The manufacturing of low-cost products, such as steel cable, cannot afford the costs of lost production due to unexpected downtime. For a factory specialising in the production of small-diameter cables, a seemingly small problem was causing significant headaches: the occasional breakage of a steel wire cable during the twisting process. This wasn’t just a minor inconvenience; it posed a safety risk and, if left unchecked, led to costly machine breakdowns. The challenge was to find a robust, reliable, and rapid solution to detect the break before it caused damage.
CUSTOMER APPLICATION
The manufacturing process involves twisting multiple steel strands into a single cable, which then moves on to the next stage. The issue lay in the transition between workstations, where the cable is unsupported and hangs in an unpredictable, catenary shape. This erratic path meant that a simple, single-point sensor wouldn’t do the job. The sensor needed to reliably detect the 3mm diameter cable across a 90mm x 20mm envelope, all while the product was moving at speed. The customer required a solution that could handle a fast-moving target with an erratic path, while maintaining a high degree of reliability.
CUSTOMER SOLUTION
Contrinex’s fibre-optic sensors provided a robust and reliable solution capable of meeting the application’s unique demands, utilising a multi-beam diffuse fibre-optic sensing head and a DIN-rail-mounted amplifier. The key to its success is the system’s ability to switch at frequencies up to 4000 Hz, making it perfect for detecting fast-moving targets. The multi-beam sensor face, at 28mm wide, easily covers the required 90mm x 20mm detection area, ensuring the cable’s presence is detected regardless of its unpredictable vertical movement.
The sensing head’s PBTP construction provides excellent protection, making it durable enough for a busy factory floor. Initial setup is a breeze, thanks to a simple manual teach-in function and a built-in LCD that displays signal strength, after which it runs without requiring constant adjustment. For added flexibility, the amplifier can be mounted remotely, and connection to the factory’s control system is straightforward with an industry-standard PNP interface. Since the installation, the factory has eliminated downtime due to broken cables and the system now immediately alerts an operator with an alarm, preventing costly breakdowns. It’s a prime example of how a highly cost-effective solution can solve a potentially expensive problem.
PRODUCT ADVANTAGES
Rapid, reliable detection of a small, fast-moving target with an erratic path,- Very cost-effective solution to a potentially costly problem,
- System switching frequency of up to 4,000 Hz,
- Exceptionally reliable detection across a 28mm wide array,
- Simple set-up and teach-in function,
- IO-Link DIN Rail amplifiers – Ideal for Industry 4 and offering Plug and Play swap-out.
Call PLUS Automation on 0121 58 222 58 or email Sales@PLUSAutomation.co.uk to discuss how they can help you #MakeSenseofSensors using Inductive, Machine Safety, Photoelectric, Pressure, Process, RFID and Ultrasonic sensors from CONTRINEX, ReeR & SATRON.
With over 2,000 sensors in stock in the UK, supported by stock held in Europe and short manufacturing lead times, PLUS Automation welcomes the opportunity to discuss improving automation and machine performance or reducing costs.
