Helping you #Make Sense of Sensors
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CRANES & MATERIAL-HANDLING APPLICATIONS Reliability and robustness is a primary concern on material handling equipment and cranes, making Contrinex’s sensors ideal.
At busy container seaports, purpose-designed container-handling vehicles called Straddle Carriers, operate around the clock, loading, unloading and stacking containers. Space utilisation is increasingly important and correctly identifying the size of container picked for each lift is essential for efficiency. Contrinex photoelectric sensors have been fitted to the Straddle Carriers to detect the container size and eliminate the need for drivers to carry out identification checks, saving time and avoiding errors. CUSTOMER APPLICATION A fleet of straddle carriers, purpose-designed container-handling vehicles, services a busy French container port. As a straddle carrier moves over a container, a central lifting beam lowers and locks onto the corner castings of the container; each lift comprises either a single 40-foot container or two 20-foot containers. Optimal utilisation of storage space is essential; correctly identifying the size of container picked for each lift is vital. Fitting carriers with sensors that detect the size and type of containers at the time of lifting eliminate the need for drivers to carry out identification checks, saving time and avoiding errors. The original mechanical sensors proved unreliable, losing calibration when subjected to continuous vibration during normal operation. Although the scheduled maintenance interval for each vehicle is 1,000 hours, mechanical sensors required recalibration at intervals of no more than two or three days. A highly stable replacement sensor system was required.
Customer Solution Highly stable, non-contact, all-electronic units from the Contrinex range of photoelectric sensors provide a reliable and cost-effective alternative. The moulded-resin sensor casings, fitted with coated- plastic sensing faces, are IP67 rated, making them virtually impervious to the harsh, salt-laden environment of a busy container port. Connection to the vehicle’s control systems is via an integral M12 connector and PVC-sheathed cable, allowing easy removal and replacement during routine maintenance. To confirm the size of the container, two pairs of diffuse sensors with background suppression are mounted centrally on each lifting beam. As the lifting beam descends, one sensor from each pair detects the presence or absence of corner castings at the central lifting points, while the other detects the presence or absence of the gap between two 20-foot containers. The combination of the two eliminates incorrect identification in the unlikely event that the first sensor returns a false- positive signal from a 40-foot container. A physically small housing and long sensing distances eliminate the risk of accidental damage arising from a mechanical collision, while rugged industry-standard housings and vacuum-encapsulated electronics minimize the effects of vibration. Operational results have been excellent; the new Contrinex sensors have eliminated calibration errors and reduced maintenance costs significantly.
APPLICATION - CONTAINER CARRIER
APPLICATION - CONTAINER CRANE
Container-handling cranes in Britain’s busy seaports operate around the clock relying upon Contrinex’s rugged inductive sensors on each hoist carriage to detect its position with respect to the crane structure and prevent it travelling outside preset limits. Because mechanical play in the hoist carriage allows a small amount of lateral drift as it travels along the crane structure, Contrinex’s long sensing distance is essential to prevent the sensor colliding with the crane structure. CUSTOMER APPLICATION Loading and unloading containers in a busy British seaport is a 24- hour activity, all year round, with optimum utilisation of storage space being essential to achieve maximum operating efficiency. Container-handling cranes operate above a storage area, positioning containers before lowering them into place. The hoist carriage on each crane travels along the length of the crane structure, traversing the width of the storage area to achieve complete coverage of the available storage space. Sensors fitted to the hoist carriage detect the ends of the structure, cutting power to the drive-motors and preventing the carriage from travelling beyond allowable limits. Mechanical play in the drive system results in the carriage drifting laterally as it travels along the crane structure. The 15mm sensing range of a competitor’s sensors were inadequate; occasionally causing sensors to collide with the crane’s structure, causing damage and interrupting operation. Better inductive sensors with increased sensing range are needed to prevent collisions.
Customer Solution Contrinex’s ‘Basic’ range of inductive sensors are highly suited for this application. Mounted in rugged 40 x 40mm polyamide glass-fibre housings, these devices from the ‘Classics’ technology family utilised a 20mm sensing distance that eliminates the risk of collisions. A 40mm sensing distance is also available for this sensor if needed and its IP68 / IP69K-rating makes it ideal for the outdoor working environment, even in a seaport. The use of industry-standard housings for these Contrinex sensors ensures that they are drop-in replacements for competitor’s devices. No modification to the mounting arrangements was necessary, incurring little downtime during the changeover to the new sensing arrangements. Communication with the crane’s control system is via a PNP changeover interface, replacing the existing two-wire arrangement; a flexible PUR-sheathed cable provides the electrical connection. The new sensor features an integral S12 connector, allowing easy removal and replacement for maintenance. A step improvement in operational performance was evident immediately after the new units were installed. The new sensors provide reliable sensing of each hoist’s position with no reported collisions since the date of installation. The customer has reported a marked reduction in crane downtime with an associated decrease in expenditure on replacement sensors. .
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CUSTOMER VALUES • Long sensing range (500mm) available in a physically small sensor. (20x30x10mm). • Exceptional resistance to extreme vibration during operation. • Optimal space utilisation with little or no reliance on operator involvement
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PRODUCT ADVANTAGES • Elimination of calibration errors during normal operation • Provides reliable, repeatable sensing in demanding operating conditions
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CUSTOMER VALUES • Reliable sensing of hoist-carriage position in a busy container seaport • Significant reduction in crane downtime • Marked decrease in maintenance costs for replacement sensors
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PRODUCT ADVANTAGES • IP68 and IP69K rating • Cost-effective high-performance sensor with exceptional reliability • Sensing distances up to 40mm in industry- standard 40 x 40mm housing
Busy container seaports rely upon the ‘24/7’ operation of specialist container-handling vehicles called Straddle Carriers for loading, unloading and stacking containers. Often located at ports, being beside the sea can mean that they have to work in an aggressive and corrosive environment, requiring frequent maintenance. Because traditional, interval-based maintenance schedules are not optimally efficient, condition-based intervention systems which minimise the risk of breakdown, are popular. European port operators therefore frequently rely upon Contrinex’s rugged, analogue-output inductive sensors to monitor components with a high risk of premature failure, maximising vehicle utilisation and reducing maintenance costs. CUSTOMER APPLICATION A fleet of straddle carriers services a busy German container port, operating round the clock in a highly aggressive environment. Frequent maintenance is necessary, but traditional, interval-based maintenance schedules are not always optimal. Condition-based intervention minimises the risk of breakdowns, while imposing fewer constraints on day-to-day operation; it also incurs cost only when necessary. As a carrier moves over a container, a central spreader beam lowers and locks onto the four corner fittings of the container. Plain plastic bearings on the carrier legs guide the container as it is raised; there is significant contamination from dirt and other debris. Bearings wear rapidly in the all-weather operating conditions. A condition-monitoring system must measure bearing thickness, repeatably and accurately, in real time and with µm resolution. Sensors must operate reliably in the harsh environment with a minimum rating of IP67. Sensor length must not exceed 70mm and a minimum sensing range of 30mm is mandatory.
Customer Solution Contrinex’s Analogue Inductive sensors, which feature ‘Extra Distance’ technology are ideal for this demanding application. These M30- diameter metal-bodied devices are IP67-rated and provide an analogue voltage (0 to 10 volt) or current (4 to 20mA) output. The sensors are less than 50mm long with a 40mm sensing range, comfortably exceeding the specified requirement. A mild steel mounting plate, fixed immediately behind the plastic bearing, locates each sensor with its sensing face in contact with the rear surface of the bearing. As a container passes over the front face of the bearing, the sensor measures the distance to the metal container wall, and thus the bearing thickness. Data is collected in real time with exceptional accuracy and resolution in the micron range. Data passes to on-board computers mounted on each carrier; connection is via a flexible cable with an easily detachable M12 connector. At intervals, carriers transmit data wirelessly to a central processor for detailed analysis. The output gives a clear indication of the condition and wear rate of each bearing, identifying any carrier requiring maintenance. Consequently, the port operator has the means to develop a genuine commercial advantage by eliminating compromise from day-to-day operating processes.
APPLICATION - BEARING MEASUREMENT
APPLICATION - RFID TRACKING OF MOBILE CONVEYOR
A manufacturer of bulk material-handling equipment uses Contrinex Radio Frequency IDentification (RFID) technology to sense the position of a large rail-mounted reclamation-conveyor operating in a hot, dusty environment. A pair of read-write modules, mounted on the machine structure, interrogates a series of RFID tags, positioned at one-meter intervals along each travel rail. The control system identifies each tag individually and determines the exact position of the machine. CUSTOMER APPLICATION During surface-mining operations, large mobile reclamation machines are used to recover bulk materials. On each machine, a bucket-wheel excavator collects material and deposits it onto a conveyor. As an area is cleared of material, the machine moves along parallel steel travel rails to the next area, allowing continuous operation without interruptions for machine repositioning. The distance between the travel rails is around 100 metres (300 ft) and travel speeds may reach 2m/sec (4.5 mph). If machine movement along the two rails is not controlled accurately, the two sides of the structure become misaligned, causing the machine to skew. In this event, production is halted while the machine is realigned; in the worst case, costly damage occurs. A sensing system is required that detects the position of each side of the machine structure accurately and reliably along the entire length of the travel rails, allowing coordinated control of the drive systems. Sensors must accommodate up to 10mm lateral movement of the machine structure across either rail and must withstand the hot, dusty environment of a desert climate.
Customer Solution Contrinex high-frequency RFID read/write modules and 30mm- diameter RFID transponder tags are ideal for this application. Rated up to IP67, the M30-diameter read/write modules have PBTP sensing faces and V2A stainless-steel housings, making them ideal for the demanding environment. The ConIdent® passive transponders require no internal power source and, with PBTP synthetic housings, have the same IP67 rating. The selected combination provides read/write distances of up to 45mm (nearly 2 in), ideal for the specified operating conditions. Tags are mounted at one-meter intervals along each travel rail, each programmed with a unique identification number. As the machine passes a tag, the read/write module reads its identification number at high speed; this is transmitted via a PROFIBUS DP interface to the customer’s control system. A simple look-up table confirms the location of the tag and thus the position of the machine, allowing movement of both sides of the structure to be synchronized without skewing. Operation is independent of the direction of travel. Contrinex ConIdent® RFID devices allow accurate and highly reliable sensing of machine position and the long sensing distance avoids any risk of collision damage. The customer enjoys extended service life and robustness not available from alternative position-detection systems, together with excellent value for money.
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CUSTOMER VALUES • Maximum vehicle utilisation with fewer constraints on operations • Real-time indication of bearing condition and wear rate • Reduced maintenance costs with minimal incidence of breakdowns • Reliable operation in a highly demanding and harsh environment
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PRODUCT ADVANTAGES • Analogue device with extended 40mm sensing range • Small physical size (less than 50mm length) • Exceptional accuracy and resolution in the micron range
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CUSTOMER VALUES • Uninterrupted production as positional identification is highly reliable. • No risk of skewing as movement of the machine structure is synchronised. • Elimination of collision damage because of sensing distance up to 45mm.
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PRODUCT ADVANTAGES • Passive RFID transponder tags require no power source and minimal maintenance. • Rugged RFID transponder tags with nylon or all-metal housings sealed to IP67. • ConIdent® technology provides extended sensing range ≤ 45mm. • Read/write units interface with a choice of industry-standard control systems or IO-Link.
BROCHURE
APPLICATION - FORKLIFT TRUCKS
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 VIDEO
PLUS Automation ® Limited © 2020 Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire. WR9 0LG
Helping you #MakeSenseofSensors
CRANES & MATERIAL- HANDLING APPLICATIONS Reliability and robustness is a primary concern on material handling equipment and cranes, making Contrinex’s sensors ideal.
Customer Solution Contrinex’s Analogue Inductive sensors, which feature ‘Extra Distance’ technology are ideal for this demanding application. These M30-diameter metal-bodied devices are IP67-rated and provide an analogue voltage (0 to 10 volt) or current (4 to 20mA) output. The sensors are less than 50mm long with a 40mm sensing range, comfortably exceeding the specified requirement. A mild steel mounting plate, fixed immediately behind the plastic bearing, locates each sensor with its sensing face in contact with the rear surface of the bearing. As a container passes over the front face of the bearing, the sensor measures the distance to the metal container wall, and thus the bearing thickness. Data is collected in real time with exceptional accuracy and resolution in the micron range. Data passes to on-board computers mounted on each carrier; connection is via a flexible cable with an easily detachable M12 connector. At intervals, carriers transmit data wirelessly to a central processor for detailed analysis. The output gives a clear indication of the condition and wear rate of each bearing, identifying any carrier requiring maintenance. Consequently, the port operator has the means to develop a genuine commercial advantage by eliminating compromise from day-to-day operating processes.
Busy container seaports rely upon the ‘24/7’ operation of specialist container-handling vehicles called Straddle Carriers for loading, unloading and stacking containers. Often located at ports, being beside the sea can mean that they have to work in an aggressive and corrosive environment, requiring frequent maintenance. Because traditional, interval-based maintenance schedules are not optimally efficient, condition-based intervention systems which minimise the risk of breakdown, are popular. European port operators therefore frequently rely upon Contrinex’s rugged, analogue-output inductive sensors to monitor components with a high risk of premature failure, maximising vehicle utilisation and reducing maintenance costs. CUSTOMER APPLICATION A fleet of straddle carriers services a busy German container port, operating round the clock in a highly aggressive environment. Frequent maintenance is necessary, but traditional, interval-based maintenance schedules are not always optimal. Condition-based intervention minimises the risk of breakdowns, while imposing fewer constraints on day-to-day operation; it also incurs cost only when necessary. As a carrier moves over a container, a central spreader beam lowers and locks onto the four corner fittings of the container. Plain plastic bearings on the carrier legs guide the container as it is raised; there is significant contamination from dirt and other debris. Bearings wear rapidly in the all-weather operating conditions. A condition-monitoring system must measure bearing thickness, repeatably and accurately, in real time and with µm resolution. Sensors must operate reliably in the harsh environment with a minimum rating of IP67. Sensor length must not exceed 70mm and a minimum sensing range of 30mm is mandatory.
APPLICATION - FORKLIFT TRUCKS
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 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 VALUES • Maximum vehicle utilisation with fewer constraints on operations • Real-time indication of bearing condition and wear rate • Reduced maintenance costs with minimal incidence of breakdowns • Reliable operation in a highly demanding and harsh environment PRODUCT ADVANTAGES • Analogue device with extended 40mm sensing range • Small physical size (less than 50mm length) • Exceptional accuracy and resolution in the micron range + + CUSTOMER VALUES • Reliable sensing of hoist-carriage position in a busy container seaport • Significant reduction in crane downtime • Marked decrease in maintenance costs for replacement sensors PRODUCT ADVANTAGES • IP68 and IP69K rating • Cost-effective high-performance sensor with exceptional reliability • Sensing distances up to 40mm in industry-standard 40 x 40mm housing + + CUSTOMER VALUES •Long sensing range (500mm) available in a physically small sensor. (20x30x10mm). • Exceptional resistance to extreme vibration during operation. • Optimal space utilisation with little or no reliance on operator involvement PRODUCT ADVANTAGES • Elimination of calibration errors during normal operation • Provides reliable, repeatable sensing in demanding operating conditions +
APPLICATION - BEARING WEAR MEASUREMENT
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
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.
APPLICATION - STRADDLE CARRIER TRUCK
Customer Solution Highly stable, non-contact, all-electronic units from the Contrinex range of photoelectric sensors provide a reliable and cost-effective alternative. The moulded-resin sensor casings, fitted with coated-plastic sensing faces, are IP67 rated, making them virtually impervious to the harsh, salt- laden environment of a busy container port. Connection to the vehicle’s control systems is via an integral M12 connector and PVC-sheathed cable, allowing easy removal and replacement during routine maintenance. To confirm the size of the container, two pairs of diffuse sensors with background suppression are mounted centrally on each lifting beam. As the lifting beam descends, one sensor from each pair detects the presence or absence of corner castings at the central lifting points, while the other detects the presence or absence of the gap between two 20-foot containers. The combination of the two eliminates incorrect identification in the unlikely event that the first sensor returns a false-positive signal from a 40-foot container. A physically small housing and long sensing distances eliminate the risk of accidental damage arising from a mechanical collision, while rugged industry-standard housings and vacuum-encapsulated electronics minimize the effects of vibration. Operational results have been excellent; the new Contrinex sensors have eliminated calibration errors and reduced maintenance costs significantly.
At busy container seaports, purpose-designed container- handling vehicles called Straddle Carriers, operate around the clock, loading, unloading and stacking containers. Space utilisation is increasingly important and correctly identifying the size of container picked for each lift is essential for efficiency. Contrinex photoelectric sensors have been fitted to the Straddle Carriers to detect the container size and eliminate the need for drivers to carry out identification checks, saving time and avoiding errors. CUSTOMER APPLICATION A fleet of straddle carriers, purpose-designed container- handling vehicles, services a busy French container port. As a straddle carrier moves over a container, a central lifting beam lowers and locks onto the corner castings of the container; each lift comprises either a single 40-foot container or two 20-foot containers. Optimal utilisation of storage space is essential; correctly identifying the size of container picked for each lift is vital. Fitting carriers with sensors that detect the size and type of containers at the time of lifting eliminate the need for drivers to carry out identification checks, saving time and avoiding errors. The original mechanical sensors proved unreliable, losing calibration when subjected to continuous vibration during normal operation. Although the scheduled maintenance interval for each vehicle is 1,000 hours, mechanical sensors required recalibration at intervals of no more than two or three days. A highly stable replacement sensor system was required.
Customer Solution Contrinex high-frequency RFID read/write modules and 30mm-diameter RFID transponder tags are ideal for this application. Rated up to IP67, the M30-diameter read/write modules have PBTP sensing faces and V2A stainless-steel housings, making them ideal for the demanding environment. The ConIdent® passive transponders require no internal power source and, with PBTP synthetic housings, have the same IP67 rating. The selected combination provides read/write distances of up to 45mm (nearly 2 in), ideal for the specified operating conditions. Tags are mounted at one-meter intervals along each travel rail, each programmed with a unique identification number. As the machine passes a tag, the read/write module reads its identification number at high speed; this is transmitted via a PROFIBUS DP interface to the customer’s control system. A simple look-up table confirms the location of the tag and thus the position of the machine, allowing movement of both sides of the structure to be synchronized without skewing. Operation is independent of the direction of travel. Contrinex ConIdent® RFID devices allow accurate and highly reliable sensing of machine position and the long sensing distance avoids any risk of collision damage. The customer enjoys extended service life and robustness not available from alternative position-detection systems, together with excellent value for money
A manufacturer of bulk material-handling equipment uses Contrinex Radio Frequency IDentification (RFID) technology to sense the position of a large rail-mounted reclamation- conveyor operating in a hot, dusty environment. A pair of read-write modules, mounted on the machine structure, interrogates a series of RFID tags, positioned at one-meter intervals along each travel rail. The control system identifies each tag individually and determines the exact position of the machine. CUSTOMER APPLICATION During surface-mining operations, large mobile reclamation machines are used to recover bulk materials. On each machine, a bucket-wheel excavator collects material and deposits it onto a conveyor. As an area is cleared of material, the machine moves along parallel steel travel rails to the next area, allowing continuous operation without interruptions for machine repositioning. The distance between the travel rails is around 100 metres (300 ft) and travel speeds may reach 2m/sec (4.5 mph). If machine movement along the two rails is not controlled accurately, the two sides of the structure become misaligned, causing the machine to skew. In this event, production is halted while the machine is realigned; in the worst case, costly damage occurs. A sensing system is required that detects the position of each side of the machine structure accurately and reliably along the entire length of the travel rails, allowing coordinated control of the drive systems. Sensors must accommodate up to 10mm lateral movement of the machine structure across either rail and must withstand the hot, dusty environment of a desert climate
+ CUSTOMER VALUES • Uninterrupted production as positional identification is highly reliable. • No risk of skewing as movement of the machine structure is synchronised. • Elimination of collision damage because of sensing distance up to 45mm. PRODUCT ADVANTAGES • Passive RFID transponder tags require no power source and minimal maintenance. • Rugged RFID transponder tags with nylon or all-metal housings sealed to IP67. • ConIdent® technology provides extended sensing range ≤ 45mm. • Read/write units interface with a choice of industry-standard control systems or IO-Link.  +
APPLICATION - RFID TRACKING OF MOBILE CONVEYOR
APPLICATION VIDEO
APPLICATION - CONTAINER CRANE
Container-handling cranes in Britain’s busy seaports operate around the clock relying upon Contrinex’s rugged inductive sensors on each hoist carriage to detect its position with respect to the crane structure and prevent it travelling outside preset limits. Because mechanical play in the hoist carriage allows a small amount of lateral drift as it travels along the crane structure, Contrinex’s long sensing distance is essential to prevent the sensor colliding with the crane structure. CUSTOMER APPLICATION Loading and unloading containers in a busy British seaport is a 24-hour activity, all year round, with optimum utilisation of storage space being essential to achieve maximum operating efficiency. Container-handling cranes operate above a storage area, positioning containers before lowering them into place. The hoist carriage on each crane travels along the length of the crane structure, traversing the width of the storage area to achieve complete coverage of the available storage space. Sensors fitted to the hoist carriage detect the ends of the structure, cutting power to the drive-motors and preventing the carriage from travelling beyond allowable limits. Mechanical play in the drive system results in the carriage drifting laterally as it travels along the crane structure. The 15mm sensing range of a competitor’s sensors were inadequate; occasionally causing sensors to collide with the crane’s structure, causing damage and interrupting operation. Better inductive sensors with increased sensing range are needed to prevent collisions.
Customer Solution Contrinex’s ‘Basic’ range of inductive sensors are highly suited for this application. Mounted in rugged 40 x 40mm polyamide glass-fibre housings, these devices from the ‘Classics’ technology family utilised a 20mm sensing distance that eliminates the risk of collisions. A 40mm sensing distance is also available for this sensor if needed and its IP68 / IP69K-rating makes it ideal for the outdoor working environment, even in a seaport. The use of industry-standard housings for these Contrinex sensors ensures that they are drop-in replacements for competitor’s devices. No modification to the mounting arrangements was necessary, incurring little downtime during the changeover to the new sensing arrangements. Communication with the crane’s control system is via a PNP changeover interface, replacing the existing two-wire arrangement; a flexible PUR-sheathed cable provides the electrical connection. The new sensor features an integral S12 connector, allowing easy removal and replacement for maintenance. A step improvement in operational performance was evident immediately after the new units were installed. The new sensors provide reliable sensing of each hoist’s position with no reported collisions since the date of installation. The customer has reported a marked reduction in crane downtime with an associated decrease in expenditure on replacement sensors.
BROCHURE