Sensor Applications for Die Protection - The …

1 Sensor Applications for Die Sensor Applications for Die ProtectionProtectionThe DiemastersThe Diemasters2100 Touhy Avenue2100 Touhy AvenueElk Grove Village, IllinoisElk Grove Village, of our Manufacture Smarter seriesWhat is Die Protection ?What is Die Protection ? A die Protection system monitors material A die Protection system monitors material movement and critical events in the movement and critical events in the stamping processstamping process The goal of die Protection is to stop the The goal of die Protection is to stop the press press beforebefore it makes a bad hit. it makes a bad Does it Work?How Does it Work? Sensors are installed in and around the dieSensors are installed in and around the die The sensors monitor The sensors monitor specificspecific events, signaling a events, signaling a controller when events occurcontroller when events occur When the system detects a problem, it will open When the system detects a problem, it will open a stop relay to stop the pressa stop relay to stop the pressProximity SensorsProximity SensorsDefinitionDefinitionA proximity Sensor is a Sensor that can A proximity Sensor is a Sensor that can detect, without actual physical contact, detect, without actual physical contact.

2 The presence of a metallic objectthe presence of a metallic objectProximity Sensor OperationProximity Sensor OperationWhen power is applied to a prox, When power is applied to a prox, an invisible sensing field extends an invisible sensing field extends from the face of the sensorfrom the face of the sensorThe Sensor actuates when a metal The Sensor actuates when a metal object touches the sensing fieldobject touches the sensing fieldThe target does not have to block The target does not have to block the sensing field, it only needs the sensing field, it only needs touch to touch the edgetouch to touch the edgeProximity Sensor PackagesProximity Sensor PackagesTubular, both threaded Tubular, both threaded and unthreaded barreland unthreaded barrelLow-profile flat packageLow-profile flat packageProx Sensor Detecting a Pilot Prox Sensor Detecting a Pilot HoleHoleStripStripSensing fieldSensing fieldProx Sensor Detecting a Pilot Prox Sensor Detecting a Pilot HoleHoleProx Sensor Detecting a Pilot Prox Sensor Detecting a Pilot HoleHoleProx Sensor Detecting a Pilot Prox Sensor Detecting a Pilot HoleHoleSpring Loaded Proximity SensorSpring Loaded Proximity SensorBottom DieBottom DieSensor Sensor CableCableSpringSpringBushingBushingStri pStripProximity Sensor at the End of the DieProximity Sensor at the End of the DieStrip too high.

3 Misses sensing fieldStrip too high, misses sensing fieldStrip too low, misses sensing fieldStrip too low, misses sensing fieldSensor with Spring Loaded Plunger Sensor with Spring Loaded Plunger FeedFeedPlungerPlungerSpringSpringCaseCa seSensorSensorSensingSensingFieldFieldMi sfeed SensingMisfeed Sensing8 mm Prox Sensor8 mm Prox SensorPlungerPlungerSpringSpringMisfeed SensingMisfeed SensingOverfeed is detectedOverfeed is detectedMisfeed SensingMisfeed SensingShortfeed is detectedShortfeed is detectedMisfeed SensingMisfeed SensingMisfeed SensingMisfeed SensingMove the Sensor closer to the plunger for more precise detectionMove the Sensor closer to the plunger for more precise detectionMisfeed SensingMisfeed SensingBack it off for looser feed tolerancesBack it off for looser feed

4 TolerancesThrough-Beam PhotosensorThrough-Beam PhotosensorAlso called opposed-mode photosensorLight beam from emitter shines directly at receiverLong range (up to 700 ) - Very high excess gainCan be made very precise by using PhotosensorERReceiver Viewing AreaEmitterBeamTarget must block half of sensing beam to actuate sensorSensing BeamThrough-Beam PhotosensorThrough-Beam PhotosensorPotential ProblemsPotential ProblemsTarget is too small to Target is too small to actuate Sensor (does not actuate Sensor (does not block half of beam)block half of beam)Object reflects the emitter Object reflects the emitter beam at the receiver. beam at the receiver. Even though target blocks Even though target blocks more than 1/2 of beam, it more than 1/2 of beam, it is not detectedis not detectedThrough-Beam Sensor with ApertureThrough-Beam Sensor with ApertureAperture (also called a slit plate )No aperture -Wide effective beamAperture installed - Narrow, more precise effective beamThrough-Beam Feed SensorThrough-Beam Feed Sensor For misfeed detection Applications where For misfeed detection Applications where Sensor can be placed at the end of the can be placed at the end of the die.

5 Can be easily retrofit into existing dies. Can be easily retrofit into existing dies. Usually used to detect the edge of material Usually used to detect the edge of material (dark-on operation).(dark-on operation). Sensor has built-in has built-in apertures. Extremely repeatable (as low as Extremely repeatable (as low as ++ ). ).Photoelectric "Fork" SensorPhotoelectric "Fork" SensorPhotoelectric "Fork" SensorPhotoelectric "Fork" SensorEmitterEmitterReceiverReceiverSens ingSensingBeamBeamSensors for Part Sensors for Part EjectionEjectionMini-Light CurtainMini-Light CurtainDiffuse Reflective SensorDiffuse Reflective SensorImpact SensorImpact SensorProximity CoilProximity CoilMini-Light CurtainMini-Light CurtainPart breaks the light beamPart breaks the light beamto actuate the sensorto actuate the sensorAvailable with eitherAvailable with eithervisible or infrared lightvisible or infrared lightCan be speed sensitiveCan be speed sensitiveUsually mounted outside the toolUsually mounted outside the toolDiffuse

6 Reflective SensorDiffuse Reflective SensorReceiver needs to see only a very small amount of Receiver needs to see only a very small amount of light from the emitter for the Sensor to actuate. light from the emitter for the Sensor to actuate. This allows the Sensor to detect small, even non This allows the Sensor to detect small, even non reflective Sensor is also prone to false actuations caused This Sensor is also prone to false actuations caused by objects in the background. by objects in the background. These sensors must be installed so that the point off These sensors must be installed so that the point off into space so that false actuations can be avoided. into space so that false actuations can be Reflective SensorDiffuse Reflective SensorDiffuse Sensor Screen Diffuse Sensor Screen Sensing AreaSensing AreaDiffuse Reflective Diffuse Reflective SensorsSensorsMaterial Buckle DetectionMaterial Buckle DetectionStripper Position MonitoringStripper Position MonitoringStripper PlateStripper PlateSensorSensor14 mm Low Profile14 mm Low ProfileProximity SensorProximity SensorSlug on top of strip, Sensor does not turn on at BDCSlug on top of strip.

7 Sensor does not turn on at BDCS tripper Position MonitoringDetecting Slug StackingDetecting Slug StackingThrough-BeamThrough-BeamPhotosen sorPhotosensorApertures shouldApertures shouldbe installed on be installed on the Slug StackingDetecting Slug StackingWithout apertures, the Sensor floods the area with apertures, the Sensor floods the area with do not block enough of beam to reliably actuate do not block enough of beam to reliably actuate Slug StackingDetecting Slug StackingProximity Coil Proximity Coil SensorSensorEnd of Stock DetectionEnd of Stock DetectionFor More Information:For More Information:SensorsSensors Magazine - Magazine - Helmers Publishing, Publishing, , NHPeterborough, NH(603) 924- 7408(603) 924- 7408 Measurements &Measurements &Measurements & Data & Data Magazine MagazinePittsburgh, PAPittsburgh, PA(412) 343-9666(412) 343-9666