Application Spotlight

Metalforming Part Out Sensing Made Easy

In certain metal forming applications, detection of parts exiting the stamping die with standard thru-beam photoelectric sensors is not always reliable. Part detection is often missed when it tumbles out of the light beams path, and having more than one set of energized emitter-receiver pairs does not always help. Light grids offer a greater area a coverage in a single sensor pair, offering a more reliable means of detection. However, even when part ejection is controlled enough to always break the light beams path, die lube mist interferes with the optics of the sensing pair and causes false triggers. That is when good old fashioned, long-range pancake or block-style inductive proximity sensors are ideal. Inductive sensors are immune to any optical inhibitors that would otherwise cause a photoelectric sensor to fail.
Benefits of using Light Grids

n Covers a broader area which increases detection reliability n Single sensor is used to increase detection area rather than setting up several sensors to increase detection area
Benefits of using Long-Range Inductive Sensors

n Immune to dirt, debris, and fluid build-up n Covers a broader detection range n Can see through non-metallic surfaces which act like a chute for ejected parts
Part Detection with Bunkered Light Grid Part Detection with Long-Range Pancake Sensor

Inductive proximity sensors have the ability to function well in die lube mist, cutting fluids and difficult industrial fluids and they are generally IP67 rated. They can also see through non-metallic substances. But these are generally plastic encapsulated and the constant contact with metal components exiting the die will prematurely end their service. So setting up one or even two cost-effective, long-range pancake or large block style sensors in a zone (and being careful to avoid cross talk) works well in this application. To increase the life of the sensor, it can be covered with a large piece of heavy duty, wear-resistant polycarbonate, or other non-metallic material to act as a chute to catch the ejected finished stamped part.
Ordercode BLG0005 BES0225 Part Number BLG 1-010-210-070-PV01-SX BESQ80KA-PAH40BS04Q Description Light grid - PNP, Dark-on, NO + 010 Vdc, 7 mm resolution Inductive Maxisensor - Flush, PNP, NO+NC, Sn = 40 mm
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www.balluff.com/Metalforming
Balluff, Inc. n 8125 Holton Drive Florence, KY 41042 n 1-800-543-8390 n www.balluff.com

PS_061 Metalforming Part Out Detection Made Easy 2012-03

Non-safety-rated light grids, sandwiched between plates of steel for impact resistance are a good option for increasing the detection area without the need to wire up and align multiple thru-beam sensors. However, when excessive die lube mist is heavy and there is no way to integrate an air knife or other blow-off mechanisms to keep the optics clear, the old tried and true long-range inductive proximity sensor for part-out applications is a safe bet.