Counting Small Electronic Components Using Fork Sensors
Small electronic components such as capacitors are produced in large quantities. Before they are packed, the objects, which are often only a few millimeters in size, must be separated on a vibrating spiral conveyor. They are then transported to the packaging station on a conveyor rail. A miniature optical fork sensor in this rail counts the components passing through it. The fork sensor detects the objects regardless of their shape, color and position. This ensures that each package always contains the correct number of parts. Related applications can be found here.

Position Control of Tools in Traysealing Machines with Fork Sensors
In the packaging industry, traysealing machines are used to seal plastic trays with foil covers under heat and pressure. Special tools are available for this purpose, which close the trays in cyclic lifting and lowering processes. In order to reliably detect the position of the tool, a miniature photoelectronic fork sensor is installed on the side, which reliably detects so-called switching flags on the tool despite the room for movement and regardless of their material and color. If the switching flag is present, the tool is lowered – a new tray can be inserted.

Position Monitoring of Robots in Block Storage Systems with Fork Sensors
In a cube storage system, vessels such as containers, boxes or crates are stacked, stored and removed by robots and transported through the storage system. To monitor the position of the robots and the number of crossings passed, two fork sensors are installed between the wheels. During travel, the light beam of the light barrier is interrupted because the bar of the rail is between the fork arms of the sensor. At intersections, the web of the rail is interrupted, the light beam hits the receiver and registers the crossing. Related applications can be found here.

Position Detection of Switching Flags by Miniature Fork Sensors
Switching flags are used in conveyor systems and machines to reliably record positions, end positions or conditions. A miniature fork sensor detects the switching flag as the fork passes through and triggers a precise switching signal. In contrast to inductive sensors, the reproducibility of the switching point remains constant regardless of the switching distance. In addition, manufacturing tolerances or slight deformations of the switching flag are reliably tolerated. Thanks to their compact format and high switching frequency, the sensors are particularly suitable for tight installation spaces and fast movement sequences.

Fill Level Monitoring When Unwinding Labels with Retro-Reflex Sensors
When automatically rolling out and applying labels, it is important to ensure that there is enough material on the roller and that there is no interruption in the process. The retro-reflex sensor serves as an early warning system to permanently check the material supply of label or film unwinders and thus prevent idle running. If there is too little material on the roller, it detects the reflector installed opposite it and switches. This allows the operator to replace the roller in good time. The required roller thickness can be individually adjusted thanks to the visible light spot.

Presence Check of Nonwoven Fabric on Coffee Capsules with Reflex Sensors
In order for hot water in coffee machines to be pressed evenly through the coffee capsules and thus ensure a uniform taste, wafer-thin white nonwoven fabric must be inserted into the capsules. Once the coffee powder has been poured into the capsules and the nonwoven fabric has been placed on it, energy reflex sensors check the presence of the nonwoven fabric. Mounted above the conveyor belt, they reliably detect the difference between the darker coffee powder and the white nonwoven fabric – even at high belt speeds. Related applications can be found here.

Distinguishing Different Car Body Parts in Automotive Production with Laser Distance Sensors Time of Flight
In the automotive industry, various types of bodywork components must be reliably detected and their position accurately determined during final assembly. Different surface shapes, degrees of gloss or colors must be recognized at the defined scanning points. There, for example, the presence of metal bolts is checked by several laser distance sensors Time of Flight with wintec and part types are differentiated from one another. Despite high reflections, gloss, angles and their installation directly next to each other, the sensors do not influence each other. Related applications can be found here.

Measurement of Soldering Paste in SMD Soldering Systems by Laser Distance Sensors Triangulation
In reflow soldering, soldering paste is applied through the openings of a template to the intended contact surfaces of a PCB using a scraper. During this process, the height of the solder paste between the two scrapers must be continuously monitored. To measure the paste height, laser distance sensors triangulation are used to precisely measure the current height of the solder paste and automatically regulate the redosing. If the paste level drops below a defined threshold value, solder paste is automatically added. This ensures an even flow of material.

Assembly Check of Fuses with Color Sensors
When installing passenger car fuse boxes, fuses of different colors are installed depending on the amperage. After inserting the fuses, a color sensor checks whether all components are correctly positioned and assigned to the correct type. For this purpose, the light reflected by the object is evaluated and converted into RGB and HSL values. This data is then compared with the specified color positions in the layout of the fuse box. Incorrect colors or missing fuses are thus immediately detected and incorrect assembly can be corrected immediately.

Detection of Caps by Color Sensors
In the pharmaceutical industry, after the filling and closing process of small bottles, it must be ensured that a cap is applied to each bottle with the matching color. A color sensor mounted above the conveyor belt records the color values of each individual lid and compares them with the stored reference colors. Thanks to its high switching frequency, the sensor operates reliably even at high flow rates. This ensures that each product gets the right closure and missorts are detected early.

Color-Coded Packaging Sorting by Color Sensors
After toys are packed, they are automatically sorted according to the color of the packaging. The packaging is differentiated by a printed color code that corresponds to the color of the toy included. A color sensor checks the printed color block and controls the forwarding of the packaging via pneumatic switches to the corresponding packaging station. Thanks to precise RGB detection and high switching frequency, the sensor can distinguish the finest color nuances even at high conveyor speeds and guide each product to the right station.

Fill-Level Measurement of Liquid Aluminum with Laser Distance Sensors Time of Flight
In the metal industry, liquid aluminum is cast into so-called ingots – these are metal bars that are manufactured for further transport. During the production of these ingots, the liquid metal level must be continuously monitored. To reliably detect the irregularly shaped and shiny metal surfaces, laser distance sensors time of flight with blue light are used. The blue laser light, the large measuring range and the high accuracy guarantee exact fill-level measurement and thus ensure the desired shape and quality of the ingots.