Helping you #Make Sense of Sensors
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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 Portuguese 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
APPLICATION - CHECK METAL WASHERS USING LONG-RANGE INDUCTIVES
A plastics manufacturer tests batches of control knobs for in-car audio systems before shipment to automotive assembly plants; each knob contains a small metal washer that occasionally becomes dislodged. A custom-built testing machine tests a tray of 70 knobs in a single cycle; long-distance inductive sensors, positioned directly below the knobs, confirm the presence of a washer in each assembly. CUSTOMER APPLICATION In operation, plastic control knobs for in-car audio systems are retained in position by small spring washers; during manufacture, a washer is fitted to each knob after molding. A Portuguese manufacturer transports batches of knobs to automotive assembly plants in transit trays, each containing 70 knobs. Occasionally, washers are omitted or become dislodged, resulting in rejection of entire batches of knobs by the customer. Manual inspection of each knob is neither practical nor cost-effective; a sensor system must test each knob in-situ in the transit tray. The size and position of the washers makes the task particularly demanding. Each 10mm-diameter washer is formed from 1mm- diameter steel wire; in a batch of knobs, located at 45mm centres in a transit tray, washers lie more than 10 millimetres above the sensors. The sensors must operate reliably in close proximity to one another, sensing the presence of the washers through the plastic tray.
Customer Solution Contrinex Extra Distance inductive sensors are ideal for this application; M18-diameter units from the Basic range operate reliably at sensing distances up to 12mm. Quasi-embeddable with chrome- plated brass bodies and PBTP sensing faces, these devices allow a minimum clearance between sensors of only 44mm, comfortably accommodating the required spacing. A bank of 70 sensors, mounted in a custom-built testing fixture, aligns exactly with the positions of the knobs in the transit tray. Locating lugs position the tray correctly and clamps secure it during the testing cycle; checking the presence of a washer in each of the 70 knobs is accomplished in a few seconds and in the event that a washer is missing, the position of the faulty knob is immediately identified. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC- sheathed cable. With an unmatched combination of extended sensing distance and exceptional packing density, Contrinex Extra Distance inductive sensors deliver highly reliable test results. Previously, the customer had no reliable means of testing a complete tray of knobs in a single operation.
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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
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CUSTOMER VALUES • Reliable, repeatable testing of complete trays of knobs in a single cycle • Testing is completed in standard transit trays with no additional handling • Immediate identification of faulty assemblies • Elimination of batch rejection by the customer
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PRODUCT ADVANTAGES • Extended sensing distances up to 12mm • Exceptional packing density with 44mm clearance • Reliable sensing of small targets through plastic tray material
APPLICATION - POST-FILLING CHECK OF ALUMINIUM CLOSURES
Plastic containers, filled with liquid food products, are hermetically sealed at a Portuguese food-processing plant. Prior to containers being capped and packed in bulk, in-line testing confirms that each one has been correctly sealed. A long-distance inductive sensor, positioned directly over the packaging line, senses the presence of an aluminium-foil seal over the top of each container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilized as seals for plastic containers filled with mustard, ketchup and other table sauces. At a Portuguese food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time and potential rejection by customers. An in-line sensor system must inspect each container and detect the presence of a foil closure, rejecting any faulty items. Each line processes containers in batches; successive batches may comprise filled containers of differing sizes. The system must accommodate containers whose heights vary by up to 20mm, without positional adjustment of sensors between batches.
Customer Solution Contrinex Extra Distance inductive sensors are ideal for this application. M30-diameter units from the range operate reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC- sheathed cable. With an unmatched combination of 40mm sensing distance in an M30- diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
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CUSTOMER VALUES • Reliable, repeatable in-line testing of a range of different-sized containers • Testing is completed without difficulty at production-line speed • Immediate identification of containers with missing closures • Elimination of manual inspection and potential batch rejection
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PRODUCT ADVANTAGES • Extended sensing distances up to 40mm • Unmatched combination of 40mm sensing distance in M30-diameter device
500 SERIES EXTENDED DISTANCE INDUCTIVES Contrinex is famous for it’s extended sensing distance inductive sensors, with the ‘500 Series’ which offers a large range of sensors and provides a vast range of solutions. 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.
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Helping you #MakeSenseofSensors
500 SERIES EXTENDED DISTANCE INDUCTIVE Contrinex is famous for it’s extended sensing distance inductive sensors, the ‘500 Series’ which offers a large range of sensors, and provides a vast range of solutions. 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 - CHECK METAL WASHERS USING INDUCTIVES
Customer Solution Contrinex Extra Distance inductive sensors are ideal for this application; M18-diameter units from the Basic range operate reliably at sensing distances up to 12mm. Quasi- embeddable with chrome-plated brass bodies and PBTP sensing faces, these devices allow a minimum clearance between sensors of only 44mm, comfortably accommodating the required spacing. A bank of 70 sensors, mounted in a custom-built testing fixture, aligns exactly with the positions of the knobs in the transit tray. Locating lugs position the tray correctly and clamps secure it during the testing cycle; checking the presence of a washer in each of the 70 knobs is accomplished in a few seconds and in the event that a washer is missing, the position of the faulty knob is immediately identified. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of extended sensing distance and exceptional packing density, Contrinex Extra Distance inductive sensors deliver highly reliable test results. Previously, the customer had no reliable means of testing a complete tray of knobs in a single operation.
A plastics manufacturer tests batches of control knobs for in-car audio systems before shipment to automotive assembly plants; each knob contains a small metal washer that occasionally becomes dislodged. A custom-built testing machine tests a tray of 70 knobs in a single cycle; long- distance inductive sensors, positioned directly below the knobs, confirm the presence of a washer in each assembly. CUSTOMER APPLICATION In operation, plastic control knobs for in-car audio systems are retained in position by small spring washers; during manufacture, a washer is fitted to each knob after molding. A Portuguese manufacturer transports batches of knobs to automotive assembly plants in transit trays, each containing 70 knobs. Occasionally, washers are omitted or become dislodged, resulting in rejection of entire batches of knobs by the customer. Manual inspection of each knob is neither practical nor cost-effective; a sensor system must test each knob in-situ in the transit tray. The size and position of the washers makes the task particularly demanding. Each 10mm-diameter washer is formed from 1mm-diameter steel wire; in a batch of knobs, located at 45mm centres in a transit tray, washers lie more than 10 millimetres above the sensors. The sensors must operate reliably in close proximity to one another, sensing the presence of the washers through the plastic tray.
+ CUSTOMER VALUES • Reliable, repeatable testing of complete trays of knobs in a single cycle • Testing is completed in standard transit trays with no additional handling • Immediate identification of faulty assemblies • Elimination of batch rejection by the customer PRODUCT ADVANTAGES • Extended sensing distances up to 12mm • Exceptional packing density with 44mm clearance • Reliable sensing of small targets through plastic tray material +
Plastic containers, filled with liquid food products, are hermetically sealed at a Portuguese food-processing plant. Prior to containers being capped and packed in bulk, in-line testing confirms that each one has been correctly sealed. A long-distance inductive sensor, positioned directly over the packaging line, senses the presence of an aluminium-foil seal over the top of each container. CUSTOMER APPLICATION Aluminium-foil closures are commonly utilized as seals for plastic containers filled with mustard, ketchup and other table sauces. At a Portuguese food-processing plant, closures are applied to filled containers passing along an automated production line, sealing the contents ready for capping and bulk packaging. From time to time, equipment malfunctions occur and containers leave the sealing station without closures in place. If unsealed containers are not detected prior to capping, entire batches of product may require manual inspection, resulting in lost production, down-time and potential rejection by customers. An in-line sensor system must inspect each container and detect the presence of a foil closure, rejecting any faulty items. Each line processes containers in batches; successive batches may comprise filled containers of differing sizes. The system must accommodate containers whose heights vary by up to 20mm, without positional adjustment of sensors between batches.
APPLICATION - POST-FILLING CHECK OF CLOSURES
Customer Solution Contrinex Extra Distance inductive sensors are ideal for this application. M30-diameter units from the range operate reliably at sensing distances up to 40mm; a single sensor thus accommodates the entire range of container heights. Robust construction with chrome-plated brass bodies and PBTP sensing faces ensures that these devices are suitable for a busy production environment. A single sensor, located immediately after the sealing station and positioned directly above the production line, provides reliable, repeatable detection of the aluminium-foil closures. With a switching frequency of up to 100Hz, this Extra Distance unit is well suited for fast-moving production where high-speed sensing is required. This Contrinex inductive sensor has an industry-standard PNP normally-open interface and an integral M12 cable connector, allowing easy removal and replacement of individual sensors for maintenance. Connection to the customer’s test equipment is via a flexible PVC-sheathed cable. With an unmatched combination of 40mm sensing distance in an M30-diameter device, the customer can now test the entire range of containers without adjusting the sensor height between batches. Contrinex Extra Distance inductive sensors deliver exceptionally reliable test results at production-line speed, without interruption.
+ CUSTOMER VALUES • Reliable, repeatable in-line testing of a range of different-sized containers • Testing is completed without difficulty at production-line speed • Immediate identification of containers with missing closures • Elimination of manual inspection and potential batch rejection PRODUCT ADVANTAGES • Extended sensing distances up to 40mm • Unmatched combination of 40mm sensing distance in M30-diameter device +
APPLICATION - COMPONENT PRESENCE CHECK OF HOSES
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 Portuguese 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).
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
+ CUSTOMER VALUES • Reliable, repeatable detection of three discrete parts in a single operation • Elimination of unsafe occurrences due to faulty hose assemblies • Highly cost-effective solution to a previously insoluble problem PRODUCT ADVANTAGES • Exceptional sensing distances in small sensor envelopes • Correction factor of 1.0 for brass allows extended sensing distance • Sensors operate in close proximity without interference +
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.
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