3 Important Detection Sensors Used For Eaton Equipment

Industrial & Manufacturing Articles

Successful automation of product manufacturing processes relies on an interconnected network of sensor modules. The sensors come in a wide range of configurations to control everything from conveyor movement to fill limits. Without the right set of sensors, the automated equipment would not build your products to spec. If a sensor goes bad, the entire system shuts down to prevent costly mishaps during the product creation process. Here are three different types of sensors your automated manufacturing equipment will use to create your products.

Photoelectric

You might already be familiar with photoelectric sensors, as they are commonly used as an auto stop safety switch for garage doors. Photoelectric sensors used in manufacturing equipment works in the same way. A light beam comes out of one end and activates electronics at the other side. The sensor can shut down equipment if it senses an obstruction that could break the machinery or injure a worker. Alternatively, these sensors are used to activate certain processes after the incomplete product comes into the work area. You can also use these sensors to count products to precisely track daily manufacturing tasks.  

There are three main types of photoelectric sensors used in automated manufacturing, including:

• Pass Through: Two part system with one beam array and one detecting sensor
• Retro Reflective: Integrated system that works with a mirror on the opposite end
• Diffuse Reflective: Single part system that bounces light off products rolling through

Limit

Instead of light, limit sensors use physical contact for detection purposes. The sensor levers must directly touch the products to verify the equipment correctly filled the product as specified. These sensors are frequently used for processed foods, beverages, art supplies, like beads and paint, ink cartridges and other products that fill a specially designed container.

Once the product activates the limit switch by pushing on the lever, the equipment stops the fill order and sends the product onto the next step of the manufacturing process. Limit switches work within milliseconds to avoid overfilling the packages, which could halt production for a lengthy cleanup. The area around limit sensors always needs to stay incredibly clean to keep debris from impeding movement of the levers.

Proximity

The proximity sensor is frequently used at the end of the manufacturing process to activate the packaging equipment. A small metal tag on the product activates the proximity sensor's electromagnetic field. Upon detecting the finished product, the sensor initiates the boxing and wrapping equipment to prepare the product for shipping.

The product must pass incredibly close to the sensor or the magnets will not pick up the signal from the metal tag. After all, the magnetic field cannot be too strong or it would incorrectly identify metal equipment components as the products. Since many manufacturers produce a number of different products, the equipment has proximity sensors placed at a specific height to detect products of varying sizes. When using this type of sensor, you may need to account for humidity and electronic interference throughout your plant to keep the electromagnetic field functioning as expected.

Keeping Your Sensors In Good Shape

You may need to regularly clean off the sensors to keep the working as intended in day-to-day operations at your manufacturing plant. The lights and cameras cannot properly perform their detection actions if the screen is obscured by dirt and debris. Furthermore, levers use for the limit and proximity sensors can end up stuck fast if debris covers the moving parts. You can prevent these issues by scheduling regular cleaning services. Cleaning professionals from websites just need to wipe off the sensors with a rag or clean out the crevices with a soft, but firm, brush.  

30 December 2014