution to a potentially costly problem
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PRODUCT ADVANTAGES • Best-of-breed response time of less than 25 milliseconds • Exceptional detection reliability with resolution of 14mm • Compact, easily accommodated design
During manufacture of automotive parking-brake cable, multiple strands of steel wire are twisted together, forming a single cable. After twisting, cable passes to the next process in an unsupported, continuous length. Occasionally, the cable breaks, compromising safety and damaging equipment. Although the cable’s exact path is unpredictable, a multi-beam fibre-optic sensor detects its presence, interrupting the process if it breaks. CUSTOMER APPLICATION During production of automotive parking-brake cable in a Portuguese factory, strands of steel wire are twisted together, forming a single cable with a nominal diameter of 3mm (0.1in). The process operates continuously, and twisted cable passes between successive work- stations in an unbroken length. Between operations, the cable is largely unsupported, assuming the form of a suspended catenary. Occasionally, a manufacturing defect causes the cable to break. In this event, safety is compromised and, unless processing is halted, machine breakdowns occur. A sensor system must detect the presence of the cable as it passes from one operation to the next, interrupting the process if it breaks. Because the cable is unsupported, its path is unpredictable and its exact position at any time, particularly in the vertical plane, is unknown. The sensor system must detect the presence of the cable reliably at any point within an envelope 90mm (3.5in) high and 20mm (0.75in) wide.
Customer Solution A Contrinex photoelectric sensor system, comprising a DIN-rail- mounted fibre-optic amplifier coupled with a multi-beam diffuse sensing head, provides an optimal solution for this application. With maximum switching frequencies of up to 4000 Hz and sensing distances of up to 150mm (6in), multi-beam fibre-optic sensors are ideal for detecting fast-moving targets. The PBTP construction of the sensing head ensures excellent mechanical protection in the production environment. The 28mm-wide sensing face of the multi-beam sensor detects targets across its entire width, providing a detection envelope that comfortably accommodates the customer’s 90mm x 20mm requirement. Initial set- up is accomplished by means of a manual teach-in function and integral signal-strength LCD, following which the system operates without manual intervention. A 2m-long fibre cable allows remote mounting of the fibre-optic amplifier; connection to the customer’s control system is via an industry-standard PNP interface and an integral M8 cable connector, allowing easy removal and replacement when necessary. The system tolerates high ambient-light conditions and detection of a broken cable is both highly reliable and immediate. If the cable breaks, the system interrupts the process and sounds an alarm, alerting the operator. Downtime arising from broken cables has been eliminated since the system has been operational.
APPLICATION - FIBRE-OPTIC BROKEN PARKING-BRAKE CABLE MONITORING
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CUSTOMER VALUES • Rapid, reliable detection of a small, fast- moving target with an erratic path • Elimination of downtime arising from broken cables • Highly cost-effective solution to a potentially costly problem
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PRODUCT ADVANTAGES • System switching frequency of up to 4000 Hz • Exceptionally reliable detection across a 90mm x 20mm envelope • Diffuse detector with simple set-up and teach- in function
PLUS Automation ® Limited © 2020 Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire. WR9 0LG
Helping you #MakeSenseofSensors
AUTOMOTIVE APPLICATIONS Contrinex supplies a vast number of automotive manufacturers and suppliers around the World and in the UK.
APPLICATION - RFID MONITORING PAINT LINE
Customer Solution Contrinex high-temperature high-frequency (HF) RFID tags are ideal for this application. These 50mm-diameter ConIdent® passive transponders with liquid-crystal polymer (LCP) housings are purpose-designed for operation at temperatures up to 250oC (482oF). They require no internal power source and are fully compliant with ISO/IEC 15693, ensuring compatibility with the customer’s existing equipment. The tags, mounted directly onto the transport frames, withstand repeated exposure to elevated temperatures and easily achieve the required service life. ConIdent® technology is also highly tolerant of surface contamination, and the tags ensure continuous error-free operation in spite of unavoidable soiling with paint overspray. These Contrinex RFID tags also boast silicone-free construction – an essential anti-contamination requirement for paint-shop applications. Contrinex transponders not only withstand the environment, they accommodate the variability of a transport frame’s travel path. Since the frame is not constrained from moving about its vertical axis, the exact path of the tag may vary from frame to frame – often by several millimetres. The system allows for this movement and produces reliable results that are independent of the exact tag position. Contrinex RFID tags provide accurate and highly reliable part identification in a demanding high-temperature environment. The customer enjoys extended service life and robustness not available from alternative transponders, together with excellent value for money.
A manufacturer of automotive-suspension coil springs uses Radio Frequency Identification (RFID) technology to identify parts and monitor process status in an automated paint shop. Parts travel on dedicated transport frames; each transport frame, suspended from an overhead conveyor, is fitted with a high-frequency, high-temperature RFID tag. During the paint-curing cycle, temperatures may rise to 250oC (482oF) for more than 30 minutes. Contrinex high- temperature transponders operate reliably in this range. CUSTOMER APPLICATION Automotive suspension components require highly durable surface finishes. A German manufacturer of suspension coil springs operates an automated paint-processing plant that degreases, spray-paints and heat-cures parts. Springs travel through the plant on dedicated transport frames. RFID tags, mounted on the frames, identify individual parts. Throughout the process, read/write modules (RWMs), compatible with ISO/IEC 15693, interrogate the tags and update a centralized control system. During the heat-curing process, the entire transport frame, complete not only with parts but also with transponder, passes through the curing oven. Curing temperatures reach 250oC (482oF) for more than 30 minutes. Temperatures this high are beyond the capabilities of many RFID tags. In the past, complex mechanical arrangements were needed to shield devices from elevated-temperature areas. The customer requires RFID tags that not only withstand the high-temperature environment but also offer complete reliability and a service life of at least 2000 temperature cycles. Compliance with ISO/IEC 15693 is mandatory to ensure compatibility with existing RWMs.
APPLICATION - LIGHT CURTAIN DETECTS PRESENCE OF PARTS
During manufacture of mechanical assemblies for automotive production, an operator uses a manually operated machine to weld metal parts together. After welding, the operator drops the assembly in a transport bin ready for dispatch. As each assembly is placed in the bin, an infrared light curtain detects its presence and confirms that the welding cycle has been completed correctly CUSTOMER APPLICATION In a Portuguese manufacturing plant, an operator loads small parts by hand onto a resistance-welding machine and initiates the PLC-controlled welding cycle. After welding, the operator drops the completed assembly into a metal bin used to transport parts directly to the customer. From time to time, unwelded parts are placed in the bin, resulting in rejection of entire batches of assemblies by the customer. Manual inspection of each assembly is impractical; a sensor system must detect the presence of each item as it is dropped into the bin and check that the corresponding welding cycle has been completed. The sensing system must not increase the process cycle- time and must detect parts as they are dropped into the open bin, which is approximately 120cm (4ft) long and 90cm (3ft) wide. Parts are around 15cm (6in) long and a sensor with a rapid response time is necessary to detect fast- moving items. Customer Solution The Contrinex range of Safetinex infrared light curtains, developed for use in high-reliability safety systems, is well- suited for this application. Comprising separate sender- and receiver-units and constructed with rugged one-piece aluminium-profile housings, these versatile sensor systems are ideal for the busy production environment. With a response time of less than 25 milliseconds and a resolution of 14mm, the Safetinex range satisfies the demanding customer specification for rapid response and reliable detection of the small parts. The compact design allows easy mounting at each end of the transport bin without impeding the operator or increasing the process cycle time. Safetinex light curtains require no direct connection between sender and receiver; The system provides two separate OSSD (Output Signal Switching Device) PNP outputs, and integral M12 connectors allow easy removal and replacement of individual units for maintenance. Connection to the customer’s PLC is via flexible PVC-sheathed cables. The system detects the presence of any item passing through the light curtain and immediately interrogates the PLC to confirm that a welding cycle has been completed since detection of the preceding item. If no welding cycle is registered, the system interrupts the process and sounds an alarm, alerting the operator.
During manufacture of automotive parking-brake cable, multiple strands of steel wire are twisted together, forming a single cable. After twisting, cable passes to the next process in an unsupported, continuous length. Occasionally, the cable breaks, compromising safety and damaging equipment. Although the cable’s exact path is unpredictable, a multi-beam fibre-optic sensor detects its presence, interrupting the process if it breaks. CUSTOMER APPLICATION During production of automotive parking-brake cable in a Portuguese factory, strands of steel wire are twisted together, forming a single cable with a nominal diameter of 3mm (0.1in). The process operates continuously, and twisted cable passes between successive work-stations in an unbroken length. Between operations, the cable is largely unsupported, assuming the form of a suspended catenary. Occasionally, a manufacturing defect causes the cable to break. In this event, safety is compromised and, unless processing is halted, machine breakdowns occur. A sensor system must detect the presence of the cable as it passes from one operation to the next, interrupting the process if it breaks. Because the cable is unsupported, its path is unpredictable and its exact position at any time, particularly in the vertical plane, is unknown. The sensor system must detect the presence of the cable reliably at any point within an envelope 90mm (3.5in) high and 20mm (0.75in) wide.
+ CUSTOMER VALUES • Uninterrupted production as part identification is highly reliable • No risk of system degradation as tags are resistant to high temperatures • Low maintenance costs in view of transponders’ extended service life • No risk of paint contamination owing to silicone-free tag construction PRODUCT ADVANTAGES • LCP-housed transponders operate at temperatures up to 250oC (482ºF) • ConIdent® technology is highly tolerant of surface contamination • Extended sensing distances up to 56mm + + CUSTOMER VALUES • Reliable, repeatable detection of fast-moving parts • Testing is completed in-cycle without increasing cycle time • Elimination of batch rejection by the customer • Highly cost-effective solution to a potentially costly problem PRODUCT ADVANTAGES • Best-of-breed response time of less than 25 milliseconds • Exceptional detection reliability with resolution of 14mm • Compact, easily accommodated design + + CUSTOMER VALUES • Rapid, reliable detection of a small, fast-moving target with an erratic path • Elimination of downtime arising from broken cables • Highly cost-effective solution to a potentially costly problem PRODUCT ADVANTAGES • System switching frequency up to 4000 Hz • Exceptionally reliable detection across a 90mm x 20mm envelope • Diffuse detector with simple set-up and teach-in function +
Customer Solution A Contrinex photoelectric sensor system, comprising a DIN- rail-mounted fibre-optic amplifier coupled with a multi-beam diffuse sensing head, provides an optimal solution for this application. With maximum switching frequencies of up to 4000 Hz and sensing distances of up to 150mm (6in), multi- beam fibre-optic sensors are ideal for detecting fast-moving targets. The PBTP construction of the sensing head ensures excellent mechanical protection in the production environment. The 28mm-wide sensing face of the multi-beam sensor detects targets across its entire width, providing a detection envelope that comfortably accommodates the customer’s 90mm x 20mm requirement. Initial set-up is accomplished by means of a manual teach-in function and integral signal- strength LCD, following which the system operates without manual intervention. A 2m-long fibre cable allows remote mounting of the fiber- optic amplifier; connection to the customer’s control system is via an industry-standard PNP interface and an integral M8 cable connector, allowing easy removal and replacement when necessary. The system tolerates high ambient-light conditions and detection of a broken cable is both highly reliable and immediate. If the cable breaks, the system interrupts the process and sounds an alarm, alerting the operator. Downtime arising from broken cables has been eliminated since the system has been operational.
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APPLICATION - FIBRE-OPTIC BRAKE CABLE MONITORING