Position and Presence Check of Connector Components via Fiber-Optic Sensors
When manufacturing plug connectors for high-voltage on-board electrical systems of electric and hybrid vehicles, they must be checked for their presence and correct position. Since these components are often asymmetrical and have different colors depending on the type, fiber-optic sensors are used. With the help of two checkpoints, they ensure that a component is in the feed and that it is correctly aligned. Their compact format makes them ideal for tight installation situations and in areas where only very little space is available for querying.

Presence Check of Steel Coils with Ultrasonic Distance Sensors
In the metalworking industry, steel coils are unwound and processed continuously. To ensure a continuous material and process flow, an ultrasonic distance sensor is mounted above the rollers. This reliably measures the distance between the sensor and the material and thus determines the coil size and the remaining quantity on the roll. Adverse ambient conditions such as dust or oil mist, ambient light and dark or shiny surfaces do not affect the measurement data accuracy.

Fill Level Monitoring of Waste Containers via Ultrasonic Distance Sensors
Recycling plants collect various waste materials, such as paper, plastic, glass and metal, in large containers. These containers must be emptied quickly once full, as failing to do so quickly enough can lead to a stoppage of production. Ultrasonic distance sensors are mounted above the tanks for continuous level monitoring. Their large working range and robust housing make them ideal for use in difficult conditions such as high dust levels, large temperature differences or changing material types.

Distance Check on Vehicle Test Bench with Ultrasonic Distance Sensor
In vehicle test benches, it is important that cars driving into the bench stand securely in the acceleration roller holder. For this purpose, an ultrasonic distance sensor is installed at the front of the car bumper which measures the distance. The control system knows the vehicle type and, in combination with the measured distance value, can determine the required position of the car between the rollers. The ultrasonic sensor reliably detects every car regardless of color, paint quality or shape.

Fill-level Measurement of Potato Chip Rejects with Ultrasonic Distance Sensor
Leftovers are created during the production of potato chips. These rejects are transported to a waste container along a feed screw. There are four flaps to ensure that the container is filled evenly. Ultrasonic distance sensors with analog output are installed next to the flaps and are used to check the fill level of the container. When the mound of rejected potato chip reaches the maximum height, the sensor switches and the flap is closed. The next flap then opens. Dust and damp surfaces have no impact on the switching behavior of the sensors in the M30 housing.

Film Tear and Fill Level Monitoring in Packaging Systems with Ultrasonic Distance Sensor
Colorful, glossy or transparent films are used in packaging plants to ensure that products are airtight and securely packed. These are conveyed by rolls and attached around the objects. Ultrasonic distance sensors monitor the roll diameter to ensure continuous material flow. Two independent switching outputs signal when there is little film left on the roll and when the roll is empty and needs to be replaced. In addition, the sensor checks whether the film is open or torn.

Stack Height Monitoring on Packaging Magazines with Ultrasonic Distance Sensor
Different colored cartons in packaging systems are stacked on top of each other in magazines before being unfolded and filled in downstream processes. In order to ensure a continuous material supply, the stacking height of the magazine is checked by an ultrasonic distance sensor. This sensor records the measured values either continuously via IO-Link or with two switching points so that the magazine can be refilled in good time. Thanks to the wide sonic cone, recesses, gaps or punches have no influence on object sensing.

Level Control of Cream in a Mixer with Ultrasonic Distance Sensor
In the pharmaceutical and cosmetics industries, ingredients of ointments or creams are mixed together in fully automated mixers. In order to perform the mixing process correctly and to achieve the correct consistency, the minimum and maximum fill levels must be continuously monitored. For this purpose, an ultrasonic distance sensor is installed above the mixer, which reliably detects the material regardless of color, condition or transparency. The fill level can be checked either via an analog measured value or by defining individual switching thresholds via IO-Link.

Presence Check of Wooden Panels in Furniture Production with Ultrasonic Distance Sensors
In the furniture industry, wooden panels with different colors, shapes, degrees of gloss and surfaces are conveyed on roller conveyor belts to the next process step. In order to monitor the transport fully automatically, the presence of the panels must be recorded at all times. The slim metric design allows installation beneath the conveyor technology in order to be able to carry out a precise presence check of the wooden panels. Even dust and chips do not influence the results of the ultrasonic sensors.

Fill-Level Measurement in a Storage Container with Ultrasonic Distance Sensor
In the automotive industry, primer liquids are used as a primer for plastic parts in storage containers at production plants. From these storage containers, the material is automatically supplied to the machines. To ensure the minimum fill level, the level in the containers must be monitored. For this purpose, an ultrasonic distance sensor with stainless steel housing is inside the container, which detects surfaces regardless of structure, color or gloss level. If the fill level falls below a defined level, the sensor switches and the ball valve must be opened for filling.

Slack Monitoring on Sheet Metal Belts with Ultrasonic Distance Sensor
Continuous material supply must be ensured in punching machines. As a material buffer, the supplied metal sheets are guided through the system in the form of a hanging loop. This compensates for the time delay between replenishment and the production processes. To monitor this process, an ultrasonic distance sensor is installed above the loop. It checks whether the sag falls below the minimum value or touches the ground. Ultrasonic measurement is not affected by even very shiny plates and dirt such as oil mist or dust.

Position Detection of Crates in Spin Dryers via Ultrasonic Sensors
In the food industry, crates are dried in spin dryers after cleaning. In order for the water to drain completely out of the crates, they must be oriented with the bottom facing upwards. The ultrasonic distance sensor mounted above the conveyor line detects the passing boxes regardless of their color, shape or mesh size. If the sensor detects a box that is on the conveyor with the bottom facing downwards, it is rejected in the next step.