Laser Sensor Detects Shiny Cylinders in Battery Production

Decentralized signal processing on the I/O module enables error detection in 10 milliseconds at the highest process speeds

Detecting shiny sheet metal cylinders in presses for battery production is a challenge for optical sensors. Especially when the objects have to be detected very quickly due to high process speeds in order to check their correct position. Mechanical sensors, which were used as an alternative here, have a high maintenance requirement and were often a source of errors due to wear or jamming. Detecting the sheet cylinders is essential, as pressing without cylinders damages the fixture and incurs high costs.

Your Benefits

High process speed due to decentralized signal processing within 10 milliseconds
Improved system availability as machine damage is prevented
Minimal wiring thanks IP67 IO-Link master
Plug-and-play sensor change as sensor settings are stored in the IO-Link-Master

From less than 30 centimeters away, the Q4X reliably detect the shiny cans

Thanks to stainless steel housing and IP69K protection, the Q4X also withstands hydraulic oil mist

The I/O module counts the signals of the Q4X and transmits the result to the controller

Q4X reliably detects even diffuse reflections

The Q4X laser sensor from Turck's opto-sensor partner Banner Engineering reliably detects even shiny objects like these sheet metal cylinders. Within 10 milliseconds, the sensor detects missing or incorrectly positioned cans.

IO-Link master enables high process speed

To realize the high process speed, the customer uses a decentralized TBEN-S IO-Link master module. Three to four Q4X sensors are connected to a master. The I/O module itself counts the inputs from the sensors and then communicates the result to the plant's controller via Ethernet/IP. This block check is easily programmed in Turcks web based configuration tool ARGEE. It allows the high process speed to be realized. If the total is not correct, the PLC stops the machine immediately, preventing damage to the fixture.

Easy maintenance with IO-Link

If a sensor is damaged or must be cleaned IO-Link simplifies the sensor change. The sensors parameters are stored in the IO-Link-Master. Like that sensor change is done in seconds as the I/O-Link master simply uses the same parameters with the spare sensor. The IP67 I/O module can be mounted directly in the hydraulic oil mist of the machine reducing cabling effort. As a multi-protocol device, it can equally well be used on controllers with Profinet or Modbus TCP.

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