Walk into any die shop in the US and nine out of ten times, we discover diffuse reflective sensors being used to detect a large part or a small part exiting a die. Many people have success using this methodology, but lubrication-covered tumbling parts can create challenges for diffuse-reflective photoelectric sensing devices for many reasons:
- Tumbling parts with many “openings” on the part itself can cause a miss-detected component.
- Overly-reflective parts can false triggering of the output.
- Dark segments of the exiting part can cause light absorption. Remember, a diffuse sensors sensing distance is based on reflectivity. Black or dark targets tend to absorb light and not reflect light back to the receiver.
- Die lube/misting can often fog over a photoelectric lens requiring maintenance or machine down time.
The solution: Super Long Range Inductive Sensors placed under chutes
Most metal forming personnel are very familiar with smaller versions of inductive proximity sensors in tubular sizes ranging from 3mm through 30mm in diameter and with square or “block style” inductive types (flat packs, “pancake types”, etc.) but it is surprising how many people are just now discovering “Super Long Range Inductive Proximity” types. Super Long Range Inductive Proximity Sensors have been used in metal detection applications for many years including Body-In-White Automotive applications, various segments of steel processing and manufacturing, the canning industry, and conveyance.
Benefits of Using A UHMW Chute + Super Long Range Inductive Proximity Sensor in Part Exit/Part-Out Applications:
- It is stronger and quieter than parts flowing over a metal chute, readily available in standard and custom widths, lengths and thicknesses to fit the needs of large and small part stampers everywhere.
- UHMW is reported to be 3X stronger than carbon steel.
- UHMW is resistant to die lubes.
- UHMW allows Super Long Range Inductive Proximity Sensors to be placed underneath and to be “tuned” to fit the exact zone dimension required to detect any part exiting the die (fixed ranges and tunable with a potentiometer). The sensing device is also always out of harm’s way.
- Provides an option for part detection in exiting applications that eliminates potential problems experienced in certain metal forming applications where photoelectric sensing solutions aren’t performing optimally.
Not every Part Exit/Part-Out application is the same and not every die, stamping application, vintage of equipment, budget for sensing programs are the same. But it’s important to remember in the world of stamping, to try as consistently as possible to think application specificity when using sensors. That is, putting the right sensing system in the right place to get the job done and to have as many technical options available as possible to solve application needs in your own “real world” metal forming operation. We believe the UHMW + Super Long Range Inductive System is such an option.
You can learn more in the video below or by visiting www.balluff.us.