Synchronization of cycle on a bag forming, filling and sealing machine with CS8 color sensor

SICK Color Sensor synchronizes the packaging process on a bag forming, filling and sealing machine using only one color element in the printed image.  As a result print marks are not necessary.

A crisps manufacturer had the special requirement that he did not want any print marks and the related read strips on the rear of the crisps bag for appearance reasons.

This task can be performed by the CS8-1 Color Sensor from SICK. A color element in the packaging design was taught once using teach-in. Using a small, precise light spot the device moves over all colors on the film and always switches when it detects the color taught. As a result a print mark is not necessary, it is possible to switch using an element in the printed image. The machine is controlled in this manner and cuts reliably at the correct point.

The crisps manufacturer was able to optimize the design of the crisps bag thanks to the CS8 color sensor, that is the manufacturer was able to avoid print marks and read lines. The sensor is easy to operate, works at high speed (up to 6 kHz), has a robust metal housing and is flexible during installation thanks to its exchangeable optics.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Packaging material, end of roll detection

A lot of packaging machines use packaging material on rolls. The moment the rolls is empty it has to be replaced. Replacing the roll when complete empty will stop the machine for a while and a smooth change over is not more possible. Replacing the roll to early would mean that too much packaging material stays on the roll which is wasted.

The line-sensor AT20 array sensor from SICK projects a line of light on the roll with packaging material. An optimum alignment related to the coil assures a maximum accuracy. The sensor detects the edges from the coil and the foil and sets the analogue output in relation to the edge of the foil. A switching output is set when the distance from the foil to is below a certain value.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Controlling the filling of tubes

With KTS and KTX contrast sensors from SICK, you can precisely control the filling and adhesion of tubes. When doing so, the sensors reliably detect the necessary control marks – a complex task since the tubes rotate quickly and consist in part of high-gloss materials and welding seams make detection more difficult. It is here that the high accuracy of the sensors comes into effect, thanks to the 50 kHz switching frequency and 5 μs jitter as well as the additional color mode.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Controlling print marks

With the KTS and KTX contrast sensors from SICK, you can control your packaging processes quickly and precisely. Thanks to TwinEye-Technology®, the KTS and KTX detect high-gloss materials and complex contrasts, even on heavily fluttering materials. The integrated color mode also enables reliable detection of even the most minor contrast differences and color features. Furthermore, the sensing range tolerance has been extended to ±5 mm for stable detection even in the most unstable material transportation systems.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

 

Fast and reliable label detection

Self-adhesive labels are applied to bottles of widely varying shape. This process must be synchronized so that the labels are applied to the bottles in the correct position and at the correct point in time. SICK’s WFS fork sensor detects the labels on the carrier material.

The slim, forked shape of the WFS fork sensor has been specially developed for the requirements of the labeling process. The design allows the sensor to be mounted directly on the edge of the dispenser. Difficulty in detecting the label gap is finally eliminated – the sensor’s switching threshold can be taught-in while the label strip is running. The improved operating concept means the sensor can be adjusted to different labels quickly, easily and reliably. The fast response time guarantees exceptional repeat accuracy.

Slim design allows flexible mounting close to the dispenser of the label which ensures higher accuracy in the process.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Edge detection/guidance from the packaging material

Edge Detection and positioning in web guide applications

Flow pack machines and wrapping machines use packaging material on film rolls. The film has to be guided in the correct position into the packaging machine. When the film is too far to the left or right the packaging is of bad quality and the packaging design could be destroyed which leads to wasted products.

The AT20 Line Array Sensors  form SICK are the only line array sensors available that have diffuse mode, making them ideal for harsh environments where dirt and dust can interfere with retro-reflective sensors. These sensors are designed for edge detection/positioning in web guide applications.

Benefit
Reduces downtime. The array sensor offered in diffuse mode, making it ideal for environments where dirt and dust can interfere with other types of solutions that require a reflector.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Checking for presence of pharmaceutical labels on cardboard boxes

Detect color-coded pharmaceutical labels

Each day, manufacturers of rinsing solutions for dialysis systems, infusions, saline solutions and sugar solutions label and pack around 11,000 cardboard boxes. Since these solutions are critical to medical efforts, it is imperative that these products be correctly identified.

Application Solution
During the packaging and labeling process, color-coded labels rapidly detect and differentiate between the various products. All cardboard boxes must be correctly labeled when they leave the packaging line so that dialysis stations, ambulances and hospitals can rely on the labels.

To ensure proper identification, SICK CS3 Color Sensors are used. These sensors are able to reliably differentiate between more than a dozen different colors and shades on the labels. A further advantage of the CS3 is its ease of teaching-in the labels to be detected directly on-site at the machine. The CS3 can reliably detect the presence or absence of a label and whether it is the correct color.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Cascading Mini Twin Safety Light Curtains Provide Safe Packaging Operation

Protection from a manual loading station in a cartoning machine by cascading 3 miniature safety light curtains in U-shape.

The French company ARIES PACKAGING develops and builds full automated solutions for handling of products as well as solutions for secondary and tertiary packaging.  Aries developed a cartoning machine with ergonomics as top priority, i.e., easy access for the machine operators. To guarantee the packaging quality the packages are transported by a gear belt with a cadence of 30 cartons/mm and with a transverse speed of 2 m/s. Taking into account the risk of injuring hands caused by the pusher of the belt, it was essential to integrate a protection system with high resolution to ensure the total safety of the operators.

Application Solution
Miniature safety light curtain in U-shape cascading provides ergonomic and safe operation.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Simplified safety mechanisms on a packing machine

The “V300 Extended” camera safety system monitors guard doors while securing assembly cell areas at the same time from “reaching over” and, together with a photoelectric sensor, can provide exit only protection on a wrap around tray packaging machine.

Challenge
A wrap around tray packing machine takes 6 or 12 drink cartons and puts them onto tray cutouts. The machine folds up the sides of each cutout and glues it to make a tray, which now provides a secure base to transport the goods. Several guard doors have to be monitored so that the machine stops if a person reaches in. The output of the machine also represents an access point to dangerous movements. One particular requirement is to safeguard the machine with electro-sensitive protective equipment which is quick and easy to install and which reacts within a specified time to an operator inserting their hand.

Application Solution
This requirement can be quickly and easily met with a “V300 Extended” camera safety system and a photoelectric sensor. This is electro-sensitive protective equipment based on image processing technology. The sensor sender and receiver are integrated in a single housing, as are the additional reset and EDM functions (Electronic Device Monitoring) to check the protection provided). To monitor the nine guard doors, the “V300 Extended” is installed in the upper right hand corner and the reflective tape is fitted to the fencing and also over the door frames. Taking account of the machine stop time, this means that the cell height can be reduced by more than half. The consequences of this include easier access, reduced safety costs, simple installation and maintenance as well as higher productivity.

Benefit
During the initial installation, or for realignment of the “V300 Extended”, there is no need at all for the time-consuming alignment of sender and receiver which would otherwise be necessary. The camera safety system is also well protected by being installed in a corner. With just a single device, several guard doors can be secured at the same time.

This is an application from SICK.
Tri-Phase Automation is a SICK distributor in Wisconsin.
Contact Tri-Phase Sales or Get A Quote

Sensors in Singulation with Odd Surfaces

Intellifeed, a manufacturer of high-speed automation equipment, has a machine that singulates small packages for the food and beverage industry, so they can be inserted into another package.

Singulation, the process of separating and aligning side-by-side or overlapping products on a conveyor, allows items such as cereal box giveaways and juice packets to be correctly packaged. Since all products are different (shiny, clear, flat, colored) and are moving at high speeds, a solution is needed that will reliably detect the distance between products on a conveyor. The machine, which separates product before it reaches a case packer or pick-and-place robot, is inadequate without an effective sensing solution.

For this application, the SICK W18 Photoelectric Sensor with foreground suppression was used. The foreground mode allows the sensor to be taught one of the rollers as the background. To sense foil pouches, irregularly shaped objects and any other hard-to-detect objects, an output is given when the background is changed.

The OES3 technology is simple to setup and has the ability to suppress reflections from the machine (machine is all SS). Plus, it complies with IP69K for wash down applications.