Helping you #Make Sense of Sensors
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A manufacturer of canned products uses inductive sensors with analogue outputs in the packaging department to check that closed cartons have the required number of cans inside. The sensor’s analogue output enables it to process different can sizes and materials in a final pre-shipment quality check for a range of product types. CUSTOMER APPLICATION Canned products are fragile, easily crushed or pierced. They are protected during delivery by being tightly packed into sturdy cardboard boxes. However, this packaging process may itself damage the cans if a fault occurs and, once the box is closed, there is no longer any possibility of a final visual check. To eliminate product faults that may have occurred during upstream processes, the customer seeks a means of verifying product quality inside the box. The solution chosen must be able to deal with all canned products in the manufacturer’s delivery range, comprising cans in different sizes and materials. This is not possible with an ordinary on-off switching sensor output. The verification process must also be integrated into a fast-moving automated packaging and pre- shipment line, accepting or rejecting each carton instantly. Customer Solution Analogue inductive sensors from the 509 Series are ideal for this application. Their Condist® oscillator technology ensures excellent environmental stability – especially to temperature – and so allows operating distances up to 3 times the standard (in this case 40 mm). The extra distance enables them to obtain a good signal not only through multiple layers of cardboard, but also from different conductive metals at varying distances, depending on can type. The customer has mounted inductive analogue sensors on two conveyor lines. By mounting them both above and below the passing lanes of cans, the double layer of cans in each carton can be checked through the box. Size M30 was chosen to yield the greatest sensing distance for the project parameters. The continuous output from these sensors is connected directly to a PLC with a high-speed analogue input card. Resolution is in the µm range and repeat accuracy is very good. The solution is durable, adaptable, reliable and simple to install.
APPLICATION - PRESENCE CHECK OF CANS IN A CARDBOARD BOX
APPLICATION - LABEL ALIGNMENT
During high-volume production of confectionery, sealed cartons of bagged candy travel by conveyor to a labelling station. Conrinex’s versatile photoelectric contrast sensor, mounted beside the conveyor, checks the label alignment and confirms the presence of print markings as each carton leaves the labelling area. If a label is blank, illegible or wrongly positioned, the carton is diverted to a holding area for investigation. CUSTOMER APPLICATION In the food-processing industry, packaged consumer products require labelling – both for identification and for batch control – before final packing. During confectionery production, sealed cartons of bagged candy travel by conveyor from carton-taping stations to a label printer- applicator, before passing to the final packing area. The printer-applicator, which is located at one side of the conveyor, produces a continuous feed of printed labels from roll-stock. As each carton passes the applicator head, the label-stock advances, peeling a single label and applying it to the side of the carton. From time to time, misfeeds or malfunctions occur within the printer- applicator, which consequently applies labels that are either blank, illegible or wrongly positioned. Failure to detect these errors results in unidentified or untraceable products arriving at subsequent operations or, critically, at the customer’s premises. A highly reliable non-contact sensor system is needed. The sensor must detect the alignment of labels and confirm the presence of print markings as cartons leave the printer-applicator, rejecting any defective cartons.
Customer Solution A photoelectric contrast sensor from the Contrinex Cubic Small range is ideal for this application. This versatile device incorporates a single- lens autocollimator, delivering a narrow optical beam that allows detection of very small features. The choice of red, green or blue LED light, auto-selectable during set-up, ensures optimal contrast resolution. Immediately after the applicator, a single sensor is mounted beside the conveyor; adjustable mounting brackets makes for easy positioning. As the label on each carton passes the detection point, changes in contrast trigger the sensor. The transition from carton surface to label body identifies the position and alignment of the label itself, while the well-defined contrast between printed content and the label body ensures reliable detection of even the smallest print marks. If the label is wrongly aligned or the print markings missing, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. An operating range up to 12mm allows adequate clearance between sensor and target, while the compact 40mm x 50mm x 15mm PBTB plastic housing is both mechanically robust and small enough to accommodate any space constraints. Set-up is accomplished either using a three-button keypad on the sensor, or via IO-Link, a standardized point-to-point serial connection protocol. Photoelectric contrast sensors are available with industry- standard push-pull 4-wire output. Connection to the customer’s control system is via a PVC-sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry.
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CUSTOMER VALUES A single solution to check different can types Reliable quality of deliveries Direct interface to a controller (0–10 VDC or 4–20 mA) Long service life Simple installation Non-visual solution
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PRODUCT ADVANTAGES Analogue output with direct interface to controller (0–10 VDC or 4–20 mA) Long sensing distances compared to market standard Excellent temperature stability Very good repeating accuracy Sensing range up to 40 mm Resolution in µm range Current and voltage outputs in same device Several switch points with a single device
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CUSTOMER VALUES • Reliable, repeatable in-line detection on a non-contact basis • Real-time rejection of unidentified or untraceable products • Remote set-up via IO-Link reduces need for manual intervention
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PRODUCT ADVANTAGES • Operating range up to 12mm with three- colour RGB emission technology • Automatic selection of best emission colour • IO-Link connectivity available at no extra cost • High switching frequency up to 10kHz • Versatile industry-standard push-pull 4-wire output • High tolerance to object position variation around 12 mm
CATALOGUE EXTRACT BROCHURE
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick-and-place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and-place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and-place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary- packaging station, a plant-wide control system prevents operation of the pick-and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom- formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non- contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and- place sequence if no bags are queued for packing.
Customer Solution Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm- diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC-sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs.
APPLICATION - DETECTING BAGS OF SWEETS AT BUFFERING STATION
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CUSTOMER VALUES • Maximum sensing range 3mm to 1.5m. • Preventative maintenance ‘stability alarm’ – Output over IO-Link, or second switched output. • Switching frequency selectable between 500Hz and 5kHz via IO-Link • IO-Link interface included for free – Ideal for Industry 4.
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PRODUCT ADVANTAGES • Reliable, repeatable in-line detection on a non-contact basis. • Elimination of errors caused by previous mechanical sensors. • Increased productivity as stability alarm flags preventative-maintenance needs. • Single sensor accommodates a range of bag sizes without repositioning. • Remote adjustment via IO-Link reduces changeover time between products
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless- steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
PACKAGING APPLICATIONS Sensors from Contrinex’s Photoelectric, Inductive, RFID and Machine Safety families are used on packaging machines due to their high performance and reliability.
PLUS Automation ® Limited © 2020 Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire. WR9 0LG
Helping you #MakeSenseofSensors
PACKAGING APPLICATIONS Sensors from Contrinex’s Photoelectric, Inductive, RFID and Machine Safety families are used on packaging machines due to their high performance and reliability.
Application-Presence Check Cans in Cardboard Box
A manufacturer of canned products uses inductive sensors with analogue outputs in the packaging department to check that closed cartons have the required number of cans inside. The sensor’s analogue output enables it to process different can sizes and materials in a final pre-shipment quality check for a range of product types. Canned products are fragile, easily crushed or pierced. They are protected during delivery by being tightly packed into sturdy cardboard boxes. However, this packaging process may itself damage the cans if a fault occurs and, once the box is closed, there is no longer any possibility of a final visual check. To eliminate product faults that may have occurred during upstream processes, the customer seeks a means of verifying product quality inside the box. The solution chosen must be able to deal with all canned products in the manufacturer’s delivery range, comprising cans in different sizes and materials. This is not possible with an ordinary on- off switching sensor output. The verification process must also be integrated into a fast-moving automated packaging and pre-shipment line, accepting or rejecting each carton instantly. Customer Solution Analogue inductive sensors from the 509 Series are ideal for this application. Their Condist® oscillator technology ensures excellent environmental stability – especially to temperature – and so allows operating distances up to 3 times the standard (in this case 40 mm). The extra distance enables them to obtain a good signal not only through multiple layers of cardboard, but also from different conductive metals at varying distances, depending on can type. The customer has mounted inductive analogue sensors on two conveyor lines. By mounting them both above and below the passing lanes of cans, the double layer of cans in each carton can be checked through the box. Size M30 was chosen to yield the greatest sensing distance for the project parameters. The continuous output from these sensors is connected directly to a PLC with a high-speed analogue input card. Resolution is in the µm range and repeat accuracy is very good. The solution is durable, adaptable, reliable and simple to install.
APPLICATION - LABEL ALIGNMENT
During high-volume production of confectionery, sealed cartons of bagged candy travel by conveyor to a labelling station. Contrinex’s versatile photoelectric contrast sensor, mounted beside the conveyor, checks the label alignment and confirms the presence of print markings as each carton leaves the labelling area. If a label is blank, illegible or wrongly positioned, the carton is diverted to a holding area for investigation. CUSTOMER APPLICATION In the food-processing industry, packaged consumer products require labelling – both for identification and for batch control – before final packing. During confectionery production, sealed cartons of bagged candy travel by conveyor from carton-taping stations to a label printer- applicator, before passing to the final packing area. The printer-applicator, which is located at one side of the conveyor, produces a continuous feed of printed labels from roll-stock. As each carton passes the applicator head, the label-stock advances, peeling a single label and applying it to the side of the carton. From time to time, misfeeds or malfunctions occur within the printer-applicator, which consequently applies labels that are either blank, illegible or wrongly positioned. Failure to detect these errors results in unidentified or untraceable products arriving at subsequent operations or, critically, at the customer’s premises. A highly reliable non-contact sensor system is needed. The sensor must detect the alignment of labels and confirm the presence of print markings as cartons leave the printer- applicator, rejecting any defective cartons.
Customer Solution A photoelectric contrast sensor from the Contrinex Cubic Small range is ideal for this application. This versatile device incorporates a single-lens autocollimator, delivering a narrow optical beam that allows detection of very small features. The choice of red, green or blue LED light, auto- selectable during set-up, ensures optimal contrast resolution. Immediately after the applicator, a single sensor is mounted beside the conveyor; adjustable mounting brackets makes for easy positioning. As the label on each carton passes the detection point, changes in contrast trigger the sensor. The transition from carton surface to label body identifies the position and alignment of the label itself, while the well- defined contrast between printed content and the label body ensures reliable detection of even the smallest print marks. If the label is wrongly aligned or the print markings missing, the sensor triggers a reject mechanism that diverts the carton to a holding area for investigation. An operating range up to 12mm allows adequate clearance between sensor and target, while the compact 40mm x 50mm x 15mm PBTB plastic housing is both mechanically robust and small enough to accommodate any space constraints. Set-up is accomplished either using a three-button keypad on the sensor, or via IO-Link, a standardized point-to-point serial connection protocol. Photoelectric contrast sensors are available with industry-standard push-pull 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry.
Customer Solution Diffuse-mode photoelectric sensors from the Contrinex C23PA family of sensors are ideal for this application. These highly reliable devices contain both a transmitter and a receiver and do not require a separate reflector, instead relying on the reflective nature of the target. Space constraints are accommodated without compromise, thanks to a maximum sensing range of 3 to 1500mm. This is adjustable via a pre-set potentiometer or via IO-Link, the standardised point-to-point serial connection protocol. Immediately before the alignment rails, a single sensor is mounted beside the conveyor; positioning sensors is simple thanks to a range of adjustable mounting brackets. As each bag passes in front of the sensor, its presence triggers the device, sending a signal to the customer’s control system. A high-intensity red LED with a 15mm-diameter light spot at the selected 500mm sensing range ensures highly reliable detection of bags in real-time. Mounted in 20mm x 30mm x 10mm miniature plastic housings, C23 photoelectric sensors are available with industry-standard PNP or NPN 3-wire or 4-wire output. Connection to the customer’s control system is via a PVC- sheathed cable with the choice of an integral M12 connector or a hermetically sealed entry. A second output provides a stability alarm in the event of reduced sensitivity, flagging the need for preventative maintenance before any performance degradation occurs.
During high-speed production of retail bags, a confectionery manufacturer conveys individual bags of sweets to a pick- and-place packing robot for secondary packaging. A highly reliable diffuse-mode photoelectric sensor, mounted beside the conveyor, detects the presence of bags as they approach the packing station and inhibits the pick-and- place sequence if no bags are queued for the packing robots. CUSTOMER APPLICATION In the food-processing industry, consumer products generally require secondary packaging – both for consolidation and for protection, before final dispatch. During confectionery production, individual bags of sweets travel by conveyor from bagging stations to a pick-and- place packing robot for secondary packaging, before passing on to the labelling and packing area. Ideally, product flow along the conveyor is continuous; in practice, interruptions occur from time to time as bagging machines require attention. In the absence of bagged products arriving at the secondary-packaging station, a plant-wide control system prevents operation of the pick- and-place robot to prevent miss-filling. Immediately prior to arrival at the secondary-packaging station, custom-formed guide rails align bags for packing. Space is limited and there is no easy access to both sides of the conveyor. A highly reliable non-contact sensor system was needed to detect the presence of bags as they approach the alignment rails; the system must inhibit the pick-and-place sequence if no bags are queued for packing.
+ CUSTOMER VALUES • Reliable, repeatable in-line quality checks on a non-contact basis • Improved quality arising from real-time detection of incorrectly packed cartons • Increased productivity as stability alarm flags preventative-maintenance needs • Single sensor accommodates a range of carton sizes without repositioning • Remote adjustment via IO-Link reduces changeover time between products PRODUCT ADVANTAGES • Maximum sensing range of 300mm with pinpoint red LED • Best-in-class background-suppression black/white behaviour • IO-Link connectivity available at no extra cost on PNP versions • Dual output with stability alarm +
APPLICATION - DETECTING SWEETS AT BUFFERING STATION
The sensors are corrosion-resistant and impervious to water ingress and has the additional benefit of offering a range of low-cost stainless-steel mounting and protection bracketry. The reliability of the sensors in the application has been excellent.
FIND OUT MORE - HERE ARE SOME SUGGESTIONS:
+ CUSTOMER VALUES • A single solution to check different can types • Reliable quality of deliveries • Direct interface to a controller (0–10 VDC  or 4–20 mA) • Long service life • Simple installation • Non-visual solution PRODUCT ADVANTAGES • Analogue output with direct interface to controller (0–10 VDC or 4–20 mA) • Long sensing distances compared to market standard • Excellent temperature stability • Very good repeating accuracy • Sensing range up to 40 mm • Resolution in µm range • Current and voltage outputs in same device • Several switch points with a single device + + CUSTOMER VALUES • Reliable, repeatable in-line detection on a non-contact basis • Real-time rejection of unidentified or untraceable products • Remote set-up via IO-Link reduces need for manual intervention PRODUCT ADVANTAGES • Operating range up to 12mm with three-colour RGB emission technology • Automatic selection of best emission colour • IO-Link connectivity available at no extra cost • High switching frequency up to 10kHz • Versatile industry-standard push-pull 4-wire output • High tolerance to object position variation around 12mm + BROCHURES VIDEOS FILLING APPLICATIONS CATALOGUE EXTRACT BROCHURE

TRANSPARENT APPS