(0121) 58 222 58 SALES@PLUSAUTOMATION.CO.UK
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HELPING YOU #MAKE SENSE OF SENSORS
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EXAMPLE APPLICATIONS

TO ILLUSTRATE THE WIDE-VARIETY OF APPLICATIONS SOLVED USING CONTRINEX SENSORS, WE HAVE POSTED A LARGE SELECTION OF EXAMPLE APPLICATIONS WHICH CAN BE SEEN BY CLICKING ON AN IMAGE. BELOW ARE A SELECTION OF SOME OF THESE APPLICATIONS:
CUSTOMER VALUES CONTINUOUS PRODUCTION AS IN-PROCESS MEASUREMENT IS HIGHLY ACCURATE WITH HIGH SAMPLING RATE DEFECTS IDENTIFIED IN REAL TIME MINIMISES REJECT COSTS NO RESTRICTIONS ON MOUNTING POSITION AS SENSORS ARE VIBRATION-RESISTANT AND TEMPERATURE-STABLE COMPATIBILITY WITH EXISTING IN-HOUSE SYSTEMS 0 TO 10V LONG SENSING DISTANCE MINIMISES RISK OF MECHANICAL DAMAGE TO THE SENSOR PRODUCT ADVANTAGES EXCEPTIONAL DETECTION ACCURACY, EXCELLENT REPEATABILITY AND RESOLUTION IN THE MICRON RANGE M) SAMPLING RATE OF 250HZ CONDIST® TECHNOLOGY PROVIDES EXTENDED SENSING RANGE 10 MM RUGGED, VIBRATION-RESISTANT WITH METAL HOUSINGS INDUSTRY-STANDARD 0 TO 10V ANALOGUE OUTPUTS
A manufacturer of industrial timing belts trusts Contrinex’s analogue inductive sensors to measure the position of steel reinforcing bands during continuous production. Two long-range, high-resolution sensors, mounted above the extruded belt profile, provide real-time positional data. The customer’s process-control system monitors the sensor’s analogue voltage outputs, alerting the operator and halting production if the values are outside allowable limits. CUSTOMER APPLICATION To enhance the strength of industrial timing belts, steel reinforcing wires are bonded into the belt carcass as part of a continuous extrusion process. The distance between the reinforcing wires and the belt teeth is a critical parameter, influencing the accuracy of the belt’s fit and other operating characteristics, including service life. Engineers can check product quality at intervals by cutting samples of extruded belts and taking optical measurements, but this process is slow and only detects faults some time after production is complete, leading to high reject costs. The customer requires a real-time system with sensors that reliable and accurately measure the position of the steel reinforcement.
CUSTOMER SOLUTION Contrinex M18-size analogue inductive sensors are ideal for this application providing an analogue voltage output with a sampling rate of at least 100Hz. The physical characteristics of the belt dictate a sensing distance of up to 10 mm with micron (µm) measurement accuracy. Contrinex’s patented Condist® technology provides a highly stable sensing performance at operating distances of ≤10 mm with exceptional detection accuracy, excellent repeatability and resolution in the micron range. The sensors sample at 250Hz, enabling accurate measurement of the position of the steel reinforcement in the fast moving belt profile, and provide continuous, non-linearised 0 to 10V analogue output signals. They are resistant to vibration and variations in ambient temperature, allowing their positioning immediately after the extrusion press in close proximity to the moving belt. Two sensors, set flush into a non-metallic plate, are mounted directly above the surface of the belt as it runs over a guide roller, giving a stable reference position. The lightly tensioned belt clears the sensing face of the devices by a few tenths of a millimetre. Connection to the customer’s control system is via a flexible cable with an easily detachable M12 connector. The introduction of Contrinex analogue inductive sensors provide small, high-accuracy, ultra-reliable sensors with a low total cost of ownership. Rather than needing to destructively test belts to inspect the position of the steel reinforcement and risking high reject costs because of the infrequent nature of the sampling, the production process is now continuously monitored.
CUSTOMER VALUES HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER (0 10 VDC OR 4 20 MA) LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE PRODUCT ADVANTAGES CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL LONG SENSING RANGE OF 40MM PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION IN µM RANGE EXCELLENT TEMPERATURE STABILITY & VERY GOOD REPEATING ACCURACY SEVERAL SWITCH POINTS WITH A SINGLE DEVICE LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION Analogue inductive sensors from Contrinex’s 509 Series are ideal for this application because their Condist® oscillator technology ensures excellent environmental stability, especially to temperature. This is key in providing sensing distances up to 3 times the standard (in this case 40 mm from the M30 sized sensor). This extra sensing distance ability 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 the can type. The customer mounted the M30 sized inductive analogue sensors which yield the greatest sensing distance above and below the passing lanes of cans so that the double layer of cans in each carton can be checked through the cardboard walls of the box. The continuous analogue current or voltage 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 excels because it is durable, adaptable, reliable and simple to install. .
To ensure that sealed cardboard cartons have the required number of tinned food cans inside them, a packaging company trusts Contrinex’s analogue inductive sensors. Using an analogue sensor enables this final pre-shipment quality check to process different sizes of can as well as manage with different material grades of can. CUSTOMER APPLICATION Canned products and their labels are protected during delivery by being tightly packed into sturdy sealed cardboard boxes. This poses a challenge to food packaging companies because retailers, particularly supermarkets require absolute accuracy in the contents of the carton, but at final inspection, the carton is already sealed and so the contents can not be visually inspected. Therefore to eliminate the risk that product faults that may have occurred during upstream processes are shipped out to the customers, the packing company needed a way to verify what tins are inside the sealed box. Because the packaging line handles a variety of cans of different sizes and materials, a conventional on-off switching inductive proximity sensor could not be used. An additional challenge is that the sensor needs to be part of a verification process integrated into a fast-moving automated packaging and pre-shipment line, accepting or rejecting each carton instantly. .
CUSTOMER VALUES HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER (0 10 VDC OR 4 20 MA) LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE PRODUCT ADVANTAGES CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL LONG SENSING RANGE OF 40MM PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION IN µM RANGE EXCELLENT TEMPERATURE STABILITY & VERY GOOD REPEATING ACCURACY SEVERAL SWITCH POINTS WITH A SINGLE DEVICE LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION Contrinex analogue inductive sensors from their Extra Distance 509 Series family are perfect for the position and distance measurement requirements of this application. The sensors provide an analogue value for the entire motion sequence of the x-ray inspection. Their excellent resolution in µm range is particularly suitable for measuring gaps and angles, detecting motion and controlling travel smoothly. The sensors are positioned to measure both the pipe carriage position, which represents the system’s zero-point and is therefore critical for correct operation and the distance between the x-ray source and the pipe surface which is critical to x-ray result quality. The analogue sensors output a continuous voltage or current analogue signal which reflects the gap between the damping element and the sensing surface. With Contrinex’s patent-protected Condist technology, these high-performance analogue sensors provide a sensing range that is more than twice the distance offered by competitors. The M30 versions used in this application offer a sensing range of 0 to 40 mm and so they can provide the flexibility required for testing the numerous pipe diameters being manufactured. The solution excels because it is durable, adaptable, reliable and was also fast and simple to install. .
The integrity of weld seams in pipes used to transport oil or gas across land or sea is ensured using x-ray testing. The x-ray test systems used for this require precision control of the distance between the x-ray source and the surface of the pipe because this is critical for the quality of the imaging data. CUSTOMER APPLICATION A producer of pipes ranging in diameter from 50mm to 2m has a x-ray testing systems integrated to the end of their production lines to ensure the pipes they manufacture will not leak and are impermeable. Pipes for pipelines for example must resist long-term exposure to harsh environments and withstand high pressures and fluctuations in temperature. Therefore, they must be guaranteed to be free from material faults and weak points, such as flaws in the weld seam, like trapped air or slag in the metal. The final inspection of the pipe involves the pipes entering an x-ray test room, which is a radiation-proof bunker. The x-ray source is positioned precisely over the pipe, while a flat panel forms the opposite pole of the system. The flat panel is located inside a large pipe or below a small one. Accurate positioning of pipe, the flat panel and the x-ray source is crucial to achieving optimum test results and therefore accurate and reliable sensors are critical to production efficiency. .
CUSTOMER VALUES ACCURATE HIGH-SPEED MEASUREMENT OF FAST-MOVING MATERIAL DISCRETE RAW-DATA OUTPUT WITH EXCEPTIONAL RESOLUTION REAL-TIME PROCESS MONITORING AND ADJUSTMENT HIGHLY RELIABLE, COST-EFFECTIVE SOLUTION PRODUCT ADVANTAGES CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL RESOLUTION
CUSTOMER SOLUTION Contrinex Analogue Output Inductive sensors are highly accurate and provide the continuous voltage or current outputs required for this application. The quasi-embeddable sensors feature a chrome-plated brass body and PBTP sensing face, with the M18-diameter sensor allowing sensing distances up to 10mm (0.4”) with resolution in the µm range. The sensor, mounted in the sensing head, moves rapidly back and forth across the web and senses through the material of the web as it feeds over the roller. It measures the distance from its sensing face – which lies a known distance from the bottom face of the head, to the top surface of the roller. It delivers a precisely calibrated, near-linear, discrete output in the range 0 to 10V or 4 to 20mA. The Contrinex inductive sensor has a sealed cable entry, ensuring fit-and-forget capability during extended periods of operation, and connects with the machine’s control system via a flexible PUR-sheathed cable. Using a custom-configured software interface, output data is displayed numerically and graphically on a screen, allowing real-time adjustment to the production process when necessary. Contrinex’s Analogue Output sensors provide a cost-effective solution that satisfies the customer’s requirements for accurate high-speed measurement with an exceptional resolution. These analogue inductive sensors are used on an almost unimaginable array of applications and industries. .
A specialised textile-testing machine measures the thickness of a moving textile web in real at a high-speed. As the web passes over a roller, a precision Contrinex analogue inductive sensor, positioned directly above the roller, rests lightly on the top of the web. It senses the distance through the material to the roller, precisely measuring the thickness of the material. CUSTOMER APPLICATION For the efficient manufacture of textiles and fabrics, the thickness of the material needs to be measured immediately after its formation to enable real-time adjustment of the production process. Therefore, a manufacturer of specialised textile-testing machines uses a high-accuracy sensor to measure the thickness of a continuously produced sheet, or web of material moving at up to 5m/s (16.4fps). Measurements are required across the full width of the textile web, which can be up to 4 metre (13ft) wide. To achieve this a sensing head is mounted on a transverse-axis carriage which lies immediately above a fixed roller, traversing the width of the web as it passes over the roller. In this application, the precision sensor is providing real-time measurements in the range 0 to 4mm with a resolution of 0.02mm (0.0008”) or better. High-frequency measurement is provided to accommodate the speed and width of the moving web. A continuous analogue output is necessary as conventional digital sensors do not provide the required resolution. .
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 LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE FLUCTUATIONS AND VIBRATIONS
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 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 realtime 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
CONTRINEXS BEST-IN-CLASS ANALOGUE INDUCTIVE SENSORS ARE ACCURATE TO MICRONS M) AND TRUSTED IN A WIDE VARIETY OF CRITICAL SYSTEMS AND INNOVATIVE MACHINES.

ANALOGUE INDUCTIVE SENSORS

ANALOGUE INDUCTIVE SENSORS - EXCEPTIONAL ACCURACY & AFFORDABILITY
PRODUCT ADVANTAGES EXCEPTIONAL ACCURACY & RESOLUTION IN MICRON RANGE HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL RESOLUTION, PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT BEST-IN-CLASS TEMPERATURE STABILITY VERY LONG SENSING RANGES UP TO 40MM CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE FLUCTUATIONS AND VIBRATIONS
Contrinex’s analogue inductive sensors offer a reliable, repeatable, highly accurate means of measuring the position of a target object. Best-in-class temperature stability and a measurement range of zero to 40mm make the sensors ideally suited for measuring linear, angular and rotational position. With detection accuracy in the micron range and the best long-range sensing capability on the market, Contrinex analogue sensors offer world-class performance with an attractive total cost of ownership.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WILL WORK TO HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
Sales@PLUSAx.co.uk (0121) 58 222 58
Helping you #Make Sense of Sensors
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Order Placement   Orders@PLUSAx.co.uk 0121 582 0835   Sales & Technical Product selection & application advice Sales@PLUSAx.co.uk 0121 58 222 58 Customer Service Price & Delivery / Lead time CustomerService@PLUSAx.co.uk 0121 582 0835 Contact Us
CUSTOMER VALUES CONTINUOUS PRODUCTION AS IN-PROCESS MEASUREMENT IS HIGHLY ACCURATE WITH HIGH SAMPLING RATE DEFECTS IDENTIFIED IN REAL TIME MINIMISES REJECT COSTS NO RESTRICTIONS ON MOUNTING POSITION AS SENSORS ARE VIBRATION-RESISTANT AND TEMPERATURE-STABLE COMPATIBILITY WITH EXISTING IN-HOUSE SYSTEMS 0 TO 10V LONG SENSING DISTANCE MINIMISES RISK OF MECHANICAL DAMAGE TO THE SENSOR PRODUCT ADVANTAGES EXCEPTIONAL DETECTION ACCURACY, EXCELLENT REPEATABILITY AND RESOLUTION IN THE MICRON RANGE M) SAMPLING RATE OF 250HZ CONDIST® TECHNOLOGY PROVIDES EXTENDED SENSING RANGE 10 MM RUGGED, VIBRATION-RESISTANT WITH METAL HOUSINGS INDUSTRY-STANDARD 0 TO 10V ANALOGUE OUTPUTS
A manufacturer of industrial timing belts trusts Contrinex’s analogue inductive sensors to measure the position of steel reinforcing bands during continuous production. Two long-range, high-resolution sensors, mounted above the extruded belt profile, provide real-time positional data. The customer’s process-control system monitors the sensor’s analogue voltage outputs, alerting the operator and halting production if the values are outside allowable limits. CUSTOMER APPLICATION To enhance the strength of industrial timing belts, steel reinforcing wires are bonded into the belt carcass as part of a continuous extrusion process. The distance between the reinforcing wires and the belt teeth is a critical parameter, influencing the accuracy of the belt’s fit and other operating characteristics, including service life. Engineers can check product quality at intervals by cutting samples of extruded belts and taking optical measurements, but this process is slow and only detects faults some time after production is complete, leading to high reject costs. The customer requires a real-time system with sensors that reliable and accurately measure the position of the steel reinforcement.
CUSTOMER SOLUTION Contrinex M18-size analogue inductive sensors are ideal for this application providing an analogue voltage output with a sampling rate of at least 100Hz. The physical characteristics of the belt dictate a sensing distance of up to 10 mm with micron (µm) measurement accuracy. Contrinex’s patented Condist® technology provides a highly stable sensing performance at operating distances of ≤10 mm with exceptional detection accuracy, excellent repeatability and resolution in the micron range. The sensors sample at 250Hz, enabling accurate measurement of the position of the steel reinforcement in the fast moving belt profile, and provide continuous, non-linearised 0 to 10V analogue output signals. They are resistant to vibration and variations in ambient temperature, allowing their positioning immediately after the extrusion press in close proximity to the moving belt. Two sensors, set flush into a non-metallic plate, are mounted directly above the surface of the belt as it runs over a guide roller, giving a stable reference position. The lightly tensioned belt clears the sensing face of the devices by a few tenths of a millimetre. Connection to the customer’s control system is via a flexible cable with an easily detachable M12 connector. The introduction of Contrinex analogue inductive sensors provide small, high-accuracy, ultra-reliable sensors with a low total cost of ownership. Rather than needing to destructively test belts to inspect the position of the steel reinforcement and risking high reject costs because of the infrequent nature of the sampling, the production process is now continuously monitored.
CUSTOMER VALUES HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER (0 10 VDC OR 4 20 MA) LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE PRODUCT ADVANTAGES CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL LONG SENSING RANGE OF 40MM PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION IN µM RANGE EXCELLENT TEMPERATURE STABILITY & VERY GOOD REPEATING ACCURACY SEVERAL SWITCH POINTS WITH A SINGLE DEVICE LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION Analogue inductive sensors from Contrinex’s 509 Series are ideal for this application because their Condist® oscillator technology ensures excellent environmental stability, especially to temperature. This is key in providing sensing distances up to 3 times the standard (in this case 40 mm from the M30 sized sensor). This extra sensing distance ability 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 the can type. The customer mounted the M30 sized inductive analogue sensors which yield the greatest sensing distance above and below the passing lanes of cans, so that the double layer of cans in each carton can be checked through the cardboard walls of the box. The continuous analogue current or voltage 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 excels because it is durable, adaptable, reliable and simple to install. .
To ensure that sealed cardboard cartons have the required number of tinned food cans inside them, a packaging company trusts Contrinex’s analogue inductive sensors. Using an analogue sensor enables this final pre-shipment quality check to process different sizes of can as well as manage with different material grades of can. CUSTOMER APPLICATION Canned products and their labels are protected during delivery by being tightly packed into sturdy sealed cardboard boxes. This poses a challenge to food packaging companies because retailers, particularly supermarkets require absolute accuracy in the cartons contents, but at final inspection the carton is already sealed and so the contents can not be visually inspected. Therefore to eliminate the risk that product faults that may have occurred during upstream processes are shipped out to the customers, the packing company needed a way to verify what tins are inside the sealed box. Because of the packaging line handles a variety of cans of different sizes and materials, a conventional on-off switching inductive proximity sensor could not be used. An additional challenge is that the the sensor needs to be part of a verification process integrated into a fast-moving automated packaging and pre-shipment line, accepting or rejecting each carton instantly. .
CUSTOMER VALUES HIGH-SPEED CHECKING OF DIFFERENT CAN TYPES SINGLE SOLUTION TO CHECK DIFFERENT CAN TYPES SIMPLE INSTALLATION - DIRECT INTERFACE TO CONTROLLER (0 10 VDC OR 4 20 MA) LONG SERVICE LIFE, HIGHLY RELIABLE, COST-EFFECTIVE PRODUCT ADVANTAGES CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL LONG SENSING RANGE OF 40MM PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT, RESOLUTION IN µM RANGE EXCELLENT TEMPERATURE STABILITY & VERY GOOD REPEATING ACCURACY SEVERAL SWITCH POINTS WITH A SINGLE DEVICE LONG SENSING DISTANCE COMPARED TO COMPETITORS
CUSTOMER SOLUTION Contrinex analogue inductive sensors from their Extra Distance 509 Series family are perfect for the position and distance measurement requirements of this application. The sensors provide an analogue value for the entire motion sequence of the x-ray inspection. Their excellent resolution in µm range is particularly suitable for measuring gaps and angles, detecting motion and controlling travel smoothly. The sensors are positioned to measure both the pipe carriage position, which represents the system’s zero-point and is therefore critical for correct operation and the distance between the x-ray source and the pipe surface which is critical to x-ray result quality. The analogue sensors output a continuous voltage or current analogue signal which reflects the gap between the damping element and the sensing surface. With Contrinex’s patent-protected Condist technology, these high-performance analogue sensors provide a sensing range that is more than twice the distance offered by competitors. The M30 versions used in this application offer a sensing range of 0 to 40 mm and so they can provide the flexibility required for testing the numerous pipe diameters being manufactured. The solution excels because it is durable, adaptable, reliable and was also fast and simple to install. .
The integrity of weld seams in pipes used to transport oil or gas across land or sea is ensured using x-ray testing. The x-ray test systems used for this require precision control of the distance between the x-ray source and the surface of the pipe because this is critical for the quality of the imaging data. CUSTOMER APPLICATION A producer of pipes ranging in diameter from 50mm to 2m has a x-ray testing systems integrated to the end of their production lines to ensure the pipes they manufacture will not leak and are impermeable. Pipes for pipelines for example must resist long-term exposure to harsh environments and withstand high pressures and fluctuations in temperature. Therefore, they must be guaranteed to be free from material faults and weak points, such as flaws in the weld seam, like trapped air or slag in the metal. The final inspection of the pipe involves the pipes entering an x-ray test room, which is a radiation-proof bunker. The x-ray source is positioned precisely over the pipe, while a flat panel forms the opposite pole of the system. The flat panel is located inside a large pipe or below a small one. Accurate positioning of pipe, the flat panel and the x-ray source is crucial to achieving optimum test results and therefore accurate and reliable sensors are critical to production efficiency. .
CLICK ON AN IMAGE TO VIEW THE BROCHURE, READ APPLICATION EXAMPLES BELOW, CLICK HERE TO VIEW THIS SENSOR ON CONTRINEXS WEBSITE, OR CALL US TO HELP GUIDE YOU THROUGH SELECTION, ANSWER QUESTIONS, OR TO HELP YOU #MAKESENSEOFSENSORS:

ANALOGUE INDUCTIVE

SENSORS

CONTRINEXS BEST-IN-CLASS ANALOGUE INDUCTIVE SENSORS ARE ACCURATE TO MICRONS M) AND TRUSTED IN A WIDE VARIETY OF CRITICAL SYSTEMS AND INNOVATIVE MACHINES.
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 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 Analogue Output Inductive sensors are highly accurate and provide the continuous voltage or current outputs required for this application. The quasi-embeddable sensors feature a chrome-plated brass body and PBTP sensing face, with the M18-diameter sensor allowing sensing distances up to 10mm (0.4”) with resolution in the µm range. The sensor, mounted in the sensing head, moves rapidly back and forth across the web and senses through the material of the web as it feeds over the roller. It measures the distance from its sensing face – which lies a known distance from the bottom face of the head, to the top surface of the roller. It delivers a precisely calibrated, near-linear, discrete output in the range 0 to 10V or 4 to 20mA. The Contrinex inductive sensor has a sealed cable entry, ensuring fit-and-forget capability during extended periods of operation, and connects with the machine’s control system via a flexible PUR-sheathed cable. Using a custom-configured software interface, output data is displayed numerically and graphically on a screen, allowing real-time adjustment to the production process when necessary. Contrinex’s Analogue Output sensors provide a cost-effective solution that satisfies the customer’s requirements for accurate high-speed measurement with an exceptional resolution. These analogue inductive sensors are used on an almost unimaginable array of applications and industries.
A specialised textile-testing machine measures the thickness of a moving textile web in real at a high-speed. As the web passes over a roller, a precision Contrinex analogue inductive sensor, positioned directly above the roller, rests lightly on the top of the web. It senses the distance through the material to the roller, precisely measuring the thickness of the material. CUSTOMER APPLICATION For the efficient manufacture of textiles and fabrics, the thickness of the material needs to be measured immediately after its formation to enable real-time adjustment of the production process. Therefore, a manufacturer of specialised textile-testing machines uses a high-accuracy sensor to measure the thickness of a continuously produced sheet, or web of material moving at up to 5m/s (16.4fps). Measurements are required across the full width of the textile web, which can be up to 4 metre (13ft) wide. To achieve this a sensing head is mounted on a transverse-axis carriage which lies immediately above a fixed roller, traversing the width of the web as it passes over the roller. In this application, the precision sensor is providing real-time measurements in the range 0 to 4mm with a resolution of 0.02mm (0.0008”) or better. High-frequency measurement is provided to accommodate the speed and width of the moving web. A continuous analogue output is necessary as conventional digital sensors do not provide the required resolution.
Click for Brochure Analogue Inductives Click for Brochure Analogue Inductive Catalogue Extract
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 LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE FLUCTUATIONS AND VIBRATIONS
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.
CUSTOMER VALUES ACCURATE HIGH-SPEED MEASUREMENT OF FAST-MOVING MATERIAL DISCRETE RAW-DATA OUTPUT WITH EXCEPTIONAL RESOLUTION REAL-TIME PROCESS MONITORING AND ADJUSTMENT HIGHLY RELIABLE, COST-EFFECTIVE SOLUTION PRODUCT ADVANTAGES CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL RESOLUTION
ANALOGUE INDUCTIVE SENSORS - EXCEPTIONAL ACCURACY & AFFORDABILITY
PRODUCT ADVANTAGES EXCEPTIONAL ACCURACY & RESOLUTION IN MICRON RANGE HIGH-SPEED MEASUREMENT WITH AN EXCEPTIONAL RESOLUTION, PRECISELY CALIBRATED, NEAR-LINEAR OUTPUT BEST-IN-CLASS TEMPERATURE STABILITY VERY LONG SENSING RANGES UP TO 40MM CONTINUOUS MEASUREMENT WITH CURRENT OR VOLTAGE ANALOGUE SIGNAL LONG LIFE, ESPECIALLY IN APPLICATIONS WITH TEMPERATURE FLUCTUATIONS AND VIBRATIONS
Contrinex’s analogue inductive sensors offer a reliable, repeatable, highly accurate means of measuring the position of a target object. Best-in-class temperature stability and a measurement range of zero to 40mm make the sensors ideally suited for measuring linear, angular and rotational position. With detection accuracy in the micron range and the best long- range sensing capability on the market, Contrinex analogue sensors offer world-class performance with an attractive total cost of ownership.
WELCOME TO PLUS AUTOMATION LTD - EXPERTS IN SENSORS, WE WORK TO HELP YOU SOLVE YOUR APPLICATIONS, IMPROVE MACHINE PERFORMANCE & RELIABILITY AND REDUCE COSTS USING CONTRINEXS EXCEPTIONAL SENSORS - LET US HELP YOU #MAKE SENSE OF SENSORS
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