Contrinex Light🔦 Detection Grids Poka-Yoke Weld✨ Assembly

A manufacturer of welded assemblies for automotive production trusts Contrinex’s highly affordable infra-red DGI light detection grids to detect when a welded part is thrown into a shipment bin. Each time a part is detected entering the bin, a PLC is triggered to check that the weld operation has successfully run and if not, production is stopped and an alarm sounded. – Read more at Grids.PLUSAx.co.uk

CUSTOMER APPLICATION

In an automotive 1st tier automotive manufacturing plant, an operator loads small parts by hand onto a resistance-welding machine and initiates the PLC-controlled welding cycle. After welding, the operator drops the completed assembly into a metal bin used to transport parts directly to the customer.

From time to time, unwelded parts are placed in the bin, resulting in rejection of entire batches of assemblies by the customer. Manual inspection of each assembly is impractical; a sensor system must detect the presence of each item as it is dropped into the bin and check that the corresponding welding cycle has been completed.

The sensing system must not increase the process cycle-time and must detect parts as they are dropped into the open bin, which is approximately 120cm (4ft) long and 90cm (3ft) wide. Parts are around 15cm (6in) long and a sensor with a rapid response time is necessary to detect fast-moving items.

CUSTOMER SOLUTION

The Contrinex DGI range of infrared light detection grids is well-suited for this application. Comprising separate sender- and receiver-units and constructed with rugged one-piece aluminium-profile housings, these versatile sensor systems are ideal for the busy production environment.

With response times from 0.8 to 4.8 milliseconds which are faster than safety light-curtains and a choice of resolutions from 0.9 to 25mm dependent upon the size of the light grid, the DGI light detection grids range exceed the demanding customer specification for rapid response and reliable detection of the small parts.

The 8m range between sender and receiver and their compact design enables easy mounting at each end of the transport bin without impeding the operator or increasing the process cycle time.

The DGI light detection grid sender only requires a power supply connection and the receiver features two Push-Pull (PNP + NPN), Light-ON+ Dark-ON, 4-pin M12 outputs, simplifying installation.

The system detects the presence of any item passing through the light curtain and immediately interrogates the PLC to confirm that a welding cycle has been completed since the detection of the preceding item. If no welding cycle is registered, the system interrupts the process and sounds an alarm, alerting the operator.

PLUS Automation aims to help you #MakeSenseofSensors, helping solve applications, improve machine performance and reliability, and reduce costs using Contrinex’s exceptional choice of sensors. Find more information and read other application examples go to www.PLUSAx.co.uk

PRODUCT ADVANTAGES

⏱️Fast – Response times from 0.8 to 4.8 milliseconds

💪Compact & robust – 40 x 20.5mm aluminium extruded housing

🔬 Exceptional resolution from 0.9mm

📏Choice of protected widths from 200mm to 2m

🔭Long sensing range – Up to 8m

🔧Fast, easy, low-cost installation with M12 plugs

💰 Low-cost solution

FIND OUT MORE

Find out more at Grids.PLUSAx.co.uk, Click to download a flyer or Click to download Contrinex’s Product Overview brochure

PLUS Automation aims to help you #MAKESENSEOFSENSORS, helping solve applications, improve machine performance and reliability, and reduce costs using Contrinex’s exceptional choice of sensors.

Find more information and read other application examples go to www.PLUSAx.co.uk