Reliable Detection of Double Layers with wenglor Products
Material-Independent Double Layer Detection
Reliable detection of double layers of metal, plastic, paper or fleece as well as transparent materials.
Reproducible Measurement Results
Short response times and high repetition accuracy ensure stable detection even with fast cycle times and changing material batches.
High Process Reliability
Early detection of multiple layers prevents faulty processing and failures.
Quick Initial Start-Up
Compact designs and standardized interfaces enable easy integration.
Measurement Arrangements for Double Sheet Detection
Single-Sided Detection with Fixed Reference Background
With single-sided double layer detection, the material thickness is detected with only one sensor, which is aligned to a stable, flat and stationary background. The measurement takes place contact-free and enables a reliable distinction between single and double layers. This arrangement is particularly suitable when installation space is limited or when only one side of the conveying path is accessible.
One-Sided Detection with Moving Reference Background
With this measuring arrangement, two sensors are positioned next to each other. One sensor measures the material thickness directly on the object, while the other continuously records the height of the moving substrate, for example a conveyor belt. The difference between the two signals is used to calculate the effective thickness of the object. If this exceeds a defined threshold value, a double layer is detected. This arrangement is particularly suitable for dynamic processes where there is no fixed reference background.
Two-Sided Detection
With two-sided double layer detection, two sensors record the material thickness from opposite sides. The contact-free measurement and subsequent offsetting of the individual values allows the thickness of the object to be determined precisely. This measuring arrangement is particularly suitable for applications with freely accessible material flow and offers high measuring accuracy.
wenglor offers a particularly user-friendly solution for two-sided double layer detection: The patented T-splitter establishes the correct connection between the main and secondary sensor and ensures that the sensors adjust automatically to the appropriate mode of operation. Initial start-up is simple via plug and play, with configuration also possible without IO-Link. If required, the T-splitter can be flexibly extended with suitable connection cables.
Alternatively, two-sided detection can also be implemented without the T-splitter.
Application Areas of Double Layer Detection
Double Layer Detection for Sheets
Feeding of Steel Plates to Laser Cutting Systems
Challenge:
Flat steel or aluminum plates are automatically fed to a laser cutting system, where precise cuts for body and structural parts are produced. If a double layer is not detected, the actual material thickness is greater than the set cutting parameters, resulting in inaccurate cutting contours.
Solution:
Flat steel or aluminum plates are automatically fed to a laser cutting system, where precise cuts for body and structural parts are produced. If a double layer is not detected, the actual material thickness is greater than the set cutting parameters, resulting in inaccurate cutting contours.
Solution:
Separation of Reinforcement Plates in the Bodyshell Construction
Challenge:
To reinforce load-bearing body structures, thin sheet metal blanks (“patches”) are automatically removed from a stack and placed on bodyshell parts by a robot. Due to adhesion or gaps containing oil, several sheets can stick together and be gripped together. A double layer changes the material thickness at the joining point and impairs the quality of the welding process.
Solution:
To reinforce load-bearing body structures, thin sheet metal blanks (“patches”) are automatically removed from a stack and placed on bodyshell parts by a robot. Due to adhesion or gaps containing oil, several sheets can stick together and be gripped together. A double layer changes the material thickness at the joining point and impairs the quality of the welding process.
Solution:
Double Layer Detection when Unwinding Coils
Challenge:
When unwinding steel strips, overlapping layers can occur due to jamming, residual oil or tension in the coil. These double layers lead to process errors, cutting problems or equipment damage. Reliable detection is required to reliable control material feed, even with varying belt thicknesses, surfaces and pull-off speeds.
Solution:
When unwinding steel strips, overlapping layers can occur due to jamming, residual oil or tension in the coil. These double layers lead to process errors, cutting problems or equipment damage. Reliable detection is required to reliable control material feed, even with varying belt thicknesses, surfaces and pull-off speeds.
Solution:
Insertion of Panels in Straightening Systems
Challenge:
To prepare for subsequent processes such as forming or cutting, flat steel plates are removed from a magazine and guided via a straightening system. If there is a double layer during removal due to adhesion or jamming, the defined directional effect is impaired, as the parameters do not match the actual material thickness.
Solution:
To prepare for subsequent processes such as forming or cutting, flat steel plates are removed from a magazine and guided via a straightening system. If there is a double layer during removal due to adhesion or jamming, the defined directional effect is impaired, as the parameters do not match the actual material thickness.
Solution:
Separation in Cutting Plants for Wood Materials
Feeding of Wooden Panels for CNC Processing
Challenge:
Chipboard, MDF or HDF panels are automatically fed to CNC milling centers in the furniture and interior finishing industry. Several panels can be removed at the same time via the gripper due to canting or friction. A double layer changes the reference plane and causes deviations in the milling depth or drilling position.
Solution:
Chipboard, MDF or HDF panels are automatically fed to CNC milling centers in the furniture and interior finishing industry. Several panels can be removed at the same time via the gripper due to canting or friction. A double layer changes the reference plane and causes deviations in the milling depth or drilling position.
Solution:
Material Supply in Laminating Plants
Panel Infeed for Thermoforming Processes
Challenge:
During automated insertion of plastic panels into thermoforming systems, several panels can be separated simultaneously due to electrostatic charge, material distortion or mechanical catching. The resulting double layer affects the even heating and deformation of the material, leading to dimensional deviations, faulty moldings and production waste.
Solution:
During automated insertion of plastic panels into thermoforming systems, several panels can be separated simultaneously due to electrostatic charge, material distortion or mechanical catching. The resulting double layer affects the even heating and deformation of the material, leading to dimensional deviations, faulty moldings and production waste.
Solution:
Double Layer Detection for Packaging Films
Challenge:
In filling and sealing stations, for example for cheese or tray packaging, lid films are pulled off rolls and applied individually. A second film can be pulled off accidentally due to static charge or material displacement. Double layers can destroy the seal, cause leaks or even hygiene contamination.
Solution:
In filling and sealing stations, for example for cheese or tray packaging, lid films are pulled off rolls and applied individually. A second film can be pulled off accidentally due to static charge or material displacement. Double layers can destroy the seal, cause leaks or even hygiene contamination.
Solution:
Infeed of Cardboard Blanks in Tray Packaging
Height Control during Yogurt Cup Infeed
Challenge:
When packaging products such as yogurt or desserts, empty plastic or aluminum cups are automatically separated and fed to the filling station. Adhesion or static charge may result in two cups being inserted one inside the other and transported together. The double layer changes the cup height and can cause variations in filling or sealing. Therefore, a reliable height check must be carried out before transfer to the filling station.
Solution:
When packaging products such as yogurt or desserts, empty plastic or aluminum cups are automatically separated and fed to the filling station. Adhesion or static charge may result in two cups being inserted one inside the other and transported together. The double layer changes the cup height and can cause variations in filling or sealing. Therefore, a reliable height check must be carried out before transfer to the filling station.
Solution:
Double Layer Detection for Tear-Off Flaps on Packaging Films
Challenge:
In packaging lines for cheese or sausage products, tear-off flaps are automatically applied to pre-punched lid foils to facilitate subsequent opening. If several flaps overlap, the film thickness changes in places. This can lead to wrinkles during winding, tolerance deviations in the cutting process or leaks at the sealed seam.
Solution:
In packaging lines for cheese or sausage products, tear-off flaps are automatically applied to pre-punched lid foils to facilitate subsequent opening. If several flaps overlap, the film thickness changes in places. This can lead to wrinkles during winding, tolerance deviations in the cutting process or leaks at the sealed seam.
Solution:
Processing Nonwovens
Challenge:
In the production of hygiene products such as wipes, diapers or medical disposables, thin nonwoven sheets are processed at high speed. Double layers or material overlays can occur due to adhesion, web distortion or errors in the winding process. These lead to uneven folds, dosing errors or faulty forming.
Solution:
In the production of hygiene products such as wipes, diapers or medical disposables, thin nonwoven sheets are processed at high speed. Double layers or material overlays can occur due to adhesion, web distortion or errors in the winding process. These lead to uneven folds, dosing errors or faulty forming.
Solution:
Feeding of Pulp Layers for Absorbent Core Forming
Challenge:
In the production of hygiene products such as diapers or incontinence articles, pulp webs are continuously pulled off rolls and transferred to the molding process. Multiple layers can overlap due to adhesion, twisting or electrostatic charge. A double layer changes the absorption effect and volume distribution.
Solution:
In the production of hygiene products such as diapers or incontinence articles, pulp webs are continuously pulled off rolls and transferred to the molding process. Multiple layers can overlap due to adhesion, twisting or electrostatic charge. A double layer changes the absorption effect and volume distribution.
Solution:
Double Layer Detection during Label Infeed
Challenge:
In labeling machines, pre-punched labels are removed from the label material. Electrostatic charges or tight windings can result in two labels being drawn in at the same time. This leads to incorrect labeling, machine downtime and increased waste. Reliable detection of very thin, sometimes transparent materials is required.
Solution:
In labeling machines, pre-punched labels are removed from the label material. Electrostatic charges or tight windings can result in two labels being drawn in at the same time. This leads to incorrect labeling, machine downtime and increased waste. Reliable detection of very thin, sometimes transparent materials is required.
Solution:
Separation in Digital Printing Systems
Automated Stacking of Insulation Materials
Challenge:
In packaging lines for EPS, mineral wool or PU insulation boards, boards are automatically separated, stacked and prepared for final packaging. Unintentional double depositing can occur due to adhesion, mechanical canting or uneven feeding. This leads to deviations in quantity, volume or package weight.
Solution:
In packaging lines for EPS, mineral wool or PU insulation boards, boards are automatically separated, stacked and prepared for final packaging. Unintentional double depositing can occur due to adhesion, mechanical canting or uneven feeding. This leads to deviations in quantity, volume or package weight.
Solution:
Feeding Gypsum Plasterboard Boards for Further Processing
Challenge:
In automated assembly lines, gypsum plasterboard boards are removed from stacked pallets and fed to individual conveyor lines or processing stations. Two or more boards can be picked up at the same time due to friction, residual moisture or uneven stacking. Double layers change the geometry and positioning of the material and affect subsequent machining steps such as drilling, milling or edge sealing.
Solution:
In automated assembly lines, gypsum plasterboard boards are removed from stacked pallets and fed to individual conveyor lines or processing stations. Two or more boards can be picked up at the same time due to friction, residual moisture or uneven stacking. Double layers change the geometry and positioning of the material and affect subsequent machining steps such as drilling, milling or edge sealing.
Solution:
Thickness Control for the Separation of Electronic Boards
Challenge:
In automated production lines in the electronics industry, assembled PCBs are separated via carrier systems and fed into various processes such as soldering, testing or packaging. Static charge or mechanical influences can cause several PCBs to stick together and be fed together. To ensure reliable separation, the thickness of the components is checked.
Solution:
In automated production lines in the electronics industry, assembled PCBs are separated via carrier systems and fed into various processes such as soldering, testing or packaging. Static charge or mechanical influences can cause several PCBs to stick together and be fed together. To ensure reliable separation, the thickness of the components is checked.
Solution:
Overview of Solutions
Double Layer and Double Sheet Detection with Sensors
| Products | Benefits | Product links | |
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Laser distance sensors triangulation |
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Go to products |
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Ultrasonic distance sensors |
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Go to products |
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Ultrasonic fork sensor for label recognition |
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Go to products |
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Inductive sensors with analog output |
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Go to products |
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Products
Laser distance sensors triangulation
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Benefits
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Product links
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Products
Ultrasonic distance sensors
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Benefits
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Product links
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Products
Ultrasonic fork sensor for label recognition
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Benefits
|
Product links
|
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Products
Inductive sensors with analog output
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Benefits
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Product links
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Downloads of Product Flyers for Double Layer and Double Sheet Detection
Laser Distance Sensors Triangulation Product Flyer
(1 MB)
This document provides an overview of the laser distance sensors triangulation.
P3 Series Product Flyer
(2 MB)
This document provides an overview of the P3 series laser distance sensors.
P1PC Series Product Flyer
(2 MB)
This document provides an overview of the P1PC series laser distance sensors.
Ultrasonic Sensors Product Flyer
(995 KB)
This document contains the product flyer for the ultrasonic sensors.
PNBC Product Flyer
(6 MB)
This document contains the product flyer for the PNBC high-performance distance sensors.
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